HYDRAULIC PC2000 -8
EXCAVATOR
SERIAL NUMBERS 20223 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.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
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1-1
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Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance
of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see "YOUR MACHINE SERIAL
NUMBERS AND DISTRIBUTOR (PAGE 1-7)".
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has
been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu
distributor before operating the machine.
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SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.
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INTRODUCTION FOREWORD
INTRODUCTION
USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Loading work
See the section "RECOMMENDED APPLICATIONS (PAGE 3-250)" for further details.
DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front and the sprocket is at the rear of the machine.
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FOREWORD INTRODUCTION
PROXIMITY VISIBILITY
The visibility of this machine in the area 1 m (3 ft 3in) from the outside surface of the machine at a height of 1.5 m
(4 ft 11 in) is shown in the diagram below. The hatched area (A) shows the area where the view is blocked by part
of the machine when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are
places that cannot be seen when operating the machine.
1-5
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PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
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Distributor name
Address
Service Personnel
Phone/Fax
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
BEFORE READING THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 4
USE OF MACHINE 1- 4
DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR'S SEAT 1- 5
PRODUCT INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
EPA REGULATIONS, ENGINE NUMBER PLATE 1- 6
SERVICE METER LOCATION 1- 7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12
PRECAUTIONS BEFORE STARTING OPERATION 2- 12
PREPARATIONS FOR SAFE OPERATION 2- 12
FIRE PREVENTION 2- 14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 15
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 17
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 17
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS 2- 18
UNAUTHORIZED MODIFICATION 2- 18
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 19
PRECAUTIONS RELATED TO CAB GLASS 2- 19
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 19
PRECAUTIONS FOR OPERATION 2- 20
PRECAUTIONS FOR JOBSITE 2- 20
STARTING ENGINE 2- 22
OPERATION 2- 24
TRANSPORTATION 2- 31
TOWING 2- 32
LIFTING OBJECTS WITH BUCKET 2- 32
PRECAUTIONS FOR MAINTENANCE 2- 33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 33
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 37
OPERATION 3- 1
MACHINE VIEW ILLUSTRATIONS 3- 2
OVERALL MACHINE VIEW 3- 2
CONTROLS AND GAUGES 3- 3
DETAILED CONTROLS AND GAUGES 3- 7
MONITORING SYSTEM 3- 7
SWITCHES (INSIDE OPERATOR'S CAB) 3- 82
SWITCHES (INSIDE CAB BASE ROOM) 3- 92
SWITCHES (OUTSIDE OF MACHINE) 3- 95
LAMP (INSIDE OPERATOR'S CAB) 3-106
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FOREWORD CONTENTS
1-9
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CONTENTS FOREWORD
1 - 10
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FOREWORD CONTENTS
1 - 11
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SAFETY SAFETY
SAFETY
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
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SAFETY SAFETY
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SAFETY SAFETY
2-4
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SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY LABELS
(1) Caution before operating or maintaining machine
(09651-03001)
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INSPECTING MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.
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2 - 13
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FIRE PREVENTION
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Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on
them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.
Do not grip the control levers or lock lever when getting on or off the machine.
Never climb on the engine hood or covers where there are no non-slip pads.
Do not get on or off the machine while holding tools in your hand.
The collapsible type side mirror can turn, so do not grab hold of it as a handrail.
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NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering serious
personal injury or death.
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UNAUTHORIZED MODIFICATION
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
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STARTING ENGINE
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OPERATION
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Always wear the seat belt. There is danger that you may be
thrown out of the operator's seat and suffer serious injury when
the brakes are applied suddenly.
Check that the movement of the machine matches the display
on the control pattern card. If it does not match, replace it
immediately with the correct control pattern card.
Check the operating condition of the machine, work equipment,
arm, boom, travel, and swing system.
Check for any problem in the sound of the machine, vibration,
heat, smell, or gauges; check also that there is no leakage of oil
or fuel.
If any problem is found, carry out repairs immediately.
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TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
Keep the work equipment approximately. 20 to 30 cm (8 to 12 in)
above the ground. In case of emergency, lower the work
equipment to the ground immediately to help stop the machine.
When travel up slopes, set the operator's cab facing uphill, when
travel down slopes, set the operator's cab facing downhill.
Always check the firmness of the ground under the front of the
machine when traveling.
When traveling downhill, lower the engine speed, keep the travel lever close to the neutral position, and travel at
low speed.
Always travel straight up or down a slope. Traveling at an angle
or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Do not travel on a slope covered with the steel plates. Even with slight slopes there is a hazard that the machine
may slip.
Travel on grass or fallen leaves with low speed. Even with slight slopes there is a hazard that the machine may
slip.
If the engine stops when the machine is traveling on a slope, move the control levers immediately to the neutral
position and start the engine again.
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OPERATING ON SLOPES
When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing
or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable
place when carrying out these operations, and operate carefully.
Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
If the machine has to be used on a slope, pile the soil to make
a platform (A) that will keep the machine as horizontal as
possible.
Do not work on a slope covered with the steel plates. Even with
slight slopes there is a hazard that the machine may slip.
PROHIBITED OPERATIONS
If the machine rolls over or falls, or the ground at the working point collapses, or a structure being demolished
collapses, it may lead to serious personal injury or death. Always observe the following.
Never dig the work face under an overhang. There is a hazard
that rocks may fall or that the overhang may collapse and fall on
top of the machine.
Do not excavate too deeply under the front of the machine. The
ground under the machine may collapse and cause the machine
to fall.
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When carrying out demolition work, do not use the impact force
of the work equipment for breaking work. There is a hazard of
damage to the work equipment and also a hazard of serious
personal injury or death being caused by flying pieces of broken
materials, or of the machine tipping over due to reaction from the
impact.
The not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other
hauling equipment. There is danger that the load may spill or the bucket may hit the dump truck and cause
serious personal injury or death.
When working on or from the top of buildings or other structures, check the strength and the structure before
starting operations. There is a hazard of the building collapsing and causing serious injury or damage.
Generally speaking, the machine is more liable to overturn when the work equipment is at the side than when it
is at the front or rear.
When using a breaker or other heavy work equipment, there is a hazard of the machine losing its balance and
tipping over. When operating on flat ground as well as on slopes.
Do not suddenly lower, swing, or stop the work equipment.
Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the machine to
tip over.
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PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling
rocks, or flooding.
Lower the work equipment completely to the ground.
When leaving the machine, set lock lever (1) to the LOCK
position (L), then stop the engine.
Always close the operator's cab door, and use the key to lock all
the equipment in order to prevent any unauthorized person from
moving the machine. Always remove the key, take it with you,
and leave it in the specified place.
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TRANSPORTATION
When the machine is transported on a trailer, there is danger of serious personal injury or death during
transportation. Always do as follows.
Always check the machine dimensions carefully. Depending on the work equipment installed, the machine
weight, transportation height, and overall length may differ.
Check beforehand that all bridges and other structures on the transportation route are strong enough to withstand
the combined weight of the transporter and the machine being transported.
The machine can be divided into parts for transportation, so when transporting the machine, please contact your
Komatsu distributor to have the work carried out.
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TOWING
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Put blocks under the track to prevent the machine from moving.
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PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, deformed, or low quality tools, or
making improper use of the tools may cause serious personal
injury.
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HANDLING BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to the OFF position.
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Danger of sparks
There is hazard that sparks will be generated, so always observe the following.
Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying
around near the battery.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing,
connect the positive (+) cable first, then connect the ground.
Tighten the battery cable terminals securely.
Secure the battery firmly in the specified position.
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NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers
or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
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3-1
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3-2
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3-3
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3-4
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X (1/2): Normal operation screen (1/2) X (2/2): Normal operation screen (2/2)
Press function switch F1 to switch between screen X (1/2) and screen X (2/2)
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(1) Engine oil pressure monitor (4) Engine oil temperature monitor
(2) Charge level monitor (5) Air cleaner clogging monitor
(3) Radiator coolant level monitor (6) Maintenance interval monitor
3-6
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MONITORING SYSTEM
X(1/2):Normal operation screen (1/2) pilot screen all lights up Y: Check before starting screen
X(2/2):Normal operation screen (2/2) Z: Maintenance interval warning screen
(A) Basic Check items (D) Meter display portion, pilot display portion
(B) Caution items (E) Monitor switches portion
(C) Emergency stop items
REMARK
One of the features of liquid crystal display panels is that there may be black spots (spots that do not light up) or white
spots (spots that stay lighted up) on the screen. If there are fewer than 10 black or white spots, this is not a failure
or a defect.
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When the starting switch is turned to the ON position, opening screen (S) is displayed.
After opening screen (S) has been displayed for 2 seconds, the screen switches to Check before starting screen
(Y).
After Check before starting screen (Y) has been displayed for 2 seconds, the screen switches to Working mode
display screen (T).
After Working mode display screen (T) has been displayed for 2 seconds, the screen switches to standard screen
(X).
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery
condition. If this happens, the display on the machine monitor may momentarily go out, but this does not indicate
any abnormality.
3-8
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When the starting switch is turned to the OFF position, ending screen (S) is displayed for 5 seconds, then the
screen goes out.
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If there is any abnormality when the engine is started, Check before starting screen (Y) switches to Maintenance
interval warning screen (Z), Warning screen (V), or Error screen (W).
After Check before starting screen (Y) has been displayed for 2 seconds, the screen switches to Maintenance
interval warning screen (Z).
After Maintenance interval warning screen (Z) has been displayed for 30 seconds, the screen switches to
standard screen (X).
After Check before starting screen (Y) has been displayed for 2 seconds, the screen switches to warning screen
(V) or Error screen (W).
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If any abnormality occurs during operations, standard screen (X) switches to Warning screen (U) or Error screen
(W).
After Warning screen (U) has been displayed for 2 seconds, it automatically switches to Warning screen (V).
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Displays basic items among the check before starting items that must be checked before starting the engine. If there
is any abnormality, monitor for the location of abnormality will light up.
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Caution Monitors
CAUTION
If the warning monitor flashes, check the problem point as soon as possible and carry out maintenance. Failure to repair the
problem may cause to failure of the machine.
These are items which need to be observed while the engine is running. If any problem occurs, items which need
to be repaired as soon as possible are displayed.
If there is any problem, the appropriate monitor lamp will flash to indicate the location of the problem.
(*): Displayed in center of screen in same way as for (1) (3) and (9)
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Emergency Monitors
CAUTION
If the monitor lights up in red, stop the engine immediately or run at low idle, check applicable location, then perform necessary
actions.
These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal
location lights up in red and buzzer sounds, perform action immediately.
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REMARK
Color when the monitor lights up for basic check items, caution items, and emergency stop items are as follows.
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Pilot Display
The pilot display at the top of the screen consists of the pilot lamps to confirm the actuation of each function.
When the starting switch is turned ON, the pilot lamp lights up when the display items are functioning.
REMARK
The swing motor is equipped with a disc brake that mechanically
stops the rotation. When the swing lock monitor is lighted up, the
brake remains applied.
Wiper Monitor
This monitor (3) shows the actuation status of the wipers.
The monitor display showing the wiper switch operating status is as follows.
ON lighted up: Continuous actuation of wiper (both upper and
lower ones)
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When the auto low idle setting is ON on the user menu, the
following displays are given.
Auto low idle lighted up: Auto low idle ON
Auto low idle out: Auto idle OFF
For details of the setting of the auto low idle, see "Auto Low
Idle Setting (PAGE 3-68)".
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3 - 25
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3 - 26
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Fuel Gauge
This meter (7) shows the amount of fuel remaining in the fuel tank.
The indicator should be in the green range during operations.
If the indicator starts to enter red range (A) during operations, it
shows that there is less than 500 liter (132.1 US gal) of fuel
remaining, so check and add fuel.
REMARK
If the indicator reaches range (B), there is less than 200 liter (52.84
US gal) of fuel remaining.
When the indicator is in red range (A) to (B), fuel level monitor (1)
lights up in red.
The correct fuel level may not be displayed for a short time when
the starting switch is turned ON, but this is not an abnormality.
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REMARK
When the indicator reaches red range (A), the hydraulic oil
temperature is as follows.
Red range (A) position: 102°C (215.6°F) or more
Red range (B) position: 105°C (221.0°F) or more
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3 - 29
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REMARK
When the indicator enters red range (A) to (B), the PTO oil temperature is as follows.
Red range position (A): More than 122°C (251.6°F)
Red range position (B): More than 125°C (257.0°F)
When the indicator is in red range (A) to (B), the PTO oil temperature monitor (E) lights up in red.
When the engine is started, if the indicator is at position (D), the PTO oil temperature is below 0°C (32.0°F) and
PTO oil temperature monitor (E) lights up in white. In this case, carry out the warming-up operation. For details,
see "Engine Warm Up (PAGE 3-212)" and "Hydraulic Equipment Warm Up (PAGE 3-214)".
REMARK
When the indicator enters red range (A) to (B), the engine oil temperature is as follows.
Red range position (A): More than 122°C (251.6°F)
Red range position (B): More than 125°C (257.0°F)
When the indicator is in red range (A) to (B), engine oil temperature monitor (E) lights up in red.
When the engine is started, if the indicator is at position (D), the PTO oil temperature is below 0°C (32.0°F) and
PTO oil temperature monitor (E) lights up in white.
In this case, carry out the warming-up operation. For details, see "Engine Warm Up (PAGE 3-212)" and
"Hydraulic Equipment Warm Up (PAGE 3-214)".
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REMARK
If the indicator enters red range (B), engine oil pressure monitor (C) lights up in red. If this happens, stop the
engine, and check the lubrication and the oil level in the oil pan.
An abnormal value of the engine oil pressure varies depending on the engine speed.
ECO Gauge
This gauge (13) shows the degree to which the fuel consumption
target is being achieved. If the gauge is in green range A, it shows
that the fuel consumption is within the target. If the gauge is in
orange range B, it shows that the fuel consumption has gone over
the target. When setting the fuel consumption target, see "ECO
Display (PAGE 3-58)".
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REMARK
It is possible to divide into truck counters 1 and 2 to distinguish the count according to the size or type of load of
the truck being loaded.
If the switch is pressed too many times by mistake during operations, it is possible to correct the count from the
user menu. For details of the procedure when correcting, see "Truck Counter Reset (PAGE 3-72)".
In addition, by keeping switch (a) or (b) pressed for approximately. 3 seconds, it is possible to reduce the count
by 1.
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REMARK
To return to the standard screen without changing the working
mode, press function switch F5.
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4. After two seconds, the pilot monitor display at the top right of
the screen is highlighted in orange.
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Auto-deceleration Switch
If the control levers are at neutral, this switch (2) automatically
lowers the engine speed and turns on the function to reduce fuel
consumption.
Auto-deceleration monitor ON: Auto-deceleration ON
Auto-deceleration monitor OFF: Auto-deceleration OFF
Each time the switch is pressed, the auto-deceleration is switched
between ON and OFF.
Auto-deceleration function
When the auto-deceleration function is ON, if the work equipment control and travel levers are returned to the N
position, the engine speed will drop after 4 seconds from the operating speed to idle speed.
This makes it possible to reduce fuel consumption.
If any lever is operated when the machine is in this condition, engine speed will return to the previous operating
speed to make it possible to perform operations.
1. When auto-deceleration switch (2) is pressed and the
auto-deceleration function is turned ON, the mode is displayed
in the center of the monitor display, and after two seconds, the
screen returns to the standard screen.
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REMARK
When the machine is shipped from the factory, the auto low idle function is set to ON.
The auto low idle function is an additional function of the auto-deceleration function.
If it is desired to turn the auto low idle function ON or OFF, please follow the procedure given in "Auto Low Idle
Setting (PAGE 3-68)".
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3 - 38
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Wiper Switch
This switch (4) actuates the front window wiper.
Each time the switch is pressed, the wiper switches INT (upper,
lower) J ON (upper, lower) J ON (upper only) J stop (goes out).
3 - 39
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REMARK
Each time wiper switch (4) is pressed, the mode is displayed in the
center of the monitor display, and after two seconds, the screen
returns to the standard screen.
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Function Switches
Function switches (7) consist of 6 switches (F1 to F6). The
function of each switch differs according to the content of each
screen.
When the monitor display shows the standard screen, the
functions are displayed as follows.
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The operation of the function switches if the initial screen is the standard screen is as follows.
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Operation of Image Display Screen When Two Camera Screens are Shown Simultaneously.
When function switch F4 is pressed on camera 1 screen display
screen, screen (a) for the camera at the rear left of the machine
and screen (b) for the camera at the rear right of the machine are
displayed.
Only the screens for the camera at the rear left of the machine
and the screen for the camera at the rear right of the machine
can be displayed at the same time.
When two screens are displayed at the same time, the display
changes more slowly than when only one screen is displayed.
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When the heavy lift switch is pressed, the boom lifting power is
increased when the boom RAISE is being operated
independently.
For details of the heavy lift switch, see "Heavy Lift Switch (PAGE
3-38)".
When the heavy lift switch is pressed, the screen returns to the
standard screen. To display the camera screen, press function
switch F3 again.
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Press the wiper switch and washer switch to operate the wipers
and washer.
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3 - 48
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3 - 49
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a b
Change engine oil 500
Replace engine oil filter 500
Replace fuel pre-filter 500
Replace fuel main filter 1000
Replace hydraulic oil drain filter 500
Replace hydraulic oil pilot filter 500
Replace hydraulic oil filter 1000
Replace hydraulic tank breather 1000
Change PTO case oil 1000
Change final drive case oil 2000
Change swing machinery case oil 1000
Change hydraulic oil 5000
Replace oil cooler accumulator 4000
a: Maintenance items
b: Default maintenance interval settings (h)
c: Time remaining until maintenance (h)
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F1: Displays next page. When on the last page, it displays the first
page.
F2: Displays previous page. When on the first page, it displays the
last page.
F3: Moves to next item (1 line down). When on the last line, it
moves to the first line on the next page.
F4: Moves to previous item (1 line up). When on the first line, it
moves to the last line on the previous page.
F5: Returns to standard screen.
F6: If pressed for more than 1.5 seconds, change to the screen to
reset the remaining time of a selected item (highlighted in
yellow)
REMARK
When resetting the remaining time, keep switch F6 pressed for at
least 1.5 seconds. If switch F6 is not kept pressed for at least 1.5
seconds, the switch operating sound can be heard, but the screen
does not switch to the screen for resetting the remaining time.
3 - 51
.
REMARK
It is desired to cancel the reset, press switch F5. The screen
returns to the maintenance list screen.
On the reset screen, if no switch is operated for more than 30
seconds, the screen automatically switches to the maintenance
list screen.
REMARK
It is desired to cancel the reset, press switch F5. The screen
returns to the maintenance list screen.
On the reconfirmation screen, if no switch is operated for more
than 30 seconds, the screen automatically switches to the
maintenance list screen.
3 - 52
.
3 - 53
.
F3: Moves to next item (1 line down). When on the last line, it
moves to the first line on the next page.
F4: Moves to previous item (1 line up). When on the first line, it
moves to the last line on the previous page.
a : Screen adjustment
b : ECO display
c : Time adjustment
d : Language selection
e : Economy mode adjustment
f : Auto Low-idle setting
g : Truck counter reset
h : Fan reverse mode
3 - 54
.
Adjusting Screen
Use this screen adjustment menu to adjust the brightness,
contrast, and back light of the screen.
3 - 55
.
REMARK
If the machine is not equipped with a camera, the selection menu
for screen adjustment is not displayed.
If screen adjustment is selected from the user menu, the
adjustment screen in Step 4 is displayed.
3 - 56
.
On the screen for Items 1) and 2), it is possible to carry out the
following operations with switches F2 to F6.
3 - 57
.
ECO Display
On this ECO display screen, is possible to set the display of the ECO indicator.
The ECO indicator displays the mean value of the accumulated fuel consumption from the time the setting was
made.
3 - 58
.
3 - 59
.
3 - 60
.
Clock Adjustment
On this clock adjustment menu, it is possible to change the setting
of the clock displayed on the pilot monitor of the standard display.
3 - 61
.
3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches F3
to F6.
Time
Adjust the hour setting.
3 - 62
.
12h/24h Mode
Choose either a 12-hour display (am/pm) or a 24-hour display.
3 - 63
.
REMARK
Daylight saving time or summer time means moving the clock
forward 1 hour to take advantage of the fact that the sun rises early
in summer. This system is used in many countries during the
summer.
3 - 64
.
Language
On this language selection menu, it is possible to select the language used on the monitor display.
3 - 65
.
3. Select the language to use for the display, then press switch
F6. The screen display changes to the selected language.
3 - 66
.
3 - 67
.
2. Select Auto Low idle setting on the user menu, then press
function switch F6.
The screen changes to the ON/OFF screen for Auto Low idle
setting.
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.
6. On the standard screen, the auto low idle monitor lights up.
When the auto low idle function is ON, after the work
equipment control levers and travel levers are placed at
Neutral, the engine speed automatically goes down to low
idle after approximately. 30 seconds has passed with the
lever is at Neutral.
3 - 69
.
If it is desired to turn the auto low idle function OFF (cancel), set the mode as follows.
1) Select OFF on the Auto Low idle setting screen, then press
function key F6.
The screen returns to User Menu.
3 - 70
.
3 - 71
.
2. Select " Truck Counter Reset" on the user menu, then press
function switch F6. The screen switches to the "Truck Counter
Reset" selection screen.
3 - 72
.
3 - 73
.
3 - 74
.
3 - 75
.
3 - 76
.
3 - 77
.
3 - 78
.
NOTICE
The fan speed is related to the engine speed. When the engine is running at low idle, the fan speed is also the minimum speed.
