Page 1 Operation & EEAM029900 Maintenance Manual PC2000 HYDRAULIC EXCAVATOR 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. This manual should be kept inside the cab for reference and periodically reviewed by all personel who will come into contact with the machine.
Page 3 FOREWORD...
Page 4: Foreword
Continuing improvements in the design of this machine may lead to addi- tional 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 injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.
Page 6: Noise Emission Levels
FOREWORD SAFETY INFORMATION Noise emission levels One labels indicating the machine noise level is affixed on the machine. q Sound pressure level at the operator's station, measured according to ISO6396 (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 2.5 dB, in accordance with ISO 11201...
Page 7: Guide To Reduce Vibration Levels On Machine
FOREWORD SAFETY INFORMATION Operating condition: (HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating) Guide to Reduce Vibration Levels on Machine The following guides can help an operator of this machine to reduce the whole body vibration levels: 1. Use the correct equipment and attachments. 2.
Page 8: Introduction
FOREWORD INTRODUCTION INTRODUCTION USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: q Digging work q Loading work See the section “RECOMMENDED APPLICATIONS (3-228)“ for further details. DIRECTIONS OF MACHINE Front Operator's seat...
Page 9: Visibility From Operator's Seat
FOREWORD INTRODUCTION VISIBILITY FROM OPERATOR'S SEAT The visibility for operator for this machine according to ISO 5006 is shown in the diagram below PROXIMITY VISIBILITY The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below.
Page 10: Circumference Visibility
FOREWORD INTRODUCTION 12M CIRCUMFERENCE VISIBILITY The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be seen when operating the machine.
Page 11: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the bottom right of the room under the operator's cab.
Page 12: Epa Regulations, Engine Number Plate
FOREWORD PRODUCT INFORMATION EPA REGULATIONS, ENGINE NUMBER PLATE This is at the top left of fuel filter (1) on the engine cylinder block, as seen from the front of the machine. (Machine of poor fuel arrangement specification) This is on top of the common rail cover on the engine cylinder block, seen from the front of the engine. EPA: Environmental Protection Agency, U.S.A.
Page 13: Service Meter Location
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU LTD. Address: 2-3-6 Akasaka Minato-ku, 101 Tokyo Japan Authorised representative: KOMATSU EUROPE INT. Address: Mechelsesteenweg 586 B-1800 Vilvoorde Belgium Distributor name Address Service Personnel Phone/Fax 1-11...
Page 14: Machine Serial Number Plate (According Directive 2006/42/Ec)
FOREWORD PRODUCT INFORMATION MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC) Machine designation/type Engine power Serial Number Product Identification Number Year of construction Manufacturer Operating mass Authorised representative 1-12...
Page 15: Declaration According Directive 2006/42/Ec Annex I Point 1.7.4.2 (C)
FOREWORD PRODUCT INFORMATION Declaration according Directive 2006/42/EC Annex I point 1.7.4.2 (c) The manufacturer/Authorized representative The manufacturer Authorized representative KOMATSU LTD. KOMATSU EUROPE INT. 2-3-6 Akasaka Mechelsesteenweg 586 Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde Japan Belgium Declares that this machine PC2000-8...
Page 16: Table Of Contents
CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL ............................1-2 SAFETY INFORMATION ................................1-3 Noise emission levels..............................1-4 Vibration levels ................................1-4 Guide to Reduce Vibration Levels on Machine ....................1-5 INTRODUCTION ..................................1-6 USE OF MACHINE ................................ 1-6 DIRECTIONS OF MACHINE............................1-6 VISIBILITY FROM OPERATOR'S SEAT ........................
Page 17 CONTENTS LIFTING OBJECTS WITH BUCKET ..........................2-31 PRECAUTIONS FOR MAINTENANCE ..........................2-33 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE..............2-33 PRECAUTIONS FOR INSPECTION AND MAINTENANCE ..................2-38 END OF SERVICE LIFE ............................2-44 OPERATION MACHINE VIEW ILLUSTRATIONS ............................3-2 OVERALL MACHINE VIEW ............................3-2 CONTROLS AND GAUGES ............................3-3 DETAILED CONTROLS AND GAUGES ..........................3-7 MONITORING SYSTEM ..............................3-7 Basic Operation of Machine Monitor ........................3-8...
Page 18 CONTENTS Additional Power Source..........................3-133 FUSE..................................3-134 CIRCUIT BREAKER..............................3-136 FUSE (IF EQUIPPED)..............................3-139 CONTROLLER................................3-140 TOOL, CAN STORAGE PLACE..........................3-141 HANDLING GREASE PUMP AND GREASE GUN....................3-141 ACCUMULATOR................................3-148 METHOD OF RELEASING PRESSURE IN ACCUMULATOR FOR HYDRAULIC CONTROL CIRCUIT ..3-149 HANDLING HYDRAULIC LADDER ...........................3-150 PROCEDURE FOR OPERATING HYDRAULIC LADDER ................3-150 ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH....3-152 HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus ..................3-156 KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED ........3-156...
Page 19 OUTLINE OF SERVICE ................................4-5 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................4-5 OIL ..................................4-5 FUEL ..................................4-6 COOLANT AND WATER FOR DILUTION ......................4-6 GREASE ................................4-7 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)..................4-7 STORING OIL AND FUEL ...........................4-8 FILTERS ................................4-8 ELECTRIC SYSTEM MAINTENANCE...........................4-9 1-17...
Page 20 CONTENTS WEAR PARTS..................................4-10 WEAR PARTS LIST ..............................4-10 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................... 4-11 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....................................4-13 TIGHTENING TORQUE SPECIFICATIONS ........................... 4-14 TIGHTENING TORQUE LIST ............................4-14 SAFETY CRITICAL PARTS..............................4-15 SAFETY CRITICAL PARTS LIST ..........................
Page 21 CONTENTS CLEAN PTO LUBRICATION OIL FILTER STRAINER ..................4-94 REPLACE HYDRAULIC OIL FILTER ELEMENT ....................4-95 REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT ..............4-96 INSPECTION OF ENGINE SUCTION HOSE CLAMP FOR LOOSENING............4-96 CHECK FOR LOOSE CLAMPS OF AFTERCOOLER HOSE................4-98 CHECK GAS PRESSURE IN ACCUMULATOR FOR OPERATION CONTROL CIRCUIT .......4-99 CHECK WELDED STRUCTURE ........................4-99 CHECK EMERGENCY LADDER ........................4-102 GREASING HYDRAULIC LADDER .........................4-103...
Page 22 CONTENTS METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL........6-19 GREASING LADDER SERVICE ARM ......................... 6-30 REPLACE FUEL TANK BREATHER ELEMENT ......................6-31 ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH ......6-32 HANDLING JUMP START RECEPTACLE ..........................6-36 GENERAL LOCATIONS ..............................
Page 23: Safety
SAFETY WARNING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 24 SAFETY SAFETY SAFETY SAFETY LABELS..............................2-42 LOCATION OF SAFETY LABELS ....................... 2-52 SAFETY LABELS............................2-62 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ..........2-112 PRECAUTIONS BEFORE STARTING OPERATION ................2-112 ENSURING SAFE OPERATION ......................2-112 UNDERSTANDING THE MACHINE ....................2-112 PREPARATIONS FOR SAFE OPERATION....................
Page 25 SAFETY SAFETY OPERATING ON SLOPES ......................... 2-272 PROHIBITED OPERATIONS ......................2-272 TRAVELING ON SNOW-COVERED OR FROZEN SURFACES ............2-292 PARKING MACHINE .......................... 2-292 TRANSPORTATION..........................2-302 LOADING AND UNLOADING......................2-302 TOWING ..............................2-312 PRECAUTIONS WHEN TOWING ...................... 2-312 LIFTING OBJECTS WITH BUCKET......................2-312 PRECAUTIONS FOR LIFTING OPERATIONS ..................
Page 26: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
Page 27: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 9JH14979B...
Page 28: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution for operation, inspection and maintenance (09651-A0481) q Warning! q Read the manual before operating, maintenance, disas- sembly, assembly and transportation. (2)Caution before operating (09802-A0480) To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments: q Honk horn to alert people nearby.
Page 29 SAFETY SAFETY LABELS (4) Caution for going close to electrical cables (09801-A0641) q Sign indicates an electrocution hazard if the machine is brought too near electric power lines. q Keep a safe distance from electric power lines. (5) Caution for operating pattern (09822-A0750) WARNING In order to prevent an accident resulting in injury or death caused by error-operation, confirm the machine motion...
Page 30 SAFETY SAFETY LABELS (7) Caution for handling accumulator (09659-A057B) q There is the hazard of explosion causing injury. q Do not disassemble the accumulator, make holes in it, weld it cut it, hit it, roll it or bring it near flame. (8) Caution for adjusting track tension (09657-A0881) q Sign indicates a hazard of flying plug from track adjuster that could cause injury.
Page 31 SAFETY SAFETY LABELS (12) Beware of work equipment (09134-A1681) q Sign indicates a hazard of being hit by the working device of the machine. q Keep away from machine during operation. (13) Caution against falling (09805-C0481) q There is the hazard of falling. q Do not step here! (14) Jump start prohibited (09842-A0481) q Start the engine only after sitting down in the operator’s...
Page 32 SAFETY SAFETY LABELS (16) Emergency Exit (09844-00050 (17) Caution about operators cab door during machine operation q Warning ! q Do not operate with the left door open. (18) Caution when handling batteries a) Never smoke or use any naked flame near the batteries, no sparks.
Page 33: General Precautions Common To Operation And Maintenance
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 34: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE KEEP MACHINE CLEAN q If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 35: Fire Prevention
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION ACTION IF FIRE OCCURS q Turn the start switch OFF to stop the engine. q Use the handrails and steps to get off the machine. q Do not jump off the machine. There is the danger of falling and suffering serious injury. PRECAUTIONS TO PREVENT FIRE q Fire caused by fuel, oil, coolant, or window washer fluid...
Page 36: Precautions When Getting On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE q Fire coming from electric wiring Short circuits in the electrical system can cause fire. To prevent fire, always observe the following. q Keep all electric wiring connections clean and securely tightened. q Check the wiring every day for looseness or damage.
Page 37: No Jumping On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE q Always face the machine and maintain at least three-point contact (both feet and one hand, or both hands and one foot) with the handrail and steps to ensure that you support yourself.
Page 38: Do Not Get Caught In Work Equipment
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not taken when parking the machine, the machine may suddenly move off by itself, and this may lead to serious personal injury or death. Always do the fol- lowing.
Page 39: Protection Against Falling, Flying, Intruding Objects
If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu dis- tributor for advice on the method of repair.
Page 40: Precautions Related To Cab Glass
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE q Depending on type of combination of work equipment, there is hazard that the work equipment may hit the cab or other parts of the machine. During operation, an interference of the work equipment with the machine may cause a serious personal injury.
Page 41: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera- tions, always check the following to confirm that there is no danger on the jobsite. q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
Page 42: Ensure Good Visibility
SAFETY PRECAUTIONS FOR OPERATION q Even going close to high-voltage cables can cause electric Voltage of Cables Safety Distance shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) 100V - 200V Over 2 m between the machine and the electric cable.
Page 43: Starting Engine
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. STARTING ENGINE USE WARNING TAGS If there is any “DANGER! Do NOT operate!“ warning tag dis- played, it means that someone is carrying out inspection and maintenance of the machine.
Page 44: Inspection And Maintenance Before Starting Engine
SAFETY PRECAUTIONS FOR OPERATION INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly problems may occur with the operation of the machine, and there is danger that this may lead to serious personal injury or death.
Page 45: Starting With Booster Cables
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. q Always wear safety goggles and rubber gloves when start- ing the engine with booster cable.
Page 46: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful attention to the surrounding area.
Page 47: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION q If there are any persons in the area around the machine, there is danger that they may be hit or caught by the machine, and this may lead to serious personal injury or death. Always observe the following before traveling. q Always operate the machine only when seated.
Page 48: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION q When passing over bridges or structures, check first that the structure is strong enough to support the weight of the machine. q 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.
Page 49: Operating On Slopes
SAFETY PRECAUTIONS FOR OPERATION q Travel on grass or fallen leaves with low speed. Even with slight slopes there is a hazard that the machine may slip. q If the engine stops when the machine is traveling on a slope, move the control levers immediately to the neu- tral position and start the engine again.
Page 50 SAFETY PRECAUTIONS FOR OPERATION q To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations. q When carrying out demolition work, do not carry out demo- lition work under the front of the machine.
Page 51: Traveling On Snow-Covered Or Frozen Surfaces
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SNOW-COVERED OR FROZEN SURFACES q Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 52: Transportation
The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING...
Page 53: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING PRECAUTIONS WHEN TOWING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or tow- ing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For towing, see “TOWING THE MACHINE (3-241)“.
Page 54 SAFETY PRECAUTIONS FOR OPERATION q Do not use the work equipment or swing to pull the load in any direction. There is danger that the hook may break and the load come off, causing the work equipment to move suddenly and cause personal injury. q Do not leave the operator's seat when there is a raised load.
Page 55: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE If there is any “DANGER! Do NOT operate!“ warning tag dis- played, it means that someone is carrying out inspection and maintenance of the machine.
Page 56: Keep Workplace Clean And Tidy
GUARDS Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu service engineer unless specific instructions are given in this manual. ONLY AUTHORIZED PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.
Page 57: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE q Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. q Turn the starting switch to the ON position. Operate the work equipment control lever back and forth, left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then move...
Page 58: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. q One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 59: Precautions When Working Under Machine Or Work Equipment
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT q Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight of the component. Never use jacks at places where the machine is damaged, bent, or twisted.
Page 60: Precautions For Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip- ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
Page 61: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE q Turn the battery isolator switch to the OFF position. In the following events, follow the switch-off procedure as described below. First turn the starting switch to the OFF position, wait at least 3 minutes, then turn off the battery isolator dis- connect switch before: q Storing the machine for one or more months;...
Page 62: Precautions With High-Temperature Coolant
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT To prevent burns from boiling water or steam spurting out when checking or draining the coolant, wait for the coolant to cool down to a temperature where the radiator cap can be touched by hand.
Page 63: Handling High-Pressure Hoses And Piping
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, please consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 64: Precautions With High-Pressure Grease When Adjusting Track Tension
Do not hit or roll the accumulator, or subject it to any impact. q When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. HANDLING OPG TOP GUARD q If any modification is applied to OPG, it may affect the strength and may not comply with the standard.
Page 65: Precautions With Compressed Air
