Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
Page 2 FOREWORD CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts, terminals and related accessories contain lead constituents are known to the State and lead compounds, chemicals of California to cause cancer, birth known to the State of California de fe c ts , a nd o th e r re p ro d u cti v e to cause cancer, birth defects and reproductive harm.
Page 3 Keep it in the pocket inside the cover of toolbox under the oper- ator's seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 4: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 5: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Ditching work • Loading work • Leveling work • Demolition work For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 6: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is located on the front left of revolving frame.
Page 7: Service Meter Location
PRODUCT INFORMATION FOREWORD SERVICE METER LOCATION This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Phone/Fax Service personnel...
Page 8: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-3 INTRODUCTION ............................1-4 MAIN USE OF MACHINE ........................1-4 DIRECTIONS OF MACHINE......................1-4 PROTECTIVE STRUCTURES ......................1-4 PRODUCT INFORMATION........................1-5 LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ..1-5 LOCATION OF ENGINE NUMBER PLATE ..................
Page 9 OTHER TROUBLE......................... 3-244 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 10 EVERY 4000 HOURS MAINTENANCE ................... 4-99 EVERY 6000 HOURS MAINTENANCE ..................4-101 SPECIFICATIONS ............................5-1 SPECIFICATIONS ............................ 5-2 SPECIFICATIONS: PC45MR-5 ......................5-2 SPECIFICATIONS: PC55MR-5 ......................5-4 ATTACHMENTS AND OPTIONS ........................6-1 PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS..............6-2 PRECAUTIONS WHEN SELECTING ....................6-2 READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY........
Page 11 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-5 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-7 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-10...
Page 12: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 13: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 14: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS LOCATION OF SAFETY LABELS: CANOPY SPEC (1) Caution for work equipment (13) Caution when changing control pattern (2) Caution for operation, inspection and maintenance (14) Prohibition of entering into swing range (3) Caution when leaving operator's seat (15) Stop rotation during inspection and maintenance (4) Caution for electric cables (16) Caution for high-temperature coolant...
Page 15 SAFETY LABELS SAFETY LOCATION OF SAFETY LABELS: CAB SPEC (1) Caution for work equipment (10) Caution for high-pressure fuel (2) Caution when changing control pattern (11) Caution for handling cable (3) Caution for adjusting track tension (12) Caution for handling battery (4) Caution when opening floor (13) Caution for high-temperature hydraulic oil (5) Caution for handling accumulator...
Page 16 SAFETY SAFETY LABELS (9) Caution for operation, inspection and maintenance (23) Caution before operating (16) Caution for handling gas spring (24) Caution for control pattern (19) Emergency escape (25) Caution for electric cables (20) Caution for blast site (machine with KOMTRAX) (26) Caution when opening or closing front window (21) Caution for using seat belt (27) Caution when stowing front window...
Page 17: Contents Of Safety Labels
SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS Caution for operation, inspection and mainte- nance “09651-03001” Caution before operating “22L-98-22160” Caution for using seat belt “09848-03000”...
Page 18 SAFETY SAFETY LABELS Caution when leaving operator's seat “09654-03001” Caution for electric cables “09801-03002”...
Page 19 SAFETY LABELS SAFETY Caution for control pattern “22N-98-51251” Caution for high-temperature coolant “20M-98-83250” Caution for high-temperature hydraulic oil “22L-98-22240”...
Page 20 SAFETY SAFETY LABELS Caution against high temperature “09817-A0753” • Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation. • Never touch when hot. Caution for handling cable “09808-03001” Caution for adjusting track tension “09657-03003”...
Page 21 SAFETY LABELS SAFETY Caution for work equipment “09134-A0881” • Sign indicates a hazard of being hit by the work equipment of the machine. • Keep away from machine during operation. Caution when opening or closing front win- (Machine with cab specification) “09839-03001”...
Page 22 SWALLOWED,INHALED, or IN EYE: immediately call a POISON CENTER or consult doctor/physician. if on CLOTHES or SKIN: wash immediately with water. Komatsu America Corp.1701 Golf Rd. Rolling Meadows,IL 60008.(731)635 6321 09664-30014 Caution for handling ROPS “22N-98-51750”...
Page 23 SAFETY LABELS SAFETY Emergency escape (Machine with cab specification) “09844-00050” Caution for blast site (Machine with KOMTRAX) “09845-13000” EXPLOSION HAZARD Unintentional detonation may be caused by an active radio transmitter in blast zone. To prevent SEVERE INJURY or DEATH, keep machine a safe distance away from a blast zone and a detonator or disconnect the wireless monitoring system in accordance with instructions...
Page 24: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 25: Preparations For Safe Operation
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PREPARATIONS FOR SAFE OPERATION PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT • Be sure that all the protective guards, covers, and mirrors are installed properly. If any of them are broken, replace it immediately. •...
Page 26 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Observe the following precautions to prepare for action if any serious personal injury or death or fire should occur. • Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them for the possibility of fires.
Page 27: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Escape from the cab by using handrail and track. • Do not jump off the machine.
Page 28 Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi- cation process (regeneration).
Page 29: Precautions When Getting On Or Off Machine
Wipe it off immediately not to slip if any. If there is any loose bolt on the handrails, tighten it securely. If the handrails are damaged or deformed, they need to be repaired immediately. Ask your Komatsu distributor for that work. •...
Page 30: Do Not Get Caught In Work Equipment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT Before standing up from the operator's seat in order to open or close the front window or to adjust the operator's seat, be sure to lower the work equipment and blade to the ground, grip the operating portion on top of the lock lever (1) to set the lock lev- er (1) to LOCK position (L), and stop the engine.
Page 31: Precautions Related To Protective Structures
• 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 consult your Komatsu distributor •...
Page 32: Protection Against Falling, Flying Or Intruding Objects
UNAUTHORIZED MODIFICATION • Komatsu will not be responsible for any personal injuries, product failures, physical loss or damage, or influ- ence on the environment resulting from modifications made without authorization from Komatsu. • Any modification made without authorization from Komatsu can create hazards. Before making a modifica- tion, consult your Komatsu distributor.
Page 33: Precautions When Running Engine Inside Building
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or ma- chine must be operated inside a building or underground, where the ventilation is poor, take steps to ensure that the en- gine exhaust gas is removed and that ample fresh air is...
Page 34: 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 serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 35 PRECAUTIONS FOR OPERATION SAFETY DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe the following.
Page 36 Prohibit other personnel from coming close to the machine during operation. • Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. 2-25...
Page 37: Start Engine
PRECAUTIONS FOR OPERATION SAFETY START ENGINE USE WARNING TAGS If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine. If the warning tag is ignored and the machine is operated, the person performing inspection or maintenance may be caught in the rotating parts or moving parts.
Page 38 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the following. • Start the engine only while sitting down in the operator's seat. •...
Page 39: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance. It is dangerous and may cause serious personal injury or death. When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention to the surroundings.
Page 40 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING • When driving the machine, drive with sprocket (1) at the rear of the machine. If sprocket (1) is at the front, the oper- ation of the travel levers will be the opposite of the actual direction of travel, so there is a hazard that the machine may travel in an unexpected direction, leading to serious injury or death.
Page 41 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN TRAVELING Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact. Always observe the following. • Do not drive the machine with excess speed, stop suddenly, and starts suddenly. It is quite dangerous. •...
Page 42 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always observe the following. • Keep the work equipment at height (a) 20 to 30 cm {7.9 to 11.8 in} above the ground. In case of emergency, lower the work equipment to the ground immediately to help stopping the machine.
Page 43 PRECAUTIONS FOR OPERATION SAFETY • Always drive the machine straight up or down a slope. Driving the machine at an angle or across the slope is ex- tremely dangerous. • Do not turn on slopes or drive across slopes. Always go down to a flat place to change the position of the machine, then drive it on to the slope again.
Page 44 SAFETY PRECAUTIONS FOR OPERATION PROHIBITED OPERATIONS If the machine turns over or falls, or the ground at the working point collapses, or a structure being demolished collapses, it may lead to serious personal injury or death. Always observe the following. •...
Page 45 PRECAUTIONS FOR OPERATION SAFETY • Do not demolish the structure above the machine. It is dangerous that broken parts may fall or the structure may collapse, and it may cause serious injury or death. • Do not perform demolition work by using the impact force of the work equipment.
Page 46 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES • Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma- chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly careful when working on slopes.
Page 47: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 48: Towing And Being Towed
SAFETY PRECAUTIONS FOR OPERATION TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a failed machine and being towed may lead to serious personal injury or death. •...
Page 49: Lifting Operation By Using Bucket With Hook
PRECAUTIONS FOR OPERATION SAFETY LIFTING OPERATION BY USING BUCKET WITH HOOK PRECAUTIONS FOR LIFTING OPERATIONS Falling of a lifted load or tipping over of the machine can cause serious personal injury or death. Always observe the following. • Do not perform lifting work on slopes, soft ground, or other places where the machine is not stable. •...
Page 50: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the "DAN- GER! Do NOT operate!" warning tag. If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 51 PRECAUTIONS FOR MAINTENANCE SAFETY STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol- lowing.
Page 52 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR OPENING AND CLOSING FLOOR • Do not open the floor on the slope ground or in windy weather, otherwise it may lead to serious personal injury or death. • Do not open the floor when the engine is running, the door (if the machine is equipped with the cab) is open, or the lock lever is in Free position, otherwise it may lead to seri- ous personal injury or death.
Page 53 PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS • Appoint a leader before starting removal or installation operations for attachments. • Place attachments that have been removed from the ma- chine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.
Page 54: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR CHECK AND MAINTENANCE PRECAUTIONS FOR WELDING Welding operations must always be performed by a qualified welder and in a place equipped with proper equip- ment. There is a hazard of gas, fire, or electric shock when performing welding, so never allow any unqualified person to perform welding.
Page 55 PRECAUTIONS FOR MAINTENANCE SAFETY When the machine is equipped with the battery disconnect switch, turn the starting switch to OFF position and, after checking that the system operating lamp is not lit, set the battery disconnect switch key to OFF position, and pull it out.
Page 56 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause serious personal injury or death. Always observe the following. • When hitting pins or bucket teeth, broken pieces may be scattered, and it may cause personal injury to the people in the surrounding area.
Page 57 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 58 If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. 2-47...
Page 59 • When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 60 SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF DEFINED LIFE PARTS • For using the machine safely for a long period, always perform periodic replacement of the defined life parts that have a particularly close relation to safety, such as hoses and the seat belt. Replacement of the defined life parts: See “PERIODIC REPLACEMENT OF DEFINED LIFE PARTS”.
Page 62: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 63: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Arm cylinder (8) Idler (2) Boom (9) Blade cylinder (3) Boom cylinder (10) Blade (4) Dirt cover (11) Bucket (5) Track (12) Bucket cylinder (6) Sprocket (13) Arm (7) Track frame...
Page 64 OPERATION GENERAL VIEW (14) Engine rear cover (16) Battery (15) Cooling cover (17) KDPF...
Page 65: Controls And Gauges Names
GENERAL VIEW OPERATION CONTROLS AND GAUGES NAMES CONTROLS AND GAUGES NAMES: CANOPY SPEC (1) Lock lever (10) Travel speed selector switch (2) L.H. work equipment control lever (11) Blade control lever (3) Travel pedal (12) Fuel control dial (4) Travel lever (13) Lamp switch (5) Swing lock cover (14) Starting switch...
Page 66 OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES: CAB SPEC (1) Lock lever (13) Temperature control switch (2) L.H. work equipment control lever (14) Air flow selector switch (3) Wiper switch (15) Air conditioner switch (4) Travel pedal (16) Fuel control dial (5) Travel lever (17) Lamp switch (6) Swing lock cover...
Page 67 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME (1) Message display (11) Auto-deceleration pilot lamp (2) Engine coolant temperature gauge (12) Guidance icon (3) Working mode display (13) Engine coolant temperature caution lamp (4) Service meter/clock (14) Aftertreatment devices regeneration pilot lamp (5) Fuel gauge (15) Aftertreatment devices regeneration disable pilot lamp...
Page 68: Other Equipment Name
OPERATION GENERAL VIEW OTHER EQUIPMENT NAME OTHER EQUIPMENT NAME: CANOPY SPEC (1) Auxiliary electric power (5) Operation and Maintenance Manual pocket (2) Cup holder (6) Grease pump holder (3) Toolbox (7) Fusible link (4) Fuse...
Page 69 GENERAL VIEW OPERATION OTHER EQUIPMENT NAME: CAB SPEC (1) Front window (9) Emergency escape hammer (2) Ceiling window (10) Small slide window (3) Door (11) AUX (if equipped) (4) Door lock release lever (12) Cup holder (5) Toolbox (13) Ashtray (if equipped) (6) Fuse (14) Grease pump holder (7) Operation and Maintenance Manual pocket...
Page 70: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, BB: Warning or Error screen (1) Gauge display...
Page 71 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, opening screen CC is displayed. • After opening screen CC is displayed for 2 seconds, the screen changes to standard screen AA. REMARK At starting of the engine, battery voltage may drop abruptly depending on the ambient temperature or battery condition, and the machine monitor may restart, but it is not a trouble.
Page 72 End screen when any message has been received If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if the message is requesting a response, make a reply to it.
Page 73 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION If there is maintenance time warning when starting the engine • If there is any maintenance time warning when starting the engine, opening screen CC changes to mainte- nance time warning screen EE.
Page 74 OPERATION EXPLANATION OF COMPONENTS If there is an abnormality when starting the engine • If there is any abnormality when starting the engine, opening screen CC changes to warning screen BB. • After opening screen CC is displayed for 2 seconds, the screen changes to warning screen BB. •...
Page 75 EXPLANATION OF COMPONENTS OPERATION For checking the details of error, press function switch “F3”, and then existing error list screen is displayed. 3-14...
