Page 1 WENAM00042 Operation & Maintenance Manual PC88MR- HYDRAULIC EXCAVATOR SERIAL NUMBERS PC88MR-10 F10236 and up 7001 and up WARNING ORIGINAL INSTRUCTIONS Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3: Wenam00042
Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 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.
Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 6: Safety Labels
Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for ques- tions regarding information in this manual.
Page 7: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201.
Page 8: Vibration Levels
VIBRATION LEVELS FOREWORD VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 9: Guide To Reduce Vibration Levels On Machine
FOREWORD VIBRATION LEVELS GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE The following guides can help an operator of this machine to reduce the whole body vibration levels: Use the correct equipment and attachments. Maintain the machine according to this manual •...
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Ditching work • Loading work • Levelling work For details of work procedure, see MACHINE OPERATIONS AND CONTROLS “RECOMMENDED APPLICA- TIONS (3-166)”.
Page 11: Directions Of Machine
FOREWORD INTRODUCTION DIRECTIONS OF MACHINE (A) Front (D) Right (B) Rear (E) Operator's seat (C) Left (F) Sprocket 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. WENAM00042...
Page 12: Visibility From Operator's Seat
INTRODUCTION FOREWORD VISIBILITY FROM OPERATOR'S SEAT The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below. Proximity visibility The figure below shows a visibility from the machine at a spot 1.0 m away from outside the machine and 1.5 m above the ground.
Page 13: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is on the left side of the mounting location of the swing bracket.
Page 14: Fluorinated Greenhouse Gases
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: Komatsu Italia Manufacturing S.p.A. Address: Via Atheste, 4 35042 Este (PD) Italy Distributor name Address...
Page 15: Serial Plate
FOREWORD SERIAL PLATE SERIAL PLATE SERIAL NUMBER MACHINE DESIGNATION/TYPE WEIGHT YEAR OF CONSTRUCTION PRODUCT IDENTIFICATION NUMBER ENGINE POWER MANUFACTURER 1-13 WENAM00042...
Page 16: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Italia Manufacturing S.p.A. Via Atheste, 4 35042 Este (PD) Italy Declares that this machine: PC88MR-10 Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive...
Page 17: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-3 SAFETY LABELS ............................. 1-4 NOISE............................... 1-5 VIBRATION LEVELS ..........................1-6 VIBRATION - OPERATING CONDITION ................... 1-6 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-7 INTRODUCTION ............................
Page 18 TABLE OF CONTENTS FOREWORD EXPLANATION OF MACHINE MONITOR EQUIPMENT ..............3-11 SWITCHES ............................3-79 CONTROL LEVERS AND PEDALS ....................3-86 OTHER EQUIPMENT ........................3-91 MACHINE OPERATIONS AND CONTROLS ..................3-109 CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ............3-109 METHOD FOR STARTING ENGINE....................3-132 METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE .........
Page 19 FOREWORD TABLE OF CONTENTS KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................4-2 PRECAUTIONS FOR REFILLING OIL OR FUEL ................4-2 WELDING INSTRUCTIONS.......................
Page 20 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-5 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-7 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-18 WENAM00042...
Page 21: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly. WENAM00042...
Page 22 SAFETY SAFETY SAFETY SAFETY LABELS ............................2-4 LOCATION OF SAFETY LABELS......................2-5 CONTENTS OF SAFETY LABELS ......................2-7 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........... 2-18 PRECAUTIONS BEFORE STARTING OPERATION................2-18 ENSURE SAFE OPERATION ......................2-18 UNDERSTAND THE MACHINE ....................... 2-18 PREPARATIONS FOR SAFE OPERATION ....................
Page 23 SAFETY SAFETY PRECAUTIONS WHEN PARKING MACHINE ................. 2-35 PRECAUTIONS FOR TRANSPORTATION..................... 2-37 PRECAUTIONS WHEN LOADING AND UNLOADING ..............2-37 TOWING AND BEING TOWED....................... 2-38 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-38 LIFTING OPERATION BY USING BUCKET WITH HOOK ..............2-39 PRECAUTIONS FOR LIFTING OPERATIONS ................
Page 24: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 25: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS RKA46331 (1) Combined safety information label (a) Warning against high-voltage cables WENAM00042...
Page 26 SAFETY LABELS SAFETY (b) Warning when leaving the operator's seat (14) Emergency escape (c) Warning no passengers (15) Caution stop rotation during inspection and main- tenance (d) Warning for operation, inspection and maintenance (16) Danger do not enter within swing range (e) Caution for blast jobsite (17) Warning for operation, inspection and mainte- (f) Warning danger of falling objects...
Page 27: Contents Of Safety Labels
SAFETY SAFETY LABELS CONTENTS OF SAFETY LABELS (1) Combined safety information label (22P-00-11272) • Warnings for operation, inspection and maintenance. • Improper operation and maintenance can cause serious in- jury or death. • Read the manual and labels before operation and mainte- nance.
Page 28 SAFETY LABELS SAFETY (d) Warning for operation, inspection and maintenance • Warning • Read the manual before operating, inspection, mainte- nance, disassembly, assembly and transportation. (e) Caution for blast jobsite Caution of an explosive hazard caused by active radio transmitter at a blast zone. •...
Page 29 SAFETY SAFETY LABELS • Before standing up from the operator's seat (such as when opening or closing the front window, or when removing or installing the bottom window, or when adjusting the opera- tor's seat), always lower the work equipment completely to the ground, set lock lever (1) securely to the LOCK position (L), then stop the engine.
Page 30 SAFETY LABELS SAFETY (4) Warning when swinging or travelling in reverse (09833-A0881) WARNING • When swinging or backing up excavator, press button to change display mode on monitor so you can see rear and side of the machine. Before moving, look around and at mirror and monitor to confirm that no one is around the machine.
Page 31 SAFETY SAFETY LABELS (7) Warning for quick coupler system (20J-00-11271) • There is a danger of an exposed person being killed by falling attachment. • Read the manual for safe operation. (8) Warning when reversing (09802-A0480) To prevent SEVERE INJURY or DEATH, do the following be- fore moving machine or its attachments: •...
Page 32 SAFETY LABELS SAFETY (11) Caution for handling cable (09808-A0881) • Sign indicates an electric hazard from handling the cable. • Read manual for safe and proper handling. (12) Caution for adjusting track tension (09657-A0881) • Sign indicates a hazard of flying plug from track adjuster that could cause injury.
Page 33 SAFETY SAFETY LABELS (15) Caution stop rotation during inspection and maintenance (09667-A088B) • Sign indicates a hazard of rotating parts such as belt, fan etc. • Turn off before inspection and maintenance. (16) Danger do not enter within swing range (09133-A1681) •...
Page 34 SAFETY LABELS SAFETY (20) Caution against falling (09805-C0641) • Sign indicates a hazard of falling. • Do not stand on the place here. (21) Caution when stowing front window (22P-00-11170) • Sign indicates a hazard from falling window. • After raising window, be sure to lock it in place with lock pins.
Page 35 SAFETY SAFETY LABELS (23) Battery main switch (22E-98-21141) (24) Caution for handling battery (09664-60001) (a) Never smoke or use any naked flame near the batteries, no sparks. (b) Always wear safety glasses when working with batteries. (c) Keep children away from batteries. KS000327 2-15 WENAM00042...
Page 36 SAFETY LABELS SAFETY (d) Caution battery acid. (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases. (25) Lock front window (22P-00-11381) (26) Lifting and fastening decals for transport (22P-00-11630) 2-16 WENAM00042...
Page 37 SAFETY SAFETY LABELS (27) Caution for wiper blade correct position (22B-00-32710) • Read manual regarding closing the front window. • Check that the wiper blade is stowed in correct position be- fore closing the front window. (28) Warning always safety belt (09848-A0480) •...
Page 38: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 39: Precautions For Inside Operator's Compartment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 40: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Use the handrails and steps to escape from the machine. •...
Page 41 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring. Fire caused from piping Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.
Page 42: Precautions When Getting On Or Off Machine
In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...
Page 43: Precautions When Standing Up From Operator's Seat
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT Before standing up from the operator's seat, such as when opening or closing the front window or ceiling window, when re- moving or installing the bottom window, or adjusting the posi- tion of the seat, always lower the work equipment completely to the ground, set lock lever (1) to lock position (L), and stop the engine.
Page 44: Do Not Get Caught In Work Equipment
No attempt should be made to repair these parts as this may have an adverse effect on component strength or durability. If such a repair is undertaken without authorisation from Komatsu there is a danger that a problem might occur that will lead to serious personal injury.
Page 45: Precautions Related To Attachments And Options
Any serious personal injury, or product failures, or physical loss or damage resulting from the use of unau- thorized attachments or parts will not be the responsibility of Komatsu. • When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential problems or safety and legal requirements. •...
Page 46: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 47: Ensure Good Visibility
SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 48 Prohibit anyone other than the operator from coming close to the machine during operation. • Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. 2-28 WENAM00042...
Page 49: Start Engine
SAFETY PRECAUTIONS FOR OPERATION START ENGINE USE WARNING TAGS If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine. If the warning tag is ignored and the machine is operated, the person performing inspection or maintenance may be caught in the rotating parts or moving parts.
Page 50: Precautions When Starting Engine
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the following. • Start the engine only while sitting down in the operator's seat. •...
Page 51: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance. It is dangerous and may cause serious personal injury or death. When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention to the surroundings.
Page 52: Precautions When Traveling
PRECAUTIONS FOR OPERATION SAFETY • Always operate the machine only when seated on the operator's seat. • Before starting to move, check again that there is no people or obstacle in the surrounding area. • Before moving, sound the horn to warn people in the surrounding area.
Page 53: Precautions When Travelling On Slopes
SAFETY PRECAUTIONS FOR OPERATION • When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate slowly and be extremely careful not to let the machine body or work equipment hit anything. PRECAUTIONS WHEN TRAVELLING ON SLOPES To prevent the machine from tipping over or slipping to the side, always observe the following.
Page 54: Precautions When Operating On Slopes
PRECAUTIONS FOR OPERATION SAFETY • Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that the machine may slip. • If the engine stops, move the control levers immediately to NEUTRAL position, set the lock lever to LOCK position, and then start the engine.
Page 55: Precautions When Operating On Snow Or Frozen Surfaces
SAFETY PRECAUTIONS FOR OPERATION • For a quick escape in an emergency, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when performing operations. • Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other hauling equipment.
Page 56 PRECAUTIONS FOR OPERATION SAFETY • Park the machine on a firm, level ground. • Select a place where there is no hazard of landslides, fall- ing rocks, or flooding. • Lower the work equipment to the ground. • When leaving the machine, set lock lever (1) to LOCK po- sition (L), then stop the engine.
Page 57: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 58: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death.
Page 59: Lifting Operation By Using Bucket With Hook
SAFETY PRECAUTIONS FOR OPERATION LIFTING OPERATION BY USING BUCKET WITH HOOK PRECAUTIONS FOR LIFTING OPERATIONS Falling of a lifted load or tipping over of the machine can cause serious personal injury or death. Always observe the following. • Do not perform lifting work on slopes, soft ground, or other places where the machine is not stable. •...
Page 60: Lifting Operation By Using Lifting Device (Optional Equipment)
PRECAUTIONS FOR OPERATION SAFETY LIFTING OPERATION BY USING LIFTING DEVICE (OPTIONAL EQUIP- MENT) The excavator used in handling operations must conform with current local regulations and be equipped with safety valves and an overload alarm in compliance with EN 474-5. For details, see “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE (3-168)”.
Page 61 SAFETY PRECAUTIONS FOR OPERATION There is a danger that the lifting eye may be damaged due to abnormal loading making it unsafe to lift. • Where possible the lifting operation should be carried out with the bucket curled in order to increase visibility and prevent any obstruction or deflection of the sling or chain away from its vertical position.
Page 62: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the "DAN- GER! Do NOT operate!" warning tag. If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 63: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE • Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. • Turn the starting switch to ON position. Operate the work equipment control lever back and forth, right and left 2 to 3 times fully to release the remaining internal pressure in the hydraulic circuit.
Page 64: Precautions When Installing, Removing, Or Storing Attachments
PRECAUTIONS FOR MAINTENANCE SAFETY • Release the remaining pressure in the hydraulic system, and place lock lever (1) to LOCK position (L). • Do not touch the control levers or pedals. When it is nec- essary to operate the control levers or pedals, always give a signal to your fellow workers to evacuate them to a safe place.