During maintenance or dismantling operations, where there is a risk of contact with hazardous chemical sub- stances, relevant safety precautions should be taken. If any doubt exists, contact your Komatsu distributor. See also disposal of DISPOSING OF WASTE MATERIALS (2-43) and MAINTENANCE OF AIR CONDI-...
Page 66: End Of Service Life
Replace or repair safety-critical parts if any defect is found, even when they have not reached the specified replacement time. q The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the machine.
Page 67: Operation
OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 68: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Power container Bucket cylinder (10) Hydraulic ladder (11) Sprocket Arm cylinder (12) Track frame Boom (13) Cab base Boom cylinder (14) Idler (15) Track shoe Top guard...
Page 69: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES VHMS download connector (10) Machine monitor 12V power supply socket (11) Foot rest Cigarette lighter (24V power supply socket) (12) Travel pedals AM/FM Radio (13) Travel levers Air conditioner control panel 2 (14) Lock lever Air conditioner control panel 1 (15) Horn switch Engine emergency stop switch...
Page 70 OPERATION MACHINE VIEW ILLUSTRATIONS STOP Step light switch (10) Ladder warning lamp Working lamp switch (11) Auto greasing warning lamp Additional lamp switch (12) Fan reverse display lamp Engine emergency stop switch (13) Rotating lamp switch (if equipped) Room lamp switch (14) Greasing mode switch Service center switch (if equipped) (15) Machine push-up switch...
Page 71 OPERATION MACHINE VIEW ILLUSTRATIONS X (1/2): Normal operation screen (1/2) X (2/2): Normal operation screen (2/2) q Press function switch F1 to switch between screen X (1/2) and screen X (2/2) Window washer switch (17) Clock/service meter Wiper selector switch (18) Auto-deceleration monitor Alarm buzzer cancel switch (19) Working mode monitor...
Page 72 OPERATION MACHINE VIEW ILLUSTRATIONS Y: Check before starting screen Z: Maintenance interval monitor screen Engine oil pressure monitor Engine oil temperature monitor Charge level monitor Air cleaner clogging monitor Radiator coolant level monitor Maintenance interval monitor...
Page 73: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM X(1/2): Normal operation screen (1/2) pilot screen all Check before starting screen...
Page 74: Basic Operation Of Machine Monitor
OPERATION DETAILED CONTROLS AND GAUGES REMARK One of the features of liquid crystal display panels is that there may be black spots (spots that do not light up) or white spots (spots that stay lighted up) on the screen. If there are fewer than 10 black or white spots, this is not a failure or a defect.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES Stopping Engine When Situation is Normal q When the starting switch is turned to the OFF position, ending screen (S) is displayed for 5 seconds, then the screen goes out. If There Is Abnormality When Starting Engine q If there is any abnormality when the engine is started, Check before starting screen (Y) switches to Mainte- nance interval warning screen (Z), Warning screen (V), or Error screen (W).
Page 76 OPERATION DETAILED CONTROLS AND GAUGES q After Maintenance interval warning screen (Z) has been displayed for 30 seconds, the screen switches to standard screen (X). q After Check before starting screen (Y) has been displayed for 2 seconds, the screen switches to warning screen (V) or Error screen (W).
Page 77: Basic Check Monitors
OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly. Displays basic items among the check before starting items that must be checked before starting the engine.
Page 78 For details of the method of confirming the maintenance interval, see “Maintenance Selector Switch (3-45)“. If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. Engine Stop Monitor This monitor (4) lights up when the engine is stopped and when the engine is being cranked.
Page 79 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic oil level monitor This monitor (5) warns the operator that the hydraulic oil level has gone down. If there is lack of hydraulic oil, the lamp lights up red, so check the oil level and add oil. 3-13...
Page 80: Caution Monitors
OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor flashes, check the problem point as soon as possible and carry out maintenance. Failure to repair the problem may cause to failure of the machine. These are items which need to be observed while the engine is running. If any problem occurs, items which need to be repaired as soon as possible are displayed.
Page 81 OPERATION DETAILED CONTROLS AND GAUGES Charge Level Monitor Monitor (1) warns the operator of an abnormality in the charg- ing system while the engine is running. If the battery is not being charged properly while the engine is running, monitor lights up red. If monitor lights up red, check the V-belt for looseness.
Page 82 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor When this monitor (5) shows low-temperature display (A), carry out the warming-up operation. For details, see “Hydraulic Equipment Warm Up (3-195)“. Continue the warming-up operation for the hydraulic equipment until monitor (6) shows the correct temperature display (B). Display (A) at low temperatures: Monitor background (D) is white Display (B) at correct temperatures: Monitor background (D) is...
Page 83 If monitor (9) does not go out even when greasing is carried out, or when there is ample grease but the monitor is lighted up red, contact your Komatsu distributor as soon as possible and have inspection carried out. Hydraulic Filter Clogging Monitor This monitor (10) warns the operator that the hydraulic filter is clogged.
Page 84: Emergency Monitors
OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
Page 85 OPERATION DETAILED CONTROLS AND GAUGES Engine Coolant Temperature Monitor Monitor (1) warns operator that the engine coolant temperature has risen. If the engine coolant temperature becomes abnormally high, the monitor shows abnormal display (C). The overheat preven- tion system is automatically actuated and the engine speed drops.
Page 86 OPERATION DETAILED CONTROLS AND GAUGES PTO Temperature Monitor This monitor (4) warns the operator that the PTO oil tempera- ture has risen. If the PTO oil temperature becomes abnormally high, abnormal display (C) is given. Stop operations and run the engine at low idling or stop the engine until the monitor changes to correct temperature display (B).
Page 87: Meter Display Portion
OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Engine pre-heating monitor (10) PTO temperature gauge Swing lock monitor (11) Engine oil temperature gauge Wiper monitor (12) Engine oil pressure gauge Auto-deceleration monitor,auto-lowidle monitor (13) ECO gauge Working mode monitor (14) Idle stop guidance Engine coolant temperature gauge (15) Truck counter display portion 1 Fuel gauge...
Page 88 OPERATION DETAILED CONTROLS AND GAUGES Pilot Display q The pilot display at the top of the screen consists of the pilot lamps to confirm the actuation of each function. q When the starting switch is turned ON, the pilot lamp lights up when the display items are functioning. Engine Pre-heating Monitor This monitor (1) displays the preheating time needed when starting the engine in temperatures below 0°C.
Page 89 OPERATION DETAILED CONTROLS AND GAUGES Wiper Monitor This monitor (3) shows the actuation status of the wipers. The monitor display showing the wiper switch operating status is as follows. ON lighted up: Continuous actuation of wiper (both upper and lower ones) ON lighted up: Continuous actuation of wiper (upper only) INT lighted up: Intermittent actuation of wiper (both upper and lower ones)
Page 90 OPERATION DETAILED CONTROLS AND GAUGES q When the auto low idle setting is ON on the user menu, the following displays are given. Auto low idle lighted up: Auto low idle ON Auto low idle out: Auto idle OFF q For details of the setting of the auto low idle, see “Auto Low Idle Setting (3-61)“.
Page 91 OPERATION DETAILED CONTROLS AND GAUGES Gauges and Meter Engine Coolant Temperature Gauge This meter (6) shows the engine coolant temperature. The indicator should be in the green range during operations. If the indicator enters the red range during operations, the over- heat prevention system is actuated.
Page 92 OPERATION DETAILED CONTROLS AND GAUGES Fuel Gauge This meter (7) shows the amount of fuel remaining in the fuel tank. The indicator should be in the green range during operations. If the indicator starts to enter red range (A) during operations, it shows that there is less than 500 liter of fuel remaining, so check and add fuel.
Page 93 OPERATION DETAILED CONTROLS AND GAUGES Display (A) at low temperatures: Monitor background (D) is white Display (B) at correct temperatures: Monitor background (D) is blue Display (C) when condition is abnormal: Monitor background (D) is red Service Meter, Clock This monitor (9) shows the total amount of time that the machine has been operated, or the present time.
Page 94 OPERATION DETAILED CONTROLS AND GAUGES PTO Temperature Gauge This meter (10) shows the PTO oil temperature. The indicator should be in the green range during operations. If the indicator starts to enter red range (A) during operations, it shows that the PTO oil temperature is more than 122°C.
Page 95 OPERATION DETAILED CONTROLS AND GAUGES Engine Oil Pressure Gauge This meter (12) shows the engine oil pressure. If the indicator starts to enter red range (A) during operations, it shows that the engine oil pressure is abnormality, Check the lubrication system and the oil level in the oil pan as soon as possible.
Page 96 OPERATION DETAILED CONTROLS AND GAUGES Truck Counter Display 1 This counter display portion (15) shows the number of loads counted for the truck. When truck counter switch (a) at the front (as seen from the front of the machine) on top of the left control lever is pressed, the count advances.
Page 97: Monitor Switches Portion
If it is desired to set so that the system automatically starts in P or E mode (default option setting) when the engine is started, please ask your Komatsu distributor to change the setting. 3-31...
Page 98 OPERATION DETAILED CONTROLS AND GAUGES Procedure for operation 1. If working mode selector switch (1) is pressed, the Working Mode screen is displayed on the monitor. 2. When function switches F3 or F4 at the bottom of the screen or working mode selector switch (1) are pressed, the mode selection changes.
Page 99 OPERATION DETAILED CONTROLS AND GAUGES Auto-deceleration Switch If the control levers are at neutral, this switch (2) automatically lowers the engine speed and turns on the function to reduce fuel consumption. Auto-deceleration monitor ON: Auto-deceleration ON Auto-deceleration monitor OFF: Auto-deceleration OFF Each time the switch is pressed, the auto-deceleration is switched between ON and OFF.
Page 100 OPERATION DETAILED CONTROLS AND GAUGES 2. On the standard screen, the Auto-deceleration monitor lights up. (When the auto-deceleration is OFF, it does not light up.) q When auto low idle function is ON q Auto low idle function This is a function that can be used when the auto-deceleration function is ON. When all the work equipment control levers and travel levers are returned to neutral during operations, the auto-deceleration function is actuated, and after approx.
Page 101 OPERATION DETAILED CONTROLS AND GAUGES Heavy Lift Switch Operate this switch (3) to increase the lifting power during operations. When the switch is turned ON, the boom lifting force is increased when the boom RAISE is being operated indepen- dently. q When switch (3) is pressed to turn it ON, the mode is dis- played in the center of the monitor display, and after 2 sec- onds, the display returns to the standard screen.
Page 102 OPERATION DETAILED CONTROLS AND GAUGES q Intermittent operation of wiper (A).(upper, lower) q Continuous operation of wiper (top, bottom) (B) q Continuous operation of wiper (top only) (C) REMARK Each time wiper switch (4) is pressed, the mode is displayed in the center of the monitor display, and after two seconds, the screen returns to the standard screen.
Page 103 OPERATION DETAILED CONTROLS AND GAUGES Window Washer Switch This switch (5) is kept continuously pressed, window washer fluid is sprayed out on the front glass. When the switch is released, the spray stops. q If switch (5) is kept pressed when the wiper is stopped, the window washer fluid will spray, and at the same time, the wiper will be actuated continuously.
Page 104 OPERATION DETAILED CONTROLS AND GAUGES Function Switches Function switches (7) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen. When the monitor display shows the standard screen, the func- tions are displayed as follows.
Page 105: Handling Function Switches
When cameras are installed (if equipped), a total of 3 cam- eras is installed at the rear left, rear center, and the rear right of the machine. q If you want to install a camera, please consult your Komatsu distributor. 3-39...
Page 106 OPERATION DETAILED CONTROLS AND GAUGES Operations on Camera 1 Image Display Screen The following explanation describes the method of operation when it is desired to display only one camera screen on the monitor. q On the standard screen, if switch F3 is pressed, the image display screen is displayed.
Page 107 OPERATION DETAILED CONTROLS AND GAUGES Operation of Image Display Screen When Two Camera Screens are Shown Simultaneously. q When function switch F4 is pressed on camera 1 screen display screen, screen (a) for the camera at the rear left of the machine and screen (b) for the camera at the rear right of the machine are displayed.
Page 108 OPERATION DETAILED CONTROLS AND GAUGES If the working mode is changed, the screen returns to the stan- dard screen. Press switch F3 again to return to the camera image display. q When the heavy lift switch is pressed, the boom lifting power is increased when the boom RAISE is being oper- ated independently.
Page 109 OPERATION DETAILED CONTROLS AND GAUGES q 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. Action When Warning is Generated When Displaying Camera Image q If an error or alarm occurs while the camera image is being displayed, the error monitor or alarm monitor is displayed...
Page 110 OPERATION DETAILED CONTROLS AND GAUGES For details of the content of the warning displays, see “Basic Check Monitors (3-11)“, “Caution Monitors (3-14)“, “Emergency Monitors (3-18)“ and “TROUBLES AND ACTIONS (3-240)“. Service Meter/Clock Display Selector Switch On the standard screen, it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor display.
Page 111 OPERATION DETAILED CONTROLS AND GAUGES Maintenance Selector Switch When switch F5 is pressed on the standard screen, the monitor display screen switches to the maintenance mode screen. The items on the maintenance display are as follows. Change engine oil Replace engine oil filter Replace fuel pre-filter Replace fuel main filter 1000...
Page 112 If the time remaining until maintenance becomes 0 hours, the remain- ing time display is highlighted in red. q If you want to change the setting for the maintenance inter- val, please consult your Komatsu distributor. 3-46...
Page 113 OPERATION DETAILED CONTROLS AND GAUGES Operations on Maintenance Interval Reset Screen On the maintenance list screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the maintenance time reset screen. Reset the remaining time on this screen. 1.
Page 114 OPERATION DETAILED CONTROLS AND GAUGES q On the User Menu screen, it is possible to carry out the fol- lowing operations with switches F3 to F6. F3: Moves to next item (1 line down). When on the last line, it moves to the first line on the next page.
Page 115 OPERATION DETAILED CONTROLS AND GAUGES q The following items can be set. a : Screen adjustment b : ECO display c : Time adjustment d : Language selection e : Economy mode adjustment f : Auto Low-idle setting g : Truck counter reset h : Fan reverse mode The operation for setting a - h is as follows.
Page 116 OPERATION DETAILED CONTROLS AND GAUGES 2. Select screen adjustment on the user menu, then press switch F6. The screen switches to the selection menu screen for screen adjustment. q On machines equipped with cameras, it is possible to adjust the brightness, contrast, and back light of the cameras screen on this menu.
Page 117 OPERATION DETAILED CONTROLS AND GAUGES 4. Use switches F2 to F6 to adjust the brightness, contrast, and back light of the selected screen. 1) Adjusting the standard screen q When the working lamp switch is in night position (a), if the standard screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode).
Page 118 OPERATION DETAILED CONTROLS AND GAUGES On the screen for Items 1) and 2), it is possible to carry out the following operations with switches F2 to F6. F2: Resets all adjusted values to default value F3: Indicator of selected item moves 1 segment to left. F4: Indicator of selected item moves 1 segment to right.
Page 119 OPERATION DETAILED CONTROLS AND GAUGES 2. Select “ECO display selection“ on the user menu, then press function switch F6. The screen switches to the tar- get setting command screen. 3. Select “ECO Display Target Select“, then press function switch F6 to display the target setting screen. 3-53...
Page 120 OPERATION DETAILED CONTROLS AND GAUGES 4. From the target setting value screen, select the fuel con- sumption that is to be the target when carrying out opera- tions. Press function switch F6 to confirm the selection. q When the gauge enters the orange range, there is no abnormality on the machine, but to protect the environ- ment, reduce the engine output to a point where there is no adverse effect on the operation.
Page 121 OPERATION DETAILED CONTROLS AND GAUGES Clock Adjustment On this clock adjustment menu, it is possible to change the set- ting of the clock displayed on the pilot monitor of the standard display. 1. On the standard screen, press switch F6. 2.
Page 122 OPERATION DETAILED CONTROLS AND GAUGES 3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches F3 to F6. q Time Adjust the hour setting. 1) If “Time“ (a) is not highlighted in yellow, press switch F6 to highlight “Time“...
Page 123 OPERATION DETAILED CONTROLS AND GAUGES q 12h/24h Mode Choose either a 12-hour display (am/pm) or a 24-hour dis- play. (b): 24-hour display (c): 12-hour display (am/pm) 1) If “12h/24h Mode“ (a) is not highlighted in yellow, press switch F6 to highlight “12h/24h Mode“ (a) in yellow. 2) Change the “12h/24h mode“...