If it is desired to raise the fan speed, use the fuel control dial to raise the engine speed.
When rotating the cooling fun in reverse while the engine is not running, switch the display to this screen with the engine
starting switch in ON position and then turn the switch to the START position. This screen does not change until after the
engine starts up, so in order to cancel it, turn the engine starting switch to the OFF position, wait for approximately. 10 seconds
and then turn the switch to the START position.
When rotating the cooling fan in reverse while the engine is not running, do not start up the engine again for approximately.
30 seconds, holding the engine starting switch at the OFF position. This is to wait for the cooling fan to come to a full stop.
3 - 79
.
3 - 80
.
9. When the screen changes to "Now Changing" in the operation in Step 8, the engine speed is automatically
reduced to low idle, and after approximately. 25 seconds, the fan returns to regular rotation. After a further
approximately. 5 seconds, the engine speed returns to the original speed.
When the fan returns to regular rotation, the screen automatically switches to the initial screen.
REMARK
If the screen in Step 1 does not switch to the screen in Step 4,
and the screen switches to a screen like the screen on the right
(red display), the fan may not switch to reverse rotation. This
system is designed to protect the equipment by restricting the
change and not allowing the fan to rotate in reverse if the water
temperature and hydraulic oil temperature do not fill the
required conditions.
If it is desired to rotate the fan in reverse, press function switch
F5 to switch to the initial screen, then run the engine at low idle
or stop the engine to carry out warming-up or cooling operation.
On the initial screen, if the coolant temperature and hydraulic oil
temperature gauge are in range (A) to (B) or (C) to (D) in the
diagram on the right, it is possible to rotate the fan in reverse.
In this case, follow the procedure from Step 1.
3 - 81
.
3 - 82
.
Starting Switch
Starting switch (1) is used to start or stop the engine.
(A): OFF position
The key can be inserted or withdrawn. Switches for the electrical
system (except room lamp), are all turned off and the engine is
stopped.
(B): ON position
Electric current flows through the charging and lamp circuits. Keep
starting switch key in the ON position while the engine is running.
(C): START position
This is the engine-start position. Keep the key at this position
during cranking. Immediately after starting the engine, release the
key. It will automatically return to the ON position (B).
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.
REMARK
It is possible to judge the status (ON/OFF) of the engine
emergency stop switch by checking the condition of indicator lamp
(L).
Lighted up: Engine emergency stop switch is at ON (emergency
stop) position
Light off: Engine emergency stop switch is at OFF (normal
operation) position
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.
NOTICE
When carrying out normal operations without using the service center,
always set the service center switch to the lock position (L).
NOTICE
It is possible to turn on the interior cab room lamp even when starting
switch is in the OFF position, do not forget to turn it off.
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.
REMARK
The rear lamp (if equipped) also lights up with the additional
lamp switch.
If a camera (if equipped) is installed to the rear counterweight,
use the rear lamp (if equipped) fortnight lighting.
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.
(a) Night position: Lamps light up, monitor illumination lights up,
monitor screen lighting is dimmed.
(b) Day position: Lamps light up, monitor illumination lights up,
illumination of monitor screen is at normal level.
(c) OFF position: Lamps go out, illumination of monitor screen is
at normal level.
Cigarette Lighter
Use this switch (9) to light cigarettes.
When the cigarette lighter is pushed in, it will return to its original
position after several seconds, so pull it out and light your cigarette.
If the cigarette lighter is removed, the socket can be used as the
power source for the yellow flashing lamp. The capacity of the
cigarette lighter is 85W (24V x 3.5A).
3 - 87
.
3 - 88
.
WARNING
When using the boom thrust force to push up the chassis when moving down from a bench, there is danger that the machine may
suddenly go down and turn over, so set to the high-pressure setting.
With this switch (13), it is possible to switch the safety valve set
pressure at the head end of the boom circuit to 2 stages.
(a): ON
(b): OFF
Effect
The shaking and spillage of load from the bucket is reduced.
Operator fatigue is reduced when operating for long periods, so
operations can be performed saftely.
REMARK
When this switch is ON, if the boom is stopped, the distance for the
boom to stop is slightly extended. Operate with care until you
become accustomed to it.
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.
WARNING
Use this switch to lock the swing when not carrying out swing operations, such as when traveling.
Be careful when operating on slopes. The load of the work equipment may cause the work equipment to swing downhill if the
swing control lever is operated, even when the swing lock switch is at the ON position.
If the swing control lever is operated immediately after setting the swing lock switch to the ON position, swing drag may occur.
To avoid danger, wait for approximately. 5 seconds after turning the swing lock switch to the ON position when relieving the
swing circuit, such as during the warming-up operation.
NOTICE
While the machine is swinging, never operate the swing lock switch or stop the engine.
Such a practice can cause damage to the swing motor disc.
Use this switch (15) to lock the upper structure and prevent it from
rotating.
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.
Horn Switch
Press switch (17) on the right work equipment control lever to
sound the horn. The same time, the flashing lights at the top front
of the cab flashes for approximately. 5 seconds to give a signal to
the dump truck and others in the surrounding area.
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.
(18) Room lamp switch (cab base room) (21) Swing holding brake cancel switch
(19) Emergency pump drive switch (rear of main pump) (22) Engine emergency stop cancel switch
(20) Emergency pump drive switch (front of main pump)
NOTICE
It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off.
Use this switch (18) to light up the room lamp inside the cab base.
ON position: Lights up
OFF position: Goes out
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.
Emergency Pump Drive Switch (For front and rear both pumps)
NOTICE
Emergency pump drive switch is provided to make it possible to perform work for a short time when there is a failure in the pump
control system. It is necessary to repair the abnormal location as soon as possible.
When "E0E" is shown on the display and this switch is pushed up to position (a), smoothness in the work is lost,
and the work equipment may be moved slightly slower than normal.
When starting up the engine with "E0E" or "E07" showing on the display and the engine does not run, move this
switch to position (c).
Then the engine may be started. After the engine startup, temporary work may become possible by pushing up
this switch to position (a).
NOTICE
This switch is installed to make it possible to carry out operation temporarily if any abnormality should occur in the swing brake
system. It is not intended for permanent use. Repair the cause of the abnormality immediately.
If the display does not show "E03", move the switch up to FREE
position (a) to make it possible to carry out work.
When the switch is moved to FREE position (a), the swing lock
monitor flashes.
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.
NOTICE
Engine emergency stop cancel switch is provided to make it possible to perform work for a short time when there is a failure in
the emergency stop switch system. It is necessary to repair the abnormal location as soon as possible.
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.
(23) Room lamp switch (front of engine room) (30) Ladder raising switch
(24) Room lamp switch (rear of engine room) (31) Ladder lowering switch
(25) Room lamp switch (pump room) (32) Step light switch
(26) Engine emergency stop switch (front of power container) (33) Step light switch
(27) Engine emergency stop switch (rear of power container) (34) Nighttime maintenance switch
(28) Engine emergency stop switch (left side of machine)(if equipped) (35) Battery isolator switch (if equipped)
(29) Engine emergency stop switch (right side of machine)(if equipped) (36) Starter isolator switch (if equipped)
3 - 95
.
NOTICE
It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off.
Use this switch (23) to light up the room lamp inside the engine
room.
ON position: Lights up
OFF position: Goes out
NOTICE
It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off.
Use this switch (24) to light up the room lamp inside the engine
room.
ON position: Lights up
OFF position: Goes out
NOTICE
It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off.
Use this switch (25) to light up the room lamp inside the pump
room.
ON position: Lights up
OFF position: Goes out
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.
WARNING
Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency
stop switch before going inside the power container. This will prevent anyone from carrying out starting operations by mistake
from the operator's seat.
REMARK
It is possible to judge the status (ON/OFF) of the engine
emergency stop switch by checking the condition of indicator lamp
(L).
Lighted up: Engine emergency stop switch is at ON (emergency
stop) position
Light off: Engine emergency stop switch is at OFF (normal
operation) position
3 - 97
.
WARNING
Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency
stop switch before going inside the power container. This will prevent anyone from carrying out starting operations by mistake
from the operator's seat.
REMARK
It is possible to judge the status (ON/OFF) of the engine
emergency stop switch by checking the condition of indicator lamp
(L).
Lighted up: Engine emergency stop switch is at ON (emergency
stop) position
Light off: Engine emergency stop switch is at OFF (normal
operation) position
3 - 98
.
WARNING
Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency
stop switch before carrying out operations under the machine or around the undercarriage. This will prevent anyone from carrying
out starting operations by mistake from the operator's seat.
REMARK
It is possible to judge the status (ON/OFF) of the engine
emergency stop switch by checking the condition of indicator lamp
(L).
Lighted up: Engine emergency stop switch is at ON (emergency
stop) position
Light off: Engine emergency stop switch is at OFF (normal
operation) position
3 - 99
.
WARNING
Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency
stop switch before carrying out operations under the machine or around the undercarriage. This will prevent anyone from carrying
out starting operations by mistake from the operator's seat.
REMARK
It is possible to judge the status (ON/OFF) of the engine
emergency stop switch by checking the condition of indicator lamp
(L).
Lighted up: Engine emergency stop switch is at ON (emergency
stop) position
Light off: Engine emergency stop switch is at OFF (normal
operation) position
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.
REMARK
For details of the method of operating the ladder, see "HANDLING
HYDRAULIC LADDER (PAGE 3-168)".
REMARK
For details of the method of operating the ladder, see "HANDLING
HYDRAULIC LADDER (PAGE 3-168)".
3 - 101
.
REMARK
The above explains the operation when the nighttime maintenance
switch is OFF.
3 - 102
.
Step lights (C) and (D) will remain lighted up until switch (34) is
turned manually to OFF position (b).
Use this switch at night for maintenance work when it is desired
to keep the steps or the passage lighted up.
It is possible to light up the step lights even when the starting
switch is OFF.
NOTICE
Do not keep the step lights lighted up for a long time when the engine is
stopped. This will drain the battery.
After using the step lights, always turn the switch to OFF position (b) and
check that the step lights go off.
3 - 103
.
NOTICE
Normally, keep the battery isolator switch at the ON position.
If you set the battery isolator switch to the OFF position, be careful of the following items.
When the engine is running, do not turn the battery isolator switch to the OFF position. Wait for at least 3 minutes after stopping
the engine before turning the battery isolator switch to the OFF position. Failure to do this may cause problems in the electrical
system.
When the battery isolator switch is turned to the OFF position, all the electrical systems are shut off, and this may result in the
memory settings for time and radio station selections being lost.
Even when the starting switch is turned to the OFF position immediately after the fan stops rotating in reverse, power is
supplied to the fan reverse rotation solenoid for a short time in order to protect the hydraulic motor. Before turning the battery
isolator switch to the OFF position, check that the fan has stopped completely.
This switch (35) is used when shutting off all the electric systems
connected to the battery.
(a) ON position
Electricity is sent to all the electrical systems connected to the
battery. Normally, keep the switch in this position.
Before starting the engine, check that this switch is at the ON
position.
3 - 104
.
(a) ON position
Electricity is sent to the electric circuit of the starting motor and
it becomes possible to start the engine.
Before starting the engine, check that this switch is at the ON
position.
3 - 105
.
(1) Engine emergency stop Indicator lamp (5) Automatic greasing warning lamp
(2) Engine emergency stop warning lamp (6) Engine emergency stop cancel warning lamp
(3) Fan reverse rotation display lamp (7) Ladder warning lamp
(4) Hydraulic oil strainer warning lamp
3 - 106
.
3 - 107
.
3 - 108
.
For the right handling of the hydraulic ladder, see "When Raising Ladder (Setting to Stowing Position) (PAGE
3-170)".
For the right handling of the service center, see "When Raising Service Arm (Setting to Stowing Position) (PAGE
6-15)".
NOTICE
If the lamp does not go out even when all the equipment is stowed, please ask your Komatsu distributor to carry out inspection
and repair.
3 - 109
.
(1) Proximity switch warning lamp (4) Engine emergency stop Indicator lamp
(2) Proximity switch warning lamp (5) Engine emergency stop Indicator lamp (if equipped)
(3) Engine emergency stop Indicator lamp (6) Engine emergency stop Indicator lamp (if equipped)
3 - 110
.
NOTICE
If either of these lamps light up red, it is necessary to check the cause and
carry out repairs, so please ask your Komatsu distributor to carry out
inspection.
3 - 111
.
Lock Lever
WARNING
When standing up from the operator's seat, push lock lever (1) down
securely to set it to LOCK position (L). If lock lever (1) is not in LOCK
position (L) and the control levers are touched by mistake, it may lead
to serious personal injury.
Check lock lever (1) is placed securely at LOCK position (L).
Be careful not to touch the work equipment control levers when pulling
lock lever (1) up or pushing it down.
This lever (1) is a device to lock the work equipment, swing, travel, and attachment (if equipped) control levers.
Push the lever (1) down to apply the lock.
This lock lever (1) is a hydraulic lock, even if it is in the lock position (L), the work equipment control lever and travel
lever will move, but the work equipment, travel motor, and swing motor will not work.
REMARK
On machines equipped with an attachment, if this lock lever (1) is set to the LOCK position (L), the attachment will
not move even when the attachment control levers or control pedals are operated.
3 - 112
.
Travel Levers
WARNING
Do not rest your foot on the pedal during operations. If the pedal is
depressed by mistake, the machine may suddenly move and cause a
serious accident. Be extremely careful when operating the pedal for
travel or steering operations. When you are not using the pedal, do not
rest your foot on it.
If the track frame is facing the rear, the direction of travel operations will
be reversed when the travel lever is operated. (The machine will travel
forward when operated in reverse, and in reverse when operated
forward; the left and right directions will also be reversed.)
When operating the travel levers, check if the track frame is facing the
front or the rear. (If the sprocket is at the rear, the track frame is facing
the front.)
With this lever (2), the travel direction of the machine is changed
from forward to reverse or from reverse to forward. The
descriptions inside parenthesis are about pedal operation.
(a)FORWARD: The travel lever is pushed forward. (The pedal is
depressed to the front.)
(b)REVERSE: The travel lever is pulled back. (The pedal is
depressed to the rear.)
N (NEUTRAL): The machine stops travel.
REMARK
If the lever is shifted to the FORWARD or REVERSE position from the Neutral position, the alarm sounds to warn
that the machine is starting to move.
3 - 113
.
Arm operation
(a) Arm OUT
(b) Arm IN
Swing operation
(c) Swing to right
(d) Swing to left
N (Neutral): The upper structure and arm are held in position and
do not move.
Right work equipment control lever (4) is used to operate the boom
and bucket.
Boom operation
(a) RAISE
(b) LOWER
Bucket operation
(c) DUMP
(d) CURL
N (Neutral): The boom and bucket are held in position and do not
move.
3 - 114
.
DOOR LOCK
Use the door lock to fix the door in position after opening it.
1. Push the door into catch (1) to lock it in position.
2. When releasing the door lock, pull back lever (2) and open
catch (1). When fixing the door in position, close the catch
securely.
3 - 115
.
NOTICE
When escaping, remove the broken pieces of the glass from the sash so that you will not cut yourself with them. Take care not
to slip on the broken and scattered pieces.
Hammer (A) is provided to help the operator get out of the cab in
emergency, when the cab door or window will not open.
Hammer (A) is installed at the front at the rear of the front left
multi-monitor (1) inside the operator's compartment.
To escape, hit window glass (B) with hammer (A) to break it, then
escape through the window.
3 - 116
.
3 - 117
.
ESCAPE PROCEDURE
WARNING
When getting on or off the machine, always face the machine and maintain at least three-point contact (both feet and one hand,
or both hands and one foot) with the handrail and steps to ensure that you support yourself.
In particular, the rope ladder will tend to swing, and there is danger of falling off, so be particularly careful to support yourself
securely when climbing down.
NOTICE
To prepare for action in emergencies, read this escape procedure properly beforehand and practice using the escape equipment
installed to the machine.
1. Open escape door (1) and check that escape door (1) is held
in position by stopper (2).
2. Remove snap hook (3) from the hook of escape door (1), then
lower rope ladder (4) to the ground.
3. Using handrails (5) and (6), support yourself and step on to
fixed ladder (7).
3 - 118
.
5. Grip fixed ladder (7) strongly and step on to rope ladder (4).
3 - 119
.
3 - 120
.
FIRE EXTINGUISHER
This is installed on the right side at the bottom of the assistant's
seat.
Details of the method of use are given on the label stuck to the fire
extinguisher. Always read and understand the instructions
beforehand in order to be prepared in case of an emergency.
REMARK
It is possible to install a total of 4 fire extinguishers: one is installed
at the bottom right of the assistant's seat and there are three other
places where additional fire extinguishers can be installed.
If you wish to have additional fire extinguishers, please consult
your Komatsu distributor.
The three places where additional fire extinguishers can be
installed are as follows.
3 - 121
.
3 - 122
.
ASHTRAY
This is on the left side of the operator's seat.
Always make sure that you extinguish the cigarette before closing
the lid.
CUP HOLDER
There are 2 cup holders at the rear left of the operator's seat.
3 - 123
.
MAGAZINE BOX
This is on the left side of the operator's seat.
Always keep the Operation and Maintenance Manual in this box so
that it can be taken out and read at any time.
HOOK
This is at the rear of the operator's compartment.
3 - 124
.
UTILITY BOX
This is under the assistant's seat.
3 - 125
.
OFF Switch
Switch (1) is used to stop the fan and air conditioner.
When OFF switch (1) is pressed, the top portion of each of set
temperature and air flow displays on display monitor (6) and air
conditioner switch (7) go out, and operation stops.
REMARK
Even if switch (1) is turned OFF, the lamp at the top of
FRESH/RECIRC selector switch (5) does not go out, but this does
not indicate any abnormality.
3 - 126
.
Fan Switch
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.
3 - 127
.
REMARK
If the mode is set to auto mode and the temperature setting is set to 18.0 °C (64.4 °F) or 32.0 °C (89.6 °F), the air
flow from the fan is always set to HIGH and does not change even when the set temperature is reached.
3 - 128
.
3 - 129
.
3 - 130
.
3 - 131
.
Auto Switch
This switch (8) automatically changes air volume, vents and air
source according to the set temperature.
When auto switch (8) is pressed, the lamp above the auto switch
lights up.
Press switch (5), then use temperature control switch (3) to set
the temperature, and run the air conditioner under automatic
control.
When the control is switched from automatic operation to
manual operation, it is possible to operate the to change air flow,
vents, and air source (RECIRC/FRESH). When manual control
is used, lamp above the auto switch goes out.
REMARK
When Auto Mode is selected, if the set temperature is set to 18.0
°C (64.4 °F) or 32.0 °C (89.6 °F), the air flow is always set to High,
but this is not a problem.
Outside air is shut off and only air inside the cab is circulated.
RECIRC
Use this setting to perform rapid cooling of the cab or when outside air is dirty.
Outside air is taken into the cab.
FRESH
Use this setting to take in fresh air when performing demisting.
Display Monitor
Display monitor (6) shows temperature setting (a), air flow (b), and
vent selection (c).
When OFF switch (1) is pressed, the display of temperature
setting (a) and air flow (b) goes out, and operation stops.
3 - 132
.
3 - 133
.
Method of Operation
The air conditioner can be operated automatically or manually. Select the method of operation as desired.
Automatic Operation
1. Turn on auto switch (8) (pressed to be ON).
Then the lamp above switch (8) lights up.
Set temperature (a) and air volume (b) are also shown on
the monitor display.
REMARK
When vent display monitor (c) displays (d) or (e), and engine
coolant temperature is low, the air flow is automatically limited to
prevent cold air from blowing out.
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.
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 displayed
on monitor (7).
2. Turn air conditioner switch (7) ON. When this is done, the lamp
above the air conditioner switch lights up.
3 - 135
.
4. Press vent selector switch (4) and select the desired vents.
When this is done, the display for vent (c) of the display monitor
changes according to the selection.
3 - 136
.
2. Press vent selector switch (4) and set vent display (c) on the
display monitor to mode display (M3) as shown in the diagram
on the right.
3 - 137
.
3. Turn air conditioner switch (7) ON. When this is done, the lamp
above the air conditioner switch lights up.
4. Set or adjust fan switch (2), temperature setting switch (3), and
FRESH/RECIRC selector switch (5) 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 displayed
on monitor (7).
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.
2. Press vent selector switch (4) and set vent display (c) on the
display monitor to the following mode.
To blow air against the top of the glass, set to mode display (M1)
or (M2) as shown in the diagram on the right.
To blow air against the top of the glass, set to mode display (M5)
or (M6) as shown in the diagram on the right.
3 - 139
.
3 - 140
.
NOTICE
Never start the air conditioner when the engine is running at high speed. It will cause failure of the air conditioner.
If water gets into the control panel, it may cause unexpected failure, so be careful not to get water on the panel. In addition,
never bring flame or fire close.
Ventilation
If you smoke when the air conditioner is on, the smoke may start to hurt your eyes, so open the window and turn
the lever to FRESH for a while to remove the smoke while continuing the cooling.
When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry out
ventilation and cooling.
Temperature Control
When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 or 6 °C (9 or 10.8
°F) lower than the outside temperature). This temperature difference is considered to be the most suitable for your
health, so always be careful to adjust the temperature properly.
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Other Functions
Self-diagnostic Function
It is possible to perform troubleshooting of various sensors and equipment used on the air conditioner.
1. Turn the starting switch key to the ON (B) position.
2. Press OFF switch (1). The temperature setting and air flow
display on the liquid crystal display portion go out and
operation stops.