Page 65: Use Proper Tools
SAFETY PRECAUTIONS FOR MAINTENANCE • It is extremely dangerous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment. If any of the con- trol levers is touched by accident, or there is damage oc- curring to the hydraulic piping, the work equipment or the machine will suddenly fall.
Page 66: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR CHECK AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. If you check and handle battery without turning battery disconnect switch to OFF position, serious personal in- jury or death by such as an electric shock may occur.
Page 67: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE • If battery electrolyte gets on your clothes or skin, wash it off immediately with large amounts of water. Danger of sparks Sparks may be generated and they can cause a fire. Always observe the following. •...
Page 68: Precautions For High-Temperature Parts
If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 69: Precautions For High Voltage
If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. 2-49...
Page 70: Handle Accumulator And Gas Spring
• When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 71 SAFETY PRECAUTIONS FOR MAINTENANCE Replacement of defined life parts: See REPLACEMENT PARTS, “PERIODIC REPLACEMENT OF DE- FINED LIFE PARTS” • The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death.
Page 72 WENAM00042...
Page 73: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section. WENAM00042...
Page 74: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (8) Working lamp (2) Bucket cylinder (9) Sprocket (3) Arm (10) Track frame (4) Arm cylinder (11) Track (5) Boom (12) Idler (6) Boom cylinder (13) Boom swing cylinder (7) Additional lamp (if equipped) (14) Blade cylinder WENAM00042...
Page 75 (18) Battery inspection cover (16) Dirt cover (19) Rear view camera (if equipped) (17) Engine hood (20) System operation lamp (24) Fusible link (21) Battery disconnect switch (25) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator (22) Grease pump holder (23) Toolbox WENAM00042...
Page 76: Cab Equipment Names
GENERAL VIEW OPERATION CAB EQUIPMENT NAMES (1) Front window (6) Fire extinguisher (if equipped) (2) Ceiling window (7) Cup holder (3) Door handle (8) Magazine box (4) Emergency escape hammer (9) Ashtray (5) Fuse WENAM00042...
Page 77: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Lock lever (15) Additional lamps switch (if equipped) (2) L.H. work equipment control lever (16) Swing lock cover (3) Travel pedal (17) Boom swing control pedal (4) Travel lever (18) Cigarette lighter (5) 1st-line attachment proportional switch (19) Room lamp switch (6) Machine monitor...
Page 78 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME (VERSION WITH REAR CAMERA) AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Wiper switch (17) Window washer switch (2) Buzzer cancel switch (18) Air conditioner control switch (3) Auto-deceleration switch (19) Charge level caution lamp (4) Service meter/clock...
Page 79 OPERATION GENERAL VIEW For detail, see “CAMERA IMAGE SELECTOR SWITCH (3-47)” and “MACHINE MONITOR EQUIPMENT NAME (3-8)”. REMARK The above figure does not show all of the caution lamp symbols. For details of the caution lamps, see “WARN- ING DISPLAY (3-18)”. WENAM00042...
Page 80 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Wiper switch (17) Window washer switch (2) Buzzer cancel switch (18) Air conditioner control switch (3) Auto-deceleration switch (19) Engine oil pressure caution lamp (4) Service meter/clock (20) Seat belt caution lamp (5) Engine coolant temperature caution lamp...
Page 81: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS REMARK The following is an explanation of devices necessary to operate the machine with images showing the rear cam- era option. All functions are, however, the same. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays.
Page 82 EXPLANATION OF COMPONENTS OPERATION For detail, see “CAMERA IMAGE SELECTOR SWITCH (3-47)” and “EXPLANATION OF MACHINE MONITOR EQUIPMENT (3-11)”. REMARK • For the user menu used for setting various items of the machine on the machine monitor, see “USER MENU DISPLAY SWITCH (3-50)”. •...
Page 83: Explanation Of Machine Monitor Equipment
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display (4) Monitor switch area (2) Pilot display (5) Guidance icon display (3) Meter display REMARK • For the user menu used for setting various items of the machine on the machine monitor, see “USER MENU DISPLAY SWITCH (3-50)”.
Page 84 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, the opening screen GG is displayed. • After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen BB.
Page 85 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While engine shutdown secondary switch (1) is ON (engine is stopped), when the starting switch is turned to ON position, the screen shown in the figure is displayed and engine does not start.
Page 86 EXPLANATION OF COMPONENTS OPERATION End screen when any message has been received If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 87 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 88 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION • If there is any abnormality when starting the engine, the check before starting screen BB changes to the maintenance time warning screen CC, warning screen FF, or error screen EE. •...
Page 89 OPERATION EXPLANATION OF COMPONENTS If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the error. Current abnor- mality screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE •...
Page 90 EXPLANATION OF COMPONENTS OPERATION If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the error. Current abnor- mality screen is displayed. WARNING DISPLAY NOTICE When any of action levels “L01” to “L04” is displayed on the machine monitor, there is abnormality in the machine.
Page 91 OPERATION EXPLANATION OF COMPONENTS (9) Caution lamp Standard screen (camera display and meter display) When 1 type of caution is generated, it is displayed on caution lamp (2). When 2 types of caution are generated, they are displayed on caution lamps (2) and (3). When 3 types of caution are generated, they are displayed on caution lamps (2), (3), and (4).
Page 92 EXPLANATION OF COMPONENTS OPERATION When displaying only meter On the standard screen (camera display, meter display), press switch F3, and only the meter is displayed. For detail, see “CAMERA IMAGE SELECTOR SWITCH”. (1) Seat belt caution lamp (5) Engine coolant temperature caution lamp (2) Action level display (6) Hydraulic oil temperature caution lamp (3) Caution lamp...
Page 93 Color of cau- Required action urgency level tion lamp Sounds contin- Lights up in red Stop the machine immediately and ask your Komatsu High uously distributor for inspection and maintenance. ↑ Sounds inter- Lights up in red Stop the work, move the machine to a safe place, and...
Page 94 EXPLANATION OF COMPONENTS OPERATION Display color/Machine condition (action level) Symbol Type of caution lamp Yellow White Blue Abnormal Abnormal Hydraulic system caution lamp (L04/L03) (L01) Abnormal Abnormal Engine system caution lamp (L04/L03) (L01) Abnormal Abnormal Auto-idle stop sudden stop caution lamp (L03) (L01) Low oil pressure...
Page 95 OPERATION EXPLANATION OF COMPONENTS CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5. While “!” is displayed, press switch F5 to shift the monitor dis- play screen to “Current Abnormality” screen. Take appropriate remedies according to the message displayed on the monitor.
Page 96 EXPLANATION OF COMPONENTS OPERATION ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature has risen abnormally high. While this lamp is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 97 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 98 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 99 “L03”. The alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. CHARGE LEVEL CAUTION LAMP Charge level caution lamp warns about abnormality in the charging system while the engine is running.
Page 100 • The lighting time of maintenance due time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on “Maintenance” tab screen, see “MAIN- TENANCE SCREEN SETTING”.
Page 101 OPERATION EXPLANATION OF COMPONENTS SEATBELT CAUTION LAMP The seat belt caution lamp lights up when the seat belt is not fastened. It goes out when the seat belt is fastened. For details of the seat belt, see “METHOD FOR FASTENING AND UNFASTENING SEAT BELT (3-129)”.
Page 102 EXPLANATION OF COMPONENTS OPERATION For detail, see “CAMERA IMAGE SELECTOR SWITCH”. Pilot display (1) Engine stop pilot lamp (7) Swing lock pilot lamp (2) Work equipment lock pilot lamp (8) Preheating pilot lamp (3) Lock lever automatic lock release pilot lamp (9) Auto-deceleration pilot lamp (4) Message display (10) Working mode display...
Page 103 OPERATION EXPLANATION OF COMPONENTS WIPER PILOT LAMP The wiper pilot lamp shows the operating state of the wind- shield wiper. The operation of the wiper switch is indicated by the pilot lamp as follows. When ON lights up: Windshield wiper operates continuously When INT lights up: Windshield wiper operates intermittently OFF: Windshield wiper stops SWING LOCK PILOT LAMP...
Page 104 Pilot lamp goes out: Air conditioner OFF MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply is made.
Page 105 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment is locked. It lights up when the work equipment is switched from the un- lock mode to the lock mode. For detail, see “LOCK LEVER (3-86)”.
Page 106 EXPLANATION OF COMPONENTS OPERATION Guidance To Avoid Hydraulic Relief If the hydraulic oil is kept relieved for more than 3 seconds dur- ing operation, the hydraulic relief deterrence message is dis- played on the monitor. The hydraulic relief deterrence message goes out 10 seconds later or when switch F5 is pressed.
Page 107 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY ENGINE COOLANT TEMPERATURE GAUGE Engine coolant temperature gauge shows the engine coolant temperature. If the indicator is in green range during operations, it is normal. If the indicator goes beyond (A) of red range during operations, the overheat prevention system operates.
Page 108 EXPLANATION OF COMPONENTS OPERATION REMARK When the indicator reaches red range (A), the hydraulic oil temperature is as follows. Red range (A) position: 102 °C or more Red range (B) position: 105 °C or more When the indicator is in red range (A) to (B), hydraulic oil temperature caution lamp (E) indicates abnormality. When the engine is started, if the indicator is at position (C), the hydraulic oil temperature is below 20 °C and hydraulic oil temperature caution lamp (E) indicates low temperature.
Page 109 OPERATION EXPLANATION OF COMPONENTS • Clock display (12-hour display) • Clock display (24-hour display) On the standard screen, when function switch F4 is pressed, it is possible to switch between the clock display and the service meter display alternately. REMARK •...
Page 110 EXPLANATION OF COMPONENTS OPERATION (A): Shows the average fuel consumption of a day (from 0:00 a.m. of the day to 0:00 a.m. of the next day). (B): Shows the split fuel consumption under measurement. (C): Shows the split fuel consumption while measurement is stopped.
Page 111 OPERATION EXPLANATION OF COMPONENTS FUNCTION SWITCHES AND GUIDANCE ICONS • There are 6 function switches (1) (F1 to F6) at the bottom of the monitor display. The function of each switch differs according to the content of each screen. • The function of each function switch (1) on each screen can be confirmed by guidance icons (2) displayed above that switch.
Page 112 EXPLANATION OF COMPONENTS OPERATION (D) Switch F5: ECO guidance erase switch (While ECO guidance is displayed) (E) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance icons frequently used and their functions are as follows: (F) Switch F1 or F3: Moves to the left item.
Page 113 For machines ready for installation of attachment, the attachment mode is added to the display. If you want to have automatic setting of P, E, L, B, ATT/P or ATT/E mode (optional default setting) when starting engine, ask your Komatsu distributor to change the setting. Procedure for operation When the working mode selector switch is pressed, the working mode selector screen is displayed on the monitor.
Page 114 EXPLANATION OF COMPONENTS OPERATION After selecting the desired mode, press function switch F6 and the mode is displayed in the center of the monitor dis- play. (Example: When the power mode is selected: “P”) After 2 seconds, the working mode display at the top right of the screen is highlighted in yellow.
Page 115 OPERATION EXPLANATION OF COMPONENTS When the auto-deceleration switch is pressed and the au- to-deceleration function is turned ON, the mode is dis- played in the center of the monitor display, and after 2 sec- onds, the screen returns to the standard screen. On the standard screen, auto-deceleration indication lamp lights up.
Page 116 EXPLANATION OF COMPONENTS OPERATION REMARK Each time the travel speed selector switch is switched, the mode is displayed on the monitor display, and after 2 seconds, the screen returns to the standard screen. WIPER SWITCH Wiper switch actuates the front window windshield wiper. Each time the switch is pressed, it changes “INT”→“ON”→...
Page 117 OPERATION EXPLANATION OF COMPONENTS REMARK Each time wiper switch is pressed, the mode is displayed in the center of the monitor display, and after 2 seconds, the screen returns to the standard screen. WINDOW WASHER SWITCH Keep pressing this switch continuously, and window washer flu- id is sprayed out on the front glass.
Page 118 EXPLANATION OF COMPONENTS OPERATION BUZZER CANCEL SWITCH Buzzer cancel switch is used to stop the alarm buzzer for the warning item where there is an abnormality. AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches. For explanation of each switch, see “HANDLE AIR CONDI- TIONER”.
Page 119 OPERATION EXPLANATION OF COMPONENTS CAMERA IMAGE SELECTOR SWITCH On the standard screen, you can select a display only for the camera image or a display only for the meter by pressing switch F3. On machines not equipped with a camera, the guidance icon related to switch F3 is not displayed.