Page 124 OPERATION DETAILED CONTROLS AND GAUGES q Daylight Saving Time (Summer time) 1) If daylight saving time is turned ON (a), the clock display becomes 1 hour earlier. If daylight saving time is turned OFF (b), the clock display returns to the set time. The selected display mode is highlighted in green.
Page 125 OPERATION DETAILED CONTROLS AND GAUGES 2. Select “Language“ on the user menu, then press switch F6. The screen switches to the language selection menu screen. 3. Select the language to use for the display, then press switch F6. The screen display changes to the selected lan- guage.
Page 126 OPERATION DETAILED CONTROLS AND GAUGES Adjusting Economy Mode With this economy mode, the engine output can be adjusted to improve the fuel consumption in E mode. 1. On the standard screen, press switch F6. 2. Select “Economy Mode Adjustment“ on the user menu, then press switch F6.
Page 127 OPERATION DETAILED CONTROLS AND GAUGES 3. Select the desired E mode from the economy mode adjust- ment selection menu. The levels that can be set are as follows. E0: Default adjustment value 0 (default set value) E1: Economy adjustment 1 q When moving from E0 to E1, the fuel consumption improves, but the production goes down by that amount.
Page 128 OPERATION DETAILED CONTROLS AND GAUGES 1. Press function switch F6 on the standard screen. 2. Select Auto Low idle setting on the user menu, then press function switch F6. The screen changes to the ON/OFF screen for Auto Low idle setting. 3.
Page 129 OPERATION DETAILED CONTROLS AND GAUGES 4. Press function switch F5 to return to the standard screen. 5. The auto low idle function is set. The mode is displayed in the center of the monitor display, and after 2 seconds, the screen returns to the standard screen.
Page 130 OPERATION DETAILED CONTROLS AND GAUGES 2. Press function switch F5 to return to the standard screen. 1) Press auto deceleration switch (1) to turn the auto decel- eration function ON. 2) When the auto deceleration function is turned ON, the mode is displayed in the center of the monitor display, and after 2 seconds, the screen returns to the standard screen.
Page 131 OPERATION DETAILED CONTROLS AND GAUGES Truck Counter Reset It is possible to correct or clear the truck counter. 1. Press function switch F6 on the standard screen. 2. Select “ Truck Counter Reset“ on the user menu, then press function switch F6. The screen switches to the “Truck Counter Reset“...
Page 132 OPERATION DETAILED CONTROLS AND GAUGES 3. Select necessary Item 01 or 02 on the “ Truck Counter Reset“ screen, then press function switch F6. The screen switches to the selected item screen. 01: TR1 CORRECT/CLEAR -> Truck Counter Display 1, it is possible to correct or clear 02: TR2 CORRECT/CLEAR ->...
Page 133 OPERATION DETAILED CONTROLS AND GAUGES 1) When correcting the truck counter on the selected item screen, operate function switches F3 or F4 to correct the counter value, then press function switch F6 to confirm. q After confirming, press function switch F5 to return to the previous screen.
Page 134 OPERATION DETAILED CONTROLS AND GAUGES 2) When resetting the truck counter on the selected item screen, press function switch F1 on the selected item screen, then press function switch F6 to confirm. The truck counter on the selected item screen is reset. q After confirming, press function switch F5 to return to the previous screen.
Page 135 OPERATION DETAILED CONTROLS AND GAUGES 3) When resetting all the truck counters, select ALL CLEAR, then press function switch F6. The screen will switch to the ALL CLEAR screen. When the ALL CLEAR screen is displayed, press function switch F6 to confirm. q After confirming, press function switch F5 to return to the previous screen.
Page 136 OPERATION DETAILED CONTROLS AND GAUGES Fan Reverse Mode q On the Fan Reverse Mode menu, it is possible to select reverse rotation of the hydraulic drive fan for the radi- ator and oil cooler. q Reverse rotation of the fan can be used for cleaning. The fan blows the air to the outside to remove insects or dirt stuck to the net.
Page 137 OPERATION DETAILED CONTROLS AND GAUGES 3. Select “Fan Reverse Mode“ on the user menu, then press function switch F6. The screen switches to “Reverse FAN ?“ on the Fan Reverse Mode screen. 4. To reverse the direction of the fan, press function switch F6.
Page 138 OPERATION DETAILED CONTROLS AND GAUGES 5. When the screen changes to “Now Changing“ in the opera- tion in Step 4, the engine speed is automatically reduced to low idling, and after approx. 25 seconds, the fan rotates in reverse. q When the fan rotates in reverse, the screen automati- cally switches to the screen on the right (yellow dis- play).
Page 139 OPERATION DETAILED CONTROLS AND GAUGES 7. When returning the fan from reverse rotation to regular rotation, press function switch F5. The screen switches to “Regularize FAN ?“ on the Fan Reverse Mode screen. 8. Press function switch F6. The screen switches to “Now Changing“...
Page 140 OPERATION DETAILED CONTROLS AND GAUGES q When the fan returns to regular rotation, the screen automatically switches to the initial screen. REMARK If the screen in Step 1 does not switch to the screen in Step 4, and the screen switches to a screen like the screen on the right (red display), the fan may not switch to reverse rotation.
Page 141: Switches (Inside Operator's Cab)
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES (INSIDE OPERATOR'S CAB) Starting switch (10) 12V power supply Fuel control dial (11) Rotating lamp switch (if equipped) Engine emergency stop switch (12) Greasing mode selector switch Service center switch (if equipped) (13) Machine push-up switch Room lamp switch (14) Boom shock-less limit switch Additional lamp switch...
Page 142 OPERATION DETAILED CONTROLS AND GAUGES Starting Switch Starting switch (1) is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electri- cal system (except room lamp), are all turned off and the engine is stopped.
Page 143 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Switch The switch (3) is used to stop the engine in emergencies. (a) ON (emergency stop) position If the switch is pressed when indicator lamp (L) is off, the engine will make an emergency stop. When this happens, indi- cator lamp (L) lights up green to indicate that the engine emer- gency stop switch has been actuated.
Page 144 OPERATION DETAILED CONTROLS AND GAUGES Room Lamp Switch NOTICE It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off. Use this switch (5) to light up the room lamp. (a) ON position: Lights up (b) OFF position: Goes out This lamp lights up even if the starting switch is at the OFF...
Page 145 OPERATION DETAILED CONTROLS AND GAUGES REMARK The rear lamp (if equipped) also lights up with the additional lamp switch. If a camera (if equipped) is installed to the rear counterweight, use the rear lamp (if equipped) fortnight lighting. Working Lamp Switch Use this switch (7) to light up the front lamps, working lamps, and monitor illumination.
Page 146 OPERATION DETAILED CONTROLS AND GAUGES Cigarette Lighter Use this switch (9) to light cigarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after several seconds, so pull it out and light your cigarette. If the cigarette lighter is removed, the socket can be used as the power source for the yellow flashing lamp.
Page 147 OPERATION DETAILED CONTROLS AND GAUGES Greasing Mode Selector Switch Use this switch (12) to switch the operating mode for the grease pump. (a) MANUAL: Grease pump is operated continuously. When using a grease gun, set to position (a) MANUAL. Manual greasing is displayed on the monitor.
Page 148 OPERATION DETAILED CONTROLS AND GAUGES Boom Shockless Control Switch Use this switch (14) to reduce the shaking of the work equip- ment when the boom is stopped. (a): ON (b): OFF Effect q The shaking and spillage of load from the bucket is reduced.
Page 149 OPERATION DETAILED CONTROLS AND GAUGES Truck Counter Switch When the switch (16) on the left work equipment control lever is pressed, the count advances on the truck counter portion on the standard screen of the multi monitor. There are 2 switches (16): (a) and (b).
Page 150: Switches (Inside Cab Base Room)
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES (INSIDE CAB BASE ROOM) (18) Room lamp switch (cab base room) (21) Swing holding brake cancel switch (19) Emergency pump drive switch (22) Engine emergency stop cancel switch (rear of main pump) (20) Emergency pump drive switch (front of main pump) Room Lamp Switch (cab base room) NOTICE...
Page 151 OPERATION DETAILED CONTROLS AND GAUGES Emergency Pump Drive Switch (For front and rear both pumps) NOTICE Emergency pump drive switch is provided to make it possible to perform work for a short time when there is a failure in the pump control system. It is necessary to repair the abnormal location as soon as possible. This switch (19),(20) makes it possible to do the work tempo- rarily or start up the engine when there is something wrong with the network (i.e.
Page 152 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Cancel Switch NOTICE Engine emergency stop cancel switch is provided to make it possible to perform work for a short time when there is a failure in the emergency stop switch system. It is necessary to repair the abnormal loca- tion as soon as possible.
Page 153: Switches (Outside Of Machine)
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES (OUTSIDE OF MACHINE) Room lamp switch (front of engine room) (30) Ladder raising switch (24) Room lamp switch (rear of engine room) (31) Ladder lowering switch (25) Room lamp switch (pump room) (32) Step light switch (26) Engine emergency stop switch (front of power container) (33) Step light switch (27) Engine emergency stop switch (rear of power container)
Page 154 OPERATION DETAILED CONTROLS AND GAUGES Room Lamp Switch (front of engine room) NOTICE It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off. Use this switch (23) to light up the room lamp inside the engine room.
Page 155 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Switch (front of power container) WARNING Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency stop switch before going inside the power container. This will prevent anyone from carrying out starting operations by mistake from the operator's seat.
Page 156 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Switch (rear of power container) WARNING Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency stop switch before going inside the power container. This will prevent anyone from carrying out starting operations by mistake from the operator's seat.
Page 157 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Switch (left side of the machine) (If equipped) WARNING Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency stop switch before carrying out operations under the machine or around the under- carriage.
Page 158 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Switch (right side of the machine) (If equipped) WARNING Actuate the engine emergency stop switch to stop the engine in emergencies. In addition, always actuate the engine emergency stop switch before carrying out operations under the machine or around the under- carriage.
Page 159 OPERATION DETAILED CONTROLS AND GAUGES Ladder lowering switch This switch (31) is used when lowering the ladder. REMARK For details of the method of operating the ladder, see “HAN- DLING HYDRAULIC LADDER (3-150)“. Step Light Switch If these switches (32) or (33) are pressed, step light (C) on top of the cab and step light (D) at the side of the ladder both light q When this switch is ON and it is released, it immediately returns to the OFF condition, but the step light continues to...
Page 160 OPERATION DETAILED CONTROLS AND GAUGES Night Maintenance Switch If this switch (34) is turned to ON position (a), step light (C) on top of the cab and step light (D) at the side of the ladder both light up. (a) ON: Lamps light up (b) OFF: Lamps go off q Step lights (C) and (D) will remain lighted up until switch (34) is turned manually to OFF position (b).
Page 161 OPERATION DETAILED CONTROLS AND GAUGES Battery Isolator Switch NOTICE Normally, keep the battery isolator switch at the ON position. If you set the battery isolator switch to the OFF position, be careful of the following items. When the engine is running, do not turn the battery isolator switch to the OFF position. Wait for at least 3 minutes after stopping the engine before turning the battery isolator switch to the OFF position.
Page 162 OPERATION DETAILED CONTROLS AND GAUGES Starter Isolator Switch (If equipped) This switch (36) is used when stopping the flow of electricity to the starting motor to make it impossible to start the engine. 9JH14966A (a) ON position Electricity is sent to the electric circuit of the starting motor and it becomes possible to start the engine.
Page 163: Lamp (Inside Operator's Cab)
OPERATION DETAILED CONTROLS AND GAUGES LAMP (INSIDE OPERATOR'S CAB) Engine emergency stop Indicator lamp Fan reverse rotation display lamp Engine emergency stop warning lamp Automatic greasing warning lamp Hydraulic oil strainer warning lamp Ladder warning lamp Engine emergency stop cancel warning lamp Engine Emergency Stop Indicator Lamp This lamp (1) displays the status (ON/OFF) of engine emer- gency stop switch (S) to the left under the lamp.
Page 164 OPERATION DETAILED CONTROLS AND GAUGES Engine Emergency Stop Lamp This lamp (2) lights up red when any of the engine emergency stop switches is at the ON (emergency stop) position. When it is lighted up red, the engine will not start even when the start- ing switch is operated.
Page 165 For the right handling of the service center, see “When Raising Service Arm (Setting to Stowing Position) (6- 18)“. NOTICE If the lamp does not go out even when all the equipment is stowed, please ask your Komatsu distributor to carry out inspection and repair. 3-99...
Page 166: Lamp (Outside Of Machine)
OPERATION DETAILED CONTROLS AND GAUGES LAMP (OUTSIDE OF MACHINE) 9JH14996A Proximity switch warning lamp Engine emergency stop Indicator lamp Proximity switch warning lamp Engine emergency stop Indicator lamp (if equipped) Engine emergency stop Indicator lamp Engine emergency stop Indicator lamp (if equipped) 3-100...
Page 167 If either of these lamps light up red, it is necessary to check the cause and carry out repairs, so please ask your Komatsu distributor to carry out inspection. Engine Emergency Stop Indicator Lamp These lamps (3) to (6) display the status (ON/OFF) of each engine emergency stop switch.
Page 168: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Left work equipment control lever Travel levers (with auto-deceleration system) (with a pedal and auto-deceleration system) Right work equipment control lever (with auto-deceleration system) Lock Lever WARNING q When standing up from the operator's seat, push lock lever (1) down securely to set it to LOCK position (L).
Page 169 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers WARNING q Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may suddenly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations.
Page 170: Door Lock
OPERATION DETAILED CONTROLS AND GAUGES N (Neutral) : The upper structure and arm are held in position and do not move. Right work equipment control lever (4) is used to operate the boom and bucket. Boom operation (a) RAISE (b) LOWER Bucket operation (c) DUMP (d) CURL...
Page 171: Emergency Escape Hammer
OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY ESCAPE HAMMER NOTICE When escaping, remove the broken pieces of the glass from the sash so that you will not cut yourself with them. Take care not to slip on the broken and scattered pieces. Hammer (A) is provided to help the operator get out of the cab in emergency, when the cab door or window will not open.
Page 172: Handling Emergency Ladder
OPERATION DETAILED CONTROLS AND GAUGES HANDLING EMERGENCY LADDER Escape door Handrail Stopper Handrail Snap hook Fixed ladder Rope ladder Handrail ESCAPE PROCEDURE WARNING When getting on or off the machine, always face the machine and maintain at least three-point contact (both feet and one hand, or both hands and one foot) with the handrail and steps to ensure that you sup- port yourself.
Page 173 OPERATION DETAILED CONTROLS AND GAUGES 1. Open escape door (1) and check that escape door (1) is held in position by stopper (2). 2. Remove snap hook (3) from the hook of escape door (1), then lower rope ladder (4) to the ground. 3.
Page 174: Precaution When Storing Rope Ladder
OPERATION DETAILED CONTROLS AND GAUGES 6. Climb down rope ladder (4) to the ground. When doing this, use handrail (8) and the rungs of fixed ladder (7). PRECAUTION WHEN STORING ROPE LADDER When storing rope ladder (4), put a step of rope ladder (4) on installation bracket (10) and attach snap hook (3) to the hook of escape door (1).
Page 175: Fire Extinguisher
If you wish to have additional fire extinguishers, please consult your Komatsu distributor. The three places where additional fire extinguishers can be installed are as follows. q (A) Rear of catwalk on top of hydraulic tank...
Page 176 OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Caps with Lock Opening the Cap 1. Insert the key into the key slot. 2. Turn the key clockwise (counterclockwise for type B), align the key groove with counter mark (3) on the cap, then open the cap.
Page 177: Ashtray
OPERATION DETAILED CONTROLS AND GAUGES ASHTRAY This is on the left side of the operator's seat. Always make sure that you extinguish the cigarette before clos- ing the lid. CUP HOLDER There are 2 cup holders at the rear left of the operator's seat. MAGAZINE BOX This is on the left side of the operator's seat.
Page 178: Hook
OPERATION DETAILED CONTROLS AND GAUGES HOOK This is at the rear of the operator's compartment. UTILITY BOX This is under the assistant's seat. 3-112...
Page 179: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel OFF switch FRESH/RECIRC selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Auto switch OFF Switch Switch (1) is used to stop the fan and air conditioner. q When OFF switch (1) is pressed, the top portion of each of set temperature and air flow displays on display monitor (6) and air conditioner switch (7) go out, and operation stops.
