Page 1 WENAM00241 Operation & Maintenance Manual PC80MR- HYDRAULIC EXCAVATOR SERIAL NUMBERS PC80MR-5E0 F70001 and up WARNING ORIGINAL INSTRUCTIONS Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should...
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
Page 5: Komatsu Machine Operator Privacy Policy
Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un- der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to MMS.
Page 6 FOREWORD • pictures, videos and sound recordings 4. Why is your personal data processed? When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea- sons: (a) Safety and security (b) Warranty (c) Misuse and theft prevention...
Page 7 (30) days after having received the request. If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you remain unsatisfied with our response, you may file a complaint with the competent data protection authority.
Page 8: Safety Information
SAFETY INFORMATION FOREWORD 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 9: Safety Labels
Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for ques- tions regarding information in this manual.
Page 10: Noise
NOISE FOREWORD NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5 dB, in accordance with ISO 11201.
Page 11: Vibration Levels
FOREWORD VIBRATION LEVELS VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 12 VIBRATION LEVELS FOREWORD • Do not repeatedly handle and lift loads 1-10 WENAM00241...
Page 13: Introduction
FOREWORD INTRODUCTION 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 For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 14: Visibility From Operator's Seat
INTRODUCTION FOREWORD In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine. VISIBILITY FROM OPERATOR'S SEAT This machine complies with the visibility standard (ISO 5006).
Page 15: Protective Structures
FOREWORD INTRODUCTION Visibility map RKA67870 PROTECTIVE STRUCTURES This machine is equipped with a structure to protect the operator conforming to ISO12117-2:2008 (ROPS) and ISO10262:1998 (OPG). 1-13 WENAM00241...
Page 16: Recommendations About Emission Control System
Ignoring the caution lamps and messages will cause the engine performance will be derated, and opera- tions can not be performed. For details see OPERATION “CAUTION LAMP LIST” and “HANDLE Komatsu Diesel Particulate Filter (KDPF)”. 1-14...
Page 17: 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 right of swing bracket.
Page 18: Fluorinated Greenhouse Gases
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturer's name: Komatsu Italia Manufacturing S.p.A Address: Via Bergoncino, 28 36025 Noventa Vicentina (VI) Italy Distributor name Address...
Page 19: Serial Plate
FOREWORD SERIAL PLATE SERIAL PLATE Serial plate SERIAL NUMBER MODEL WEIGHT YEAR OF CONSTRUCTION PRODUCT IDENTIFICATION NUMBER ENGINE POWER MANUFACTURER Serial plate (Road homologation) TOTAL MAX. WEIGHT HOMOLOGATION No. 22E-98-31290 SERIAL NUMBER MANUFACTURER WEIGHT MODEL PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION HOMOLOGATION NUMBER ENGINE POWER 1-17...
Page 20: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Italia Manufacturing S.p.A. Via Bergoncino, 28 36025 Noventa Vicentina (VI) Italy Declares that this machine: PC80MR-5E0 Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive...
Page 21: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 KOMATSU MACHINE OPERATOR PRIVACY POLICY ................1-3 SAFETY INFORMATION .......................... 1-6 SAFETY LABELS ............................. 1-7 NOISE............................... 1-8 VIBRATION LEVELS ..........................1-9 VIBRATION - OPERATING CONDITION ................... 1-9 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............
Page 22 TABLE OF CONTENTS FOREWORD EXPLANATION OF COMPONENTS ......................3-9 EXPLANATION OF MACHINE MONITOR EQUIPMENT ..............3-9 SWITCHES ............................3-63 CONTROL LEVERS AND PEDALS ....................3-71 OTHER EQUIPMENT ........................3-76 MACHINE OPERATIONS AND CONTROLS ..................3-101 CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ............3-101 METHOD FOR STARTING ENGINE....................
Page 23 FOREWORD TABLE OF CONTENTS 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..................4-2 PRECAUTIONS FOR REFILLING OIL OR FUEL ................
Page 24 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 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 1-22 WENAM00241...
Page 25: 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. WENAM00241...
Page 26: 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 27: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS RKA83870 (1) Caution for work equipment (2) Danger do not enter within swing range WENAM00241...
Page 28: Contents Of Safety Labels
SAFETY LABELS SAFETY (3) Caution for high-temperature coolant and hydraulic (17) Caution for overload machine (18) Control levers operational function diagram (4) Caution for adjusting track tension (19) Caution when standing in operator's cab (5) Caution stop rotation during inspection and mainte- (20) Caution when stowing front window nance (21) Emergency escape...
Page 29 SAFETY SAFETY LABELS (3) Caution for high temperature coolant and hydraulic oil (09653-A0481) • Never remove the cap when the engine is at operating (high) temperature. Steam or high temperature oil blowing up from the radiator or hydraulic tank will cause personal injury and/or burns.
Page 30 SAFETY LABELS SAFETY (6) Caution for handling cable (09808-A0881) • Sign indicates an electric hazard from handling the cable. • Read manual for safe and proper handling. (7) Battery main switch (22E-98-21141) (8) Caution for handling accumulator and gas spring (09659-A057B) •...
Page 31 SAFETY SAFETY LABELS (11) Warning for operation, inspection and maintenance (09651-A0481) Read the manual before operating, inspection, maintenance, disassembly, assembly and transportation. 09651-A0481 (12) Warning when leaving the operator's seat (09654-A0841) • Before standing up from operator's seat. • Lower the work equipment to the ground and move safety lock lever (located near seat) to lock position to avoid hit- ting unlocked operation levers.
Page 32 SAFETY LABELS SAFETY (14) Lifting and fastening decals for transport (22P-00-11630) (15) Warning when reversing (09802-A0480) To prevent SEVERE INJURY or DEATH, do the following be- fore moving machine or its attachments: • Sound horn to alert people nearby. Be sure no one is on or near machine or in swing area. Rotate cab for full view of travel path if it can be done safe- Use spotter if view is obstructed.
Page 33 SAFETY SAFETY LABELS 3rd line attachment: 22E-98-31260 22E-98-31150 (17) Caution for overload machine Do not exceed the specified lifting load. Standard boom: 22E-98-31160 2-piece boom: 22E-98-31180 3rd line attachment: 22E-98-31270 22E-98-31160 (18) Control levers operational function diagram (22E-98-31240) 22E-98-31240 (19) Caution when standing in operator cab (09839-A0481) •...
Page 34 SAFETY LABELS SAFETY • Before standing up from the operator's seat (such as when opening or closing the front window, or when removing or installing the bottom window, or when adjusting the opera- tor's seat), always lower the work equipment completely to the ground, set lock lever securely to the LOCK position (L), then stop the engine.
Page 35 SAFETY SAFETY LABELS (21) Emergency escape (09844-00050) (22) Attachment connection with hydraulic quick coupler (22N-98-31930) DANGER If the hydraulic quick coupler connection decal (code 22N-98-31930) is not present on the machine, check for a similar decal of the quick coupler manufacturer. Refer to the instructions in the quick coupler manufacturer 22N-98-31930 manual considering the operations following as a guide...
Page 36 ROPS may provide less protection if it has been structural- ly damaged or involved in roll-over. 22E-54-22412 Produced by Komatsu Italia Manufacturing S.p.A. Via Bergoncino 28, 36025 Noventa Vicentina (VI), Italy • Always wear seat belt when moving. (26) Caution for handling battery...
Page 37 SAFETY SAFETY LABELS (d) Caution battery acid. (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases. (27) Lock lever automatic lock cancel and pump secondary drive switches (22N-98-53730) For details see OPERATION “SWITCHES”. (28) Caution for high-pressure fuel (6271-81-2981) 6271-81-2981 2-13...
Page 38 SAFETY LABELS SAFETY (29) Warning for quick coupler system (22N-98-53830) • There is a danger of an exposed person being killed by falling attachment. • Read the manual for safe operation. 2-14 WENAM00241...
Page 39: 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 40: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY KEEP MACHINE CLEAN • If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 41 If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage the hoses and cause the high-pressure oil to spurt out, leading to fire and personal injury. Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). 2-17 WENAM00241...
Page 42: Precautions When Getting On Or Off Machine
Be sure to securely tighten the loosen bolts of the handrail. If the handrail is broken or deformed, it should be repaired immediately. Ask your Komatsu distributor to perform this work. • Do not grip the control levers or lock lever when getting on or off the machine.
Page 43 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 to the ground, set the lock lever to LOCK position (L), and stop the engine.
Page 44: Do Not Get Caught In Work Equipment
• 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 45: Unauthorized Modification
NANCE 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 46: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 47 SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 48: Start Engine
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. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 49 SAFETY PRECAUTIONS FOR OPERATION • Before starting the engine, check that lock lever is in LOCK position (L). • Adjust the mirrors so that the rear of the machine can be seen easily from the operator's seat. • Adjust the angle of camera (if installed) so that the sur- rounding area can be seen clearly from the operator's seat.
Page 50: 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 51 SAFETY PRECAUTIONS FOR OPERATION • Always operate the machine only when seated on the operator's seat. • Before starting to move, check again that there is no people or obstacle in the surrounding area. • Before moving, sound the horn to warn people in the surrounding area.
Page 52 PRECAUTIONS FOR OPERATION SAFETY • When passing over bridges or structures, check first that the structure is strong enough to support the weight of the machine. When passing on a public road, check with authorities concerned and observe their instruction. •...
Page 53 SAFETY PRECAUTIONS FOR OPERATION • 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 54 PRECAUTIONS FOR OPERATION SAFETY • Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall. • For a quick escape in an emergency, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when performing operations.
Page 55: 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 56: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY • Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. (1) Chocks (2) Ramp (3) Ramp width...
Page 57: Lifting Operation By Using Lifting Device (Optional Equipment)
SAFETY PRECAUTIONS FOR OPERATION • Use wire rope that conforms to the specified standard. • Do not perform any lifting operation with a load heavier than the specified lifting load. It may cause a seri- ous accident such as tipping over of the machine. •...