Page 120 EXPLANATION OF COMPONENTS OPERATION Other mode operations while displaying camera image display screen Even while the camera image display screen is displayed, it is possible to operate the following modes. • The air conditioner can be operated. When the air conditioner switch is operated, the screen switches to “A/C Setting”...
Page 121 OPERATION EXPLANATION OF COMPONENTS • Press the wiper switch and washer switch to operate the wipers and washer. Even if the wiper switch or washer switch is pressed, the camera image display screen does not switch to another screen or return to the standard screen display. Actions against warning during camera image display If a trouble occurs on the machine while the camera image dis- play screen is being displayed, the caution lamp flashes at the...
Page 122 EXPLANATION OF COMPONENTS OPERATION USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
Page 123 OPERATION EXPLANATION OF COMPONENTS (c) Maintenance • Check and reset of various maintenance times (d)“Monitor Setting” • “Screen Adjustment” • “Screen Adjustment (Camera)” • “Clock Adjustment” • “Language” • “Operator ID” (e) Mail Check • Check of mail contents and reply to mail On the user menu screen, it is possible to perform the following operations with switches F1 to F6.
Page 124 EXPLANATION OF COMPONENTS OPERATION F3: Moves to the next item (1 line below). When on the last line, it moves to the first line. F4: Moves to the previous item (1 line above). When on the first line, it moves to the last line. F5: Returns the screen to the standard screen.
Page 125 OPERATION EXPLANATION OF COMPONENTS Operation on “Operation Records” screen On “Operation Records” screen, you can perform the following operations by pressing switch F3 to F5. F3: Displays the next page. When on the last page, it displays the first page. F4: Displays the previous page.
Page 126 EXPLANATION OF COMPONENTS OPERATION CHECK FUEL CONSUMPTION RECORD Select “Average Fuel Consumption Record” (3) from “Energy Saving Guidance” menu screen, then press switch F6. On “Average Fuel Consumption Record” menu, display the graph of hourly average fuel consumption during “Last 12 hours”...
Page 127 OPERATION EXPLANATION OF COMPONENTS Deleting “Average Fuel Consumption Record” When switch F1 (“CLEAR”) is pressed, the reconfirmation screen shown in the figure is displayed. When the switch F6 is pressed, graphs of data of “Last 12 hours” and “Last 7 days” are both deleted, and the screen returns to the “Average Fuel Consumption Record”...
Page 128 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE It is possible to change the display of fuel consumption gauge (5) and the setting of Display/Non-display. Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. 3-56 WENAM00042...
Page 129 OPERATION EXPLANATION OF COMPONENTS “Average Fuel Consumption Display” screen appears. • “1 Day” Displays the average fuel consumption from 0:00 a.m. of the day to 0:00 a.m. of the next day. • “Split Time” Displays the average fuel consumption during “Split Time”...
Page 130 EXPLANATION OF COMPONENTS OPERATION Select “ECO Gauge display” (8) from “Configurations” screen, then press switch F6. “ECO Gauge Display” setting screen appears. • “ON”: Displays the ECO gauge (7) on the standard screen. • “OFF”: Does not display ECO gauge (7) on the stand- ard screen.
Page 131 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE It is possible to change the setting of Display/Non-display of ECO guidance (10). Select “ECO Guidance display” (11) from “Configurations” screen, then press switch F6. “ECO Guidance Display” setting screen appears. •...
Page 132 EXPLANATION OF COMPONENTS OPERATION Select “ECO Guidance Display at Key OFF” (13) from “Configurations” screen, then press switch F6. The setting screen for “ECO Guidance Display at Key OFF” appears. • “ON”: Displays ECO Guidance (12) on the end screen. •...
Page 133 OPERATION EXPLANATION OF COMPONENTS ADJUST ECONOMY MODE Select “Economy Mode Adjustment” (1) on “Machine Setting” menu screen, then press switch F6. On the “Economy Mode Adjustment menu”, you can adjust the engine output in E mode. In the Economy Mode, the higher the selected number starting from E0 becomes, the lower the engine output becomes.
Page 134 EXPLANATION OF COMPONENTS OPERATION On “Breaker Setting” screen shown in the figure, select breaker, and press switch F6. On the “Breaker Setting” screen shown in the figure, you can perform the following operations with switches F1 to F1: Changes the name of the selected breaker setting. F2: Changes the oil flow rate of the selected breaker set- ting.
Page 135 OPERATION EXPLANATION OF COMPONENTS The “Breaker Oil Flow Rate Setting” screen is displayed. On the “Breaker Oil Flow Rate Setting” screen, you can perform the following operations with switches F3 to F6. F3: Decreases the flow rate by 1 level. F4: Increases the flow by 1 level.
Page 136 EXPLANATION OF COMPONENTS OPERATION Select an attachment to change its name on “Attachment Setting” screen, then press switch F6. The “Attachment Name Setting” screen is displayed. On the “Attachment Name Setting” screen, you can per- form the following operations with switches F1 to F6. F1: “CLEAR”...
Page 137 OPERATION EXPLANATION OF COMPONENTS AUTO IDLE STOP TIMER SETTING The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with the lock lever in LOCK position for a set time. The auto idle stop function operates only when the following conditions are satisfied. •...
Page 138 EXPLANATION OF COMPONENTS OPERATION When countdown reaches 0, the engine stops and the screen changes to the Auto Idle Stop in Operation screen. To prevent battery discharging, turn off unnecessary switches. REMARK While the auto idle stop is activated, only the engine is stopped and the machine monitor, inverter, etc., as well as the electrical components including the air conditioner, ra- dio, lamps, and wipers keep their states before the engine...
Page 139 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on “Maintenance Due Time Reset” screen On the “Maintenance” menu screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the “Maintenance Due Time Reset”...
Page 140 EXPLANATION OF COMPONENTS OPERATION The reconfirmation screen is displayed. If switch F6 is pressed again, the remaining time is reset and the screen returns to the “Maintenance” menu screen. REMARK • When canceling the reset, press switch F5. The screen returns to the “Maintenance” menu screen. •...
Page 141 OPERATION EXPLANATION OF COMPONENTS REMARK • If the light switch is at night mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode). • If the light switch is at day mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (day mode).
Page 142 EXPLANATION OF COMPONENTS OPERATION “Screen Adjustment (Camera)” Use “Screen Adjustment (Camera)” to adjust brightness of the camera screen. Select “Screen Adjustment (Camera)” (2) on “Monitor Set- ting” menu screen, then press switch F6. Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value.
Page 143 OPERATION EXPLANATION OF COMPONENTS GPS SYNCHRONIZATION SETTING On machines equipped with KOMTRAX, turning on “GPS Syn- chronization” menu enables automatic setting of the monitor's date and time in accordance with the clock of GPS. F3: Moves to the next item (1 line below). Moves to the top line when on the bottom line.
Page 144 EXPLANATION OF COMPONENTS OPERATION When date display (C) is highlighted in yellow, operate the switches as follows to change day display (C). If it is not necessary to change the day, press switch F6. F3: Calendar goes back 1 day. F4: Calendar advances 1 day.
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “12h/24h Mode” (d) on “Clock Adjustment” screen, then press switch F6. “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below). Moves to the top line when it is on the bottom line. F4: Moves to the previous item (1 line above).
Page 146 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 147 OPERATION EXPLANATION OF COMPONENTS When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID” on “Monitor Setting” menu screen. Select operator ID (5) on “Monitor Setting” menu screen, then press switch F6 for 1 second. “Operator ID Change”...
Page 148 EXPLANATION OF COMPONENTS OPERATION • When you press switch F6 after inputting the ID which is not registered to “Operator ID Change” screen, a message is displayed below and the screen returns to “Monitor Setting” menu screen. In this case, the identified ID is not changed. •...
Page 149 In this case, the identified ID is not changed. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this menu (e). When there is any message, the message display of the standard screen lights up.
Page 150 EXPLANATION OF COMPONENTS OPERATION CHECK MESSAGE On the standard screen, press switch F6. When there is any message, message display (1) lights While message display (1) is lit, press switch F6, and mail confirmation menu (e) directly opens. Select mail confirmation menu (e), and you can read the arrived message.
Page 151: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) 1st-line attachment proportional switch (10) Room lamp switch (2) Breaker control switch (11) Pump secondary drive switch (3) Horn switch (12) Swing parking brake cancel switch (4) Starting switch (13) Lock lever automatic lock cancel switch (5) Fuel control dial (14) Engine shutdown secondary switch (6) Lamp switch...
Page 152 EXPLANATION OF COMPONENTS OPERATION (D): HEAT (preheating) position When starting in cold weather, turn the key to this position. When the key is turned to HEAT (preheating) position (D), the HEAT pilot lamp lights up. Keep the key at this position until the HEAT pilot lamp flashes.
Page 153 OPERATION EXPLANATION OF COMPONENTS ATTACHMENT 1 PROPORTIONAL SWITCH The 1st-line attachment proportional switch is used to operate the attachment. For handling of the 1st-line attachment proportional switch, see “HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT”. ATTACHMENT 2 PROPORTIONAL SWITCH The 2nd-line attachment proportional switch is used to operate the attachment.
Page 154 EXPLANATION OF COMPONENTS OPERATION HORN SWITCH The horn switch is used to sound the horn. Press the horn switch on the R.H. work equipment control lev- er, and the horn sounds. ROOM LAMP SWITCH NOTICE If the room lamp is left to be turned on, the batteries may be exhausted.
Page 155 • After moving the machine or work equipment temporarily by operating this switch, stop the engine, return the switch to normal position (b), and then ask your Komatsu distribu- tor for repair. REVOLVING LAMP SWITCH (if equipped)
Page 156 OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch. • If the engine shutdown secondary switch is moved to engine stop position by mistake while the ma- chine is operating normally, “Engine Shutdown Secondary SW in Operation”...
Page 157 OPERATION EXPLANATION OF COMPONENTS • When the starting switch is turned to ON position while the engine shutdown secondary switch is in the engine stop position (a), “Engine Shutdown Secon- dary SW in Operation” is displayed on the machine monitor. If this screen is displayed, return the engine shutdown secondary switch to normal position (b).
Page 158: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS (1) Lock lever (5) Blade control lever (with auto-deceleration system) (2) L.H. work equipment control lever (with auto-decel- (6) Swing lock cover eration system) (7) Boom swing control pedal (with auto-deceleration (3) Travel lever (with pedal and auto-deceleration sys- system) tem) (8) 2-piece boom control pedal (if equipped)
Page 159 When the hydraulic oil temperature is low (When the hydraulic oil temperature caution lamp in- dicates low temperature) • When the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends • When system has failure •...
Page 160 EXPLANATION OF COMPONENTS OPERATION To cancel the lock, return the lock lever to LOCK position (L), check that each control lever and the attachment switch are in neutral, and then release the lock lever again. TRAVEL LEVER WARNING • If you perform operations with your foot on the pedal, the machine may suddenly start if you depress the pedal by mistake, and this may lead to serious person- al injury or death.
Page 161 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER The blade control lever is used to control the blade. (a): LOWER (b): RAISE SWING LOCK COVER WARNING When you do not swing the boom, lock the swing operation with the swing lock cover. If it is not locked and the control pedal is touched by mistake, this may cause a serious injury or death.
Page 162 EXPLANATION OF COMPONENTS OPERATION WORK EQUIPMENT CONTROL LEVER The left work equipment control lever is used to operate the arm and upper structure. Swing control (a): Swing RIGHT (b): Swing LEFT Arm control (c): Arm IN (d): Arm OUT N (NEUTRAL) The upper structure and arm are held in position and do not move.
Page 163: Other Equipment
OPERATION EXPLANATION OF COMPONENTS OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING CEILING WINDOW WARNING When leaving the operator's seat, set the lock lever securely to LOCK position. If the lock lever is at FREE position and the control lever, control pedal, or control switch is touched by mistake, it is dangerous and may cause serious personal injury or death.
Page 164 Check that the wiper blade is stowed in the right stay. If the wiper blade is stowed in wrong stowing position (b), lift it to move to the correct stowing position (a), or ask your Komatsu distributor for repair. (a) Correct stowing position The wiper blade is on the cab.
Page 165 OPERATION EXPLANATION OF COMPONENTS Hold lower handle (C) with your left hand from inside the operator's cab, and with your right hand, grip top handle (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window. REMARK You may not use the two grips (A) on the left and right top sides of the front window to pull up the front window.
Page 166 Check that the wiper blade is stowed in the right stay. If the wiper blade is stowed in wrong stowing position (b), lift it to move to the correct stowing position (a), or ask your Komatsu distributor for repair. (a) Correct stowing position The wiper blade is on the cab.
