Page 1 Operation & UENAM01321 Maintenance Manual PC700LC HYDRAULIC EXCAVATOR SERIAL NUMBER PC700LC-11 - 80013 and up PC700LC-11 - K70001 and up WARNING ORIGINAL INSTRUCTIONS Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 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 Keep it in the magazine box on the left side of the operator's seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 6: Safety Labels
Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for ques- tions regarding information in this manual.
Page 7: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201...
Page 8: Vibration Levels
ISO 7096. For PC700LC-11 The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s , the uncertainty for this value is 1.06 m/s...
Page 9 FOREWORD VIBRATION LEVELS • Do not jump down from the cab or machine • Do not repeatedly handle and lift loads...
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Ditching work • Loading work • Levelling work For details of work procedure, see MACHINE OPERATIONS AND CONTROLS “RECOMMENDED APPLICA- TIONS”.
Page 11: Visibility From Operator's Seat
FOREWORD INTRODUCTION (E) Operator's seat (F) Sprocket In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine. VISIBILITY FROM OPERATOR'S SEAT This machine complies with the visibility standard ISO 5006.
Page 12: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 13: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is located on the right bottom of the operator's cab.
Page 14: Fluorinated Greenhouse Gases
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU UK Ltd Address: Durham Road Birtley Chester-le-Street County Durham DH3 2QX United Kingdom Distributor name...
Page 15: Serial Plate
FOREWORD SERIAL PLATE SERIAL PLATE KS000853 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER WEIGHT 1-13...
Page 16: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: KOMATSU UK Ltd Durham Road Birtley Chester-le-Street County Durham DH3 2QX Declares that this machine: PC700LC-11 Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive...
Page 17: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-3 SAFETY LABELS ............................. 1-4 NOISE............................... 1-5 VIBRATION LEVELS ..........................1-6 VIBRATION - OPERATING CONDITION ................... 1-6 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-6 INTRODUCTION ............................
Page 18 TABLE OF CONTENTS FOREWORD GENERAL VIEW............................3-2 MACHINE EQUIPMENT NAME ......................3-2 CAB EQUIPMENT NAMES........................ 3-4 CONTROLS AND GAUGES NAMES ....................3-5 EXPLANATION OF COMPONENTS ......................3-8 EXPLANATION OF MACHINE MONITOR EQUIPMENT ..............3-8 SWITCHES ............................3-88 CONTROL LEVERS AND PEDALS ....................3-96 OTHER EQUIPMENT ........................
Page 19 OTHER TROUBLE......................... 3-245 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 20 CONSUMABLE PARTS ........................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-5 USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE ................................7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-7 INDEX................................8-1 1-18...
Page 21: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 22: 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 23: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 24 SAFETY LABELS SAFETY 1. Caution regarding the operation, inspection, and 6. Stop rotation during inspection and maintenance maintenance 7. Emergency escape (a) Caution for operation, inspection and maintenance 8. Caution against falling (b) Caution before operating 9. Caution against falling (c) Caution when leaving operator's seat 10.
Page 25: Contents Of Safety Labels
SAFETY SAFETY LABELS CONTENTS OF SAFETY LABELS Warning regarding the operation, inspection, and maintenance “2A5–00–21180” • Inappropriate operation and maintenance may result in se- rious injury or death. • Read this manual and labels thoroughly before starting the operation or maintenance. •...
Page 26 SAFETY LABELS SAFETY (c) Caution when leaving 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. • Sudden and unwanted machine movement can cause seri- ous injury or death.
Page 27 SAFETY SAFETY LABELS (f) Caution when standing Before standing up from the operator's seat or when adjusting the operator's seat, always lower the work equipment complete- ly to the ground, set lock lever (1) securely to the LOCK posi- tion (L), then stop the engine. If you accidentally touch the control levers (pedals) when they are not locked, there is a hazard that the machine may sudden- ly move and cause serious injury or property damage.
Page 28 SAFETY LABELS SAFETY Caution for high-temperature coolant and hy- draulic 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 29 SAFETY SAFETY LABELS Stop rotation during inspection and mainte- nance “09667-A0481” • Sign indicates a hazard of rotating parts, such as belt. • Turn off before inspection and maintenance. Emergency escape “09844-00050” • This is an emergency exit when the cab door will not open. In emergency, smash the window pane with an equipped hammer and get through there.
Page 30 SAFETY LABELS SAFETY Caution against falling “09805-C0481” • Sign indicates a hazard of falling. • Do not stand on this place here. Caution when swinging and traveling in re- verse “09833-A0881” • When swinging or backing up excavator, press button to change display mode on monitor so you can see rear and side of machine.
Page 31 SAFETY SAFETY LABELS Caution for work equipment “09134-A1681” • Sign indicates a hazard of being hit by the working device of the machine. • Keep away from machine during operation. Caution for handling battery “09664-62F11” • Never smoke or use any naked flame near the batteries, no sparks.
Page 32 SAFETY LABELS SAFETY Caution for high-pressure fuel “6271-81-2980” • When the engine is running, high-pressure fuel is generat- ed in the engine fuel piping. Do not remove or loosen fuel system piping when engine is running. • When carrying out inspection or maintenance, stop the en- gine and wait at least 30 seconds to allow internal pressure 6271-81-2980 to go down.
Page 33: 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 34: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 35 Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi- cation process (regeneration).
Page 36: Precautions When Getting On Or Off Machine
In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...
Page 37: Do Not Get Caught In Work Equipment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE LIFTING OF PERSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel. NO PEOPLE ON ATTACHMENTS Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering serious personal injury or death.
Page 38: Precautions Related To Protective Structures
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 39: Precautions Related To Attachments And Options
• Any personal injuries, product failures, physical loss or damage, or influence on the environment resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. • When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential problems or safety and legal requirements.
Page 40: 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 41 Based upon the information supplied in the visibility map the site operator may wish to provide additional meas- ures where it is felt necessary or provide additional instruction to personnel. Scale - 1 grid line is equal to 1m. For PC700LC-11 2-21...
Page 42 PRECAUTIONS FOR OPERATION SAFETY Map with mirror, rear view and side camera or mirror and KOMVISION visibility aids fitted. Although the machine is equipped with mirrors and cameras to ensure good visibility, there are places that can- not be seen from the operator's seat. Be careful when performing operation. When driving the machine or performing operations in places with poor visibility, it is dangerous and may cause serious personal injury or death because it is difficult to check obstacles and condition of the jobsite.
Page 43: 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 44 PRECAUTIONS FOR OPERATION SAFETY CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE Perform the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If these checks are not performed properly, problems may occur with the operation of the machine, and there is a danger that may lead to serious personal injury or death.
Page 45: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables. • When connecting a normal machine to a failed machine with the jumper cables, always use the normal machine with the same battery voltage as the failed machine.
Page 46 PRECAUTIONS FOR OPERATION SAFETY • If there are any people in the area around the machine, there is danger that they may be hit or caught by the machine, and this may lead to serious personal injury or death. Before starting travel or swing, be sure to observe the following.
Page 47 SAFETY PRECAUTIONS FOR OPERATION • When using the machine, to prevent serious personal injury or death caused by the work equipment or by the machine tipping over due to overloading, do not use the machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine.
Page 48 PRECAUTIONS FOR OPERATION SAFETY • 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. • Do not drive the machine on a slope covered with the steel plates. Even with slight slopes there is a hazard that the machine may slip.
Page 49 SAFETY PRECAUTIONS FOR OPERATION • 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 50 PRECAUTIONS FOR OPERATION SAFETY • Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other hauling equipment. There is a danger that the load may spill or the bucket may hit the dump truck and cause serious personal injury or death.
Page 51: 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 52: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY undercarriage of the machine. On a rainy day, in particular, be extremely careful since the ramp surface is slippery. • Always turn the auto-deceleration switch OFF (cancel). If the machine is operated with the auto-decelera- tion system ON (activated), there is danger that the engine speed will suddenly rise, the machine will sud- denly move off, or the machine travel speed will become faster.
Page 53 SAFETY PRECAUTIONS FOR OPERATION Location of boom cylinder safety valves (A), (B) and arm cylinder safety valve (C). PRECAUTIONS FOR LIFTING OPERATIONS • Determine the signals to be used and place a signalman in position. • To prevent the machine from tipping over or falling, carry out the operation on flat ground. •...
Page 54 PRECAUTIONS FOR OPERATION SAFETY • Do not use the work equipment or swing to pull the load in any direction. There is a danger that the hook may be break and the load come off, causing the work equipment to move suddenly and cause personal injury.
Page 55: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 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 56 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 57 SAFETY PRECAUTIONS FOR MAINTENANCE • Rotating parts such as the fan, fan belt are dangerous that they may easily catch a body part or an object someone wears. Be careful not to come close to the rotating part. • Never drop or insert tools or other objects into the fan, fan belt, or other rotating parts.
Page 58: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur. Al- ways observe the following. • Make sure the hoists or hydraulic jacks you use are in good condition and strong enough to handle the weight of the component.
Page 59 SAFETY PRECAUTIONS FOR MAINTENANCE HANDLE BATTERY When checking and handling the battery, turn the starting switch to OFF position and check that the system op- erating lamp is not lit. Turn the battery disconnect switch to OFF position, and remove the key. Danger of battery exploding When the battery is being charged, flammable hydrogen gas is generated.
Page 60 PRECAUTIONS FOR MAINTENANCE SAFETY • When hitting pins or bucket teeth, broken pieces may be scattered, and it may cause personal injury to the people in the surrounding area. Always check that there is no one in the surrounding area. •...
Page 61 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 62 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 63 • 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 64 PRECAUTIONS FOR MAINTENANCE SAFETY • The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval.
Page 65: Precautions For Def
SAFETY PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 67: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 68: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (8) Sprocket (2) Bucket link (9) Track frame (3) Bucket cylinder (10) Track shoe (4) Arm (11) Idler (5) Arm cylinder (12) OPG (operator protection guard) (if equipped) (6) Boom (13) Toolbox (7) Boom cylinder...
Page 69 OPERATION GENERAL VIEW Details of parts A and B (14) Komatsu Closed Crankcase Ventilation (hereafter (18) Battery disconnect switch KCCV) ventilator (19) System operating lamp (15) SCR (20) Circuit breaker (16) KDPF (21) Grease gun holder (17) Battery...
Page 70: Cab Equipment Names
GENERAL VIEW OPERATION CAB EQUIPMENT NAMES (1) Front window (7) Fire extinguisher (if equipped) (2) Ceiling window (8) Emergency escape hammer (3) Door lock release lever (9) Magazine box (4) Drink box (10) Cup holder (5) Fuse (11) AUX (6) Auxiliary electric power (if equipped) (12) Ashtray...
Page 71: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Radio (14) Swing lock switch (2) Lock lever (15) Machine push-up switch (3) L.H. work equipment control lever (16) Boom shock absorbing control switch (if equip- ped) (4) One-touch power maximizing switch (17) Lower wiper switch (if equipped) (5) Travel pedal (18) Revolving lamp switch (if equipped)
Page 72 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Wiper switch (22) Lock lever pilot lamp (2) Buzzer cancel switch (23) Aftertreatment devices regeneration pilot lamp (3) Auto-deceleration switch (24) Aftertreatment devices regeneration disable pilot lamp (4) Service meter/clock...
Page 73 OPERATION GENERAL VIEW REMARK The above figure does not show all of the caution lamp symbols.
Page 74: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION 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, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
Page 75 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, the opening screen GG is displayed. • After the opening screen GG is displayed for 2 seconds, the screen changes to the check before starting screen BB.
Page 76 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While engine shutdown secondary switch (1) is ON (engine is stopped), when the starting switch is turned to ON position, the screen shown in the figure is displayed and engine does not start.