Page 58 PRECAUTIONS FOR OPERATION SAFETY • Do not swing or operate the work equipment suddenly. There is a danger that this may cause the load to swing and the machine to become unstable or tip over. • Do not leave the operator's seat while the load is being lifted. •...
Page 59 SAFETY PRECAUTIONS FOR OPERATION • If the load is to be lifted at a height where this is not possi- ble, the sling or chain must only be guided by the back wall of the bucket and not any other part of the machine. 2-35 WENAM00241...
Page 60: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 61 SAFETY PRECAUTIONS FOR MAINTENANCE • Lower the work equipment to the ground and stop the en- gine before performing any inspection and maintenance. • Turn the starting switch to ON position. Operate the work equipment control lever back and forth, right and left a few times fully to release the remaining internal pressure in the hydraulic circuit.
Page 62 PRECAUTIONS FOR MAINTENANCE SAFETY • Release the remaining pressure in the hydraulic system, and place lock lever to LOCK position (L). • Do not touch the control levers or pedals. When it is nec- essary to operate the control levers or pedals, always give a signal to your fellow workers to evacuate them to a safe place.
Page 63: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE • It is extremely dangerous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment. If any of the con- trol levers is touched by accident, or there is damage oc- curring to the hydraulic piping, the work equipment or the machine will suddenly fall.
Page 64 PRECAUTIONS FOR MAINTENANCE SAFETY • Do not use or charge the battery if the battery electrolyte is below LOWER LEVEL mark. This may cause an explosion. Always perform periodic inspection of the battery electrolyte level, and add purified water (such as a commercial battery fluid) to UPPER LEVEL mark. •...
Page 65 SAFETY PRECAUTIONS FOR MAINTENANCE • If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, pieces might be scattered, and it may cause serious personal injury or death. Always wear protective eyeglasses and gloves. •...
Page 66 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 67 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. HANDLE ACCUMULATOR AND GAS SPRING This machine is equipped with an accumulator.
Page 68 • 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 69: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section. WENAM00241...
Page 70: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME RKA67920 WENAM00241...
Page 71 OPERATION GENERAL VIEW (1) Bucket (14) Cabin door (2) Bucket cylinder (15) Revolving lamp (if equipped) (3) Arm (16) Working lamp (4) Arm cylinder (17) Working lamp on arm (if equipped) (5) Boom (18) Working lamp on arm (6) Boom cylinder (19) Dirt cover (7) Blade (20) Engine rear cover...
Page 72: Controls And Gauges Names
GENERAL VIEW OPERATION CONTROLS AND GAUGES NAMES RKA67940 (1) Lock lever (9) Machine monitor (2) L.H. work equipment control lever (10) R.H. work equipment control lever (3) 2-piece boom control pedal (if equipped) (11) Travel speed selector switch (4) Wiper switch (12) Blade control lever (5) Travel pedal (13) Temperature control switch...
Page 73 OPERATION GENERAL VIEW (17) Lamp switch (26) Breaker operation switch (18) Starting switch (27) Room lamp switch (19) Quick coupler activation switch (if equipped) (28) Pump secondary drive switch (20) Revolving lamp switch (if equipped) (29) Lock lever automatic lock cancel switch (21) Quick coupler switch (if equipped) (30) Engine shutdown secondary switch (22) 2nd/3rd line attachment proportional switch (if...
Page 74 GENERAL VIEW OPERATION (13) Engine coolant temperature caution lamp (17) Lock lever automatic lock cancel pilot lamp (14) Aftertreatment devices regeneration pilot lamp (18) Lock lever pilot lamp (15) Aftertreatment devices regeneration disable pilot (19) Seat belt caution lamp lamp (16) Preheating pilot lamp REMARK The above figure does not show all of the caution lamp symbols.
Page 75: Other Equipment Name
OPERATION GENERAL VIEW OTHER EQUIPMENT NAME RKA82370 (1) Front window (6) Fuse (2) Ceiling window (7) Emergency escape hammer (3) Door (8) Small slide window (4) Door lock release lever (9) Fire extinguisher (if equipped) (5) Power supply outlet (10) Cup holder WENAM00241...
Page 76 GENERAL VIEW OPERATION (11) Fusible link (13) Tool boxes (12) Ashtray (if equipped) WENAM00241...
Page 77: 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 78 EXPLANATION OF COMPONENTS OPERATION 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. BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While the engine shutdown secondary switch is in ON (engine is stopped) position (a), when the starting switch is turned to...
Page 79 EXPLANATION OF COMPONENTS 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 80 EXPLANATION OF COMPONENTS OPERATION 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 81 OPERATION EXPLANATION OF COMPONENTS For checking the details of error, press function switch “F3”, and then existing error list screen is displayed. 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. •...
Page 82 EXPLANATION OF COMPONENTS OPERATION If there is any error existing, “!” is displayed on top of switch “F3”. For checking the details of error, press function switch “F3”, and then existing error list screen is displayed. 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.
Page 83 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 84 EXPLANATION OF COMPONENTS OPERATION CAUTION LAMP LIST NOTICE • These caution lamps do not guarantee the condition of the machine. Do not simply rely on the caution lamp when performing check before starting (start-up inspection). Always get off the machine and check each item directly. •...
Page 85 OPERATION EXPLANATION OF COMPONENTS Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue Low oil pressure Engine oil pressure caution lamp (L03) Air cleaner clogging caution Clogged lamp Abnormal Charge level caution lamp (L03) Hydraulic quick Hydraulic quick coupler cau- coupler system tion lamp...
Page 86 EXPLANATION OF COMPONENTS OPERATION Operation on “Current Abnormality” screen On “Current Abnormality” screen, you can perform the following operations with function switches “F1”, “F2”, and “F3”. Function switch “F1” Displays the next page. When on the last page, it displays the first page.
Page 87 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 88 When action level “L03” is displayed 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.
Page 89 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 90 • 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 91 When there is an abnormality: The caution lamp lights up in red and the alarm buzzer sounds intermittently and indicates action level “L03”. Stop the machine immediately and ask your Komatsu distribu- tor for inspection. REMARK RKA48750 This indicator comes on with a red light also when the quick coupler locking/unlocking operations are carried out.
Page 92 EXPLANATION OF COMPONENTS OPERATION 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 93 OPERATION EXPLANATION OF COMPONENTS AUTO-DECELERATION PILOT LAMP The auto-deceleration pilot lamp shows the setting of the auto- deceleration function either ON or OFF. The pilot lamp display when the auto-deceleration switch is op- erated is as follows. Auto-deceleration pilot lamp lights up Auto-deceleration is turned on Auto-deceleration pilot lamp goes out Auto-deceleration is turned off...
Page 94 EXPLANATION OF COMPONENTS OPERATION “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” ATT/E mode (For operations emphasizing fuel consumption out of those of 2-way attachments like crusher) (For machines ready for installation of attachment) TRAVEL SPEED DISPLAY...
Page 95 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. 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.
Page 96 EXPLANATION OF COMPONENTS OPERATION The aftertreatment devices regeneration pilot lamp lights up during regeneration of the exhaust gas aftertreatment devices. It goes out when the regeneration is completed. AFTERTREATMENT DEVICES REGENERATION DISABLE PILOT LAMP Aftertreatment devices regeneration disable pilot lamp lights up when the aftertreatment devices are set not to be regenerated.
Page 97 OPERATION EXPLANATION OF COMPONENTS 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 98 EXPLANATION OF COMPONENTS OPERATION REMARK • The graduation of gauge may not indicate correctly for a short time after the starting switch is turned to ON position, but this is not an abnormality. • The graduation of gauge may not indicate correctly for a short time when the machine is operated on a slope or it is stopped, but this is not an abnormality.
Page 99 OPERATION EXPLANATION OF COMPONENTS 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 100 EXPLANATION OF COMPONENTS OPERATION When monitor display is standard screen The types of guidance icons and functions of function switches are as follows. For the details of each function, see the detailed explanation of each item. Function switch “F1” Display/non-display of auto-deceleration pilot lamp can be switched.
Page 101 OPERATION EXPLANATION OF COMPONENTS REMARK • Even if some icons look the same, their display positions and corresponding function switches may differ in accordance with the screens to be displayed. • For the guidance icons and their functions not explained previously, see the pages where the control meth- ods of respective screens are explained.
Page 102 When the working mode is changed and screen returns to the standard screen, auto-deceleration function is automatically selected. Ask your Komatsu distributor to change the setting if you want to have the automatic setting of “P”, “E”, “L”, “B”, “ATT/P” or “ATT/E” modes (optional default setting) when starting the engine.
Page 103 OPERATION EXPLANATION OF COMPONENTS When buzzer cancel icon is displayed, if you press function switch “F8”, alarm buzzer for abnormality of warning items stops sounding. REMARK The buzzer cannot be stopped depending on the content of the warning. USER MENU On the standard screen, press switch “F4”...
Page 104 EXPLANATION OF COMPONENTS OPERATION (B) “Machine Setting” • “Breaker Setting” (if equipped) • “Attachment Setting” (if equipped) • “Auto Idle Stop Timer Set” RKA83630 (C) “Aftertreatment Devices Regeneration” • Setting for“Regeneration Disable” • Operation of “Manual Stationary Regeneration” RKA83640 (D) “NOx Control System Info” •...
Page 105 OPERATION EXPLANATION OF COMPONENTS (G) Mail check • Check of mail contents and reply to mail RKA83660 On the user menu screen, you can perform the following opera- tions with function switches “F1” to “F4”, “F6”, and “F7”. Function switch “F1” Moves to the next item (1 line below).
Page 106 EXPLANATION OF COMPONENTS OPERATION CHECK OPERATING RECORD Select “Operation Records” on “Working Record” menu screen, and then press function switch “F4”. If you select each item of “Operation Records” screen, each data on daily basis or on a split measurement period basis are displayed at the bottom.
Page 107 OPERATION EXPLANATION OF COMPONENTS REMARK The displayed value of fuel consumption and the fuel consumption rate may differ from the actual value due to the operating conditions of the customers (fuel, weather or work contents, etc.). Switching of displayed graph On “Ave Fuel Consumpn Record”...