Page 167 OPERATION EXPLANATION OF COMPONENTS Grip right and left handles (A), and pull down lever (B) to release the lock. Grip handle (C) at the bottom of the front window with your left hand and handle (D) at the top with your right hand, push to the front, then lower slowly.
Page 168 EXPLANATION OF COMPONENTS OPERATION Removal of front window (lower side) Open the front window (upper side), then hold grip (1), pull up, and remove the lower side window. REMARK If sand or dust is collected at the bottom of the front win- dow (lower side), it will be difficult to remove the window.
Page 169 OPERATION EXPLANATION OF COMPONENTS Turn lock (2) 90 deg. counterclockwise to LOCK posi- tion (L) to fix the upper side of the glass. NOTICE When stowing the glass, lock it securely and check that there is no play. If there is play or the lock is not properly applied, there is danger that the glass may fall.
Page 170 EXPLANATION OF COMPONENTS OPERATION To escape from the operator's cab, use hammer to break the glass and escape through the window. COVER WITH LOCK Use the starting switch key to open and close the locks on the covers. For the locations of the lockable covers, see “LOCK (3-176)”. Insert the key as far as it will go to the shoulder (A).
Page 171 OPERATION EXPLANATION OF COMPONENTS ASHTRAY Ashtray is on the left side of the operator's cab. Always extinguish your cigarette before putting it in the ashtray, then be sure to close the lid (A). When removing ashtray, open the lid (A), hold ashtray body (B), and twist it.
Page 172 POWER SUPPLY OUTLET NOTICE When installing an electrical component which is not a product of Komatsu, limit its capacity to maxi- mum 240 W in the 24 V specification (equivalent to 10 A). When installing an electrical component of ca- pacity larger than above value, consult your Komatsu distributor.
Page 173 OPERATION EXPLANATION OF COMPONENTS 24 V power source NOTICE Do not use as a power supply for 12 V equipment. This will cause failure of the equipment. When cigarette lighter (A) is removed, the lighter socket can be used as a power source. The capacity of the cigarette lighter is 85 W (24 V x 3.5 A).
Page 174 EXPLANATION OF COMPONENTS OPERATION (14) 5 A Air conditioner ECU power source (15) 5 A Key ACC signal (16) 10 A Room lamp, system operating lamp (17) 20 A Monitor, Pump controller (18) 30 A Engine controller (19) 5 A Air conditioner ECU backup Optional power supply (continuous power (20) 10 A supply)
Page 175 Do not let water, mud, or beverage spill on the controller. This will cause failures. • If any problem occurs in the controller, do not repair it by yourself. Contact your Komatsu distribu- tor for repair. The chassis controller and KOMTRAX controller are installed inside the rear cover at the rear of the operator's cab.
Page 176 EXPLANATION OF COMPONENTS OPERATION GREASE PUMP HOLDER Open the cover on the left side of the machine, and you see the grease pump storage place. When storing the grease pump, pass its nozzle through the hole at the end until it stops. FIRE EXTINGUISHER (if equipped) A fire extinguisher is prepared at the rear part inside the opera-...
Page 177 Even if the starting switch is in OFF position, the controller may operate. The system operating lamp lights up at this time, but it is not a failure. • After the starting switch has been turned OFF, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. 3-105 WENAM00042...
Page 178 2,000 hours. • If the engine is operated without KCCV filter element or if a filter element other than the Komatsu genuine one is used, the engine sucks oil and foreign material which can cause a failure. Always install Komatsu genuine KCCV filter element.
Page 179 The machine information you can check with KOMTRAX includes the following; “Machine position”, “service me- ter”, “working hours”, “fuel consumption”, etc. Your Komatsu distributor uses the above machine information for supply of service to the customers, improve- ment of our products and service, etc.
Page 180 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 181: Machine Operations And Controls
Accumulation of flammable material or leakage of fuel or oil around the high temperature parts such as the engine muffler or battery may cause fire. Check carefully, and if any problem is found, repair it or contact your Komatsu distributor. If the machine is inclining, make it level before checking.
Page 182 12. Check the bucket with hook for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, ask your Komatsu distribu- tor for repair. 13. Check and clean the camera Check the camera for any abnormality.
Page 183 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day. METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK Swing the upper structure so that inspection cover (1) is between the tracks.
Page 184 MACHINE OPERATIONS AND CONTROLS OPERATION After checking, cleaning, and replacing, press the knob of dust indicator (3) to return the red piston to its original po- sition. Remove hood support lever (2) and fix it to the lever lock securely. Close engine hood (1).
Page 185 OPERATION MACHINE OPERATIONS AND CONTROLS Open inspection cover (7). Set valve (8) to CLOSE position (S). Place a container under the fuel prefilter cartridge to re- ceive the fuel. Loosen drain valve (6) and drain water and sediments from transparent cup (4), and also drain all the fuel from fuel prefilter cartridge (3).
Page 186 MACHINE OPERATIONS AND CONTROLS OPERATION “State A” When setting the machine posture to state A, follow the procedure below. Start the engine, and run it at low speed. Lower the blade to the ground. Retract the arm and bucket cylinders. Swing the boom to the center.
Page 187 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK The oil level will vary depending upon the oil temperature. Accordingly, use the followings as a guide: • Before starting the operation: Around L level (Oil temperature 10 to 30 °C) • Normal operation: Around H Level (Oil temperature 50 to 80 °C) If oil is added in state B, pressurize the hydraulic tank by performing steps 6) to 8).
Page 188 MACHINE OPERATIONS AND CONTROLS OPERATION Close dirt cover (1). METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work.
Page 189 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to make the repair. • Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clog- ged with dirt or dust, wash the battery cap to clear the breather hole.
Page 190 Check that the filter placed at the end of the pipe is clean. • In case of malfunction of the refilling automatic stop system, consult the Komatsu local Distributor and do not use the system until the problem is solved.
Page 191 OPERATION MACHINE OPERATIONS AND CONTROLS Check that battery disconnect switch (S) is in ON position (I). Insert the key into starting switch and turn it to ON position (B). Release the lock (1) and open the cover (2). Open the right hand side door (3). Remove the filling hose (4).
Page 192 MACHINE OPERATIONS AND CONTROLS OPERATION Connect the filling hose (4) to quick coupler socket (5) lo- cated inside the side door (3). Check if the valve is open and put the free end of the refilling hose in the container for fuel.
Page 193 After checking, turn the starting switch back to OFF posi- tion. If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. METHOD FOR CHECKING HORN Turn the starting switch to ON position.
Page 194 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the lock lever to LOCK position to pre- vent any accidental contact with the control levers. •...
Page 195 OPERATION MACHINE OPERATIONS AND CONTROLS Pull up reclining adjustment lever (2) and set the seat back to a position which is comfortable for operation, then release reclin- ing adjustment lever (2). REMARK Sit with your back against the backrest when adjusting. If your back is not touching the backrest, it may suddenly move for- ward.
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION Fore-and-aft adjustment of seat unit Pull fore-aft adjustment lever (5) to the right, adjust the seat to the desired position, then release fore-aft adjustment lever (5). The operator's seat, right and left control levers, and lock lever all slide (move) together.
Page 197 OPERATION MACHINE OPERATIONS AND CONTROLS Mirror (A): Machine L.H. front mirror Mirror (B): Machine rear mirror PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) Adjust the mirror so that the operator can see a person at the rear left of the machine. If the mirror is removed, install it to the position shown in the figure.
Page 198 MACHINE OPERATIONS AND CONTROLS OPERATION Adjust the mirror so that the rear side of the machine is re- flected in the mirror as shown in the figure. If mirror does not move smoothly when adjusting its angle, loosen mirror fixing bolt (1). Tightening torque of bolt (1) 15.7 to 19.6 Nm {1.6 to 2.0 kgm} Check that you can see a person within 1 m away from...
Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the angle of the rear view camera so that people within 1 m away from the machine's rear part (W) appears in the ma- chine monitor at the operator's seat. If the image on the monitor is not aligned correctly, adjust mounting angle (A) of the rear view camera in the following procedure.
Page 200 MACHINE OPERATIONS AND CONTROLS OPERATION Remove bolts (4) (2 places). Remove cover (1). Loosen mounting bolts (5) (3 places) of the camera, and adjust camera installing angle (A) so that the side of cam- era matches the edge of bracket (B). After adjusting, tighten bolts (5).
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 202 On the input display screen displayed on the monitor, input the password and push input confirmation switch F6 (3). REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the pass- word. 3-130...
Page 203 ID number and press input confirmation switch F6 (3). REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identification function. Perform the following inspection on the machine monitor.
Page 204: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL WEATHER WARNING • Start the engine only while sitting down in the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death.
Page 205 OPERATION MACHINE OPERATIONS AND CONTROLS Turn starting switch key (3) to START position (C). The engine will start. When the engine starts, release the starting switch key (3). The key will return automatically to ON position (B). REMARK When the engine is started, the battery voltage may sud- denly drop depending on the temperature and the battery condition.
Page 206 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not start the engine with the fuel control dial near the maximum speed position. If you do so, the engine parts may be damaged. • Do not keep the key in starting switch (3) at the START position continuously for more than 20 seconds.
Page 207 OPERATION MACHINE OPERATIONS AND CONTROLS After preheating monitor (4) goes out, turn starting switch key (3) to START position (C). The engine will start. When the engine starts, release the starting switch key (3). The key will return automatically to ON position (B). NOTICE •...
Page 208: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 209 METHOD FOR RUNNING-IN THE NEW MACHINE 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.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (2) to the middle between Low idle (MIN) and High idle (MAX) to run the engine at a medium speed. Run the engine with no load until engine coolant temperature caution lamp (1) displays proper temperature. •...
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS Turn fuel control dial (2) to Low idle (MIN) position. The engine automatic warm-up is canceled, and the en- gine speed is lowered. REMARK Turbo protect function takes priority over the engine automatic warm-up. When the turbo protect function activates, run the engine at low idle even the engine coolant temperature is 30 °C or less.
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION For detail, see “METHOD FOR ENGINE WARM-UP OPERATION (3-137)”. Set the working mode to P mode (heavy-duty operation mode). Warm up the hydraulic component quickly. For the details of the working mode setting procedure, see “WORKING MODE SELECTOR SWITCH (3-41)”.
Page 213 • Fuel level caution lamp (13): Displays appropriate lev- 11. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 12. Hydraulic system warm-up operation in cold weather NOTICE In cold temperatures (ambient temperature below 0, even when the hydraulic oil temperature cau- tion lamp displays the proper temperature, perform the "warm-up operation for hydraulic equipment...
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (3) to the High idle (MAX) posi- tion. Repeat the work equipment operation of step 6 for 3 to 5 minutes. Check that hydraulic oil temperature caution lamp (6) displays proper temperature. •...
Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS Travel (Lo) control FORWARD (A) <--> REVERSE Boom swing control You can swing the boom with the boom swing control ped- Blade control LOWER (a) <--> RAISE (b) Attachment control For attachment operations (if equipped), change the work- ing mode to the attachment mode.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION 15. Check that hydraulic oil temperature caution lamp (6) dis- plays proper temperature. • Display (A) when temperature is proper: Caution lamp background (C) is blue. • Display (B) when temperature is low: Caution lamp background (C) is white.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS Display of working mode P mode E mode For heavy-duty operations For fuel economy conscious operations L mode B mode For operations requiring fine control For breaker operations ATT/P mode ATT/E mode For operations of 2-way attachment such as crusher For operations of 2-way attachment such as crusher (fuel economy conscious operations) 3-145...
Page 218: Method For Stopping Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stopping the engine. NOTICE If the engine is stopped abruptly, the service lives of com- ponent parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency.
Page 219: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE 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 to the direction of the operation of the travel levers or travel pedals (front and rear travel are reversed, left...
Page 220 (4) slowly. When traveling, check that the alarm sounds normally. If the travel alarm does not sound, contact your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up opera- tion.
Page 221 (4) slowly. When traveling, check that the alarm sounds normally. If the travel alarm does not sound, contact your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up opera- tion.
Page 222: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE 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 directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine.
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS CHANGE DIRECTION OF MACHINE When turning left, return the left travel lever to the neutral posi- tion. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.