Page 77 EXPLANATION OF COMPONENTS End screen when any message has been re- ceived. If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turned the starting switch to ON position to re- check the message, and if the message is requesting a re- sponse, make a reply to it.
Page 78 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 79 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION • If there is any abnormality when starting the engine, the check before starting screen BB changes to the maintenance time warning screen CC, warning screen FF, or error screen EE. •...
Page 80 EXPLANATION OF COMPONENTS OPERATION If there is any abnormality currently generated, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the error. Current Abnor- mality screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE 3-14...
Page 81 OPERATION EXPLANATION OF COMPONENTS • If any abnormality occurs during operation, the standard screen AA changes to warning screen FF-(1) or the error screen EE. • After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2).
Page 82 EXPLANATION OF COMPONENTS OPERATION (1) Seat belt caution lamp (6) Engine coolant temperature caution lamp (2) Caution lamp (7) Hydraulic oil temperature caution lamp (3) Caution lamp (8) Fuel level caution lamp (4) Caution lamp (9) Caution lamp (5) Action level display Standard screen (camera display and meter display) When 1 type of caution is generated, it is displayed on caution lamp (2).
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 inspection and maintenance. ↓ Does not Lights up in...
Page 84 EXPLANATION OF COMPONENTS OPERATION Caution lamps and display colors Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue High temperature Engine coolant temperature Low temper- Normal caution lamp ature (L02) High temperature Hydraulic oil temperature Low temper- Normal caution lamp...
Page 85 OPERATION EXPLANATION OF COMPONENTS Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue Low oil level Engine oil level caution lamp (L01) Low coolant level Radiator coolant level cau- tion lamp (L01) Abnormal Charge level caution lamp (L03) Clogged Air cleaner clogging caution...
Page 86 EXPLANATION OF COMPONENTS OPERATION CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5 While “!” is displayed, press switch F5 to shift the monitor dis- play screen to the Current Abnormality screen. Take appropriate remedies according to the message displayed on the monitor.
Page 87 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature is abnormally high. While this monitor is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 88 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 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 EXPLANATION OF COMPONENTS OPERATION DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low. Whenever the caution lamp lights up in red, immediately add DEF. Fault conditions that result in activation of the Inducement strat- egy for engine derates to prompt to maintain or repair the emis- sion control system.
Page 91 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 92 EXPLANATION OF COMPONENTS OPERATION Ask your Komatsu distributor for inspection and maintenance as needed. ENGINE OIL PRESSURE CAUTION LAMP Engine oil pressure caution lamp warns about abnormality of engine lubricating oil pressure. When oil pressure is low The caution lamp lights up in red and indicates action level “L03”.
Page 93 OPERATION EXPLANATION OF COMPONENTS Ask your Komatsu distributor for inspection and maintenance. CHARGE LEVEL CAUTION LAMP Charge level caution lamp warns about abnormality in the charging system while the engine is running. When abnormal The caution lamp lights up in red and indicates action level “L03”.
Page 94 EXPLANATION OF COMPONENTS OPERATION OVERLOAD CAUTION LAMP When carrying out lifting operations, always set the machine to L mode and engage the overload caution isolation switch. This sets the machine to optimum operating conditions and enables the overload warning device. Warning of overload condition (monitor panel warning display and buzzer sounding) will only function when in L mode.
Page 95 • 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 the maintenance tab screen, see“MAIN- TENANCE SCREEN SETTING” .
Page 96 EXPLANATION OF COMPONENTS OPERATION Pilot display (1) Engine stop pilot lamp (8) Swing lock pilot lamp (2) Lock lever pilot lamp (9) One-touch power maximizing pilot lamp (3) Aftertreatment devices regeneration pilot lamp (10) Preheating pilot lamp (4) Aftertreatment devices regeneration disable pilot (11) Auto-deceleration and automatic low idle pilot lamp lamp...
Page 97 OPERATION EXPLANATION OF COMPONENTS WIPER PILOT LAMP The wiper pilot lamp shows the operating state of the wind- shield wiper. The operation of the wiper switch is indicated by the pilot lamp as follows. When ON lights up: Windshield wiper operates continuously When INT lights up: Windshield wiper operates intermittently When nothing lights up: Wiper stops AUTO-DECELERATION AND AUTOMATIC LOW IDLE PILOT LAMP...
Page 98 Pilot lamp goes out: Air conditioner OFF MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply is made.
Page 99 OPERATION EXPLANATION OF COMPONENTS ENGINE STOP PILOT LAMP The engine stop pilot lamp is displayed while the engine is stopped. It goes out when the engine is started. AFTERTREATMENT DEVICES REGENERATION PILOT LAMP CAUTION • Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regeneration.
Page 100 EXPLANATION OF COMPONENTS OPERATION It goes out when the lock lever is set in FREE position. ECO GUIDANCE The guidance for energy saving operation to reduce the fuel consumption may be displayed during operation. The details of the guidance are as follows: Idling stop guidance If no operation is performed for more than 5 minutes, and the engine is idling, the idling stop message is displayed on the...
Page 101 OPERATION EXPLANATION OF COMPONENTS E mode recommendation guidance If light-load work is continued for more than 10 minutes in P mode, E mode recommendation message is displayed. When working on light load, set the working mode to E mode to re- duce the unnecessary fuel consumption.
Page 102 EXPLANATION OF COMPONENTS OPERATION DEF low level guidance If the operable time estimated from the current DEF level and the latest average DEF consumption is shorter than 8 hours, the low DEF level message is displayed. The low DEF level message goes out after more than 10 sec- onds or if the switch F5 is pressed.
Page 103 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature. If the indicator is in green range during operation, it is normal. When the indicator nears the red range (A) during operation, the hydraulic oil temperature has reached 102 °C or more.
Page 104 EXPLANATION OF COMPONENTS OPERATION • Service meter display • Clock display (12-hour display) • Clock display (24-hour display) On the standard screen, when switch F4 is pressed, it is possi- ble to switch between the clock display and the service meter display alternately.
Page 105 OPERATION EXPLANATION OF COMPONENTS REMARK Although there is no abnormality on the machine when the gauge enters the yellow range, for the conservation of global environment reduce the engine output to a point where there is no adverse effect on the operation. Perform energy saving operations within the green range.
Page 106 EXPLANATION OF COMPONENTS OPERATION MONITOR SWITCHES (1) Function switch (5) Wiper switch (2) Working mode selector switch (6) Window washer switch (3) Auto-deceleration switch (7) Buzzer cancel switch (4) Travel speed selector switch (8) Air conditioner switch FUNCTION SWITCHES AND GUIDANCE ICONS •...
Page 107 OPERATION EXPLANATION OF COMPONENTS (A) Switch F3: Camera image selector switch. (B) Switch F4: Service meter/clock display selector switch (C) Switch F5: Current Abnormality display switch (Only while caution lamp is lit) (D) Switch F5: ECO guidance erase switch (While ECO guidance is displayed) (E) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance icons fre-...
Page 108 (2) at the top right of the ma- chine monitor display. Ask your Komatsu distributor to change the setting if you want to have an automatic setting of P, E, and L mode (optional de- fault setting) when starting the engine.
Page 109 OPERATION EXPLANATION OF COMPONENTS REMARK To return to the standard screen without changing the working mode, press switch F5. After selecting the desired mode, press switch F6 and the mode is displayed in the center of the monitor display. (Example: When the power mode is selected: P) The working mode display at the top right of the screen is highlighted in yellow after 2 seconds.
Page 110 EXPLANATION OF COMPONENTS OPERATION Function of auto-deceleration When the auto-deceleration function is enabled, if the work equipment lever and travel lever are returned to NEUTRAL position, the engine speed will drop after approximately 4 seconds from the operating speed to the idle speed.
Page 111 OPERATION EXPLANATION OF COMPONENTS TRAVEL SPEED SELECTOR SWITCH WARNING • When loading to or unloading from a trailer, always drive the machine at low speed (set the travel speed selector switch to Lo) and never operate the travel speed selector switch during travel. •...
Page 112 EXPLANATION OF COMPONENTS OPERATION WIPER SWITCH Wiper switch actuates the front windshield wiper. Each time the switch is pressed, it changes INT → ON → stop (lamp goes out). Wiper pilot lamp INT lights up: Windshield wiper operates inter- mittently Wiper pilot lamp ON lights up: Windshield wiper operates con- tinuously Wiper pilot lamp off: Windshield wiper stops...
Page 113 OPERATION EXPLANATION OF COMPONENTS WINDOW WASHER SWITCH Keep pressing this switch continuously, and window washer flu- id is sprayed out on the front glass. When releasing the switch, the spray stops. • If keep pressing the switch when the wiper is stopped, the window washer fluid is sprayed out.
Page 114 F3 is not displayed. Even if switch F3 is press- ed, the screen will not switch to the camera image display. A maximum of 3 cameras can be installed. If you want to install another camera, consult your Komatsu distributor. 3-48...
Page 115 OPERATION EXPLANATION OF COMPONENTS Operation of camera image display screen Operate the following for changing the camera image display on the monitor. • On standard screen LL, the camera image is always displayed on the left part of the monitor. •...
Page 116 EXPLANATION OF COMPONENTS OPERATION • Press switch F3, and the screen returns to the standard screen. Operation of image display screen when two camera images are shown simulta- neously • Even if No.1 through No. 3 cameras are installed, only the images from the No.
Page 117 OPERATION EXPLANATION OF COMPONENTS Other mode operations while camera image is displayed Even during the camera image is displayed, it is possible to op- erate following modes. • The air conditioner can be operated. When the air conditioner switch is operated, the screen switches to the air conditioner control screen.
Page 118 EXPLANATION OF COMPONENTS OPERATION • Press the auto-deceleration switch to turn the auto-decel- eration function ON/OFF. Even if the auto-deceleration switch is pressed, the cam- era image display does not switch to another screen or re- turn to the standard screen. •...
Page 119 OPERATION EXPLANATION OF COMPONENTS • If the caution lamp is displayed, press switch F6 to return to the standard screen, and check the content of the ab- normality or warning display. While the caution lamp is flashing, if no lever is operated for 10 seconds or more, the screen automatically returns to the standard screen.
Page 120 EXPLANATION OF COMPONENTS OPERATION USER MENU The user menu consists of the following kinds. Press the switches F1 and F2 to move to right and left for selecting the menu screens. (a): Energy Saving Guidance (b): Machine Setting (c): Aftertreatment Devices Regeneration (d): SCR Information (e): Maintenance (f): Monitor Setting...
Page 121 OPERATION EXPLANATION OF COMPONENTS (d) SCR Information • Check of DEF level • Urea SCR system information (e) Maintenance • Check and resetting of various Maintenance Times (f) Monitor Setting • "Screen Adjustment" • Screen Adjustment (Camera) • "Clock Adjustment" •...
Page 122 EXPLANATION OF COMPONENTS OPERATION F1: Moves to the left menu. When it is on the left end menu, it moves to the right end menu. F2: Moves to the right menu. When on the right end menu, it moves to the left end menu. F3: Moves to the next item (1 line below).
Page 123 OPERATION EXPLANATION OF COMPONENTS CHECK OPERATING RECORD Select the Operation Records (1) from the Energy Saving Guid- ance menu screen, then press switch F6. On the Operation Records menu, the working hours, Average Fuel Consumption, Actual working hours, Ave. Fuel Consump- tion (Actual Working), Fuel Consumption, Idling Hours and E mode time ratio on daily basis or on a split measurement peri- od basis are displayed.
Page 124 EXPLANATION OF COMPONENTS OPERATION REMARK ECO guidance denotes displaying the guidance for energy sav- ing operation. This display may appear on the standard screen while the machine is in operation. CHECK FUEL CONSUMPTION RECORD Select the Average Fuel Consumption Record (3) from the En- ergy Saving Guidance menu screen, then press switch F6.