3. If the "∨" and "∧" parts of temperature setting switch (3) are
kept pressed at the same time for at least 3 seconds, the
troubleshooting mode is displayed on the liquid crystal display
portion.
When more than one failure is detected, press the "∨" or "∧" portion of temperature setting switch (3) to display
the failures in turn.
After completing the troubleshooting, press OFF switch (1) again to return to the normal display.
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.
If any problem is detected by the self-diagnostic function, contact your Komatsu distributor perform inspection and
repair.
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RADIO
Control Panel
(1) Power switch, Volume control knob, Balance (5) AS/PS button
control knob (6) Preset station buttons (1,2,3,4,5,6)
(2) SEL button (7) Display
(3) FM/AM selection button (8) Time reset button
(4) Display selection button (9) Tuning button
SEL button
Each time this button (2) is pressed, the mode changes as follows: VOL (volume) J BAS (bass) J TRE (treble) J
BAL (balance). The mode is displayed on display (7). For details of each mode, see "Method of Operating Mode
(PAGE 3-147)".
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.
AS/PS button
This button (5) actuates the auto store and preset scan functions.
Auto store
If this button is kept pressed for at least 2 seconds during radio reception, it will automatically search for six
available AM and FM stations each, starting with the lowest frequency and going up to the highest frequency.
These frequencies can then be saved in the preset memory.
Preset scan
If this button is pressed within 2 seconds, it is possible to select one of the already preset stations. Wait for 6 sec.
after pressing the button and then press the button again to select the next preset station. If it is impossible to
receive the preset frequency, the selection advances after 1 second to the next preset station.
REMARK
The preset button can be used to save the frequency manually. To save the frequency automatically, use the Auto
store button.
Display
This display (7) shows the reception band, frequency, preset No., and time.
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.
Controls of Radio
REMARK
It is also possible to save to the Preset button by using the auto
store button.
Method of Tuning
1. Press power switch (1) and display the frequency on display (7).
2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual
tuning.
Manual tuning
Press tuning button (9) until the frequency is displayed on display (7).
< button: Frequency moves down
> button: Frequency moves up
When the frequency reaches the top or bottom frequency, it automatically continues as follows: Top J Bottom, or
Bottom J Top.
Auto tuning
Press tuning button (9) for at least 3 seconds. When a station is picked up, the tuning automatically stops. To
search for the next station, press the tuning button again for at least 3 seconds.
< button: Frequency moves down
> button: Frequency moves up
If this button is pressed during auto tuning, the auto tuning will be cancelled and the setting will return to the
frequency in use before the button was pressed.
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.
REMARK
With each mode, the display is returned automatically to its original setting after 5 seconds.
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.
Antenna
NOTICE
Before transporting the machine or putting it inside a building, stored the antenna to prevent any interference.
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.
NOTICE
Do not use this as the power supply for 12V equipment.
It will cause failure of the equipment.
Pull out the connector plug for taking out electric power from the
rear side of the panel.
Maximum usable electric power is 85 W (24 V x 3.5 A).
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FUSE
This is installed to the power board inside the cab base room.
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
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.
Spare fuses are stored on the back of the fuse holder cover.
(1) 30A
(2) 20A
(3) 10A
(4) 5A
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.
CIRCUIT BREAKER
If there is a surge of current, the circuit breaker shuts off the electric circuit and protects the electrical components
and wiring from burning out.
When restoring the electrical circuit that has been shut off, push in the reset button that sprang out when the circuit
was cut off. If the electric circuit is working properly, the reset button will stay pushed in. If it springs out again
immediately when it is pushed in, it is necessary to inspect the electrical circuit.
Circuit Breaker(A)
This is installed to the power board inside the cab base room.
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.
Circuit Breaker(B)
The panel board is installed under the left floor step.
REMARK
This circuit breaker is a large-size breaker installed to circuits
where a large-capacity current is flowing. In the same way as
normal fuses and circuit breakers installed to the power board
inside the cab base room, this circuit breaker protects the electrical
components and wiring from burning out if there is a surge of
current.
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.
Fuse
No. Circuit name
capacity
1 20A Pump controller 2
2 20A Pump controller 1
3 30A Work lamp
4 30A Head lamp (right)
5 30A Head lamp (left)
6 20A Right bank engine controller
7 20A Left bank engine controller
8 20A Starting switch, Pump controller, Monitor
VHMS controller, ORBCOMM controller,
9 20A
Electric priming pump (if equipped)
10 20A VHMS controller
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.
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
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.
CONTROLLER
NOTICE
Do not let water, mud, or juice spill on the controller. This will cause failures.
If any problem occurs in the controller, do not repair it by yourself. Please contact your Komatsu distributor for repairs.
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The grease gun is set near the step for getting on or off the
machine at the platform on the right side of the machine.
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.
Method Of Use
When adding grease with grease gun (1), keep the engine running at a medium speed and then add grease.
1. Set the greasing mode selector switch on the left side of the
operator's seat inside the cab room to the MANUAL position.
2. Remove grease gun (1) from holder (2), then move to the
greasing posture.
3. Pull lever (3) of grease gun (1) with your finger. When lever (3)
is pulled, the greasing pump is automatically actuated and
discharges grease. When you release lever (3), the supply of
grease stops.
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.
When removing the nozzle at tip of the grease gun from the
grease fitting, carefully angle the tip of nozzle slightly and
remove it.
When there is only a small amount of grease left in the grease
can, the pump will not pump out grease, so move the grease to
the center or fill the can with new grease.
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.
Supplying Grease
When replacing grease can
When replacing the grease can, do as follows.
2. Remove quick couplers (5), (6), (7), wiring harness (8), wiring
clamp (9) and mounting bolts (10).
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.
6. Remove follower plate (17) from the center of the grease can.
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.
7. Using lifting hook (18), remove the grease can from the
machine.
8. Remove clamp (19) from the grease can and install it to the
new grease can that will replace the old grease can.
NOTICE
Be careful not to drop clamp (19) when lifting the grease can up, and
tighten it securely.
REMARK
If grease can is equipped with refill port (3) as an optional
specification, hook (20) is installed, so Step 9 above is
unnecessary.
9. Insert follower plate (17) into the newly installed grease can.
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.
10. Lift up grease can cover (16), align shaft (21) and shaft (22)
with follower plate holes (A) and (B), then insert the shafts.
11. Insert wire (23) of the grease level sensor through hole (C) in
grease can cover (16).
12. Be careful not to drop wire (23) into the grease can when
inserting it. Insert grease can cover (16) until it is in tight
contact with the grease can itself.
13. Set the grease can on the machine, then set the grease can
cover (16) in the reverse order to Steps 1 - 5.
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.
REMARK
The procedure for replacing the grease can, when it is broken,
differs only in the steps for removing and installing hose (3) for the
grease charging line. For the procedure for replacing the grease
can, follow the above instructions (Supplying Grease (PAGE
3-160)).
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.
ACCUMULATOR
WARNING
The accumulator is charged with high-pressure nitrogen gas, improper operation may cause an explosion which could lead to
serious injury or damage. When handling the accumulator, always do as follows:
Pressure in the control circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in the
direction that oil spurts out when performing the operation.
Loosen the bolts slowly.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Contact your Komatsu distributor for proper disposal.
This machine is equipped with an accumulator in the control circuit. The accumulator is a device to store oil pressure
for the control circuit. Because an accumulator is installed, the control circuit can be actuated for a short time even
after the engine is stopped. As a result, if the control lever is moved in the LOWER direction, the work equipment
will go down under its own weight.
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REMARK
These accumulators are installed to protect the oil cooler from
abnormal pressure in the hydraulic circuit, and to improve the
reliability of the hydraulic equipment.
1. Stow hydraulic ladder and service arm (if equipped). For detail of stowage procedure, see "PROCEDURE FOR
OPERATING HYDRAULIC LADDER (PAGE 3-168)" and "PROCEDURE FOR OPERATING SERVICE ARM
(PAGE 6-13)".
2. Lower the work equipment to the ground.
3. Stop the engine.
4. Turn the engine starting switch to the ON position.
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.
5. Move the lock lever (1) to the free position (F), and operate the
work equipment control lever and the attachment operation
pedal (optional) back and forth and to the left and right up to the
stroke end in order to release pressure from the respective
control circuits.
6. Start up the engine and stop it in a few seconds. And then carry
out the work 3 and 4 above.
7. Continue the operation in Step 4 until the hissing noise of
pressure oil can no longer be heard. (approximately. 2 to 3
times)
8. Push down lock lever (1) to locking position (L) to lock the
control lever and attachment operation pedal. However,
pressure cannot be released completely, so when removing
the accumulator for the control circuit, loosen the screw slowly
and do not stand in the direction of hydraulic oil spurting out.
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.
NOTICE
If the ladder is at the lowered position, the proximity switch does not detect
that the ladder is stowed, so PPC (hydraulic pilot) lock is applied and it is
impossible to swing or drive the machine, or operate the work equipment.
If this happens, the ladder warning lamp inside the operator's cab lights
up in red. For details, see "Ladder Warning Lamp (PAGE 3-109)".
This lock is cancelled when the ladder is stowed.
If the lock is not cancelled even when the ladder is stowed, see "ACTION
WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN
PROXIMITY SWITCH (PAGE 3-171)".
Before operating the ladder, check that there is no obstacle in the ladder
operating range. There is danger that if the ladder hits any obstacle the
ladder or the obstacle may break.
NOTICE
Check that the lock lever is in the LOCK position.
When the lock lever is in the FREE position, the hydraulic ladder cannot be
operated.
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.
2. Keep ladder lowering switch (3) on switch box (1) pressed until
the ladder automatically stops.
REMARK
The hydraulic ladder can be lowered also when the engine is not
running, but its move is not as fast as when the engine is running.
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.
REMARK
The hydraulic ladder can be raised only when the engine is
running.
When you are climbing down the machine with the hydraulic
ladder stored, use the steps provided on the right side of the
machine.
REMARK
If the engine is stopped for a long time, the ladder may come down under its own weight, but this does not indicate
any abnormality.
It is possible to prevent the ladder from coming down under its own weight by fitting the ladder lowering
prevention chain to the hook on the machine.
If the angle when the ladder comes down under its own weight is within 5 degrees, when the engine is started,
the ladder will automatically return to the stowing position, so before starting the engine, check that there is no
one near the ladder.
If the angle when the ladder comes down under its own weight is more than 5 degrees, the ladder will not return
automatically to the stowing position, so press the ladder raising switch to stow the ladder.
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.
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH
If it is impossible to swing or drive the machine, or operate the work equipment even when the hydraulic ladder is
stowed, there is probably a problem with the proximity switch. Check the proximity switch as follows.
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.
6. Adjust with adjustment nuts (4) and (5) of proximity switch (1)
so that clearance (C) between proximity switch (1) and plate
(3) installed to hydraulic ladder is 4 to 6 mm (0.16 to 0.23 in).
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.
WARNING
When the following procedure is used to disconnect the connector of the proximity switch and connect it to another connector,
the PPC (hydraulic pilot) lock is always released, so it will be possible for the machine to move.
This change in the combination of the connectors is a temporary measure to enable the machine can be moved to a safe place.
After moving the machine, contact your Komatsu distributor immediately and ask for repairs to be carried out.
The machine can move, so this is extremely dangerous. For this reason, when carrying out this operation, always set the
hydraulic ladder to the stowing position and fix the ladder lowering prevention chain to the hook on the machine.
NOTICE
When the changing the combination of the connectors, be careful not to mistake the connections.
1. Turn the starting switch to the OFF position, remove the key, wait for approximately. 1 minute, then remove the
negative (-) terminal of the battery.
2. On the right side inside the cab base room there is the
connector for the PPC (proportional pressure control pilot)
lock.
3. Remove bolts (1) and (2) of the clamp holding the connector
cable.
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.
6. Connect the negative (-) terminal of the battery, start the engine, then check that it is possible to operate the
travel, swing, and work equipment.
If they cannot be operated, there is probably some other cause, so ask your Komatsu distributor to carry out
investigation.
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.
BASIC PRECAUTIONS
WARNING
Never disassemble, repair, modify, or move the KOMTRAX Plus or cables. This may cause failure or fire on the KOMTRAX Plus
equipment or the machine itself. (Your Komatsu distributor will carry out removal and installation of KOMTRAX Plus.)
Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected
wires may cause failure or fire on the KOMTRAX Plus equipment or the machine itself.
REMARK
There is absolutely no need to inspect or operate the KOMTRAX Plus, but if any abnormality is found, please
contact your Komatsu distributor.
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.
BASIC PRECAUTIONS
WARNING
Never disassemble, repair, modify, or move the KOMTRAX Plus, communications terminal, antenna, or cables. This may cause
failure or fire on the KOMTRAX Plus communications terminal or the machine itself. (Your Komatsu distributor will carry out
removal and installation of the KOMTRAX Plus and communications terminal.)
Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected
wires may cause failure or fire on the KOMTRAX Plus communications terminal or the machine itself.
For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm (8.7 in) from the pacemaker.
The radio waves may have an adverse effect on the operation of the pacemaker.
Near the blasting jobsite, there may be a danger of unexpected explosion due to use of interactive wireless communication
device of KOMTRAX Plus and resulting serious personal injury. Make sure to operate the machine away from the blasting
jobsite. If you have to operate the machine within 12 m (39 ft 4 in) from the blasting jobsite or the remote blasting device, ask
your Komatsu distributor to disconnect power source cable of KOMTRAX Plus in advance.
If there are any restriction or law of the territory or country where the machine equipped with this device is used, such
restriction or law has a priority than this warning.
KOMTRAX Plus specifications are as follows.
Rated horsepower: 5 to 10 W
Operating frequency: 148 to 150 MHz
NOTICE
Please contact your Komatsu distributor before installing a top guard or other attachment that covers the antenna.
Be careful not to get water on the communications terminal or wiring.
REMARK
The communications terminal uses wireless communications, so it cannot be used inside tunnels, underground,
inside buildings, or in mountain areas where radio waves cannot be received. Even when the machine is outside,
it cannot be used in areas where the radio signal is weak or in areas outside the wireless communication service
area.
There is absolutely no need to inspect or operate the KOMTRAX Plus or communications terminal, but if any
abnormality is found, please contact your Komatsu distributor.
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Walk-around Checks
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual like
loose bolts and nuts, leakage of fuel, oil and coolant. Also check the condition of the work equipment and the
hydraulic system.
Also check for loose wiring, play, and collection of dust at places that reach high temperature.
WARNING
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts.
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu
distributor.
Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check for cracks, excessive wear, play in work equipment, cylinders, linkage, and hoses. If any problem is
found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator.
Check for dirt accumulated around the engine and radiator. Also check for flammable material (dry leaves, twigs,
etc.) around the battery, engine muffler, turbocharger, or other high temperature engine parts. If any dirt or
flammable materials are found, remove them.
For the method of removing dirt from the radiator, see "CLEAN AND INSPECT RADIATOR FINS, OIL COOLER
FINS, FUEL COOLER AND AFTER COOLER FINS (PAGE 4-76)".
5. Inspection of PTO lubrication tube, hose and strainer for oil leaks
Check these parts for oil leaks. If any leak is found, repair that leaking spot.
6. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, and joints
Check for oil leakage. If any problem is found, repair the area where oil is leaking.
7. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers.
If any problem is found, repair it.
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.
3 - 178
.
WARNING
Under normal circumstances, do not open the radiator cap. When checking the cooling water, check the reservoir tank.
Immediately after the engine is stopped, the coolant is at high temperature. In addition, pressure has accumulated inside the
radiator. If the cap is opened under these conditions, it will cause burns. Wait for the temperature to go down, then operate
the lever of the reservoir tank to release the pressure.
REMARK
For details of the method of draining and adding coolant to machines equipped with a service center (option), see
"Method of Draining, Adding Coolant (PAGE 6-23)".
1. Open cover (1) at the front of the power container on the right
side of the machine.
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.
2. Check that the coolant is between the FULL and LOW range
on reservoir tank (2). If the level is low, raise cap lever (4) of
cap (3) at the top of reservoir tank (2) to release the internal
pressure in reservoir tank (2).
3. Remove cap (5) from the water filler port, then add coolant.
4. After adding coolant, tighten cap (5) securely, then lower the
cap lever to secure cap (3) in place.
5. If the reserve tank (2) becomes empty, there is probably water
leakage. After checking, repair any abnormality immediately. It
no abnormality is found, check the level (6) of the water in the
radiator. If it is low, add COOLANT of the same density in
radiator according to the COOLANT density table in "CLEAN
INSIDE OF COOLING SYSTEM (PAGE 4-27)", then add
COOLANT to the reserve tank (2).
REMARK
Add coolant to the radiator as follows.
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.
1) Open cover (6) at the rear of the container on the right side
of the machine, and use it as a place to stand. Remove bolt
(7) to open cover (6).
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.
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
REMARK
For details of the method of draining and adding engine oil to machines equipped with a service center (option), see
"Method of Draining, Adding Engine Oil (PAGE 6-17)".
When the engine is at idle, use the ENGINE IDLING side of the
dipstick and check the H and L marks.
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.
5. If the oil is above the H mark, loosen drain valve (P1) of the oil
pan.
The oil will go down to drain valve (P2).
Next, open drain valve (P2) under the revolving frame and drain the
excess oil. When doing this, be careful not to get oil over yourself.
When draining the oil, use the drain hose in the toolbox and
install it to oil drain valve (P2). Be careful not to let the drained
oil spray out when draining it.
(Drain hose part No.: 07287-02618)
6. If the oil level is correct, tighten drain valves (P1) and (P2) and oil filler cap (F) securely.
7. Close the door of the power container at the front of the machine.
REMARK
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine
before checking.
If the machine is at an angle, make it horizontal before checking.
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.
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames
near fuel because it is highly flammable and dangerous.
REMARK
For machines equipped with service center, see "Method of Adding Fuel (PAGE 6-25)".
For machines equipped with fuel quick charge, see "PROCEDURE FOR OPERATING FUEL CHARGE (PAGE
6-5)".
1. Use sight gauge (G) at the rear face of the fuel tank to check
that the fuel tank is full.
2. If the fuel is not visible in the sight gauge, add fuel through oil
filler (F) and check that it appears in sight gauge (G).
Fuel tank capacity: 3,400 liter (898.3 US gal)
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.
WARNING
Engine parts and oils are heated to a high temperature immediately after the engine has stopped. A casual touch can cause a
scald. So begin the work great care.
When the oil filler plug is removed, heated oil may spurt out. Loosen the plug gradually and with care to release the internal
pressure.
REMARK
For details of the method of draining and adding hydraulic oil to machines equipped with a service center (option),
see "Method of Draining, Adding Hydraulic Oil (PAGE 6-22)".
1. Park the machine on the level ground and set the work
equipment in a posture shown at right. Then check the oil level
and add oil if necessary. [The machine held in working posture
(1)]
2. If the work equipment is not in the condition shown in the
diagram on the right, start the engine, run the engine at low
speed, retract the arm and bucket cylinders, lower the boom,
put the bucket teeth in contact with the ground to set the work
equipment in the posture shown in the diagram on the right,
then stop the engine.
3. Within 15 seconds after stopping the engine, turn starting
switch to the ON position, and operate the control levers (work
equipment, travel) in each direction to release the internal
pressure.
4. Use oil level gauge (G) at the rear of the hydraulic tank on the
right side of the machine to check the oil level. The oil should
be within the range specified for the oil temperature. If the oil
level is low, add oil.
Use scale plate (A) when measuring with the gauge.
The oil level differs according to the oil temperature and the
way the work equipment is lowered to the ground. Measure
with the gauge according to the level check table on the
next page.
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.
3 - 186
.
REMARK
When the working posture is (2) in the diagram on the right, the
correct oil level on the gauge label is range (a2) at normal
temperature and (b2) at high temperature.
5. If the level is below the correct line, add oil through filler port (F)
at the top of the hydraulic tank.
NOTICE
Do not add oil above the correct level. This may damage the hydraulic
circuit and cause the oil to spurt out.
6. If the oil level is above the correct level, do as follows to drain the oil.
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.
WARNING
If oil has been added to above the correct level, stop the engine, wait for the hydraulic oil to cool down, then drain the excess oil
from drain plug (P1).
When draining the oil, use either drain plugs (P1) and (P2) at the
bottom of the hydraulic tank or drain plugs (P3) at the bottom of the
hydraulic sub tank.
Loosen drain plug (P1), then loosen plug (P2) and drain the oil.
After draining the oil, tighten drain plugs (P1) and (P2).
Loosen 2 drain plugs (P3) at the bottom of the hydraulic sub tank
and drain the oil. The outlet port for draining the oil is drain tube
(B). When draining the oil, be careful not to get oil over yourself.
After draining, tighten 2 drain plugs (P3).
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.
REMARK
Even though the oil is at the correct level, when the machine is in the following posture, "Abnormal Hydraulic Oil
Level" may be displayed, but this causes no problem for operation.
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.
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
NOTICE
When checking the oil level, park the machine on the level ground and start checking more than 15 minutes after the engine has
stopped.
REMARK
For details of the method of draining and adding PTO case oil to machines equipped with a service center (option),
see "Method of Draining, Adding PTO Case Oil (PAGE 6-20)".
2. If the oil level is not between the H and L marks on the dipstick,
add oil through the dipstick guide.
When the engine is at idle, use the ENGINE IDLING side of
the dipstick and check the H and L marks.
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.
If any lamp does not light up, there is probably a broken bulb or disconnection, so ask your Komatsu distributor to
carry out repairs.
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.