Page 76 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE • If any abnormality occurs during operation, standard screen AA changes to warning screen BB. • After warning screen BB-(1) and (3) are displayed for 2 seconds, the screen automatically changes to warn- ing screen BB-(2) and (4).
Page 77 EXPLANATION OF COMPONENTS OPERATION For checking the details of error, press function switch “F3”, and then existing error list screen is displayed. 3-16...
Page 78 OPERATION EXPLANATION OF COMPONENTS WARNING DISPLAY NOTICE Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab- normality of the machine. Take appropriate actions following the list of action level displays and required actions. The caution lamp that lights up in red when an action level is displayed warns operator to stop the ma- chine urgently, stop or pause the current operation.
Page 79 Stop the operation, and run the engine at medium speed with │ mittently no load or stop it. │ If the condition is not improved, ask your Komatsu distributor ↓ for the inspection and maintenance. Does not Lights up in...
Page 80 OPERATION EXPLANATION OF COMPONENTS Caution lamps and display colors Display color/Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue High temperature Engine coolant temperature Low temper- Normal caution lamp ature (L02) Fuel level caution lamp Low level Normal Abnormal Abnormal...
Page 81 EXPLANATION OF COMPONENTS OPERATION CURRENT ABNORMALITY LIST DISPLAY If there is any abnormality currently generated, “!” is displayed on top of function switch “F3”. While “!” is displayed, if you press function switch “F3”, monitor display screen is shifted to “Current Abnormality” screen. Take appropriate remedies according to the message displayed on the monitor.
Page 82 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 83 The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 84 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 85 • The lighting time of maintenance time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on “Maintenance” menu screen, see “MAINTENANCE SCREEN SETTING”.
Page 86 OPERATION EXPLANATION OF COMPONENTS PILOT DISPLAY AND GAUGE DISPLAY Pilot display (1) Aftertreatment devices regeneration pilot lamp (6) Message display (2) Aftertreatment devices regeneration disable pilot (7) Working mode display lamp (8) Travel speed display (3) Preheating pilot lamp (9) Auto-deceleration pilot lamp (4) Lock lever pilot lamp (5) Lock lever automatic lock cancel pilot lamp Gauge display...
Page 87 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY The pilot display consists of the pilot lamps to check the actuation of each function. When the starting switch is in ON position, the pilot lamps light up when the display items are functioning. PREHEATING PILOT LAMP The preheating pilot lamp is displayed while the engine is pre- heated before started.
Page 88 OPERATION EXPLANATION OF COMPONENTS “E” E mode (For operations with emphasis on fuel consumption) “B” B mode (For breaker operations) (For machines ready for in- stallation of attachments) “ATT/P” ATT/P mode (For operations of 2-way attachments like crusher) (For machines ready for installation of attachment) “ATT/E”...
Page 89 EXPLANATION OF COMPONENTS OPERATION TRAVEL SPEED DISPLAY On the travel speed display, the selected travel mode is displayed. “Lo” Low-speed travel “Hi” High-speed travel REMARK Each time the travel mode is switched by the travel speed selector switch, it lights up in yellow at the center of the monitor display, and 2 seconds later, it lights up in blue again.
Page 90 OPERATION EXPLANATION OF COMPONENTS MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “CHECK MESSAGE”. Lights up in green There is an unread message. Lights up in blue There is any read message to which no reply is made.
Page 91 EXPLANATION OF COMPONENTS OPERATION AFTERTREATMENT DEVICES REGENERATION PILOT LAMP CAUTION • Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regeneration. Stay away from the exhaust pipe outlet to prevent yourself from getting burnt. Keep combustible materials away from the exhaust pipe outlet to prevent a fire. •...
Page 92 OPERATION EXPLANATION OF COMPONENTS LOCK LEVER PILOT LAMP The lock lever pilot lamp lights up when the lock lever is in LOCK position. It goes out when the lock lever is set in FREE position. LOCK LEVER AUTOMATIC LOCK CANCEL PILOT LAMP The lock lever automatic lock cancel pilot lamp lights up when the lock lever automatic lock cancel switch is set to CANCEL position.
Page 93 EXPLANATION OF COMPONENTS OPERATION GAUGE DISPLAY ENGINE COOLANT TEMPERATURE GAUGE Engine coolant temperature gauge displays the engine coolant temperature in 19 graduations. When the graduation of gauge is in green range (B) during op- erations, it is normal. When the graduation of gauge is in red range (A) during opera- tions, the overheat prevention system is actuated, and engine coolant temperature caution lamp (D) lights up in red.
Page 94 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE Fuel gauge displays the fuel level in 19 graduations. When the graduation of gauge is in green range (A) during op- erations, it is normal. When the graduation of gauge goes in red range (B) during op- erations, the remaining fuel level is 14 ℓ...
Page 95 EXPLANATION OF COMPONENTS OPERATION SERVICE METER / CLOCK The service meter/clock shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even if the machine is not moving. The service meter advances 0.1 every 6 operation minutes, regardless of the engine speed.
Page 96 OPERATION EXPLANATION OF COMPONENTS FUEL CONSUMPTION GAUGE Fuel consumption gauge shows the average fuel consumption of the machine. One day display Displays the average fuel consumption of a day (from 0:00 a.m. of the day to 0:00 a.m. of the next day). Split (under measurement) display Displays the split fuel consumption under measurement.
Page 97 EXPLANATION OF COMPONENTS OPERATION ECO GAUGE ECO gauge shows the instantaneous fuel consumption. The instantaneous fuel consumption means the fuel consump- tion rate at each moment, which varies with the work load and engine speed. (A) Green range The instantaneous fuel consumption is at good to medium lev- (B) Yellow range The instantaneous fuel consumption is at a bad level.
Page 98 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCHES (1) Function switch FUNCTION SWITCHES AND GUIDANCE ICONS • There are 8 function switches (1) (“F1” to “F8”) at the bot- tom and right side of the monitor display. The function of each switch differs in accordance with the content of each screen.
Page 99 EXPLANATION OF COMPONENTS OPERATION Function switch “F8” Alarm buzzer stops sounding. (Only when the alarm buzzer is actuated.) When monitor display is user menu screen The types of guidance icons and functions of function switches differ with the contents of the displayed screen, but representa- tive guidance icons frequently used and their functions are as follows: Function switch “F1”...
Page 100 OPERATION EXPLANATION OF COMPONENTS FUNCTION SWITCHES The operation of the function switches in the standard screen AUTO-DECELERATION FUNCTION Perform the setting of auto-deceleration function after starting the engine. When the auto-deceleration function is ON, if the work equipment control lever and travel lever are returned to NEUTRAL position, the engine speed will drop from the operating speed to idle speed approximately 4 seconds later, and fuel consumption is reduced.
Page 101 If you want to have automatic setting of P, E, B, ATT/P or ATT/E mode (optional default setting) when starting engine, ask your Komatsu distributor to change the setting. How to use working mode selecting function Change the setting of auto idle stop function after starting the engine.
Page 102 OPERATION EXPLANATION OF COMPONENTS After the working mode is set, the working mode is dis- played in yellow in the center of the monitor display. 2 seconds later, yellow returns to blue. BUZZER CANCEL FUNCTION Perform the setting of working mode selection after starting the engine. When buzzer cancel icon is displayed, if you press function switch “F8”, alarm buzzer for abnormality of warning items stops sounding.
Page 103 EXPLANATION OF COMPONENTS OPERATION USER MENU On the standard screen, press switch “F4” to display the user menu screen on the monitor display on which you can make various settings for the machine. The user menu consists of the following kinds. The right and left menu screens can be changed by pressing the function switches “F6”...
Page 104 OPERATION EXPLANATION OF COMPONENTS (c) “Aftertreatment Devices Regeneration” • Setting for“Regeneration Disable” • Operation of “Manual Stationary Regeneration” (d) “Maintenance” • Check and reset of various maintenance times (e) “Monitor Setting” • “Screen Adjustment” • “Clock Adjustment” • “Language” (f) Mail check •...
Page 105 EXPLANATION OF COMPONENTS OPERATION Function switch “F4” Displays the setting screen for the selected item. Function switch “F6” Moves to the left menu. When on the left end menu, it moves to the right end menu. Function switch “F7” Moves to the right menu. When on the right end menu, it moves to the left end menu.
Page 106 OPERATION EXPLANATION OF COMPONENTS WORKING RECORD On each item of “Working Record” menu screen, you can dis- play and set the notification relevant to operation state of the machine. • “Operation Records” • “Ave Fuel Consumpn Record” • “Configurations” CHECK OPERATING RECORD Select “Operation Records”...
Page 107 EXPLANATION OF COMPONENTS OPERATION CHECK FUEL CONSUMPTION RECORD Select “Ave Fuel Consumpn Record” on “Working Record” menu screen, and then press function switch “F4”. On “Ave Fuel Consumpn Record” screen, display the graph of hourly average fuel consumption during the last 12 hours or the graph of daily fuel consumption during the last 1 week.
Page 108 OPERATION EXPLANATION OF COMPONENTS • Last 1 week display Deleting of record Perform the resetting of fuel consumption record after starting the engine. When you press switch “F8”, the reconfirmation screen is displayed. If you press function switch “F4”, graphs data of the last 12 hours and the last 1 week are both deleted, and the screen returns to “Ave Fuel Consumpn Record”...
Page 109 EXPLANATION OF COMPONENTS OPERATION CHANGE DISPLAY SETTING Select “Configurations” on “Working Record” menu screen, and then press function switch “F4”. On “Configurations” menu, you can change the following set- tings. • Setting of “Ave Fuel Consumption Display” • Switching Display/Non-display of “ECO Gauge Display” •...
Page 110 OPERATION EXPLANATION OF COMPONENTS SET DISPLAY OF FUEL CONSUMPTION GAUGE Perform the setting of fuel consumption display after starting the engine. On “Ave Fuel Consumption Display” screen, the display of fuel consumption gauge can be set 1 Day display or Split Time dis- play or Non-display.
Page 111 EXPLANATION OF COMPONENTS OPERATION REMARK If you select Split Time measurement, “SPLIT” is displayed at the top right of “Operation Records” screen. If you want to stop the measurement, press function switch “F8” on “Operation Records” screen, and move to “Split Time Information”...
Page 112 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE Set the ECO gauge to be displayed or not to be displayed after starting the engine. It is possible to change the setting of Display/Non-display of the ECO gauge. Select “ECO Gauge Display” on “Configurations” menu screen, and then press function switch “F4”.
Page 113 EXPLANATION OF COMPONENTS OPERATION SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE Perform the setting of fuel target value of ECO gauge display after starting the engine. It is possible to change the target fuel consumption value (the upper limit value of the green range) of the ECO gauge.
Page 114 OPERATION EXPLANATION OF COMPONENTS MACHINE SETTINGS On each item of “Machine Setting” menu screen, setting related to the machine can be performed. • “Breaker Setting” (if equipped) • “Attachment Setting” (if equipped) • “Auto Idle Stop Timer Set” BREAKER SETTING For the machine(s) ready for installation of breaker, you can select the setting of B mode from 5 patterns on “Breaker Setting”...
Page 115 EXPLANATION OF COMPONENTS OPERATION Function switch “F6” Changes the flow rate of the selected breaker setting. Function switch “F7” Changes the name of the selected breaker setting. Changing the Breaker Setting name Change the name of breaker setting after starting the engine. You can change the name of each pattern for the breaker setting as you like.
Page 116 OPERATION EXPLANATION OF COMPONENTS Select the breaker setting to change its flow rate on “Breaker Setting” screen, and then press function switch “F6”. The “Breaker Oil Flow Rate Setting” screen is displayed. On “Breaker Oil Flow Rate Setting” screen, you can per- form the following operations with function switches “F3”, “F4”, “F6”, and “F7”.
Page 117 EXPLANATION OF COMPONENTS OPERATION ATTACHMENT SETTING For the machine(s) ready for installation of attachment, you can select the setting of ATT/P and ATT/E modes from 5 patterns on “Attachment Setting” screen, or you can set it to “No Attachment”. For each pattern on “Attachment Setting” screen, you can change its name displayed on the machine monitor. For each pattern on “Attachment Setting”...
Page 118 OPERATION EXPLANATION OF COMPONENTS Select an attachment setting to change its name on “At- tachment Setting” screen, and then press function switch “F7”. “Attachment Name Setting” screen is displayed. On “Attachment Name Setting” screen, you can perform the following operations with function switches “F1” to “F4”, “F6”, “F7”, and “F8”.
Page 119 EXPLANATION OF COMPONENTS OPERATION The “2-Way Attachment Oil Flow Rate Setting” screen is displayed. On “2-Way Attachment Oil Flow Rate Setting” screen, you can perform the following operations with function switches “F3”, “F4”, “F6”, and “F7”. Function switch “F3” Returns to “Attachment Setting” screen without changing the flow rate.
Page 120 OPERATION EXPLANATION OF COMPONENTS AUTO IDLE STOP TIMER SETTING NOTICE Battery runs out faster because the only engine stops when auto idle stop function is actuated. Actuate the auto idle stop function after a lapse of 15 minutes of running the engine at high idle and in P mode.
Page 121 EXPLANATION OF COMPONENTS OPERATION “Auto Idle Stop Timer Set” confirmation screen is dis- played. Press function switch “F4” on “Auto Idle Stop Timer Set” confirmation screen. If you press function switch “F3”, the screen returns to “Au- to Idle Stop Timer Set” selection screen. “Auto Idle Stop Timer Set”...
Page 122 OPERATION EXPLANATION OF COMPONENTS If you press function switch “F4”, the screen changes to “Auto Idle Stop in Operation” screen. Turn off unnecessary switches according to the screen in- structions. REMARK With the auto idle stop function, only the engine is stop- ped.
Page 123 EXPLANATION OF COMPONENTS OPERATION AFTERTREATMENT DEVICES REGENERATION Each item of “Aftertreatment Devices Regeneration” menu screen is for settings and operations of the aftertreatment devi- ces regeneration. 3-62...