Page 125 OPERATION EXPLANATION OF COMPONENTS Switching of displayed graph Press F2 on the Average Fuel Consumption Record screen to change the currently displayed graph to another. REMARK There are 2 types of graphs. One shows hourly average fuel consumption during the last 12 hours and the other is daily average fuel consumption during the last 1 week.
Page 126 EXPLANATION OF COMPONENTS OPERATION CHANGE DISPLAY SETTING Select Configurations (4) from the Energy Saving Guidance menu screen, then press switch F6. On the Configurations menu, following operations are availa- ble. • Setting the Average Fuel Consumption Display • Switching ON/OFF of the ECO Gauge Display •...
Page 127 OPERATION EXPLANATION OF COMPONENTS Select Average Fuel Consumption Display (6) from the Configurations screen, then press switch F6. On this screen, it is possible to perform the following oper- ations with switches F3 to F6. F3: Moves to the next item (1 line below). When on the last line, it moves to the first line on the next page.
Page 128 EXPLANATION OF COMPONENTS OPERATION REMARK When you select the split measurement, the measurement stop switch (STOP) is displayed on the Operation Records screen and the ECO Guidance Records screen. When you stop the measurement, move from Energy Saving Guidance menu (a) screen to the Operation Records (1) screen or ECO Guidance Records (2) screen, then press the measure- ment stop switch F1 (STOP).
Page 129 OPERATION EXPLANATION OF COMPONENTS On the Configurations screen, it is possible to perform the fol- lowing operations with switches F3 to F6. F3: Moves to the next item (1 line below). When on the last line, it moves to the first line on the next page. F4: Moves to the previous item (1 line above).
Page 130 EXPLANATION OF COMPONENTS OPERATION Select ECO Guidance display (11) from the Configurations screen, then press switch F6. ECO Guidance Display setting screen appears. ON: Displays ECO Guidance (10) on the standard screen. OFF: Does not display ECO Guidance (10) on the stand- ard screen.
Page 131 OPERATION EXPLANATION OF COMPONENTS The setting screen for ECO Guidance Display at Key OFF screen appears. ON: Displays ECO Guidance (12) on the end screen. OFF: Does not display ECO Guidance (12) on the end screen. On this screen, it is possible to perform the following operations with switches F3 to F6.
Page 132 EXPLANATION OF COMPONENTS OPERATION The production at heavy load can be improved by changing the output of P mode with “Power Mode Adjustment”. The following is the setting levels. P0: Heavy load P1: Normal Selecting the P0 for the normal or light load operation such as a civil engineering has only a small effect on the production.
Page 133 OPERATION EXPLANATION OF COMPONENTS Operation on "Economy Mode Adjustment" screen On "Economy Mode Adjustment" screen, you can perform the following operations with switches F3 to F6. F3: Moves to the next item (1 line below). When it is on the last line, it moves to the first line.
Page 134 EXPLANATION OF COMPONENTS OPERATION Press the switch F5. The screen returns to the standard screen. The automatic low idle function is enabled. The mode is displayed in the center of the monitor display, and the screen returns to the standard screen after 2 sec- onds.
Page 135 OPERATION EXPLANATION OF COMPONENTS The screen returns to the user menu. Press the switch F5. The screen returns to the standard screen. Press the auto-deceleration switch (1) to enable the auto- deceleration function. When the auto-deceleration function is enabled, the mode is displayed in the right side of the monitor display, and the screen returns to the standard screen 2 seconds later.
Page 136 EXPLANATION OF COMPONENTS OPERATION The auto-deceleration monitor lights up on the standard screen. (It goes out when the auto-deceleration function is disabled.) REVERSE HYDRAULIC FAN The hydraulic fan reverse mode (fan reverse rotation) can be used to remove insects and dirt sticking to the radiator core by blowing air outward of the machine with the fan.
Page 137 OPERATION EXPLANATION OF COMPONENTS When switch F6 is pressed in the screen shown in the fig- ure, the fan rotation direction is reversed. (If switch F5 is pressed, the screen returns to the previous screen.) When the screen shown in the figure is displayed, the engine speed is set to low idle automatically and the fan starts rotating in reverse in approximately 15 seconds.
Page 138 EXPLANATION OF COMPONENTS OPERATION To return the fan rotation direction from reverse to normal, press the switch F5 on the screen shown in the figure. Press the switch F6 when the confirmation screen shown in the figure is displayed. (If switch F5 is pressed, the screen returns to the previous screen.) If the screen shown in the figure is displayed, the engine speed is set to low idle automatically and the fan rotation...
Page 139 OPERATION EXPLANATION OF COMPONENTS REMARK • In some cases, the screen in step 3 does not change to that in step 4 and the screen shown in the figure is dis- played and the fan does not rotate in reverse. This hap- pens when the fan rotation is controlled not to be reversed for the hydraulic oil temperature condition to protect the components.
Page 140 EXPLANATION OF COMPONENTS OPERATION Select the set time on “Auto Idle Stop Timer Setting” screen shown in the figure, then press the switch F6. You can perform the following operations with switches F3 to F6 on “Auto Idle Stop Timer Setting” screen. F3: Moves to the next item (1 line below).
Page 141 OPERATION EXPLANATION OF COMPONENTS REMARK While the auto idle stop function is in operation, the number of engine stopping times is displayed as “L01” at and after 1000 and as “L03” at and after 2000 on the monitor when the engine is not running at low idle .
Page 142 EXPLANATION OF COMPONENTS OPERATION MAINTENANCE SCREEN SETTING Each item of the setting menu (e) on "Maintenance" screen is used for displaying and setting the notification relevant to main- tenance. The items on "Maintenance" display are as follows. Air Cleaner Cleaning or Change Coolant Change Additional Hyd Oil Filter Change Fuel Prefilter Change...
Page 143 • 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 If you keep pressing the switch F6 for at least 1.5 seconds on "Maintenance" menu screen, the screen changes to "Maintenance Due Time Reset"...
Page 144 EXPLANATION OF COMPONENTS OPERATION Select screen adjustment (1) on the “Monitor Setting” menu screen, then press switch F6. Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one notch. F4: Moves the indicator to the right by one notch.
Page 145 OPERATION EXPLANATION OF COMPONENTS Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one notch. F4: Moves the indicator to the right by one notch. F5: Cancels the change and returns the screen to “Monitor Setting”...
Page 146 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 setting function may not work. • While“GPS synchronization” menu is turned on, the menu for “Calendar” (b) and “Time” (c) cannot be se- lected.
Page 147 OPERATION EXPLANATION OF COMPONENTS TIME SETTING Adjust the time of the monitor clock. REMARK As long as “GPS Synchronization” is turned on, “Time” menu is not selectable. Select “Time” (c) on “Clock Adjustment” screen, then press switch F6. The “Time” screen is displayed. When the hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D).
Page 148 EXPLANATION OF COMPONENTS OPERATION “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below). Moves to the top line when it is on the bottom line. F4: Moves to the previous item (1 line above). Moves to the bottom line when it is on the top line.
Page 149 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 150 EXPLANATION OF COMPONENTS OPERATION Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second. The “Operator ID Change” screen is displayed. • Input the already registered ID on the “Operator ID Change” screen and press F6. Then, the identified ID can be changed.
Page 151 OPERATION EXPLANATION OF COMPONENTS WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is available without SKIP, the identified ID number is not displayed in the “Operator ID” column of “Monitor Setting” screen. Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second.
Page 152 MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this message display menu (g). When there is any message, the message display at the left end of the standard screen lights up.
Page 153 OPERATION EXPLANATION OF COMPONENTS In case of a message requesting for reply, the column of “Numeric Input: []” is displayed in place (2) of the mail con- firmation menu (g). Make a reply to the message. REMARK • (3) is the subject of the received message. When no message is received, “No message”...
Page 154: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES (1) Starting switch (10) Horn switch (2) Fuel control dial (11) One-touch power maximizing switch (3) Cigarette lighter (12) Room lamp switch (4) Lamp switch (13) Pump secondary drive switch (5) Swing lock switch (14) Swing parking brake cancel switch (6) Machine push-up switch (15) Staircase lighting switch (if equipped) (7) Lower window wiper switch (if equipped)
Page 155 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting switch is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electri- cal system (except room lamp) are all turned off, and the en- gine is stopped.
Page 156 EXPLANATION OF COMPONENTS OPERATION Swing lock switch is used to lock the upper structure so that it cannot swing. (a) ON position The swing lock is always applied, and the upper structure does not swing even when the swing is operated. In this condition, the swing lock pilot lamp lights up.
Page 157 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH NOTICE If the room lamp is left to be turned on, the batteries may be exhausted. Always turn the switch to OFF position after using room lamp. Use room lamp switch to light up the room lamp. (a) ON position Lights up (b) OFF position...
Page 158 EXPLANATION OF COMPONENTS OPERATION If the Current Abnormality list includes any of the hydraulic sys- tem errors “DXA3KB”, “DXA2KB”, “DXA3KA” or “DXA2KA”, you can perform operation temporarily by setting this switch to "Emergency" position (a). SWING PARKING BRAKE CANCEL SWITCH NOTICE Swing operations can be performed temporarily with swing parking brake cancel switch when there is a problem in the swing parking brake system.
Page 159 • After moving the machine or work equipment temporarily by operating this switch, stop the engine, return the switch to normal position (b), and then ask your Komatsu distribu- tor for repair. REVOLVING LAMP SWITCH (if equipped) Revolving lamp switch is used to light up the yellow revolving lamp on top of the cab.
Page 160 OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch. • If the engine shutdown secondary switch is moved to the "stop engine" position by mistake while the machine is operating normally, “Engine Shutdown Secondary SW In Operation”...
Page 161 OPERATION EXPLANATION OF COMPONENTS This seat heater switch is used to warm the seat. (a) OFF Stops the seat heating. (b) ON Start the seat heating and the seat becomes warm. MACHINE PUSH-UP SWITCH Machine push-up switch is used to set the safety valve pres- sure on the head side of the boom circuit to 2 stages.
Page 162: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS (1) Lock lever (4) R.H. work equipment control lever (with auto-de- celeration system) (2) Travel levers (with pedal and auto-deceleration system) (3) L.H. work equipment control lever (with auto-decel- eration system) LOCK LEVER WARNING •...
Page 163 • When the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends • Before setting the lock lever to FREE position, make sure that all control levers and pedals are set to NEUTRAL position.
Page 164 EXPLANATION OF COMPONENTS OPERATION TRAVEL LEVER WARNING • If you perform operations with your foot on the pedal, the machine may suddenly start if you de- press the pedal by mistake, and this may lead to serious personal injury or death. Be extremely careful when using the pedal for travel and steering operations, and do not put your foot on the pedal when it is not necessary.
Page 165: Other Equipment
OPERATION EXPLANATION OF COMPONENTS The R.H. work equipment control lever is used to operate the boom and bucket. Boom control (a): Boom RAISE (b): Boom LOWER Bucket control (c): Bucket DUMP (d): Bucket CURL N (NEUTRAL) The boom and bucket are held in position and do not move. OTHER EQUIPMENT EMERGENCY ESCAPE HAMMER CAUTION...
Page 166 EXPLANATION OF COMPONENTS OPERATION Use the door lock to keep and fix the door opened. Push the door against catch (1) to lock it in position. When closing the door, push down lever (2) on the left side of the operator's seat, and the catch is released. When keeping the door open, fix it securely to the catch.
Page 167 OPERATION EXPLANATION OF COMPONENTS DRINK BOX It is provided on the rear right side of the operator's seat to store drinks. Air according to the setting of the air conditioner blows into the drink box. MAGAZINE BOX Located on the left side of the operator's seat. Keep Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary.