Page 108 EXPLANATION OF COMPONENTS OPERATION 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” screen. REMARK Press function switch “F3” to cancel the data deletion (clear) operation.
Page 109 OPERATION EXPLANATION OF COMPONENTS 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. Select “Ave Fuel Consumption Display” on “Configura- tions” menu screen, and then press function switch “F4”. “Ave Fuel Consumption Display”...
Page 110 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 111 OPERATION EXPLANATION OF COMPONENTS Function switch “F1” Moves to the next item (1 line below). When on the last line, it moves to the first line. Function switch “F2” Moves to the previous item (1 line above). When on the first line, it moves to the last line. Function switch “F3”...
Page 112 EXPLANATION OF COMPONENTS OPERATION • “Breaker Setting” (if equipped) • “Attachment Setting” (if equipped) • “Auto Idle Stop Timer Set” RKA83630 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 113 OPERATION EXPLANATION OF COMPONENTS 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. You can use alphabet letters (A to Z), Arabic numerals (0 to 9), symbols (#, *, +, -, and /), and the blank (space).
Page 114 EXPLANATION OF COMPONENTS OPERATION 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 115 OPERATION EXPLANATION OF COMPONENTS “Attachment Setting” screen is displayed. Select proper setting matching to the installed attachment on “Attachment Setting” screen, and then press function switch “F4”. Setting of ATT/P and ATT/E mode is changed. On “Attachment Setting” screen, you can perform the fol- lowing operations with function switches “F1”...
Page 116 EXPLANATION OF COMPONENTS OPERATION “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”. Function switch “F1” Moves to the previous alphabet, numeral, or symbol. Function switch “F2”...
Page 117 OPERATION EXPLANATION OF COMPONENTS Function switch “F4” Enters the flow rate setting and returns the screen to “Attachment Setting” screen. Function switch “F6” Decreases the flow rate by 1 level. Function switch “F7” Increases the flow rate by 1 level. It is not possible to change the flow rate for “No Attachment”...
Page 118 EXPLANATION OF COMPONENTS OPERATION Function switch “F4” The screen changes to “Auto Idle Stop Timer Set” confirmation screen. REMARK • If you select “OFF”, the auto idle stop function does not operate. • You cannot select a time longer than that specified in the service menu. “Auto Idle Stop Timer Set”...
Page 119 OPERATION EXPLANATION OF COMPONENTS When countdown continues and reaches 0, the engine stops and the guidance icon on the bottom right lights up in red. If you press the function switch “F4”, the screen changes to “Auto Idle Stop in Operation” screen. Turn off the unnecessary switches according to the screen instructions.
Page 120 • 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 121 OPERATION EXPLANATION OF COMPONENTS “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 122 EXPLANATION OF COMPONENTS OPERATION Operate the function switches “F3”, “F4”, “F6”, “F7”, and “F8” to adjust the brightness of the screen. Function switch “F3” Cancels the change of brightness of the screen and the screen returns to “Monitor Setting” menu screen. Function switch “F4”...
Page 123 OPERATION EXPLANATION OF COMPONENTS When on the first line, it moves to the last line. Function switch “F3” Returns the screen to “Monitor Setting” menu screen. Function switch “F4” Displays the setting screen for the selected item. REMARK • “Calendar” and “Time” need to be readjusted since they are reset after a long-term storage. •...
Page 124 EXPLANATION OF COMPONENTS OPERATION REMARK • When the machine is in the environment where the radio waves from GPS cannot be received, such as inside of a building, the automatic adjustment may not function. • While “GPS Synchronization” is turned “ON”, the item of “Calendar” and “Time” cannot be selected. CALENDAR SETTING Perform the setting of calendar after starting the engine.
Page 125 OPERATION EXPLANATION OF COMPONENTS Select “Time” on “Clock Adjustment” menu screen, and then press function switch “F4”. “Time” screen is displayed. Change the time according to the following operation. You can change the numeral displayed in yellow. Function switch “F1” Puts back the numeral by 1.
Page 126 EXPLANATION OF COMPONENTS OPERATION Function switch “F1” Moves to the next item (1 line below). When on the last line, it moves to the first line. Function switch “F2” Moves to the previous item (1 line above). When on the first line, it moves to the last line. Function switch “F3”...
Page 127 OPERATION EXPLANATION OF COMPONENTS LANGUAGE SETTINGS Set the 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, Serbian, and Turkish Select “Language”...
Page 128 MESSAGE DISPLAY 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”. RKA83670 Message is distinguished as follows according to the lighting states of the message display.
Page 129 • 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 130 EXPLANATION OF COMPONENTS OPERATION REPLY TO MESSAGE If a message requests reply, press function switch “F4”, and the screen moves to the screen for replying to the message. On the screen for replying to the message, input the num- ber of selected item as an input value. The number of selected item is written in place (1) of the message text on mail confirmation menu screen.
Page 131: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES RKA68060 (1) Wiper switch (12) 2nd/3rd line attachment proportional switch (if equipped) (2) Travel speed selector switch (13) 2nd line activation switch (if equipped) (3) Temperature control switch (*) (14) Horn switch (4) Air flow selector switch (*) (15) 1st line attachment proportional switch (5) Air conditioner switch (*) (16) Breaker operation switch...
Page 132 EXPLANATION OF COMPONENTS OPERATION 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 133 OPERATION EXPLANATION OF COMPONENTS 1ST LINE ATTACHMENT PROPORTIONAL SWITCH The 1st line attachment proportional switch is used to operate the attachment. For handling of the 1st line attachment proportional switch, see section “ATTACHMENTS AND OPTIONS”. 2ND LINE ACTIVATION SWITCH The 2nd line activation switch is used to activate the 2nd line. For handling of this switch, see ATTACHMENTS AND OP- TIONS.
Page 134 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 135 OPERATION EXPLANATION OF COMPONENTS The travel speed is automatically set to low-speed travel (Lo) when the starting switch key is turned to ON position. Each time the travel speed selector switch is pushed, travel mode changes repeatedly as Lo → Hi → Lo. Check the travel mode setting at travel speed display on the machine monitor.
Page 136 EXPLANATION OF COMPONENTS OPERATION Use room lamp switch to light up the room lamp. It does not light up when the starting switch is at OFF position. (a), (b) ON position Lights up (c) OFF position PUMP SECONDARY DRIVE SWITCH NOTICE •...
Page 137 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. 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.
Page 138 EXPLANATION OF COMPONENTS OPERATION Raise cover (1) and open it. Turn the engine shutdown secondary switch to “ENGINE STOP” position (a) and the engine stops. (a) ENGINE STOP When abnormal (switch is set to upper position) (b) NORMAL When normal (switch is set to lower position) •...
Page 139: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS RKA68070 (1) Lock lever (4) Swing lock cover (2) L.H. work equipment control lever (5) Boom swing control pedal (3) 2-piece boom control pedal (if equipped) (6) R.H. work equipment control lever (3) Travel lever (with pedal) (7) Blade control lever LOCK LEVER...
Page 140 • 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 141 OPERATION EXPLANATION OF COMPONENTS If you press function switch “F3” on “Lock Lever Auto Locked” screen, the screen returns to the pop-up display screen of it. To cancel the lock lever automatic lock function, return the lock lever to LOCK position (L) according to “Lock Lever Auto Locked”...
Page 142 EXPLANATION OF COMPONENTS OPERATION The travel lever is used to change the direction of travel be- tween forward and reverse. ( ) shows the pedal operation. (a) FORWARD The lever is pushed forward (The front side of pedal is depressed) (b) REVERSE The lever is pulled back (The rear side of pedal is depressed)
Page 143 OPERATION EXPLANATION OF COMPONENTS BOOM SWING CONTROL PEDAL Boom swing control pedal is used to swing the boom. (a) Swing RIGHT Depress right of the boom swing control pedal. (b) Swing LEFT Depress left of the boom swing control pedal. (N) NEUTRAL Boom is held at current position.
Page 144: Other Equipment
EXPLANATION OF COMPONENTS OPERATION OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING CAB FRONT WINDOW 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 145 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 146 EXPLANATION OF COMPONENTS OPERATION Set the lock lever securely to LOCK position (L). Be sure to operate the lock lever by the operating portion on the top. Hold the right and left handles (1) at the center part of front window (inside).
Page 147 OPERATION EXPLANATION OF COMPONENTS EMERGENCY ESCAPE HAMMER CAUTION • If it is necessary to break the window glass with the hammer, be extremely careful not to get injured with scattered pieces of broken glass. • To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through the window.
Page 148 EXPLANATION OF COMPONENTS OPERATION CAB DOOR HANDLE Pull the cab door handle (1) while it is not locked, and the door opens to the full open position. OPEN KNOB FOR CAB DOOR Pull the open knob for the cab door, and the cab door opens to the full open position.
Page 149 OPERATION EXPLANATION OF COMPONENTS CUP HOLDER The cup holder is located on the rear right of the operator's seat. RKA82650 ASHTRAY An ashtray is located on the right side of the operator's seat. It is magnet type, so you can install it to appropriate place each time.
Page 150 EXPLANATION OF COMPONENTS OPERATION Fuse capacities and circuit names No. Capacity Name of circuit TVC resistor power, service connector, work 5 A lamp switch connector, relay work lamp 10 A Quick coupler switch, power for solenoid valve 5 A PPC lock switch Room lamp, radio, windshield wiper, rear wind- 10 A shield (if equipped) Power PPC lever switches, buzzer, travel speed,...
Page 151 OPERATION EXPLANATION OF COMPONENTS REMARK A fusible link is the large-sized fuse wiring installed in the high current flowing part of the circuit. It protects electrical parts and wiring from burning out due to abnormal current, in the same way as an ordinary fuse.
Page 152 EXPLANATION OF COMPONENTS OPERATION If the operator sees the need to have the fire extinguisher avail- able on the machine, he must provide for its installation, secur- ing behind the operator's seat. RKA82660 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.
Page 153 OPERATION EXPLANATION OF COMPONENTS Battery disconnect switch is installed in the box on the left side of the machine and it is used to cut out the electricity from the battery. REMARK Operate this switch while system operating lamp is OFF. RKA68150 RKA68140 (O): OFF position...
