Komatsu PC490LC Installation And Instruction Manual

page of 492

/ 492
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

Operation &

Maintenance Manual

PC490

PC490LC

HYDRAULIC EXCAVATOR

SERIAL NUMBERS

PC490-11

- 85006

PC490LC-11 - 85006

PC490-11

- K70001

PC490LC-11 - K70001

WARNING

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read

this manual before operating or maintaining this

machine. This manual should be kept inside the cab for

reference and periodically reviewed by all personnel who

will come into contact with the machine.

-11

and up

ORIGINAL INSTRUCTIONS

UENAM01105

Table of Contents

Chapters

Table of Contents

Summary of Contents for Komatsu PC490LC

Page 1 UENAM01105 Maintenance Manual PC490 PC490LC HYDRAULIC EXCAVATOR SERIAL NUMBERS PC490-11 - 85006 and up PC490LC-11 - 85006 and up PC490-11 - K70001 and up PC490LC-11 - K70001 and up WARNING Unsafe use of this machine may cause serious injury or ORIGINAL INSTRUCTIONS death.
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 PC490-11, PC490LC-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 0.25 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 (3-205)”.
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: Service Meter Location
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) 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: PC490-11 PC490LC-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 ......................3-9 EXPLANATION OF MACHINE MONITOR EQUIPMENT ..............3-9 SWITCHES ............................3-90 CONTROL LEVERS AND PEDALS ....................3-98 OTHER EQUIPMENT ........................
Page 19 OTHER TROUBLE......................... 3-263 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 ................7-5 LUBRICATION CHART ........................7-5 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ..7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 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 SAFETY SAFETY SAFETY LABELS ............................2-4 LOCATION OF SAFETY LABELS......................2-5 CONTENTS OF SAFETY LABELS ......................2-7 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........... 2-18 PRECAUTIONS BEFORE STARTING OPERATION................2-18 ENSURE SAFE OPERATION ......................2-18 UNDERSTAND THE MACHINE ....................... 2-18 PREPARATIONS FOR SAFE OPERATION ....................
Page 23 SAFETY SAFETY PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES........2-37 PRECAUTIONS WHEN PARKING MACHINE ................. 2-37 PRECAUTIONS FOR TRANSPORTATION..................... 2-38 PRECAUTIONS WHEN LOADING AND UNLOADING ..............2-38 TOWING AND BEING TOWED....................... 2-39 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-39 LIFTING OPERATIONS ..........................
Page 24: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 25: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS KS000848...
Page 26 SAFETY LABELS SAFETY KS000850 1. Combined safety information label 9. Caution against falling (a) Warning for operation, inspection and maintenance 10. Danger do not enter within swing range (b) Warning when leaving the operator's seat 11. Caution against work equipment (c) Warning no passengers 12.
Page 27: Contents Of Safety Labels
SAFETY SAFETY LABELS 25. Warning for operation, inspection and mainte- 26. Caution for high-temperature resistance nance CONTENTS OF SAFETY LABELS Combined safety information label (1) (2A5-00-21180) • Warnings for operation, inspection and maintenance. • Improper operation and maintenance can cause serious in- jury or death.
Page 28 SAFETY LABELS SAFETY Warning no passengers • c. No passengers allowed to ride on the machine while it is moving. Warning danger of falling objects • d. Do not operate where a danger of falling objects exists. Consult your dealer for fitting of FOPS (FALLING OBJECT PROTECTIVE STRUCTURE) protection.
Page 29 SAFETY SAFETY LABELS Control levers operational function diagram f. Control levers operating pattern. In order to prevent an accident resulting in injury or death caused by error-operation, confirm the machine motion and in- dicated operating pattern, when operating machines. Pay atten- tion to the circumference and operate slowly when confirming the machine motion.
Page 30 SAFETY LABELS SAFETY Warning when reversing • h. Take care when reversing. To prevent SEVERE INJURY or DEATH, do the following be- fore moving machine or its attachments: • Sound horn to alert people nearby. Be sure no one is on or near machine or in swing area. Rotate cab for full view of travel path if it can be done safe- Use spotter if view is obstructed.
Page 31 SAFETY SAFETY LABELS Caution for handling accumulator and gas spring (4) Caution for handling accumulator and gas spring (09659- A057B) • There is a hazard of explosion causing injury. • Do not disassemble the accumulator, make holes in it, weld it, cut it, roll it or bring it near a flame. Caution for adjusting track tension (5) Caution for adjusting track tension (09657-A0881) •...
Page 32 SAFETY LABELS SAFETY Emergency escape (8) Emergency escape (09844-00050) Caution against falling (9) Caution against falling (09805-C0481) • Sign indicates a hazard of falling. • Do not stand on the place here. Danger do not enter within swing range (10) Prohibited to enter swing radius (09133-A3281) •...