Page 224: Method For Swinging Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SWINGING MACHINE WARNING • The tail of the machine extends outside the tracks. Be- fore swinging, check safety around the machine by us- ing the mirrors and visually. • If the travel levers or travel pedals are operated when the engine speed is decreased by the auto-decelera- tion function, the engine speed will suddenly increase.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS • Boom control Move the R.H. work equipment control lever back and forth. You can operate the boom. • Bucket control Move the R.H. work equipment control lever to the right and left. You can operate the bucket. •...
Page 226: Handle Working Mode
MACHINE OPERATIONS AND CONTROLS OPERATION HANDLE WORKING MODE METHOD FOR SELECTING WORKING MODE Use working mode selector switch (1) to select the working mode that matches the operating conditions or purpose. This will make it possible to perform operations efficiently. Use the following procedure to select the most efficient working mode.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS Select a desired working mode and press function switch The change is entered and the screen returns to the stand- ard screen. If function switch F5 is pressed, the screen returns to the standard screen without changing the mode. •...
Page 228: Prohibited Operations
MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITED OPERATIONS WARNING • Do not operate the work equipment control lever when the machine is traveling. • If any lever is operated when the auto-deceleration is being actuated, the engine speed will sudden- ly increase, so be careful when operating. PROHIBITION OF OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging, nor use the dropping force of the bucket as a mattock, breaker, or pile driver. This will drastically reduce the life of the machine. PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig.
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces. As a result, large vibration occurs in the machine and can crack the work equipment or frame.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF SWINGING OR TRAVELING WHEN ROCK IS ON TOP OF TRACK ASSEMBLY If the machine travels or swings with crushed stones, soil, or sand on the track, they hit and damage the undercover and frame.
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION When driving on rough ground (rock-bed, etc.), direct the idler (1) having the cushion mechanism in the travel direction and drive the machine at low speed. GROUND WHOLE THE BOTTOM SIDE OF BLADE TO SUPPORT MACHINE When using the blade as an outrigger, never support the ma- chine with only one end of the blade.
Page 233: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELING Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the under- carriage), and this will cause damage to the machine. For this reason, always remove any obstacles or drive the machine around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS FOR HITTING BLADE AGAINST OBJECTS DURING OPERATING BLADE Be careful not to hit the blade against rocks or boulders. This will cause premature damage to the blade or cylinders. PRECAUTIONS FOR BLADE POSITION DURING BACKHOE OPERATION When digging in front of the blade, take care that the boom cyl- inder does not touch the blade.
Page 235: Precautions For Working On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR WORKING ON SLOPE WARNING • Swinging operations or operating the work equipment on slopes machine may lose its balance and turn over. Avoid such operations as much as possible. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION When traveling up a steep hill of more than 15 deg., set the work equipment to the posture shown in the figure. a: 20 to 30 cm (8 to 12 in) BRAKING ON DOWNHILL SLOPE Put the travel lever in NEUTRAL position. This will cause the brake to be automatically applied. IF ENGINE STOPS ON SLOPE If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket to the ground, stop the machine, then start the engine again.
Page 237: Method For Escaping From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ESCAPING FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out. When track on either side gets stuck NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.
Page 238: Recommended Applications
MACHINE OPERATIONS AND CONTROLS OPERATION RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attach- ments. DIGGING WORK 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 figure (angle between "bucket cylinder and link"...
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS SIDE DITCHING WORK The operator can perform ditching work in a narrow space by combining swing and boom swing operations. LOADING WORK In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator.
Page 240: Method For Lifting Objects With Lifting Device
In the absence of such a device, the machine can only be used as an earth moving machine. If the machine is not equipped with the appropriate hook, contact the Komatsu distributor. Fitting a lifting hook must be monitored and certified by the competent Authorised Body.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS The lifting capacities outlined in the tables relate to machines equipped with a standard bucket. 3-169 WENAM00042...
Page 242: Method For Replacing And Inverting Bucket
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR REPLACING AND INVERTING BUCKET WARNING • When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When performing this operation, always wear goggles, hard hat, gloves, and other personal protec- tive items.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • Perform installation in the reverse order to removal. • Fit O-ring (3) to arm (5) as shown in the figure since it is damaged easily when bucket (4) is installed. After inserting the pin, fit it in the regular groove. Install the lock bolt and nut of each pin.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION Invert the removed bucket. Align arm (5) with mounting hole (1) of link (6). Align link (6) with mounting hole (2) of arm (5). Insert grease-coated pins (A) and (B) into hole (1) and hole (2) respectively. REMARK Fit O-ring (3) to mounting portion (1) of arm (5) and bucket (4).
Page 245: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Place the machine on a firm and level place. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, put blocks to the track shoes. As an additional safety measure, thrust the bucket into the ground.
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION Lower the bucket horizontally until the bottom touches the ground. Lower the blade to the ground. Set lock lever (3) in LOCK position (L). Check the engine coolant temperature and engine oil pres- sure with the machine monitor. •...
Page 247: Method For Checking After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING AFTER FINISHING WORK Perform it after stopping the engine. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant. If any problems are found, repair them. Fill the fuel tank.
Page 248: Lock
MACHINE OPERATIONS AND CONTROLS OPERATION LOCK Lock position Always lock the following places. (1) Operator's cab door (2) Toolbox and grease pump storage cover (3) Engine hood (4) Dirt cover (5) Battery inspection cover (6) Air conditioner fresh air filter storage cover REMARK Use the starting switch key to lock and unlock all these places.
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING ENGINE HOOD CAUTION • When opening or closing the engine hood, place the machine on a level ground, lower the work equipment to the ground, stop the engine, then perform the operation. •...
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION For checks before starting For maintenance other than checks before starting METHOD FOR LOCKING ENGINE HOOD Hold the grip of hood (2) and remove hood support lever (3) from the hood fixing position. Securely fix hood support lever (3) to the lever lock. Lower and press the hood slowly to lock it securely.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING DIRT COVER CAUTION • Never stand on the cover. You may slip and fall. • When inspecting or servicing the inside of the cover, be sure to fix the cover open by using the cov- er support lever.
Page 252 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR LOCKING DIRT COVER Hold the grip of hood (2) and remove hood support lever (3) from the hood fixing position. Securely fix cover support lever (3) to the lever lock. Lower and press the cover slowly and lock it securely. Insert the key into the key slot.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING BATTERY INSPECTION COVER Insert the key into key slot (1). Turn the key counterclockwise and remove it. Pull knob (2) and open cover (3). Remove cover support lever (4) from mounting hole (5) of cover (3).
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION Position (A): OPEN Position (B): LOCK Lock Close the door and insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key. 3-182 WENAM00042...
Page 255: Handle Air Conditioner
If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner system cau- tion lamp lights up on the monitor screen. If the air condi- tioner system caution lamp lights up, ask your Komatsu distributor for inspection and repair. VENTILATION •...
Page 256: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Fan switch (7) Monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Sunlight sensor (5) Auto switch OFF SWITCH This switch is used for stopping the fan and air conditioner.
Page 257 OPERATION HANDLE AIR CONDITIONER Monitor display and air flow Monitor display Air flow rate Air flow "low" Air flow "medium 1" Air flow "medium 2" Air flow "medium 3" Air flow "medium 4" Air flow "high" TEMPERATURE SET SWITCH Use the temperature set switch to adjust the temperature inside the cab.
Page 258 HANDLE AIR CONDITIONER OPERATION (A): Rear vent (2 places) (B1): Face vent (1 place) (B2): Foot vent (1 place) (C): Foot vent (1 place) (D): Front window glass vent (2 places) Air blows out from the vents marked with ○. Vent Monitor display Air vent mode...
Page 259 OPERATION HANDLE AIR CONDITIONER AUTO SWITCH Use the auto switch for automatic selection of the air flow, vents, and air source (FRESH/RECIRC) according to the set temperature. • Press this switch, then use temperature control switch (1) to set the temperature, and run the air conditioner under automatic control.
Page 260: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION AIR CONDITIONER SWITCH Use air conditioner switch for turning the air conditioner (cool- ing, dry heating) ON or OFF. • Press air conditioner switch when the fan is operating (when display (b) is shown on the display monitor). The air conditioner is switched ON and starts to work.
Page 261 OPERATION HANDLE AIR CONDITIONER Set temperature (a) and air flow rate (b) are displayed on “A/C Setting” screen. Use temperature control switch (3) to set to the desired temperature. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated auto- matically to provide the set temperature.
Page 262 HANDLE AIR CONDITIONER OPERATION METHOD FOR MANUAL OPERATION Press fan switch (2) and adjust the air flow. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting” screen of the moni- tor. Press air conditioner switch (8) to turn it ON.
Page 263 OPERATION HANDLE AIR CONDITIONER Press vent selector switch (4) and select the desired vents. At this time, the display of vent (c) on “A/C Setting” screen of the monitor changes according to the selection. Press FRESH/RECIRC selector switch (6) and select recir- culation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
Page 264 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. Press fan switch (2) and adjust the air flow. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting”...
Page 265 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING DEFROSTER Press fan switch (2) and adjust the air flow rate. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting” screen of the moni- tor.
Page 266 HANDLE AIR CONDITIONER OPERATION Press temperature control switch (3) and set temperature to 32.0 of maximum heating. Adjust vents (A), (B1), and (B2) so that the air blows onto the window glass. (Vents (C) and (D) are fixed and cannot be adjusted.) When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, press air conditioner switch (8) to turn it ON.
Page 267: Handle Radio
OPERATION HANDLE RADIO HANDLE RADIO • To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 268: Stow Antenna
HANDLE RADIO OPERATION The preset number is shown for 0.5 seconds, and then the frequency is displayed. STOW ANTENNA Before transporting the machine putting it inside a building, store the antenna to prevent any interference. Loosen antenna mounting bolt (1) and store the antenna at position (A).
Page 269: Handle Road Liners And Rubber Shoes
OPERATION HANDLE ROAD LINERS AND RUBBER SHOES HANDLE ROAD LINERS AND RUBBER SHOES (Road liner, rubber shoe specification) RECOMMENDED USE OF ROAD LINERS AND RUBBER SHOES The road liner and rubber shoes have good features which the steel shoes does not have. However, if they are used similarly to the steel shoes, their features are not used fully.
Page 270 HANDLE ROAD LINERS AND RUBBER SHOES OPERATION • If the rubber parts of the road liner are worn and damaged and the mounting bolt heads are damaged, re- place the shoes with new ones immediately. If the head of a bolt is crushed, that bolt cannot be removed. •...
Page 271 OPERATION HANDLE ROAD LINERS AND RUBBER SHOES When traveling uphills in reverse do not steer on the line between the level ground and the slope. If it is obliged to steer while traveling uphills, steer slowly. Do not travel with either track raised on a slope or convex ground surface (with the machine leaning ap- proximately 10 deg.
Page 272 HANDLE ROAD LINERS AND RUBBER SHOES OPERATION The rubber shoes come off in the following cases. • When the machine is steered while the rubber shoes cannot move sideway because of a material to ride over or another thing. • When the idler or track rollers deviate from the core metal because of misalignment of the rubber shoes.
Page 273: Transportation
OPERATION TRANSPORTATION TRANSPORTATION PRECAUTIONS FOR TRANSPORTING MACHINE When transporting the machine, observe all related laws and regulations, and be careful to assure safety. SELECT TRANSPORTATION METHOD When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS (5-2)”.
Page 274: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER WARNING Always observe the following when loading or unloading the machine from a trailer. • Select the firm, level ground when loading or unload- ing the machine. Maintain a safe distance from the road shoulder •...
Page 275 OPERATION TRANSPORTATION WARNING Always observe the following regarding the ramps and trailer platform. • Use ramps with ample width, length, thickness, and strength and install them with a maximum slope of 15 deg. When using piled soil, compact the piled soil fully to prevent the slope face from collapsing. •...
Page 276 TRANSPORTATION OPERATION When loading, set the work equipment to the front of the machine and set the blade to the rear, and set the under- carriage and the upper structure in parallel. Before moving the machine onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer.
Page 277 OPERATION TRANSPORTATION • Securing the machine when using tie-down point (1) Tie one end of each chain or wire rope of appropriate strength to the tie-down holes on the track frame. X: 50 to 100 mm (Keep the chains off the track frame.) •...
Page 278 TRANSPORTATION OPERATION Apply the trailer brakes securely, then put chocks (1) under the tires to prevent the trailer from moving. Set right and left ramps (2) parallel to each other and equally spaced to the right and left of center (3) of the trail- er.
Page 279: Method For Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
Page 280 TRANSPORTATION OPERATION Swing the upper structure so that the work equipment is on the sprocket (1) side. At this time, set the track frame and upper structure in par- allel. Extend the bucket cylinder and arm cylinder fully, then low- er the work equipment to the ground using the boom cylin- der as shown in the figure.