Page 154 If the data are lost, when you try to start the engine next time, “L04” is displayed on the machine moni- tor and the engine may not start. If the engine cannot be started, ask your Komatsu distributor for inspection and repair. REMARK •...
Page 155 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 156 EXPLANATION OF COMPONENTS OPERATION 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 157 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 158 EXPLANATION OF COMPONENTS OPERATION 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 159 OPERATION EXPLANATION OF COMPONENTS 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 RKA83920 REMARK...
Page 160 EXPLANATION OF COMPONENTS OPERATION • 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 161 OPERATION EXPLANATION OF COMPONENTS 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 162 EXPLANATION OF COMPONENTS OPERATION On the user menu, press function switches “F6” and “F7” to display“Aftertreatment Devices Regeneration” screen. RKA83930 Select “Regeneration Disable” on “Aftertreatment Devices Regeneration” screen, and then press function switch “F4”. “Regeneration Disable” confirmation screen is displayed. RKA83940 On “Regeneration Disable”...
Page 163 OPERATION EXPLANATION OF COMPONENTS While regeneration is being performed: Regeneration is disabled When aftertreatment devices regeneration pilot lamp (1) is displayed on the standard screen On the standard screen, if you press function switch “F4”, “Aftertreatment Devices Regeneration” screen is dis- played.
Page 164 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 165 “L04 (Se- vere Inducement)” is displayed. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “NOx Con- trol System Info”...
Page 166 EXPLANATION OF COMPONENTS OPERATION “NOx Control System Info” screen message (5): “2 EGR system inspection and maintenance”. NOx Control System Info Move the machine to the safe place and contact your Ko- EGR system has abnormality. matsu Distributor. The duration of “Escalated Warning” is 36 hour. The re- EGR system inspection and maining time (Minutes) to “Mild Inducement”...
Page 167 Komatsu may suspend KOMTRAX communication in the following cases. • When Komatsu judges that KOMTRAX is used by an unregistered customer. • When Komatsu judges that KOMTRAX is used in a country or region where its use is not authorized. 3-99 WENAM00241...
Page 168 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 169: 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 170 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 171 OPERATION MACHINE OPERATIONS AND CONTROLS Remove screws (1) and cover (2). Place a container under drain hose to receive fuel. RKA68120 Open drain valve (3) to discharge the sediment and water in the bottom together with the fuel. Be careful not to get fuel on yourself. When clean fuel flows out, close drain valve (3).
Page 172 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • If transparent cup (4) is dirty or it is difficult to see the inside, clean transparent cup (4) when replacing fuel pre-filter cartridge (3). • When the drain valve (7) has been removed during the cleaning operation, coat O-ring with grease and tighten until it contacts the bottom.
Page 173 OPERATION MACHINE OPERATIONS AND CONTROLS Lock securely with cover support lever (2). Check the oil level through sight gauge (G). If the oil level is in the range shown below, it is proper. State A: Within range "a" State B: Within range "b" If the oil level is below level L, the hydraulic oil is insuffi- cient.
Page 174 MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever securely to LOCK position (L). Stop the engine. By doing so, the hydraulic tank is pressurized. NOTICE If the hydraulic tank is not pressurized, air is sucked in the pump and it affects the components badly.
Page 175 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.
Page 176 • 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 177 OPERATION MACHINE OPERATIONS AND CONTROLS When the fuel level caution lamp lights up in red, check the fuel level with fuel level gauge (2) on the monitor. When the fuel gauge pointer indicates the red range, the fuel quantity is 20 ℓ or less. After checking, turn the starting switch (1) back to OFF po- sition.
Page 178 Check that the filter placed at the end of the pipe is clean. • In case of malfunction of the refilling automatic stop system, consult the Komatsu local Distributor and do not use the system until the problem is solved.
Page 179 OPERATION MACHINE OPERATIONS AND CONTROLS Open the dirt cover (1) fully and it will be secured by the cover support lever (2). Take out hose (3) from the box beside hydraulic tank and insert it in the fuel barrel placed close to the machine. Remove the cap of the fuel tank (F).
Page 180 After checking, turn the starting switch back to OFF posi- tion. If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. METHOD FOR CHECKING HORN Turn the starting switch to ON position.
Page 181 OPERATION MACHINE OPERATIONS AND CONTROLS Method for tilting seat Operate the lever (2) to tilt the seat to the desired position, and then release the lever. Tilt adjustment range: -8°, -3°, 0°, +3°, +8° (5 stages) Height adjustment: -37 mm, +23 mm REMARK The backrest can be tilted to a greater degree by pushing the seat forward.
Page 182 MACHINE OPERATIONS AND CONTROLS OPERATION Method for reclining backrest Pull up reclining adjustment lever (3) and set the backrest to a position which is comfortable for operation, then release reclin- ing adjustment lever (3). REMARK Sit with your back against the backrest when adjusting. If your back is not touching the backrest, it may suddenly move for- ward.
Page 183 OPERATION MACHINE OPERATIONS AND CONTROLS Mirrors (A) and (A1) Front left mirrors Mirror (B) Right side mirror RKA68520 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRRORS Adjust the mirror support in a way that will enable you to see the people in the rear left hand side with the mirror (A) and in the lateral front right hand side with the mirror (A1).
Page 184 MACHINE OPERATIONS AND CONTROLS OPERATION Adjust the mirror (A) so that the side of the machine is re- flected in the mirror as shown in the figure. Adjust the mirror (A1) in a way that will enable to view all the front of machine.
Page 185 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the right side mirror in such a way that the operator seated in its seat is able to view the machine rear side and per- sons standing at a distance of 1 m from the machine. RKA68540 Adjust the mirror so that the rear side of the machine is re- flected in the mirror as shown in the figure.
Page 186 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR FASTENING SEAT BELT Hold grip (2) and pull out the belt from retractable device (1). Check that the belt is not twisted, and then inset tongue (3) into buckle (4) securely. Pull the belt lightly to check that it is properly set. REMARK •...
Page 187 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the lock lever is se- curely at LOCK position. RKA63490 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 188: Method For Starting Engine
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 189 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not turn the starting motor continuously for 20 seconds or longer. If the engine does not start, wait for 2 minutes or so, and then try to start the engine again. RKA63490 Check that lock lever (1) is at LOCK position (L). If lock lever (1) is at FREE position (F), the engine does not start.
Page 190: Method For Operations And Checks After Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION If the preheating pilot lamp does not light up, or it lights up and then goes out to inform that the engine preheating has been completed, turn the key in starting switch (3) to START position (C). The engine starts.
Page 191 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 192 MACHINE OPERATIONS AND CONTROLS OPERATION 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 193 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 the lock lever (2) to LOCK position (L). Operate the following levers and pedals, and check that the machine does not move.
Page 194 MACHINE OPERATIONS AND CONTROLS OPERATION Set the working mode to P mode on the machine monitor (1). It quickens the warm-up of the hydraulic component. For the working mode setting, see “WORKING MODE SE- LECTION”. Move the lock lever (2) slowly and securely to FREE posi- tion (F).
Page 195 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), perform warm-up operation for hydraulic system in cold weather.
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION Boom operation RAISE (h) ←→ LOWER (j) Arm operation IN (f) ←→ OUT (g) Bucket operation CURL (m) ←→ DUMP (k) Swing operation RIGHT (d) ←→ LEFT (e) RKA64020 Travel (Lo) operation FORWARD (n) ←→ REVERSE (p) Boom swing operation RIGHT (q) ←→...
Page 197: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Attachment operation For attachment operations (if equipped), change the work- ing mode to the attachment mode (ATT). Warm-up operation for hydraulic component is completed. METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stop- ping the engine.
Page 198: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION REMARK When the key in starting switch (1) is turned to OFF posi- tion (A), the engine stops but the power supply to the ma- chine is not turned off immediately. The controller terminates the system after recording the operation state of the machine.
Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TRAVELING FORWARD Move the lock lever (1) slowly and securely to FREE posi- tion (F). RKA63590 RKA63210 Set the machine state in the posture shown in the figure. Operate the R.H. and L.H. work equipment control lev- ers (2) and (3), and raise the work equipment to the height (a) of 40 to 50 cm.
Page 200 (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. 3-132 WENAM00241...
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TRAVELING REVERSE Move the lock lever (1) slowly and securely to FREE posi- tion (F). RKA63590 RKA63210 Set the machine state in the posture shown in the figure. Operate the R.H. and L.H. work equipment control lev- ers (2) and (3), and raise the work equipment to the height (a) of 40 to 50 cm.
Page 202 (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. METHOD FOR STOPPING MACHINE Avoid a sudden stop. Stop the machine gradually.
Page 203: Method For Steering Machine
OPERATION MACHINE OPERATIONS AND CONTROLS Set right and left travel levers (1) in NEUTRAL position (N). The machine stops. RKA63601 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).
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION (A) Left turn in forward Push the right travel lever forward. The machine turns left in forward. (B) Left turn in reverse Pull the right travel lever backward. The machine turns left in reverse. REMARK When turning right, read the preceding procedure by replacing the word "left"...
Page 205: Method For Swinging Machine
OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION FOR COUNTER-ROTATION TURN • Counter-rotation turn to left Pull the left travel lever toward you. Push the right travel lever forward. The machine make a counter-rotation turn to the left. • Counter-rotation turn to right Pull the right travel lever toward you.
Page 206: Method For Operating Work Equipment
MACHINE OPERATIONS AND CONTROLS OPERATION Move L.H. work equipment control lever (1) to the right and left. The upper structure swings. (a) Swing RIGHT The upper structure swings to the right. (b) Swing LEFT The upper structure swings to the left. When you do not swing the upper structure, set L.H.
Page 207 OPERATION MACHINE OPERATIONS AND CONTROLS • Arm operation Move the L.H. work equipment control lever back and forth. Arm moves in or out. • Boom operation Move the R.H. work equipment control lever back and forth. Boom moves up or down. 3-139 WENAM00241...