Page 33 SAFETY SAFETY LABELS Caution for work equipment (11) Keeping out of working range area (09134-A1681) • Sign indicates a hazard of being hit by the working device of the machine. • Keep away from the machine during operation. Caution do not start by short-circuiting (12) Prohibition of short-circuit start (09842-A0481) Warning for quick coupler system (13) Warning for use of hydraulic quick coupler piping system...
Page 34 SAFETY LABELS SAFETY Warning when swinging or travelling in reverse (14) Warning when swinging or travelling in reverse (09833- A0881) WARNING • When swinging or backing up excavator, press button to change display mode on monitor so you can see rear and side of the machine.
Page 35 SAFETY SAFETY LABELS (d) Caution battery acid. (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases. Caution when replacing fresh air filter (16) Caution when replacing fresh air filter (208-00-71261) • After replacing fresh air filter, remember to remove key from cover as the key may get damaged when cab door is opened.
Page 36 SAFETY LABELS SAFETY Caution for high-temperature (19) Caution for high-temperature (09817-K064B) Warning for handling ROPS (20) Caution for machine with ROPS (09620-J2001, 09620- A3001) • If any modification is applied to the ROPS, it may affect the strength and may not comply with the standard. •...
Page 37 SAFETY SAFETY LABELS Caution for handling DEF (23) DEF (Diesel Exhaust Fluid) (09632-60800) • To avoid engine damage or fire, fill with Diesel Exhaust Fluid (DEF) only. • Never use diesel fuel. Caution for handling DEF (24) Caution for handling DEF (09632-61480) •...
Page 38: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 39: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 40: Prevent Fire
Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). 2-20...
Page 41: Precautions When Getting On Or Off Machine
When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting the work to prevent fire hazards due to highly heated exhaust gas during KDPF re- generation. For the setting procedure, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-115)”. Explosion caused by lighting equipment •...
Page 42: Lifting Of Personnel Prohibited
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Never jump on or off the machine. Never get on or off a moving machine. • If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 43: Do Not Get Caught In Work Equipment
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 44: Protection Against Falling, Flying Or Intruding Objects
No attempt should be made to repair these parts as this may have an adverse effect on component strength or durability. If such a repair is undertaken without authorisation from Komatsu there is a danger that a problem might occur that will lead to serious personal injury.
Page 45: Precautions Related To Cab Glass
When installing optional parts or attachments which are not written in this manual, the machine weight must not exceed ROPS certified value. Always contact your Komatsu distributor before installing. • Installing some work equipment combinations may cause interference and damage with the cab or other parts of the machine during operation and could cause serious personal injury or death.
Page 46: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 47: Ensure Good Visibility
SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 48 PRECAUTIONS FOR OPERATION SAFETY Map with mirror and rear view camera visibility aids fitted 2-28...
Page 49: Check Signs And Signalman's Signals
SAFETY PRECAUTIONS FOR OPERATION Map with mirror, rear view camera, side camera visibility aids fitted Although this 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 for obstacles and condition of the jobsite.
Page 50: 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 51: Precautions When Starting Engine
SAFETY PRECAUTIONS FOR OPERATION • Perform the walk-around check securely according to “METHOD FOR WALK-AROUND CHECK (3-144)”. • Remove all dirt from the surface of the lens of the headlamps and working lamps, and check that they light up correctly. •...
Page 52: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • 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 53: When Travelling In Forward Or Reverse And Swinging
SAFETY PRECAUTIONS FOR OPERATION WHEN TRAVELLING IN FORWARD OR REVERSE AND SWINGING • When driving the machine, drive with sprocket (1) at the rear of the machine. If sprocket (1) is at the front, the oper- ation of the travel levers will be the opposite of the actual direction of travel, so there is a hazard that the machine may travel in an unexpected direction, leading to serious injury or death.
Page 54: Precautions When Travelling On Slopes
PRECAUTIONS FOR OPERATION SAFETY slopes. If the machine is operated with the auto-deceleration system ON (activated), the engine speed will rise and the machine travel speed may suddenly become faster. • Try to avoid travelling over obstacles. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed.
Page 55: Precautions When Operating On Slopes