Page 281: Cold Weather Operation
When handling the coolant containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground sur- face.
Page 282: Precautions After Daily Work Completion In Cold Weather
COLD WEATHER OPERATION OPERATION Electrolyte Temper- ature 20 °C 0 °C –10 °C –20 °C Charging Rate (%) 1.28 1.29 1.30 1.31 1.26 1.27 1.28 1.29 1.24 1.25 1.26 1.27 1.23 1.24 1.25 1.26 • As the battery capacity drastically drops in low temperatures, cover or remove the battery from the ma- chine, store the battery in a warm place, and install it again the next morning.
Page 283: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 284 PRECAUTIONS FOR LONG-TERM STORAGE OPERATION • Insert the battery disconnect switch key and turn it to ON position. • If the machine is stored for a long period with the battery disconnect switch OFF or the battery terminal dis- connected, the clock information and radio tuning information may be lost. In this case, set the information again.
Page 285: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system before starting the engine. Always check the fuel level to prevent running out of fuel. If the engine has stopped due to run out of fuel, all air must be sufficiently bled from the fuel circuit.
Page 286: Precautions For Towing Machine
TROUBLES AND ACTIONS OPERATION • When performing bucket CURL operation from a high posi- tion for digging under no load, the bucket speed drops mo- mentarily at the horizontal position. • The bucket or arm wobbles by itself during heavy-duty dig- ging operations.
Page 287: Precautions For Severe Job Condition
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR SEVERE JOB CONDITION • When performing digging operations in water, if the work equipment mounting pin goes into the water, per- form greasing every time the operation is performed. • For heavy-duty operations and deep digging, perform greasing of the work equipment mounting pins every time before operation.
Page 288: Precautions For Discharged Battery
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 289 OPERATION TROUBLES AND ACTIONS METHOD FOR REMOVING BATTERY Open engine hood (1). Lock the engine hood securely with the hood support lever. Open battery inspection cover (2). Lock the battery inspection cover securely with the cover support lever. Remove wing nuts (3) (2 places). Remove rubber cover (4).
Page 290 TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Follow the instruction manual accompanying the battery charger, and observe the following. •...
Page 291 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 292 TROUBLES AND ACTIONS OPERATION Start engine WARNING Check both of normal machine and failed machine that the lock lever is set to LOCK position. Check also that all the control levers are in NEUTRAL position. Make sure the clips are firmly connected to the battery terminals. Start the engine of the normal machine and run it at high idle (max.
Page 293: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 294 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 295 Improper oil is used. (Viscosity is im- Replace oil. See METHOD FOR US- proper.) ING FUEL, COOLANT AND LUBRI- CANTS ACCORDING TO AMBIENT TEMPERATURE and KOMATSU GENUINE LUBRICANTS. Clogged oil filter cartridge Replace cartridge. See EVERY 500 HOURS MAINTENANCE. Oil leakage due to improper connec- Check, repair.
Page 296 F5 to dis- play “Current Abnormality” and check the details and remedy. Take the actions according to the message shown on the ma- chine monitor, and check the failure code, and then ask your Komatsu distributor for repair, as necessary. 3-224 WENAM00042...
Page 297 “CA559” appears on “Current Abnormality” screen, replace both fuel main filter and fuel prefilter immediately. If “CA2249” or “CA559” does not disappear even after the replacement, ask your Komatsu distributor for inspection immediately, even though the machine can perform normal operation.
Page 298 WENAM00042...
Page 299: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section. WENAM00042...
Page 300: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 301: Avoid Mixing Oil
MAINTENANCE PRECAUTIONS FOR MAINTENANCE • 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. AVOID MIXING OIL Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil.
Page 302: Outline Of Maintenance
Komatsu distributor. • When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend you to use the Komatsu oil clinic to check the characteristics of the oil in detail. FUEL •...
Page 303 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (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.
Page 304 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 305 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 306: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, carefully clean the electric system to prevent corrosion.
Page 307: Standard Tightening Torque For Bolts And Nuts
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, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 308 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Tightening torque Width Nominal - No. of across Target value Allowable range threads "a" flats "b" (mm) Nm kgm Nm kgm 9/16-18UNF 35 to 54 3.5 to 5.5 11/16-16UN 54 to 93 5.5 to 9.5 13/16-16UN 10.5...
Page 309: Maintenance Schedule
See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE WHEN REQUIRED ............................4-14 METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER ..........
Page 310 MAINTENANCE SCHEDULE MAINTENANCE METHOD FOR CHECKING OIL LEVEL IN PTO GEAR CASE, ADDING OIL ......... 4-66 METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ............4-67 METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS....4-69 METHOD FOR CHECKING FAN BELT TENSION AND REPLACING FAN BELT ........4-69 EVERY 2000 HOURS MAINTENANCE ......................
Page 311: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket dig- ging operations, so set the maintenance intervals as follows. Replace hydraulic filter element On a new machine, replace the element after the first 100 to 150 hours, then perform further replacement of the element ac- cording to the table.
Page 312: Maintenance Procedure
MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear personal protective items such as protective eyeglasses and dust mask. NOTICE If inspection, cleaning, or maintenance is performed while the engine is running, dirt enters into the en- gine and damages it.
Page 313 MAINTENANCE MAINTENANCE PROCEDURE Remove clips (5) (3 pieces) and remove cover (6). NOTICE Never remove inner element (8). Dusts may enter, causing the engine failure. Remove outer element (7). NOTICE When cleaning cover (6), do not remove vacuator valve (9). Clean the inside of the air cleaner body and cover (6).
Page 314 MAINTENANCE PROCEDURE MAINTENANCE • Peel off a seal after cleaning the element each time. After cleaning, illuminate the inside of the element with an electric bulb to check. If any holes or thin places are found, replace the outer element. If the element has a small hole or thin part, replace it.
Page 315 MAINTENANCE MAINTENANCE PROCEDURE Replace element Open battery inspection cover (4) on the left side of the machine. Remove clips (5) (3 pieces) and remove cover (6). Remove outer element (7). Do not remove inner element (8) at this time. NOTICE When cleaning cover (6), do not remove vacuator valve (9).
Page 316: Method For Cleaning Inside Of Cooling System
MAINTENANCE PROCEDURE MAINTENANCE Set a new outer element (7). Align matchmarks (11) on the body and cover (6). Install cover (6) and fix it with clip (5). Replace the seal stuck to cover (6) with a new one. Press the button of dust indicator (3) and return the red piston.
Page 317 NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (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.
Page 318 MAINTENANCE PROCEDURE MAINTENANCE Remove cover mounting bolt (3) (3 places) and remove undercover (4). Remove center cover (5) and inspection cover (6). Check that the coolant temperature is low enough to make it possible to touch the radiator cap surface by bare hand, turn radiator cap (7) slowly until it hits the stopper, and re- lease the pressure.
Page 319 MAINTENANCE MAINTENANCE PROCEDURE 14. To complete the warm-up operation of the hydraulic equip- ment more quickly, set the working mode to P mode (heavy-duty mode). For the details of the working mode setting procedure, see “METHOD FOR SELECTING WORKING MODE (3-154)”. 15.
Page 320: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE Repeating the operations from step 1 to 4 moves the pointer of the engine coolant temperature caution lamp (4) upward. The pointer of the engine coolant temperature caution lamp moves down temporarily around the center of gauge (A). Then, continue the operation for approximately 10 minutes.
Page 321: Method For Checking Looseness And Tightening Road Liner Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE Check for looseness of the track shoe bolt (1). If any looseness of the bolt is found, tighten it in order shown in the figure. Tightening: 98.1 to 137 Nm (10 to 14 kgm) Check that the nut and shoe are in close contact with the link contact surface.
Page 322 Continue to pump in grease until S becomes 0 mm. If the tension is still loose, the pins and bushings are excessively worn, so they must be either turned 180 deg. or replaced. Ask your Komatsu distributor for repair. 4-24 WENAM00042...
Page 323: Method For Checking Road Liner
When replacing only part of the road liner, use the special road liner removal tool. Order the tool from your Komatsu distributor. METHOD FOR CHECKING RUBBER SHOES (Rubber shoe specification) If the rubber shoe track is in the following condition, it must be repaired or replaced. Ask your Komatsu distribu- tor for repairs or replacement. 4-25 WENAM00042...
Page 324 MAINTENANCE PROCEDURE MAINTENANCE Lug height • When lug height (a) is reduced to 5 mm or less, replace the rubber shoes track with a new one. If lug height (a) is reduced by wear, the drawbar pull will drop. (1) Track roller (2) Rubber shoe •...
Page 325: Method For Checking And Adjusting Rubber Shoes Track Tension
A crack up to 30 mm long or 10 mm deep does not need to be repaired. For judgment of replacement, repair, and continuation of use of the rubber shoe track, consult your Komatsu distributor. METHOD FOR CHECKING AND ADJUSTING RUBBER SHOES TRACK TENSION (Rubber shoe specification) •...
Page 326: Method For Replacing Rubber Shoes
NOTICE The idler cushion must be removed and adjusted when the rubber shoes are replaced with the road liner or steel shoes. Accordingly, be sure to ask your Komatsu distributor for the replacement. Items to be prepared • Grease pump...
Page 327 MAINTENANCE MAINTENANCE PROCEDURE • Steel pipe METHOD FOR REMOVING RUBBER SHOES WARNING • Never loosen plug (1) more than 1 turn. If plug (1) is loosened more than 1 turn, there is a dan- ger of plug (1) flying out under the high internal pres- sure of the grease.
Page 328 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR INSTALLING RUBBER SHOES Raise the machine off the ground by using the boom and arm. When doing this, operate the levers slowly. Engage the rubber shoe track with the sprocket and place it over the idler. Rotate the sprocket in reverse direction (A), push in the rubber shoe track, and stop the rotation.
Page 329: Method For Changing Shoes
WARNING The idler cushion must be removed and adjusted when the steel shoes or road liner are replaced with the rubber shoes, or reversely. Accordingly, be sure to ask your Komatsu distributor for the replace- ment. METHOD FOR CHANGING FROM STEEL SHOES OR ROADLINERS TO RUBBER...
Page 330 If it is impossible to remove the teeth using this procedure, for safety reasons, it is advisable to have the tooth re- moved by a Komatsu Distributor. Use a rounded bar of slightly less diameter than that of the pin to be extracted.
Page 331: Method For Adjusting Bucket Clearance
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR ADJUSTING BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance. Lower the work equipment to the ground, set it in a stable condition, stop the engine, and set the lock lever securely to LOCK position (L).
Page 332: Method For Checking And Maintenance Air Conditioner
MAINTENANCE PROCEDURE MAINTENANCE Check the fluid level in window washer tank (1). If the level is low, add window washer fluid for automobile. Be careful not to let dirt or dust get in when adding fluid. Mixture ratio of pure washer fluid and water The proper mixing proportion varies with the ambient temperature.
Page 333 (C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributor to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 334: Method For Checking, Cleaning And Lubricating Slide Door Rail And Roller
Spray rail (1) and roller (2) thoroughly with lubricant. After spraying with lubricant, slide the door and check that the door opens and closes smoothly. If the movement is not smooth, consult your Komatsu distributor. METHOD FOR CHECKING, CLEANING AND LUBRICATING SLIDE DOOR STOP- Prepare lubricant.
Page 335: Method For Checking Stopper Clearance In Opening Front Door Is Up
Rubber stopper (1) may be worn partially, but it does not affect the function as long as there is no backlash or clearance. If there is any clearance, consult your Komatsu distributor. METHOD FOR REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER...
Page 336: Method For Washing Washable Floor
MAINTENANCE PROCEDURE MAINTENANCE Place a container to catch drained oil under the filter ele- ment. Turn filter case (1) counterclockwise and remove it. Remove element (2). Remove plug (3) from filter case (1). After checking that the hydraulic oil temperature has drop- ped, turn filter case (1) counterclockwise, remove it, then take out element (2).
Page 337 MAINTENANCE MAINTENANCE PROCEDURE Swing the upper structure slowly so that water drain holes (1) in the cab floor are at a low position. Lower the work equipment to the ground and set the ma- chine in a stable condition. Set the lock lever to LOCK position (L). Stop the engine.
Page 338 MAINTENANCE PROCEDURE MAINTENANCE Put blocks under the track, and thrust the edge of the blade in the ground. Use block WARNING Select a firm flat place. Put strong blocks under the undercarriage to stabilize the machine and be extremely careful when per- forming the operation.