CAUTION
If fuses frequently break or the circuit breaker is frequently actuated, or if there are signs of short circuits on the electric wiring,
investigate the cause immediately and ask your Komatsu distributor to carry out repairs.
Keep the top of the battery clean. Check the breather holes in the battery caps. If they are clogged with mud, wash the battery
cap and remove the clogging.
Check that no fuses or circuit breakers are damaged. Check that the specified capacity fuses are being used.
Check that there are no disconnections of the electric wiring and that there are no signs of short circuits. Check also
for loose terminals and tighten if necessary.
Be particularly careful to check the battery, starting motor, and alternator wiring.
Always check that no flammable materials are accumulated around the battery. Remove any such materials.
Please consult your Komatsu distributor about investigating causes and carrying out repairs.
REMARK
The fuse box and circuit breaker (A) are installed to the power board inside the cab base room.
Circuit breaker (B) is installed to the panel board under the left floor step.
For an explanation about the fuse box and circuit breaker, see "FUSE (PAGE 3-150)" and "CIRCUIT BREAKER
(PAGE 3-152)".
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.
NOTICE
Never use trichlene for washing the inside of the tank.
Use diesel fuel only.
REMARK
Drain valve (2) at the bottom of the fuel tank is always open, except
during transportation, so there is no need to operate it.
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.
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.
Fuel is highly flammable and dangerous. Never bring flames near fuel.
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.
3. Pull up fuel shut-off lever (A) installed at the front of the main
pump inside the pump room to shut off the fuel supply circuit
from the fuel tank.
7. After completing the water drain operation, bleed the air. Use the same procedure as when replacing the fuel
filter cartridge.
For details of the method of bleeding the air, see "BLEEDING AIR FROM FUEL CIRCUIT (PAGE 4-47)".
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Check Monitor
Carry out the following inspection to prevent failure to give warnings because of broken lamp bulbs on the machine
monitor or defective operation of the buzzer.
1. Before starting the engine, turn the starting switch to the ON
position and check that all monitors and gauges light up for
approximately. 3 seconds and that the alarm buzzer sounds
properly.
2. If any lamp does not light up or the buzzer does not sound,
there is probably a broken bulb or disconnection, so ask your
Komatsu distributor to carry out inspection.
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Adjustment
Seat Adjustment
WARNING
When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental
contact with the control levers.
Always adjust the operator's seat before starting each operation or when the operators change shift.
Push your back against the backrest of the operator's seat and adjust so that you can depress the brake pedal
fully. In addition, adjust the seat so that you can operate the control levers and switches freely.
An air compressor built into the seat is used for adjustments (C), (D), and (I), so turn the engine starting switch
to the ON position before adjusting.
NOTICE
There is danger of damage to the air compressor, so do not keep lever (3) operated continuously for more than 1 minute.
If the operator raises his body from the seat or changes the
amount of weight applied to the seat during adjustment, the air
in the suspension may be discharged.
When operators change shifts, the new operator should push
lever (3) down to release all the air in the suspension. Then the
new operator should carry out the weight adjustment again.
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REMARK
When the seat is pushed down, the air is discharged. The air makes a sound when it is discharged, but this does
not indicate any failure.
When lever (3) is pushed down, the seat height may suddenly go down to the minimum adjustment height. This
occurs when the suspension reaction is smaller than the operator's weight, so it does not indicate any failure.
REMARK
The seat can be reclined more when the seat is pushed to the front.
The amount of reclining decreases as the seat is pushed back, so
when moving the seat back, return the seat back to the upright
position.
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Rearview Mirrors
The rear view mirrors are installed to the following numeral for
places.
Loosen nuts (1), bolts (2), and screws (3) holding the mirror,
then adjust to a position which gives the best view from the
operator's seat.
In particular, adjust so that people to the left and right side at the
rear of the machine can be seen.
When installing the mirrors, adjust so that it is possible to see
people (or objects of a height of 1 m and diameter of 30 cm) at
the left and right sides at the rear of the machine.
(A1)(A2): Adjust the angle of (A1) and (A2) mirrors the way a view
in the rear on the left side can be seen.
(B): Adjust the angle of (B) mirror the way a view of the catwalk can
be seen.
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(D1): Adjust the angle of (D1) mirror the way a view of the fuel tank
right lower portion can be seen.
(D2): Adjust the angle of (D2) mirror the way a view of the right
lower portion in the rear.
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Seat Belt
WARNING
Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged,
replace the seat belt.
Even if there are no signs of damage, replace belts in accordance with the following schedule:
5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Always wear the seat belt during operations.
Fit the seat belt so that it is not twisted.
REMARK
The date of seat belt manufacture attached to the seat belt is the start of the 5-year period. It is not the start of the
3-year period of actual usage.
Removing Belt
Press button (5) in buckle (4), and remove tongue (3) from buckle (4).
The belt is automatically wound in, hold grip (2) and return the belt slowly to wind-in device (1).
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4. Insert the key in starting switch (4), turn the key to the ON
position (B), then carry out the following checks.
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3) If the hydraulic oil gauge goes out but caution lamp (23)
stays lighted up in red, carry out inspection immediately of
the red lighted item.
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6) If either of the following 5 engine emergency stop switches is ON (emergency stop) position, the lamp at the
side of the engine emergency stop switch that is ON (emergency stop) will light up green. Turn the
emergency stop switch to the right and turn it OFF (normal circumstances) position. The green lamp will go
out.
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For details of the operation of the engine emergency stop switch, see "Stopping in Emergencies (PAGE 3-224)".
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STARTING ENGINE
WARNING
Start the engine only after sitting down in the operator's seat.
Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury
or fire.
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Never use starting aid fluids as they may cause explosions.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
NOTICE
Before starting the engine, check that fuel control dial (2) is at the low
idle (MIN) position. If the fuel control dial is at the full speed (MAX)
position, the engine will accelerate suddenly and cause damage to the
engine parts.
Do not keep the key in starting switch (3) at the START position
continuously for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes, then start again
from the beginning.
After the engine starts, wait for the engine oil pressure monitor to go
out. Do not touch the control levers or control pedal while the engine oil
pressure monitor is lighted up.
This machine is equipped with an engine automatic preheating device that functions to start the engine preheating
automatically.
If the ambient temperature is low, the preheating monitor will light up when the key in starting switch (3) is turned to
the ON position to inform the operator that preheating has been started automatically.
1. Check the lock lever (1) is in the LOCK position (L). If the lock
lever (1) is in the FREE position (F), the engine does not start.
2. Set fuel control dial (2) to the low idle (MIN) position.
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REMARK
If the ambient temperature is low, the engine may not start even
when the key in the starting switch (3) is kept at the START position
for 20 seconds. If this happens, wait for at least 2 minutes, then
start again from the beginning.
5. After the engine starts, release the key in starting switch (3).
The key will automatically return to the ON position (B).
REMARK
When the engine is started, the battery voltage may suddenly drop
depending on the temperature and the battery condition. If this
happens, the display on the machine monitor may momentarily go
out, but this does not indicate any abnormality.
6. Even if the engine starts, wait for the engine oil pressure
monitor to go out. Do not touch the control levers or control
pedal while the engine oil pressure monitor is lighted up.
NOTICE
If the engine oil pressure monitor does not go out even after 4 to 5 seconds
have passed, stop the engine immediately. Check the oil level, check for
leakage of oil, and take the necessary action.
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REMARK
Regardless of the ambient temperature, it is possible to start the
engine preheating manually.
1. Turn the key in starting switch (3) to the left from OFF position
(A). The preheating monitor lights up and engine preheating
starts.
(Preheating continues while the key in starting switch (3) is held
at the left position.)
2. The preheating monitor starts lighting approximately 30
seconds after preheating starts and then goes off in
approximately 10 seconds.
3. After the preheating monitor goes off, turn the key in starting
switch (3) to START position (C). The engine will start.
If the engine cannot be started with the above procedure, wait for
at least two minutes, then start again from Step 1.
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There are two types of warm-up operation: warm up the engine and warm up the hydraulic equipment. In addition,
depending on the environment, the method of carrying out the warm-up operation may differ, so carry out the
warm-up operation according to the items given in the appropriate section.
(When only the engine is warmed up, the hydraulic equipment is not warmed up, so always carry out the warm-up
operation for the hydraulic equipment separately from the warm-up operation for the engine. Warm up the hydraulic
equipment thoroughly ensures that the hydraulic oil is warmed up and that warm hydraulic oil circulates in all the
control circuits.)
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NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points when
breaking in the machine.
Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
Engine Warm Up
NOTICE
Do not accelerate the engine suddenly until the warm-up operation has
been completed.
Do not run the engine at low idle or high idle under no load for more than
20 minutes. This will have an adverse effect on the environment, and
will also have an adverse effect on the internal structure of the engine.
If it is necessary to run the engine at idle for more than 20 minutes, apply
a load from time to time or run at a mid-range speed.
After the engine starts, do not start operating the machine immediately. First, carry out the following operations and
checks.
1. This machine is equipped with an automatic engine warm-up system, so if the engine water temperature is
below 30°C (86°F) after the engine is started, the engine warm-up operation starts automatically. When the
engine automatic warm-up operation starts, the engine speed is maintained at a speed higher than the normal
low idle speed.
If the engine water temperature goes above 30°C (86°F) or if the warm-up operation has been continued for
more than 10 minutes, the automatic warm-up operation is cancelled and the engine speed drops to the normal
low idle speed.
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3. Turn fuel control dial (2) to a point midway between low idle
(MIN) and full speed (MAX), run the engine under no load at a
mid-range speed until engine coolant temperature monitor (1)
displays the correct temperature.
If the engine coolant temperature monitor displays the correct temperature, the engine warm-up operation is
completed.
After checking that the engine coolant temperature monitor displays the correct temperature, carry out the warm-up
operation for the hydraulic equipment.
NOTICE
Canceling automatic warm-up operation
If it becomes necessary in an emergency to cancel the automatic warm-up operation or to lower the engine speed to low idle, do
as follows.
1) Turn fuel control dial (2) to the full speed (MAX) position
and hold it for 3 seconds.
2) When fuel control dial (2) is returned to the low idle (MIN)
position, the engine speed will drop.
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2. Turn swing lock switch (2) ON and check that the swing lock
monitor lights up.
4. Move lock lever (3) slowly to the FREE position (F), then raise
the bucket from the ground.
5. Turn fuel control dial (4) to a point midway between low idle
(MIN) and full speed (MAX).
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NOTICE
When the work equipment is retracted, take care that it does not interfere with the machine body or ground.
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13. Check that the hydraulic oil temperature monitor and engine coolant temperature monitor are displaying the
correct temperature, then check that all the gauges and caution monitors on the machine monitor are in the
following status.
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14. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu
distributor.
In cold temperatures [ambient temperature below 0 °C (32 °F)], even when the hydraulic oil temperature monitor
displays the correct temperature, carry out additional Step 15 to warm up all the hydraulic equipment.
15. Turn fuel control dial (4) to the full speed (MAX) position, repeat
Steps 6 to 9 for 3 to 5 minutes, then check again that the
hydraulic oil temperature monitor is displaying the correct
temperature.
If it is not displaying the correct temperature, repeat Steps 6 to
9 for 3 to 5 minutes until hydraulic oil temperature monitor (7)
displays the correct temperature.
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For both normal temperatures and cold temperatures, carry out the following operation.
16. Check that fuel control dial (4) is at a point midway between low
idle (MIN) and full speed (MAX).
If it is not at the midway position, set it to the midway position
and run the engine at a mid-range speed before operating.
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2) E mode
For operations with emphasis on fuel economy
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.
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Normal Stopping
NOTICE
If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Do not stop the
engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed
to allow it to cool down gradually, and then stop it.
REMARK
It is possible to install a turbo timer on this machine.
Please consult your Komatsu distributor regarding installation of a
turbo timer.
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Stopping in Emergencies
NOTICE
Use this engine emergency stop switch to stop the engine in emergencies.
Normally, keep the engine emergency stop switch at the OFF (normal operation) position.
Press engine emergency stop switch (S) installed inside the cab
and set it to ON (emergency stop) position (a).
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1. Turn the head of engine emergency stop switch (S) to the right.
The switch will spring out slightly and will be reset to OFF
(normal operation) position (b). When doing this, check set
indicator lamp (L) is off.
REMARK
When the engine is stopped with the emergency stop switch, there is no need to bleed air from the fuel circuit.
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NOTICE
This engine emergency stop switch is mainly for use when carrying out inspection and maintenance inside the engine room. It
will prevent anyone from starting the engine by mistake from the operator's seat. Normally, keep the engine emergency stop
switch at the OFF (normal operation) position.
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1. Turn the head of engine emergency stop switch (S) to the right.
The switch will spring out slightly and will be reset to OFF
(normal operation) position (b). When doing this, check set
indicator lamp (L) is off.
REMARK
When the engine is stopped with the emergency stop switch, there is no need to bleed air from the fuel circuit.
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NOTICE
This engine emergency stop switch is for use when carrying out inspection and maintenance under the machine or around the
undercarriage. It will prevent anyone from starting the engine by mistake from the operator's seat.
Normally, cancel the engine emergency stop switch.
Pull rope (R) of the engine emergency stop switch installed at the
left or right side of the machine.
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REMARK
When the engine is stopped with the emergency stop switch, there is no need to bleed air from the fuel circuit.
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NOTICE
Use fuel shut-off lever to prevent fuel from flowing out from the fuel tank in emergencies, such as fire.
When stopping the engine in normal circumstances, follow the procedure in "Normal Stopping (PAGE 3-223)".
When starting the engine again after it has stopped, move fuel
shut-off lever (1) up again and check that fuel shut-off lever (1)
does not move.
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When starting the engine again after it has stopped, move fuel
shut-off lever (1) up again and check that fuel shut-off lever (1)
does not move.
REMARK
Fuel shut-off valve (3) is installed to the bottom of the fuel tank
to reduce the spread of fire if any fire should occur. This makes
it possible to prevent the fuel inside the fuel tank from flowing
out even if the fuel piping hoses are burned.
Fuel shut-off valve (3) is connected to fuel shut-off lever (1) and
fuel shut-off cable (2) and interlocks with them.
When having stopped the engine, operating the fuel shut-off
valve, bleed air from the fuel circuit before starting the engine
again.
REMARK
Even if fuel shut-off lever (1) or the fuel shut-off cable are operated,
the engine will stop, but engine emergency stop lamp (4) does not
light up.
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MACHINE OPERATION
WARNING
Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear
(if the sprocket is at the front), the machine moves in the opposite direction from the operation of the travel levers or travel
pedals (front and rear travel is reversed, left and right steering is reversed).
Before starting the machine off, check that the area around the machine is safe, and sound the horn.
Do not allow anyone to enter the area around the machine.
Clear any obstacles from the travel path.
There is a blind spot at the rear of the machine, so be particularly careful when traveling in reverse.
If the travel levers or travel pedals is operated when the auto deceleration is being actuated, the engine speed will suddenly
rise, so be careful when operating.
When traveling, check that the alarm sounds normally.
2. Turn fuel control dial (3) towards the full speed (MAX) position
to increase the engine speed.
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2. Operate the right and left travel levers (5), or the right or left travel pedals (6) as follows:
When sprocket (A) is situated at the rear of the machine;
Start the machine either by pushing lever (5) forward slowly or
by stepping on the front part of pedal (6) slowly.
3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu
distributor for repair.
REMARK
In cold temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation.
In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil and
mud from the undercarriage.
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2. Operate the right and left travel levers (5), or the right or left travel pedals (6) as follows:
When sprocket (A) is at the rear of the machine:
Slowly pull the levers (5) backward, or slowly depress the rear
part of the pedals (6) to move the machine backward.
3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu
distributor for repair.
REMARK
In cold temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation.
In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil and
mud from the undercarriage.
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Stopping Machine
Avoid stopping suddenly. Give yourself ample room when stopping.
1. Put the left and right travel levers (1) in the neutral position,
then stop the machine.
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Steering
WARNING
Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket).
When the sprocket is at the front, the direction of operation of the travel levers or control pedals is the opposite from the direction
of movement of the machine.
REMARK
When turning to the right, operate the left travel lever in the same
way.
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REMARK
When turning to the right, operate the right travel lever in the same
way.
REMARK
When using counter-rotation to turn right, pull the right travel lever
back and push the left travel lever forward.
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SWINGING
WARNING
The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe.
If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will
suddenly rise, operate the levers carefully.
1. Before starting the swing operation, turn swing lock switch (1)
OFF and check that swing lock monitor (2) has gone out.
(a): ON position
(b): OFF position
3. When not using the swing, turn swing lock switch (1) ON.
Check that swing lock monitor (2) lights up.
(a): ON position
(b): OFF position
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Swing control
Move the left work equipment control lever to the left or right to
swing the upper structure.
Boom control
Move the right work equipment control lever to the front or rear
to operate the boom.
Bucket control
Move the right work equipment control lever to the left or right to
operate the bucket.
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When the work equipment control lever is moved to the N position while the machine is idle, the engine speed lowers
to the medium revolution in approximately. 4 seconds owing to the function of the auto deceleration device, even
if the fuel control dial is in the FULL position.
REMARK
This machine is equipped with an accumulator in the operation circuit. For this reason, the work equipment can be
lowered to the ground, even when the engine is not running. To do that, turn the engine starting switch to the ON
position and the lock lever to the FREE position, and then operate the work equipment control lever to lower, but all
these steps need to be done within 15 seconds after the engine stops.
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WORKING MODE
Working Mode
The mode selector switch can be used to switch the mode to match operating conditions and purpose, thereby
enabling work to be performed efficiently.
Make effective use of each mode as follows.
Use the working mode selector switch to set to the most efficient
working mode for the type of job.
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PROHIBITED OPERATIONS
WARNING
If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate
the control lever.
If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful
when operating.
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.
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.
When carrying out operations in such a place, pile soil under the
front of the track or take other measures to stabilize the machine
before starting the operation.
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.
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.
Traveling
Traveling over boulders, tree stumps, or other obstacles will cause
a big shock to the chassis (and in particular to the tracks), and this
will cause damage to the machine. For this reason, always remove
any obstacles or travel around them, or take other steps to avoid
traveling over such obstacles as far as possible.
If there is no way to avoid traveling over an obstacle, reduce the
travel speed, keep the work equipment close to the ground, and try
to travel so that the center of the track passes over the obstacle.
NOTICE
When driving the machine out of water, if the angle of the machine exceeds
15 degrees, the rear of the upper structure will go under water, and water
will be thrown up by the cooling fan. This may cause the fan to break.
Be extremely careful when driving the machine out of water.
Do not drive the machine in water deeper than the center of carrier
roller (1).
Supply grease to the parts which have been under water for a long
time until the used grease is projected out of the bearings (around
the bucket pin, in particular).
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TRAVELING ON SLOPES
WARNING
Turning or operating the work equipment when working on slopes may
cause the machine to lose it balance and turn over, so avoid such
operations.
It is particularly dangerous to swing downhill when the bucket is loaded.
If such operations have to be performed, pile soil to make a platform (A)
on the slope so the machine is kept horizontal during operation.
Do not work on a slope covered with the steel plates. Even with slight
slopes there is a hazard that the machine may slip.
Do not travel up or down steep slopes. There is a danger that the
machine may turn over.
When traveling, raise the bucket approximately. 100 to 150 cm (3 to 11
in) from the ground.
Do not travel downhill in reverse.
Never turn on slopes or travel across slopes.
Always go down to a flat place to perform these operations. It may be
longer, but it will ensure safety.
Always operate or travel in such a way that it is possible to stop safely
at any time if the machine slips or becomes unstable.
When traveling uphill, if the shoes slip or it is impossible to travel uphill
using only the force of the tracks, do not use the pulling force of the arm
to help the machine travel uphill. There is danger that the machine may
turn over.
1. When traveling down steep hills, use the fuel control lever and
travel lever to keep the travel speed low.
When traveling down a slope with a grade of more than 15
degrees, set the machine to the posture shown in the diagram
on the right and reduce the engine speed when traveling.
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.
Traveling Downhill
Put the travel lever in the neutral position. This will cause the brake to be automatically applied.
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NOTICE
When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground. (Never push
with the teeth). The angle between the boom and arm should be 90 degrees to 110 degrees.
The same applies when using the inverted bucket.
When only one side is stuck in mud, use the bucket to raise the
track, then lay boards or logs and drive the machine out.
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RECOMMENDED APPLICATIONS
In addition to the following, it is possible to further increase the range of applications by using various attachments.
Backhoe Work
A backhoe is suitable for excavating areas that are lower than the
machine.
When the condition of the machine is as shown in the diagram on
the right (angle between [bucket cylinder and link] and [arm
cylinder and arm] is (A)), the maximum excavation force is
obtained from the pushing force of each cylinder.
When excavating, use this angle effectively to optimize your
working efficiency.
The range for excavating with the arm is from (B) away from the
machine to (C) towards the machine.
There may be some differences depending on the excavation
depth, but try to stay within the above range rather than operating
the cylinder to the end of its stroke.
(A): 90 degrees
(B): 45 degrees
(C): 30 degrees
Loading Work
In places where the swing angle is small, set the dump truck in a
place where it is easy for the operator to see. This makes
operations more efficient.
When loading, it is easier to carry out the loading operation from
the rear of the dump truck body, and more of the soil can be loaded
to the sides.
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BUCKET REPLACEMENT
WARNING
When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury.
When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment.
When the bucket is removed, place it in a stable condition.
If pins are hit with a strong force, there is a hazard that the pin may fly out and injure people in the surrounding area. Make sure
that there is no one in the surrounding area before starting the operation.