Page 208 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 209: Handle Working Mode
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 210: Prohibited Operations
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATING WORKING MODE Press function switch “F5” on the standard screen of ma- chine monitor. The screen changes to “Working Mode” screen. On “Working Mode” screen, press function switches “F1”, “F2”, and “F5” to select the appropriate working mode. After selecting the working mode, press function switch “F4”.
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF OPERATIONS USING HYDRAULIC CYLINDERS TO STROKE If the work equipment is used with the cylinder rod operated to its stroke end (fully extended or fully retracted), and given im- pact by some external force, the hydraulic cylinders may be damaged, causing personal injury.
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING MACHINE DROPPING FORCE Do not use the dropping force of the machine for digging. 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.
Page 213 OPERATION MACHINE OPERATIONS AND CONTROLS In this case, prepare an embankment, etc. in front of the track to stabilize the machine. PROHIBITION OF SWINGING OR TRAVELLING 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 214 MACHINE OPERATIONS AND CONTROLS OPERATION 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 215: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELING Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the under- carriage), and this will cause damage to the machine. For this reason, always remove any obstacles or drive the machine around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION 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 217: Precautions For Working On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS 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 218: Method For Escaping From Mud
MACHINE OPERATIONS AND CONTROLS OPERATION 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, and drive the machine.
Page 219: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ESCAPING WHEN TRACKS ON BOTH SIDES ARE STUCK When the tracks on both sides get stuck, pull out the machine according to the following procedure. Place logs, wooden blocks, etc. under the tracks according to the above procedure.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION SIDE DITCHING WORK Ditching work can be performed in a narrow space by combin- ing swing and boom swing operations. LOADING WORK In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator.
Page 221: Method For Lifting Objects With Lifting Device
In the absence of such a device, the machine can only be used as an earth moving machine. If the machine is not equipped with the appropriate hook, contact the Komatsu distributor. Fitting a lifting hook must be monitored and certified by the competent Authorised Body.
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION Standard arm 22E-98-31160 2-piece boom 22E-98-31180 3rd line attachment 3-154 WENAM00241...
Page 223: 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 224 MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever to LOCK position (L). Stop the engine. REMARK When removing the pins, place the bucket so that it is in light contact with the ground. If the bucket contacts strongly to the ground, the resist- ance at pins will be increased and it will be difficult to re- move the pins.
Page 225: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Place the machine on a firm and level place. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, block the tracks from movement.
Page 226: Method For Checking After Finishing Work
MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever (6) to LOCK position (L). Check that the machine monitor (7) is in the following states. (8) Engine coolant temperature gauge The graduation of gauge is within normal range. (9) Fuel gauge The graduation of gauge is within normal range.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS (3) Dirt cover (4) Tool box cover (5) Engine rear cover RKA68570 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 228 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING ENGINE HOOD Insert the key into the key slot. Turn the key counterclockwise (A) and remove it. Position (A): OPEN Position (B): LOCK While pushing engine hood opening knob (1), hold the hood grip and open hood (2).
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key clockwise (B) and remove it. Position (A): OPEN Position (B): CLOSE RKA68581 METHOD FOR OPENING AND CLOSING DIRT COVER CAUTION • Never stand on the cover. You may slip and fall. • When inspecting or servicing the inside of the cover, be sure to fix the cover open by using the cov- er support lever.
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING DIRT COVER Insert the key into the key slot. Turn the key counterclockwise (A) and remove it. Position (A): OPEN Position (B): LOCK While pushing dirt cover release knob (1), hold the cover grip and open cover (2).
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR LOCKING DIRT COVER Hold the grip of hood (2) and remove hood support lever (3) from the hood fixing position. Securely fix cover support lever (3) to the lever lock. Lower and press the cover slowly and lock it securely. RKA68443 Insert the key into the key slot.
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING OPERATOR CAB DOOR Insert the starting switch key into the key slot (1). Turn the starting switch key to “OPEN” position (A), and then remove the starting switch key. Position (A) OPEN Position (B) LOCK Hold the cab door handle (2) to open the cab door.
Page 233 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 234: Handle Air Conditioner
HANDLE AIR CONDITIONER OPERATION HANDLE AIR CONDITIONER • 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 235 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 236: 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 237 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 238: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 239: Handle Rubber And Road Liners Shoes
OPERATION HANDLE RUBBER AND ROAD LINERS SHOES 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 240: Precautions For Using Rubber And Road Liners Shoes
HANDLE RUBBER AND ROAD LINERS SHOES OPERATION • If the rubber parts of the road liner are worn and damaged and the mounting bolt heads are damaged, re- place the shoes with new ones immediately. If the mounting bolt heads are crushed, they cannot be removed or installed anymore. •...
Page 241 OPERATION HANDLE RUBBER AND ROAD LINERS SHOES When traveling uphills in reverse do not steer on the line between the level ground and the slope. If it is obliged to steer while traveling uphills, steer slowly. Do not travel with either track raised on a face of slope or convex ground surface (with the machine leaning approximately 10 °...
Page 242 HANDLE RUBBER AND ROAD LINERS SHOES OPERATION When the machine travels further in reverse, clear- ance (b) is made between track roller (1), idler (3), and rubber shoe (2). Rubber shoe (2) comes off under this condition. • When the machine is steered while the rubber shoe cannot move sideway because of a material to ride over or anoth- er thing.
Page 243: 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 244: 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 245 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 246 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). RKA63210 Operate the work equipment control lever to swing the up- per structure so that the work equipment is on the sprocket side.
Page 247 OPERATION TRANSPORTATION 11. Place the machine at the specified position on the trailer. METHOD FOR SECURING MACHINE NOTICE • Prevent the damage to the bucket cylinder during transportation, put a block under the tip of the bucket link so that the bucket cylinder does not touch the floor. •...
Page 248 TRANSPORTATION OPERATION (Keep the chains off the track frame.) 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 the center (3) of the trailer.
Page 249 OPERATION TRANSPORTATION Check that the travel speed display shows Lo and the au- to-deceleration is OFF (cancel). If Hi is displayed, press the travel speed selector switch to change the travel speed to Lo. Turn the fuel control dial to Low idle (MIN) position (a). Set the lock lever to FREE position (F).
Page 250: 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 251 OPERATION TRANSPORTATION Start the engine. Swing the upper structure so that the work equipment is on the sprocket (1) side. At this time, set the track frame and upper structure in par- allel. Extend the bucket cylinder and arm cylinder fully, then low- er the work equipment to the ground using the boom cylin- der as shown in the figure.
Page 252: 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 253: Precautions After Daily Work Completion In Cold Weather
OPERATION COLD WEATHER OPERATION 1.24 1.25 1.26 1.27 1.23 1.24 1.25 1.26 • When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it from the machine to place it in the warm place. Restore it again before the operation. •...
Page 254: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. 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 255 OPERATION PRECAUTIONS FOR LONG-TERM STORAGE • Insert the key into the battery disconnect switch and turn the key to ON position. • If the machine is stored for a long period with the battery disconnect switch OFF, the time information of the clock and radio (if equipped) tuning information may be lost.
Page 256: 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 257: Precautions For Towing Machine
OPERATION TROUBLES AND ACTIONS • 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. • When performing bucket CURL operation from a high posi- tion for digging under no load, the bucket speed drops mo- mentarily at the horizontal position.
Page 258: Precautions For Severe Job Condition
TROUBLES AND ACTIONS OPERATION • If the machine sinks in mud and cannot get out under its own power, or if the machine tows a heavy object, use a wire rope as shown in the figure. • Place pieces of wood between the wire ropes and the ma- chine to prevent damage to the ropes and the machine.
Page 259: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 260 TROUBLES AND ACTIONS OPERATION METHOD FOR REMOVING BATTERY Loosen screws (1) and remove the side cover (2). RKA68610 Remove nuts (3) and rubber cover (4) on the battery. RKA68620 Remove the cable (5) on the negative (-) terminal side (ground side) first. Remove the connecting cable (6) on the positive (+) termi- nal side.
Page 261 OPERATION TROUBLES AND ACTIONS Allowable tightening torque: 5,5 Nm Install the connecting cable on the positive (+) terminal side. Connect positive (+) terminal side (6) first. Install the cable (5) on the negative (-) terminal side (ground side). Cover the top surface of the battery with the rubber cover (4). Install the rubber cover with nuts (3).
Page 262 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 263: 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 264 Replace. (*) (starting switch is at ON position). 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 265 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Steam spurts out from top of radiator Lowered coolant level, leakage of Check, add coolant, repair. See (pressure valve). coolant CHECKS BEFORE STARTING. Loose fan belt Adjust fan belt tension. See EVERY 500 HOURS MAINTENANCE.
Page 266 (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 267: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section. WENAM00241...
Page 268: 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 269: Avoid Mixing Oil
MAINTENANCE PRECAUTIONS FOR MAINTENANCE • 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. • Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. •...
Page 270: 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 271 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 272 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 273: 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 274 OUTLINE OF MAINTENANCE MAINTENANCE • The inspection and maintenance include check of the hydraulic oil level, replacement of filters, changing of the hydraulic oil. • When high-pressure hoses have been removed, check that there is no damage to O-rings. If any damage is found, replace O-ring.
Page 275: 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 276 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Tightening torque Width Nominal - No. of across Target value Allowable range threads "a" flats "b" (mm) Nm kgm Nm kgm 9/16-18UNF 35 to 54 3.5 to 5.5 11/16-16UN 54 to 93 5.5 to 9.5 13/16-16UN 10.5...
Page 277: 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 WHEN REQUIRED ............................4-13 METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER .......... 4-13 METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ..............
Page 278: Maintenance Interval For Hydraulic Breaker
MAINTENANCE SCHEDULE MAINTENANCE EVERY 2000 HOURS MAINTENANCE ......................4-65 METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER... 4-65 METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR CONTROL CIRCUIT) ......................4-69 METHOD FOR CHECKING AND REPLACING FUEL SYSTEM AND COOLING SYSTEM HOSES ..4-73 METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR ...........