Page 124 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on Maintenance Due Time Reset screen Perform the resetting of maintenance due time after starting the engine.
Page 125 EXPLANATION OF COMPONENTS OPERATION “Maintenance Due Time Reset” screen is displayed. Press function switch “F4” on “Maintenance Due Time Re- set” screen. The screen switches to the reconfirmation screen. REMARK • When canceling the reset, press function switch “F3”. The screen returns to “Maintenance” screen. •...
Page 126 OPERATION EXPLANATION OF COMPONENTS MONITOR SETTINGS On each item of “Monitor Setting” menu screen, you can per- form the setting related to the monitor. • “Screen Adjustment” • “Clock Adjustment” • “Language” SCREEN ADJUSTMENT Adjust the screen after starting the engine. Use “Screen Adjustment”...
Page 127 EXPLANATION OF COMPONENTS OPERATION CLOCK ADJUSTMENT “Clock Adjustment” menu screen is used to change the setting of the clock displayed on the standard screen. Select “Clock Adjustment” on “Monitor Setting” menu screen, and then press function switch “F4”. “Clock Adjustment” screen is displayed. The items related to “Clock Adjustment”...
Page 128 OPERATION EXPLANATION OF COMPONENTS GPS SYNCHRONIZATION SETTING Perform the setting of GPS synchronization after starting the engine. For the machines equipped with KOMTRAX, you can configure automatic adjustment of the date and time of machine monitor in accordance with the clock of GPS on “GPS Synchronization” screen. Select “GPS Synchronization”...
Page 129 EXPLANATION OF COMPONENTS OPERATION CALENDAR SETTING Perform the setting of calendar after starting the engine. The date of the machine monitor can be adjusted on “Calendar” screen. REMARK As long as “GPS Synchronization” is turned “ON”, item in “Calendar” is not selectable. Select “Calendar”...
Page 130 OPERATION EXPLANATION OF COMPONENTS TIME SETTING Perform the setting of the time after starting the engine. The time of the machine monitor can be adjusted on “Time” screen. REMARK As long as “GPS Synchronization” is turned “ON”, you cannot select the item of “Time”. Select “Time”...
Page 131 EXPLANATION OF COMPONENTS OPERATION SWITCH 12H/24H DISPLAY MODE Perform the setting of 12h/24h mode after starting the engine. On “12h/24h Mode” screen, you can set the display mode of clock. Select “12h/24h Mode” on “Clock Adjustment” menu screen, and then press function switch “F4”. “12h/24h Mode”...
Page 132 OPERATION EXPLANATION OF COMPONENTS DAYLIGHT SAVING TIME (SUMMER TIME) SETTING Perform the setting of daylight saving time after starting the engine. On “Daylight Saving Time” screen, you can set the clock display forward 1 hour. Select “Daylight Saving Time” on “Clock Adjustment” menu screen, and then press function switch “F4”.
Page 133 EXPLANATION OF COMPONENTS OPERATION LANGUAGE SETTINGS Perform the setting of language after starting the engine. On “Language” screen, you can select the language displayed on the machine monitor. The languages that can be selected are as follows. Japanese, English, German, French, Spanish, Portuguese, Italian, Swedish, Dutch, Danish, Norwegian, Fin- nish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Estonian, Latvian, Lithuanian, Bulgarian, Greek, Ro- manian, Croatian and Serbian Select “Language”...
Page 134 On machines equipped with KOMTRAX, when message pilot lamp is lit on the standard screen, you can see the messages from your Komatsu distributor on the mail check menu screen by pressing function switch “F4”. Message is distinguished as follows according to the lighting states of the message display.
Page 135 • When the message display lights up in blue, it means that no reply has been made yet to any read message to your Komatsu distributor. Reply to the message according to the replying method mentioned as follows: • If the starting switch is turned to OFF position when there...
Page 136 OPERATION EXPLANATION OF COMPONENTS CHECK MESSAGE When the message pilot lamp lights up on the standard screen, press function switch “F4”. The screen changes to the mail confirmation menu screen. On the mail confirmation screen, you can read the arrived message.
Page 137 EXPLANATION OF COMPONENTS OPERATION REPLY TO MESSAGE If a message requests reply, press the function switch “F4”, and the screen moves to the message reply screen. On the message reply screen, input the number of select- ed item as an input value. The number of selected item is written in the place (1) of the message text on mail confirmation menu screen.
Page 138: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES SWITCHES: CANOPY SPEC (1) Horn switch (5) Starting switch (2) Travel speed selector switch (6) Pump secondary drive switch (3) Fuel control dial (7) Lock lever automatic lock cancel switch (4) Lamp switch (8) Engine shutdown secondary switch 3-77...
Page 139 EXPLANATION OF COMPONENTS OPERATION SWITCHES: CAB SPEC (1) Wiper switch (8) Lamp switch (2) Horn switch (9) Starting switch (3) Travel speed selector switch (10) Pump secondary drive switch (4) Temperature control switch (11) Lock lever automatic lock cancel switch (5) Air flow selector switch (12) Engine shutdown secondary switch (6) Air conditioner switch...
Page 140 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting switch is used to start or stop the engine. (A) OFF position The electrical current to the electrical system is cut, and the en- gine stops. The key can be inserted into or removed from the starting switch.
Page 141 EXPLANATION OF COMPONENTS OPERATION LAMP SWITCH Lamp switch is used to light up the working lamp and monitor illumination. (a) Night position Lamps light up and monitor illumination is set to night mode. (b) Day position Lamps light up and monitor illumination is set to day mode. (c) OFF position Lamps go out.
Page 142 OPERATION EXPLANATION OF COMPONENTS TRAVEL SPEED SELECTOR SWITCH WARNING • When loading to or unloading onto/from a trailer, always drive the machine at low speed (set it to Lo), and never operate the travel speed selector switch during travel. • If the travel speed is switched between high-speed and low-speed while the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 143 EXPLANATION OF COMPONENTS OPERATION WIPER SWITCH (Machine with cab specification) CAUTION • Do not keep pressing it for 10 seconds or more at the position of injecting washer fluid. • Do not press it at the position of injecting washer fluid when the washer tank is empty. Wiper switch actuates the wiper at the front window glass.
Page 144 OPERATION EXPLANATION OF COMPONENTS PUMP SECONDARY DRIVE SWITCH NOTICE • Use the pump secondary drive switch only in an emergency. Repair the problem as soon as possi- ble. • If the pump secondary drive switch is moved to “Emergency” position by mistake while the machine is operating normally, “L03”...
Page 145 CANCEL position (a), the lock lever automatic lock cancel pilot lamp lights up. After moving the machine or work equipment temporarily by operating this switch, stop the engine, return the switch to NORMAL position (b), and then ask your Komatsu distributor for repair. 3-84...
Page 146 OPERATION EXPLANATION OF COMPONENTS ENGINE SHUTDOWN SECONDARY SWITCH NOTICE The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Ask for repair of the problem part as soon as possible.
Page 147: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS (1) Lock lever (5) Boom swing control pedal (2) L.H. work equipment control lever (6) R.H. work equipment control lever (3) Travel lever (with pedal) (7) Blade control lever (4) Swing lock cover (8) Floor lock release lever 3-86...
Page 148 • When the hydraulic oil temperature is low • When the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends • When the system has a problem • Before setting the lock lever to FREE position, make sure that all control levers and control pedals are set to NEUTRAL position.
Page 149 EXPLANATION OF COMPONENTS OPERATION While the lock lever automatic lock function is being actuated, the display pops up, and the guidance icon on the right bottom lights up in red. If you press the function switch “F4”, the screen changes to “Lock Lever Auto Locked”...
Page 150 OPERATION EXPLANATION OF COMPONENTS TRAVEL LEVER WARNING • If you perform operations with your foot on the pedal, the machine may suddenly start if you depress the pedal by mistake, and this may lead to serious person- al injury or death. Be extremely careful when using the pedal for travel and steering operations, and do not put your foot on the pedal when it is not necessary.
Page 151 EXPLANATION OF COMPONENTS OPERATION BLADE CONTROL LEVER NOTICE If you continue the digging operation with blade for 1 hour or more, be careful about increase of the en- gine coolant temperature. The blade control lever is used to operate the blade. (a) Blade LOWER The blade control lever is pushed forward.
Page 152 OPERATION EXPLANATION OF COMPONENTS FLOOR LOCK RELEASE LEVER WARNING • When opening and closing cab or floor, observe the warning and precautions for the work. Wrong operation may cause serious personal injury or death. • Do not open and close the cab or floor when the machine is on a slope. •...
Page 153 The control pattern is set to the standard control meth- od (ISO pattern). • If it is necessary to change the control pattern, ask your Komatsu distributor. • The operations in the control patterns other than the ISO pattern are explained in "Attachments and op- tions".
Page 154 OPERATION EXPLANATION OF COMPONENTS The R.H. work equipment control lever is used to operate the boom and bucket. Boom operation (e): Boom RAISE (f): Boom LOWER Bucket operation (g): Bucket DUMP (h): Bucket CURL (N) NEUTRAL The boom and bucket are held in position and do not move. 3-93...
Page 155: Other Equipment
EXPLANATION OF COMPONENTS OPERATION OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING CAB FRONT WINDOW (Machine with cab specification) WARNING • When opening or closing the front window and door, etc., always set the lock lever to LOCK posi- tion. If the lock lever is at FREE position and the control lever, control pedal, or control switch is touched by mistake, it may cause serious personal injury or death.
Page 156 OPERATION EXPLANATION OF COMPONENTS While pushing down the handle locks (2) with your thumb, pull the right and left handles (1) backward to open the front window. Hold the right and left handles (1), and pull up the front window backward slantwise. When it does not move any more to the rear side of cab, push the right and left handles (1) upward and fix the front window securely.
Page 157 EXPLANATION OF COMPONENTS OPERATION PROCEDURES FOR CLOSING UPPER CAB FRONT WINDOW CAUTION When closing the front window (upper side), lower it slowly and be careful not to get your hand caught. Stop the machine on a level ground, lower the work equipment to the ground, then stop the engine. Set the lock lever securely to LOCK position (L).
Page 158 OPERATION EXPLANATION OF COMPONENTS SLIDE WINDOW (Machine with cab specification) CAUTION Keep your hand or head inside the window when driving or operating the machine. The window at the right side of cab is sliding type small win- dow, and you can open or close it. EMERGENCY ESCAPE HAMMER (Machine with cab specification) CAUTION...
Page 159 EXPLANATION OF COMPONENTS OPERATION CAB DOOR CAUTION • Cab door must be checked to be locked either at the open position or closed position. • Always place the machine on a level ground when opening or closing the cab door. Avoid opening or closing the door on a slope, since there is a danger that the operating effort may sudden- ly change.
Page 160 OPERATION EXPLANATION OF COMPONENTS OPEN LOCK FOR CAB DOOR Use this to fix the cab door in position after opening it or when getting in and out the machine. Push the cab door against the catch part (1) to lock it in position.
Page 161 EXPLANATION OF COMPONENTS OPERATION CUP HOLDER CUP HOLDER: CANOPY SPEC The cup holder is located on the rear right of the operator's seat. CUP HOLDER: CAB SPEC The cup holder is located on the rear left of the operator's seat. ASHTRAY (Machine with cab) (if equipped) An ashtray is located on the right side of the operator's seat.
Page 162 • If any damage or problem is found at the floor opening lock part, stop the work, close the floor, and then ask your Komatsu distributor for repair. • Do not remove the floor mounting bolts (A). The floor may jump up unexpectedly and it is danger- ous.
Page 163 EXPLANATION OF COMPONENTS OPERATION Set the lock lever to LOCK position (L). Be sure to operate the lock lever by the operating por- tion on the top. Put the wooden blocks on the front and rear sides of the tracks so that the machine does not move. 9 J A 0 5 4 6 6 3-102...
Page 164 OPERATION EXPLANATION OF COMPONENTS METHOD FOR OPENING FLOOR UNIT METHOD FOR OPENING FLOOR UNIT: CANOPY SPEC Remove the triangle cover fixing bolts (1) (M10, 3 pieces), and remove the triangle cover (2). Remove the cover fixing bolts (3) (M8, 4 pieces), and re- move the cover (4).
Page 165 EXPLANATION OF COMPONENTS OPERATION Open the inspection window (9). While pulling the floor lock release lever (10) to FREE po- sition (F) with your left hand, hold the handle (11) with your right hand and push it up to the direction of arrow (approxi- mately 45 °) to release the floor lock.
Page 166 OPERATION EXPLANATION OF COMPONENTS 11. Insert the second lock pin (15) into the locking hole (16) securely from inside. 12. Turn the lock pin (15) until its upper part (hook to prevent from coming off) catches the pin (17) of inserting part se- curely.
Page 167 EXPLANATION OF COMPONENTS OPERATION METHOD FOR OPENING FLOOR UNIT: CAB SPEC Remove the triangle cover fixing bolts (1) (M10, 3 pieces), and remove the triangle cover (2). Remove the floor tilt fixing bolts (3) (M14, 2 pieces). Pull the engine rear cover (4) backward to open it. Open the engine rear cover (4) fully and it is secured by rod (5).
Page 168 OPERATION EXPLANATION OF COMPONENTS While pulling the floor lock release lever (8) to FREE posi- tion (F) with your left hand, hold the handle (9) with your right hand and push it up to the direction of arrow (approxi- mately 45 °) to release the floor lock. Hold the handle (9) and push it up to the direction of arrow (approximately 45 °) to raise the floor.
Page 169 Before closing the floor, check the wiring harness, piping, and seat inside floor and in the revolving frame for damage or problem. If any damage or problem is found, ask your Komatsu distributor for repair. METHOD FOR CLOSING FLOOR UNIT: CANOPY SPEC Remove the lock pin (15) of second lock, and insert it into holder hole (18).
Page 170 156.8 to 196.0 Nm {16.0 to 20.0 kgm, 116 to 145 lbft} REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. Close the engine rear cover (6). Tighten the floor tilt fixing bolts (5) (M14, 2 pieces).