SAFETY PRECAUTIONS FOR OPERATION • When driving the machine up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm above the ground, and drive it at low speed. •...
Page 56 PRECAUTIONS FOR OPERATION SAFETY • It is dangerous to work under an overhang. Mudslide or rockfall may occur, or the overhang may collapse. Never perform digging under an overhang. • Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
Page 57: Precautions When Operating On Snow Or Frozen Surfaces
SAFETY PRECAUTIONS FOR OPERATION • In the operation using the fork or grapple, do not attempt to pick up an object with the tips. The picked up object can easily slip off. Machine may be damaged, or personal injury or death may occur. PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES •...
Page 58: 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 59: Towing And Being Towed
SAFETY PRECAUTIONS FOR OPERATION • When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and grade. • When swinging the upper structure on the loading platform, lower the work equipment, retract it, and per- form the operation slowly.
Page 60 PRECAUTIONS FOR OPERATION SAFETY • Do not use the work equipment or swing to pull the load in any direction. There is danger that the hook may break and the load come off, causing the work equipment to move suddenly and cause personal injury. •...
Page 61: 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 62: Guards
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 63: Precautions When Installing, Removing, Or Storing Attachments
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 64: 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 65: Handle Battery
SAFETY PRECAUTIONS FOR MAINTENANCE HANDLE BATTERY Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. Danger of battery exploding When the battery is being charged, flammable hydrogen gas is generated and may explode.
Page 66: Precautions For High-Temperature Coolant
PRECAUTIONS FOR MAINTENANCE SAFETY • If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, pieces might be scattered, and it may cause serious personal injury or death. Always wear protective eyeglasses and gloves. •...
Page 67: Precautions For High-Pressure Fuel
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 68: Precautions For High-Pressure Grease When Adjusting Track Tension
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 69: Precautions For Compressed Air
• 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 70 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 71: 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 73: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 74: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (7) Sprocket (2) Bucket cylinder (8) Track frame (3) Arm (9) Track (4) Arm cylinder (10) Idler (5) Boom (11) Engine hood (6) Boom cylinder...
Page 75 OPERATION GENERAL VIEW Detail of A and B parts (12) Komatsu Closed Crankcase Ventilation (hereafter (17) Battery disconnect switch KCCV) ventilator (18) System operating lamp (13) SCR (19) Fusible link (14) KDPF (20) Grease pump holder (15) Toolbox (16) Battery...
Page 76: 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 77: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES KS000852 (1) Radio (4) One-touch power maximizing switch (2) Lock lever (5) Travel pedal (3) L.H. work equipment control lever (6) Travel lever...
Page 78 GENERAL VIEW OPERATION (7) Horn switch (24) Swing parking brake cancel switch (8) Machine monitor (25) Lock lever automatic lock cancel switch (9) R.H. work equipment control lever (26) 1st attachment proportional control switch (10) Starting switch (27) 2nd attachment proportional control switch (if equipped) (11) Fuel control dial (28) Breaker switch...
Page 79 OPERATION GENERAL VIEW (9) Engine coolant temperature gauge (25) Message display (10) Engine coolant temperature caution lamp (26) Air conditioner pilot lamp (11) Fuel gauge (27) Wiper pilot lamp (12) Fuel level caution lamp (28) Swing lock pilot lamp (13) DEF level gauge (29) Engine preheating pilot lamp or One-touch power maximizing pilot lamp (14) DEF level caution lamp...
Page 80 GENERAL VIEW OPERATION AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Wiper switch (22) Charge level caution lamp (2) Buzzer cancel switch (23) Radiator coolant level caution lamp (3) Auto-deceleration switch (24) Seat belt caution lamp (4) Service meter/clock (25) Engine stop pilot lamp (5) Engine coolant temperature caution lamp...
Page 81: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
Page 82 EXPLANATION OF COMPONENTS OPERATION For detail, see “CAMERA IMAGE SELECTOR SWITCH (3-51)”. AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display (4) Monitor switch area (2) Pilot display (5) Guidance icon display (3) Meter display REMARK •...
Page 83 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 switches to the check before starting screen BB.
Page 84 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 85 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 86 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 87 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 88 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 3-16...