Page 168 EXPLANATION OF COMPONENTS OPERATION NOTICE While removing the ashtray, if it is stuck in the console cover and hard to be removed, open lid (A) of ashtray, then hold the ashtray body (B) and twist it to remove. If you hold lid (A) of ashtray and twist it, the ashtray may break.
Page 169 OPERATION EXPLANATION OF COMPONENTS Fuse capacities and circuit names Fuse ca- Name of circuit pacity Pump secondary drive switch, swing parking brake cancel switch Machine push-up, boom vibration control PPC oil pressure lock solenoid, starting motor cut-off relay Window washer, cigarette lighter Horn, flash light Ribbon heater relay Revolving lamp...
Page 170 EXPLANATION OF COMPONENTS OPERATION CIRCUIT BREAKER NOTICE Before restoring the circuit breaker, be sure to turn the starting switch to OFF position. • Check the circuit breaker inside the circuit breaker box in the grease pump box cover on the front right of the ma- chine if the turning of the starting switch to ON position does not operate the starting motor.
Page 171 OPERATION EXPLANATION OF COMPONENTS TOOL BOX Store the tools in it. This is located rearward of the engine on the left side of the machine. FIRE EXTINGUISHER (if equipped) A fire extinguisher is provided at the rear part inside the opera- tor's cab.
Page 172 Even if the starting switch is in OFF position, the controller may operate. The lamp lights up in this case, but it is not abnormal. • After the starting switch has been turned to OFF position, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. 3-106...
Page 173 OPERATION EXPLANATION OF COMPONENTS GREASE PUMP The grease pump is stored in the grease pump box on the right side of the machine. METHOD FOR USING GREASE PUMP The grease pump (3) feeds the grease gun (4) with grease when it is actuated by turning on the power switch (1) and the remote switch (2).
Page 174 EXPLANATION OF COMPONENTS OPERATION Pressure gauge Greasing in progress When tip is clogged The grease gun (4) stops discharging the grease when the lever is released. Turn off only the remote switch (2) when the greasing is finished. PRECAUTIONS WHEN USING GREASE PUMP NOTICE Release the remaining pressure from the hose by turning off the remote switch (2) only, so that the internal pressure...
Page 175 OPERATION EXPLANATION OF COMPONENTS Remove the wing bolts (2) (3 places) of the grease can (1), and remove the cover (3) together with the grease pump. Remove the follower plate (4) inside the grease can. Fill the grease can (1) with new grease. Place the follower plate (4) on the surface of the grease.
Page 176 OPERATION REMARK Store the spare grease can in the storage place on the rear of the cab. HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration.
Page 177 OPERATION EXPLANATION OF COMPONENTS In that case, KDPF soot accumulation caution lamp (2) lights up. If this lamp lights up, stop the machine in a safe place and perform the manual stationary regeneration. If fan reverse operation is performed while the aftertreatment devices regeneration pilot lamp and the KDPF soot accumula- tion caution lamp are lit, the accumulated soot may not be burnt sufficiently and the filtering function may not be improved.
Page 178 • 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 fil- ters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 179 OPERATION EXPLANATION OF COMPONENTS REMARK If heavy-duty operation is performed for more than 30 minutes with the fuel control dial between Low idle (MIN) position and High idle (MAX) position, soot is accumulated much and action level “L03” may be displayed. However, this does not indicate abnormality.
Page 180 EXPLANATION OF COMPONENTS OPERATION When the degree of emergency is high • KDPF soot accumulation caution lamp (2) lights up in red and the action level “L03” lights up in red (3). • If the lock lever is set to LOCK position or all the work equipment control levers are set in NEUTRAL, the screen changes to “Aftertreatment Devices Regeneration”...
Page 181 OPERATION EXPLANATION OF COMPONENTS Set the fuel control dial to Low idle (MIN) position. Press switch F6 to display the “Aftertreatment Devices Re- generation” screen. Select manual stationary regeneration, check again that there is no person or combustible material around the machine, then press switch F6.
Page 182 EXPLANATION OF COMPONENTS OPERATION REMARK • The explanation of the manual stationary regeneration is displayed in 3 parts on the monitor panel. When switch F6 is pressed, the regeneration can be started immediately, regardless of which part is displayed. When switch F5 is pressed, the screen returns to the standard screen.
Page 183 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 soot accumulation level (4). The manual stationary regeneration starts at soot accumulation level “4” or higher and finishes when all the level lamps go out.
Page 184 EXPLANATION OF COMPONENTS OPERATION While regeneration is not being performed: Setting for the regeneration disable (When the aftertreatment devices regeneration pilot lamp is not displayed on the standard screen) Press switch F6 on the standard screen. Operate switches F1 and F2 to select “Aftertreatment De- vices Regeneration”...
Page 185 OPERATION EXPLANATION OF COMPONENTS REMARK • When the regeneration is disabled, the aftertreatment devi- ces regeneration disable pilot lamp (2) is displayed with hatch on the standard screen. • The setting of the regeneration disable is canceled by turn- ing starting switch to OFF position. When the automatic re- generation needs to be kept disabled, perform the above procedure each time you start the engine.
Page 186 EXPLANATION OF COMPONENTS OPERATION Select the regeneration disable, press switch F6, and the regeneration stops. REMARK The regeneration performed to protect the system may not be stopped, but this is not a failure. 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...
Page 187 The Komatsu Urea system also monitors recurrences of abnormalities of the system. Inducement in the recur- rences is activated when another abnormality occurs within 40 hours after the first abnormality is fixed. The Komatsu’s Urea is composed of two major systems, which are the DEF system and the SCR catalyst Ass’y. 3-121...
Page 188 In addition, it may cause fail- ures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu dis- tributor. About the operation of Urea SCR system The Urea SCR system automatically starts operating as soon as the engine is started.
Page 189 OPERATION EXPLANATION OF COMPONENTS Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in cold weather, but this is not malfunction. Inducement strategy when the DEF tank Level becomes low When the amount of DEF in the tank goes low, the Inducement strategy will be activated.
Page 190 EXPLANATION OF COMPONENTS OPERATION • Warning: 2 gradations of the DEF level gauge light up in the red range. The DEF level caution lamp (1) lights up in red. No audible alert. No action level is displayed. Press F6 to display the “SCR Information” screen. “SCR Information”...
Page 191 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (4): 3 “Engine power is under deration.” Add DEF to the DEF tank immediately. • Severe Inducement: The audible alert sounds in “Continuous alarm”. No gradation of the DEF level gauge lights up. The DEF level caution lamp (1) lights up in red.
Page 192 If “L03” is dis- played, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 193 OPERATION EXPLANATION OF COMPONENTS • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow. Note: Action Level “L01” once shows up in yellow on the machine monitor (2) for 2 seconds and goes out. Press F6 to display the “SCR Information” screen. “SCR Information”...
Page 194 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Mild Inducement”.
Page 195 “Final Inducement”, the engine speed is fixed to low idle. 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 “SCR Information” screen of the user menu.
Page 196 EXPLANATION OF COMPONENTS OPERATION • Warning: The audible alert sounds in “Intermittent alarm”. The KDPF system caution lamp (1) lights up in red. The action level “L03” lights up in red at action level dis- play (3). Press F6 to display the “SCR Information” screen. “SCR Information”...
Page 197 “Temporary Restoration from Inducement” in this man- ual. If Inducement advances to “Severe Inducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor.
Page 198 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (5): 5 “Engine is run- ning at low idle.” Engine speed is fixed at low idle to disable practical ma- chine operation. Move the machine to a safe place and contact your Ko- matsu Distributor.
Page 199 OPERATION EXPLANATION OF COMPONENTS Press F6 while the pop-up menu screen B is displayed. The “Engine power Recovery” window will be displayed. If F6 is not pressed for 30 seconds, “Standard Screen” will be displayed, and start again by pressing F6. The remaining number of operations of “Temporary Resto- ration from inducement”...
Page 200 If a recurrence occurs, “Severe Inducement” will be activated. If this occurs, utilize “Temporary Restoration from Inducement” and move the machine to a safe place, and contact your Komatsu distributor. The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not cor- rected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final Inducement”...
Page 201 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 202 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 203: Machine Operations And Controls
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Always perform the following inspections and cleaning every day before starting engine for the day's work.
Page 204 12. Check the bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, ask your Komatsu distribu- tor for repair. 13. Check and clean the camera Check the camera for any abnormality.
Page 205 OPERATION MACHINE OPERATIONS AND CONTROLS The water separator forms one unit with fuel prefilter (1). Check for water and sediment. It is possible to judge the water level and amount of sedi- ment by looking through the transparent cup (2). NOTICE If the water in transparent cup (2) freezes, wait until the frozen water has melted completely, then follow...
Page 206 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 207 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not add oil above the H line. It may damage the oil circuit and cause the oil to spurt out. If oil has been refilled exceeding H level, swing the up- per structure until the drain plug (P) beneath the hy- draulic tank comes between the right and left tracks.
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE, ADDING WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Remove the dipstick (G) and wipe off oil on it with a cloth.
Page 209 OPERATION MACHINE OPERATIONS AND CONTROLS Open the cover on the left side of the machine, and check it with the dipstick (G). The oil level should be between the (H) and (L) marks on the dipstick (G). If the oil level is below the mark L, add oil through the dip- stick pipe hole.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. REMARK •...
Page 211 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to 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 212 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the starting switch to ON position. When the fuel level caution lamp (1) lights up in red, check the fuel level with fuel gauge (2) on the machine monitor. When the fuel gauge pointer is in the red range, the fuel quantity is 97 ℓ...
Page 213 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may need to be replaced.
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION After checking, turn the starting switch back to OFF posi- tion (A). Open up cover (2) at the right side of the machine, clean blue DEF tank filler cap (3) and surrounding area. Turn the cap counterclockwise. The caps of DEF tanks are blue, as required by emission regulations.
Page 215 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 216 MACHINE OPERATIONS AND CONTROLS OPERATION • Always adjust the operator's seat before starting each operation or when the operators change shift. • Adjust the operator's seat so that control levers and switches can be operated freely and easily with the operator's back against the backrest.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION Move the headrest up or down to the desired height. Amount of adjustment: 60 mm (2 stages) NOTICE When adjusting the headrest height, operate it so that the shaft of the headrest becomes straight. If it is forcibly twis- ted, the installation part may be broken.
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION Pull the fore-aft adjustment lever (8) to the right, set the seat to the desired position, then release the lever. The operator's seat, right and left control levers, and lock lever move together. Fore-and-aft adjustment: 180 mm (9 stages) METHOD FOR ADJUSTING AIR SUSPENSION SEAT HARDNESS Air suspension seat (if equipped)
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR REMOVING AND INSTALLING HEADREST METHOD FOR REMOVING HEADREST When the headrest is not necessary, remove it according to the following procedure. Pull up the headrest 80 mm or more. The headrest is pulled out. NOTICE When removing the headrest, operate it so that the shaft of the headrest becomes straight.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work. • The machine is placed on a level ground. •...
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the mirror (1). Tightening torque of mounting bolt (2): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting position (3): 15 mm Mounting angle (4): 15 ° NOTICE • Tighten the right and left bolts of each bracket alter- nately so that their right and left clearances (R) and (L) become equal.
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION Adjust the mirror so that you can see a person at the rear right end of the machine. Adjust the mirror with your hand so that the side of the ma- chine is reflected in the mirror as shown in the figure. Check that you can see a person at the rear right end of the machine.
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the stay (1). Mounting position (2): 15 mm Mounting angle (3): 47 ° Adjust the mirror (4). Tightening torque of mounting bolt (5): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting position (6): 62 mm Mounting angle (7): 4 ° Mounting angle (8): 6 °...