Page 180 OPERATION DETAILED CONTROLS AND GAUGES Fan Switch Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. q Press the ∧ switch to increase the air flow; press the ∨ switch to reduce the air flow. q During auto operation, the air flow is automatically adjusted.
Page 181 OPERATION DETAILED CONTROLS AND GAUGES REMARK If the mode is set to auto mode and the temperature setting is set to 18.0 °C or 32.0 °C, the air flow from the fan is always set to HIGH and does not change even when the set temperature is reached. Vent Selector Switch Switch (4) is used to select the vents.
Page 182 OPERATION DETAILED CONTROLS AND GAUGES q Rear vents (A) (A1): Rear vents (top) 2 places (A2): Rear vents (bottom) 2 places q Face vents (B) (B1): Face vent (left) 1 place (B2): Face vent (right) 1 place q Foot vents (C) (C1): Foot vent (front) 1 place (C2): Foot vent (rear) 1 place 3-116...
Page 183 OPERATION DETAILED CONTROLS AND GAUGES q Defroster vent (D) (D1): Defroster vent (left) 1 place (D2): Defroster vent (right) 1 place (D3): Defroster vents (front) 3 places Auto Switch This switch (8) automatically changes air volume, vents and air source according to the set temperature. q When auto switch (8) is pressed, the lamp above the auto switch lights up.
Page 184 OPERATION DETAILED CONTROLS AND GAUGES REMARK When Auto Mode is selected, if the set temperature is set to 18.0 °C or 32.0 °C, the air flow is always set to High, but this is not a problem. FRESH/RECIRC Selector Switch Use this switch (5) to select circulation of the air inside the cab or intake of fresh air from the outside.
Page 185: Method Of Operation
OPERATION DETAILED CONTROLS AND GAUGES Method of Operation The air conditioner can be operated automatically or manually. Select the method of operation as desired. Automatic Operation 1. Turn on auto switch (8) (pressed to be ON). q Then the lamp above switch (8) lights up. q Set temperature (a) and air volume (b) are also shown on the monitor display.
Page 186 OPERATION DETAILED CONTROLS AND GAUGES Stopping Automatic Operation Press OFF switch (1). Set temperature (a) and air volume (b) disappear from the monitor display, and the lamps above auto switch (8) and air conditioner switch (7) go off, stopping the operation of the air conditioner.
Page 187 OPERATION DETAILED CONTROLS AND GAUGES 3. Press temperature setting switch (3) and adjust tempera- ture inside the cab. 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
Page 188 OPERATION DETAILED CONTROLS AND GAUGES Operation with Cold Air to Face and Warm Air to Feet To operate with cold air blowing to the face and warm air blow- ing to the feet, set as follows. 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7).
Page 189 OPERATION DETAILED CONTROLS AND GAUGES Defroster Operation 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7). 2. Press vent selector switch (4) and set vent display (c) on the display monitor to the following mode.
Page 190 OPERATION DETAILED CONTROLS AND GAUGES q To blow air against the top of the glass, set to mode display (M5) or (M6) as shown in the diagram on the right. 3. Press FRESH/RECIRC selector switch (5) to set to intake of outside air.
Page 191: Use Air Conditioner With Care
OPERATION DETAILED CONTROLS AND GAUGES Use Air Conditioner with Care NOTICE q Never start the air conditioner when the engine is running at high speed. It will cause failure of the air conditioner. q If water gets into the control panel, it may cause unexpected failure, so be careful not to get water on the panel.
Page 192 “ portion of temperature setting switch (3) to dis- play the failures in turn. q After completing the troubleshooting, press OFF switch (1) again to return to the normal display. If any problem is detected by the self-diagnostic function, contact your Komatsu distributor perform inspection and repair. 3-126...
Page 193: Radio
OPERATION DETAILED CONTROLS AND GAUGES Function to Switch Set Temperature Display Between Fahrenheit and Celsius It is possible to switch the set temperature display between °F and °C. ∨ ∧ If the “ “ and “ “ portions of temperature setting switch (3) are pressed at the same time for more than 5 seconds while the fan is running, the temperature display will switch between °F and °C.
Page 194 OPERATION DETAILED CONTROLS AND GAUGES Power switch, Volume control knob, Balance control knob Press this knob (1) to turn the power for the radio on. The frequency is displayed on display (7). Press the knob again to turn the power off. Turn the knob clockwise to increase the volume;...
Page 195: Controls Of Radio
OPERATION DETAILED CONTROLS AND GAUGES Time Reset Button Use this button (8) when adjusting the time. For details of the method of adjusting the time, see “Setting Correct Time (3-131)“. H: Hour M: Minute ADJ: Sets to 00 minutes Tuning Button (TUNING) Use this button (9) to change the frequency.
Page 196 OPERATION DETAILED CONTROLS AND GAUGES Method of Tuning 1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and man- ual tuning.
Page 197 OPERATION DETAILED CONTROLS AND GAUGES Setting Correct Time 1. Press display selector button (4) to display the time. After 5 seconds, the display will return to the frequency dis- play and the time cannot be corrected. If this happens, press display selector button (4) again. 2.
Page 198: Use Radio With Care
OPERATION DETAILED CONTROLS AND GAUGES Antenna NOTICE Before transporting the machine or putting it inside a building, stored the antenna to prevent any interfer- ence. q If the reception of the signal is weak or there is interfer- ence, extend the antenna. When setting to a station with a strong signal, shorten the antenna to set to a weaker input.
Page 199: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 24V Power Source NOTICE Do not use this as the power supply for 12V equipment. It will cause failure of the equipment. Pull out the connector plug for taking out electric power from the rear side of the panel.
Page 200: Fuse
OPERATION DETAILED CONTROLS AND GAUGES FUSE This is installed to the power board inside the cab base room. NOTICE Before replacing fuses, be sure to first turn the starting switch to the OFF position, wait over one minute, then switch off the battery isolator switch. The fuses protect the electrical equipment and wiring from burning out.
Page 201 OPERATION DETAILED CONTROLS AND GAUGES Fuse Capacities and Circuit Names Fuse Name of circuit capacity Swing holding brake solenoid valve Machine push-up solenoid valve, Boom anti-vibration solenoid valve PPC hydraulic lock solenoid valve, Starting motor cut relay Cigarette lighter Horn, Flash light Bottom dump solenoid valve Rotating lamp Spare lamp...
Page 202: Circuit Breaker
OPERATION DETAILED CONTROLS AND GAUGES CIRCUIT BREAKER If there is a surge of current, the circuit breaker shuts off the electric circuit and protects the electrical components and wiring from burning out. When restoring the electrical circuit that has been shut off, push in the reset button that sprang out when the circuit was cut off.
Page 203 OPERATION DETAILED CONTROLS AND GAUGES Circuit Breaker(B) The panel board is installed under the left floor step. REMARK This circuit breaker is a large-size breaker installed to circuits where a large-capacity current is flowing. In the same way as normal fuses and circuit breakers installed to the power board inside the cab base room, this circuit breaker protects the elec- trical components and wiring from burning out if there is a surge of current.
Page 204 OPERATION DETAILED CONTROLS AND GAUGES Circuit Breaker Capacity And Name Of Circuit Circuit breaker (A) Fuse Circuit name capacity Pump controller 2 Pump controller 1 Work lamp Head lamp (right) Head lamp (left) Right bank engine controller Left bank engine controller Starting switch, Pump controller, Monitor VHMS controller, ORBCOMM controller, Electric priming pump (if equipped)
Page 205: Fuse (If Equipped)
OPERATION DETAILED CONTROLS AND GAUGES FUSE (IF EQUIPPED) This is installed to the power board inside the cab base room. NOTICE Before replacing fuses, be sure to first turn the starting switch to the OFF position, wait over one minute, then switch off the battery isolator switch.
Page 206: Controller
NOTICE q Do not let water, mud, or juice spill on the controller. This will cause failures. q If any problem occurs in the controller, do not repair it by yourself. Please contact your Komatsu dis- tributor for repairs. (1): Engine controller There are two engine controllers: one each on the left and right sides of the engine body.
Page 207: Tool, Can Storage Place
OPERATION DETAILED CONTROLS AND GAUGES TOOL, CAN STORAGE PLACE The standard tool set is stored in a toolbox placed in the cab base room in the machine's front direction. HANDLING GREASE PUMP AND GREASE GUN The grease pump is stored under the center maintenance floor (right side of machine).
Page 208 OPERATION DETAILED CONTROLS AND GAUGES Method Of Use When adding grease with grease gun (1), keep the engine running at a medium speed and then add grease. 1. Set the greasing mode selector switch on the left side of the operator's seat inside the cab room to the MANUAL position.
Page 209 OPERATION DETAILED CONTROLS AND GAUGES q When removing the nozzle at tip of the grease gun from the grease fitting, carefully angle the tip of nozzle slightly and remove it. q When there is only a small amount of grease left in the grease can, the pump will not pump out grease, so move the grease to the center or fill the can with new grease.
Page 210 OPERATION DETAILED CONTROLS AND GAUGES 3. After loosening hexagonal screw (11) of the grease level sensor, lift up limit switch (12), remove cap (13), then remove spring (14). 4. Remove 2 wing nuts (15). 5. Lift up grease can cover (16) vertically to remove it. 6.
Page 211 OPERATION DETAILED CONTROLS AND GAUGES 7. Using lifting hook (18), remove the grease can from the machine. 8. Remove clamp (19) from the grease can and install it to the new grease can that will replace the old grease can. NOTICE Be careful not to drop clamp (19) when lifting the grease can up, and tighten it securely.
Page 212 OPERATION DETAILED CONTROLS AND GAUGES 10. Lift up grease can cover (16), align shaft (21) and shaft (22) with follower plate holes (A) and (B), then insert the shafts. 11. Insert wire (23) of the grease level sensor through hole (C) in grease can cover (16).
Page 213 2. After supplying grease, remove the connection hose from the grease pressure feed pump. A: From grease pressure feed pump B: To grease can q Komatsu does not handle grease pressure feed pumps, but if the charging port is necessary, please contact your Komatsu distributor. REMARK...
Page 214: Accumulator
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Contact your Komatsu distributor for proper disposal. This machine is equipped with an accumulator in the control circuit. The accumulator is a device to store oil pres- sure for the control circuit.
Page 215: Method Of Releasing Pressure In Accumulator For Hydraulic Control Circuit
OPERATION DETAILED CONTROLS AND GAUGES q Accumulator for oil cooler circuit There are six at the oil cooler end inside the power con- tainer at the rear left of the machine. REMARK These accumulators are installed to protect the oil cooler from abnormal pressure in the hydraulic circuit, and to improve the reliability of the hydraulic equipment.
Page 216: Handling Hydraulic Ladder
OPERATION DETAILED CONTROLS AND GAUGES HANDLING HYDRAULIC LADDER PROCEDURE FOR OPERATING HYDRAULIC LADDER WARNING Before operating the ladder, check that there is no one inside the operating range of the ladder. There is danger that anyone inside the operating range may suffer injury by being hit or caught up by the ladder.
Page 217 OPERATION DETAILED CONTROLS AND GAUGES When Lowering Ladder (Setting to Position for Use) 1. If ladder lowering prevention chain (2) is fitted to the hook on the machine, remove the hook and fit it to the ladder. 2. Keep ladder lowering switch (3) on switch box (1) pressed until the ladder automatically stops.
Page 218: Action When Machine Does Not Move Because Of Failure In Proximity Switch
OPERATION DETAILED CONTROLS AND GAUGES 2. When protruding portion (5) of the ladder contacts stopper (6), release switch (4). 3. If the engine is to be stopped for a long time when the lad- der is stowed, fit ladder lowering prevention chain (2) to the hook on the machine.
Page 219 OPERATION DETAILED CONTROLS AND GAUGES 3. Lower the hydraulic ladder. For details, see “When Lower- ing Ladder (Setting to Position for Use) (3-151)“. 4. Cover the front of proximity switch (1) installed to the hydraulic ladder with steel plate (2) and check that actua- tion display lamp (L) lights up.
Page 220 This change in the combination of the connectors is a temporary measure to enable the machine can be moved to a safe place. After moving the machine, contact your Komatsu distributor immediately and ask for repairs to be carried out.
Page 221 6. Connect the negative (-) terminal of the battery, start the engine, then check that it is possible to operate the travel, swing, and work equipment. If they cannot be operated, there is probably some other cause, so ask your Komatsu distributor to carry out investigation.
Page 222: Handling Machines Equipped With Komtrax Plus
Komatsu distributor to remove the KOMTRAX Plus communications terminal or to carry out action to stop communications. q If you do not obey the above precautions, neither Komatsu nor your Komatsu distributor can take any respon- sibility for any problem that is caused or for any loss that results.
Page 223 12 m (39 ft 4 in) from the blasting jobsite or the remote blasting device, ask your Komatsu distributor to discon- nect power source cable of KOMTRAX Plus in advance.
Page 224: Machine Operations And Controls
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor. Perform the following inspections and cleaning every day before starting engine for the day's work.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS 6. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, and joints Check for oil leakage. If any problem is found, repair the area where oil is leaking. 7. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers.
Page 226: Checks Before Starting
OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING q Under normal circumstances, do not open the radiator cap. When checking the cooling water, check the reservoir tank.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Check that the coolant is between the FULL and LOW range on reservoir tank (2). If the level is low, raise cap lever (4) of cap (3) at the top of reservoir tank (2) to release the internal pressure in reservoir tank (2).
Page 228 OPERATION MACHINE OPERATIONS AND CONTROLS 1) Open cover (6) at the rear of the container on the right side of the machine, and use it as a place to stand. Remove bolt (7) to open cover (6). 2) After removing cover (8), loosen radiator cap (9) slowly to release the pressure, then push cap (9) in and loosen it further to remove it.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. REMARK For details of the method of draining and adding engine oil to machines equipped with a service center (option), see “Method of Draining, Adding Engine Oil (6-20)“.
Page 230 OPERATION MACHINE OPERATIONS AND CONTROLS 5. If the oil is above the H mark, loosen drain valve (P1) of the oil pan. The oil will go down to drain valve (P2). Next, open drain valve (P2) under the revolving frame and drain the excess oil.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING q Engine parts and oils are heated to a high temperature immediately after the engine has stopped. A casual touch can cause a scald. So begin the work great care. q When the oil filler plug is removed, heated oil may spurt out.
Page 232 OPERATION MACHINE OPERATIONS AND CONTROLS The correct hydraulic oil levels in working posture (1) are as fol- lows. q When the hydraulic oil is at normal temperature (15 - 30 °C) , the correct oil level is in blue range (a1) on the gauge label shown in the diagram on the right.
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When the working posture is (2) in the diagram on the right, the correct oil level on the gauge label is range (a2) at normal tem- perature and (b2) at high temperature. 5. If the level is below the correct line, add oil through filler port (F) at the top of the hydraulic tank.
Page 234 OPERATION MACHINE OPERATIONS AND CONTROLS When draining the oil, use either drain plugs (P1) and (P2) at the bottom of the hydraulic tank or drain plugs (P3) at the bot- tom of the hydraulic sub tank. q When using drain plugs (P1) and (P2) at bottom of hydrau- lic tank Loosen drain plug (P1), then loosen plug (P2) and drain the oil.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS q When starting a machine off when it has been stopped on a steep slope Check Oil Level in PTO Case, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.
Page 236 (1) Rotating lamp (2) Room lamp (3) Additional lamp (4) Working lamp (5) Step lamp If any lamp does not light up, there is probably a broken bulb or disconnection, so ask your Komatsu distributor to carry out repairs. 3-170...
Page 237 CAUTION If fuses frequently break or the circuit breaker is frequently actuated, or if there are signs of short circuits on the electric wiring, investigate the cause immediately and ask your Komatsu distributor to carry out repairs. Keep the top of the battery clean. Check the breather holes in the battery caps. If they are clogged with mud, wash the battery cap and remove the clogging.
Page 238 OPERATION MACHINE OPERATIONS AND CONTROLS Drain Water And Sediment from Fuel Tank NOTICE Never use trichlene for washing the inside of the tank. Use diesel fuel only. 1. Prepare a container to catch the drained fuel and take steps to prevent the sediment and water from splashing and making the surrounding area dirty.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS Check for Water and Sediment in Water Separator, Drain Water WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri- ous burns. Wait for the temperature to go down before starting the operation. q Fuel is highly flammable and dangerous.
Page 240 OPERATION MACHINE OPERATIONS AND CONTROLS 2. It is possible to judge the water level and amount of sedi- ment by looking through transparent cap (1). If there is any water or sediment collected at the bottom, set a container to catch the drain water under drain hose (3). 3.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS 4. Loosen plug (2) and drain the water. 5. Screw plug (2) in as soon as water has drained off and fuel begins to flow out from drain hose (3). q Tightening torque: 0.2 - 0.45 Nm (0.02 - 0.046 kgm) 6.