Page 89 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 90 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 91 OPERATION EXPLANATION OF COMPONENTS For detail, see “CAMERA IMAGE SELECTOR SWITCH (3-51)”. (1) Seat belt caution lamp (5) Engine coolant temperature caution lamp (2) Caution lamp (6) Hydraulic oil temperature caution lamp (3) Caution lamp (7) Fuel level caution lamp (4) Action level display (8) Caution lamp Standard screen (only meters are displayed)
Page 92 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 93 OPERATION EXPLANATION OF COMPONENTS Caution lamps and display colors Display color/Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue High temperature Engine coolant temperature Low temper- Normal caution lamp ature (L02) High temperature Hydraulic oil temperature Low temper- Normal caution lamp ature...
Page 94 EXPLANATION OF COMPONENTS OPERATION 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 95 OPERATION EXPLANATION OF COMPONENTS CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5 While “!” is displayed, press switch F5 to shift the monitor dis- play screen to the Current Abnormality screen. Take appropriate remedies according to the message displayed on the monitor.
Page 96 EXPLANATION OF COMPONENTS OPERATION ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature is abnormally high. While this monitor is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 97 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 98 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 99 OPERATION EXPLANATION OF COMPONENTS DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tanlk 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 100 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 101 GINE OIL PAN, ADDING OIL (3-151)”. If the oil level drops again in a short time, the engine oil may be leaking. For the inspection and maintenance, ask your Komatsu distributor. RADIATOR COOLANT LEVEL CAUTION LAMP Radiator coolant level caution lamp warns about drop of radia- tor coolant level.
Page 102 The caution lamp lights up in yellow and indicates action level “L01”. The air conditioner system has abnormality. Ask your Komatsu distributor for inspection and maintenance as soon as possible. MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displays notices and alarms concerning maintenance time.
Page 103 • The lighting time of maintenance due time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on the maintenance tab screen, see “MAIN- TENANCE SCREEN SETTING (3-78)”.
Page 104 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY AND METER DISPLAY 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 pilot lamp lamp...
Page 105 OPERATION EXPLANATION OF COMPONENTS For detail, see “CAMERA IMAGE SELECTOR SWITCH (3-51)”. 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 pilot lamp...
Page 106 EXPLANATION OF COMPONENTS OPERATION SWING LOCK PILOT LAMP Swing lock pilot lamp informs that the swing lock is being actu- ated. Lights up: The swing lock is being actuated. When the swing lock switch is turned ON (LOCK), this lamp lights up.
Page 107 OPERATION EXPLANATION OF COMPONENTS ATT/E: ATT/E mode (for operations of 2-way attachments like crusher in emphasis of fuel consumption) For the location of the working mode selector switch, see “MACHINE MONITOR EQUIPMENT NAME (3-6)”. TRAVEL SPEED DISPLAY The travel speed display shows the set mode of the travel speed.
Page 108 When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regeneration disable to prevent fire hazards due to highly heated exhaust gas while aftertreat- ment devices regenerating. For details of the setting method, see “HANDLE Komatsu Diesel Partic- ulate Filter (KDPF) (3-115)”.
Page 109 For the procedures of cancellation of the regeneration disable setting, and setting of manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-115)”. LOCK LEVER PILOT LAMP The lock lever pilot lamp lights up when the lock lever is in LOCK position.
Page 110 EXPLANATION OF COMPONENTS OPERATION Guidance To Avoid Hydraulic Relief If the hydraulic oil is kept relieved for more than 3 seconds dur- ing operation, the hydraulic relief deterrence message is dis- played on the monitor. The hydraulic relief deterrence message goes out 10 seconds later or when switch F5 is pressed.
Page 111 OPERATION EXPLANATION OF COMPONENTS When stopping the engine during the aftertreatment devices re- generation, stop the regeneration first according to “PROCE- DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-122)”, then stop the engine after run- ning it at low idle for approximately 5 minutes. The information about engine stop operation during the after- treatment devices regeneration goes out 10 seconds later or when switch F5 is pressed.
Page 112 EXPLANATION OF COMPONENTS OPERATION Display (G) when temperature is low: Caution lamp background (K) is white. Display (H) when temperature is proper: Caution lamp back- ground (K) is blue. Display (J) when temperature is abnormal: Caution lamp back- ground (K) is red. HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature.
Page 113 OPERATION EXPLANATION OF COMPONENTS REMARK When the indicator reaches red range (B), the remaining fuel is 76 ℓ or less. When the indicator is in red range (B), fuel level monitor (D) lights up in red. The correct fuel level may not be displayed for a short time after the starting switch is turned to ON position, but this is not abnormal.