Page 279: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear protective eyeglasses, dust mask, or other protective equipment. NOTICE •...
Page 280 MAINTENANCE PROCEDURE MAINTENANCE Release the hooks (4) and remove the cover (5). RKA68640 Hold the outer element (6), rock it lightly up and down and to the right and left, and pull the outer element (6) out while turning it to the right or left. When outer element (6) is removed, check that the inner element (9) does not come out of position and is not at an angle.
Page 281 MAINTENANCE MAINTENANCE PROCEDURE 13. After the cleaning, illuminate the inside of the element with an electric bulb to check. If any holes or thin places are found, replace the outer ele- ment with a new one. 14. Remove the cover of cloth or tape attached to inner ele- ment (9).
Page 282 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 283 MAINTENANCE MAINTENANCE PROCEDURE If any dust is attached to the vacuator valve (8) installed to the cover (5), remove it. NOTICE • Do not clean and reuse the inner element. Replace the inner element with a new one at the same time when the outer element is replaced. •...
Page 284: Method For Cleaning Inside Of Cooling System
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 285 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 286 MAINTENANCE PROCEDURE MAINTENANCE Place containers to catch the coolant under the drain hose installed to drain plug (6) and under coolant drain plug (7) of the engine cylinder block. Open drain plug (6) at the bottom of the radiator. Remove drain plug (7) of the cylinder block and drain the coolant.
Page 287 MAINTENANCE MAINTENANCE PROCEDURE 17. Operate the work equipment control levers according to the following procedure. NOTICE When the work equipment is operated, take care that it does not interfere with the machine or ground. Move R.H. work equipment control lever slowly in the direction of bucket CURL position (D).
Page 288: Method For Checking Battery Electrolyte Level
MAINTENANCE PROCEDURE MAINTENANCE 26. Drain the coolant in reservoir tank (8). 27. Clean the inside of the reservoir tank. 28. Add coolant up to the middle between FULL and LOW. 29. Stop the engine. 30. Approximately 3 minutes later, add coolant to near the mouth of the water filler port.
Page 289 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. Mount the side cover (2) and fix it with screws (1).
Page 290: Method For Cleaning Fuel Prefilter Element
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. Install the battery. For detail of battery installation see OPERATION “METHOD FOR INSTALLING BAT- TERY”...
Page 291: Method For Checking Looseness And Tightening Steel Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE Turn the transparent cup (6) counterclockwise to remove it. Remove the transparent cup (6) without spilling the fuel. If the fuel spills, wipe them off with cloth thoroughly. Be careful not to lose the red ring in transparent cup (6). RKA68194 Remove the element (7) from top of the fuel prefilter.
Page 292: Method For Checking Looseness And Tightening Road Liner Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE Check steel shoe bolt (1) for looseness. If any looseness of the bolt is found, retighten it according to the following procedure. Tighten the bolt in the order shown in the figure. Tightening torque: 98.1 to 137 Nm {10 to 14 kgm} Check that the nut and shoe are in close contact with the link contact surface.
Page 293 MAINTENANCE MAINTENANCE PROCEDURE Tighten the bolt in the order shown in the figure. Tightening torque: 117 to 216 Nm {18 to 22 kgm} Check that the nut and shoe are in close contact with the link contact surface. METHOD FOR CHECKING AND ADJUSTING STEEL SHOES AND ROADLINERS TRACK TENSION The wear of the pins and bushings of the undercarriage depends on the working condition and soil condition.
Page 294: Method For Checking Road Liner
If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. 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 •...
Page 295: Method For Checking Rubber Shoes
When replacing only part of the road liner, use the special road liner removal tool. For the tools, consult your Komatsu distributor. 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 •...
Page 296: Method For Checking And Adjusting Rubber Shoes Track Tension
A crack max. 30 mm in length and max. 10 mm 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 297: Method For Replacing Rubber Shoes
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. METHOD FOR REPLACING RUBBER SHOES WARNING •...
Page 298 MAINTENANCE PROCEDURE MAINTENANCE Set the machine in the posture shown in the figure. Start the engine and run it at low idle. Set the lock lever to FREE position (F). Operate the work equipment control lever to swing the up- per structure to make it right angle with the undercarriage.
Page 299 MAINTENANCE MAINTENANCE PROCEDURE Insert the steel pipes (2) between the rubber shoe track and track frame. Turn the sprocket in reverse direction (A). The rubber shoe track is lifted off the idler by steel pipe (2). Slide the rubber shoe track sideway (B) and remove it. METHOD FOR INSTALLING RUBBER SHOES Engage the rubber shoe track with the sprocket and place it over the idler.
Page 300: Method For Changing Shoes
WARNING The idler cushion must be removed and adjusted when the steel shoes or road liner are replaced with the rubber shoes, or reversely. Accordingly, be sure to ask your Komatsu distributor for the replace- ment. METHOD FOR REPLACING BUCKET TEETH Replace the bucket teeth before the adapter starts to wear.
Page 301: Method For Adjusting Bucket Axial Play
MAINTENANCE MAINTENANCE PROCEDURE Clean the mounting surfaces and insert the ring (3) in the slot of the tooth holder (4). RKA27480 Insert the new tooth (2) in the tooth holder, partially push the pin (1) manually, then insert it with a hammer and block the tooth on the bucket.
Page 302: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE PROCEDURE MAINTENANCE Set the work equipment in the position shown in the figure, then stop the engine and set the lock lever to LOCK posi- tion (L). A: Arm B: Bucket Measure the amount of play "a". REMARK Measurement is easier if you move the bucket to one side so that all the play can be measured at one place (the left side in the figure).
Page 303: Method For Checking And Maintenance Air Conditioner
MAINTENANCE MAINTENANCE PROCEDURE Check the fluid level in the window washer tank. RKA68444 If the level is low, add window washer fluid for automobile. Be careful not to let dirt or dust get in when adding fluid. When adding the window washer fluid, use line (H) marked on the window washer tank as a guideline.
Page 304 RKA68830 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. 4-38...
Page 305: Method For Washing Washable Floor
MAINTENANCE MAINTENANCE PROCEDURE 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 306: 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), inside the dirt cover (1 place) and inside the engine hood (1 place).
Page 307: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT Bleeding air from pump Perform it when any hydraulic component or oil is replaced. NOTICE If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be generated and this may cause a premature damage to the pump.
Page 308 MAINTENANCE PROCEDURE MAINTENANCE Operate each cylinder 4 to 5 more times to each stroke end. All air is bled. Bleeding air from swing motor Perform it only when the oil inside the swing motor case is drained. NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. Run the engine at low idle.
Page 309: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE Run the engine at low idle and swing the upper structure 90 ° to bring the work equipment to the side of the track. Push up the machine until the track is raised slightly from the ground. Perform idle rotation of track for 2 minutes. Repeat this procedure on both the right and left sides.
Page 310: Method For Checking Oil Level In Swing Machinery Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE Set the machine to the greasing posture shown on the fig- ure, lower the work equipment to the ground, and stop the engine. By using a grease pump, pump in grease through the grease fittings shown by arrows. (1) Arm and Bucket connection pin (1 place) After greasing, wipe off any old grease that is pushed out.
Page 311: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Pull out dipstick (G). Wipe off the oil from the dipstick with a cloth. Fully insert dipstick (G) into the dipstick pipe, then remove Check the oil level with dipstick (G). The oil level should be between H and L marks on the dip- stick.
Page 312 MAINTENANCE PROCEDURE MAINTENANCE (1) Boom foot pin (2 places) (2) Boom cylinder foot pin (1 place) (3) Boom cylinder rod end pin (1 place) (4) Arm cylinder foot pin (2 place) (5) Arm cylinder rod end (1 place) (6) Boom and arm connection pin (1 place) (7) Bucket cylinder foot pin (1 place) (8) Arm-Link connection pin (1 place) (9) Link connection pin (2 places)
Page 313 MAINTENANCE MAINTENANCE PROCEDURE Set the boom to the swing neutral position and supply grease to the pin. Swing the boom to the left stroke end and supply grease to the pin. Swing the boom to the right and left several times. (13) Boom swing cylinder rod end pin (1 place) (14) Boom swing cylinder foot pin (1 place) (15) Blade cylinder foot pin (1 place)
Page 314: 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 315: Every 500 Hours Maintenance
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 316 Remove the drain plug (P) slowly to drain the oil so that you do not get splashed with the oil. Check the drained oil. If there are excessive metal particles or foreign materials, contact your Komatsu distributor. Install the drain plug (P). RKA68340 Open engine hood (1).
Page 317: Method For Replacing Fuel Prefilter Element
When replacing the parts, Komatsu recommends using Komatsu genuine parts. • 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. Never use a substitute.
Page 318 MAINTENANCE PROCEDURE MAINTENANCE • Cloth Open engine hood (1). Lock securely with hood support lever (2). RKA68180 Place a container under drain hose (3) to receive the wa- ter. Turn the handle (4) to CLOSE position (S), and loosen the drain plug (5).
Page 319: Method For Replacing Fuel Main Filter Cartridge
When replacing the parts, Komatsu recommends using Komatsu genuine parts. • 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. Never use a substitute.
Page 320 MAINTENANCE PROCEDURE MAINTENANCE Turn the handle (3) of the water separator (4) to CLOSE position (S). Place a container under the fuel filter to catch the fuel. RKA68197 Turn the fuel filter cartridge (5) counterclockwise by using the filter wrench, and remove it. After removing the fuel filter cartridge (7), fuel drips down from the fuel filter head.
Page 321: Method For Checking Swing Pinion Grease Level, Add Grease
Check that the grease is not milky white. Total amount of grease: 5.5 ℓ (5.0 kg) If the grease is milky white, it needs to be replaced. Ask your Komatsu distributor to replace it. Install grease filler port cover (4) with bolts (3). RKA69030 Remove cover support lever (2) and fix it to the lever lock securely.
Page 322: Method For Checking And Cleaning Radiator Fins, Oil Cooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
If the rubber hose is cracked or become fragile, ask your RKA68970 Komatsu distributor for replacement. Check the hose clamps for looseness. If the hose clamps are loosened, tighten them. Remove hood support lever (2) and fix it to the lever lock securely.