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Adjust the mirror so that the side of the machine is reflec- ted in it as shown in the figure. METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE WARNING • Adjust the camera always before starting the work. You cannot secure the visibility and a serious personal injury or death may result if the camera is not adjusted properly.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS If the image on the monitor is not aligned correctly, remove the cover (1), and adjust the mounting angle (A) of the camera. Angle (A) can be adjusted within the range from 35 to 80°. Remove the bolt cover (2) by inserting a flat-head screw- driver or the like into the hole (3) of the bolt cover (2), and push the inside claw (B) to remove the cover.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 227 F6. If a password is set, the input display screen will be indi- cated on the monitor screen. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the password. 3-161...
Page 228 If any caution lamp does not light up or the buzzer does not sound, there is probably a failure in the caution lamp, so ask your Komatsu distributor for repair. After approximately 2 seconds, the screen will change to the working mode/travel speed display. Then, it will switch to the standard screen.
Page 229: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS If the maintenance time has passed for certain items, maintenance time caution lamp (17) is lit in red for 30 sec- onds. Press switch F6, check the item, and perform main- tenance immediately. For details of the method of checking the maintenance in- terval, see “MAINTENANE SCREEN SETTING”...
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (2) to Low idle (MIN) position. Turn the key in starting switch (3) to ON position (B). REMARK If the ambient temperature is low, the preheating pilot lamp lights up and automatic preheating is performed. Keep the key in starting switch (3) at ON position (B) until the pre- heating pilot lamp goes out.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE If the engine oil pressure caution lamp does not go out in 4 to 5 seconds, stop the engine immediately. Check the oil level, oil leakage, etc. and take proper meas- ures. REMARK White smoke may be discharged for a short time immedi- ately after the engine is started or during the aftertreatment devices regeneration in the cold season, but this is not a failure.
Page 232: Method For Operations And Checks After Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION • When the turbo protect function is actuated, the engine speed is held at approximately 1000 rpm or less, regardless of the position of the fuel control dial. • When the turbo protect function is actuated, the engine speed is held at approximately 1000 rpm or less, even if the fuel control dial is operated.
Page 233 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION If the engine coolant temperature goes 30 °C or more or if the warm-up operation is continued for more than 10 minutes, the automatic warm-up operation is cancelled and the engine speed drops to the normal speed at low idle.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CANCELLING AUTOMATIC WARM-UP OPERATION When you are forced to urgently cancel the automatic warm-up operation or to lower the engine speed to Low idle (MIN), do as follows. Turn fuel control dial (2) to High idle (MAX) position and hold it for 3 seconds or more.
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR HYDRAULIC SYSTEM WARM-UP OPERATION WARNING • Before performing the warm-up operation for the hy- draulic equipment, set the swing lock switch (2) on, check on the monitor that the swing lock is actuated, then start the warm-up operation.
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS Set the working mode to P mode (heavy-duty operation mode). The hydraulic component is warmed up quickly. For the details of the working mode setting procedure, see “WORKING MODE SELECTOR SWITCH”. Move lock lever (3) slowly to FREE position (F), then raise the bucket from the ground.
Page 238 Fuel gauge (17): Indicator in green range • Fuel level caution lamp (18): Displays appropriate lev- 11. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. NOTICE In cold temperatures (ambient temperature below 0 °C), even when the hydraulic oil temperature caution lamp displays the proper temperature, perform the "Hydraulic system warm-up operation in...
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS Turn fuel control dial (4) to High idle (MAX) position. Repeat the work equipment operation of step 6 for 3 to 5 minutes. • Display (A) when temperature is proper: Caution lamp background (C) is blue. •...
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION When performing swing operations, release swing lock switch (2), check that swing lock pilot lamp (19) is not lit, then operate the swing. • Travel (Lo) operation: FORWARD (A) ←→ REVERSE 15. Check that hydraulic oil temperature caution lamp (7) dis- plays proper temperature.
Page 241: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Press the working mode selector switch (20) of the ma- chine monitor to select the working mode to be used. For changing the working mode, see “WORKING MODE SELECTOR SWITCH”. Display of working mode P mode For heavy-duty operations E Mode For operations with emphasis on fuel consumption...
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE Do not stop the engine abruptly except in an emergency. Otherwise, the service lives of component parts of the en- gine will be reduced. If the engine is overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradu- ally, and then stop it.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • When the key in starting switch (1) is turned to OFF (A) position, the engine stops, but the machine's main power supply is not turned off immediately. This is because that the power is supplied for the con- troller to save the operating condition and then finish the system.
Page 244: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE WARNING • Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction to the direction of the operation of the travel levers or travel pedals (front and rear travel are reversed, right...
Page 245 R.H. and L.H. travel pedals (6) slowly. When travelling, check that the travel alarm sounds normally. If the travel alarm does not sound, ask your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warm-up operation.
Page 246 R.H. and L.H. travel pedals (6) slow- When travelling, check that the travel alarm sounds nor- mally. If the travel alarm does not sound, ask your Komatsu dis- tributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warm-up operation.
Page 247: Method For Steering Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine.
Page 248: Method For Swinging Machine
MACHINE OPERATIONS AND CONTROLS OPERATION • (A): Forward left turn Return the left travel lever from FORWARD to NEUTRAL position. The machine turns forward LEFT. • (B): Reverse left turn Return the left travel lever from REVERSE to NEUTRAL position. The machine turns in reverse LEFT.
Page 249: Method For Operating Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS When swinging the upper structure, do as follows. Before swinging, turn swing lock switch (1) OFF (can- celed). (a): ON position (b): OFF position Check that swing lock pilot lamp (2) is not lit. Operate L.H. work equipment control lever (3) to swing the upper structure.
Page 250: Handle Working Mode
MACHINE OPERATIONS AND CONTROLS OPERATION • Swing control Move the L.H. work equipment control lever to the right and left. The upper structure swings. • Boom control Move the R.H. work equipment control lever back and forth. You can operate the boom. •...
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Working Applicable operations mode Normal digging or loading operations P mode (production conscious operation) Normal digging or loading operations E Mode (fuel consumption conscious operation) L mode Positioning operations (fine control operations) Set the working mode according to the following procedure. Press the working mode selector switch (1).
Page 252: Prohibited Operations
MACHINE OPERATIONS AND CONTROLS OPERATION Press the L.H. knob switch once and keep it pressed. The operating power increases as long as the switch is press- REMARK However, the increased power is automatically stopped after 8.5 seconds. This function is not actuated when the working mode is set to L mode.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects. This is not only dangerous, but also drastically reduces the life of the machine. PROHIBITION OF OPERATIONS USING TRAVEL FORCE Do not use the travel force to perform excavation by digging the bucket into the ground.
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig. This can apply an excessive force to the chassis and buck- et, and the machine may break.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces. As a result, large vibration occurs in the machine and can crack the work equipment or frame.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION 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 257: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS DO NOT TRAVEL LONG -TIME CONTINUOUSLY If the machine travels continuously at high speed for 1.5 hours or more, the temperature of lubricating oil inside the track roll- ers and final drive will rise up. This may cause breakage to the oil seal or leakage of oil.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION PERMISSIBLE DEPTH OF WATER, SOIL AND DIRT NOTICE When driving the machine out of water, if the angle of the machine exceeds 15 °, the rear of the upper structure will go under water, and water will be thrown up by the cooling fan.
Page 259: 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 260: Method For Escaping From Mud
MACHINE OPERATIONS AND CONTROLS OPERATION When travelling up a steep hill of more than 15°, set the work equipment to the posture shown in the figure. When travelling up a steep slope, extend the work equip- ment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm above the ground, and travel at low speed.
Page 261: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS Track on one side stuck NOTICE When using the boom or arm to raise the machine, push the ground by using the bottom of the bucket. At this time, set the angle between the boom and the arm at 90°...
Page 262: Effective Use Of Hydraulic Excavator
Reducing excavation at high position • Operation at minimum swing angle • Traveling at low engine speed We can provide our users the training for operating methods to increase the productivity and to reduce the fuel consumption. Contact your Komatsu distributor for details. 3-196...
Page 263: Method For Replacing And Inverting Bucket
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR REPLACING AND INVERTING BUCKET WARNING • When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When performing this operation, always wear protective eyeglasses, hard hat, gloves, and other protective equipment.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION Remove the stopper at the pin end, and remove the pins (A) and (B) to remove the bucket. REMARK After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, be care- ful not to damage them.
Page 265: 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 266: Method For Checking After Finishing Work
MACHINE OPERATIONS AND CONTROLS OPERATION Lower the bucket horizontally until the bottom touches the ground. Set lock lever (3) in LOCK position (L). Check the engine coolant temperature and engine oil pres- sure with the machine monitor. • If the engine coolant temperature gauge is in the red range, cool down the coolant until the gauge enters the green range, and stop the engine.
Page 267: Lock
OPERATION MACHINE OPERATIONS AND CONTROLS LOCK Position to be locked Always lock the following places. (1) Operator's cab door Always close the window. (2) Fuel tank filler port (3) Engine hood (6 places) (4) Battery box cover (5) Left side door of the machine (6) Hydraulic tank filler port (7) Air conditioner FRESH air filter intake port (8) DEF tank filler port cover...
Page 268 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK Insert the key into the key slot. Turn the key counterclockwise and open the cover by pulling the cover handle. Position (A): OPEN Position (B): LOCK METHOD FOR LOCKING COVER WITH LOCK Close the cover and insert the key into the key slot.
Page 269 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING ENGINE HOOD Insert the key into key slot (1). Turn the key counterclockwise (A) and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) Pull the lever grip (2) and remove the bottom of the lever from the hook.
Page 270 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING DEF TANK FILLER CAP COVER CAUTION • When opening or closing the DEF tank filler cap cover, place the machine on a level place, lower the work equipment to the ground, stop the engine, then perform the operation. •...
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR LOCKING DEF TANK FILLER CAP COVER Pull the stay (3) toward you and unlock the stay. Lower the cover. Turn the key clockwise to lock, and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR OPENING AND CLOSING CAB DOOR When opening the door (locked door) Insert the key into the key slot.
Page 272: Handle Air Conditioner
If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner system caution lamp lights up on the monitor screen. If the air conditioner system caution lamp lights up, ask your Komatsu distributor for inspec- tion and repair. Ventilation •...
Page 273: Explanation Of Air Conditioner Equipment
OPERATION HANDLE AIR CONDITIONER EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Sunlight sensor (5) Auto switch OFF SWITCH This switch is used for stopping the fan and air conditioner.
Page 274 HANDLE AIR CONDITIONER OPERATION Monitor display and air flow Monitor display Air flow rate Air flow "low" Air flow "medium 1" Air flow "medium 2" Air flow "medium 3" Air flow "medium 4" Air flow "high" TEMPERATURE SET SWITCH Use the temperature set switch to adjust the temperature inside the cab.
Page 275 OPERATION HANDLE AIR CONDITIONER (A): Rear vent (4 places) (B1): Face vent (1 place) (C): Foot vent (1 place) (D): Front window glass vent (2 places) (B2): Front window glass vent (1 place) Air blows out from the vents marked with ○. Vent LCD display Air vent mode...
Page 276 HANDLE AIR CONDITIONER OPERATION FRESH/RECIRC AIR SELECTOR SWITCH Use FRESH/RECIRC air selector switch to switch the air source between recirculation of the air inside the cab and in- take of fresh air from the outside. During automatic operation, the selection of inside air (RE- CIRC) and outside air (FRESH) is performed automatically.
Page 277: Method For Operating Air Conditioner
OPERATION HANDLE AIR CONDITIONER SUNLIGHT SENSOR Sunlight sensor automatically adjusts the flow of air from the vents to match the strength of the sun's rays. In addition, it au- tomatically detects changes in the temperature inside the cab caused by changes in the strength of the sun's rays beforehand and automatically adjusts the temperature.