Page 242 OPERATION MACHINE OPERATIONS AND CONTROLS Inspection of Additional Water Separator and Drain of Water and Sediments (Only poor fuel arrangement specification machines) WARNING Do not bring any fire or flame close. The water separator serves to separate moisture mixed in the fuel. NOTICE If float (1) goes above level line (2), there is danger that the separated water may be sucked into the engine.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Pull up fuel shut-off lever (A) installed at the front of the main pump inside the pump room to shut off the fuel supply circuit from the fuel tank. (S): Shut off (O): Open 3.
Page 244 3 seconds and that the alarm buzzer sounds properly. 2. If any lamp does not light up or the buzzer does not sound, there is probably a broken bulb or disconnection, so ask your Komatsu distributor to carry out inspection. 3-178...
Page 245: Adjustment
OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to pre- vent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q Push your back against the backrest of the operator's seat and adjust so that you can depress the brake pedal fully.
Page 246 OPERATION MACHINE OPERATIONS AND CONTROLS (D) Seat height adjustment Carry out adjustment of the seat weight before adjusting the seat height. Adjustment of the seat height and adjust- ment of the seat weight are both carried out with lever (3). q The seat height adjustment uses an air system, and it can be adjusted steplessly.
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS (G) Adjustment of headrest angle Move headrest (7) to the front or rear to adjust it to the desired angle. Amount of adjustment: 38° (H) Adjustment of headrest height Move headrest (7) up or down to adjust it to the desired height. Amount of adjustment: 100 mm (I) Lumbar support Operate switch (6) to give suitable tension to the lumbar region.
Page 248 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors q The rear view mirrors are installed to the following numeral for places. A: Installed to cab at front left of machine B: Installed to floor around cab at front left of machine C: Installed to handrail at rear left of machine D: Installed to handrail at right center of machine q Loosen nuts (1), bolts (2), and screws (3) holding the mir-...
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS (C1): Rear on the left side (C2): Adjust the angle of (C2) mirror the way a view in the rear of the counterweight left portion can be seen. (D1): Adjust the angle of (D1) mirror the way a view of the fuel tank right lower portion can be seen.
Page 250: Seat Belt
OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING q Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. q Even if there are no signs of damage, replace belts in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, which- ever date comes first.
Page 251: Operations Before Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When starting the engine, check that the lock lever is securely at the LOCK position. If the lock lever is not locked securely and the control levers or control pedal are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
Page 252 If any monitor does not light up or the buzzer does not sound, there is probably a failure in the monitor, so ask your Komatsu distributor to carry out repairs. 2) After approx. 2 seconds, the screen switches to the work- ing mode display monitor.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS 1/2 and 2/2 monitor screens can be switched by pressing func- tion switch F1. 3) If the hydraulic oil gauge goes out but caution lamp (23) stays lighted up red, carry out inspection immediately of the red lighted item.
Page 254 OPERATION MACHINE OPERATIONS AND CONTROLS Engine emergency stop switch (inside cab) Engine emergency stop switch (front of power container) Engine emergency stop switch (rear of power container) Engine emergency stop switch (left side of the machine) (if equipped) Engine emergency stop switch (right side of the machine) (if equipped) For details of the operation of the engine emergency stop switch, see “Stopping in Emergencies (3-203)“.
Page 255: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE WARNING q Start the engine only after sitting down in the operator's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 256 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Set fuel control dial (2) to the low idling (MIN) position. 3. Turn the key in starting switch (3) to ON position (B). If the ambient temperature is low, the preheating monitor lights up and automatic preheating is carried out. Keep the key in starting switch (3) at the ON position (B) until the preheating monitor goes out.
Page 257 OPERATION MACHINE OPERATIONS AND CONTROLS 6. Even if the engine starts, wait for the engine oil pressure monitor to go out. Do not touch the control levers or con- trol pedal while the engine oil pressure monitor is lighted NOTICE If the engine oil pressure monitor does not go out even after 4 to 5 seconds have passed, stop the engine immedi- ately.
Page 258: After Starting Engine
Breaking-in the New Machine NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How- ever, operating the machine under full load before breaking the machine in can adversely affect the perfor- mance and shorten the machine life.
Page 259: Engine Warm Up
OPERATION MACHINE OPERATIONS AND CONTROLS Engine Warm Up NOTICE q Do not accelerate the engine suddenly until the warm- up operation has been completed. q Do not run the engine at low idling or high idling under no load for more than 20 minutes. This will have an adverse effect on the environment, and will also have an adverse effect on the internal structure of the engine.
Page 260 OPERATION MACHINE OPERATIONS AND CONTROLS (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white If the engine coolant temperature monitor displays the correct temperature, the engine warm-up operation is com- pleted.
Page 261: Hydraulic Equipment Warm Up
OPERATION MACHINE OPERATIONS AND CONTROLS Hydraulic Equipment Warm Up WARNING q Before carrying out the warming-up operation for the hydraulic equipment, turn the swing lock switch ON, check on the monitor that the swing lock is actuated, then start the warming-up operation. q When warming up the hydraulic equipment, check that there is no person or obstacle in the surrounding area, then sound the horn and start the operation.
Page 262 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Turn swing lock switch (2) ON and check that the swing lock monitor lights up. 3. To complete the warm-up operation of the hydraulic equip- ment more quickly, set the working mode to P mode (heavy-duty mode).
Page 263 OPERATION MACHINE OPERATIONS AND CONTROLS 6. Move right work equipment control lever (5) slowly in the direction to pull in the bucket (D). Operate the lever to the end of its travel and hold it in position for 30 seconds. 7.
Page 264 1/2 and 2/2 monitor screens can be switched by pressing func- tion switch F1. 14. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu dis- tributor. In cold temperatures (ambient temperature below 0 °C), even when the hydraulic oil temperature monitor dis- plays the correct temperature, carry out additional Step 15 to warm up all the hydraulic equipment.
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS 15. Turn fuel control dial (4) to the full speed (MAX) position, repeat Steps 6 to 9 for 3 to 5 minutes, then check again that the hydraulic oil temperature monitor is displaying the correct temperature. If it is not displaying the correct temperature, repeat Steps 6 to 9 for 3 to 5 minutes until hydraulic oil temperature monitor (7) displays the correct temperature.
Page 266: Operation After Completion Of Warm-Up Operation
OPERATION MACHINE OPERATIONS AND CONTROLS q Travel (Lo) operation FORWARD (A) ←→ REVERSE (B) 18. Check that hydraulic oil temperature monitor (7) is display- ing the correct temperature. If the hydraulic oil temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 6 to 10 until the display is the correct temper- ature.
Page 267 OPERATION MACHINE OPERATIONS AND CONTROLS q Working mode monitor display 1) P mode For heavy-duty operations 2) E mode For operations with emphasis on fuel economy 3) Heavy lift mode For assisting operations 3-201...
Page 268: Stopping The Engine
REMARK It is possible to install a turbo timer on this machine. Please consult your Komatsu distributor regarding installation of a turbo timer. 2. Turn the key in starting switch (1) to the OFF position. 3. Remove the key from starting switch (1).
Page 269: Stopping In Emergencies
OPERATION MACHINE OPERATIONS AND CONTROLS Stopping in Emergencies Operating Engine Emergency Stop Inside Cab NOTICE Use this engine emergency stop switch to stop the engine in emergencies. Normally, keep the engine emergency stop switch at the OFF (normal operation) position. Press engine emergency stop switch (S) installed inside the cab and set it to ON (emergency stop) position (a).
Page 270 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Turn the starting switch key to the ON position. 3. Check that engine emergency stop warning lamp (C) on the console panel to the left of the operator's seat inside the cab is off. 4.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS q If the key in the starting switch is turned to the ON position when engine emergency stop switch (S) is at ON (emer- gency stop) position (a), engine emergency stop warning lamp (C) on the console panel to the left of the operator's seat inside the cab lights up.
Page 272 OPERATION MACHINE OPERATIONS AND CONTROLS Operating Engine Emergency Stop from Ground (If equipped) NOTICE This engine emergency stop switch is for use when carrying out inspection and maintenance under the machine or around the undercarriage. It will prevent anyone from starting the engine by mistake from the operator's seat.
Page 273 OPERATION MACHINE OPERATIONS AND CONTROLS 1. Pull rope (R) of the engine emergency stop switch. Indica- tor lamp (L) goes out and the engine emergency stop is cancelled. 2. Turn the starting switch key to the ON position. 3. Check that engine emergency stop warning lamp (C) on the console panel to the left of the operator's seat inside the cab is off.
Page 274: Stopping When Fire Occurs
OPERATION MACHINE OPERATIONS AND CONTROLS Stopping When Fire Occurs NOTICE Use fuel shut-off lever to prevent fuel from flowing out from the fuel tank in emergencies, such as fire. When stopping the engine in normal circumstances, follow the procedure in “Normal Stopping (3-202)“. Procedure for Stopping Engine from Ground Pull down fuel shut-off lever (1) installed at the front right of the machine.
Page 275 OPERATION MACHINE OPERATIONS AND CONTROLS q When starting the engine again after it has stopped, move fuel shut-off lever (1) up again and check that fuel shut-off lever (1) does not move. REMARK Fuel shut-off valve (3) is installed to the bottom of the fuel tank to reduce the spread of fire if any fire should occur.
Page 276: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING q Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction from the operation of the travel levers or travel pedals (front and rear travel is reversed, left and right steering is reversed).
Page 277: Moving Machine Forward
Start the machine either by pulling lever (5) back slowly or by stepping on the rear part of pedal (6) slowly. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
Page 278: Moving Machine Backward
Slowly push the levers (5) forward, or slowly depress the front part of the pedals (6) to move the machine backward. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
Page 279 OPERATION MACHINE OPERATIONS AND CONTROLS 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3-213...
Page 280: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the direction of operation of the travel levers or control pedals is the opposite from the direction of movement of the machine.
Page 281 OPERATION MACHINE OPERATIONS AND CONTROLS Steering when Traveling When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.
Page 282: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING q The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. q If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully.
Page 283: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
Page 284 OPERATION MACHINE OPERATIONS AND CONTROLS q Bucket control Move the right work equipment control lever to the left or right to operate the bucket. When the work equipment control lever is moved to the N position while the machine is idling, the engine speed lowers to the medium revolution in approx.
Page 285: Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match operating conditions and purpose, thereby enabling work to be performed efficiently. Make effective use of each mode as follows. When the starting switch is turned to the ON position, the work- ing mode is automatically set to P mode.
Page 286: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING q If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. q If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
Page 287 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as s pickaxe, breaker, or pile driver. This will drastically reduce the life of the machine. Operations Using Bucket as Lever Do not use the bucket to lever rocks out.
Page 288 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Digging at an Angle without Engaging Teeth Do not swing the upper structure when digging hard rock at a position higher than the machine if the bucket teeth will not penetrate the rock. The teeth will slip on the rock surface and generate excessive vibration of the machine, and this will lead to cracking of the work equipment or frame.
Page 289 OPERATION MACHINE OPERATIONS AND CONTROLS Swinging or Traveling When Rock Is on Top of Track Assembly Do not swing the upper structure or travel if there is in the rock on top of the track assembly. It will contact the undercover or frame and cause damage.
Page 290: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 291: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING q Turning or operating the work equipment when work- ing on slopes may cause the machine to lose it bal- ance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 292 OPERATION MACHINE OPERATIONS AND CONTROLS 2. When traveling up a steep hill of more than 15°, set the work equipment to the posture shown in the diagram on the right. Traveling Downhill Put the travel lever in the neutral position. This will cause the brake to be automatically applied. Engine Stopped on Slope q 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 293: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD When operating, be careful not to get stuck in mud. If the machine gets stuck in mud, do as follows to get the machine out. q If the machine push-up switch (1) is set to position (b), the pushing force of the boom is increased to make it easier for the machine to escape from mud.
Page 294: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine. When the condition of the machine is as shown in the diagram on the right (angle between [bucket cylinder and link] and [arm cylinder and arm] is 90°), the maximum excavation force is...
Page 295: Bucket Replacement
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING q When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equip- ment.
Page 296 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Remove pin (1) from the arm mounting hole and pin (2) from the link mounting hole, then remove the bucket. q With pin (1), remove grease piping cover (3) and grease piping (4), then remove cover (5) and use the removal tap in the side face of the pin to remove the pin (both left and right).
Page 297: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING q Avoid stopping suddenly. Give yourself ample room when stopping. q When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably neces- sary to park the machine on a slope, insert blocks underneath the track shoes.
Page 298: Check Before Shut Off Engine
OPERATION MACHINE OPERATIONS AND CONTROLS 4. Set lock lever (3) to LOCK position (L). CHECK BEFORE SHUT OFF ENGINE Check on the machine monitor display the engine coolant and oil temperatures, hydraulic oil temperature, PTO oil tempera- ture, engine hydraulic pressure and remaining fuel amount. If an abnormality is found in any of them, take proper action after stopping the engine and in reference to “TROUBLES AND ACTIONS (3-240)“.
Page 299: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Door of operator's cab Always remember to close the window. (2) Door of cab base room (3) Fuel tank filler port (4) Hydraulic tank filler port (5) Power container front door (5 places) (6) Power container rear door (3 places) (7) Battery case cover (2 places) (8) Air conditioner box cover...
Page 300: Transportation
PRECAUTIONS FOR TRANSPORTATION WARNING This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. METHOD OF LIFTING UNITS FOR TRANSPORTATION WARNING q Never raise the machine with any worker on it.
Page 301: Cold Weather Operation
NOTICE Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recom- mend the use of any coolant other than Komatsu genuine supercoolant (AF-NAC). The coolant is already diluted with distilled water, so it is not flammable.
Page 302: Battery
OPERATION COLD WEATHER OPERATION Battery WARNING q The battery generates flammable gas. Do not bring fire or sparks near the battery. q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 303: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 304: Long Term Storage
OPERATION LONG TERM STORAGE LONG TERM STORAGE BEFORE STORAGE NOTICE To protect the hydraulic cylinder piston rod while in stor- age, keep the work equipment in the posture shown at right. (This prevents rust from developing on the piston rod) When putting the machine in storage for a long time (more than one month), do as follows.
Page 305: After Storage
NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it. q Wipe off the grease from the hydraulic cylinder rods.
Page 306: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. q For details of the method of bleeding the air, see “BLEEDING AIR FROM FUEL CIRCUIT (4-45)“. q For details of the poor fuel arrangement specification machines (if equipped), see “Bleeding air from fuel circuit with the electric priming pump (4-47)“.