Page 323: Method For Cleaning Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING AIR CONDITIONER FRESH/RECIRC FILTERS WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear protective equipment such as protective eyeglasses and dust mask. NOTICE • As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently.
Page 324: 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 325: Method For Checking Fan Belt Tension And Replacing Fan Belt
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). 10.
Page 326: Every 1000 Hours Maintenance
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 327 MAINTENANCE MAINTENANCE PROCEDURE Remove the cap of oil filler port (F) gradually to release the internal pressure. Release the internal pressure. RKA69060 Remove the cover mounting bolt (3), and remove the cov- er (4). The cover (4) may be jumped out by spring (5). While pressing down the cover (4), remove the cover mounting bolt (3).
Page 328: Method For Change Oil In Swing Machinery Case
MAINTENANCE PROCEDURE MAINTENANCE 12. Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end. 13. Set the lock lever securely to LOCK position (L). 14. Stop the engine. 15. Tighten the cap of oil filler port (F) on the hydraulic tank se- curely.
Page 329: Method For Changing Oil In Final Drive Case
MAINTENANCE MAINTENANCE PROCEDURE Open the dirt cover (1) fully and it will be secured by the cover support lever (2). RKA68445 Add oil through the pipe for dipstick (G) by the refill capaci- Check the oil level in the swing machinery case. Check that the oil level is between H and L of dipstick (G).
Page 330: Method For Checking Oil Leakage In Flywheel Housing
MAINTENANCE PROCEDURE MAINTENANCE Bring plug (P) to the lowest position. Place the oil container to catch oil under plug (P). By using a hexagonal wrench, remove plugs (P), (G), and (F) , and drain the oil. Tighten plug (P) . Add the refill capacity of engine oil through oil filler port (F).
Page 331: Every 1500 Hours Maintenance
RKA69130 METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. EVERY 1500 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours should be performed at the same time.
Page 332 MAINTENANCE PROCEDURE MAINTENANCE Set the lock lever to FREE position (F). Operate the blade control lever to lower the blade to the ground. Operate the work equipment control lever to swing the upper structure. Bring the drain plug at the bottom of the hydraulic tank to the middle between the left and right tracks.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE Loosen the bolts (3) and remove the undercover (4). RKA69180 Loosen the hose clamp (5), remove the hose (6) and drain the oil. Remove bolt (7), remove the flange (8), strainer (9) and re- move dirt, etc. stuck to the tube, and then wash it in clean diesel fuel or flushing oil.
Page 334 MAINTENANCE PROCEDURE MAINTENANCE 16. Set the lock lever to FREE position (F). RKA63210 17. 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. 18.
Page 335: 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 336 MAINTENANCE PROCEDURE MAINTENANCE Set the lock lever to FREE position (F). Place the machine on a firm, level ground. RKA63210 Set the work equipment to the posture shown in the figure according to the following procedure. Operate the work equipment control levers, and re- tract arm cylinder and bucket cylinder to their stroke end (maximum reach posture of arm and bucket).
Page 337 • 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 338 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT Start the engine. Set the lock lever to FREE position (F). Place the machine on a firm, level ground. RKA63210 Set the work equipment to the posture shown in the figure according to the following procedure.
Page 339: Method For Checking And Replacing Fuel System And Cooling System Hoses
Ask your Komatsu distributor to perform this work. 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 340: Every 3000 Hours Maintenance
METHOD FOR CHECKING ECU AND RELATED SENSORS AND ACTUATORS Inspect the appearance and wirings of the ECU and related sensors and actuators and check the occurrence status of error history on monitor machine. Ask your Komatsu distributor to inspect, repair or replace. EVERY 4000 HOURS MAINTENANCE Maintenance for every 100, 250, 500, 1000 and 2000 hours should be performed at the same time.
Page 341: 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 342: Every 6000 Hours Maintenance
RKA69160 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. 4-76 WENAM00241...
Page 343: Specifications
SPECIFICATIONS WENAM00241...
Page 344 Item Unit PC80MR-5E0 Machine weight (including blade) kg 8070 Bucket capacity m 0.20 Engine model Komatsu 4TNV98C-DM diesel engine SAE J1995 (Gross) 46.2/2200 Rated horsepower kW/rpm ISO 9249/ SAE J1349 44.2/2200 (Net) CO2 Value [g/ Family name Parent engine model...
Page 345 SPECIFICATIONS SPECIFICATIONS Steel shoes specification 1650 mm arm speci- 2000 mm arm speci- Item Unit fication fication Overall length mm 6059 6253 Overall height mm 2712 2712 Overall width mm 2229 2229 Shoe width mm Tail swing radius mm 1395 1395 Overall length of track mm...
Page 346 SPECIFICATIONS SPECIFICATIONS Road liner specification 1650 mm arm speci- 2000 mm arm speci- Working ranges (mm) Unit fication fication Max. digging reach mm 6774 7120 Max. digging depth mm 3970 4319 Max. digging height mm 6323 6565 Max. vertical wall digging depth mm 2874 3190...
Page 347: Explanation Of Lift Capacity Chart
SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART EXPLANATION OF LIFT CAPACITY CHART WARNING The excavator used in handling operations must conform with current local regulations and be equip- ped with safety valves and an overload alarm in compliance with EN 474-5. For detail see “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE”.
Page 348 EXPLANATION OF LIFT CAPACITY CHART SPECIFICATIONS Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping). RKA69210 WENAM00241...
Page 349: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section. WENAM00241...
Page 350: 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 351 ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS • The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight when it is stopped in a raised position) also becomes greater. Do not stop the work equip- ment in air.
Page 352: Quick Coupler System
Check that the valve is correctly set. • Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu dealer. Standard calibration: 245–255 bar (24.5–25.5 MPa)
Page 353 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM Always check the valve calibration. RKA69240 (1) Quick coupler activation switch (4a) Hydraulic quick coupler connection (Lock line) (2) Quick coupler switch (4b) Hydraulic quick coupler connection (Unlock line) (3) Adjustable pressure regulating valve WENAM00241...
Page 354 • At the start, the machine performs a self-check and verifies the operation of the buzzer. In case the buzzer is not functioning properly, contact the Komatsu distributor. • The European Norm requires that the LOCK position must be seen from the operator's position.
Page 355 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM Depending on the design of the quick coupler it may be necessary to operate one of the hydraulic functions of the machine (bucket, boom, arm or swing) to raise the pressure in the hydraulic system. The quick coupler will now release the attachment/bucket.
Page 356: 2-Piece Boom
2-PIECE BOOM ATTACHMENTS AND OPTIONS 2-PIECE BOOM 2-PIECE BOOM COMPONENTS RKA69260 (1) First boom (3) Second boom (2) Boom cylinder (4) 2-piece boom cylinder 2-PIECE BOOM CONTROL PEDAL The 2-piece boom control pedal is situated at the left of travel levers.
Page 357: Specifications
ATTACHMENTS AND OPTIONS 2-PIECE BOOM Set the machine to the greasing posture shown on the figure, lower the work equipment to the ground, and stop the engine. By using a grease pump, pump in grease through the grease fittings shown by arrows. RKA69261 (1) Link connection pin (1 place) (6) Arm cylinder foot pin (2 place)
Page 358 2-PIECE BOOM ATTACHMENTS AND OPTIONS Item Unit 1650 mm arm specification 2000 mm arm specification Overall length mm 6083 6301 Overall height (Road Liner) 2734 2734 mm Overall height (Iron shoes) 2712 2712 RKA69290 6-10 WENAM00241...
Page 359: Explanation Of Lift Capacity Chart
ATTACHMENTS AND OPTIONS 2-PIECE BOOM Road liner specification Working ranges (mm) Unit 1650 mm arm specification 2000 mm arm specification Max. digging reach mm 7378 7723 Max. digging depth mm 3976 4330 Max. digging height mm 7592 7922 Max. vertical wall digging depth mm 3133 3442...
Page 360 2-PIECE BOOM ATTACHMENTS AND OPTIONS Working conditions • Bucket: 600 mm - 151 kg • Width shoe: 450 mm • With fully extended bucket cylinder. • On a compact horizontal level ground. • If object handling is performed with other tool installed, the weight difference of the tool shall be deducted from value of this table.
Page 361: Handle Bucket With Hook
HANDLE BUCKET WITH HOOK HANDLE BUCKET WITH HOOK When using the bucket with hook, check that there is no damage to the hook, stopper, or hook mount. If there is any problem, ask your Komatsu distributor. PRECAUTIONS FOR OPERATION PRECAUTIONS FOR LIFTING OPERATION •...
Page 362: Handle Machine Ready For Installation Of Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT RKA69330 (1) Selector valve (3) Breaker operation switch (2) 1st line attachment proportional switch SELECTOR VALVE The selector valve switches the flow of the hydraulic oil.
Page 363: Method For Removing And Installing Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 1ST LINE ATTACHMENT PROPORTIONAL SWITCH 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 364 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Set the lock lever to FREE position (F). RKA63210 Operate each control lever (work equipment, travel) and attachment control switch fully in each direction within 15 seconds after the engine is stopped to release the internal pressure in the hydraulic circuit.
Page 365 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Remove the cap of oil filler port (F) gradually to release the internal pressure. Release the internal pressure. RKA69060 Remove the hoses on the attachment side. Install the plugs to outlets (2 places). The plugs are used to prevent the attachment from making incorrect operation caused by mixing in of foreign matter.
Page 366 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Place the attachment on a horizontal place, install pin (A) and then pin (B) in this order to the arm. Lower the attachment to the ground and stop the engine. Turn the starting switch to ON position (B).
Page 367 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Set the lock lever to LOCK position (L). Turn the starting switch to OFF position (A). Open dirt cover (1). Open dirt cover (1) fully and it will be secured by cover support lever (2).