Page 278 HANDLE AIR CONDITIONER OPERATION Use temperature control switch (2) to set to the desired temperature. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated auto- matically to provide the set temperature.
Page 279 OPERATION HANDLE AIR CONDITIONER METHOD FOR MANUAL OPERATION Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor. Turn air conditioner switch (2) ON. Use temperature control switch (3) to set to the desired temperature.
Page 280 HANDLE AIR CONDITIONER OPERATION Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the monitor changes according to the selection. Press FRESH/RECIRC air selector switch (5) and select recirculation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
Page 281 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blow- ing to the feet, set as follows. Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor.
Page 282 HANDLE AIR CONDITIONER OPERATION Turn on the air conditioner switch (3). Adjust fan switch (1), temperature control switch (4) and FRESH/RECIRC selector switch (5) to the desired posi- tions. 3-216...
Page 283 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING DEFROSTER Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor. Press vent selector switch (2) and set vent display on the monitor to (f) or (g) as shown in drawing.
Page 284 HANDLE AIR CONDITIONER OPERATION Press FRESH/RECIRC selector switch (3) and set it to FRESH mode. Press temperature control switch (4) and set temperature on the monitor to 32.0 of maximum heating. Adjust vents (A), (B1), and (B2) so that the air blows onto the window glass. (Vents (C) and (D) are fixed and cannot be adjusted.) When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify...
Page 285: Handling Radio
OPERATION HANDLING RADIO HANDLING RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them. •...
Page 286 HANDLING RADIO OPERATION DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display. Each time you press this button, frequency, clock and band are shown on the display in this order. If 1.5 seconds passes while a band is shown, a frequency will be displayed. As long as AUX is selected, this button alternately switches the display between AUX and the clock.
Page 287: Method For Controlling Radio
OPERATION HANDLING RADIO Open cap (a). Connect a portable audio equipment by using a commer- cially available audio cable. Press band/AUX selector button (1) to select “AUX”. METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency.
Page 288 HANDLING RADIO OPERATION METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING) Press band/AUX selector button (1) and select FM or AM. Hold down sound control button (2). When a proper frequency is picked up, it is automatically registered to preset memories 1 to 6. METHOD FOR CALLING PRESET Press band/AUX selector button (1) and select FM or AM.
Page 289 OPERATION HANDLING RADIO METHOD FOR ADJUSTING SOUND BALANCE Press sound control button (1) to light up “BAL” on the dis- play. You can adjust the sound (balance). Press tuning/time adjustment button (2) to adjust the sound (balance). Press the △ button, and the speaker output on the R •...
Page 290: Stow Antenna
If the installation is needed, remove the front cover (1), and connect the speaker wires and the antenna to the radio cas- sette player. For the installation, consult your Komatsu distributor. Do not operate the radio in the L.H. console if a radio cassette player is installed to this place.
Page 291: Transportation
Note that the weight and dimension given in “SPECIFICATIONS” (weight and dimension) may differ accord- ing to the type of track shoe or arm, or other attachments. • Consult your Komatsu distributor for details of the procedure for transporting machines equipped with a pro- tective guard for the operator's cab. •...
Page 292: Precautions For Loading Machine
Fix the machine securely to prevent it from slipping side- ways in particular. MACHINE CONFIGURATION FOR TRANSPORTATION The machine can be disassembled in three kits or in four kits for transportation. When transporting the machine, ask your Komatsu distributor for disassembling. 3-226...
Page 293 OPERATION TRANSPORTATION Transportation of the machine as four kits (A) Upper structure (B) Undercarriage (C) Work equipment (D) Others Style of packing of each kit Upper structure + undercarriage Item Unit PC700LC 4020 6590 Shoe width Overall width 3485 Weight 43800 Upper structure Fix the upper structure to the truck by using chains and blocks.
Page 294 TRANSPORTATION OPERATION Undercarriage If the warning tag is displayed on the work equipment control lever, do not start the engine. Item Unit PC700LC Q'ty 1440 5810 Weight 11000 x 2 Work equipment • Boom Reinforced Standard Type Unit SE boom boom boom 7550...
Page 295 OPERATION TRANSPORTATION • Arm Reinforced Type Unit Standard arm Semi-long arm Long arm SE arm 4870 5650 6580 4230 4870 1210 1220 1340 1490 1240 Overall width Weight 3220 3740 4160 3530 3330 • Bucket (with side cutter and shroud) Item Unit 2040...
Page 296: Spread And Narrow Track Frame Gauge
TRANSPORTATION OPERATION Others • Counterweight Item Unit 1320 3190 Weight 9360 • Cat walk (1) (common to all models) Item Unit 2460 1230 Weight • Cat walk (2) (common to all models) Item Unit 1910 Weight SPREAD AND NARROW TRACK FRAME GAUGE PRECAUTIONS FOR SPREADING AND NARROWING TRACK FRAME GAUGE WARNING •...
Page 297 OPERATION TRANSPORTATION Remove the center frame mounting bolts (1) (16 pieces each on the front and rear side on one side). Swing the upper structure to a right angle to track frame (A) to be retracted, and lift the machine off the ground by using the work equipment as a jack.
Page 298 TRANSPORTATION OPERATION Pull the track frame until it reaches the stopper, then lower the machine to the ground, and tighten the bolts (1) (16 pieces each on the front and rear on one side). Tightening torque: 1960 to 2450 Nm {200 to 250 kgm} Work on the track frame on the other side in the same way.
Page 299: Cold Weather Operation
If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 300: Precautions After Daily Work Completion In Cold Weather
COLD WEATHER OPERATION OPERATION REMARK Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table. Electrolyte Temper- ature 20 °C 0 °C –10 °C –20 °C Charging Rate (%) 1.28 1.29 1.30 1.31 1.26 1.27 1.28 1.29 1.24 1.25 1.26 1.27...
Page 301 Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM- MENDED FUEL, COOLANT, AND LUBRICANT”. If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-235...
Page 302: 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 hydraulic cylinder piston rods.
Page 303 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of the drained DEF according to the local regulations and rules.
Page 304: 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 it up with fuel and bleed air from the fuel system before stating. Always check the fuel level to prevent running out of fuel. If the engine has stopped because of running out of fuel, all the air in the fuel circuit must be bled by using the fuel feed pump.
Page 305: Phenomena That Are Not Failures
OPERATION TROUBLES AND ACTIONS After the engine starts, run it for approximately 5 minutes to bleed all air from the fuel circuit. After approximately 5 minutes, stop the engine. Then, start the engine as usual. PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: •...
Page 306: 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 on the right. • Place pieces of wood between the wire ropes and the ma- chine to prevent damage to the ropes and the machine.
Page 307: 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 308 TROUBLES AND ACTIONS OPERATION Remove and install the battery cable • Disconnect the ground cable (normally connected to the negative (-) terminal) first. If any tool touches between the positive (+) terminal and the chassis, there is a hazard of sparks being generated.
Page 309 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Always follow the instructions in the precautions for dis- charged battery and the instruction manual accompanying the charger, and observe the following.
Page 310 TROUBLES AND ACTIONS OPERATION START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 311: 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 312 PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 313 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy Engine oil pressure monitor lights up.
Page 314 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Starting motor operates but engine Add fuel by referring to CHECKS BE- Fuel is insufficient. does not start. FORE STARTING. Fuel filter is clogged. Replace the fuel filter. Repair the place where air is mixed Air is mixed in the fuel system.
Page 315 ING FUEL PREFILTER CARTRIDGE” and “METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE”. If “CA2249” or “CA559” does not disappear even after the replacement, ask your Komatsu distributor for inspection and repair immediately, even though the machine can perform normal operation.
Page 317: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 318: 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 319: Precautions For Scr Assembly
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine stops the parts around SCR device may be at high temperature. DUSTY JOBSITES When working at dusty jobsites, observe the following. •...
Page 320: Close Engine Hood Securely
PRECAUTIONS FOR MAINTENANCE MAINTENANCE CLOSE ENGINE HOOD SECURELY When closing the engine hood after inspection or maintenance, make sure that the catch is securely locked. If the engine hood catch is not locked, there is a danger that the engine hood may open.
Page 321: 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 322 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 323 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 324 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 325: Handle Electrical Components
Never install any electrical components other than those 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. •...
Page 326: 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 327 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Outside Tightening torque (Nm {kgm}) diame- ter of Width across thread flats “b” Target value Allowable range portion (mm) “a” (mm) 3430 to 4220 {335.0 to 3830 {390.0} 430.0} Torque list for hoses Tighten the hoses to the torque shown in the table.
Page 328: Maintenance Schedule
See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) .......... 4-16 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) ..........
Page 329: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR BREAKER) ........................4-60 METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ..........4-60 METHOD FOR REPLACING DEF TANK BREATHER ELEMENT............4-61 METHOD FOR CHECKING AND REPLACING ALTERNATOR AND AIR CONDITIONER COMPRESSOR DRIVE BELT............................
Page 330: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE SCHEDULE MAINTENANCE Replace hydraulic filter element On a new machine, replace the element after the first 100 to 150 hours, then perform further replacement of the element ac- cording to the table. Change oil in hydraulic tank Change the oil according to the table. Replace additional filter element for breaker (if equip- ped) Use a guideline of 250 hours for use of the breaker (operating...
Page 331 MAINTENANCE MAINTENANCE SCHEDULE Fuel main fil- Replace. Replace. Replace. Replace. ter cartridge 4-15...
Page 332: Maintenance Procedure
Change oil in PTO case • Change oil in final drive case Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. For the method of adjustment, see EVERY 1000 HOURS MAINTENANCE and EVERY 2000 HOURS MAINTE- NANCE.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE Check that air cleaner clogging caution lamp (1) on the ma- chine monitor is lit. If the air cleaner clogging caution lamp lights up, clean the air cleaner element. METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT NOTICE •...
Page 334 MAINTENANCE PROCEDURE MAINTENANCE After cleaning, light up the inside of the element with a lighting bulb to see if the element has a small hole or a thin part. Replace it if it has any of these. Remove the cover of cloth or tape attached to inner ele- ment (6).
Page 335 MAINTENANCE MAINTENANCE PROCEDURE Lock the tip of hook (2) on the protrusion of the air cleaner body. Lock the hooks (2) diagonally, (top and bottom, right and left) in the same way as when tightening the bolts. Always install the cover (3) so that vacuator (4) faces the ground (A).
Page 336 MAINTENANCE PROCEDURE MAINTENANCE Clean the dust sticking inside the air cleaner body (7) and on the cover (3) by using a clean cloth or brush. If any dust is attached to the vacuator valve (4) installed to the cover (3), remove it. NOTICE •...
Page 337: Method For Cleaning Inside Of Cooling System
Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF- NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 338 MAINTENANCE PROCEDURE MAINTENANCE 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. To maintain the anti-corrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of Non-Amine Engine Coolant between 30% and 64%.
Page 339: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE Stop the engine and open the drain valves (6), (7), and (8) to drain the water. After draining the water, clean with detergent liquid. For draining the water, follow the instructions of the clean- ing agent to be used. Close the drain valves (6), (7), and (8).
Page 340: Method For Checking And Adjusting Track Tension
Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened by the above procedure, ask your Komatsu distributor for repair. METHOD FOR INCREASING TRACK TENSION...
Page 341: Method For Replacing Bucket Teeth (Kmax)
Check the track tension again, and if the tension is not cor- rect, adjust it again. If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. METHOD FOR DECREASING TRACK TENSION WARNING There is danger of plug (1) flying out under the high internal pressure of the grease.
Page 342 Broken pieces may fly during the replacement work, so always wear the protective equipment such as protective eyeglasses and gloves. • If the tooth pin cannot be removed by this method, ask your Komatsu distributor to have the re- placement performed for safety. •...