When removing the pins, do not stand behind the bucket. In addition, be extremely careful not to put your foot under the bucket
while standing at the side for the work.
When removing or inserting pins, be extremely careful not to get your fingers caught.
Never insert your fingers into the pin holes when aligning the holes.
Stop the machine on a firm and flat surface and do the work. When performing joint work, appoint a lead and follow
that person's instructions and signals.
Replacement
1. Place the bucket in contact with a flat surface.
NOTICE
When removing the bucket, set the bucket cylinder facing down as shown
in the diagram in the right to prevent the front link from jumping up under
the weight of the bucket cylinder.
REMARK
When removing the pins, place the bucket so that it is in light
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.
2. Remove pin (1) from the arm mounting hole and pin (2) from
the link mounting hole, then remove the bucket.
With pin (1), remove grease piping cover (3) and grease
piping (4), then remove cover (5) and use the removal tap in
the side face of the pin to remove the pin (both left and
right).
With pin (2), remove stopper (6) on the inside of the link,
then use the removal tap on the outside face of the pin to
remove the pin (both left and right).
NOTICE
After removing the pins, make sure that mud or sand does not get on them.
Dust seals are fitted at both ends of the bushings, be careful not to damage
them.
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3. Align the arm with hole (A), align the link with hole (B), then coat
pins (1) and (2) with grease, and install them.
REMARK
Carry out the installation in the opposite order from removal.
When installing the bucket, the O-ring is easily damaged, so fit
the O-ring into the groove in bushing (a) at the bucket end (E).
After inserting the pin, move the O-ring to the specified groove
(b).
After fitting the stopper bolts, stoppers, collars, and covers to
each pin, carry out greasing of the pin.
(C): Arm (D): Seal (E): Bucket
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PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
When stopping the machine, select flat hard ground and avoid
dangerous places. If it is unavoidably necessary to park the machine on
a slope, insert blocks underneath the track shoes. As an additional
safety measure, thrust the bucket into the ground.
If the control lever is touched by accident, the work equipment or the
machine may move suddenly, and this may lead to a serious accident.
Before leaving the operator's compartment, always set the lock lever
securely to LOCK position.
1. Put the left and right travel levers (1) in the neutral position,
then stop the machine.
2. Turn fuel control dial (2) to lower the engine speed to low idle.
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.
LOCKING
Always lock the following places.
(1) Door of operator's cab
Always remember to close the window.
(2) Door of cab base room
(3) Fuel tank filler port
(4) Hydraulic tank filler port
(5) Power container front door (5 places)
(6) Power container rear door (3 places)
(7) Battery case cover (2 places)
(8) Air conditioner box cover
(9) Breather cover on top of fuel tank
REMARK
Apart from the cab door, the other locks use the starting switch key.
3 - 255
.
TRANSPORTATION OPERATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
Select the method of transportation to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)".
Note that the weight and dimensions given in SPECIFICATIONS may differ according to the type of shoe or arm,
or other attachments.
TRANSPORTATION POSTURE
The machine can be divided into the following units for transportation: upper structure, operator's cab, crawler
frame, center frame, work equipment, and counterweight. When transporting the machine, please consult your
Komatsu distributor.
3 - 256
.
NOTICE
Please use Komatsu genuine SUPERCOOLANT (AF-NAC) for the COOLANT. As a basic rule, we do not recommend the use of any
COOLANT other than SUPERCOOLANT (AF-NAC).
3 - 257
.
Battery
WARNING
The battery generates flammable gas. 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 a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the
battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte
Temperature 20°C 0°C -10°C -20°C
Charging (68°F) (32°F) (14°F) (-4°F)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
The battery's capacity drastically drops at a low ambient temperature. Therefore either cover it with a moisture-
free sheet, or remove it from the machine after the day's work, keep in a warm place and install again next day.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the
day's work to prevent diluted electrolyte in the battery from freezing during the night.
3 - 258
.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, observe the following precautions.
Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to
prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
Park the machine on hard, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.
After operation in water or mud, remove water from undercarriage as described below to extend undercarriage
service life.
1. Swing 90 degrees with engine at low idle and bring the work
equipment to the side of the track.
2. Jack up the machine until the track is raised slightly from the
ground. Rotate the track under no load. Repeat this procedure
on both the left and right sides.
3 - 259
.
NOTICE
To protect the hydraulic cylinder piston rod while in storage, keep the work
equipment in the posture shown at right.
(This prevents rust from developing on the piston rod)
When putting the machine in storage for a long time (more than one month), do as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level
ground and cover the machine with canvas.
Completely fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
Lock each control lever and pedal with the lock lever and pedal lock.
To prevent rust, fill with COOLANT to give a density of at least 30% for the engine coolant.
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat
moving parts. At the same time, also charge the battery.
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month to
lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In addition,
check the refrigerant level twice a year.
3 - 260
.
AFTER STORAGE
NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after
starting the engine. If there is water in the oil, change all the oil.
Bleed the air from the work equipment cylinder circuits. For details of the method of bleeding the air, see
"BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE 4-49)".
3 - 261
.
The arm speed will drop momentarily when the bucket teeth are
more or less horizontal.0
When starting or stopping the swing, noise will be emitted from the brake valve.
When traveling at low speed down steep slopes, a noise is emitted from the travel motor.
3 - 262
.
NOTICE
The maximum towing capacity for this machine is 1,079 kN (110,027 kg).
Always carry out towing operations within the maximum towing capacity.
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 on the
right.
Place pieces of wood between wire ropes and body to prevent
damage to ropes and body.
When towing a machine, travel at a speed of less than 1 km/h for
a distance of only a few meters to a place that is suitable for
carrying out repairs.
This is for use only in emergencies.
3 - 263
.
DISCHARGED BATTERY
WARNING
It is dangerous to charge a battery when installed on a machine. Make
sure that it is removed before charging.
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do anything that will
cause sparks.
Battery electrolyte is dilute sulfuric acid, and it will attack your clothes
and skin. If it gets on your clothes or on your skin, immediately wash it
off with a large amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
When handling batteries, always wear safety glasses and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger
that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
3 - 264
.
Battery Charges
When charging the battery, if the battery is not handled correctly,
there is a hazard that the battery may explode. Always follow the
instructions of "DISCHARGED BATTERY (PAGE 3-264)" and the
instruction manual accompanying the charger, and do as follows.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the correct voltage is not selected, the charger
may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the negative (-)
charger clip of the charger to the negative (-) terminal of the
battery. Be sure to attach the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set
it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause
an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level
to the UPPER LEVEL line.
3 - 265
.
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, always wear safety
glasses.
Be careful not to let the normal machine and problem machine contact
each other. This prevents sparks from generating near the battery which
could ignite the hydrogen gas given off by the battery. If hydrogen gas
explodes, it could cause serious injury.
Be careful not to make a mistake when connecting a booster cable. In
the last connection (to the upper structure frame), a spark will be
caused, connect the cable to a spot as far away from the battery as
possible. (Avoid the work equipment, however, because it is not a good
conductor)
When removing the booster cable, exercise good care so that the
booster cable clips may not contact each other, or they contact the
chassis.
NOTICE
The starting system for this machine uses 24V. For the normal machine, also use a 24V battery.
The size of the booster cable and clip should be suitable for the battry size.
The battery of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the lock levers and parking brake levers of both machine are in the LOCK position.
Check that each lever is in the NEUTRAL position.
NOTICE
When a booster cable is connected to a battery of this machine, the battery
has to be one on the inside of the machine (i.e. the one on the hydraulic
tank side).
3 - 266
.
3 - 267
.
WARNING
Always check that the lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed.
Check also that all the control levers are in the neutral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, try again after 2 minutes or so.
3 - 268
.
OTHER TROUBLE
Electrical System
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 269
.
Chassis
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 270
.
Engine
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 271
.
3 - 272
.
3 - 273
.
REMARK
If no point of contact telephone number has been registered, no
telephone number is displayed.
It is necessary to register the telephone number, please ask your
Komatsu distributor to carry out the registration.
3 - 274
.
4-1
.
MAINTENANCE INFORMATION
Do not perform any inspection and maintenance operation that is not found in this manual.
Fuel Strainer
If your machine is equipped with a fuel strainer, do not remove it while fueling.
Welding Instructions
Cut off power. Wait for approximately. one minute after turning off the engine starting switch key, and then
disconnect the negative (-) terminal of the battery.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
4-2
.
Dusty Jobsite
When working at dusty worksites, do as follows:
Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let
the fins become clogged.
Replace the fuel filter more frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Clean the fuel tank breather and make sure that dust is not accumulated.
Clean in the hydraulic tank breather and make sure the dust is not accumulated.
Clean and replace the hydraulic tank element more frequently.
When checking and replacing the oil or filters, move the machine to a place where there is no dust and take care
to prevent dust from entering the system.
4-3
.
OUTLINE OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil.
When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the
old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the
small amount of oil remaining in the piping mixes with the new oil.)
Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed
in the table below.
Item Type
Engine oil pan Engine oil EO15W40DH (Komatsu genuine parts)
PTO case
Swing machinery case Powertrain oil TO30 (Komatsu genuine parts)
Final drive case
Hydraulic oil system Powertrain oil TO10 (Komatsu genuine parts)
Radiator Supercoolant (AF-NAC) (Komatsu genuine parts) (density: 30% or above)
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil at the specified interval.
Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil.
4-4
.
FUEL
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified for the temperature in the Operation and Maintenance Manual.
If the fuel is used at temperatures lower than the specified temperature (particularly at temperatures below -15
°C (5°F), the fuel will solidify.
If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and this may
result in problems such as a drop in output.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an
electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low
viscosity fuel with low lubricating ability is used, the durability may drop markedly.
4-5
.
GREASE
Grease is used to prevent seizure and noises at the joints.
This construction equipment is used under heavy-duty conditions. Always use the recommended grease and
follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance
Manual.
Grease fittings not included in the maintenance section are grease fittings for overhaul, so they do not need
grease.
If any part becomes stiff after being used for long time, add grease.
Always wipe off all of the old grease that is pushed out when greasing.
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.
Do not mix hyper- white grease as it hardens.
4-6
.
Others
Measurements are made of items such as the ratio of water in the oil, density of the COOLANT, ratio of fuel in
the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
OIL SAMPLING
Sampling interval
250 hours: Engine
500 hours: Other components
4-7
.
FILTERS
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are found,
contact your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Use of Komatsu genuine filter elements is strongly recommended.
4-8
.
WEAR PARTS
Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the
machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.
Replacement
Item Part No. Part Name Q'ty
frequency
Engine oil filter 600-211-1340 Cartridge 4
Fuel pre-filter 600-319-3440 Cartridge 2
Every 500 hours
Pilot filter 21T-60-31410 Element 1
service
Drain filter 113-60-23160 Cartridge 2
Pump drain filter 21T-60-31450 Cartridge 3
Fuel main filter 600-319-3520 Cartridge 2
Fuel tank breather (*) 421-60-35170 Element 1
Hydraulic tank breather 421-60-35170 Element 2 Every 1000 hours
209-60-77532 Element 3 service
Hydraulic oil filter
(07000-B5180) (O-ring) (3)
Swing motor cooling 20Y-62-51691 Element 2
filter element 706-76-71390 (O-ring) (2)
Every 4000 hours
Accumulator of oil cooler line 21T-64-33840 Accumulator 6
service
Air cleaner 600-185-6100 Element Ass'y 2
21N-62-31221 Element 4
(07000-12055) (O-ring) (4)
Line filter
(07000-12070) (O-ring) (4)
(07001-02070) (O-ring) (4)
21T-70-34580 Tooth (XS type) 5
(21T-70-34461) (Pin) (5) When required
Bucket 427-70-13611 Side shroud 4
21N-939-3330 Pin 8
(209-939-7110) (Shim) (16)
(209-939-7120) (Shim) (8)
Air conditioner RECIRC filter 208-979-7620 Element 2
Air conditioner fresh air filter 17M-911-3530 Element 2
(*): For machines equipped with a service center (option) or fuel quick charger (option), the fuel tank breather
element forms one unit with the cap (Part number: 21T-04-31170).
For details of the loading specification machine, see "WEAR PARTS (PAGE 7-21)".
4-9
.
* If these fuels are used, there is danger that serious trouble may occur because of early deterioration of the engine
oil or early wear of the internal parts of the engine. If the local situation makes it necessary to use these fuels,
always remember the following.
1) Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil
based on the result.
2) Always be aware that oil change interval is extremely shorter than standard.
3) Be sure to carry out periodic engine inspection by distributor's expert since change interval of periodic
replacement parts and overhaul interval are also shorter.
4 - 10
.
4 - 11
.
Swing Final
Engine machinery Hydraulic
PTO drive Fuel Cooling
Oil case oil Grease
case case tank system
pan system
Front Rear (each)
Specified Liter 128.0 36.0 30.0 30.0 85.0 2400.0 3400.0 180.0 200.0
capacity US gal 33.82 9.51 7.93 7.93 22.46 634.08 898.28 47.56 52.84
A
Refill Liter 120.0 36.0 30.0 30.0 85.0 1300.0 - - 200.0
capacity US gal 31.70 9.51 7.93 7.93 22.46 343.46 - - 52.84
Specified Liter 130.0 36.7 31.2 31.0 85.0 2401.1 3409.6 182.5 201.4
capacity US gal 34.35 9.70 8.24 8.19 22.46 634.37 900.82 48.22 53.21
B
Refill Liter 122.0 36.7 31.2 31.0 85.0 1301.1 - - 201.4
capacity US gal 32.23 9.70 8.24 8.19 22.46 343.75 - - 53.21
A: Only machines not equipped with service center
B: Only machines equipped with service center
NOTICE
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an
electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low
viscosity fuel with low lubricating ability is used, the durability may drop markedly.
Note 1: HTHS ( High-Temperature High-Shear Viscosity 150°C (302°F)), specified by ASTM D4741 must be equal
to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: If the machine is equipped with an auto-greasing system, see "HANDLING GREASE PUMP AND GREASE
GUN (PAGE 3-157)".
Note 5: COOLANT
1) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
SUPERCOOLANT (AF-NAC) is strongly recommended wherever available.
2) For details of the density of the COOLANT, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-27)".
COOLANT is supplied already diluted. In this case, add the pre-diluted fluid to keep the tank full. (Never dilute the
COOLANT with ordinary water.)
3) To maintain the anticorrosion properties of COOLANT, always keep the density of COOLANT between 30% and
64%.
4 - 12
.
4 - 13
.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was
replaced.
13/16 -16UN 27 103 10.5 75.9 84 to 132 8.5 to 13.5 61.5 to 97.6
1 -14UNS 32 157 16.0 115.7 128 to 186 13.0 to 19.0 94.0 to 137.4
1·3/16 -12UN 36 216 22.0 159.1 177 to 245 18.0 to 25.0 130.2 to 180.8
1·7/16 -12UN-2B 41 215 22.0 158.4 176 to 234 18.0 to 24.0 130.2 to 173.6
4 - 14
.
4 - 15
.
4 - 16
.
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
CLEAN PTO LUBRICATION OIL FILTER STRAINER 4- 19
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
CHANGE OIL IN SWING MACHINERY CASE 4- 19
CHANGE OIL IN PTO CASE 4- 19
CHANGE OIL IN FINAL DRIVE CASE 4- 19
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)
CHECK WELDED STRUCTURE 4- 19
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 20
CLEAN INSIDE OF COOLING SYSTEM 4- 27
CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 30
CHECK AND ADJUST TRACK TENSION 4- 31
REPLACE BUCKET TEETH (XS) 4- 36
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 4- 42
CHECK AND MAINTENANCE AIR CONDITIONER 4- 43
CLEAN LINE FILTER, REMOVE DIRT 4- 45
CHECK SEALS AROUND ENGINE COOLING 4- 46
BLEEDING AIR FROM FULE CIRCUIT 4- 47
BLEEDING AIR FROM HYDRAULIC SYSTEM 4- 49
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4- 61
4 - 17
.
4 - 18
.
MAINTENANCE PROCEDURE
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
Carry out the following maintenance only after the first 100 hours of operation on new machines.
Clean strainer of PTO lubricating oil filter
For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE.
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
Carry out the following maintenance only after the first 500 hours of operation on new machines.
Change oil in swing machinery case
Change oil in PTO case
Change oil in final drive case
For details of the method of replacing or maintaining, see EVERY 1000 HOURS and EVERY 2000 HOURS
SERVICE.
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)
Carry out the following maintenance only after the first 4000 hours of operation on new machines.
Check welded structure
For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE.
4 - 19
.
WHEN REQUIRED
NOTICE
Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel light up. If the element is
cleaned frequently before the air cleaner clogging monitor light up, the air cleaner will not be able to display its performance
fully, and the cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element.
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will enter the engine and cause damage to
the engine. Always stop the engine before carrying out these operations.
Checking
If air cleaner clogging monitor (1) of the monitor panel flashes,
clean the air cleaner element.
4 - 20
.
REMARK
Use dust indicator (4) as a guideline for the cleaning interval for the
air cleaner element.
If tip (D) of the yellow piston enters the red range (7.5 kPa) (E), it
is time to clean the element.
There are 2 dust indicators (4): they can be seen when the door
of the power container at the front of the machine is opened.
4 - 21
.
NOTICE
Before and after cleaning the element, do not leave or keep it in direct sunlight.
NOTICE
Never remove the inner element (6). It will allow dirt to enter and cause
failure of the engine.
Do not use a screwdriver or other tool.
2. Hold the outer element (5), rock it lightly up and down and to
the left and right, and rotate the element to the left and right to
pull it out.
3. When the outer element (5) has been removed, check that the
inner element has not come out of position and is not at an
angle. If is at an angle, insert your hand and push it in straight.
4. After removing the outer element (5), cover the inner element
(6) with a clean cloth or tape to prevent dirt or dust from
entering.
5. Wipe off or brush off the dirt stuck to cover (3) and the inside of
the air cleaner body (7).
NOTICE
When cleaning the element, do not hit or beat it against anything.
6. Direct dry compressed air (less than 0.2 MPa {2.1 kg/cm2, 30.0
PSI}) to the outer element from inside along its folds, then
direct it from outside along its folds and again from inside.
1) Replace the outer element which has been cleaned 6
times repeatedly or used throughout a year. Replace the
inner element at the same time.
2) Replace both inner and outer elements when the air cleaner clogging monitor (1) lights up soon after
installing the cleaned outer element even though it has not been cleaned 6 times.
4 - 22
.
NOTICE
Do not use an element whose folds or gasket or seal are damaged.
If the element or O-ring are cleaned and used again after they have been used for more than one year, it will cause problems.
Do not use them again.
9. Check that there is no dirt or oil stuck to the seal portion of the new element or cleaned element. Wipe off any
dirt or oil.
10. Push the outer element in straight with your hand when installing it to the air cleaner body.
If the outer element is held and rocked lightly up and down and to the left and right while pushing it in, the outer
element can be inserted easily.
NOTICE
Be sure to install the air cleaner element facing in the correct direction.
Install so that the bottom of the air cleaner element cylinder (face where no
hole is drilled) (B), (C) is at cover (3) end. If the direction of installation is
mistaken, there is danger that it will cause breakage of the air cleaner
element or serious damage to the engine.
4 - 23
.
NOTICE
When inserting the element, if the rubber at the tip is swollen or the outer
element is not pushed in straight, and cover (3) is assembled by force to
hook (2), there is danger that the hook and air cleaner body may be
damaged, so be careful when assembling.
12. After cleaning and replacing the element, press the reset
button of dust indicator (4). The yellow piston will return to its
original place.
4 - 24
.
Replacing Element
1. Remove hooks (2) of each air cleaner (6 places), then remove
cover (3).
2. Hold the outer element (5), rock it lightly up and down and to
the left and right, and rotate the element to the left and right to
pull it out.
Do not remove inner element (6) when doing this.
3. When the outer element (5) has been removed, check that the
inner element has not come out of position and is not at an
angle. If is at an angle, insert your hand and push it in straight.
4. Wipe off or brush off the dirt stuck to cover (3) and the inside of
the air cleaner body (7).
NOTICE
The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the
same time.
If the inner element is not installed properly and the outer element and cover are installed, there is danger that the outer element
will be damaged.
The seal portion on imitation parts lacks precision, and allows the entry of dust, which leads to damage of the engine. Do not
use such imitation parts.
5. Remove inner element (6), then quickly install the new inner element.
Insert the inner element securely so that it does not move.
6. Push the new outer element (5) in straight with your hand when installing it to the air cleaner body.
If the element is held and rocked lightly up and down and to the left and right while pushing it in, the element can
be inserted easily.
4 - 25
.
NOTICE
Be sure to install the air cleaner element facing in the correct direction.
Install so that the bottom of the air cleaner element cylinder (face where no
hole is drilled) (B), (C) is at cover (3) end. If the direction of installation is
mistaken, there is danger that it will cause breakage of the air cleaner
element or serious damage to the engine.
NOTICE
When inserting the element, if the rubber at the tip is swollen or the outer
element is not pushed in straight, and cover (3) is assembled by force to
hook (2), there is danger that the hook and air cleaner body may be
damaged, so be careful when assembling.
4 - 26
.
Stop the machine on level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant according to the table below.
Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours. As a
basic rule, we do not recommend the use of any COOLANT other than SUPERCOOLANT (AF-NAC). If you use
another COOLANT, it may cause serious problems, such as corrosion of the engine and aluminum parts of the
cooling system.
To maintain the anticorrosion properties of COOLANT, always keep the density of COOLANT between 30% and
64%.