Page 171 EXPLANATION OF COMPONENTS OPERATION METHOD FOR CLOSING FLOOR UNIT: CAB SPEC Remove the lock pin (13) of the second lock, and insert it into holder hole (16). If it is hard to remove the lock pin (13), hold the handle (9) and while pulling it up, remove the lock pin (13).
Page 172 REMARK • If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. • When the air cleaner has been moved downward, re- store it to the original position, and install the air clean- er mounting bracket with bolts (A).
Page 173 EXPLANATION OF COMPONENTS OPERATION POWER SUPPLY OUTLET 12 V power supply NOTICE After using the receptacle for external electric equipment, always close the cap. If the cap is left open, rainwater, etc. enters and may cause short circuit. Capacity of this power supply is 120 W (12 V x 10 A). Use the power outlet as a power supply for the lighting equip- ment, etc.
Page 174 OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE When replacing the fuse, make sure to turn the starting switch to OFF position, and then disconnect the negative (-) terminal of the battery. For the machines equipped with a battery disconnect switch, set the battery disconnect switch to OFF position.
Page 175 EXPLANATION OF COMPONENTS OPERATION Machine with cab specification No. Capacity Name of circuit Working lamp relay, additional working lamp re- 5 A lay, and pump secondary drive switch 10 A Solenoid valve 5 A PPC hydraulic lock solenoid 10 A Room lamp, radio, and windshield wiper 10 A Travel alarm, fuel pump, and horn 10 A...
Page 176 OPERATION EXPLANATION OF COMPONENTS FUSIBLE LINK NOTICE When replacing the fuse, make sure to turn the starting switch to OFF position, and then disconnect the negative (-) terminal of the battery. For the machines equipped with a battery disconnect switch, set the battery disconnect switch to OFF position.
Page 177 EXPLANATION OF COMPONENTS OPERATION TOOL BOX Store the tools and warning tags in it. It is located inside the cover under the operator's seat. GREASE PUMP HOLDER It is located inside the dirt cover on the front right of the machine. Keep the grease pump hooked on this holder while it is not used.
Page 178 OPERATION EXPLANATION OF COMPONENTS HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
Page 179 Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 180 OPERATION EXPLANATION OF COMPONENTS When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in yellow (action level (3): “L01”), screen (A) is displayed first. • The action level goes out 2 seconds later, and the screen changes back to standard screen (B).
Page 181 If the work is continued without performing the manual stationary regeneration, and the quantity of soot exceeds the allowable limit, action level “L04” lights up. If action level display “L04” lights up, ask your Komatsu distributor for repair. The maximum engine output power and maximum engine speed are limited to protect the engine and KDPF system.
Page 182 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION CAUTION Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt. Keep combustible materials away from the exhaust pipe outlet and around the aftertreatment devices to prevent a fire.
Page 183 EXPLANATION OF COMPONENTS OPERATION Select “Manual Stationary Regeneration”, check again that there is no person or combustible material around the ma- chine, and then press the function switch “F4”. If the machine needs to be moved again to secure safety, move it to a safe place and repeat the procedure from step REMARK •...
Page 184 OPERATION EXPLANATION OF COMPONENTS • If the monitor switch is not operated for 30 seconds, the explanation of the manual stationary regeneration is displayed for 30 seconds, and then the screen re- turns to the standard screen. To display the explanation of the manual stationary re- generation again, press the function switch “F4”...
Page 185 EXPLANATION OF COMPONENTS OPERATION REMARK • The progress of the manual stationary regeneration performed when soot is accumulated can be checked by the number of lighting lamps of the soot accumulation level (4). The manual stationary regeneration starts at the soot accumulation level “4” or higher and finishes when all the level lamps go out.
Page 186 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING If there is combustible material around the machine and the active regeneration that increases the exhaust tem- perature must not be performed, the automatic active aftertreatment devices regeneration can be disabled. The regeneration can be disabled while aftertreatment devices are in regeneration.
Page 187 EXPLANATION OF COMPONENTS OPERATION On “Regeneration Disable” confirmation screen, press function switch “F4”. REMARK If you press function switch “F3”, regeneration is not disa- bled and the screen returns to “Aftertreatment Devices Re- generation” screen. The screen returns to “Aftertreatment Devices Regenera- tion”...
Page 188 OPERATION EXPLANATION OF COMPONENTS On “Regeneration Disable” confirmation screen, press function switch “F4”. REMARK If you press function switch “F3”, regeneration is not disa- bled and the screen returns to “Aftertreatment Devices Re- generation” screen. The screen returns to “Aftertreatment Devices Regenera- tion”...
Page 189 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING CAUTION When canceling the regeneration disable, move the machine to a safe place and check that there is no person or combustible matter around the machine, and start the cancel operation. On the standard screen, if you press function switch “F4”, “Aftertreatment Devices Regeneration”...
Page 190 OPERATION EXPLANATION OF COMPONENTS If soot accumulation level (4) is lit 3 or more, the regenera- tion is started automatically. REMARK • When canceling the regeneration disable, set the lock lever to LOCK position and set the fuel control dial to Low idle (MIN) position, then cancel the regeneration disable.
Page 191 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 192: Machine Operations And Controls
Accumulation of combustible material or leakage of fuel or oil around the high temperature parts such as the engine muffler or battery may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. •...
Page 193 11. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one.
Page 194 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day. METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK NOTICE Do not use trichloroethylene to clean the inside of tank. Items to be prepared Container to catch the fuel Set the machine in the posture shown in the figure.
Page 195 MACHINE OPERATIONS AND CONTROLS OPERATION Pull the cooling cover (3) backward to open it. Turn the rod (4) to LOCK position (L), and fix the cooling cover (3) with the rod. Place a container under the drain hose to catch the fuel. Open the drain valve (5) to discharge the sediment and water which is accumulated in the bottom together with the fuel.
Page 196 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING DUST INDICATOR Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2). Check if the red piston is protruded at the arrow part of dust indicator (3).
Page 197 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT The water separator forms one unit with the fuel prefilter. Pull the engine rear cover (1) backward to open it. Open the engine rear cover (1) fully and it is secured by rod (2).
Page 198 OPERATION MACHINE OPERATIONS AND CONTROLS Set the machine in the posture shown in the figure. Start the engine. Set the lock lever to FREE position. Be sure to operate the lock lever by the operating portion on the top. Operate the work equipment control lever slowly to the right and left to swing the upper structure so that the fuel prefilter comes between the tracks.
Page 199 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 200 OPERATION MACHINE OPERATIONS AND CONTROLS Pull the cooling cover (3) backward to open it. Turn the rod (4) to LOCK position (L), and fix the cooling cover (3) with the rod. Check the oil level through sight gauge (G). It is appropriate if the oil level is between H and L. If the oil level is below level L, the hydraulic oil is insuffi- cient.
Page 201 MACHINE OPERATIONS AND CONTROLS OPERATION Loosen the bolt (7) of the hydraulic tank, move the plate (8) on the oil filler port (F), and turn the cap of the oil filler port (F) slowly to remove it. Release the internal pressure. Add the hydraulic oil through oil filler port (F) until the oil level comes between levels H and L of sight gauge (G).
Page 202 OPERATION MACHINE OPERATIONS AND CONTROLS Set the lock lever securely to LOCK position (L). Be sure to operate the lock lever by the operating por- tion on the top. Stop the engine. Tighten the cap of oil filler port (F) on the hydraulic tank securely.
Page 203 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check it with the reservoir tank when the engine is cold. • Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radia- tor.
Page 204 OPERATION MACHINE OPERATIONS AND CONTROLS Check the coolant level in reservoir tank (5). If the coolant level is within the range between FULL and LOW, the coolant amount is at a proper level. If the coolant level is below LOW, add coolant of the same density according to the coolant density table in “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS AC- CORDING TO AMBIENT TEMPERATURE”...
Page 205 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Pull engine rear cover (1) toward you to open it.
Page 206 • If fuses are frequently blown out or if there are traces of short-circuiting on the electric wiring, im- mediately ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 207 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL WARNING • Fuel is highly flammable and dangerous. Do not bring any open flame close. • When adding fuel, never spill the fuel or let it overflow. This may cause fire. •...
Page 208 Turn the starting switch to ON position. Check that the horn sounds immediately when the horn switch is pressed. If the horn does not sound, ask your Komatsu distributor for repair. After checking, turn the starting switch back to OFF posi- tion.
Page 209 REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. Pull the engine rear cover (4) backward to open it. Open the engine rear cover (4) fully and it is secured by rod (5).
Page 210 Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgm, 116 to 145 lbft} REMARK If any of the floor tilt fixing bolt is damaged, replace it with a Komatsu genuine part of the same size. Close the engine rear cover (4). 3-149...
Page 211 REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. If it is loosened, retighten the bolts (2 places) in the trian- gle cover at the left side of the machine as well.
Page 212 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the lock lever to LOCK position to pre- vent any malfunction due to accidental contact with the control levers. NOTICE If the seat position is adjusted while the parts, tools, or empty cans are left around the operator's seat, the peripheral parts or operator's seat may be damaged.
Page 213 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING MIRRORS WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may lead to a serious personal injury or death. CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work.
Page 214 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING MIRRORS: CAB SPEC Mirror (A) Left front mirror Mirror (B) Right front mirror Mirror (C) Right rear mirror PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work.
Page 215 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work. • The machine is placed on a level ground. •...
Page 216 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 217 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the lock lever is se- curely at LOCK position. Check that the lock lever (1) is at LOCK position (L). If the lock lever (1) is in FREE position (F), the engine does not start.
Page 218 Press the lamp switch (3) and check if the working lamps light up. If the working lamps do not light up, broken bulb or wire breakage is suspected. Ask your Komatsu distributor for repair. Press the horn switch (4) and check that the horn sounds.
Page 219: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING ENGINE WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death. •...
Page 220 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key in starting switch (3) to ON position (B). REMARK If the ambient temperature is low, the preheating pilot lamp lights up and automatic preheating is performed. Keep starting switch (3) key at ON position (B) until the preheating pilot lamp goes out.
Page 221 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE If the engine oil pressure caution lamp does not go out in 4 to 5 seconds, stop the engine immediately. Check the oil level, oil leakage, etc. and take proper meas- ures. REMARK White smoke may be discharged for a short time immedi- ately after the engine is started or during the aftertreatment devices regeneration in the cold season, but this is not a failure.
Page 222: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 223 METHOD FOR RUNNING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 224 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ENGINE WARM-UP OPERATION NOTICE • Do not perform operations or operate the levers sharply while the hydraulic oil is at low tempera- ture. Be sure to perform the warm-up operation. This will extend the service life of the machine. •...
Page 225 If any problem is found, perform maintenance or repair. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. Set lock lever (2) to LOCK position (L). Be sure to operate the lock lever (2) by the operating por- tion on the top.
Page 226 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR HYDRAULIC SYSTEM WARM-UP OPERATION WARNING • Before warming up the hydraulic component, check that there is no person or obstacle in the area around the machine, then sound the horn and start the opera- tion.
Page 227 If any problem is found, perform maintenance or repair. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. In cold weather (ambient temperature is less than 0 °C {less than 32 °F} ), perform the warm-up operation for hydraulic system in cold weather.
Page 228 OPERATION MACHINE OPERATIONS AND CONTROLS Before starting the operation, turn the fuel control dial (5) to the point (c) of 2/3 between Low idle (MIN) position (a) and High idle (MAX) position (b). Operate each control lever and control pedal to circulate the warm hydraulic oil to all control circuits. Repeat the following operation slowly 3 to 5 times before starting the actual work.
Page 229 MACHINE OPERATIONS AND CONTROLS OPERATION Blade operation LOWER (s) ←→ RAISE (t) Attachment operation (if equipped) (For the machine equipped with attachment control pedal) (For the machine equipped with proportional lever) For attachment operations, change the working mode to the attachment mode to perform. Warm-up operation for hydraulic component is completed.
Page 230: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stop- ping the engine. NOTICE • Do not stop the engine abruptly except in an emergen- cy. Otherwise, the service lives of component parts of the engine will be reduced.
Page 231: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE WARNING • Check that the direction of the track frame is proper before operating the travel levers or travel ped- als. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the oppo- site direction to the direction of the operation of the travel levers or travel pedals (front and rear travel are reversed, right and left steering are reversed).
Page 232 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TRAVELING FORWARD Move the lock lever (1) slowly and securely to FREE posi- tion (F). Be sure to operate the lock lever (1) by the operating por- tion on the top. Set the machine state in the posture shown in the figure. Operate the R.H.
Page 233 (Lo), although high-speed travel (Hi) is lit in travel speed display. When traveling, check that the travel alarm sounds nor- mally. If the alarm does not sound, ask your Komatsu distributor for repair. 3-172...
Page 234 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TRAVELING REVERSE Move the lock lever (1) slowly and securely to FREE posi- tion (F). Be sure to operate the lock lever (1) by the operating por- tion on the top. Set the machine state in the posture shown in the figure. Operate the R.H.
Page 235 (Lo), although high-speed travel (Hi) is lit in travel speed display. When traveling, check that the travel alarm sounds nor- mally. If the alarm does not sound, ask your Komatsu distributor for repair. 3-174...
Page 236 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING MACHINE Avoid a sudden stop. Stop the machine gradually. Set right and left travel levers (1) in NEUTRAL position (N). The machine stops. 3-175...
Page 237: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the directions of operations of the travel levers or travel pedals are the opposite to the direction of movement of the machine.
Page 238 OPERATION MACHINE OPERATIONS AND CONTROLS CHANGE DIRECTION OF MACHINE When turning left (A) Forward left turn Return the left travel lever from FORWARD to NEUTRAL posi- tion. The machine turns left in forward. (B) Reverse left turn Return the left travel lever from REVERSE to NEUTRAL posi- tion.