Page 343: Method For Removing Slinging Loop
MAINTENANCE MAINTENANCE PROCEDURE Push out the pin (1) in the direction of arrow with a ham- mer, and remove the tooth (2). Clean the mounting face. Fit a new tooth (2) in the adapter. Push in the pin (1), and rotate it clockwise with a socket wrench by 90 °.
Page 344 MAINTENANCE PROCEDURE MAINTENANCE NOTICE The following problems may occur if you operate the machine without removing the slinging loop. • The slinging loop at tooth tip interferes with the boom when moving the arm to IN position and the bucket to CURL position. •...
Page 345: Method For Replacing Bucket Teeth (Horizontal Pin Type)
Place a bar on the head of pin (1), hit the bar with a ham- mer to knock out the pin, then remove tooth (2). REMARK If it cannot be removed by this method, ask your Komatsu distributor to have the replacement performed. 4-29...
Page 346: Method For Adjusting Bucket Clearance
MAINTENANCE PROCEDURE MAINTENANCE Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket. METHOD FOR ADJUSTING BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance.
Page 347: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID If air is in the window washer fluid, check the fluid level in window washer tank (1). If the level is low, add window washer fluid for automobile. Be careful not to let dirt or dust get in when adding fluid.
Page 348: Method For Replacing Additional Filter Element For Breaker
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low. Con- tact your Komatsu distributor to have refrigerant added. If the air conditioner is operated with the refrigerant gas level low, it will cause damage to the compressor.
Page 349: Method For Washing Washable Floor
MAINTENANCE MAINTENANCE PROCEDURE Remove the plug (3) from the filter case (1), and drain oil in the case. After checking that the hydraulic oil temperature has drop- ped, turn the filter case (1) counterclockwise, remove it, then take out the element (2). Clean the removed parts, then install the new element (2) and O-ring (4).
Page 350 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING WASHABLE FLOOR MAT Stop the machine on a level ground, lower the bucket to the ground, stop the engine, and then perform the cleaning When washing the floor mat, use a brush to remove the dust, or directly water the mat to wash it with a brush.
Page 351 MAINTENANCE MAINTENANCE PROCEDURE Lower the work equipment to the ground and set the ma- chine in a stable condition. Operate the control grip (g) of the lock lever (1) to set it se- curely to LOCK position (L) and stop the engine. Pull out projections (2) (6 places) on the back of the floor mat and remove the floor mat.
Page 352 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR SETTING MACHINE AT ANGLE You can set the machine at an angle by using a slope or blocks. Consider the condition of the machine and select the safe method. METHOD FOR USING SLOPE WARNING Select a solid and smooth slope. Always block the tracks from movement, and thrust the work equipment into the ground.
Page 353: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT CAUTION Cancel the automatic warm-up operation, and start the engine to perform the air bleeding. NOTICE • Bleed air according to the following order. • Pump (for work equipment and swing) •...
Page 354 MAINTENANCE PROCEDURE MAINTENANCE • When the oil inside the swing motor case is drained Run the engine at low idle, loosen the hose (4) at port S, and check that oil oozes out from the port S hose (4). NOTICE At this time, do not perform the swing operation.
Page 355: Method For Cleaning Line Filter And Removing Dirt
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING LINE FILTER AND REMOVING DIRT If any abnormality is found in hydraulic components such as pumps, remove the dirt from the line filter as fol- lows. Before removing the line filter, release the internal pressure in the hydraulic circuit by referring to “METHOD FOR RELEASING PRESSURE IN ACCUMULATOR”.
Page 356: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE Set a container to catch the oil under the pilot line filter. Remove the plug (1). Take out the strainer (2) and wash it. Replace the O-ring (3) with a new one. Install the washed strainer (2). •...
Page 357 MAINTENANCE MAINTENANCE PROCEDURE (1) Boom cylinder foot pin (2 places) (2) Boom foot pin (2 places) (3) Boom cylinder rod pin (2 places) (4) Arm cylinder foot pin (1 place) 4-41...
Page 358: Every 100 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE (5) Boom and arm connection pin (1 place) (6) Bucket cylinder foot pin (1 place) (7) Arm cylinder rod pin (1 place) (8) Arm and link connection pin (1 place) (9) Arm and bucket connection pin (1 place) (10) Link connection pin (2 places) (11) Bucket cylinder rod pin (1 place) (12) Bucket and link connection pin (1 place)
Page 359: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Lower the work equipment to the ground. By using a grease pump, apply grease to the grease fit- tings marked by arrows (3 places). After greasing, wipe off any old grease that is pushed out. EVERY 250 HOURS MAINTENANCE Maintenance for every 10 hours service should be performed at the same time.
Page 360: Method For Checking Battery Electrolyte Level
MAINTENANCE PROCEDURE MAINTENANCE Set the TOP mark at the top to make the TOP mark and plug (P) are positioned as shown in the right figure. Remove the plug (F) by using the handle. When the oil level is within the range of 10 mm below the lower edge of the plug hole, the oil level is appropriate.
Page 361: Every 500 Hours Maintenance
If it is added to above the bottom tip of the sleeve, use a syringe to remove it. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, con- sult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 362 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Refill capacity of oil pan: 48 ℓ...
Page 363: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 364 MAINTENANCE PROCEDURE MAINTENANCE Turn the valve (1) at the bottom of the fuel tank to CLOSE position (S). Open the engine hood. Place a container to catch the fuel under the fuel prefilter cartridge (2). Loosen the drain valve (3) and drain the water and sedi- ment from the transparent cup (4), and also drain all the fuel accumulated in the filter cartridge (2).
Page 365: Method For Checking Swing Pinion Grease Level, Add Grease
MAINTENANCE MAINTENANCE PROCEDURE NOTICE • When filling the filter cartridge with fuel, do not re- move the cap (B) at centre. Always fill with fuel from small holes (A) (8 places) on the dirty side. • After filling with fuel, remove the cap (B) at centre and install the fuel filter.
Page 366: Method For Checking And Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
Measure with the ruler by inserting it into the position (A) shown in the right figure. Check that the grease is not milky white. If the grease is milky white, it needs to be replaced. Ask your Komatsu distributor to replace it. Total amount of grease: 31 ℓ (28 kg ) Install the cover (2) with bolt (1).
Page 367: Method For Cleaning Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE Loosen the bolt (5) on the top cover (4) on the engine body, and slide the cover (4) rearward. Check the front and rear surfaces of oil cooler fins (6), ra- diator fins (7), aftercooler fins (8), air conditioner condens- er fins (9), and fuel cooler fins (10).
Page 368 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING RECIRCULATION AIR FILTER Remove wing bolts (1) from the inspection window at the bottom rear left inside the operator's cab. Take out the recirculation air filter. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash it in a neutral detergent.
Page 369: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE REMARK • The fresh air filter must be installed facing it in the cor- rect direction. • When installing, insert long end (L) of filter (5) into duct (6) first. If short end (S) is inserted first, filter (5) will get stuck with protrusion (B) of the sheet metal •...
Page 370: Method For Replacing Hydraulic Oil Filter Element
(4). If there is excessive metal powder or foreign material in the strainer (5), contact your Komatsu distributor. Check the bottom of the filter case for dirt or other materi- al, and remove any if found.
Page 371: Method For Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE For details, see “METHOD FOR INSTALLING HYDRAULIC OIL FILLER PORT CAP”. 11. Start the engine and run it at low idle for 10 minutes to bleed air. 12. Stop the engine. REMARK Leave the machine as it is for at least 5 minutes, and then start the operation. This will remove the air bub- bles in the oil inside the tank.
Page 372: Method For Changing Oil In Pto Case
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN PTO CASE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. NOTICE Park the machine on a flat ground and stop the engine.
Page 373: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 374: Method For Checking All Tightening Points Of Engine Intake Pipe Clamps
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR CHECKING WELDED STRUCTURE (Color check) Cracks on the welded structure can be easily seen by visual check with the color check.
Page 375 MAINTENANCE MAINTENANCE PROCEDURE (A) Important inspection part (F) Front • Revolving frame • Center frame 4-59...
Page 376: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Breaker)
METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRES- SURE IN ACCUMULATOR (FOR BREAKER) (if equipped) A special tool is needed for checking and charging of nitrogen gas. Ask your Komatsu distributor to perform this work. METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING •...
Page 377: Method For Replacing Def Tank Breather Element
If the machine is operated without DEF tank breather element attached, or with the element other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without DEF tank breather element at- tached, nor use the element other than Komatsu genuine parts.
Page 378: Every 2000 Hours Maintenance
TIONER COMPRESSOR DRIVE BELT Special tools are required for inspection and replacement of the alternator and air conditioner compressor drive belt. Ask your Komatsu distributor for inspection and replacement. REMARK As the automatic belt tensioner for the alternator and air conditioner compressor drive belt is installed, no belt tension adjustment is required.
Page 379: Method For Cleaning Hydraulic Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE Set the TOP mark at the top to make the TOP mark and plug (P) are positioned as shown in the right figure. Place the oil container to catch the oil under the plug (P). Remove the plugs (P) and (F) by using the handle, and drain the oil.
Page 380: 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 have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 381 MAINTENANCE MAINTENANCE PROCEDURE The accumulator is installed to the position shown in the figure. METHOD FOR CHECKING ACCUMULATOR FUNCTION CAUTION Be sure that no person or obstacle is around the machine before performing the inspection. Check the nitrogen gas charge pressure as follows. Place the machine on a firm, level ground.
Page 382 If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulator for the hy- draulic circuit has probably dropped. Ask your Komatsu distrib- utor for inspection. This completes the inspection. After completion of the inspection, set the work equipment lock lever to LOCK position and turn the starting switch to OFF position (A).
Page 383: Method For Checking Alternator
If the engine is started frequently, have this inspection performed every 1000 hours. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. METHOD FOR REPLACING KCCV FILTER ELEMENT WARNING After the engine has been operated, all the parts are still very hot.
Page 384 MAINTENANCE NOTICE • Komatsu recommends using Komatsu genuine parts for replacement parts. • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil.
Page 385 MAINTENANCE MAINTENANCE PROCEDURE After the ring (3) comes off, remove the case (4) from body (2), and remove the element (5). There may be oil accumulated or sticking in the case and element. Take care not to spill the oil when replacing the element.
Page 386 MAINTENANCE PROCEDURE MAINTENANCE Take extreme care when inserting it so that the protrusion (9) in the case fits to the rubber lip (10) of the element. Align the position of ◇ mark (8) on the case with that of ◇ mark (11) of the filter body label, then install the case to the filter body.
Page 387: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 388 MAINTENANCE PROCEDURE MAINTENANCE Turn the cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5). Insert the filter removal tool (3) into the bottom of the DEF pump and thrust in by hand. Check that the filter removal tool (3) is fully inserted to the end.
Page 389: Every 4000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Pull the filter (6) up while pushing in the tip of filter removal tool (3), and remove it. Return the removed spacer (5) to the filter removal tool (3), and keep them. 10. Insert a new filter and a new element into the bottom of DEF pump, and lightly tighten them with hand.
Page 390: Method For Checking Water Pump
PPC accumulator Attachment additional accumulator METHOD FOR CHECKING WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor to perform disassembly, repair, or replacement. CHECK OPERATING CONDITION OF COMPRESSOR Ask your Komatsu distributor for inspection.
Page 391: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner. Ask your Komatsu dis- tributor for replacement. The accumulator is installed to the position shown in the figure.
Page 392: Every 4500 Hours Maintenance
Check fuel spray prevention caps (1) to (11) and fuel spray prevention cover (12) visually or with your fingers to see if any of them has slipped off, or the rubber portion is hardened. If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 10, 100, 250 and 500 hours should be performed at the same time.