When selecting COOLANT, investigate the lowest temperature in the past and decide the density for the COOLANT
from the COOLANT density table below. When actually deciding the density for the COOLANT, set it approximately
10°C (18°F) below lowest temperature. The density must be over 30% at least. If the density of obtained COOLANT
is higher than the necessary density for lowest temperature, dilute it with adequate distilled water, and then fill it into
the tank.
If there is any unclear point, please contact your Komatsu distributor.
4 - 27
.
WARNING
COOLANT is toxic. When open the drain valve, be careful not to get coolant on you.
If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
REMARK
For details of the method of draining and adding coolant to machines equipped with a service center (option), see
"Method of Draining, Adding Coolant (PAGE 6-23)".
COOLANT is already diluted with distilled water, so it is not flammable. (For details of the distilled water, see
"COOLANT AND WATER FOR DILUTION (PAGE 4-5)"). Check the density with a COOLANT tester.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to use when filling with coolant.
4 - 28
.
10. Remove cover (8) at the top of the power container, then turn
radiator cap (9) slowly to remove it.
11. Fill with city water through the water filler port of radiator cap (9)
until water overflows from the radiator.
12. Add city water to the reservoir tank through the water filler of reservoir tank cap (5) to fill up to the FULL line.
13. Close radiator cap (9). Leave reservoir tank cap (5) off.
14. Start the engine and run for approximately. 10 minutes at low idle.
15. Stop the engine and open drain valves (6) and (7) to drain the water.
16. After draining the water, use a detergent to wash the tank. For details of the method of washing, see the method
of use provided with the detergent.
17. Close drain valves (6) and (7).
18. Remove drain plug (10) under reservoir tank (2) to drain all detergent liquid in reservoir tank (2).
19. Install drain plug (10).
20. Add coolant through the water filler port up to the mouth of the port. For details of the COOLANT density, see
"COOLANT DENSITY TABLE".
21. Close radiator cap (9).
22. Add coolant to the reservoir tank (2) up to the H level.
23. To bleed the air from the coolant, run the engine at low idle for 5 minutes, then run for a further 5 minutes at high
idle. When doing this, leave cap (5) of the reservoir tank removed.
24. Close cap (5) of the reservoir tank.
4 - 29
.
Tightening
1. Tighten first to a tightening torque of 686 ± 69 Nm (70 ± 7 kgm, 506.3 ± 50.6 lbft), then check that the nut and
shoe are in tight contact with the link mating surface.
2. After checking, further tighten to the tightening torque of 150 degrees ± 10 degrees.
4 - 30
.
The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil, so
inspect the track tension frequently in order to maintain the standard tension.
Stop the machine on firm, horizontal ground when carrying out the inspection and maintenance.
Checking
1. Run the engine at low idle, then move the machine forward for
a distance equal to the track length on ground, and slowly stop
the machine.
2. Place wooden bar (3) on top of the track from No. 2 roller (1) to
No. 3 roller (2).
3. Measure the maximum deflection between bottom surface of
the wooden bar and top surface of the track shoe.
Deflection "a" should be 10 to 30 mm (0.4 to 1.2 in).
4 - 31
.
Adjustment
If the track tension is not at the standard value, adjust it in the following manner.
2. Set the fuel control dial to a point midway between low idle
(MIN) and full speed (MAX), and run the engine at a mid-range
speed.
4 - 32
.
NOTICE
Do not carry out this forward / reverse operation on a slippery surface
(such as steel plates).
Even if protrusion (A) of the hydraulic cushion cylinder plunger (3) is
within the specified value, HIC circuit charge pressure may be low, so
carry out Step 3 correctly.
REMARK
If the end of hydraulic cushion cylinder plunger (3) is located
around center of inspection hole of crawler frame, the protrusion is
almost within the specified value.
4 - 33
.
WARNING
There is danger of plug (1) flying out under the high internal pressure of the grease. Never loosen plug (1) more than 1 turn.
Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1).
If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor.
NOTICE
Before pumping in grease, check that protrusion (A) of hydraulic cushion
cylinder (2) plunger (3) is within the specified value on both the left and
right. Check the protrusion of the hydraulic cushion cylinder again after
pumping in grease. If it is not within the correct range, loosen the plug (1)
one turn to release the grease and adjust. If that protrusion of hydraulic
cushion cylinder cannot be within the specified value, please ask your
Komatsu distributor to carry out adjustment.
CAUTION
Do not simply pump grease into the grease cylinder to adjust the track tension without adjusting with the hydraulic cushion
cylinder. An excessive load will be brought to bear on the undercarriage, and there is danger of damage to the undercarriage.
4 - 34
.
REMARK
The protrusion of grease cylinder plunger is set between 30 to 45
mm at shipment from factory.
WARNING
Always use the following procedure. It is extremely dangerous to use any other procedure to release the grease.
If the track link does not become loose, ask your Komatsu distributor to carry out repairs.
4 - 35
.
Replace teeth
Replace the bucket teeth 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 equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position.
There is a hazard that fragments will fly during the replacement work, so always wear protective equipment like safety glasses
and gloves.
If the tooth pins cannot be removed in this procedure, for safety's sake, be sure to ask your Komatsu distributor for the
replacement.
NOTICE
When replacing the bucket teeth, be sure to replace all of them at once. Should all the bucket teeth be not replaced at a time,
the bucket will likely be deformed.
In order to prevent a tooth from slipping off, also replace the pins with new ones when replacing the teeth.
1. Set the bucket with the bottom of the bucket on block (3) so that
pin (1) can be removed, then stop the engine.
4 - 36
.
6. Clean the mounting surface, fit new tooth (2) to the adapter,
insert new pin (1), then tighten 90 degrees clockwise with the
socket wrench to lock the pin and complete the installation.
REMARK
Turn the tooth upside down and rotate the installation positions.
Such practice allows wear on the teeth to develop evenly, the
lifetime to be extended, and the replacement frequency to be
reduced.
NOTICE
In order to prevent a tooth from a slip-off, insert a pin from the inside (in the
direction indicated with an arrow) for tooth (4) and (5) on both edges of the
bucket.
4 - 37
.
WARNING
It is dangerous if the work equipment moves by mistake when the wear cap are being replaced.
Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position.
There is a hazard that fragments will fly during the replacement work, so always wear protective equipment like safety glasses
and gloves.
If the tooth pins cannot be removed in this procedure, for safety's sake, be sure to ask your Komatsu distributor for the
replacement.
1. Set the bucket with the bottom of the bucket on block (3) so that
pin (1) can be removed, then stop the engine.
4 - 38
.
6. Take off wear cap (6) after removing tooth (2), and then clean
the cap mounting face and mounting hole (7).
7. Install new wear cap (6) by fitting it in adapter mounting hole
(7).
8. Clean the tooth mounting face, fit tooth (2) in the adapter, insert
pin (1) and then lock the pin by turning a socket wrench
clockwise to 90 degrees to install the tooth.
NOTICE
In order to prevent a tooth from a slip-off, insert a pin from the inside (in the
direction indicated with an arrow) for tooth (4) and (5) on both edges of the
bucket.
4 - 39
.
WARNING
If the slinging loop is caught on any part of the bucket (tooth, lip shroud,
wear cap, adapter, side shroud), remove it. If digging operations are
carried out without removing the slinging loop, there is danger that the
slinging loop may break and pieces may fly around.
It is dangerous if the machine begins to move while the slinging loop is
being removed. Hold the work equipment in a stable posture, stop the
engine and make sure to put the lock lever to the LOCK position.
When removing the slinging loop, wear protective tools like safety
glasses. There is a danger that metal pieces of the broken slinging loop
are sent flying around.
Never hit the tooth against a boulder for the purpose of removing the
slinging loop.
There is the danger that the broken slinging loop will be sent flying
around in pieces, causing a personal injury.
NOTICE
If the machine is operated without the slinging loop being removed, the following problems will possibly arise.
When the work equipment is pulled back, the slinging loop at the tip of the tooth interferes with the boom.
The cracks caused when the slinging loop breaks may extend to various parts of the main body (tooth, lip shroud, wear cap,
adapter, side shroud) and damage the main body of the parts.
The slinging loop may break during the digging work and its broken pieces are mixed in the sand, earth and stones to be
loaded.
Be sure to remove the slinging loop in the following steps.
1. Put block (3) under the bottom of the bucket and stop the
engine.
4 - 40
.
NOTICE
When cutting the slinging loop at each part of the bucket, cut at the
following cutting positions (A) to (A) or (B) to (B), according to the shape
of the loop.
In addition, when doing this, be careful that the cutting surface does not
cut into the main body of the bucket parts.
4 - 41
.
4 - 42
.
WARNING
If the refrigerant used in the air conditioner 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.
Do not bring any flame close to any point where the refrigerant gas is leaking.
Run the engine at full speed and operate the air conditioner at
maximum airflow, then check the flow of refrigerant gas (R134a) in
the refrigerant circuit through the sight glass (2) (inspection
window) of the receiver (1).
REMARK
When bubbles appear, there is lack of refrigerant gas, so have
your service shop add refrigerant immediately.
Total volume of refrigerant: 950 g (2.095 lb)/each unit [total for
2 units: 1,900 g (4.19 lb)]
If it is not replaced but refilled, refill it until bubbles disappear in
sight glass, and add 200 g more (as a reserve).
(If it is insufficient, refill will be needed in a short time.)
4 - 43
.
4 - 44
.
After assembling the line filter again, bleed the air. For details, see "BLEEDING AIR FROM HYDRAULIC SYSTEM
(PAGE 4-49)".
4 - 45
.
F: Area around radiator at front of engine R: Area around oil cooler at rear of engine
(right side of machine) (left side of machine)
Check from inside the engine room that there is no gap caused by deformation or peeling of the sponge sealing
material around the engine cooling.
NOTICE
If there is a change to high water temperature when operating the engine over several days when there is no change in the ambient
temperature, a possible reason is peeling of the sealing material around the engine cooling or creation of a gap caused by
deformation. If nothing is done to correct this problem, there will be deterioration in the heat balance and increase in noise. Take
action as soon as possible. When doing this, please contact your Komatsu distributor.
4 - 46
.
WARNING
After the engine is stopped, all parts are at high temperature, so there is danger of suffering burns. Wait for all parts to cool
down before starting the operation.
When the air breather of the supply pump or the air bleed plug at the top of the fuel filter head is opened, the residual pressure
may spray out fuel. Loosen the plug and breather slowly before opening.
NOTICE
The common rail type fuel injection system used on this machine consists of higher precision parts than the conventional
injection pump and nozzle. This means that problems are more likely to occur when dust or dirt gets in. If any dirt should be stuck
to any part of the fuel system, use fuel to wash it off completely.
1. Loosen air bleed plug (1) at the top of the fuel filter head. (One
place each on left and right sides of engine)
2. Remove locknut (3) from priming pump lever (4), then pump
priming pump lever (4) 50 to 100 times and check that fuel
comes out from air bleed plug (1). When fuel comes out,
tighten plug (1). (One place each on left and right sides of
engine)
4 - 47
.
3. Open air breather (6) at the side of supply pump (5), then pump
priming pump lever (4) approximately. 5 to 15 times. With this
operation, fuel will start to overflow from air breather (6). When
no more bubbles come out with the fuel, tighten air breather (6).
(One place each on left and right sides of engine)
Tightening torque: 4.9 to 6.9 Nm {0.5 to 0.7 kgm, 3.6 to 5.1 lbft}
5. If the air bleed operation does not go well, return to Step 3 and start again.
6. For normal starting, turn the key in the starting switch to the START position. The engine will start.
When starting the engine, do not run the starting motor for more than 20 seconds continuously.
If it is necessary to keep it continuously running, provide a more than 2 minute interval between trials.
4 - 48
.
NOTICE
Bleed air from the hydraulic system in the following steps.
1. Hydraulic pump (those for work equipment and hydraulically driven cooling fan)
2. Hydraulic motor (those for swing and travel)
3. Swing holding brake circuit
4. Front idler cushion circuit
5. Pilot piping (those for pilot selector valve circuit and main valve PPC circuit)
6. Work equipment circuit\T
Run the engine at less than 1000 rpm and operate the cylinders slowly.
Do not use sudden stopping and starting to raise the cylinder pressure; do not operate the cylinder to the end of its stroke.
Be particularly careful to operate slowly for the first operation of each cylinder (return stroke).
When a cylinder is operated for the first time, there is a large amount of air inside the circuit, so the work equipment will not
move for more than 10 seconds. Do not operate the lever fully to make the work equipment move.
Fill the pumps and other equipment with clean oil of NAS 7 class or above, and use a clean container for the oil.
4 - 49
.
Name of pump
Hydraulic pump P1, P2
Swing pump PF
1. Loosen air bleed plug (1) and check that oil oozes out from the air bleeder.
2. If oil does not ooze out, remove the drain hose from the pump case and fill the pump case with hydraulic oil
through drain port (2).
Oil will come out from the drain hose when it is removed, so fix the mouthpiece of the hose at a position higher
than the oil level in the hydraulic tank.
3. After completing the air bleed operation, tighten air bleed plug (1), then install the drain hose.
NOTICE
If the drain hose is installed first, oil will spurt out from plug (1) hole. If the pump is operated without filling the pump case with
hydraulic oil, abnormal heat will be generated and this may cause premature damage to the pump.
4 - 50
.
Travel Motor
1. Start the engine and run it at low idle.
2. Loosen air bleed plug (2) of the travel motor 1 to 2 turns.
Loosen the air bleed plugs for both the motors.
3. When no more milky white oil comes out from air bleed plug (2)
of the travel motor, tighten the plug.
This completes the air bleed operation.
Swing Motor
1. Start the engine and run it at low idle.
2. Repeat swinging and braking operation 5 to 6 times.
4 - 51
.
CAUTION
If air is not bled at all, or bled but insufficiently, there is a possibility that the machine starts up with the parking brake still applied.
Therefore, be sure to bleed air from the circuit.
REMARK
A bleeder is provided for both the front and rear swing motors.
REMARK
Air bleeding through swing operation can be achieved with fine operation of the swing hydraulic switch to the extent
that it turns on (ON lights up).
4 - 52
.
4 - 53
.
4. Remove plug (6) on the bottom of the check valve block (5) and
loosen air bleeding plug (7) on the side approximately by 1
turn.
5. Start the engine and run it at low idle for 2 to 3 minutes.
Tightening torque
Air bleeding plug (3),(7),(1): 58.8 to 88.3 Nm (6 to 9 kgm , 43.4
to 65.1 lbft)
Plug (6): 3.9 to 6.9 Nm (0.4 to 0.7 kgm , 2.9 to 5.1 lbft)
REMARK
Always tighten plug (1) last.
Close all the drain valve and air bleed valves completely.
After bleeding the air, check and adjust the track tension. For details, see "CHECK AND ADJUST TRACK
TENSION (PAGE 4-31)".
4 - 54
.
After the removal and installation of the pilot selector valve and the disconnection and connection of the pilot selector
valve circuit, bleed air from the pilot selector valve circuit in the following manner.
REMARK
If air is not bled at all or bled but insufficiently, there is a possibility that the working speed lowers in complex
operation, so be sure to follow the air bleeding instructions.
4 - 55
.
REMARK
Air bleeding can be achieved with fine operation of each lever to
the extent that each hydraulic switch turns on (ON lights up).
4 - 56
.
REMARK
If air is not bled at all or bled but insufficiently, there is a possibility of a time lag while in the operation or an abnormal
noise from the PPC lever, so be sure to follow the air bleeding instructions.
REMARK
Air bleeding can be achieved with fine operation of each lever to the extent that each hydraulic switch turns on (ON
lights up).
4 - 57
.
4 - 58
.
4 - 59
.
2. Keep the engine running at low idle and operate each cylinder
from a point 100 mm (3.9 in) before the end of the stroke to
extend the cylinder slowly (take at least 10 seconds) to the end
of its stroke, then hold the work equipment control lever at the
full stroke for 3 minutes.
3. Keep the engine running at high idle and operate each cylinder
from a point 100 mm (3.9 in) before the end of the stroke to
extend the cylinder slowly (take at least 10 seconds) to the end
of its stroke, then hold the work equipment control lever at the
full stroke for 1 minute.
The operation in Steps 1 to 3 will bleed the air from inside the cylinder.
If the engine is run at high speed from the beginning, and the cylinder is operated to the end of its stroke, the air
inside the cylinder may damage the piston packing.
4 - 60
.
4 - 61
.
4 - 62
.
4 - 63
.
Prepare a handle.
4 - 64
.
WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is danger of explosion, 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 a large amount of water and consult a
doctor.
NOTICE
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte
level is too high, it may leak and cause damage to the paint surface or corrode other parts.
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from
freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
Open cover (1) at the rear of the cab base on the left side of the
machine. The batteries are installed at portion (A).
4 - 65
.
REMARK
If distilled water is added to above the UPPER LEVEL (U.L.) line,
use a syringe to lower the level to the UPPER LEVEL (U.L.) line.
Neutralize the removed fluid with baking soda (sodium
bicarbonate), then flush it away with a large amount of water or
consult your Komatsu distributor or battery maker.
4 - 66
.
REMARK
If water is added to above the bottom tip of the sleeve, use a pipette
to remove electrolyte. Neutralize the removed electrolyte with
sodium bicarbonate, then flush it away with a large amount of
water. If necessary, contact your Komatsu distributor or your
battery maker.
4 - 67
.
4 - 68
.
Checking
1. Remove cover (3) at the front of the engine. When 6 bolts (4)
are removed, the cover will come off.
A: Alternator pulley
B: Drive pulley
4 - 69
.
Adjustment
1. Loosen bolts and nuts (5) to (8) in number order and move the
alternator.
If nut (9) is tightened, the belt tension is increased; if nut (9)
is loosened, the belt tension is reduced.
2. After adjusting the belt, tighten bolts and nuts (5) to (8) in the
reverse order (from (8) to (5)). Finally, tighten nut (9).
Check each pulley for damage, wear of the V-groove, and
wear of the V-belt. Check in particular that the V-belt does
not contact the bottom of the V-groove.
If the V-belt is elongated and there is no more allowance for
adjustment, or if the belt is cracked or cut, replace the belt.
When the V-belt has been replaced, adjust again after
running for 1 hour.
3. Install cover (3).
4 - 70
.
WARNING
When carrying out inspection and adjustment, set to the engine stop
position as follows. Press engine stop switch (1) installed at the front of
the power container on the left side of the machine, or engine stop switch
(2) installed at the rear of the power container on the right side of the
machine. For details of the method of operating engine stop switches (1)
and (2), see "Stopping in Emergencies (PAGE 3-224)".
Checking
1. Remove cover (3). When bolts (4) and (5) are removed, the
cover will come off.
4 - 71
.
Adjustment
1. Loosen bolts and nuts (6) to (9) in number order and move the
compressor.
If nut (10) is tightened, the belt tension is increased; if nut
(10) is loosened, the belt tension is reduced.
2. After adjusting the belt, tighten bolts and nuts (6) to (9) in the
reverse order (from (9) to (6)). Finally, tighten nut (10).
Check each pulley for damage, wear of the V-groove, and
wear of the V-belt. In particular, check if the V-belt is in
contact with the bottom of the V-groove.
If the belt is elongated and there is no more margin for
adjustment, or if it is cut or cracked, replace the belt.
3. Install cover (3).
4 - 72
.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
NOTICE
After the machine has been operated for 6 months, even if it has not been operated for 500 hours, change the engine oil and
replace the filter cartridge after 6 months.
REMARK
For details of the method of draining and adding engine oil to machines equipped with a service center (option), see
"Method of Draining, Adding Engine Oil (PAGE 6-17)".
4 - 73
.
2. Loosen drain valve (P1) in the oil pan. The oil will go down to
drain valve (P2).
3. Open drain valve (P2) slowly through the drain control hole in the engine under cover and drain the oil. When
doing this, be careful not to get oil over yourself.
When draining the oil, use the drain hose in the toolbox, install it to oil drain valve (2), and be careful not to
let the drained oil spray out when draining it.
(Drain hose part number: 07287-02618)
After draining the oil, close drain valves (P1) and (P2).
Press drain valves (P1) and (P2), then turn them to open or close them, and carry out the drain operation.
4. If the filter cartridge is removed immediately after the engine is stopped, oil will spill out. Wait for at least 10
minutes after stopping the engine before starting the replacement operation.
5. Using a filter wrench, turn filter cartridge (1) counterclockwise
to remove it.
6. Clean the filter holder, fill the new filter cartridge with clean oil, coat the thread and packing surface of the new
filter cartridge with clean oil (or coat it thinly with grease), then install it to the filter holder.
REMARK
Check that there is no old packing stuck to the filter holder. If there is any old packing stuck to the filter, it will cause
leakage of oil.
7. When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten a
further 3/4 to 1 turn.
4 - 74
.
8. After replacing the filter cartridge, add oil through oil filler port
(F) so that the oil level is between the H and L marks on dipstick
(G).
9. Run the engine for a short time at low idle, then stop the
engine. Check that the oil level gauge is between the H and L
marks. For details, see "Check Oil Level in Engine Oil Pan,
Add Oil (PAGE 3-182)".
10. After checking, install oil filler port (F).
4 - 75
.
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER
FINS
WARNING
If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure
water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.
NOTICE
When using compressed air, to prevent damage to the fins, keep a distance from the fins. In particular, with the aftercooler, if
compressed air is directed at an angle of 45 degrees, the nozzle should be at least 300 mm (11.8 in) from the fins.
Avoid directing compressed air at the core perpendicularly as far as possible. If the fins are damaged, it will cause leakage of
water or overheating.