Page 307: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Page 308: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING q It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charging. q When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
Page 309: Battery Charges
OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled cor- rectly, there is a hazard that the battery may explode. Always follow the instructions of “DISCHARGED BATTERY (3-242)“ and the instruction manual accompanying the charger, and do as follows.
Page 310: Starting Engine With Booster Cables
OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows. Connecting and Disconnecting Booster Cables WARNING q When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. q When starting the engine with a booster cable, always wear safety glasses.
Page 311 OPERATION TROUBLES AND ACTIONS Booster Cable Connection for Battery Isolator Installation Machine If the problem machine is equipped with the battery isolator switch (option), turn the starting switch OFF on both the problem machine and the normal machine, then turn the battery isolator switch of the problem machine OFF. After that, connect the booster cable as follows in the order shown by the numbers in the diagram.
Page 312: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even •Defective wiring...
Page 313: Chassis
OPERATION TROUBLES AND ACTIONS Chassis q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Lack of hydraulic oil...
Page 314: Engine
OPERATION TROUBLES AND ACTIONS Engine q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Engine oil level is low in oil pan (suck-...
Page 315 •Refer to “Radiator water level (combustion or mechanical) monitor lights up“ as above Error code is displayed on monitor Alarm buzzer sounds Please contact your Komatsu distributor Engine suddenly loses power Combustion noise occasionally •Defective nozzle (•Replace nozzle) make breathing sound •Low-grade fuel being used...
Page 316: Electronic Control System
(*) If the display of “CA2249“ or “CA559“ still does not disap- pear after the replacement, ask your Komatsu distributor Abnormality in electronic governor system for an inspection immediately, even though normal oper- ation of the machine is still possible.
Page 317: Point Of Contact To Telephone When Error Occurs
REMARK If no point of contact telephone number has been registered, no telephone number is displayed. It is necessary to register the telephone number, please ask your Komatsu distributor to carry out the registration. 3-251...
Page 318 OPERATION TROUBLES AND ACTIONS 3-252...
Page 319: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 320: Maintenance Information
Check the service meter reading every day to see if the time has come for any necessary maintenance to be per- formed. Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the machine. Komatsu Genuine Lubricants For lubrication of the machine, use the Komatsu genuine lubricants.
Page 321 MAINTENANCE MAINTENANCE INFORMATION Do not Drop Things Inside Machine q When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and will lead to failure.
Page 322 MAINTENANCE MAINTENANCE INFORMATION Checks After Inspection and Maintenance Works If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: q Checks after operation (with engine stopped) q Have any inspection and maintenance points been forgotten? q Have all inspection and maintenance items been performed correctly? q Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...
Page 323: Outline Of Service
Komatsu distributor. q When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil.
Page 324: Fuel
COOLANT AND WATER FOR DILUTION q Komatsu genuine Supercoolant (AF-NAC) has the important function of preventing corrosion as well as pre- venting freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Page 325: Grease
Do not mix hyper- white grease as it hardens. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.
Page 326: Storing Oil And Fuel
Perform sampling at regular fixed intervals. q Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. STORING OIL AND FUEL q Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 327: Electric System Maintenance
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. q Never install any electric components other than those specified by Komatsu. q External electro-magnetic interference may cause malfunction of the control system controller, before install- ing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 328: Wear Parts List
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 329: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT q Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 330 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT Ambient temperature, Reservoir Fluid type Recommended Komatsu Fluids degrees Celsius -30°C 30°C Komatsu EOS0W30 (Note. 1) -25°C 40°C Komatsu EOS5W40 (Note. 1) Engine oil pan Engine oil -20°C 40°C Komatsu EO10W30-DH -15°C 50°C Komatsu EO15W40-DH 0°C...
Page 331: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
G2-T or G2-TE is recommended. Note. 5: Coolant 1) <Komatsu genuine Supercoolant (AF-NAC) has the important function of anticorrosion as well as antifreeze. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Page 332: Tightening Torque Specifications
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 333: Safety Critical Parts
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. 4-15...
Page 334: Safety Critical Parts List
MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST Periodic Replacement Parts Replacement Interval Fuel hose (fuel tank to fuel pre-filter) Fuel hose (fuel pre-filter to priming pump) Fuel hose (priming pump to supply pump) After-cooler hose (front side) After- cooler hose (rear side) Fuel return hose (fuel injection pump to fuel cooler) Fuel return hose (fuel cooler to fuel tank) Fuel spill hose (engine to fuel tank)
Page 335: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) CLEAN PTO LUBRICATION OIL FILTER STRAINER ..................4-194 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) CHANGE OIL IN SWING MACHINERY CASE....................4-194 CHANGE OIL IN PTO CASE ..........................
Page 336 MAINTENANCE MAINTENANCE SCHEDULE EVERY 1000 HOURS MAINTENANCE REPLACE FUEL MAIN FILTER CARTRIDGE....................4-854 REPLACE FUEL TANK BREATHER ELEMENT ....................4-894 CHANGE OIL IN SWING MACHINERY CASE ....................4-904 CHANGE OIL IN PTO CASE ..........................4-924 CLEAN PTO LUBRICATION OIL FILTER STRAINER ..................4-944 REPLACE HYDRAULIC OIL FILTER ELEMENT .....................
Page 337: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)4 Carry out the following maintenance only after the first 100 hours of operation on new machines. q Clean strainer of PTO lubricating oil filter For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE. INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)4 Carry out the following maintenance only after the first 500 hours of operation on new machines.
Page 338: When Required
MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING q When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. q When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places or where the foothold is poor, be careful not to fall because of the reac- tion when pulling out the outer element.
Page 339 MAINTENANCE MAINTENANCE PROCEDURE Replace element, O-ring When one year has passed since the element was installed, or if air cleaner clogging monitor (1) on the monitor panel lights up immediately after it has been cleaned, replace external ele- ment (5), internal element (6), and O-ring (8). REMARK Use dust indicator (4) as a guideline for the cleaning interval for the air cleaner element.
Page 340 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Outer Element NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 1. Remove hooks (2) of each air cleaner (6 places), then remove cover (3). NOTICE q Never remove the inner element (6). It will allow dirt to enter and cause failure of the engine.
Page 341 MAINTENANCE MAINTENANCE PROCEDURE 7. If small holes or thinner parts are found on the element when it is checked by shining a light through it after clean- ing, replace the element. 8. Remove the cloth or tape covering inner element (6). NOTICE q Do not use an element whose folds or gasket or seal are damaged.
Page 342 MAINTENANCE MAINTENANCE PROCEDURE NOTICE When inserting the element, if the rubber at the tip is swol- len or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE 2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out. Do not remove inner element (6) when doing this. 3.
Page 344 MAINTENANCE MAINTENANCE PROCEDURE 7. Replace O-ring (8) of cover (3) with a new part. NOTICE When inserting the element, if the rubber at the tip is swol- len or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling.
Page 345: Clean Inside Of Cooling System
Komatsu genuine Supercoolant (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Supercoolant (AF-NAC). Supercoolant (AF-NAC) has excellent anticorrosion, anti- freeze and cooling properties and can be used continuously for two years or 4000 hours.
Page 346 When changing the coolant or when handling the coolant containing coolant that has been drained during repair of radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Coolant is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 347 MAINTENANCE MAINTENANCE PROCEDURE 5. Set a container under drain valve (7) under the machine to catch the coolant and water mix. 6. Install a drain hose (approx. 2 m) to drain valve (7). 7. Open drain valve (6). 8. Open drain valve (7) and drain the water. 9.
Page 348: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening 1. Tighten first to a tightening torque of 686 ± 69 Nm (70 ± 7 kgm), then check that the nut and shoe are in tight contact with the link mating surface.
Page 349 MAINTENANCE MAINTENANCE PROCEDURE Checking 1. Run the engine at low idle, then move the machine forward for a distance equal to the track length on ground, and slowly stop the machine. 2. Place wooden bar (3) on top of the track from No. 2 roller (1) to No.
Page 350 MAINTENANCE MAINTENANCE PROCEDURE 3. Thrust bucket teeth into the ground to prevent the machine to travel, then relief hydraulic valve (4 to 5 seconds) with forward / reverse operation of right travel lever (2). Repeat this operation 5 to 6 times. NOTICE q Do not carry out this forward / reverse operation on a slippery surface (such as steel plates).
Page 351 1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu dis- tributor.
Page 352 Always use the following procedure. It is extremely dangerous to use any other procedure to release the grease. If the track link does not become loose, ask your Komatsu distributor to carry out repairs. 1. Loosen plug (1) a little at a time to release the grease.
Page 353: Replace Bucket Teeth (Xs)
There is a hazard that fragments will fly during the replacement work, so always wear protective equip- ment like safety glasses and gloves. q If the tooth pins cannot be removed in this procedure, for safety's sake, be sure to ask your Komatsu distributor for the replacement.
Page 354 MAINTENANCE MAINTENANCE PROCEDURE 4. Fit a socket wrench to the head of pin (1), then turn it coun- terclockwise 90° to release the lock of the pin. 5. Push pin (1) out by hand or with a hammer in the direction of the arrow to remove the teeth (2).
Page 355 There is a hazard that fragments will fly during the replacement work, so always wear protective equip- ment like safety glasses and gloves. q If the tooth pins cannot be removed in this procedure, for safety's sake, be sure to ask your Komatsu distributor for the replacement.
Page 356 MAINTENANCE MAINTENANCE PROCEDURE 5. Push pin (1) out by hand or with a hammer in the direction of the arrow to remove the teeth (2). 6. Take off wear cap (6) after removing tooth (2), and then clean the cap mounting face and mounting hole (7). 7.
Page 357 MAINTENANCE MAINTENANCE PROCEDURE How to Remove Slinging Loop WARNING q If the slinging loop is caught on any part of the bucket (tooth, lip shroud, wear cap, adapter, side shroud), remove it. If digging operations are carried out without removing the slinging loop, there is danger that the slinging loop may break and pieces may fly around.
Page 358 MAINTENANCE MAINTENANCE PROCEDURE 2. Within 15 seconds after stopping the engine, move each control lever (for work equipment and travel) to the full stroke in all directions to release the internal pressure. 3. Check that the work equipment is in a stable condition, then set the lock lever to the LOCK position (L).
Page 359: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1)Add ethyl alcohol window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
Page 360: Check And Maintenance Air Conditioner
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND MAINTENANCE AIR CONDITIONER Check Level of Refrigerant (gas) WARNING If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.
Page 361: Clean Line Filter, Remove Dirt
MAINTENANCE MAINTENANCE PROCEDURE CLEAN LINE FILTER, REMOVE DIRT If there is any abnormality in the pump or other hydraulic equip- ment, remove the dirt from inside the line filter as follows. q Before removing the dirt from the line filter, remove the cap from oil filler port (F) at the top of the hydraulic tank to release the pressure inside the hydraulic circuit.
Page 362: Check Seals Around Engine Cooling
If nothing is done to correct this problem, there will be deterioration in the heat balance and increase in noise. Take action as soon as possible. When doing this, please contact your Komatsu distributor. 4-44...
Page 363: Bleeding Air From Fuel Circuit
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM FUEL CIRCUIT In the following cases, carry out the procedure given below to bleed the air from the fuel circuit. q When fuel filter has been replaced q When engine has run out of fuel q When starting the engine for the first time after replacing the supply pump or modifying the piping or any other parts WARNING...
Page 364 MAINTENANCE MAINTENANCE PROCEDURE 2. Remove locknut (3) from priming pump lever (4), then pump priming pump lever (4) 50 -100 times and check that fuel comes out from air bleed plug (1). When fuel comes out, tighten plug (1). (One place each on left and right sides of engine) Tightening torque: 7.8 - 9.8 Nm {0.8 - 1 kgm} 3.
Page 365 MAINTENANCE MAINTENANCE PROCEDURE Bleeding air from fuel circuit with the electric priming pump (Only poor fuel arrangement specification machines) Poor fuel arrangement specification machines is equipped with an electric priming pump to bleed the air from the fuel circuit. In the following cases, use the procedure below to bleed the air. q When fuel filter has been replaced q When engine has run out of fuel q When starting the engine for the first time after replacing the supply pump or modifying the piping or any other...
Page 366 MAINTENANCE MAINTENANCE PROCEDURE (Right side) 3. Turn electric priming pump switch (3) to the ON position (A). Lamp (4) flashes and the electric priming pump starts. Release electric priming pump switch (3). Switch (3) will return automatically to the original position (N). REMARK While lamp (4) is flashing, the electric priming pump is actuated for 30 seconds and then stops for 10 seconds.
Page 367: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see “STARTING ENGINE (3-189)“. If it is necessary to refer to the items for starting the engine, mov- ing the machine off, steering, or stopping, see the OPERATION section. NOTICE Bleed air from the hydraulic system in the following steps.
Page 368 MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM PUMP Use the same procedure for bleeding air from the work equipment and hydraulic drive fan pumps. When the pump has been replaced or the oil in the hydraulic tank has been changed, bleed the air from the pump to prevent overheating of the pump.
Page 369 MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM MOTOR Travel Motor 1. Start the engine and run it at low idling. 2. Loosen air bleed plug (2) of the travel motor 1-2 turns. Loosen the air bleed plugs for both the motors. 3.
Page 370 MAINTENANCE MAINTENANCE PROCEDURE REMARK Air bleeding through swing operation can be achieved with fine operation of the swing hydraulic switch to the extent that it turns on (ON lights up). BLEEDING AIR FROM IDLER CUSHION CIRCUIT Bleed the air from the idler cushion circuit before pumping grease into the hydraulic charge grease cylinder. 1.
Page 371 MAINTENANCE MAINTENANCE PROCEDURE 4. Remove plug (6) on the bottom of the check valve block (5) and loosen air bleeding plug (7) on the side approximately by 1 turn. 5. Start the engine and run it at low idling for 2-3 minutes. 6.
Page 372 MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM PILOT SELECTOR VALVE CIRCUIT After the removal and installation of the pilot selector valve and the disconnection and connection of the pilot selector valve circuit, bleed air from the pilot selector valve circuit in the following manner. REMARK If air is not bled at all or bled but insufficiently, there is a possibility that the working speed lowers in complex oper- ation, so be sure to follow the air bleeding instructions.
Page 373 MAINTENANCE MAINTENANCE PROCEDURE 1. Start up the engine and loosen bleeder (A) and (B). A bleeder is fitted to pilot selector valve (1) and (2) one each. 2. Operate arm DIGGING and bucket DIGGING or arm DIG- GING and DUMPING simultaneously while keeping the engine running at low idling, check that oil free of air bub- bles begins to flow out of bleeder (A) and then tighten bleeder (A).
Page 374 MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM MAIN VALVE PILOT PIPING After the removal and installation of the main valve and the disconnection and connection of the PPC hose, bleed air from the pilot selector valve circuit in the following manner. REMARK If air is not bled at all or bled but insufficiently, there is a possibility of a time lag while in the operation or an abnor- mal noise from the PPC lever, so be sure to follow the air bleeding instructions.
Page 375 MAINTENANCE MAINTENANCE PROCEDURE Rear Side of Main Valve (R) Machine's rear side (1) Arm DUMP (4 locations) (2) Boom LOWER (2 locations) (3) Bucket DUMP (4 locations) (4) Left travel forward (2 locations) (5) Right travel forward (2 locations) 4-57...