Page 239: Method For Swinging Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SWINGING MACHINE WARNING • The tail of the machine extends outside the tracks. Visually check safety around the machine before swinging. • When performing swing operation on a slope, the ma- chine may lose its balance and turn over. Avoid such operation as much as possible.
Page 240: Method For Operating Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATING WORK EQUIPMENT WARNING For control patterns other than the standard control method (ISO pattern), see ATTACHMENTS AND OP- TIONS. Use the control levers to operate the work equipment. When the levers are released, they return to NEUTRAL position and the work equipment is held in that position. •...
Page 241 MACHINE OPERATIONS AND CONTROLS OPERATION • Bucket operation Move the R.H. work equipment control lever to the right and left. Bucket moves in or out. • Boom swing operation Depress either right or left of the Boom swing control ped- Boom swings either right or left.
Page 242 OPERATION MACHINE OPERATIONS AND CONTROLS • Blade operation Move the blade control lever back and forth. Blade moves up or down. REMARK This machine is equipped with an accumulator in the control circuit. For some time after stopping the engine, even if the engine is stopped, if the starting switch key is turned to ON position, and the lock lever is set to FREE position, following work equipment operations are possible.
Page 243: Handle Working Mode
MACHINE OPERATIONS AND CONTROLS OPERATION HANDLE WORKING MODE NOTICE Do not perform breaker operations in any mode other than the breaker mode. Otherwise, the breakage of hydraulic component will occur. Select the working mode that matches the operating conditions or purpose. This will make it possible to perform operations efficiently.
Page 244: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING Do not operate the work equipment control lever when the machine is traveling. PROHIBITION OF OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects. It drastically reduces the life of the machine, and is also danger- ous.
Page 245 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging, nor use the dropping force of the bucket as a mattock, breaker, or pile driver. This will drastically reduce the life of the machine. PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig.
Page 246 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces. As a result, large vibration occurs in the machine and can crack the work equipment or frame.
Page 247 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF SWINGING OR TRAVELING WHEN ROCK IS ON TOP OF TRACK ASSEMBLY If the machine travels or swings with crushed stones, soil, or sand on the track, they hit and damage the undercover and frame.
Page 248 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF HIGH-SPEED TRAVEL OPERATIONS ON ROUGH GROUND If the machine travels on rough ground (rock-bed, etc.) at high speed, large push-up loads are applied to the chassis, thus the service life of the chassis is shortened. When driving on rough ground (rock-bed, etc.), direct the idler (1) having the cushion mechanism in the travel direction and drive the machine at low speed.
Page 249: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELING Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the under- carriage), and this will cause damage to the machine. For this reason, always remove any obstacles or drive the machine around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 250 OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR BLADE POSITION DURING BACKHOE OPERATION When performing the backhoe operation near the blade, take care that the boom cylinder does not touch the blade. Dig with the blade at the rear usually, and dig in front of the blade only when required.
Page 251: Precautions For Working On Slope
MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS FOR WORKING ON SLOPE WARNING • When performing the swing operation or operating the work equipment on slopes, machine may lose its bal- ance and tip over. Avoid such operations as much as possible. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 252 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK Drive the machine down with sprocket (1) downward. If the machine travels down with sprocket (1) upward, the tracks may be loosened and may jump teeth. When driving the machine up steep hills of 15 ° or more, set the machine to the posture shown in the figure with bucket height (b) at 20 to 30 cm {7.9 to 11.8 in} , and drive the machine.
Page 253: Method For Escaping From Mud
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ESCAPING FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out. METHOD FOR ESCAPING WHEN TRACK ON ONE SIDE IS STUCK NOTICE Use the bottom of bucket to push the ground.
Page 254: 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 attach- ments. DIGGING WORK BACKHOE WORK It is suitable for excavating areas that are lower than the machine. When the condition of the work equipment is as shown in the figure (angle (a) between bucket cylinder and link, and angle (b) between arm cylinder and arm is 90 °), the maximum exca-...
Page 255 MACHINE OPERATIONS AND CONTROLS OPERATION LOADING WORK In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator. Loading is easier and capacity becomes greater if you place the machine at the rear of the dump truck than if loading is done from the side.
Page 256: Method For Replacing Bucket
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR REPLACING BUCKET WARNING • When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When performing this operation, always wear protective eyeglasses, helmet, gloves, and other pro- tective equipment.
Page 257 MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever to LOCK position (L). Be sure to operate the lock lever by the operating por- tion on the top. Stop the engine. REMARK When removing the pins, place the bucket so that it is in light contact with the ground.
Page 258: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Park the machine on a firm, level ground. Do not park the machine on a slope. Block the tracks from movement if it is unavoidably necessary to park the machine on a slope.
Page 259 MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever (6) to LOCK position (L). Be sure to operate the lock lever (6) by the operating por- tion on the top. Check that the machine monitor (7) is in the following states.
Page 260: Method For Checking After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING AFTER FINISHING WORK Perform it after stopping the engine. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant. If any problems are found, repair them. Fill the fuel tank.
Page 261 MACHINE OPERATIONS AND CONTROLS OPERATION Lock positions for the machine with cab specification (1) Operator's cab door Always close the window. (2) Dirt cover (3) Engine rear cover COVER WITH LOCK Use the starting switch key to open and close the covers with locks. Insert the starting switch key as far as it will go to shoulder (A) and turn it.
Page 262 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING ENGINE REAR COVER CAUTION • When opening or closing the engine rear cover, place the machine on a level ground, lower the work equipment to the ground, stop the engine, and then perform the operation. •...
Page 263 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR LOCKING ENGINE REAR COVER While lifting up the rod (4), close the engine rear cover (3) a little to release it from the groove of rod (4). The engine rear cover (3) will be free. Close the engine rear cover (3) and push it to fix securely.
Page 264 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING COOLING COVER CAUTION When performing check and maintenance for inside of the cooling cover, open the engine rear cover, and then open the cooling cover. Always open the engine rear cover fully until it is fixed with the rod. Fix the cooling cover securely with the rod at LOCK position.
Page 265 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CLOSING COOLING COVER Set the rod (3) to FREE position (F). The cooling cover (2) becomes free. While pulling up the cooling cover opening lever (1), close the cooling cover (2). Push down the cooling cover opening lever (1), and secure the cooling cover.
Page 266 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING DIRT COVER CAUTION • Never stand on the cover, otherwise, you may slip and fall. • Open the dirt cover fully, and check that it is fixed with the cover supporting lever when performing check and maintenance of the inside.
Page 267 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR LOCKING DIRT COVER Hold dirt cover (3) and pull up cover support lever (4) slightly. Dirt cover (3) becomes free. Close dirt cover (3) gently and push it to fix securely. Insert the starting switch key into key slot (1). Turn the starting switch key to “LOCK”...
Page 268 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR (Machine with cab specification) WARNING • Before releasing the door lock, always place the machine on a level ground. • Do not release the door lock when the machine is on a slope. The cab door may suddenly close and pinch your hand, and it causes injury.
Page 269 MACHINE OPERATIONS AND CONTROLS OPERATION Hold the handle inside cab door, and push the cab door to the door lock (3), and fix it securely. Check that the cab door is securely fixed to the door lock (3). 3-208...
Page 270 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR LOCKING OPERATOR CAB DOOR Lower the door lock cancel lever (4) to release the door lock (3). Hold the handle inside the cab door and pull the cab door, and hold the cab door handle (2) to close the cab door. Insert the starting switch key into the key slot (1).
Page 271: Handle Air Conditioner
HANDLE AIR CONDITIONER OPERATION HANDLE AIR CONDITIONER (Machine with cab specification) • When the air conditioner is not used every day, to prevent loss of the film of oil at various parts, run the air conditioner with the engine at low speed from time to time and perform cooling or dry heating for several minutes.
Page 272 OPERATION HANDLE AIR CONDITIONER TEMPERATURE CONTROL SWITCH Use the temperature control switch to adjust the inside temper- ature. Lower the inside temperature. Turn the temperature control switch counterclockwise. Raise the inside temperature. Turn the temperature control switch clockwise. AIRFLOW SELECTOR SWITCH Air flow selector switch can adjust air flow in 3 levels.
Page 273: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION AIR CONDITIONER SWITCH Each time the air conditioner switch is pressed, operation (ON) and stop (OFF) is switched. When the air conditioner switch is turned to operation (ON), the lamp inside the air conditioner switch lights up. METHOD FOR OPERATING AIR CONDITIONER METHOD FOR STARTING AIR CONDITIONER Turn the air flow selector switch, and adjust the air flow.
Page 274 OPERATION HANDLE AIR CONDITIONER Turn the louver of each vent to adjust to the desired vent direction. Change the FRESH/RECIRC air selector lever to select ei- ther FRESH (a) or RECIRC (b). METHOD FOR STOPPING AIR CONDITIONER Press the air conditioner switch, and turn it off. The lamp inside the switch goes out.
Page 275: Handle Rubber And Road Liners Shoes
HANDLE RUBBER AND ROAD LINERS SHOES OPERATION HANDLE RUBBER AND ROAD LINERS SHOES RECOMMENDED USE OF RUBBER AND ROAD LINERS SHOES The rubber shoes and road liners have good features which the steel shoes do not have. However, if it is used similarly to the steel shoes, its features are not used fully.
Page 276: Prohibited Operations When Using Rubber And Road Liners Shoes
OPERATION HANDLE RUBBER AND ROAD LINERS SHOES PROHIBITED OPERATIONS WHEN USING RUBBER AND ROAD LINERS SHOES Do not perform the following work. • If the machine is operated or swung on crushed stones, very irregular hard rock-bed, reinforcing bars, scrap steel, edges of steel plates, the rubber shoes and road liners can be damaged.
Page 277: Precautions For Using Rubber And Road Liners Shoes
HANDLE RUBBER AND ROAD LINERS SHOES OPERATION PRECAUTIONS FOR USING RUBBER AND ROAD LINERS SHOES When operating, observe the following. • Do not make a pivot turn on a concrete road since rubber marks are made on the road surface. •...
Page 278 OPERATION HANDLE RUBBER AND ROAD LINERS SHOES Do not travel with either track raised on a face of slope or convex ground surface (with the machine leaning approximately 10 ° or more) and the other track on the level ground. Travel with both tracks on the same level to protect the rubber shoes and road liners from being damaged.
Page 279 HANDLE RUBBER AND ROAD LINERS SHOES OPERATION • When the machine is steered while the rubber shoe cannot move sideway because of a material to ride over or anoth- er thing. • When the idler or track rollers deviate from the core metal because of misalignment of the rubber shoes.
Page 280: Transportation
OPERATION TRANSPORTATION TRANSPORTATION PRECAUTIONS FOR TRANSPORTING MACHINE SELECT TRANSPORTATION METHOD When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS”. Note that the weight and dimension shown in “SPECIFICATIONS” may differ in accordance with the type of track shoe or arm, or other attachments.
Page 281: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER Precautions for loading and unloading operations WARNING Always observe the following when loading or unloading the machine onto/from a trailer. • Select the firm, level ground when loading or unload- ing the machine.
Page 282 OPERATION TRANSPORTATION Precautions for ramps and platform WARNING Always observe the following regarding the ramps and platform. • Use ramps with ample width, length, thickness, and strength and install them with a slope of 15 ° or less. When using piled soil for the platform, compact the piled soil fully to prevent the slope face from collaps- ing.
Page 283 TRANSPORTATION OPERATION If Hi is displayed, press the travel speed selector switch to change the travel speed to Lo. Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating portion on the top. Operate the work equipment control lever to swing the up- per structure so that the work equipment is on the sprocket side.
Page 284 OPERATION TRANSPORTATION 11. Place the machine at the specified position on the trailer. METHOD FOR SECURING MACHINE NOTICE • To prevent damage to the bucket cylinder during transportation, put a wooden block under the tip of the bucket link to prevent the bucket cylinder from touching the floor. •...
Page 285 TRANSPORTATION OPERATION PROCEDURES FOR UNLOADING MACHINE Park a trailer on a flat and firm place. Maintain a safe distance from the road shoulder. Apply the brake of the trailer securely. Set the chocks (1) to the tires to secure the trailer. Set the right and left ramps (2) parallel to each other and equally spaced to the right and left of center (3) of the trail- er.
Page 286 OPERATION TRANSPORTATION Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating portion on the top. 10. Set the machine in the posture shown in the figure. Pull the blade control lever backward to raise the blade.
Page 287: Method For Lifting Machine
The method of lifting differs depending on the attachments and options installed. For the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS”. When lifting the machine, perform the operation on a flat ground according to the following procedure.
Page 288 OPERATION TRANSPORTATION Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating por- tion on the top. Operate the work equipment control lever to swing the upper structure so that the work equipment is on the sprocket side (A).
Page 289 TRANSPORTATION OPERATION Install shackle to the hole (1 place) for lifting at the bracket of boom, and set the wire rope. NOTICE • Be sure to use all 3 holes for lifting. Do not sling the machine with the boom swung or upper structure swung.
Page 290: Cold Weather Operation
• When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 291 COLD WEATHER OPERATION OPERATION BATTERY WARNING • Do not bring any open flame near the battery. Otherwise, it may explode since the battery generates the flammable gas. • Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 292: Precautions After Daily Work Completion In Cold Weather
OPERATION COLD WEATHER OPERATION PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER WARNING Performing idling 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 293: Precautions For Long-Term Storage
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION PRECAUTIONS FOR LONG-TERM STORAGE PREPARATION FOR LONG-TERM STORAGE NOTICE When storing the machine (more than 1 month), set the machine in the posture shown in the figure to protect the hydraulic cylinder piston rods. (To prevent the cylinder piston rods from rusting) When putting the machine in storage for a long time (more than 1 month), do as follows.
Page 294: Maintenance During Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. Perform the following items when using the machine after long-term storage. • Wipe off the grease from the piston rods of the hydraulic cylinder.