On dusty job sites, carry out this inspection every day, regardless of the maintenance interval.
On the menu for reversing a rotation direction of the hydraulically driven cooling fan in the user menu, the rotation
direction of the fan can be reversed both on the radiator side and on the oil cooler side.
By blowing out wind from the fan toward the outside of the machine, the fan can serve as a cleaner to get rid of dead
insects and dust stuck to the dustproof nets. For more details, see "Fan Reverse Mode (PAGE 3-77)".
4 - 76
.
1. Remove bolts (2) of top of duct door (1) on the radiator side
(right side of machine) and oil cooler side (left side of machine),
then open door (1).
Each door is installed with 6 bolts (2).
A: Oil cooler
B: Radiator
4 - 77
.
3. Use compressed air to blow off the dirt, mud, or leaves clogging the radiator fins, oil cooler fins, fuel cooler fins,
and aftercooler fins. At the same time, clean door (1) also.
Steam or water may be used instead of compressed air.However, when carrying out powerful steam cleaning
(high-pressure machine wash) of the heat exchange equipment (radiator, oil cooler, aftercooler, fuel cooler),
maintain sufficient distance from the machine when carrying out the operation. If steam cleaning (high-pressure
machine wash) is carried out at close range, there is danger that the internal fins of the heat exchange
equipment may be deformed, and this will cause early clogging and breakage.
4. Check the rubber hoses, and if there are any cracked or brittle hoses, replace them. Check also for loose hose
clamps.
For details of the tightening torque for the aftercooler hose clamps, see "CHECK FOR LOOSE CLAMPS OF
AFTERCOOLER HOSE (PAGE 4-99)".
4 - 78
.
NOTICE
As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there
will be an abnormal noise from the air conditioner unit.
4 - 79
.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner
unit.
4 - 80
.
1. Using the filter wrench, turn the filter cartridge to the left and
remove it.
2. Fill the new filter cartridge with hydraulic oil, coat the packing
surface with oil, then install it.
When installing it, bring the packing surface into contact with
the seal surface of the filter holder, then tighten a further 1/2 to
3/4 turns.
NOTICE
When replacing the cartridge, check if there are any iron particles or
foreign material stuck to the bottom of the filter case or the outside of the
cartridge. If such materials are stuck to the cartridge of filter case, there is
probably an abnormality in the hydraulic circuit.
Please ask your Komatsu distributor to carry out inspection and repair.
REMARK
The drain filter cartridge consists of the following 2 cartridges.
(1): Hydraulic pump drain filter cartridges (3 places)
(2): Swing, travel motor drain filter cartridges (2 places)
1. Using the filter wrench, turn the filter cartridge to the left and
remove it.
2. Fill the new filter cartridge with hydraulic oil, coat the packing
surface with oil, then install it.
When installing it, bring the packing surface into contact with
the seal surface of the filter holder, then tighten a further 1/2 to
3/4 turns.
NOTICE
When replacing the cartridge, check if there are any iron particles or
foreign material stuck to the bottom of the filter case or the outside of the
cartridge. If such materials are stuck to the cartridge of filter case, there is
probably an abnormality in the hydraulic circuit.
Please ask your Komatsu distributor to carry out inspection and repair.
REMARK
The drain filter cartridge consists of the following 2 cartridges.
(1): Hydraulic pump drain filter cartridges (3 places)
(2): Swing, travel motor drain filter cartridges (2 places)
4 - 81
.
1. Using the filter wrench, turn filter cartridge (1) to the left and
remove it.
2. Fill the new filter cartridge with hydraulic oil, coat the packing
surface with oil, then install. When installing, bring the packing
surface into contact with the seal surface of the filter holder,
then tighten a further 1/2 to 3/4 turns.
NOTICE
When replacing the cartridge, check if there are any iron particles or
foreign material stuck to the bottom of the filter case or the outside of the
cartridge. If such materials are stuck to the cartridge of filter case, there is
probably an abnormality in the hydraulic circuit.
Please ask your Komatsu distributor to carry out inspection and repair.
4 - 82
.
REMARK
For details of the method of draining and adding swing machinery case oil to machines equipped with a service
center (option), see "Method of Draining, Adding Swing Machinery Case Oil (Front) (PAGE 6-18), Method of
Draining, Adding Swing Machinery Case Oil (Rear) (PAGE 6-19)".
4 - 83
.
NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection
pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is
stuck to any part, use fuel to wash it off completely.
1. Pull fuel shut-off lever (A) installed to the front of the main pump
inside the pump room, and close the fuel supply circuit from the
fuel tank.
4 - 84
.
7. Clean the filter holder, fill the new filter cartridge with clean fuel, coat the packing surface thinly with oil, then
install to the filter holder.
NOTICE
When adding fuel, do not remove cap (B). Always add fuel from the 8
small holes (A) on the dirty side.
After adding fuel, remove cap (B) and install the fuel filter.
Always fill with clean fuel. Be careful not to let any dirt or dust get into
the fuel. In particular, center portion is the clean side, so do not remove
cap (B) when adding fuel. Be careful not to let dirt or dust get into center
portion on the clean side.
8. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
9. Install drain hose (4).
10. Check that the drain plug at the bottom of the water separator cup is tightened securely.
Tightening torque: 0.2 to 0.45 Nm (0.02 to 0.046 kgm, 0.1 to 0.3 lbft)
4 - 85
.
11. Replace the filter cartridge and bleed the air. When replacing the fuel main filter cartridge (every 1000 hours),
see "REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-87)".
12. Push down fuel shut-off lever (A) installed to the front of the
main pump inside the pump room so that it can supply fuel.
13. Start the engine, check that there is no leakage of fuel from the filter seal surface or water separator mounting
surface, then run for approximately. 10 minutes at low idle.
4 - 86
.
NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection
pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is
stuck to any part, use fuel to wash it off completely.
1. Pull fuel shut-off lever (A) installed to the front of the main pump
inside the pump room, and close the fuel supply circuit from the
fuel tank.
4 - 87
.
2. Set the container to catch the fuel under the filter cartridge.
3. Using a filter wrench, turn filter cartridge (2) counterclockwise
to remove it.
4. Clean the filter holder, coat the packing surface of the new filter
cartridge thinly with oil, then install the filter cartridge to the filter
holder.
NOTICE
Do not fill the fuel filter cartridge with fuel.
Remove cap (B) and install the fuel filter.
5. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
4 - 88
.
6. After replacing filter cartridge (2), loosen air bleed plug (3) of
the filter cartridge, then push down fuel shut-off lever (A) to
open the fuel supply circuit from the fuel tank. The procedure
for opening the circuit is the reverse of the order for closing the
circuit.
7. After completing the replacement of fuel filter cartridge (2),
bleed the air.
8. Add fuel to the fuel tank until full (to FULL mark on the fuel
gauge).
9. After replacing filter cartridge (2), loosen air bleed plug (3).
10. Remove locknut (5) of priming pump lever (4), pump priming
pump lever (4) to discharge bubbles from air bleed plug (3).
Check that only fuel comes out.
11. Tighten air bleed plug (3).
Tightening torque: 4.9 to 6.9 Nm {0.5 to 0.7 kgm, 3.6 to 5.1 lbft}
12. Push in the priming pump lever (4), then tighten locknut (5) to
hold priming pump lever (4) in position.
Use a genuine Komatsu part for the fuel filter cartridge. After replacing the filter cartridge, run the engine, and check
for any fuel leakage from the filter seal surface.
4 - 89
.
NOTICE
For machines equipped with the optional service center, see "REPLACE
FUEL TANK BREATHER ELEMENT (PAGE 6-27)".
For machines equipped with the optional fuel quick charge, see
"REPLACE FUEL TANK BREATHER ELEMENT (PAGE 6-7)".
4 - 90
.
REMARK
For details of the method of draining and adding swing machinery case oil to machines equipped with a service
center (option), see "Method of Draining, Adding Swing Machinery Case Oil (Front) (PAGE 6-18), Method of
Draining, Adding Swing Machinery Case Oil (Rear) (PAGE 6-19)".
Pull out dipstick (G), then add the specified amount of engine oil through dipstick guide (F).
4 - 91
.
4 - 92
.
NOTICE
Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the
oil level.
REMARK
For details of the method of draining and adding PTO case oil to machines equipped with a service center (option),
see "Method of Draining, Adding PTO Case Oil (PAGE 6-20)".
1. Loosen drain plugs (P) and (Q) under the PTO casing to drain
oil and tighten them after draining.
When draining the oil, use the drain hose in the toolbox,
install it to oil drain valve (2), and be careful not to let the
drained oil spray out when draining it.
(Drain hose part number: 07287-02618)
4 - 93
.
2. Add a specified amount of power train oil from oil filler port (F).
4 - 94
.
2. Take out strainer (2), remove all dirt stuck to strainer (2), then
wash it in flushing oil.
If the strainer (2) is broken, replace it with a new part.
3. Install strainer (2), then install filter case (1).
NOTICE
Set strainer (2) with the hole facing in the direction of the arrow when
installing.
4 - 95
.
1. Remove the cap from oil filler port (F) on top of the fuel tank to
release the internal pressure.
2. Loosen 4 bolts, then remove cover (1).
When doing this, the cover may fly out under the force of spring
(2), hold the cover down when removing the bolts.
3. After removing spring (2), valve (3) and strainer (5), take out
element (4).
If there are any metal particles or foreign material at the
bottom of strainer (5) or the element case, please contact
your Komatsu distributor.
4. Clean the removed parts in flushing oil.
5. Install the new element in the place where old element (4) was
installed.
6. Set valve (3), strainer (5) and spring (2) on top of the element.
7. Set cover (1) in position, push it down by hand, and install the
cover with the mounting bolts.
NOTICE
After replacing the element, install cover (1) and tighten mounting bolts
(6) of cover (1) to the specified tightening torque.
Tightening torque: 98 to 123 Nm {10.0 to 12.5 kgm, 72.3 to 90.4 lbft}
Do not use mounting bolts (6) more than 4 times. For safety reasons,
replace the bolts with new bolts. Even if they have not been used 4
times, if the thread is damaged, replace with new bolts.
REMARK
Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank.
11. Check for oil leakage and wipe off any spilled oil.
4 - 96
.
4 - 97
.
4 - 98
.
Position of clamps
F: Area around radiator at front of engine R: Area around oil cooler at rear of engine
(right side of machine) (left side of machine)
Tightening torques
Clamp (1): 24.0 to 25.0 Nm (2.45 to 2.55 kgm, 17.7 to 18.4 lbft)
Clamp (2): 10.0 to 11.0 Nm (1.02 to 1.12 kgm, 7.4 to 8.1 lbft)
Clamp (3): 24.0 to 25.0 Nm (2.45 to 2.55 kgm, 17.7 to 18.4 lbft)
Clamp (4): 10.0 to 11.0 Nm (1.02 to 1.12 kgm, 7.4 to 8.1 lbft)
4 - 99
.
NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release
the remaining pressure inside the hydraulic circuit if a failure occurs on the machine.
4 - 100
.
It is easy to use a color check to check visibly for cracks in welded structures. After the first 4000 hour inspection,
check the revolving frame, center frame, boom, and arm every 1000 hours.
In particular, carry out a color check on the important check points (marked with a circle).
The procedure for the color check is as follows.
1. Prepare the materials needed for the color check. (Detergent, penetrating agent, developing solution)
2. Spray with detergent and wash to remove all the dirt and oil from the place to be checked.
3. After washing, dry the area, then spray with penetrating agent and leave for 5 to 20 minutes.
4. Spray with detergent, then clean the surface with a cloth.
5. Clean the surface again, then spray with developing solution.
6. Leave for 15 to 20 minutes, then check visually for cracks.
If there are any cracks, color can be seen.
7. If there are any cracks, carry out the repair procedure to repair.
Revolving frame
(A): Important check points
4 - 101
.
Center frame
(A): Important check points
Boom
(A): Important check points
4 - 102
.
Arm
(A): Important check points
4 - 103
.
NOTICE
With a rope ladder (1), even if there is no visual wear or damage, the rope
will deteriorate with time, so there is danger of a drop in the strength of the
rope. For this reason, always replace the rope every two years.
4 - 104
.
REMARK
Destination for grease pumped in through each grease fitting
(1): Ladder cylinder head pin (5)
(2): Ladder link pin (front) (6)
(3): Ladder link pin (rear) (7)
(4): Ladder cylinder bottom pin (8)
4 - 105
.
NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
2. Turn the starting switch to the ON position (B), then set the lock
lever to the FREE position (F).
3. After carrying out Step 2, operate each work equipment control
lever and attachment control pedal fully to the front, rear, right,
and left 2 to 3 times within 15 seconds to release the internal
pressure in the hydraulic circuit.
4 - 106
.
5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to
eliminate the internal pressure in the hydraulic circuit.
6. Place a container under the filter element (7) to catch the oil.
Front side swing motor filter element
4 - 107
.
7. Move the valve lever installed to front side swing motor filter
element to position (S). (2 places, before and after the filter)
4 - 108
.
14. After replacing the front side swing motor filter element, return
the valve lever to position (O). (2 places, before and after the
filter)
4 - 109
.
Oil refill capacity: 85 liter (22.4 US gal) (each, left and right)
Prepare a handle.
4 - 110
.
Prepare a scale.
4 - 111
.
4 - 112
.
Check visually and touch by hand to check that there are no loose mounting bolts for high-pressure piping clamps
(1) to (34) in the diagram and no hardening of any rubber parts. If any problem is found, the part must be replaced.
In this case, please ask your Komatsu distributor to carry out the replacement.
NOTICE
If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or
breakage occurring due to vibration and wear at the connections of high-pressure piping. Always check that the proper
high-pressure piping clamps are correctly installed.
4 - 113
.
4 - 114
.
NOTICE
Even if the operating time has not reached 4000 hours, if the machine has been used for 2 years, replace the accumulator.
1. Remove the cap from oil filler port (F) at the top of the hydraulic
tank to release the internal pressure.
2. Hold union (1) in position and turn accumulator body (2) (width
across flats: 27 mm (1.1 in)) to remove each accumulator (x 6),
then replace the accumulators with new parts.
4 - 115
.
REMARK
For details of the method of draining and adding hydraulic oil to machines equipped with a service center (option),
see "Method of Draining, Adding Hydraulic Oil (PAGE 6-22)".
4 - 116
.
5. Loosen drain plugs (P1) and (P2) at the suction tube portion at
the rear bottom left of the machine, and drain the oil.
The outlet port for draining the oil is drain tube (A). When
draining the oil, be careful not to get oil over yourself.
After draining the oil, tighten drain plugs (P1) and (P2).
6. Remove cover (1) at the top of the hydraulic tank, pull the top
of rod (3) up from the top and take out spring (2) and strainer
(4).
7. Remove any dirt stuck to strainer (4), then wash it in flushing
oil. If strainer (4) is damaged, replace it with a new part.
8. When installing, insert strainer (4) in protruding portion (5)
inside the tank, and assemble.
4 - 117
.
9. Add the specified amount of hydraulic oil through oil filler port
(F). When adding the oil, watch sight gauge (G), and check
that the oil is at the correct level.
NOTICE
Do not add oil above the correct level. This may damage the hydraulic
circuit and cause the oil to spurt out.
4 - 118
.
REMARK
When the working posture is (2) in the diagram on the right, the
correct oil level on the gauge label is range (a2) at normal
temperature and (b2) at high temperature.
10. After changing the hydraulic oil and cleaning the filter element strainer, bleed the air from inside the circuit.
4 - 119
.
4 - 120
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit PC2000-8
Operating weight
kg (lb) 200,000 (441,000)
[including 1 operator, 80 kg (176 lb)]
Bucket capacity m3 (cu.yd) 12.0 (15.7)
Name of engine - Komatsu SAA12V140E-3 diezel engine
Engine horsepower (GROSS) kW (HP) / rpm 728 (976) / 1,800
A Overall length mm (ft in) 17,030 (55'10")
B Overall height mm (ft in) 7,135 (23'5")
C Overall width (*1) mm (ft in) 7,490 (24'7")
D Track width mm (ft in) 810 (2'8")
E Height of cab mm (ft in) 7,030 (23'1")
F Tail swing radius mm (ft in) 5,980 (19'8")
G Length of track mm (ft in) 7,445 (24'5")
H Tumbler center distance mm (ft in) 5,780 (18'12")
Min. ground distance mm (ft in) 825 (2'7")
Travel speed km/h (MPH) 2.7 (1.7)
Swing speed rpm 4.8
(*1): Equipped with a hydraulic ladder
NOTICE
For details of the loading specification machine, see "SPECIFICATION (PAGE 7-19)".
5-2
.
SPECIFICATIONS SPECIFICATIONS
NOTICE
For details of the loading specification machine, see "SPECIFICATION (PAGE 7-19)".
5-3
.
.
6-1
.
6-2
.
ATTACHMENT GUIDE
WARNING
Please read the instruction manual for the attachment and the sections of this manual related to attachments and options.
When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor
before installing.
Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety, but
may also have an adverse effect on the operation of the machine and the life of the equipment.
Any injuries, accidents, or damage resulting from the use of unauthorized attachments or options will not be the responsibility
of Komatsu.
Select the combination of boom, arm, and bucket from the combinations shown in the table below.
z: General operations
{: Light operations
: Heavy-duty operations (crusher specification)
FRONT GUARD
This is a device to protect the operator. Be sure to use the part in a jobsite where there is a danger of flying fragments
like crushed stone pieces.
6-3
.
X Position for stowing fuel quick charge lever (4) Lock plate
Y Position for adding fuel to fuel quick charge lever (5) Lever operating handle
(1) Fuel quick charge lever (6) Stopper
(2) Fuel filler port (Wiggins ZN2B) *1 (7) Proximity switch
(3) Fuel filler cap (8) Shock absorber
*1: When adding oil through this oil filler port, an oil filler pump unit and nozzle (Wiggins- made ZZ9A1 or an
equivalent) are required.
6-4
.
NOTICE
After completing the fuel filling operation, check that the lock bar of the lever operating handle is securely held in position by
the lock plate. If it is not held in position and the machine is operated, there is danger that the vibration of the machine may
cause the fuel quick charge lever to fly out and break.
If the fuel quick charge lever has come down and is at the fuel charge position, the proximity switch is actuated and the PPC
(proportional pressure control pilot) lock is applied, so it will be impossible to swing or drive the machine, or operate the work
equipment. When the fuel quick charge lever is stowed, the lock is released
If the fuel quick charge lever is stowed, but the lock is not released, see "ACTION WHEN MACHINE DOES NOT MOVE BECAUSE
OF FAILURE IN PROXIMITY SWITCH (PAGE 6-8)".
Prepare for an oil filler pump unit and nozzle (Wiggins- made ZZ9A1 or an equivalent).
1. Raise lever operating handle (1) slightly with your right hand
and push the hatched portion of lock plate (2) in the diagram on
the right with the palm of your left hand or the tip of your finger.
2. When lock bar (3) comes out of the oblong hole in the lock plate
(2), release lock plate (2) and move your left hand to hold lever
operating handle (1), then use both hands to lower lever
operating handle (1).
6-5
.
6. Pull lever operating handle (1) slightly (towards the rear of the
machine) and push up the bent part of stopper (4) to the lock
release position (the slightly upward bent position shown in the
diagram on the right).
7. Push lever operating handle (1) slightly towards the front of the
machine, then push up until lock bar (3) enters the oblong hole
in lock plate (2).
Do not touch lock plate (2) when doing this.
8. Push lock plate (2) slightly to check that lock bar (3) is securely
held in the oblong hole of lock plate (2).
6-6
.
1. Open breather cover (1) on top of the fuel tank. (This is locked
or unlocked using the starting switch key)
2. Remove the cap (with element) of breather (2) and replace with
a new part.
3. Close breather cover (1).
6-7
.
3. Lower the fuel quick charge to the fuel filling position. For
details, see "PROCEDURE FOR OPERATING FUEL
CHARGE (PAGE 6-5)".
4. Cover the front of proximity switch (1) installed to the fuel quick
charge lever with steel plate (2) and check that actuation
display lamp (L) lights up.
If actuation display lamp (L) lights up
Proximity switch (1) is working properly, so adjust as follows
to make actuating display lamp (L) light up correctly.
If actuation display lamp (L) does not light up
There is probably a problem with proximity switch (1), so
change the combination of the connectors. For details, see
"ACTION WHEN PROXIMITY SWITCH HAS FAILED
(PAGE 6-10)".
6-8
.
6. Adjust with adjustment nuts (4) and (5) of proximity switch (1)
so that clearance (C) between proximity switch (1) and plate
(3) installed to fuel quick charge lever is 4-6 mm (0.16 - 0.23 in).
6-9
.
WARNING
When the following procedure is used to disconnect the connector of the proximity switch and then connect it to another
connector, the PPC (proportional pressure control pilot) lock will always remain released (the machine can move), regardless of
the operation of the fuel quick charge.
This change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place.
After moving the machine, contact your Komatsu distributor immediately and ask for repairs to be carried out.
The machine can move, so this is extremely dangerous. For this reason, do not use the fuel quick charge to fill with fuel when
the combination of the connectors has been changed.
If it is necessary to add fuel before the repair of the proximity switch has been completed, add fuel through the fuel filler at the
top of the fuel tank. For details, see "Check Fuel Level, Add Fuel (PAGE 3-184)".
NOTICE
When the changing the combination of the connectors, be careful not to mistake the connections.
1. Turn the starting switch to the OFF position, remove the key, wait for approximately. 1 minute, then remove the
negative (-) terminal of the battery.