Page 339: Method For Checking Gas Spring
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. Gas springs are installed inside the left console (1 place), at the cab ceiling window (2 places on right and left), and inside the engine hood (1 place).
Page 340 MAINTENANCE PROCEDURE MAINTENANCE NOTICE If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be generated and this may cause a premature damage to the pump. Bleed air securely. Run the engine at low idle. Open the engine hood.
Page 341 MAINTENANCE MAINTENANCE PROCEDURE Bleeding air from swing motor Perform it only when the oil inside the swing motor case is drained. NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. Run the engine at low idle. Loosen hose (3).
Page 342 MAINTENANCE PROCEDURE MAINTENANCE Bleeding air from attachment (when installed) Perform it when any hydraulic component or oil is replaced. NOTICE If the air bleeding procedure is specified on the attachment by the manufacturer, bleed the air according to that procedure. If a breaker or other attachment is installed, perform the air bleeding procedure until the air is completely bled from the attachment circuit.
Page 343: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING”. • Method For Draining Water and Sediment From Fuel Tank • Method For Checking Dust Indicator • Method For Checking Water Separator, Draining Water and Sediment •...
Page 344: Every 100 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 100 HOURS MAINTENANCE METHOD FOR LUBRICATING WORK EQUIPMENT NOTICE If any unusual noise is generated from any greasing point, perform greasing regardless of the greasing interval. Perform greasing every 10 hours for the first 50 hours operation on a new machine. After the machine is subjected to digging work in the water, be sure to grease the wet pins.
Page 345 MAINTENANCE MAINTENANCE PROCEDURE Pull out dipstick (G). Wipe off the oil from the dipstick with a cloth. Fully insert dipstick (G) into the dipstick pipe, then remove Check the oil level with dipstick (G). The oil level should be between H and L marks on the dip- stick.
Page 346: Every 250 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 250 HOURS MAINTENANCE METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Accordingly, wait until they have cooled down before starting the work. •...
Page 347 If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufac- turer.
Page 348 (sodium bicarbonate), then flush it away with a large amount of water. If nec- essary, consult your Komatsu distributor or your battery manufacturer. If it is possible to use indicator to check electrolyte level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 349: Method For Checking And Adjusting Air Conditioner Compressor Belt Tension
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION Check air conditioner compressor belt tension Open engine hood (1). Securely lock the hood with hood support lever (2). Remove bolt (3) of the fan guard. Loosen bolt (4) and move the fan guard in the arrow direc- tion.
Page 350 Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks of the belt. Ask your Komatsu distributor for replacement of the belt. 4-52...
Page 351: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 100 and 250 hours should be performed at the same time. METHOD FOR LUBRICATING NOTICE • If any unusual noise is generated from any greasing point, perform greasing regardless of the greasing interval.
Page 352 MAINTENANCE PROCEDURE MAINTENANCE (9) Link connection pin (2 places) (10) Bucket cylinder rod end pin (1 place) (11) Bucket and Link connection pin (2 place) (12) boom swing bracket pin (2 places) Supply grease to the boom swing bracket pin according to the following procedure.
Page 353 MAINTENANCE MAINTENANCE PROCEDURE (13) Boom swing cylinder rod end pin (1 place) (14) Boom swing cylinder foot pin (1 place) (15) Blade cylinder foot pin (1 place) (16) Blade cylinder rod end (1 place) (17) Blade foot pin (2 places) After greasing, wipe off any old grease that is pushed out.
Page 354: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 355 MAINTENANCE MAINTENANCE PROCEDURE Open inspection cover (1). Turn valve (2) to CLOSE position (S). Open engine hood (3). Securely lock the hood with hood support lever (4). Place a container under the fuel prefilter cartridge to re- ceive the fuel. Loosen drain valve (5) and drain water and sediments from transparent cup (6), and also drain all the fuel from fil- ter cartridge (7).
Page 356: Method For Checking Swing Pinion Grease Level, Add Grease
MAINTENANCE PROCEDURE MAINTENANCE NOTICE • When filling the filter cartridge with fuel, do not re- move cap (B). Always fill with fuel from 8 small holes (A) on the dirty side. • After filling with fuel, remove cap (B) and install the fuel filter.
Page 357: Method For Lubricating Swing Circle
Check that the grease is not milky white. Total amount of grease: 5.5 ℓ If the grease is milky white, it needs to be replaced. Ask your Komatsu distributor to replace it. Install grease filler port cover (4) with bolts (3). Install cover (2) with bolt (1).
Page 358 MAINTENANCE PROCEDURE MAINTENANCE Open engine hood (1). Securely lock the hood with hood support lever (2). Open battery inspection cover (3) on the left side of the machine. Securely lock the cover with cover support lever (4). Remove wing screws (5) (4 pieces) and remove net (6). Clean net (6).
Page 359: Method For Cleaning Air Conditioner Fresh/Recirc Air Filters
MAINTENANCE MAINTENANCE PROCEDURE 13. After inspecting and cleaning, install net (6) as it was. METHOD FOR CLEANING AIR CONDITIONER FRESH/RECIRC AIR FILTERS WARNING • When using compressed air, there is a danger that dirt may scatter and cause personal injury. Al- ways wear personal protective items such as protective eyeglasses and dust mask.
Page 360: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE REMARK The fresh air filter must be installed facing it in the correct direction. When installing, insert the long (L) end of filter (2) into the filter case first. If the short (S) end is installed first, cover (1) will not close.
Page 361: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours should be performed at the same time. METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Wait for the temperature to go down, and start the work.
Page 362 MAINTENANCE PROCEDURE MAINTENANCE Open dirt cover (1). Lock securely with cover support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). Remove the cap of oil filler port (F) gradually to release the internal pressure.
Page 363: Method For Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGE OIL IN SWING MACHINERY CASE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. Refill capacity: 2.8 ℓ...
Page 364: Method For Checking Oil Level In Pto Gear Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE • Hexagonal wrench Bring plug (P) to the lowest position. Place the oil container to catch oil under plug (P). By using a hexagonal wrench, remove plugs (P), (G), and (F) , and drain the oil. Tighten plug (P) . Add the refill capacity of engine oil through oil filler port (F).
Page 365: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 366 MAINTENANCE PROCEDURE MAINTENANCE Open inspection cover (1). Turn valve (2) to CLOSE position (S). Open engine hood (3). Securely lock the hood with hood support lever (4). Place a container under filter cartridge (5) to receive the fuel. Turn filter cartridge (5) counterclockwise by using the filter wrench, and remove it.
Page 367: Method For Checking All Tightening Points Of Engine Intake Pipe Clamps
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR CHECKING FAN BELT TENSION AND REPLACING FAN BELT Special tools are required for the inspection and replacement.
Page 368: Every 2000 Hours Maintenance
• Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 369 If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulator for the hy- draulic circuit has probably dropped. Ask your Komatsu distrib- utor for inspection. This completes the inspection. After completion of the inspection, set the lock lever to LOCK position and turn the starting switch to OFF position.
Page 370 MAINTENANCE PROCEDURE MAINTENANCE Method for releasing pressure in hydraulic circuit Lower the work equipment to the ground. REMARK Close the crusher attachment jaws, etc. Set the lock lever to LOCK position (L). Perform the following procedure within 15 seconds. REMARK After the engine stops, the accumulator pressure decrea- ses gradually.
Page 371: Method For Checking Alternator And Starting Motor
Turn the starting switch to OFF position (A). METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for in- spection and repairs. If the engine is started frequently, have this inspection performed every 1000 hours.
Page 372 MAINTENANCE PROCEDURE MAINTENANCE The KCCV ventilator is located in the positions shown in the figure. By using tools, loosen bolt (3) and nut (4) of elbow (2) above KCCV ventilator (1). Move loosened bolt (3) and nut (4) along the groove of el- bow (2) to position (A) shown in the figure.
Page 373 MAINTENANCE MAINTENANCE PROCEDURE By using the filter wrench, loosen cover (7) of KCCV venti- lator (1). At this time, tube (5) and hose (6) rotate together with cov- er (7). After removing cover (7) from ventilator body (8), remove element (9). Oil may be accumulated in or sticking to cover (7) and ele- ment (9).
Page 374 MAINTENANCE PROCEDURE MAINTENANCE Tighten the cover until clearance (B) between it and body is eliminated with the bare hand or by using a filter wrench. At this time, check that bolt-fixed position (C) of tube (5) is within the range of the groove of elbow (2). REMARK As a mark, notch (D) is made on the plate.
Page 375: Every 4000 Hours Maintenance
METHOD FOR CHECKING WATER PUMP Check for play of the pulley, oil leakage, water leakage, and clogging of weep hole (drain hole). If anything ab- normal is found, ask your Komatsu distributor for disassembly and repair or replacement. 4-77 WENAM00042...
Page 376: Method For Replacing Accumulator (For Control Circuit)
• Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 377: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
(6 places) for the high-pressure piping between the supply pump and the common rail. If there are any problems, the replacement must be performed. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,...
Page 378: Every 5000 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 5000 HOURS MAINTENANCE Maintenance for every 100, 250, 500 and 1000 hours service should be performed at the same time. METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 379 MAINTENANCE MAINTENANCE PROCEDURE Open dirt cover (1). Lock securely with cover support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). Remove the cap of oil filler port (F) gradually to release the internal pressure.
Page 380 MAINTENANCE PROCEDURE MAINTENANCE 16. Loosen the bolts (4 pieces) and remove cover (7). At this time, cover (7) may jump out under the force of spring (8). Remove the bolts while pressing the cover (7) down a. 17. Hold the top of rod (9), pull it up, and remove spring (8) and strainer (10).
Page 381: Specifications
SPECIFICATIONS WENAM00042...
Page 382 2100 mm arm Item Unit specification specification specification Machine weight (including blade) kg 8640 Bucket capacity m 0.20 Engine model Komatsu SAA4D95LE-6 diesel engine SAE J1995 50.7/1950 (Gross) Rated horsepower kW/rpm ISO 9249/ SAE 48.8/1950 J1349 (Net) Overall length mm 6255 6350...
Page 383 SPECIFICATIONS SPECIFICATIONS Road liner specification 1650 mm arm 1900 mm arm 2100 mm arm Working ranges (mm) Unit specification specification specification Max. digging reach mm 6935 7150 7345 Max. digging depth mm 4160 4385 4615 Max. digging height mm 6570 6685 6750 Max.
Page 384: Explanation Of Lift Capacity Chart
EXPLANATION OF LIFT CAPACITY CHART SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART WARNING The excavator used in handling operations must conform with current local regulations and be equip- ped with safety valves and an overload alarm in compliance with EN 474-5. For detail see “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE (3-168)”.
Page 385 SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping). RKA46601 WENAM00042...
Page 386 WENAM00042...
Page 387: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section. WENAM00042...
Page 388: Precautions For Using Attachment And Options
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any not authorized by Komatsu. Any personal injury, failure, or property damage caused by the use of unauthorized attachments or options will not be the responsibility of Komatsu.
Page 389 ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS • The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight when it is stopped in a raised position) also becomes greater. Do not stop the work equipment in air.
Page 390: Quick Coupler System
Check that the valve is correctly set. • Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu dealer. LOCATIONS (1) Quick coupler switch...
Page 391 This machine has a system installed to give a warning if there is a failure to maintain pressure in the quick coupler system. If the buzzer sounds in the cab make sure that the cause is clarified be- fore continuing work. In particular check for leaks in the system. If in doubt call your Komatsu dis- tributor.
Page 392 QUICK COUPLER SYSTEM ATTACHMENTS AND OPTIONS Operate switch (1), and with switch (1) in position “B” press and hold button (2) on the left hand lever, to activate quick coupler. NOTICE The switch has a safety lock mechanism to prevent ac- cidental operation.
Page 393: 2-Piece Boom
ATTACHMENTS AND OPTIONS 2-PIECE BOOM 2-PIECE BOOM 2-PIECE BOOM COMPONENTS (1) First boom (3) Second boom (2) Boom cylinder (4) 2-piece boom cylinder 2-PIECE BOOM CONTROL PEDAL The 2-piece boom control pedal is situated at the left of travel levers. It controls the extension and folding of the 2-piece boom ac- cording to the movements indicated.