Page 295: Troubles And Actions
TROUBLES AND ACTIONS OPERATION TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system before starting the engine. Always check the fuel level to prevent running out of fuel. If the engine has stopped due to run out of fuel, all air must be sufficiently bled from the fuel circuit.
Page 296 OPERATION TROUBLES AND ACTIONS Turn handle (8) of fuel prefilter (7) to OPEN position (O). Loosen air bleeding bolt (9) of the fuel prefilter by 2 to 3 turns. When the fuel including no air bubbles comes out from air bleeding bolt (9), tighten air bleeding bolt (9). Turn the key in starting switch to ON position (B).
Page 297: Phenomena That Are Not Failures
TROUBLES AND ACTIONS OPERATION PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: • When the arm is operated IN from a high position for dig- ging under no load, the arm speed drops momentarily at the vertical position.
Page 298: Precautions For Towing Machine
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR TOWING MACHINE WARNING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death. •...
Page 299: Precautions For Discharged Battery
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch (if equipped) keys to OFF positions.
Page 300 OPERATION TROUBLES AND ACTIONS METHOD FOR REMOVING AND INSTALLING BATTERY WARNING Stop the engine, and turn the starting switch and the battery disconnect switch (if equipped) keys to OFF positions when handling the battery. METHOD FOR REMOVING BATTERY CAUTION Remove the ground cable (normally connected to the negative (-) terminal) first. If any tool touches between the positive (+) terminal and the chassis, there is a hazard of sparks being generated.
Page 301 TROUBLES AND ACTIONS OPERATION METHOD FOR INSTALLING BATTERY CAUTION • When installing the battery, connect the ground cable last. • When replacing the battery, secure the battery body with the battery mounting hardware. • To prevent a fire, install the rubber cover above the battery so that it envelops the battery and it is not flipped.
Page 302 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Follow the instruction manual accompanying the battery charger, and observe the following. •...
Page 303 TROUBLES AND ACTIONS OPERATION START ENGINE WITH JUMPER CABLES WARNING • Never contact the positive (+) terminal and negative (-) terminal when connecting the cables. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 304 OPERATION TROUBLES AND ACTIONS METHOD FOR STARTING ENGINE Check both of normal machine and failed machine that the lock lever is set to LOCK position. Check also that all the control levers are in NEUTRAL position. Make sure the clips are firmly connected to the battery terminals. Start the engine of the normal machine and run it at high idle (max.
Page 305: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 306 OPERATION TROUBLES AND ACTIONS PHENOMENA AND ACTIONS FOR CHASSIS • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm, Lack of hydraulic oil Set oil to specified level.
Page 307 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 308 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Starting motor operates but engine Lack of fuel Add fuel. See CHECKS BEFORE does not start. STARTING. Air in fuel system Bleed air. See EVERY 500 HOURS MAINTENANCE. Water in fuel system Drain the entrained water.
Page 309 (emergency) position enables operations temporarily. For details of the pump secondary drive switch, see “PUMP SECONDARY DRIVE SWITCH”. Immediately ask your Komatsu distributor for an inspection and repair after the operation. Telephone number for the point of contact if an error occurs When an error screen is displayed on the machine monitor, press the function switch “F3”...
Page 310: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 311: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 312: Dusty Jobsites
MAINTENANCE PRECAUTIONS FOR MAINTENANCE DUSTY JOBSITES When working at dusty jobsites, observe the following. • Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. • Clean the radiator core frequently to avoid clogging. • Clean and replace the fuel filter frequently.
Page 313: Checks After Inspection And Maintenance
PRECAUTIONS FOR MAINTENANCE MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to personal injury. Always observe the following. Checks after operation (with engine stopped) • Have any inspection and maintenance points been forgotten? •...
Page 314: Outline Of Maintenance
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu...
Page 315 The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible.
Page 316 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 317 Make sure that the oil is well mixed before sampling. • Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor.
Page 318: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 319: Handle Hydraulic Components
OUTLINE OF MAINTENANCE MAINTENANCE HANDLE HYDRAULIC COMPONENTS • The hydraulic system is at high temperature during and just after operation. During operations, it is also un- der high pressure, so when performing inspection and maintenance of hydraulic related equipment, be careful of the following points.
Page 320: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 321 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Taper seal Outside Tightening torque Width diame- across Target value Allowable range ter of flats “b” hose “a” (mm) lbft lbft (mm) 32.5 34 to 63 3.5 to 6.5 25.3 to 47.0 57.9 59 to 98 6.0 to 10.0...
Page 322: Maintenance Schedule
Check the maintenance interval and perform maintenance by referring to “MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER”. • Ask your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ..........4-15 WHEN REQUIRED ............................
Page 323: Maintenance Interval For Hydraulic Breaker
MAINTENANCE SCHEDULE MAINTENANCE METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER... 4-89 METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR CONTROL CIRCUIT) ......................4-93 METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR ........... 4-97 EVERY 3000 HOURS MAINTENANCE ......................
Page 324: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) Until first 100 hours operation, perform the following maintenance every 10 hours. • Lubrication of swing equipment • Lubrication of work equipment For details of the method of replacement or maintenance, see “EVERY 100 HOURS MAINTENANCE”. 4-15...
Page 325: When Required
MAINTENANCE PROCEDURE MAINTENANCE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear protective eyeglasses, dust mask, or other protective equipment. NOTICE •...
Page 326 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT NOTICE • Do not use a screwdriver or other tool. • When cleaning the element, do not hit it or hit anything with the element. • Before and after cleaning the element, do not leave or keep it under direct sunlight. METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT ON MACHINE EQUIPPED WITH SINGLE ELEMENT Release the hooks (4) and remove the cover (5).
Page 327 MAINTENANCE PROCEDURE MAINTENANCE NOTICE • Do not use the outer element with damaged pleats or a damaged gasket or seal. • If the outer element and O-ring are cleaned and used again after they are used for more than 1 year, it will cause problems.
Page 328 MAINTENANCE MAINTENANCE PROCEDURE Check that TOP mark arrow (A) on cover (5) is point- ing upward. When the cover (5) is installed, check that the clear- ance between air cleaner body (7) and cover (5) is not too large. If the clearance is too large, remove the cover (5), and then install it again.
Page 329 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT ON MACHINE EQUIPPED WITH DOUBLE ELEMENT NOTICE Never remove the inner element. If it is removed, dirt will enter and can cause an engine trouble. Release the hooks (4) and remove the cover (5). Hold the outer element (6), rock it lightly up and down and to the right and left, and pull out the outer element (6) while turning it to the right or left.
Page 330 MAINTENANCE MAINTENANCE PROCEDURE NOTICE • Do not use the outer element with damaged pleats or a damaged gasket or seal. • If the outer element and O-ring are cleaned and used again after they are used for more than 1 year, it will cause problems.
Page 331 MAINTENANCE PROCEDURE MAINTENANCE Check that TOP mark arrow (A) on cover (5) is point- ing upward. When the cover (5) is installed, check that the clear- ance between air cleaner body (7) and cover (5) is not too large. If the clearance is too large, remove the cover (5), and then install it again.
Page 332 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING AIR CLEANER ELEMENT METHOD FOR REPLACING AIR CLEANER ELEMENT ON MACHINE EQUIPPED WITH SINGLE ELEMENT Release the hooks (4) and remove the cover (5). Hold the outer element (6), rock it lightly up and down and to the right and left, and pull out the outer element (6) while turning it to the right or left.
Page 333 MAINTENANCE PROCEDURE MAINTENANCE Lock the tip of hook (4) on the protrusion of air cleaner body (7). Check that TOP mark arrow (A) on cover (5) is point- ing upward. When the cover (5) is installed, check that the clear- ance between air cleaner body (7) and cover (5) is not too large.
Page 334 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING AIR CLEANER ELEMENT ON MACHINE EQUIPPED WITH DOUBLE ELEMENT Release the hooks (4) and remove the cover (5). Hold the outer element (6), rock it lightly up and down and to the right and left, and pull it out while turning it to the right or left.
Page 335 MAINTENANCE PROCEDURE MAINTENANCE Install the cover (5). Align the mark on cover (5) with the mark on air clean- er body (7). Lock the tip of hook (4) on the protrusion of air cleaner body (7). Check that TOP mark arrow (A) on cover (5) is point- ing upward.
Page 336: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 337 MAINTENANCE PROCEDURE MAINTENANCE • Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable. • Check the density with a coolant tester. Items to be prepared • A container whose capacity is enough to receive the coolant of specified capacity •...
Page 338 MAINTENANCE MAINTENANCE PROCEDURE Place a container to catch the coolant under the drain hose installed to the drain valve (6). REMARK For the machine with air conditioner, the drain valve (6) is located at the position shown in the figure. Open the drain valve (6) to drain the coolant.
Page 339 MAINTENANCE PROCEDURE MAINTENANCE 18. Drain the coolant in the reservoir tank (7). 19. Clean the inside of the reservoir tank (7). 20. Add coolant up to the middle between FULL and LOW. 21. Stop the engine. 22. Approximately 3 minutes later, add coolant to near the mouth of the water filler port.
Page 340: Method For Checking Battery Electrolyte Level
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL WARNING • Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it will reduce the service life of the battery. In addition, it may cause an explosion. •...
Page 341 UPPER LEVEL line. Neutralize the removed replenishment water for a battery with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu dis- tributor or battery manufacturer. After adding, tighten cap (3) securely.
Page 342 (UPPER LEVEL line). Neutralize the removed replenishment water for a battery with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery manufacturer. After adding, tighten cap (3) securely.
Page 343: Method For Cleaning Fuel Prefilter Element
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING FUEL PREFILTER ELEMENT WARNING Do not bring any open flame close. Items to be prepared Container to catch the fuel Set the machine in the posture shown in the figure. Start the engine. Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating por- tion on the top.
Page 344 MAINTENANCE MAINTENANCE PROCEDURE Pull the cooling cover (3) backward to open it. Turn the rod (4) to LOCK position (L), and fix the cooling cover (3) with the rod. Loosen the bolts (5) and remove the undercover (6). Place a container under the fuel prefilter to catch the fuel. Turn the handle (7) to CLOSE position (S), and loosen the drain plug (8).
Page 345 MAINTENANCE PROCEDURE MAINTENANCE 11. Remove the element (11) from top of the fuel prefilter. 12. Clean the inside of transparent cup (10) and element (11) with diesel fuel or flushing oil. 13. After cleaning, install the element (11) and O-ring (12) to transparent cup (10).
Page 346: Method For Checking Looseness And Tightening Steel Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING LOOSENESS AND TIGHTENING STEEL TRACK SHOE BOLTS NOTICE If the machine is used with steel shoe bolts loose, they will break. If any looseness of the shoe bolt is found, retighten it. Check steel shoe bolt (1) for looseness. If any looseness of the bolt is found, retighten it according to the following procedure.
Page 347: Method For Checking Looseness And Tightening Road Liner Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING LOOSENESS AND TIGHTENING ROAD LINER SHOE BOLTS NOTICE If the machine is used with road liner shoe bolts loose, they will break. Tighten any loose shoe bolts immediately. Check for looseness of the road liner shoe bolt (1). If any looseness of the bolt is found, retighten it according to the following procedure.
Page 348 0 mm {0 in} . If the track tension is still loose, the pins and bushings are ex- cessively worn. Ask your Komatsu distributor to turn the bushing 180° or replace it. To check if the tension is correct, run the engine at low idle, and move the machine slowly forward by an amount equal to the length of track on ground.
Page 349 Check the track tension again, and if the tension is not correct, adjust it again. If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. 4-40...
Page 350: Method For Checking Road Liner
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING ROAD LINER If the road liners are in the following condition, they must be replaced. Ask your Komatsu distributor to replace it. Lug height • When lug height (a) is reduced to 5 mm and below ...
Page 351: Method For Checking Rubber Shoes
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING RUBBER SHOES If the rubber shoe is in the following condition, it must be repaired or replaced. Ask your Komatsu distributor for repair or replacement. Lug height • When lug height (a) is reduced to 5 mm and below ...
Page 352: Method For Checking And Adjusting Rubber Shoes Track Tension
A crack max. 30 mm {max. 1.2 in} in length and max. 10 mm {max. 0.4 in} in depth does not need to be repaired. For judgment of replacement, repair, and continuation of use of the rubber shoe, consult your Komatsu distribu- tor. METHOD FOR CHECKING AND ADJUSTING RUBBER SHOES TRACK TENSION •...
Page 353 Check the track tension again, and if the tension is not correct, adjust it again. If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. 4-44...
Page 354: Method For Replacing Rubber Shoes
Also, never put your body under the rubber shoes or track frame during the replacement work. NOTICE The idler cushion must be removed and adjusted when the rubber shoes are replaced with the steel shoes or road liner. Accordingly, be sure to ask your Komatsu distributor to perform the work. Items to be prepared •...
Page 355 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REMOVING RUBBER SHOES WARNING • Grease is pumped into the track tension adjustment system under high pressure. If the adjustment is performed with the procedure oth- er than following, grease drain plug (1) may fly out and cause serious injury or death.
Page 356: Method For Changing Shoes
METHOD FOR CHANGING SHOES WARNING The idler cushion must be removed and adjusted when the steel shoes or road liner are replaced with the rubber shoes, or reversely. Accordingly, be sure to ask your Komatsu distributor for the replace- ment. 4-47...
Page 357: Method For Replacing Bucket Teeth
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING BUCKET TEETH WARNING • It is dangerous if the work equipment moves by mistake when the bucket tooth is being replaced. Set the work equipment in a stable condition, set the lock lever securely to LOCK position, and stop the engine.
Page 358 MAINTENANCE MAINTENANCE PROCEDURE Use a hammer and bar to drive out the lock pin (2). If the bar is set against rubber pin lock (3) when it is hit, the rubber pin lock (3) may break. Set it against the back of lock pin (2). After removing the lock pin (2) and rubber pin lock (3), check them.