Page 368 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 13. Connect the attachment piping provided by the attachment manufacturer. Joint screw size is as follows. Right side of arm (1) (bucket line) (standard): 13/16-16 Left side of arm (2) (bucket line) (standard): 13/16-16 Right side of arm (3) (1st line) (standard): 1"3/16-12 Left side of arm (4) (1st line) (standard): 1"7/16-12 RKA69360...
Page 369: Method For Operating Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR OPERATING ATTACHMENT CHECK POINTS WHEN USING BREAKER • Is the selector valve in position (A) for breaker (1 way)? If it is not in position (A) for breaker (1 way), turn it to the position.
Page 370 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Select breaker mode “B” with function switches “F1” or “F2” or “F5”. While breaker mode “B” is selected, press function switch “F4” or leave it as it is for 5 seconds. Working mode is set to breaker mode “B”, and the screen returns to the standard screen.
Page 371 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Press the breaker operation switch. The breaker operates. CHECK POINTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER • Is selector valve in position (B) for general attachment such as crusher, etc. (2 way)? If it is not in the position (B) for general attachment such as crusher, etc.
Page 372 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Select attachment mode “ATT/P” or “ATT/E” with function switches “F1” or “F2” or “F5”. While attachment mode “ATT/P” or “ATT/E” is selected, press function switch “F4” or leave it as it is for 5 seconds. Attachment mode is set to “ATT/P”...
Page 373: Specifications
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT SPECIFICATIONS Hydraulic specifications (breaker mode) Max. flow rate (engine speed: at 2200 rpm) 115 ℓ/min Safety valve setting pressure 26.5 MPa {270 kg/cm } Hydraulic specifications (attachment mode) Max. flow rate (engine speed: at 2200 rpm) 125 ℓ/min Safety valve setting pressure 26.5 MPa {270 kg/cm...
Page 374: Handle Machine Ready For Installation Of Attachment (2Nd Line)
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (2nd LINE) ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT (2nd LINE) EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT (2nd LINE) RKA69331 (1) Selector valve (2) 2nd line attachment proportional switch SELECTOR VALVE The selector valve switches the flow of the hydraulic oil.
Page 375: Method For Connecting Hydraulic Circuit (2Nd Line)
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS (2nd LINE) If the operation mode selection switch is not set on the ATT/P or ATT/E mode, this switch cannot be activated. Flow rate can be adjusted according to the operating amount of 2nd line attachment proportional switch.
Page 376 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (2nd LINE) ATTACHMENTS AND OPTIONS Set the lock lever to FREE position (F). RKA63210 Operate each control lever (work equipment, travel) and attachment control switch fully in each direction within 15 seconds after the engine is stopped to release the internal pressure in the hydraulic circuit.
Page 377 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS (2nd LINE) Remove the cap of oil filler port (F) gradually to release the internal pressure. Release the internal pressure. 10. Check that the hydraulic oil temperature is low. 11. Rotate the levers (1) to the close position (orthogonal to the pipes).
Page 378 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (2nd LINE) ATTACHMENTS AND OPTIONS 15. Before starting the engine, check that the selector valve is in the correct position. • Pos. a: when using the breaker • Pos. b: when general attachments such as crusher are used 16.
Page 379: Method For Operating Attachment (2Nd Line)
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS (2nd LINE) Operate attachment proportional switch on the left control lever. METHOD FOR OPERATING ATTACHMENT • Adjust attachment oil flow rate. For the adjustment method of attachment flow rate, see “ATTACHMENT SETTING”.
Page 380: Handle Machine Ready For Installation Attachment (3Rd Line)
HANDLE MACHINE READY FOR INSTALLATION ATTACHMENT (3rd LINE) ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION ATTACH- MENT (3rd LINE) EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT (3rd LINE) RKA82410 (1) 2nd line activation switch (3) 3rd line (2) Attachment proportional switch (2nd-3rd line) 2ND LINE ACTIVATION SWITCH When the switch is pressed, activates the 2nd hydraulic line.
Page 381: Method For Connecting Hydraulic Circuit And Operating Attachment (3Rd Line)
HANDLE MACHINE READY FOR INSTALLATION ATTACHMENT (3rd ATTACHMENTS AND OPTIONS LINE) The activation of the 2nd line is marked by a light positioned at the left side of operator's seat. RKA45920 2ND/3RD LINE ATTACHMENT PROPORTIONAL SWITCH The oil flow is adjusted by moving the proportional switch on the left control lever. If the operation mode selection switch is not set on the ATT/P or ATT/E mode, this switch cannot be activated.
Page 382 HANDLE MACHINE READY FOR INSTALLATION ATTACHMENT (3rd LINE) ATTACHMENTS AND OPTIONS METHOD FOR OPERATING BREAKER • Adjust breaker oil flow rate. For the adjustment method of breaker flow rate, see “BREAKER SETTING”. • Set the engine output at 80 %. •...
Page 383 HANDLE MACHINE READY FOR INSTALLATION ATTACHMENT (3rd ATTACHMENTS AND OPTIONS LINE) Operate attachment proportional switch on the left control lever. LIFTING CAPACITY DIAGRAM WARNING The excavator used in handling operations must conform with current local regulations and be equip- ped with safety valves and an overload alarm in compliance with EN 474-5. For detail see OPERATION “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE”.
Page 384 HANDLE MACHINE READY FOR INSTALLATION ATTACHMENT (3rd LINE) ATTACHMENTS AND OPTIONS Lifting capacity diagram (2-piece boom) Overload diagram (2-piece boom) 6-36 WENAM00241...
Page 385 HANDLE MACHINE READY FOR INSTALLATION ATTACHMENT (3rd ATTACHMENTS AND OPTIONS LINE) Lifting capacity diagram (standard boom) Overload diagram (standard boom) 6-37 WENAM00241...
Page 386: Arm/Pin Information
ARM/PIN INFORMATION ATTACHMENTS AND OPTIONS ARM/PIN INFORMATION RKA82390 160 mm 160 mm -0.50 -0.50 -0.050 -0.050 50 mm 50 mm -0.089 -0.089 6-38 WENAM00241...
Page 387: 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 388: Track Shoes Selection
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS Opening Capacity Tooth width Model mounting m Short arm Long arm (Body) mm General dig- Bucket Horizontal 0.242 ○ ○ ging Light duty bucket Horizontal 0.287 Loading ○ ○ Ditches clean- Light duty bucket 1500 ○...
Page 389: 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 390 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm off the ground. Do not raise it off the ground unnecessarily. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 391 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not use the mount to gather in pieces of rock. Do not work by using the swing force. Do not move the chisel while performing breaking operation. Do not perform breaker operation in horizontal or upward direc- tion.
Page 392 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Do not perform the operation with bucket cylinder rod extended fully to raise the machine off the ground. Do not perform the breaker work with any cylinder at the stroke end.
Page 393 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Grease the breaker while holding it in the right posture shown below. • Lower the chisel perpendicularly to the ground. • Insert the grease gun perpendicularly to the greasing point. Wrong posture 6-45 WENAM00241...
Page 394 WENAM00241...
Page 395: Replacement Parts
REPLACEMENT PARTS WENAM00241...
Page 396: Periodic Replacement Of Defined Life Parts
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Parts for periodic replacement...
Page 397: 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 398: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the engine, pow- er train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recom- mend any commercially available lubricant additive. •...
Page 399 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT Standard boom - Lubrication chart The symbols used in the lubrication chart are explained in the following table. Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan...
Page 400 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS 2-piece boom - Lubrication chart The symbols used in the lubrication chart are explained in the following table. Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan...
Page 401: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
250 hours. For changing maintenance time of machine monitor, ask your Komatsu distributor to perform. Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Page 402: 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. WENAM00241...
Page 403: Index
INDEX INDEX Symbols Attachment - Remove........... 6-15 Attachment - Remove / Install.......6-15 12H24H display mode - Switch......3-57 Attachment - Set........... 3-46 1st line attachment proportional switch..3-65,6-15 Attachment (2nd line) - Operate......6-30 2-Piece boom............6-8 Attachment (3rd line) - Connect hydraulic circuit and 2-Piece boom components........
Page 404 INDEX Clock - Adjust............3-54 Engine - Check starting condition and unusual noise.. Cold weather operation........3-184 ..............3-123 Cold weather operation information....3-184 Engine - Operate / Check after starting....3-122 Comparison of road liners, rubber shoes and steel Engine - Operate / Check before starting....3-119 shoes............
Page 405 Gas spring - Check..........4-40 KDPF system caution lamp........3-19 Gauge display............3-29 Keep machine clean..........2-16 General attachment such as crusher etc - Operate..Komatsu Diesel Particulate Filter (KDPF) - Handle................6-24 ...............3-86 General attachment such as crusher, etc. - Check Komatsu genuine lubricants........4-2 points when using..........
Page 406 ...............3-10 Machine monitor equipment name......3-5 Machine operations and controls......3-101 Machine ready for installation attachment (3rd line) - Perform KOWA (Komatsu Oil Wear Analysis)..4-6 Handle............6-32 Periodic replacement of defined life parts.....2-44 Machine ready for installation of attachment..6-14 Permissible depth of water, soil and dirt.....
Page 407 INDEX Precautions for blade position during backhoe opera- Precautions when operating on snow or frozen surfa- tion............... 3-148 ces..............2-30 Precautions for charging battery......3-193 Precautions when parking machine...... 2-31 Precautions for check and maintenance....2-39 Precautions when removing and installing....6-2 Precautions for cold weather........
Page 408 INDEX Start engine with jumper cables......2-25 Start the machine after long-term storage..3-186 Radiator fin / Oil cooler fin / Fuel cooler fin / Condens- Starting switch............3-64 er fin - Check / Clean........4-56 Steel shoes and road liners - Check / Adjust track Radio - Handle............
Page 409 INDEX Visibility from operator's seat........ 1-12 Warning display.............3-14 Warranty of rubber and road liners shoes...3-171 Washable floor - Wash..........4-39 Water separator - Check / Drain water and sediment...............3-103 Wear well-fitting clothes and protective equipment................2-15 Welding instructions..........4-2 When handling accumulator and gas spring..2-43 When operating on slopes........

Komatsu PC80MR-5E0 Operation & Maintenance Manual

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