Page 376 MAINTENANCE MAINTENANCE PROCEDURE Front side of main valve (F) Machine's front side (1) Arm DIGGING (3 locations) (2) Boom RAISE (3 locations) (3) Bucket DIGGING (4 locations) (4) Right travel backward (2 locations) (5) Left travel backward (2 locations) 4-58...
Page 377 MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT After changing the oil in the hydraulic tank or replacing the line filters, after removing any hydraulic cylinder or work equipment piping, or after removing any pump or cushion piping, it is necessary to bleed the air from the hydraulic circuit.
Page 378: Method For Releasing Internal Pressure In Hydraulic Circuit
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT RELEASING PRESSURE IN ACCUMULATOR CIRCUIT RELEASING INTERNAL PRESSURE IN PILOT CIRCUIT 1. After stopping the engine, turn the engine starting switch to the ON position and move the lock lever to the FREE posi- tion.
Page 379 MAINTENANCE MAINTENANCE PROCEDURE RELEASING INTERNAL PRESSURE IN HYDRAULIC IDLER CUSHION 1. Lower the work equipment to the ground and stop the engine. Operate the work equipment control lever for sev- eral times to release the remaining pressure in the piping. Slowly loosen oil filler cap (F) of the hydraulic tank and release the internal pressure inside the tank.
Page 380: Inspection Of Additional Water Separator And Cleaning Of Casing Interior
MAINTENANCE MAINTENANCE PROCEDURE INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTE- RIOR (Only poor fuel arrangement specification machines) WARNING Do not bring any fire or flame close. NOTICE q When carrying out inspection and maintenance of the fuel system, the particularly careful not to let any dirt or dust get in.
Page 381 MAINTENANCE MAINTENANCE PROCEDURE 3. Put a container to catch drain water under drain hose pro- vided in the lower part of the revolving frame. 4. Loosen water drain plug (1) to drain fuel in the casing. If the fuel cannot be drained, remove air intake plug (2). [Width across flats: 14 mm (0.6in)] The fuel will drain from water drain plug (1).
Page 382: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see “Checks Before Starting (3-160)“ in the OPERATION section. q Check coolant level, add coolant q Check oil level in engine oil pan, add oil q Check fuel level, add fuel q Check oil level in hydraulic tank, add oil q Check oil level in PTO case, add oil q Check air cleaner for clogging...
Page 383: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri- ous burns. Wait for the temperature to go down before starting the operation. q If there is still pressure remaining inside the case, the oil or plug may fly out.
Page 384: Check Level Of Battery Electrolyte
MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler- ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
Page 385 (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When it is Impossible to Check Electrolyte Level from Side of Battery If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows.
Page 386: Check And Tighten Track Frame And Axle Connecting Bolts
If the 12 bolts (1) connecting the track frame and axle are loose and the machine is used without tightening them, they will break. If any loose bolts are found, ask your Komatsu distribu- tor to tighten them. q Tightening torque: 4658 ± 245 Nm {475 ± 25 kgm}...
Page 387 MAINTENANCE MAINTENANCE PROCEDURE Checking 1. Remove cover (3) at the front of the engine. When 6 bolts (1) are removed, the cover will come off. 2. The deflection should be 10 to 15 mm when a point mid- way between the alternator and the drive pulley is pressed with a finger force of approx.
Page 388: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE MAINTENANCE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST There are 2 air conditioner compressors installed to the engine. WARNING When carrying out inspection and adjustment, set to the engine stop position as follows. Press engine stop switch (1) installed at the front of the power container on the left side of the machine, or engine stop switch (2) installed at the rear of the power container on the right side of the machine.
Page 389 MAINTENANCE MAINTENANCE PROCEDURE 2. The deflection should be approx. 6 mm (0.24 inch) when a point midway between the drive pulley and the air condi- tioner compressor pulley is pressed with a finger force of approx. 58.8 N {approx. 6 kg}. A: Compressor pulley B: Drive pulley Adjustment...
Page 390: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 250 hours service should be carried out at the same time. CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.
Page 391 MAINTENANCE MAINTENANCE PROCEDURE 2. Loosen drain valve (P1) in the oil pan. The oil will go down to drain valve (P2). P1: Oil pan drain valve P2: External takeoff drain valve 3. Open drain valve (P2) slowly through the drain control hole in the engine under cover and drain the oil. When doing this, be careful not to get oil over yourself.
Page 392: Clean And Inspect Radiator Fins, Oil Cooler Fins, Fuel Cooler And After Cooler Fins
MAINTENANCE MAINTENANCE PROCEDURE 7. When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten a further 3/4 - 1 turn. 8. After replacing the filter cartridge, add oil through oil filler port (F) so that the oil level is between the H and L marks on dipstick (G).
Page 393 MAINTENANCE MAINTENANCE PROCEDURE 1. Remove bolts (2) of top of duct door (1) on the radiator side (right side of machine) and oil cooler side (left side of machine), then open door (1). Each door is installed with 6 bolts (2). A: Oil cooler B: Radiator 2.
Page 394 MAINTENANCE MAINTENANCE PROCEDURE 3. Use compressed air to blow off the dirt, mud, or leaves clogging the radiator fins, oil cooler fins, fuel cooler fins, and aftercooler fins. At the same time, clean door (1) also. Steam or water may be used instead of compressed air.However, when carrying out powerful steam cleaning (high-pressure machine wash) of the heat exchange equipment (radiator, oil cooler, aftercooler, fuel cooler), maintain sufficient distance from the machine when carrying out the operation.
Page 395: Clean Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently.
Page 396 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Fresh Air Filter 1. There are 2 air conditioners installed inside the air condi- tioner box at the rear of the cab. 2. Open cover (4) of the air conditioner box. Pull out and remove fresh air filter (5) from inside. 3.
Page 397: Check, Replace Hydraulic Pump Drain Filter Cartridge
If such materials are stuck to the cartridge of filter case, there is probably an abnormality in the hydraulic circuit. Please ask your Komatsu distributor to carry out inspection and repair. REMARK The drain filter cartridge consists of the following 2 cartridges.
Page 398: Replace Pilot Filter Cartridge
If such materials are stuck to the cartridge of filter case, there is probably an abnormality in the hydraulic circuit. Please ask your Komatsu distributor to carry out inspec- tion and repair. CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...
Page 399: Replace Fuel Pre-Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 400 MAINTENANCE MAINTENANCE PROCEDURE 1. Pull fuel shut-off lever (A) installed to the front of the main pump inside the pump room, and close the fuel supply cir- cuit from the fuel tank. (S): Shut off (O): Open 2. Set a container under the fuel pre-filter cartridge to catch the fuel.
Page 401 MAINTENANCE MAINTENANCE PROCEDURE 3. Disconnect drain hose (4) for water separator cup (3). 4. Using the filter wrench, turn filter cartridge (2) to the left and remove it. 5. After removing the cartridge, turn cup (3) of the water sepa- rator installed to the bottom of the cartridge to the left and remove it.
Page 402 MAINTENANCE MAINTENANCE PROCEDURE 11. Replace the filter cartridge and bleed the air. When replacing the fuel main filter cartridge (every 1000 hours), see “REPLACE FUEL MAIN FILTER CARTRIDGE (4-85)“. 12. Push down fuel shut-off lever (A) installed to the front of the main pump inside the pump room so that it can supply fuel.
Page 403: Every 1000 Hours Maintenance
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 404 MAINTENANCE MAINTENANCE PROCEDURE 1. Pull fuel shut-off lever (A) installed to the front of the main pump inside the pump room, and close the fuel supply cir- cuit from the fuel tank. (S): Shut off (O): Open 2. Set the container to catch the fuel under the filter cartridge. 3.
Page 405 MAINTENANCE MAINTENANCE PROCEDURE With the poor fuel arrangement specification machine, two fuel filters are additionally installed to the engine block (one each on left and right). (This gives a total of two each on the left and right.) NOTICE q Do not fill the fuel filter cartridge with fuel. q Remove cap (B) and install the fuel filter.
Page 406 12. Push in the priming pump lever (4), then tighten locknut (5) to hold priming pump lever (4) in position. Use a genuine Komatsu part for the fuel filter cartridge. After replacing the filter cartridge, run the engine, and check for any fuel leakage from the filter seal surface.
Page 407: Replace Fuel Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL TANK BREATHER ELEMENT 1. Remove nut (2) of breather assembly (1) at the top surface of the fuel tank, then remove cover (3). 2. Replace breather element (4) with a new part. 3. Install cover (3) and nut (2). NOTICE q For machines equipped with the optional service cen- ter, see “REPLACE FUEL TANK BREATHER ELEMENT...
Page 408: Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. REMARK For details of the method of draining and adding swing machinery case oil to machines equipped with a service center (option), see “Method of Draining, Adding Swing Machinery Case Oil (Front) (6-22), Method of Draining,...
Page 409 MAINTENANCE MAINTENANCE PROCEDURE q Rear swing machinery 5. The oil level should be between H and L marks on the dip- stick (G). If the oil does not reach the L mark, add oil through oil filler port (F). 6. If the oil level is above the H mark, loosen drain valve (P) to drain excess oil from the power train and check the oil level again.
Page 410: Change Oil In Pto Case
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN PTO CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.
Page 411 MAINTENANCE MAINTENANCE PROCEDURE 2. Add a specified amount of power train oil from oil filler port (F). 4-93...
Page 412: Clean Pto Lubrication Oil Filter Strainer
MAINTENANCE MAINTENANCE PROCEDURE CLEAN PTO LUBRICATION OIL FILTER STRAINER WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. q When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Page 413: Replace Hydraulic Oil Filter Element
If there are any metal particles or foreign material at the bottom of strainer (5) or the element case, please contact your Komatsu distributor. 4. Clean the removed parts in flushing oil. 5. Install the new element in the place where old element (4) was installed.
Page 414: Replace Hydraulic Tank Breather Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT WARNING q Immediately after the engine is stopped, the oil and parts are at high temperature, and this will cause burns. Wait for the temperature to go down before starting the operation. q When replacing the breather element, remove cap (F) of the oil filler port.
Page 415 MAINTENANCE MAINTENANCE PROCEDURE 4-97...
Page 416: Check For Loose Clamps Of Aftercooler Hose
MAINTENANCE MAINTENANCE PROCEDURE CHECK FOR LOOSE CLAMPS OF AFTERCOOLER HOSE Check that the tightening torque for the aftercooler hose clamps is as specified. q Position of clamps Area around radiator at front of engine Area around oil cooler at rear of engine (right side of machine) (left side of machine) q Detail of clamp portion A.
Page 417: Check Gas Pressure In Accumulator For Operation Control Circuit
2. Check that the tip of the bucket drops at least 1 m. If the tip of the bucket drops less than 1 m, the charge pressure inside the accumulator is low, so contact your Komatsu distributor. CHECK WELDED STRUCTURE (Color check) It is easy to use a color check to check visibly for cracks in welded structures.
Page 418 MAINTENANCE MAINTENANCE PROCEDURE q Revolving frame (A): Important check points q Center frame (A): Important check points 4-100...
Page 419 MAINTENANCE MAINTENANCE PROCEDURE q Boom (A): Important check points q Arm (A): Important check points 4-101...
Page 420: Check Emergency Ladder
MAINTENANCE MAINTENANCE PROCEDURE CHECK EMERGENCY LADDER Check rope ladder (1), fixed ladder (2), handrail (3), and mounting bracket (4). Check that there is no wear, damage, or other abnormality. If any problem is found, replace with genu- ine parts. NOTICE With a rope ladder (1), even if there is no visual wear or damage, the rope will deteriorate with time, so there is danger of a drop in the strength of the rope.
Page 421: Greasing Hydraulic Ladder
MAINTENANCE MAINTENANCE PROCEDURE GREASING HYDRAULIC LADDER Set the hydraulic ladder to the lowered position as shown in the diagram on the right, then pump in grease with a grease gun through grease fittings (1) to (4). REMARK Destination for grease pumped in through each grease fitting (1): Ladder cylinder head pin (5) (2): Ladder link pin (front) (6) (3): Ladder link pin (rear) (7)
Page 422: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri- ous burns.
Page 423: Check Grease Level In Swing Pinion, Add Grease
Total grease capacity: 80 liter, 72 kg CHECK ALTERNATOR, STARTING MOTOR There is the possibility that the brush has worn out, or the bearing has run short of grease, so call on your Komatsu distributor for an inspection or repairs.
Page 424: Every 4000 Hours Maintenance
Add grease with a grease gun through grease fitting (2) on engine mount (1). CHECK WATER PUMP Check that there is no leakage of water from around the water pump. If there is any problem, ask your Komatsu distributor to carry out disassembly and repair or replacement. 4-106...
Page 425: Check For Looseness Of High-Pressure Piping Clamp, Hardening Of Rubber
Check visually and touch by hand to check that there are no loose mounting bolts for high-pressure piping clamps (1) - (34) in the diagram and no hardening of any rubber parts. If any problem is found, the part must be replaced. In this case, please ask your Komatsu distributor to carry out the replacement. RIGHT SIDE...
Page 426: Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
If any problem is found, the part must be replaced. In this case, please ask your Komatsu distributor to carry out the replacement.
Page 427: Replace Accumulator In Oil Cooler Circuit
MAINTENANCE MAINTENANCE PROCEDURE REPLACE ACCUMULATOR IN OIL COOLER CIRCUIT WARNING Immediately after the engine is stopped, the oil and parts are at high temperature, and this will cause burns. Wait for the temperature to go down before starting the operation. NOTICE Even if the operating time has not reached 4000 hours, if the machine has been used for 2 years, replace the accumulator.
Page 428: Every 5000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING q Immediately after the engine is stopped, the oil and parts are at high temperature, and this will cause burns.
Page 429 MAINTENANCE MAINTENANCE PROCEDURE 5. Loosen drain plugs (P1) and (P2) at the suction tube por- tion at the rear bottom left of the machine, and drain the oil. q The outlet port for draining the oil is drain tube (A). When draining the oil, be careful not to get oil over yourself.
Page 430 MAINTENANCE MAINTENANCE PROCEDURE 9. Add the specified amount of hydraulic oil through oil filler port (F). When adding the oil, watch sight gauge (G), and check that the oil is at the correct level. NOTICE Do not add oil above the correct level. This may damage the hydraulic circuit and cause the oil to spurt out.
Page 431 MAINTENANCE MAINTENANCE PROCEDURE REMARK When the working posture is (2) in the diagram on the right, the correct oil level on the gauge label is range (a2) at normal tem- perature and (b2) at high temperature. 10. After changing the hydraulic oil and cleaning the filter element strainer, bleed the air from inside the circuit. 4-113...
Page 432: Every 8000 Hours Maintenance
Please ask your Komatsu distributor to replace the injector assembly. REPLACE HIGH-PRESSURE PIPING CLAMP Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPRAY PREVENTION CAP Contact your Komatsu distributor to have the fuel spray prevention cap replaced. 4-114...
Page 433: Specifications
SPECIFICATIONS...
Page 434 Operating weight 200,000 (including 1 operator, 80 kg) Bucket capacity m³ 12.0 Name of engine Komatsu SAA12V140E-3 diezel engine 713 / 1,800 (ISO 9249) Engine power kW / rpm 728 / 1,800 (ISO 14396) A Overall length 17,030 B Overall height...
Page 435 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC2000-8 A Max. digging reach 15,780 B Max. digging depth 9,235 C Max. digging height 13,410 D Max. vertical wall depth 2,710 E Max. dumping height 8,650 F Max. reach at ground level 15,305 NOTICE...
Page 436 SPECIFICATIONS SPECIFICATIONS...
Page 437: Attachments And Options
ATTACHMENTS AND OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 438: General Precautions For Safety
There may also be problems of the attachment or option hitting the operator's cab. q Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu.
Page 439: Precautions When Using
ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY PRECAUTIONS WHEN USING When long or heavy work equipment is installed, remember the following precautions. Before starting operations, move the machine to a safe place and carry out a test operation to make sure that you fully understand the move- ment, center of gravity, and working range of the machine.
Page 440: Attachment Guide
When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing. q Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment.
Page 441: Front Guard
4. Please consult with your distributor for the correct selection of buckets and attachments to suit the application. The recommendations are given as a guide only, based on typical conditions. Select the combination of boom, arm, and bucket from the combinations shown in the table below. PC2000-8 1-Piece Boom Max Bucket Vol- 2.9 m Arm...
Page 442: Handling Fuel Quick Charge
ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE HANDLING FUEL QUICK CHARGE GENERAL LOCATIONS Position for stowing fuel quick charge lever Lock plate Position for adding fuel to fuel quick charge lever (5) Lever operating handle Fuel quick charge lever Stopper Fuel filler port (Wiggins ZN2B) *1 Proximity switch Fuel filler cap...