2. On the right side inside the cab base room there is the
connector for the PPC (proportional pressure control pilot)
lock.
3. Remove bolts (1) and (2) of the clamp holding the connector
cable.
6 - 10
.
6. Connect the negative (-) terminal of the battery, start the engine, then check that it is possible to operate the
travel, swing, and work equipment.
If they cannot be operated, there is probably some other cause, so ask your Komatsu distributor to carry out
investigation.
6 - 11
.
6 - 12
.
NOTICE
If the service arm is at the lowered position, the proximity switch does not detect that the service arm is stowed, so PPC (hydraulic
pilot) lock is applied and it is impossible to swing or drive the machine, or operate the work equipment.
If this happens, the ladder warning lamp inside the operator's cab lights up in red. For details, see "Ladder Warning Lamp
(PAGE 3-109)".
This lock is cancelled when the service arm is stowed.
If the lock is not cancelled even when the service arm is stowed, see "ACTION WHEN MACHINE DOES NOT MOVE BECAUSE
OF FAILURE IN PROXIMITY SWITCH (PAGE 6-28)".
Before operating the service arm, check that there is no obstacle in the service arm operating range. There is danger that if the
service arm hits any obstacle the service arm or the obstacle may break.
6 - 13
.
REMARK
When the lock lever is in the FREE position, the service arm
cannot be operated.
It is possible to lower the service arm even when the engine is
running. In this case, the movement of the service arm will be
faster than when the engine is stopped.
When the service arm is lowered with the engine running, the
service arm will automatically be reset to the stowing position if
the service arm is not lowered to the range where the automatic
stowing mechanism is actuated (when the height of the tip of the
service arm from the ground is less than 2.0 m (6 ft 7 in)).
6 - 14
.
3. Check that the service center switch (2) is at the FREE position
(F).
4. Keep pulling service arm RAISE switch (4)(Green) at the rear
of the swing circle until the service arm reaches the automatic
stop position.
5. After stowing the service arm, return service center switch (2)
to the LOCK position (L).
NOTICE
When not using the service arm, always set the service to the switch to the
LOCK position.
If it is at the FREE position, it becomes possible to operate the service arm
from the ground, so there is danger that this may lead to a serious accident.
REMARK
The service arm RAISE operation is possible only when the engine
is started.
If the engine is stopped for a long time, the service arm may go
down under its own weight, but this does not indicate any
abnormality.
If the angle that the service arm has gone down under its own
weight is less than 15 degrees, the service arm will
automatically be reset to the stowing position, so check that
there is no one near the service arm before starting the engine.
If the angle that the service arm has gone down under its own
weight is more than 15 degrees, the service arm is not
automatically reset to the stowing position, so pull the service
arm RAISE switch to stow the service arm.
6 - 15
.
REMARK
Komatsu does not handle force-feed pumps, but if a force-feed pump coupler is needed, please consult your
Komatsu distributor.
NOTICE
Before connecting the service center coupler and force-feed pump coupler, wipe off all dirt, oil, or other foreign material from
each coupler to prevent dirt from getting inside the piping.
When adding lubricant and coolant, always check that the amount is the specified amount.
6 - 16
.
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
3. Set drain valve (P) of the oil pan to open position (O).
4. Remove the cap of engine oil coupler (1) and connect the
force-feed pump coupler securely.
5. Start to drain and add engine oil.
6. After completing the draining and adding of engine oil, remove
the force-feed pump coupler.
7. Install the cap to the coupler.
8. Set drain valve (P) of the oil pan to shut position (S).
9. Run the engine for a short time at low idle, then stop the
engine. Check that the oil level gauge (G) is between the H
and L marks. For details, see "Check Oil Level in Engine Oil
Pan, Add Oil (PAGE 3-182)".
10. After checking, install oil filler port (F).
6 - 17
.
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
3. Remove the cap of swing machinery oil (front) coupler (1) and
connect the force-feed pump coupler securely.
4. Start to drain and add swing machinery oil.
5. After completing the draining and adding of swing machinery
oil, remove the force-feed pump coupler.
6. Install the cap to the coupler.
7. Set drain valve (P) under the machine to shut position (S).
8. Check that the oil level is between the H and L marks on the dipstick. For details, see "CHECK OIL LEVEL IN
SWING MACHINERY CASE, ADD OIL (PAGE 4-83)".
9. After checking, insert dipstick (G).
10. Immediately after changing the oil, oil level is variable.
So operate for one hour, then check the oil level again.
6 - 18
.
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
2. Set drain valve (P) under the machine to open position (O).
3. Remove the cap of swing machinery oil (rear) coupler (1) and
connect the force-feed pump coupler securely.
4. Start to drain and add swing machinery oil.
5. After completing the draining and adding of swing machinery
oil, remove the force-feed pump coupler.
6. Install the cap to the coupler.
7. Set drain valve (P) under the machine to shut position (S).
8. Check that the oil level is between the H and L marks on the dipstick. For details, see "CHECK OIL LEVEL IN
SWING MACHINERY CASE, ADD OIL (PAGE 4-83)".
9. After checking, insert dipstick (G).
10. Immediately after changing the oil, oil level is variable.
So operate for one hour, then check the oil level again.
6 - 19
.
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
NOTICE
Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the
oil level.
2. Set drain plug (P) at the bottom of the PTO case to open
position (O).
6 - 20
.
3. Remove the cap of PTO oil coupler (1) and connect the
force-feed pump coupler securely.
4. Start to drain and add PTO oil.
5. After completing the draining and adding of PTO oil, remove
the force-feed pump coupler.
6. Install the cap to the coupler.
7. Set drain valve (P) under the PTO case to shut position (S).
8. Check that the oil level is between the H and L marks on the dipstick. For details, see "Check Oil Level in PTO
Case, Add Oil (PAGE 3-190)".
9. After checking, insert dipstick (G).
6 - 21
.
WARNING
Immediately after the engine is stopped, the oil and parts are at high temperature, and this will cause burns. Wait for the
temperature to go down before starting the operation.
When removing the cap from the oil filler, oil may spurt out, so turn it slowly to release the internal pressure, then remove it.
When removing holder cover of the strainer, the cover is under pressure from spring and may fly out, so loosen the 4 bolts
gradually.
5. Remove the cap of hydraulic oil coupler (5) and connect the
force-feed pump coupler securely.
6. Start to drain and add hydraulic oil.
7. Before adding hydraulic oil, remove the strainer. After adding
oil, install the strainer again. For details, see "CHANGE OIL IN
HYDRAULIC TANK, CLEAN STRAINER (PAGE 4-116)".
8. After completing the draining and adding of hydraulic oil,
remove the force-feed pump coupler.
9. Install the cap to the coupler.
10. Check that the oil is at the correct level. For details, see "Check Oil Level in Hydraulic Tank, Add Oil (PAGE
3-185)".
11. After checking, install oil filler port (F).
6 - 22
.
WARNING
Immediately after the engine is stopped, the coolant is at high temperature. In addition, the radiator is under high internal
pressure. If the cap is opened under these conditions, it will cause burns. Wait for the temperature to go down, then open the
cap slowly to release the pressure.
When cleaning the cooling system with the engine running, set the lock lever to the LOCK position to prevent the machine from
moving.
For details of the procedure for starting the engine, see "BEFORE STARTING ENGINE (PAGE 3-177)" and "STARTING ENGINE
(PAGE 3-208)".
The Supercoolant is already diluted with distilled water, so it is not flammable.
Anti-freeze is toxic. When draining or adding Supercoolant, be careful not to get the mixture containing Supercoolant over you.
If it gets in your eyes, flush your eyes with a large amount of fresh water and see a doctor at once.
When changing the coolant or draining the coolant from the radiator before carrying out repairs, ask a specialist company to
handle any coolant containing antifreeze, or contact your Komatsu distributor. Antifreeze is toxic, so never pour it into
drainage water ditches or drain it onto the ground surface.
NOTICE
Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any
coolant other than Komatsu genuine supercoolant.
For other details, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-27)".
6 - 23
.
5. Set drain valve (P) under the machine to open position (O).
11. Set drain valve (P) under the machine to shut position (S).
12. Push down cap lever (4) of cap (3) at the top of the sub tank, then install water filler cap (5).
13. Check that the coolant in the reserve tank is in the range between the FULL and LOW marks. For details, see
"Check Coolant Level, Add Coolant (PAGE 3-179)".
6 - 24
.
WARNING
Fuel causes fire, so be extremely careful not to let the fuel overflow when filling with fuel. If any fuel spills, wipe it off
completely. If it spills onto the ground, remove the soil that is contaminated with fuel.
Fuel is a dangerous substance that catches fire easily, so never bring it near to any flame or fire.
Before adding fuel, lower the work equipment to the ground, stop the engine, and set the lock lever to the LOCK position.
1. Remove the cap of fuel coupler (1) and connect the force-feed
pump coupler securely.
2. Start to fill with fuel.
Fuel tank capacity: 3,409.6 liter (900.82 US gal)
3. After completing the filling of fuel, remove the force-feed pump
coupler.
4. Install the cap to the coupler.
REMARK
After the completion of adding grease, the lamp lights up in red
to show that the adding of grease has been completed, and at
the same time, the shut-off valve on the machine closes and the
supply of grease stops automatically.
Releasing the remaining pressure from inside the grease
supply hose may take several seconds or several tens of
seconds. Keep pressing the remaining pressure release switch
until the coupler can be removed.
6 - 25
.
REMARK
Destination for grease pumped in through each grease fitting
(1): Service arm cylinder bottom pin (A)
(2): Service arm cylinder head pin (B)
(3): Service arm link pin (C)
6 - 26
.
1. Open breather cover (1) on top of the fuel tank. (This is locked
or unlocked using the starting switch key)
2. Remove the cap (with element) of breather (2) and replace with
a new part.
3. Close breather cover (1).
6 - 27
.
6 - 28
.
5. Stow the service arm. For details, see "When Raising Service
Arm (Setting to Stowing Position) (PAGE 6-15)".
6. Adjust with adjustment nuts (4) and (5) of proximity switch (1)
so that clearance (C) between proximity switch (1) and plate
(3) installed to service arm is 4 to 6 mm (0.16 to 0.23 in).
6 - 29
.
WARNING
When the following procedure is used to disconnect the connector of the proximity switch and then connect it to another
connector, the PPC (proportional pressure control pilot) lock will always remain released (the machine can move), regardless of
the operation of the service center.
This change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place.
After moving the machine, contact your Komatsu distributor immediately and ask for repairs to be carried out.
The machine can move, so this is extremely dangerous. In addition, do not carry out greasing operations using the service
center with the combination of the connectors changed.
If it is necessary to add fuel by the time that the proximity switch is repaired, add fuel through the fuel filler port on top of the
fuel tank. For details, see "Check Fuel Level, Add Fuel (PAGE 3-184)".
NOTICE
When the changing the combination of the connectors, be careful not to mistake the connections.
1. Turn the starting switch to the OFF position, remove the key, wait for approximately. 1 minute, then remove the
negative (-) terminal of the battery.
2. On the right side inside the cab base room there is the
connector for the PPC (proportional pressure control pilot)
lock.
3. Remove bolts (1) and (2) of the clamp holding the connector
cable.
6 - 30
.
6. Connect the negative (-) terminal of the battery, start the engine, then check that it is possible to operate the
travel, swing, and work equipment.
If they cannot be operated, there is probably some other cause, so ask your Komatsu distributor to carry out
investigation.
6 - 31
.
(1) Jump start receptacle (2) External power source insertion socket
6 - 32
.
3. Open cover (1) of the battery box at the left side of the machine
(rear of cab base).
4. Insert the external power source cable through external power
source insertion port (2).
5. Remove the cap of jump-start receptacle (3), then connect the
external power source cable to jump-start receptacle (3).
6. Close cover (1) of the battery box.
8. Start the engine. For details of the procedure for starting the engine, see "STARTING ENGINE (PAGE 3-208)".
6 - 33
.
6 - 34
.
7-1
.
7-2
.
EXPLANATION OF COMPONENTS
SWITCHES
The following explanation contains details of only the switches that are different from the standard specification
machine (backhoe specification machine).
For explanation of switches (1) to (16), see "SWITCHES (INSIDE OPERATOR'S CAB) (PAGE 3-82)".
7-3
.
Horn Switch
Press switch (17) on the right work equipment control lever to
sound the horn. The same time, the flashing lights at the top front
of the cab flashes for approximately. 5 seconds to give a signal to
the dump truck and others in the surrounding area.
If the button (19) at the tip of the right work equipment control lever
is depressed, the front bucket will open.
7-4
.
OPERATIONS
OPERATION OF WORK EQUIPMENT
WARNING
If the lever is operated in the deceleration range, the engine speed will suddenly rise. Operate the levers carefully.
If the work equipment control levers are operated quickly, the engine speed will suddenly rise. Operate the levers carefully.
The work equipment is operated with the left work equipment control lever and right work equipment control lever.
The left work equipment control lever operates the arm, swing, and bottom dump (CLOSE); the right work equipment
control lever operates the boom, bucket, and bottom dump (OPEN).
The relationship between the operation of the lever and the movement of the work equipment is as shown in the
diagram on the right.
When the lever is released, it returns to the HOLD position and the work equipment is held in position.
If the work equipment control levers are returned to the neutral position when the machine is stopped, even if the
fuel control dial is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a
mid-range speed.
REMARK
If the key in the starting switch is turned ON within 15 seconds after stopping the engine, it is possible to lower the
work equipment to the ground by operating the levers.
In addition, the levers can also be operated to release any remaining pressure inside the hydraulic cylinder circuit
and to lower the boom after loading the machine on a trailer.
Arm operation
(A): Arm OUT
(B): Arm IN
Swing operation
(A): Left swing
(B): Right swing
7-5
.
Boom operation
(A): Boom RIASE
(B): Boom LOWER
Bucket operation
(A): Bucket DUMP
(B): Bucket CURL
7-6
.
7-7
.
Do not Carry Out Operations with the Hydraulic Cylinder at the End of its Stroke.
If the cylinder is operated to the end of its stroke during operations,
a large force will be brought to bear on the stopper inside the
cylinder, and this will reduce the service life of the machine, so
leave room (distance a) at the end of the stroke as far as possible.
7-8
.
7-9
.
7 - 10
.
EXCAVATOR WORK
In addition to the following, it is possible to further increase the range of applications by using various attachments.
Shovel Work
This is suitable for digging a place which is higher than the
machine's position. It is most efficient if the arm s digging angle is
from vertical to 60i forward, and the arm cylinder is used effectively.
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 if the excavator is placed beside the dump truck
for loading. This way means more earth can be loaded more
effectively than by a loader working behind the truck.
7 - 11
.
Releasing Pressure from Work Equipment Circuit, Swing Circuit, Travel Circuit
WARNING
The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release
the pressure in the circuit before starting. If the pressure is not released, high pressure oil may spurt out and cause serious
personal injury.
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature
to go down before starting the operation.
When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the pressure before removing the cap.
4. Start the engine, run for approximately. 10 seconds, then stop the engine again.
Do not run the engine at more than 1000 rpm.
Set the work equipment control levers to the HOLD position.
5. Operate each work equipment control lever to the full stroke within 5 to 6 seconds after stopping the engine.
Repeat Steps 4 to 5 three times.
7 - 12
.
TRANSPORTATION
The machine can be divided into the following units for transportation: upper structure, operator's cab, crawler
frame, center frame, work equipment, and counterweight. When transporting the machine, please consult your
Komatsu distributor.
7 - 13
.
MAINTENANCE
EVERY 10 HOURS MAINTENANCE
WARNING
If any abnormal sound is heard from lubricating points of the work equipment, carry out greasing, regardless of the inspection
or maintenance interval.
If the control lever is touched by mistake, the work equipment or machine may suddenly move and cause serious personal
injury. Before standing up from the operator's seat, always set the lock lever securely to the LOCK position.
Greasing of the work equipment is normally carried out automatically, but if any abnormal noise is heard from the
pins, carry out greasing manually through the grease fittings for each injector.
At the same time, ask your Komatsu distributor to check the automatic greasing system.
For details of the procedure for manual greasing, see "HANDLING GREASE PUMP AND GREASE GUN (PAGE
3-157)".
LUBRICATTING
1. Using the greasing gun, pump in grease through grease fittings (F) of injectors (J) installed to points (A) to (D)
in the diagram below. (26 places)
2. After greasing, wipe off any old grease that was pushed out.
7 - 14
.
(1) F&R bucket connector pin (RH) (5) Bottom dump cylinder bottom pin (RH)
(2) F&R bucket connector pin (LH) (6) Bottom dump cylinder bottom pin (LH)
(3) Bottom dump cylinder head pin (RH) (F) Grease fitting
(4) Bottom dump cylinder head pin (LH)
(7) Arm top pin (RH1) (14) Bucket cylinder bottom pin (LH)
(8) Arm top pin (LH1) (15) Boom top pin (RH)
(9) Arm top pin (RH2) (16) Boom top pin (LH)
(10) Arm top pin (LH2) (17) Bucket cylinder head (RH)
(11) Arm cylinder head pin (RH) (18) Bucket cylinder head (LH)
(12) Arm cylinder head pin (LH) (F) Grease fitting
(13) Bucket cylinder bottom pin (RH)
7 - 15
.
(19) Boom foot pin (RH) (23) Arm cylinder head pin (RH)
(20) Boom foot pin (LH) (24) Arm cylinder head pin (LH)
(21) Arm cylinder bottom pin (RH) (F) Grease fitting
(22) Arm cylinder bottom pin (LH)
7 - 16
.
7 - 17
.
7 - 18
.
SPECIFICATION
PC2000-8 (LOADING SHOVEL)
7 - 19
.
7 - 20
.
WEAR PARTS
Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the
machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.
(*): For machines equipped with a service center (option) or fuel quick charger (option), the fuel tank breather
element forms one unit with the cap (Part number: 21T-04-31170).
7 - 21
.
{: Can be used
: Cannot be used
7 - 22
.
INDEX
INDEX
<A> <F>
ACCUMULATOR 3-165 FIRE EXTINGUISHER 3-121
AFTER STARTING ENGINE 3-211 FUSE 3-150
AIR CONDITIONER CONTROLS 3-126 FUSE (IF EQUIPPED) 3-155
ASHTRAY 3-123
ATTACHMENT GUIDE 6- 3 <G>
COMBINATIONS OF WORK GENERAL OPERATION
EQUIPMENT 6- 3 INFORMATION 3-246
AUXILIARY ELECTRIC POWER 3-149 GENERAL PRECAUTIONS COMMON
TO OPERATION AND MAINTENANCE 2- 12
<B> DO NOT GET CAUGHT IN
BEFORE READING THIS MANUAL 1- 2 WORK EQUIPMENT 2- 17
BEFORE STARTING ENGINE 3-177 FIRE PREVENTION 2- 14
BUCKET REPLACEMENT 3-251 PRECAUTIONS BEFORE
STARTING OPERATION 2- 12
<C> PRECAUTIONS RELATED TO
CAP WITH LOCK 3-122 ATTACHMENTS AND OPTIONS 2- 19
CHECK BEFORE SHUT OFF ENGINE 3-254 PRECAUTIONS RELATED TO
CIRCUIT BREAKER 3-152 CAB GLASS 2- 19
COLD WEATHER OPERATION 3-257 PRECAUTIONS RELATED TO
AFTER COLD WEATHER SEASON 3-259 PROTECTIVE STRUCTURES 2- 17
AFTER DAILY WORK COMPLETION 3-259 PRECAUTIONS WHEN GETTING
COLD WEATHER OPERATION ON OR OFF MACHINE 2- 15
INFORMATION 3-257 PRECAUTIONS WHEN
COMBINATION OF WORK RUNNING ENGINE INSIDE
EQUIPMENT 7- 22 BUILDING 2- 19
COMBINATION OF WORK PREPARATIONS FOR SAFE
EQUIPMENT 7- 22 OPERATION 2- 12
CONTROL LEVERS AND PEDALS 3-112 PROTECTION AGAINST
CONTROLLER 3-156 FALLING, FLYING, INTRUDING
CONTROLS AND GAUGES 3- 3 OBJECTS 2- 18
UNAUTHORIZED MODIFICATION 2- 18
<D> GENERAL PRECAUTIONS FOR
DETAILED CONTROLS AND GAUGES 3- 7 SAFETY 6- 2
DIRECTIONS OF MACHINE 1- 4 PRECAUTIONS WHEN
DOOR LOCK 3-115 REMOVING OR INSTALLING 6- 2
PRECAUTIONS WHEN SELECTING 6- 2
<E> PRECAUTIONS WHEN USING 6- 2
ELECTRIC SYSTEM MAINTENANCE 4- 8 READ THE INSTRUCTION
EMERGENCY ESCAPE HAMMER 3-116 MANUAL THOROUGHLY 6- 2
EMERGENCY EXIT FROM
OPERATOR'S CAB 3-115 <H>
EPA REGULATIONS, ENGINE HANDLING EMERGENCY LADDER 3-117
NUMBER PLATE 1- 6 ESCAPE PROCEDURE 3-118
ESCAPE FROM MUD 3-249 PRECAUTION WHEN
EXCAVATOR WORK 7- 11 STORING ROPE LADDER 3-120
EXPLANATION OF COMPONENTS 7- 3 HANDLING FUEL QUICK CHARGE 6- 4
8-1
.
INDEX
8-2
.
INDEX
8-3
.
INDEX
<Y>
YOUR MACHINE SERIAL NUMBERS
AND DISTRIBUTOR 1- 7
8-4
.
.
©
2012 KOMATSU
All Rights Reserved
Printed in Japan 08-12