Page 393: Every 5000 Hours Maintenance
Check the fuel spray prevention caps (1) and (2) visually or with a finger to see if any of them has slipped off, or if the rubber portion is hardened. If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. EVERY 5000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500 and 1000 hours should be performed at the same time.
Page 394: Every 8000 Hours Maintenance
Ask your Komatsu distributor for replacement of the engine high-pressure piping. METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps. EVERY 9000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500, 1000 and 4500 hours service should be performed at the same time.
Page 395: Method For Replacing Fuel Spray Prevention Cap On Fuel Doser Piping
Special techniques and tools are required for this work. Ask your Komatsu distributor for replacement of the fuel spray prevention cap on fuel doser. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-79...
Page 397: Specifications
SPECIFICATIONS...
Page 398: Specifications: Pc700Lc-11
Unit (7.3m/3.5m) (6.6m/2.9m) Operating weight kg 66900 67400 Bucket capacity m Engine model Komatsu SAA6D140E-7 diesel engine SAE J1995 (gross) 327 / 1800 Rated horse- kW / min ISO 9249 /SAE J1349 325 / 1800 power (net) A Overall length mm...
Page 399: Explanation Of Lift Capacity Chart (1-Piece Boom)
Maximum reach at ground mm 12380 11295 level EXPLANATION OF LIFT CAPACITY CHART (1-PIECE BOOM) 1-Piece Boom - PC700LC-11 LEGEND A: Reach from swing centre B: Bucket hook height OF: Lifting capacity (rating overfront) OS: Lifting capacity (rating overside) LEGEND...
Page 400 SPECIFICATIONS SPECIFICATIONS (1) Position of lifting point (2) Arm length (3) Boom length (4) Hydraulic pressure WORKING CONDITIONS: Bucket Specification Shoe Width 7.3 m Boom 2.8 m / 3100 kg 610 mm 7.6m Boom 2.7 m / 2430 kg 610 mm •...
Page 401 SPECIFICATIONS SPECIFICATIONS For 7.6m Boom...
Page 402 SPECIFICATIONS SPECIFICATIONS...
Page 403: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 404: 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 405 ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS • The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight when it is stopped in a raised position) also becomes greater. Do not stop the work equipment in air.
Page 406: Handle Bucket With Hook
If the bucket with hook is turned 180 ° and used for operations, it will hit the arm during the bucket DUMP operation. Be careful when using it. If you are planning to newly install a hook, ask your Komatsu distributor for installation.
Page 407: Handle Machine Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS ON MACHINE EQUIPPED WITH AT- TACHMENT KS001587 (1) Stop valve (3)Lock pin (2) Attachment control pedal (breaker) STOP VALVE The stop valve stops the flow of the hydraulic oil.
Page 408 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS ATTACHMENT CONTROL PEDAL WARNING Do not carry out operations with your foot on the pedal. If the pedal is depressed by mistake, the attach- ment may suddenly move and cause a serious personal injury or death. Lock the pedal with the lock pin when pedal operation is not necessary.
Page 409: Method For Hydraulic Circuit Connection
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT NOTICE • When using the breaker, if the lock pin is set to posi- tion (c) and the pedal is operated in direction (B), it will cause damage or defective operation of the breaker. To prevent this, when using the breaker, always set the lock pin to position (b).
Page 410: Method For Removing And Installing Attachment
REMARK Method of connection varies depending on the attachment manufacturer because size of the fitting, added accumula- tor, etc. are different. Consult your Komatsu distributor. PEDAL OPERATION AND OIL FLOW OF MACHINE EQUIPPED WITH ATTACH- MENT The direction of operation of the pedal and the path of the oil flow is as shown in the diagram below.
Page 411 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR REMOVING ATTACHMENT Turn the starting switch to the ON (B) position, then set the lock lever to the FREE position (F). Operate each work equipment control lever and attach- ment control pedal fully to the front, rear, right, and left a few times within 15 seconds to release the internal pres- sure in the hydraulic circuit.
Page 412 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Remove the hoses on the attachment side. Fit blanking flange assembly (3) at the stop valve bracket. Install the plugs to the two outlets. The plugs are used to prevent the attachment from incor- rect operation caused by mixing in of foreign matter.
Page 413 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Set the lock lever to FREE position (F). Operate each work equipment control lever and attach- ment control pedal fully to the front, rear, right, and left a few times within 15 seconds to release the internal pres- sure in the hydraulic circuit.
Page 414: Long-Term Storage
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Follow the procedure below for setting the stop valve to FREE position (F) or LOCK position (L). Remove the bolt (1) and washer (2). Rotate valve to furthest position clockwise or anti- clockwise.
Page 415: Arm/Pin Information
ATTACHMENTS AND OPTIONS ARM/PIN INFORMATION ARM/PIN INFORMATION C - C KS000578 +0.5 464 mm 456 mm 110 mm PC700LC-11 -0.5 Boom/Arm +0.5 +0.5 7.3m/3.5m 115 mm 115 mm 556 mm +0.1 +0.5 +0.5 464 mm 456 mm 125 mm PC700LC-11 -0.5...
Page 416: 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 417: Track Shoes Selection
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS 4.66 / 3650 3.59 / 3375 3.24 / 2600 Bucket 1.5 t/m / kg 4.00 / 3425 3.10 / 3200 2.70 / 2175 Bucket 1.8 t/m / kg Max Allowable Bucket 1910 1780 1600 Width mm Values shown are in accordance with EN474-5:2006+A1:2009 (E) TRACK SHOES SELECTION...
Page 418: Komvision
• If the normal range cannot be confirmed in the confirmation of the camera visibility, it is necessary to adjust the monitor screen. Ask your Komatsu distributor to perform this work. • The machine monitor image may not be displayed due to darkness at night or in a tunnel, fog, snow, rain, cloud of dust, etc.
Page 419: Explanation Of Machine Monitor Equipment
ATTACHMENTS AND OPTIONS KomVision (9) Fuel consumption gauge (27) Aftertreatment devices regeneration pilot lamp (10) Service meter (28) Aftertreatment devices regeneration disable pilot lamp (11) Working mode display (29) Message display (12) Travel speed display (30) Air conditioner pilot lamp (13) Camera switch display (31) Engine oil level caution lamp (14) Clock...
Page 420: Warning Display
KomVision ATTACHMENTS AND OPTIONS (3) Meter display (5) Guidance icon display (4) Monitor switch part (6) Camera image display REMARK • If environmental temperature of the machine monitor is high, brightness may be automatically reduced to protect the liquid crystal. •...
Page 421: Camera System Caution Lamp
The machine monitor will not show the image from the defec- tive camera. Physically make sure the adjacent safety around the machine. Consult your Komatsu distributor for inspection and mainte- nance. CAMERA CONTROLLER CAUTION LAMP The caution lamp comes on in yellow with action level "L01"...
Page 422 KomVision ATTACHMENTS AND OPTIONS (3) Camera image (4) Camera switch display KomVision synthesizes the images of 4 cameras and displays the image from 300 ° above the machine. The shaded area in the figure is not displayed on the monitor screen even if the camera images are synthesized. Since this image is electronically synthesized, the objects in the image may be displayed double or distortions or misalignment may occur in the shaded areas of the back of the machine (A)
Page 423: Monitor Display Selector Switch
ATTACHMENTS AND OPTIONS KomVision The guide line is displayed as follows: Display area Display color Quadrangle (A) in which the rear of the machine is inscribed when the machine swings Quadrangle + 2 m (B) in which Yellow the rear of the machine is in- scribed when the machine swings MONITOR DISPLAY SELECTOR SWITCH...
Page 424: Camera Image Selector Switch
KomVision ATTACHMENTS AND OPTIONS AA: Standard screen, BB: Enlarged bird's eye view display, CC: Camera image screen • On the standard screen AA, the synthesized image to show the area around the machine from above and the image of the camera loaded into the machine are displayed on the left and right sides of the machine monitor, respectively.
Page 425: Method For Checking Before Starting
If the traffic cone can be seen on the monitor screen, it is nor- mal. If the traffic cone cannot be seen on the monitor screen, ask your Komatsu distributor for adjustment of the cam- era image. TROUBLES AND ACTIONS When the monitor does not respond or displays no camera image, consult your Komatsu distributor.
Page 427: Replacement Parts
REPLACEMENT PARTS...
Page 428: 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 429: 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 430: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 431: Lubrication Chart
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT NOTICE Use DEF as the aqueous urea solution for SCR system. DEF is a colorless transparent 32.5 % aqueous urea solu- tion. The quality of DEF is prescribed in ISO22241-1. Always use DEF that conforms to this quality standard. ®...
Page 432 USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBI- ENT TEMPERATURE Ambient temperature, de- Recommended grees Celsius( °C） Reservoir Fluid type Komatsu Fluids Engine oil for KDPF used in cold EOS5W30-LA terrain (KES) (Oil Change interval 250 hours) EOS5W40-LA (KES) (Note.1)
Page 433: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Note 6: The DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after the engine is started. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 435: Index
INDEX INDEX Symbols Auto switch............3-209 Auto-deceleration and automatic low idle pilot lamp..12H/24H display mode - Switch......3-81 ...............3-31 Auto-deceleration switch........3-43 Automatic low idle setting........3-67 Automatic operation - Start......... 3-211 Accumulator - Check function....... 4-65 Automatic operation - Stop......... 3-212 Accumulator for control circuit - Check / Release ni- Automatic warm-up operation - Cancel....3-169 trogen gas charge pressure......4-64...
Page 436 INDEX Checks before starting........2-25,4-40 Ditching work............3-196 Chemical hazard........... 2-43 Do not disassemble recoil spring......2-42 Cigarette lighter.............3-89 Do not drop things inside machine......4-2 Circuit breaker.............3-104 Do not get caught in work equipment....2-17 Clock - Adjust..........3-79,3-223 Do not go close to high-voltage cables....2-20 Cold weather operation........3-233 Do not travel long time continuously....
Page 437 INDEX Ensure good visibility..........2-21 Function switches and guidance icons....3-40 Ensuring safe operation........2-13 Fuse..............3-102 Every 10 hours maintenance........ 4-40 Every 100 hours maintenance......4-42 Every 1000 hours maintenance......4-53 General character and precautions for handling...2-45 Every 2000 hours maintenance......4-62 General precautions common to operation and main- Every 250 hours maintenance......
Page 438 Machine monitor - Basic operation when starting en- Keep work place clean and tidy......2-35 gine in normal situation........3-9 Komatsu Closed Crankcase Ventilation (KCCV) 3-121 Machine monitor - Operate when operator identifica- Komatsu genuine lubricants........4-2 tion function is available with skip....3-83 Komatsu genuine replacement parts......
Page 439 Pedal - Operate / oil flow of machine equipped with Precautions for towing and being towed....2-32 attachment............6-8 Precautions for towing machine......3-239 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Precautions for transportation.......2-31 Periodic replacement of defined life parts.....2-43 Precautions for transporting machine....3-225 Permissible depth of water soil and dirt....
Page 440 INDEX Precautions when parking machine...... 2-30 Radio - Control............3-221 Precautions when removing and installing....6-2 Radio - Handle............ 3-219 Precautions when running engine inside building.2-19 Read the operation and maintenance manual thor- Precautions when selecting........6-2 oughly.............. 6-2 Precautions when standing up from operator's seat..Read this manual............
Page 441 INDEX Sunlight sensor........... 3-211 Visibility from operator's seat........1-9 Swing circle - Lubricate.........4-42 Volume control button......... 3-219 Swing lock pilot lamp..........3-30 Swing lock switch..........3-89 Swing machinery case - Change oil......4-55 Warning display..........3-15,6-18 Swing machinery case - Check oil level / Add oil3-142 Washable floor - Wash..........4-33 Swing parking brake cancel switch.......

Komatsu PC700LC-11 Operation & Maintenance Manual

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