Page 443: Procedure For Operating Fuel Charge
ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE PROCEDURE FOR OPERATING FUEL CHARGE WARNING q Fuel causes fire, so be extremely careful not to let the fuel overflow when filling with fuel. If any fuel spills, wipe it off completely. If it spills onto the ground, remove the soil that is contaminated with fuel. q Fuel is a dangerous substance that catches fire easily, so never bring it near to any flame or fire.
Page 444 ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE 1. Raise lever operating handle (1) slightly with your right hand and push the hatched portion of lock plate (2) in the diagram on the right with the palm of your left hand or the tip of your finger.
Page 445 ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE 7. Push lever operating handle (1) slightly towards the front of the machine, then push up until lock bar (3) enters the oblong hole in lock plate (2). q Do not touch lock plate (2) when doing this. 8.
Page 446: Replace Fuel Tank Breather Element
ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE REPLACE FUEL TANK BREATHER ELEMENT For machines equipped with the fuel quick charge, the fuel tank breather is different from the breather on the machine is not equipped with the fuel quick charge. Use the following procedure to replace the fuel tank breather element every 1000 hours.
Page 447: Action When Machine Does Not Move Because Of Failure In Proximity Switch
ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH If it is impossible to swing or drive the machine, or operate the work equipment even when the fuel quick charge lever is stowed, there is probably a problem with the proximity switch.
Page 448 This change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place. After moving the machine, contact your Komatsu distributor immediately and ask for repairs to be carried out.
Page 449 ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE 2. On the right side inside the cab base room there is the con- nector for the PPC (proportional pressure control pilot) lock. 3. Remove bolts (1) and (2) of the clamp holding the connec- tor cable.
Page 450 6. Connect the negative (-) terminal of the battery, start the engine, then check that it is possible to operate the travel, swing, and work equipment. If they cannot be operated, there is probably some other cause, so ask your Komatsu distributor to carry out investigation.
Page 451: Handling Service Center
ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER HANDLING SERVICE CENTER GENERAL LOCATIONS Position for stowing service center (10) PTO oil coupler Position for use (11) Hydraulic oil coupler Service arm (12) Coolant coupler Service panel (13) Engine oil coupler Service arm cylinder (14) Fuel coupler Proximity switch (15) Grease coupler...
Page 452: Procedure For Operating Service Arm
ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER PROCEDURE FOR OPERATING SERVICE ARM WARNING Before operating the service arm, check that there is no one inside the operating range of the service arm. There is danger that anyone inside the operating range may suffer injury by being hit or caught up by the service arm.
Page 453 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER When Lowering Service Arm (Setting to Position for Use) 1. Check the lock lever (1) is at the LOCK position (L). When lock lever (1) is in FREE position (F), the service arm can- not be operated.
Page 454 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER When Raising Service Arm (Setting to Stowing Position) 1. Check the lock lever (1) is at the LOCK position (L). When lock lever (1) is in FREE position (F), the service arm can- not be operated. 2.
Page 455: Method Of Draining, Adding Lubricant And Coolant From Service Panel
ZZ9A1 Grease coupler REMARK Komatsu does not handle force-feed pumps, but if a force-feed pump coupler is needed, please consult your Komatsu distributor. NOTICE q Before connecting the service center coupler and force-feed pump coupler, wipe off all dirt, oil, or other foreign material from each coupler to prevent dirt from getting inside the piping.
Page 456 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER Method of Draining, Adding Engine Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. q Refill capacity for oil pan: 122 liter 1.
Page 457 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER 3. Set drain valve (P) of the oil pan to open position (O). 4. Remove the cap of engine oil coupler (1) and connect the force-feed pump coupler securely. 5. Start to drain and add engine oil. 6.
Page 458 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER Method of Draining, Adding Swing Machinery Case Oil (Front) WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. q Oil refill capacity: 31.2 liter 1.
Page 459 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER Method of Draining, Adding Swing Machinery Case Oil (Rear) WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. q Oil refill capacity: 31.0 liter 1.
Page 460 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER Method of Draining, Adding PTO Case Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.
Page 461 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER 3. Remove the cap of PTO oil coupler (1) and connect the force-feed pump coupler securely. 4. Start to drain and add PTO oil. 5. After completing the draining and adding of PTO oil, remove the force-feed pump coupler.
Page 462 Antifreeze is toxic, so never pour it into drainage water ditches or drain it onto the ground surface. NOTICE q Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not rec- ommend the use of any coolant other than Komatsu genuine supercoolant.
Page 463 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER Stop the machine on level ground, then stop the engine. 2. Open cover (1) at the front of the power container on the right side of the machine. 3. Check that the surface temperature of the cap of reservoir tank (2) is cool enough to be touched by hand, then raise cap lever (4) of cap (3) at the top of the reservoir tank, and release the pressure inside the reservoir tank.
Page 464 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER 11. Set drain valve (P) under the machine to shut position (S). 12. Push down cap lever (4) of cap (3) at the top of the sub tank, then install water filler cap (5). 13.
Page 465 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER Method of Adding Fuel WARNING q Fuel causes fire, so be extremely careful not to let the fuel overflow when filling with fuel. If any fuel spills, wipe it off completely. If it spills onto the ground, remove the soil that is contaminated with fuel. q Fuel is a dangerous substance that catches fire easily, so never bring it near to any flame or fire.
Page 466: Greasing Ladder Service Arm
ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER GREASING LADDER SERVICE ARM Grease the ladder once every 1000 hours. Set the service center to the lowered position as shown in the diagram on the right, then pump in grease with a grease gun through grease fittings (1) to (3).
Page 467: Replace Fuel Tank Breather Element
ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER REPLACE FUEL TANK BREATHER ELEMENT For machines equipped with the service center, the fuel tank breather is different from the breather on the machine is not equipped with the service center. Use the following procedure to replace the fuel tank breather element every 1000 hours.
Page 468: Action When Machine Does Not Move Because Of Failure In Proximity Switch
ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH If it is impossible to swing or drive the machine, or operate the work equipment even when the service center is stowed, there is probably a problem with the proximity switch. Check the proximity switch as follows. Check Proximity Switch 1.
Page 469 This change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place. After moving the machine, contact your Komatsu distributor immediately and ask for repairs to be carried out.
Page 470 ATTACHMENTS AND OPTIONS HANDLING SERVICE CENTER 2. On the right side inside the cab base room there is the con- nector for the PPC (proportional pressure control pilot) lock. 3. Remove bolts (1) and (2) of the clamp holding the connec- tor cable.
Page 471 6. Connect the negative (-) terminal of the battery, start the engine, then check that it is possible to operate the travel, swing, and work equipment. If they cannot be operated, there is probably some other cause, so ask your Komatsu distributor to carry out investigation.
Page 472: Handling Jump Start Receptacle
ATTACHMENTS AND OPTIONS HANDLING JUMP START RECEPTACLE HANDLING JUMP START RECEPTACLE GENERAL LOCATIONS Jump start receptacle External power source insertion socket CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE 1. Check that the starting switch key is at OFF position (A). 2. Set the battery isolator switch to OFF position (b). q For details of the battery isolator switch, see “Battery Isolator Switch (3-95)“.
Page 473 ATTACHMENTS AND OPTIONS HANDLING JUMP START RECEPTACLE 3. Open cover (1) of the battery box at the left side of the machine (rear of cab base). 4. Insert the external power source cable through external power source insertion port (2). 5.
Page 474: Orbcom Controller (Communications Terminal)
It is possible to send machine data without stopping the machine by using the satellite communications functions of ORBCOMM communications company. Please ask your Komatsu distributor to make the initial setting when opening the communications system. For further details, see “KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED (3-156)“...
Page 475: Loading Shovel
LOADING SHOVEL WARNING When using a loading shovel specification, the method for operation is different in some way from the standard machine. This section gives the explanation for the parts that are different.
Page 476: Machine View Illustrations
LOADING SHOVEL MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Sprocket Bottom dump cylinder Track frame Bucket cylinder Track shoe (10) Idler Arm cylinder (11) Boom cylinder Boom...
Page 477: Explanation Of Components
LOADING SHOVEL EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS SWITCHES Starting switch (11) Rotating lamp switch (if equipped) Fuel control dial (12) Greasing mode selector switch Engine emergency stop switch (13) Machine push-up switch Service center switch (if equipped) (14) Boom shock-less limit switch Room lamp switch (15) Swing lock switch Additional lamp switch...
Page 478 LOADING SHOVEL EXPLANATION OF COMPONENTS Horn Switch Press switch (17) on the right work equipment control lever to sound the horn. The same time, the flashing lights at the top front of the cab flashes for approx. 5 seconds to give a signal to the dump truck and others in the surrounding area.
Page 479: Operations
LOADING SHOVEL OPERATIONS OPERATIONS OPERATION OF WORK EQUIPMENT WARNING If the lever is operated in the deceleration range, the engine speed will suddenly rise. Operate the levers carefully. If the work equipment control levers are operated quickly, the engine speed will suddenly rise. Operate the levers carefully.
Page 480 LOADING SHOVEL OPERATIONS Boom operation (A): Boom RIASE (B): Boom LOWER Bucket operation (A): Bucket DUMP (B): Bucket CURL Bottom dump operation (A): OPEN (B): CLOSE...
Page 481: Precautions During Operation
LOADING SHOVEL OPERATIONS PRECAUTIONS DURING OPERATION WARNING q When the arm is pushed out to the front, the speed momentarily becomes slow around the vertical posi- tion of the arm. q Turning or operating the work equipment when work- ing on slopes may cause the machine to lose it bal- ance and turn over, so avoid such operations.
Page 482 LOADING SHOVEL OPERATIONS Do not Carry Out Operations with the Hydraulic Cylinder at the End of its Stroke. If the cylinder is operated to the end of its stroke during opera- tions, a large force will be brought to bear on the stopper inside the cylinder, and this will reduce the service life of the machine, so leave room (distance a) at the end of the stroke as far as possible.
Page 483 LOADING SHOVEL OPERATIONS It is Prohibited to Grip Rocks. Do not use the bottom dump bucket to grip rocks. It is Prohibited to Use the Bucket for Leaving Operations. Using the rear bucket to carry out leveling operations will bring an excessive force to bear on the work equipment, so do not use the rear bucket in this way.
Page 484 LOADING SHOVEL OPERATIONS Scraping-down Operations are Prohibited. Never use the front bucket of a bottom-dump bucket to scrap down rocks or soil. Digging Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment. It is better to excavate it after breaking up by some other means.
Page 485: Excavator Work
LOADING SHOVEL OPERATIONS EXCAVATOR WORK In addition to the following, it is possible to further increase the range of applications by using various attachments. Shovel Work This is suitable for digging a place which is higher than the machine's position. It is most efficient if the arm s digging angle is from vertical to 60i forward, and the arm cylinder is used effectively.
Page 486: Precautions When Disassembling Machine
LOADING SHOVEL PRECAUTIONS WHEN DISASSEMBLING MACHINE PRECAUTIONS WHEN DISASSEMBLING MACHINE RELEASING PRESSURE When disassembling the machine or removing the piping during inspection or maintenance, always release the pressure as follows. Releasing Pressure from Work Equipment Circuit, Swing Circuit, Travel Circuit WARNING q The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting.
Page 487: Transportation
TRANSPORTATION The machine can be divided into the following units for transportation: upper structure, operator's cab, crawler frame, center frame, work equipment, and counterweight. When transporting the machine, please consult your Komatsu distributor. MACHINE CONFIGURATION FOR TRANSPORT WARNING q Never raise the machine with any worker on it.
Page 488: Maintenance
At the same time, ask your Komatsu distributor to check the automatic greasing system. For details of the procedure for manual greasing, see “HANDLING GREASE PUMP AND GREASE GUN (3-141)“.
Page 489 LOADING SHOVEL MAINTENANCE (A): Injector installed on the bucket F&R bucket connector pin (RH) Bottom dump cylinder bottom pin (RH) F&R bucket connector pin (LH) Bottom dump cylinder bottom pin (LH) Bottom dump cylinder head pin (RH) Grease fitting Bottom dump cylinder head pin (LH) (B): Injector installed on the arm Arm top pin (RH1) (14) Bucket cylinder bottom pin (LH)
Page 490 LOADING SHOVEL MAINTENANCE (C): Injector installed on the boom (19) Boom foot pin (RH) (23) Arm cylinder head pin (RH) (20) Boom foot pin (LH) (24) Arm cylinder head pin (LH) (21) Arm cylinder bottom pin (RH) Grease fitting (22) Arm cylinder bottom pin (LH) (D): Injector installed on the chassis (25) Boom cylinder bottom pin (RH) Grease fitting...
Page 491 LOADING SHOVEL MAINTENANCE q Greasing point chart 7-17...
Page 492 LOADING SHOVEL MAINTENANCE Injector installed location Lubrication point F&R bucket connector pin (RH) F&R bucket connector pin (LH) Bottom dump cylinder head pin (RH) (A)Bucket Bottom dump cylinder head pin (LH) Bottom dump cylinder bottom pin (RH) Bottom dump cylinder bottom pin (LH) Arm top pin (RH1) Arm top pin (LH1) Arm top pin (RH2)
Page 493: Specification
LOADING SHOVEL SPECIFICATION SPECIFICATION PC2000-8 (LOADING SHOVEL) Item Unit PC2000-8 Operating weight 180,000 Bucket capacity m³ 11.0 Name of engine Komatsu SAA12V140E-3 diezel engine 713 / 1,800 (ISO 9249) Engine power kW / rpm 728 / 1,800 (ISO 14396) A Overall length...
Page 494 LOADING SHOVEL SPECIFICATION PC2000-8 (LOADING SHOVEL) Working ranges Unit PC2000-8 A Max. digging reach 13,170 B Max. reach at ground level 11,940 C Max. digging height 14,450 D Max. digging depth 3,190 E Min. reach at ground level 7,090 F Min. swing radius (work equipment)
Page 495: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 496: Combination Of Work Equipment
LOADING SHOVEL COMBINATION OF WORK EQUIPMENT COMBINATION OF WORK EQUIPMENT WARNING Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
Page 497 INDEX...
Page 498 INDEX...
Page 499 INDEX INDEX <A> PRECAUTIONS BEFORE STARTING OPERATION ............2-11 ACCUMULATOR ............3-148 PRECAUTIONS RELATED TO ATTACHMENTS AND AFTER STARTING ENGINE ........3-192 OPTIONS ..............2-17 AIR CONDITIONER CONTROLS........3-113 PRECAUTIONS RELATED TO CAB GLASS...2-18 ASHTRAY..............3-111 PRECAUTIONS RELATED PROTECTIVE ATTACHMENT GUIDE............6-4 STRUCTURES ............2-16 COMBINATIONS OF WORK EQUIPMENT ....6-4 PRECAUTIONS WHEN GETTING ON OR OFF AUXILIARY ELECTRIC POWER.........3-133 MACHINE ..............2-14...
Page 500 MACHINE VIEW ILLUSTRATIONS......3-2,7-2 LUBRICANT ............. 4-11 OVERALL MACHINE VIEW ........3-2 RECOMMENDED BRANDS, RECOMMENDED MAGAZINE BOX ............3-111 QUALITY FOR PRODUCTS OTHER THAN KOMATSU MAINTENANCE.............7-14 GENUINE OIL ............4-13 EVERY 10 HOURS MAINTENANCE .......7-14 MAINTENANCE INFORMATION ........4-2 MAINTENANCE PROCEDURE........4-19 <S> CHECK BEFORE STARTING ........4-64 SAFETY................
Page 501 INDEX <V> Vibration levels ..............1-4 VISIBILITY FROM OPERATORSSEAT'......1-7 <W> WEAR PARTS ............4-10,7-21 WEAR PARTS LIST ..........4-10,7-21 WORK EQUIPMENT CONTROLS AND OPERATIONS ............3-217 WORKING MODE ............3-219 <Y> YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ............1-11...
Page 502 INDEX...
Page 503 COLOPHON...

Komatsu PC2000-8 Operation & Maintenance Manual

Foreword

Before Reading this Manual

Safety Information

Introduction

Product Information

Safety Labels

General Precautions Common to Operation and Maintenance

Precautions for Operation

Precautions for Maintenance

Operation

Machine View Illustrations

Detailed Controls and Gauges

Contents

Machine Operations and Controls

Transportation

Cold Weather Operation

Long Term Storage

Troubles and Actions

Maintenance

Maintenance Information

Outline of Service

Wear Parts

Recommended Fuel, Coolant, and Lubricant

Tightening Torque Specifications

Safety Critical Parts

Maintenance Schedule

Maintenance Procedure

Quick Links

Related Manuals for Komatsu PC2000-8

Summary of Contents for Komatsu PC2000-8