Page 359 MAINTENANCE PROCEDURE MAINTENANCE Fit the bucket tooth (1) to adapter (4), and check that when tooth (1) is pressed strongly, the rear face of the hole for the pin of bucket tooth (1) is at the same level as the rear face of the hole for the pin of adapter (4).
Page 360: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID (Machine with cab specification) If the window washer fluid does not come out, check the fluid level in the window washer tank. Open dirt cover (1). Open dirt cover (1) fully and it will be secured by cover support lever (2).
Page 361: Method For Checking And Maintenance Air Conditioner
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER (Machine with cab specification) CHECK AND MAINTENANCE ITEMS Some check and maintenance items of the air conditioner are to be performed periodically and the others are to be performed when required. Perform the check and maintenance according to the following list, and use the air conditioner effectively.
Page 362 Transparent with no color REMARK When there are bubbles, the refrigerant (gas) level is low, so ask your Komatsu distributor to add refrigerant. If the air conditioner continues to run with low refrigerant (gas) level, it will cause damage to the compressor.
Page 363: Method For Lubricating Boom Swing Cylinder Foot Pin
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR LUBRICATING BOOM SWING CYLINDER FOOT PIN Items to be prepared • Grease pump • Cloth Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
Page 364 MAINTENANCE MAINTENANCE PROCEDURE By using a grease pump, pump in grease through grease fittings (7). After greasing, wipe off any old grease that is pushed out. Install cover (6) with bolts (5). Turn rod (4) to FREE position (F), and close cooling cover (3).
Page 365: Method For Washing Washable Floor
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR WASHING WASHABLE FLOOR WARNING • Select a firm flat place for work. • If the control levers or control pedals are touched by mistake, there is danger that the machine may suddenly move and cause serious personal injury or death. Always set the lock lever securely to LOCK position before leaving the operator's seat.
Page 366: Method For Checking Gas Spring
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to perform this work. Gas springs are installed inside the left console (1 place), at the cab front window (1 place each on right and left), and under the floor (1 place).
Page 367: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT METHOD FOR BLEEDING AIR FROM PUMP NOTICE Abnormal heat will be generated if the pump is operated without filling the pump case with hydraulic oil. It may cause a premature damage to the pump. Bleed air securely. Open the dirt cover (1).
Page 368 MAINTENANCE MAINTENANCE PROCEDURE Loosen the bleeder (9). When the oil in which air is not mixed oozes out of bleeder (9), air bleeding is completed. After bleeding air, tighten the bleeder (9). Install the bracket (8) with bolts (7). Tighten the cap of oil filler port (F) on the hydraulic tank. Return the plate (4) on the oil filler port (F) of the hydraulic tank to its original position, and fix it with bolt (3).
Page 369 MAINTENANCE PROCEDURE MAINTENANCE Turn the fuel control dial to Low idle (MIN) position (a). Operate each cylinder of the work equipment to approxi- mately 100 mm {approximately 3.9 in} before the stroke end 4 to 5 times. Take care not to move the cylinder to the stroke end. Turn the fuel control dial to High idle (MAX) position (b).
Page 370 MAINTENANCE MAINTENANCE PROCEDURE 15. Close the dirt cover (1). METHOD FOR BLEEDING AIR FROM ATTACHMENT (When the machine is equipped with attachment) NOTICE • If the method of air bleeding from the attachment is specified by the manufacturer, bleed the air ac- cording to the specified procedure.
Page 371: Method For Checking Swing Pinion Grease Level, Add Grease
Before opening and closing of the floor, thoroughly read “METHOD FOR OPENING AND CLOSING FLOOR UNIT”, and then start the operation, or ask your Komatsu distributor to perform the work. Open the floor.
Page 372: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING”. • Drain water and sediment from fuel tank • Check dust indicator • Check water separator, drain water and sediment • Check oil level in hydraulic tank, add oil •...
Page 373: Every 100 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 100 HOURS MAINTENANCE METHOD FOR LUBRICATING METHOD FOR LUBRICATING SWING SYSTEM WARNING Never swing the upper structure while greasing swing circle and swing pinion. NOTICE Perform greasing every 10 hours for the first 100 hours operation on a new machine. Items to be prepared Grease pump By using a grease pump, pump in grease through the...
Page 374: Method For Lubricating Work Equipment
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR LUBRICATING WORK EQUIPMENT NOTICE • If any unusual noise is generated from any greasing point, perform the greasing regardless of the greasing interval. • Perform greasing every 10 hours for the first 100 hours operation on a new machine. •...
Page 375 MAINTENANCE PROCEDURE MAINTENANCE (6) Blade cylinder foot pin (1 place) (7) Blade cylinder rod end (1 place) (8) Blade foot pin (2 places) (9) Boom cylinder foot pin (1 place) (10) Boom swing bracket pin (2 places) (11) Boom swing cylinder rod end pin (1 place) (12) Boom foot pin (2 places) (13) Boom cylinder rod end (1 place) (14) Arm cylinder foot pin (1 place)
Page 376: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION (Machine with cab specification) Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
Page 377: Method For Cleaning Air Conditioner Recirc Air Filter
If the V-belt is stretched and has no allowance for ad- justment, or has slipping sound or squeak because of cuts or cracks of the belt, ask your Komatsu distributor to replace it. When the new V-belt is installed, readjust it after oper- ating for 1 hour.
Page 378: Every 500 Hours Maintenance
Check the drained oil. If there are excessive metal powder or foreign material, contact your Komatsu distributor. Install the drain plug (P). Pull the engine rear cover (1) backward to open it.
Page 379 MAINTENANCE PROCEDURE MAINTENANCE After replacing the engine oil filter cartridge, refill with the specified level of engine oil through oil filler port (F). 10. Run the engine at low idle for a while and then stop it. 11. Check the oil level in the engine oil pan. Check that the oil level is between H and L marks on dip- stick (G).
Page 380: Method For Replacing Fuel Prefilter Element
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any fuel prefilter element other than a Komatsu genuine part is used, foreign material may get in and cause problems with the injection system.
Page 381 MAINTENANCE PROCEDURE MAINTENANCE Set the lock lever to LOCK position (L). Be sure to operate the lock lever by the operating por- tion on the top. Stop the engine. Pull the engine rear cover (1) backward to open it. Open the engine rear cover (1) fully and it is secured by rod (2).
Page 382 MAINTENANCE MAINTENANCE PROCEDURE Turn the handle (7) to CLOSE position (S), and loosen the drain plug (8). Drain the water until the red ring (9) contacts to the bottom of transparent cup (10). Tighten the drain plug (8). 10. Turn the transparent cup (10) counterclockwise to remove Remove the transparent cup (10) without spilling the fuel.
Page 383: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 384 MAINTENANCE MAINTENANCE PROCEDURE Turn the rod (4) to LOCK position (L), and fix the cooling cover (3) with the rod. Turn the handle (6) of fuel prefilter (5) to CLOSE position (S). Place a container under the fuel filter to catch the fuel. Turn the fuel filter cartridge (7) counterclockwise by using the filter wrench, and remove it.
Page 385 MAINTENANCE PROCEDURE MAINTENANCE When tightening with a filter wrench, be extremely careful not to dent or damage the filter. 10. Turn the handle (6) of fuel prefilter (5) to OPEN position (O). 11. After completing the replacement of the fuel filter cartridge, bleed air from the fuel circuit. For bleeding air, see “PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT”.
Page 386: Method For Checking And Cleaning Radiator Fins, Oil Cooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND CLEANING RADIATOR FINS, OIL COOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS WARNING If the compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by use of it, there is a danger of personal injury.
Page 387 Visually check the rubber hose connected to the heat exchange equipment. If the rubber hose is cracked or become fragile, ask your Komatsu distributor for replacement. Check the hose clamps for looseness. If the hose clamps are loosened, tighten them.
Page 388: Method For Cleaning Air Conditioner Fresh Air Filter
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER (Machine with cab specification) WARNING When using the compressed air, there is a danger that dirt may scatter and cause personal injury. Wear the protective equipment such as the protective eyeglasses and dust mask. NOTICE •...
Page 389: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 390 MAINTENANCE MAINTENANCE PROCEDURE Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end. Set the work equipment in the posture shown in the figure. Set the lock lever securely to LOCK position (L). Be sure to operate the lock lever by the operating portion on the top.
Page 391: Method For Checking Oil Level In Final Drive Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 392: Method For Checking Fan Belt Tension And Replacing Fan Belt
Before opening and closing of the floor, thoroughly read “METHOD FOR OPENING AND CLOSING FLOOR UNIT”, and then start the operation, or ask your Komatsu distributor to perform the work. •...
Page 393 Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks. When replacing the belt with a new one, ask your Komatsu distributor to perform the work. When the new V-belt is installed, readjust it after operating for 1 hour.
Page 394: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours should be performed at the same time. METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 395 MAINTENANCE PROCEDURE MAINTENANCE Remove the cover mounting bolt (5), and remove the cov- er (6). The cover (6) may be jumped out by spring (7). While pressing down the cover (6), remove the cover mounting bolt (5). After removing the spring (7) and valve (8), take out the el- ement (9).
Page 396: Method For Changing Oil In Final Drive Case
Add the refill capacity of oil through plug (F) hole. When oil begins to overflow from plug (G) hole, install plugs (G) and (F). METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. 4-87...
Page 397: Every 1500 Hours Maintenance
If the crankcase breather does not work normally, the engine does not conform to the exhaust gas regulations under usage period. It is necessary to check the diaphragm for damage and the spring for breakage. Special tools are needed for inspection and maintenance, so ask your Komatsu distributor to perform this work. 4-88...
Page 398: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 100, 250, 500 and 1000 hours should be performed at the same time. METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 399 MAINTENANCE PROCEDURE MAINTENANCE Set the lock lever to LOCK position (L). Be sure to operate the lock lever by the operating por- tion on the top. Stop the engine. Open the dirt cover (1). Open the dirt cover (1) fully and it will be secured by the cover support lever (2).
Page 400 MAINTENANCE MAINTENANCE PROCEDURE Loosen the hose clamp (7) and remove the hose (8). 10. Loosen the bolts (9) and remove the tube (10). 11. Remove the O-ring (11) and strainer (12) from tube (10), remove dirt, etc. stuck to the tube, and then wash it in clean diesel fuel or flushing oil.
Page 401 MAINTENANCE PROCEDURE MAINTENANCE 19. Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end. Set the work equipment in the posture shown in the figure. 20. Set the lock lever securely to LOCK position (L). Be sure to operate the lock lever by the operating portion on the top.
Page 402: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to perform this work. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 403 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING FUNCTION OF ACCUMULATOR CAUTION Be sure that no person or obstacle is around the machine before performing the inspection. Start the engine. Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating portion on the top.
Page 404 • If the work equipment does not go down or stops at halfway, ask your Komatsu distributor for inspection. Nitrogen gas charge pressure in accumulator for con- trol circuit may be decreased. After checking the nitrogen gas charge pressure in accu- mulator, set the lock lever to LOCK position (L).
Page 405 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT Start the engine. Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating portion on the top. Place the machine on a firm, level ground. Set the work equipment to the posture shown in the figure according to the following procedure.
Page 406: Method For Checking Alternator And Starting Motor
Turn the starting switch to OFF position (A). METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for in- spection and repairs. If the engine is started frequently, have this inspection performed every 1000 hours.
Page 407: Every 3000 Hours Maintenance
If the fuel injection system does not operate normally, engine performance cannot be obtained thoroughly. It is necessary to check and clean the fuel injection system. Special tools are needed for inspection and mainte- nance, so ask your Komatsu distributor to perform this work. 4-98...
Page 408: Every 4000 Hours Maintenance
Engine oil filter hose Work equipment hydraulic Main pump delivery hose system Pump delivery hose Pump branch hose Ask your Komatsu distributor for Main pump LS hose replacement. External work equipment hose Boom foot connection hose • Boom cylinder hose •...
Page 409: Method For Replacing Accumulator (For Control Circuit)
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to perform this work. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 410: Every 6000 Hours Maintenance
MAINTENANCE PROCEDURE EVERY 6000 HOURS MAINTENANCE Maintenance for every 100, 250, 500, 1000, 1500, 2000 and 3000 hours should be performed at the same time. METHOD FOR CLEANING KDPF Ask your Komatsu distributor for cleaning the inside of KDPF. 4-101...
Page 412: Specifications
SPECIFICATIONS...
Page 413: Specifications: Pc45Mr-5
Operating weight kg { lb} 4870 {10739} 4990 {11003} m Bucket capacity 0.14 {0.18} { cu.yd} Engine model Komatsu 4D88E-7 diesel engine Rated horsepower SAE J1995 (Gross) kW • 29.1 {39.0} /2400 {2400} 29.1 {39.0} /2400 {2400} { HP} / min ISO 9249/ SAE J1349 (Net) 28.3 {38.0} /2400 {2400}...
Page 414 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC45MR-5 A Maximum digging reach mm {ft in} 6040 {19' 10"} B Maximum digging depth mm {ft in} 3675 {12' 1"} C Maximum digging height mm {ft in} 5730 {18' 10"} D Maximum vertical wall digging depth mm {ft in} 3070 {10' 1"}...
Page 415: Specifications: Pc55Mr-5
Operating weight kg { lb} 5150 {11356} 5270 {11621} m Bucket capacity 0.16 {0.21} { cu.yd} Engine model Komatsu 4D88E-7 diesel engine Rated horsepower SAE J1995 (Gross) kW • 29.1 {39.0} /2400 {2400} 29.1 {39.0} /2400 {2400} { HP} / min •...
Page 416 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC55MR-5 A Maximum digging reach mm {ft in} 6220 {20' 5"} B Maximum digging depth mm {ft in} 3770 {12' 4"} C Maximum digging height mm {ft in} 5915 {19' 6"} D Maximum vertical wall digging depth mm {ft in} 3030 {9' 11"} E Maximum dumping height mm {ft in}...