Page 394: Method For Lubricating 2-Piece Boom
2-PIECE BOOM ATTACHMENTS AND OPTIONS METHOD FOR LUBRICATING 2-PIECE BOOM NOTICE Perform greasing every 500 hours. If any unusual noise is generated from any greasing point, perform greasing regardless of the greasing interval. Perform greasing every 10 hours for the first 50 hours operation on a new machine. After the machine is subjected to digging work in the water, be sure to grease the wet pins.
Page 395: Specifications
ATTACHMENTS AND OPTIONS 2-PIECE BOOM SPECIFICATIONS Item Unit 1650 mm arm specification 1900 mm arm specification Overall length mm 5787 6103 Overall height mm 2760 2760 WENAM00042...
Page 396 2-PIECE BOOM ATTACHMENTS AND OPTIONS Working ranges (mm) Unit 1650 mm arm specification 1900 mm arm specification Max. digging reach mm 7586 7836 Max. digging depth mm 4425 4675 Max. digging height mm 8017 8259 Max. vertical wall digging depth mm 3785 4022...
Page 397: Explanation Of Lift Capacity Chart
ATTACHMENTS AND OPTIONS 2-PIECE BOOM EXPLANATION OF LIFT CAPACITY CHART WARNING The excavator used in handling operations must conform with current local regulations and be equip- ped with safety valves and an overload alarm in compliance with EN 474-5. For detail see “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE (3-168)”. Legend A: Reach from swing centre B: Bucket hook height...
Page 398 2-PIECE BOOM ATTACHMENTS AND OPTIONS Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping). RKA47481 Caution for overloading machine 6-12 WENAM00042...
Page 399: Handle Bucket With Hook
HANDLE BUCKET WITH HOOK HANDLE BUCKET WITH HOOK When using the bucket with hook, check that there is no damage to the hook, stopper, or hook mount. If there is any problem, ask your Komatsu distributor. PRECAUTIONS FOR OPERATION PRECAUTIONS FOR LIFTING OPERATIONS •...
Page 400: Handle Machine Ready For Installation Of Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS (1) Selector valve (4) 2nd-line attachment proportional switch (2) 1st-line attachment proportional switch (5) Additional filter for breaker (3) Breaker operation switch (6) Accumulator (for low pressure) SELECTOR VALVE The selector valve switches the flow of the hydraulic oil.
Page 401 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENT 1 PROPORTIONAL SWITCH Operate the 1st-line attachment proportional switch when using general attachments. You can increase or decrease the flow rate by controlling the switch stroke. The attachment does not operate unless the attachment mode is set on the machine monitor.
Page 402: Hydraulic Circuit
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS The 2nd-line attachment proportional switch operates the 2nd attachment circuit (e.g. clamshell rotation). The 2nd-line attach- ment proportional switch is a roller proportional control switch. Rolling the switch up produces rotation in one direction, rolling down produces rotation in the opposite direction.
Page 403: Method For Removing And Installing Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR REMOVING AND INSTALLING ATTACHMENT WARNING Lower the attachment to the ground and stop the engine. METHOD FOR REMOVING ATTACHMENT Lower the attachment to the ground and stop the engine. Turn the starting switch to ON position (B).
Page 404 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Set the lock lever to LOCK position (L). Turn the starting switch to OFF position (A). Open dirt cover (1). Lock securely with cover support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F).
Page 405 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 13. Pull out the mounting pins (2 places), remove the attach- ment, then install the bucket. For the installation procedure of the bucket, see “METHOD FOR REPLACING AND INVERTING BUCKET”. After installing the bucket, check the oil level in the hydraulic tank.
Page 406 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Operate each control lever (work equipment, travel) and attachment control switch fully in each direction within 15 seconds after the engine is stopped to release the internal pressure in the hydraulic circuit. Set the lock lever to LOCK position (L).
Page 407 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Open dirt cover (1). 10. Lock securely with cover support lever (2). 11. Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). 12. Remove the cap of oil filler port (F) gradually to release the internal pressure.
Page 408 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 17. Check the position of the valve (V). • Pos. a: for exclusion of bucket cylinder (with wrench supplied rotate the valve clockwise) • Pos. b: for activation of bucket cylinder (with wrench supplied rotate the valve counterclockwise) RKA63780 18.
Page 409: Method For Operating Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR OPERATING ATTACHMENT WARNING If the travel levers or travel pedals are operated when the engine speed is decreased by the auto-decel- eration function, the engine speed will suddenly increase. Be careful. METHOD FOR OPERATING BREAKER NOTICE When performing breaker operations, use the breaker mode.
Page 410 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Press working mode selector switch (1) or press switches F3 or F4 to select Breaker Mode B. Breaker mode B is highlighted in yellow. With breaker mode B highlighted in yellow, enter the selec- tion by performing either of the following operations.
Page 411 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT • Is the selector valve in the dirt cover set to the position for general attachment such as crusher? • Is lock bar (2) for the selector valve in the dirt cover instal- led to the position for general attachment such as crusher? For other precautions when handling the attachment, follow the instruction manual from the attachment manufacturer and use the attachment correctly.
Page 412: Long-Term Storage
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS LONG-TERM STORAGE NOTICE If you set the working mode to BREAKER/ATTACHMENT and operate the switch while no breaker and no general attachment are installed, the machine may overheat. If the equipment is not to be used for a long time, do as follows. Set the selector valve to the position for general attachment such as crusher.
Page 413: Handle Machine Ready For Powertilt (3Rd Line)
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR POWERTILT (3rd LINE) HANDLE MACHINE READY FOR POWERTILT (3rd LINE) EXPLANATION OF COMPONENTS RKA63790 (1) 2nd line activation switch (3) 3rd line (2) Attachment proportional switch (2nd-3rd line) 2nd LINE ACTIVATION SWITCH When the switch is pressed, activates the 2nd hydraulic line. 6-27 WENAM00042...
Page 414: Method For Operating Powertilt
HANDLE MACHINE READY FOR POWERTILT (3rd LINE) ATTACHMENTS AND OPTIONS Pressing the switch again, the 2nd line is deactivated and re- turns the 3rd line. It controls the extension and folding of the 2-piece boom ac- cording to the movements indicated. RKA63800 The lights (a) and (b) positioned above the monitor indicate the selection of 2nd or 3rd line.
Page 415 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR POWERTILT (3rd LINE) The proportional equipment switch is used for the equipment operation. USING BREAKER WHIT 3rd LINE • You can not activate the 3rd line when the working mode is B. Select the ATT/P working mode. •...
Page 416 HANDLE MACHINE READY FOR POWERTILT (3rd LINE) ATTACHMENTS AND OPTIONS LIFTING CAPACITY DIAGRAM WARNING The excavator used in handling operations must conform with current local regulations and be equip- ped with safety valves and an overload alarm in compliance with EN 474-5. For detail see “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE (3-168)”.
Page 417 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR POWERTILT (3rd LINE) Lifting capacity diagram with boom 6-31 WENAM00042...
Page 418 HANDLE MACHINE READY FOR POWERTILT (3rd LINE) ATTACHMENTS AND OPTIONS Lifting capacity diagram with 2-piece boom 6-32 WENAM00042...
Page 419 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR POWERTILT (3rd LINE) Lifting capacity diagram with boom - Overload alarm Overload diagram with 2-piece boom - Overload alarm 6-33 WENAM00042...
Page 420: Attachments And Options
• Installing attachments or optional equipment without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the ma- chine and the life of the equipment.
Page 421 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS Opening Opening Tooth Capacity width width Model mounting Short arm Long arm SAE/CECE (Side cut- (Body) ter) Narrow dig- Narrow bucket Vertical 0.13/0.11 ○ ○ ging Vertical Narrow dig- Narrow bucket 0.20/0.18 ○ ○ ging Horizontal Vertical...
Page 422: Track Shoes Selection
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS TRACK SHOES SELECTION Select the appropriate track shoe to match the operating conditions. Track shoe selection Check the ground to work in Use column of Use category table, and then check Category column. Classification by use Classi- Precautions when using fication...
Page 423: Recommended Attachment Operations
Select the optimum attachment model for the hydraulic excavator body. The attachments and models ready for installation differ according to the machine body. For details of the selection of the attachments or the models, consult your Komatsu distributor. HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows.
Page 424 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm off the ground. Do not raise it off the ground unnecessarily. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 425 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not use the mount to gather in pieces of rock. Do not work by using the swing force. Do not move the chisel while performing breaking operation. Do not perform breaker operation in horizontal or upward direc- tion.
Page 426 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Do not perform the operation with bucket cylinder rod extended fully to raise the machine off the ground. Do not perform the breaker work with any cylinder at the stroke end.
Page 427 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Grease the breaker while holding it in the right posture shown below. • Lower the chisel perpendicularly to the ground. • Insert the grease gun perpendicularly to the greasing point. Wrong posture 6-41 WENAM00042...
Page 428 WENAM00042...
Page 429: Replacement Parts
REPLACEMENT PARTS WENAM00042...
Page 430: Periodic Replacement Of Defined Life Parts
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Parts for periodic replacement...
Page 431: Consumable Parts
When replacing parts, Komatsu recommends using 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 the latest part number when ordering parts. CONSUMABLE PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 432: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 433: Lubrication Chart
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT LUBRICATION CHART • The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication interval. Keep this chart in the magazine box inside the cab so that the people concerned can refer it any time dur- ing lubrication.
Page 434 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter WENAM00042...
Page 435: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
250 hours. For changing maintenance time of machine monitor, ask your Komatsu distributor to perform. Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Page 436: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Non-Amine Engine Coolant (AF-NAC) is supplied in diluted state, so always fill up with it. (Never dilute it with water) RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. WENAM00042...
Page 437: Index
INDEX INDEX Symbols Automatic warm-up operation - Cancel....3-138 Avoid mixing oil............4-3 12H/24H display mode - Switch......3-72 2-Piece boom............6-7 2-Piece boom components........6-7 Backhoe work............. 3-166 2-Piece boom control pedal......3-89,6-7 Basic operation of machine monitor......3-12 2nd line activation switch........6-27 Basic operation of machine monitor when starting en- 3rd line..............
Page 438 INDEX Check signs and signalman's signals....2-27 Checks after inspection and maintenance....4-3 ECO gauge............3-37 Checks and adjustment before starting engine.... ECO gauge - Set target fuel consumption value...3-58 .............2-29,3-109 ECO guidance............3-33 Checks before starting........2-31,4-45 ECO guidance record - Check......3-53 Cigarette lighter.............3-80 Economy mode - Adjust........3-61 Clock - Adjust............3-70...
Page 439 Fuel level caution lamp......... 3-25 Keep work place clean and tidy......2-42 Fuel main filter cartridge - Replace....... 4-67 Komatsu Closed Crankcase Ventilation (KCCV) 3-106 Fuel prefilter cartridge - Replace......4-56 Komatsu genuine lubricants........4-2 Fuel spray prevention cap - check for missing and Komatsu genuine replacement parts......
Page 440 Machine ready for installation of attachment - Handle................6-14 Machine ready for Powertilt - Handle....6-27 Machine settings........... 3-60 Perform KOWA (Komatsu Oil Wear Analysis)..4-6 Magazine box............3-98 Periodic replacement of defined life parts..2-50,7-2 Main use of machine..........1-8 Permissible depth of water, soil and dirt..... 3-162 Maintenance during long-term storage....
Page 441 INDEX Precautions for high-pressure oil......2-48 Product information..........1-11 Precautions for high-temperature coolant.....2-47 Prohibited operations........2-34,3-156 Precautions for high-temperature oil.....2-47 Prohibition of digging operation at an angle without Precautions for high-temperature parts....2-48 engaging teeth..........3-158 Precautions for hitting blade against objects during Prohibition of digging operation on hard rocky ground.
Page 442 INDEX Rubber shoes - Check.......... 4-25 Swing pinion - Check grease level / Add grease.. 4-58 Rubber shoes - Install........... 4-30 Switches..............3-79 Rubber shoes - Remove........4-29 System caution lamp..........3-25 Rubber shoes - Replace........4-28 System operating lamp........3-105 Rubber shoes to steel shoes or roadliners - Change................4-31 Rubber shoes track tension - Check.....4-27 Temperature set switch........
Page 443 INDEX Window washer fluid - Check level / Add....4-33 Window washer fluid - select........ 2-50 Window washer switch..........3-45 Wiper pilot lamp............ 3-31 Wiper switch............3-44 Work equipment - Lubricate........4-46 Work equipment - Operate........3-152 Work equipment control lever....... 3-90 Work equipment lock pilot lamp......3-33 Working lamp - Check.........3-121 Working mode.............3-154 Working mode - Display........3-31...

Komatsu PC88MR-10 Operation & Maintenance Manual

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