Page 418: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 419: Precautions For Using Attachment And Options
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any not authorized by Komatsu. Any personal injury, failure, or property damage caused by the use of unauthorized attachments or options will not be the responsibility of Komatsu.
Page 420: Precautions For Using
ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS PRECAUTIONS FOR USING Keep the following precautions in your mind when long or heavy work equipment is installed. Before starting operations, move the machine to a safe place and perform a test operation to make sure that you fully under- stand the movement, center of gravity, and working range of the machine.
Page 421: Handle Bucket With Hook
ATTACHMENTS AND OPTIONS HANDLE BUCKET WITH HOOK When using the bucket with hook, check that there is no damage to the hook, stopper, or hook mount. If there is any problem, ask your Komatsu distributor. PRECAUTIONS FOR OPERATION PRECAUTIONS FOR LIFTING OPERATION •...
Page 422: Handle Machine Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT CON- TROL PEDAL (1) Selector valve (3) Attachment control pedal (2) Attachment lock cover...
Page 423 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS EXPLANATION OF COMPONENTS ON MACHINES WITH PROPORTIONAL LEV- (1) Selector valve (3) Breaker operation switch (2) 1st-line attachment proportional switch (4) Horn switch...
Page 424 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT SELECTOR VALVE The selector valve switches the flow of the hydraulic oil. Position (a) When general attachments such as crusher are used Position (b) When using the breaker Width across flats of the square part of spool (1) is 9 mm {0.354 in} .
Page 425 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS ATTACHMENT 1 PROPORTIONAL SWITCH (For the machine equipped with proportional lever) Use the 1st-line attachment proportional switch when operating general attachments such as crusher, etc. Flow rate can be adjusted according to the operating amount of 1st-line attachment proportional switch.
Page 426: Method For Changing Over And Connecting Hydraulic Circuit Of Machines Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR CHANGING OVER AND CONNECTING HYDRAULIC CIR- CUIT OF MACHINES READY FOR INSTALLATION OF ATTACHMENT METHOD FOR CONNECTING HYDRAULIC CIRCUIT OF MACHINES READY FOR INSTALLATION OF ATTACHMENT NOTICE Since the pressure of attachment hydraulic circuit of this machine is set to 17.2 MPa {175 kg/cm 2490 PSI}, check the withstand pressure of installed attachment.
Page 427 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Operate the lever 3 to 4 times to the end of its stroke. For the machine equipped with attachment control pedal, set the attachment lock cover to FREE position (F). Operate the attachment repeatedly (approximately 10 times) to bleed the air completely from the attachment circuit.
Page 428 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR CHANGING OVER HYDRAULIC CIRCUIT OF MACHINES WITH AT- TACHMENT Change over the hydraulic circuit corresponding to the attachment installed according to the following proce- dure. Loosen wing nut (B), and remove selector valve stopper (A).
Page 429: Method For Operating Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS METHOD FOR OPERATING ATTACHMENT CHECK POINTS WHEN USING BREAKER • Is selector valve (1) in position (b) for breaker (1 way)? If it is not in position (b) for breaker (1 way), turn it to the position.
Page 430 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR OPERATING BREAKER NOTICE Use the breaker mode when performing breaker operations. Otherwise, the breaker will be damaged. METHOD FOR OPERATING BREAKER OF MACHINES WITH ATTACHMENT CON- TROL PEDAL WARNING •...
Page 431 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS METHOD FOR OPERATING BREAKER OF MACHINES WITH PROPORTIONAL LEVER WARNING If you do not perform breaker operation or 2-way attachment operation, set the working mode to normal mode. When the working mode is selected, if you press 1st-line attachment proportional switch or breaker op- eration switch by mistake, this may lead to serious personal injury or death.
Page 432 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT CHECK POINTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER • Is selector valve (1) in position (a) for general attachment such as crusher, etc. (2 way)? If it is not in the position (a) for general attachment such as crusher, etc.
Page 433 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS METHOD FOR OPERATING GENERAL ATTACHMENT SUCH AS CRUSHER ETC METHOD FOR OPERATING GENERAL ATTACHMENT SUCH AS CRASHER ETC OF MACHINES WITH ATTACHMENT CONTROL PEDAL WARNING • If the pedal is operated when the auto-deceleration is being actuated and the engine speed is drop- ped, the engine speed will suddenly increase, so be careful when operating.
Page 434 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR OPERATING GENERAL ATTACHMENT SUCH AS CRASHER ETC OF MACHINES WITH PROPORTIONAL LEVER WARNING If you do not perform breaker operation or 2-way attachment operation, set the working mode to normal mode.
Page 435: Long-Term Storage
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 436: Battery Disconnect Switch
ATTACHMENTS AND OPTIONS BATTERY DISCONNECT SWITCH BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running. The large current generated by the alternator may burn the electric parts and cause a fire. When operating the battery disconnect switch, always stop the engine. •...
Page 437 BATTERY DISCONNECT SWITCH ATTACHMENTS AND OPTIONS REMARK Operate this switch while the system operating lamp is off. (O) OFF position Switch key (1) can be pulled out (and inserted) and the current from the battery is cut out. (I) ON position The current from the battery flows into the circuit.
Page 438: System Operating Lamp
If the data are lost, when you try to start the engine next time, “L04” is displayed on the machine monitor and the engine may not start. If the engine cannot be started, ask your Komatsu distribu- tor for inspection and repair. REMARK •...
Page 439: Handle Heater
HANDLE HEATER ATTACHMENTS AND OPTIONS HANDLE HEATER EXPLANATION OF HEATER COMPONENTS (1) Heater switch HEATER SWITCH Heater switch is used to warm up inside of operator's compart- ment. Warm air flow can be adjusted in 2 levels with heater switch. Use this switch after the engine coolant is warmed up.
Page 440: Method For Using Heater
ATTACHMENTS AND OPTIONS HANDLE HEATER METHOD FOR USING HEATER If the ambient temperature is low, use the heater. Pull the engine rear cover (1) backward to open it. Open the engine rear cover (1) fully and it is secured by rod (2).
Page 441: Handle Radio
HANDLE RADIO ATTACHMENTS AND OPTIONS HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them.
Page 442 ATTACHMENTS AND OPTIONS HANDLE RADIO PRESET BUTTON If you register the desired stations to the preset button beforehand, you can select each station by touching this button once. It is possible to preset 6 stations each for both AM and FM. DISPLAY SELECTOR BUTTON Use the display selector button to change the display between frequency and clock.
Page 443 HANDLE RADIO ATTACHMENTS AND OPTIONS NOTICE • A stereo miniature plug can be connected. Read the instruction manual of the equipment to connect carefully. • As a power source, use the battery attached to the equipment to connect. If you use an electric power supply installed to the machine, the noise may occur. •...
Page 444: Method For Controlling Radio
ATTACHMENTS AND OPTIONS HANDLE RADIO METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency. Press the △ button, and the frequency increases; •...
Page 445 HANDLE RADIO ATTACHMENTS AND OPTIONS METHOD FOR REGISTERING PRESET Hold down one of 1 to 6 of preset button (1) while listening to the radio. The currently received frequency is registered to the preset number corresponding to the pressed button. “Example”...
Page 446: Stow Antenna
ATTACHMENTS AND OPTIONS HANDLE RADIO METHOD FOR ADJUSTING CLOCK Press display selector button (1) to display the clock. Hold down display selector button (1) to flash the “HOUR” display portion. You can adjust the hour. Press tuning/time adjustment button (2) to adjust the hour. If you press △...
Page 447: Control Patterns Other Than Standard Control Method (For Machines Equipped With Operation Pattern Change-Over Valve)
CONTROL PATTERNS OTHER THAN STANDARD CONTROL METH- OD (FOR MACHINES EQUIPPED WITH OPERATION PATTERN CHANGE-OVER VALVE) ATTACHMENTS AND OPTIONS CONTROL PATTERNS OTHER THAN STANDARD CON- TROL METHOD (FOR MACHINES EQUIPPED WITH OPER- ATION PATTERN CHANGE-OVER VALVE) WARNING • When operating the machine, check that the display of the control pattern card is matched to the operation of the machine to prevent personal injury by malfunction.
Page 448: Method For Changing Control Patterns
CONTROL PATTERNS OTHER THAN STANDARD CONTROL METH- OD (FOR MACHINES EQUIPPED WITH OPERATION PATTERN ATTACHMENTS AND OPTIONS CHANGE-OVER VALVE) ISO pattern Backhoe pattern METHOD FOR CHANGING CONTROL PATTERNS WARNING • When operating the machine, check that the display of the control pattern card is matched to the operation of the machine to prevent personal injury by malfunction.
Page 449 CONTROL PATTERNS OTHER THAN STANDARD CONTROL METH- OD (FOR MACHINES EQUIPPED WITH OPERATION PATTERN CHANGE-OVER VALVE) ATTACHMENTS AND OPTIONS Machine with canopy specification The control pattern card is located at the right side of the operator's seat. Machine with cab specification The control pattern card is located at the right side of the operator's seat.
Page 450: Attachments And Options
• Installing attachments or optional equipment without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the ma- chine and the life of the equipment.
Page 451: Recommended Attachment Operations
Select the optimum attachment model for the hydraulic excavator body. The attachments and models ready for installation differ according to the machine body. For details of the selection of the attachments or the models, consult your Komatsu distributor. HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows.
Page 452 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm {approximately 2 in} off the ground. Do not let the machine come further off the ground than this amount. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 453 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not use the mount to gather in pieces of rock. Do not work by using the swing force. Do not move the chisel while performing breaking operation. Do not perform breaker operation in horizontal or upward direc- tion.
Page 454 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Extending the bucket cylinder rod fully and thrusting to raise the machine off the ground Do not perform breaker work with any cylinder at the stroke end.
Page 455 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Grease the breaker while keeping it in the right posture shown below. Lower the chisel to the ground perpendicularly. Insert the grease pump perpendicularly to the greasing point. Wrong posture Do not perform greasing when the hydraulic breaker is lowered to the ground.
Page 456: Breakers
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS BREAKERS WARNING When the machine is used with the breaker installed, its safety decreases because the weight of the breaker is larger and the work contents of the breaker is less safe than that of the bucket. Do not operate the machine sharply since the machine may tip over.
Page 457 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not perform work where broken pieces fall onto the ma- chine. Do not work on a ground which cannot bear the machine weight or breaking impacts. Do not perform work near the undercarriage of the machine. Do not work while the machine is inclined on debris, etc.
Page 458 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Always face the material to be broken at right angles. If the breaker bites into the material diagonally, an excessive force is applied to it and the machine is damaged. Do not extend the bucket cylinder or arm cylinder sharply. Do not raise the boom sharply.
Page 460: Replacement Parts
REPLACEMENT PARTS...
Page 461: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses 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 defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 462: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 463: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 464: Lubrication Chart
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT LUBRICATION CHART • The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication interval. • Even if the same symbol is used in the lubrication chart, the recommended genuine oil may differ according to the lubrication points and the ambient temperature.
Page 465 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS Symbol Meaning of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Supply grease Manual. Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level Change engine oil filter...
Page 466: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
The coolant 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 coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 467: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
In this case, fill up the tank with pre-diluted fluid. (Never dilute the Non-Amine Engine Coolant with ordinary water.) RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 468: Index
INDEX INDEX Symbols Attachment - Set........... 3-56 Attachment 1 proportional switch......6-8 12H24H display mode - Switch......3-70 Attachment control pedal........6-7 Attachment lock cover..........6-7 Attachments and options........6-33 Auto idle stop timer - Set........3-59 Accumulator - Check function....... 4-94 Auto-deceleration function........3-39 Accumulator - Function.........
Page 469 INDEX Checks after inspection and maintenance....4-4 Dust indicator - Check.........3-135 Checks and adjustment before starting engine.... Dusty jobsite............4-3 .............2-26,3-131 Checks before starting........2-28,4-63 Clock - Adjust..........3-66,6-29 ECO gauge............3-36 Cold weather operation........3-229 ECO gauge - Set target fuel consumption value...3-52 Cold weather operation information....
Page 470 INDEX Explanation of radio equipment......6-24 General attachment such as crusher etc of machines with proportional lever - Operate....6-17 General attachment such as crusher, etc. - Check points when using.......... 6-15 Fan belt - Check tension / Replace.......4-83 General precautions common to operation and main- Filter................
Page 471 Machine - Stop............3-175 KDPF system caution lamp........3-22 Machine - Swing..........3-178 Keep machine clean..........2-14 Machine - Travel forward........3-171 Komatsu Diesel Particulate Filter (KDPF) - Handle..Machine - Travel reverse........3-173 ..............3-117 Machine - Unload..........3-224 Komatsu genuine lubricants........4-2 Machine equipment name........3-2...
Page 472 Precautions for towing and being towed....2-37 Precautions for towing machine......3-237 Precautions for transportation.......2-36 Precautions for transporting machine....3-219 Perform KOWA (Komatsu Oil Wear Analysis)..4-8 Precautions for traveling........3-188 Periodic replacement of defined life parts.....2-49 Precautions for traveling on slopes.......2-31 Permissible depth of water, soil and dirt.....
Page 473 Sound control button..........6-25 Pump - Bleed air........... 4-58 Specifications..........5-2,6-18 Pump secondary drive switch....... 3-83 Specifications - PC45MR-5........5-2 Specifications - PC55MR-5........5-4 Standard tightening torque for bolts and nuts..4-11 Radiator fin / Oil cooler fin / Fuel cooler fin / Condens- Start engine............2-26...
Page 474 INDEX Toolbox..............3-116 Towing and being towed........2-37 Transportation............. 3-219 Transportation method - Select......3-219 Travel lever............3-89 Travel speed display..........3-28 Travel speed selector switch.........3-81 Troubles and actions...........3-234 Tuning/time adjustment button......6-24 Two workers for maintenance when engine is running ...............2-41 Unauthorized modification........2-21 Understanding the machine........

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Komatsu PC45MR-5 Operation And Maintenance Manual

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