Page 114 EXPLANATION OF COMPONENTS OPERATION ECO GAUGE ECO gauge shows the instantaneous fuel consumption. The instantaneous fuel consumption means the fuel consump- tion rate at each moment, which varies with the work load and engine speed. When the gauge is in green range A, the instantaneous fuel consumption is at Good to Medium level.
Page 115 OPERATION EXPLANATION OF COMPONENTS REMARK • Immediately after turning the starting switch to ON position and during the engine is running, DEF level cau- tion lamp (1) lights up in white. However, this does not indicate abnormality. • In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi- mately 1 hour.
Page 116 EXPLANATION OF COMPONENTS OPERATION FUNCTION SWITCHES AND GUIDANCE ICONS • There are 6 function switches (1) (F1 to F6) at the bottom of the monitor display. The function of each switch differs according to the content of each screen. • On each screen, you can confirm the function of switches (1) by guidance icons (2) displayed on top of the switch.
Page 117 OPERATION EXPLANATION OF COMPONENTS (F) Switch F1: Moves to the left item. (When on the left end, it moves to the right end.) (G) Switch F2: Moves to the right item. (When on the right end, it moves to the left end.) (H) Switch F3: Moves to the item below (forward).
Page 118 If you want to have automatic setting of P, E, L, B, ATT/P or ATT/E mode (optional default setting) when starting engine , ask your Komatsu distributor to change the setting. How to use working mode selector switch When working mode selector switch (2) is pressed, the Working Mode selector screen is displayed on the monitor.
Page 119 OPERATION EXPLANATION OF COMPONENTS After 2 seconds, the screen returns to the standard screen. The working mode display highlighted in yellow in step 4 returns to blue. REMARK When setting the working mode to B mode, to ensure safe- ty, the buzzer sounds and at the same time, the message in the illustration is displayed.
Page 120 EXPLANATION OF COMPONENTS OPERATION When the auto-deceleration switch is pressed and the au- to-deceleration function is turned ON, the mode is dis- played in the center of the monitor display, and after 2 sec- onds, the screen returns to the standard screen. On the standard screen, auto-deceleration pilot lamp lights (When the auto-deceleration is OFF, the indication lamp goes out.)
Page 121 OPERATION EXPLANATION OF COMPONENTS REMARK Each time the travel speed selector switch is switched, the mode is displayed on the monitor display, and after 2 seconds, the screen returns to the standard screen. WIPER SWITCH Wiper switch actuates the front window windshield wiper. Each time the switch is pressed, it changes INT →...
Page 122 EXPLANATION OF COMPONENTS OPERATION REMARK Each time wiper switch is pressed, the mode is displayed in the center of the monitor display, and after 2 seconds, the screen returns to the standard screen. WINDOW WASHER SWITCH Keep pressing this switch continuously, and window washer flu- id is sprayed out on the front glass.
Page 123 OPERATION EXPLANATION OF COMPONENTS REMARK The buzzer cannot be stopped according to the content of the warning. AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches. For explanation of each switch, see "HANDLE AIR CONDI- TIONER (3-218)". FUNCTION SWITCHES The operation of the function switches in the standard screen CAMERA IMAGE SELECTOR SWITCH On the standard screen, you can select a display only for the camera image or a display only for the meter by...
Page 124 EXPLANATION OF COMPONENTS OPERATION A maximum of 3 cameras can be installed. If you want to install another camera, consult your Komatsu distributor. Operation of camera image display screen Operate the following for changing the camera image display on the monitor.
Page 125 OPERATION EXPLANATION OF COMPONENTS • On the standard screen, when switch F3 is pressed, No. 1 camera image is displayed in full-screen. • Display of camera image is changed each time switch F1 is pressed. No. 1 camera image is displayed in full-screen. No.
Page 126 EXPLANATION OF COMPONENTS OPERATION • Press switch F3, and the screen returns to the standard screen. Other mode operations while camera image is displayed Even during the camera display, it is possible to operate follow- ing modes. • The air conditioner can be operated. When the air conditioner switch is operated, the screen switches to the air conditioner control screen.
Page 127 OPERATION EXPLANATION OF COMPONENTS • Press the travel speed selector switch to change the travel speed. For the travel speed selector switch, see “TRAVEL SPEED SELECTOR SWITCH (3-48)”. When the travel speed is changed, the travel speed dis- play at the top right of the monitor display is highlighted in yellow for 2 seconds, then returns to blue.
Page 128 EXPLANATION OF COMPONENTS OPERATION Actions against warning during camera image display • If any abnormality is generated on the machine while the camera image is displayed, the caution lamp flashes at the top left of the screen. • 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.
Page 129 OPERATION EXPLANATION OF COMPONENTS USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
Page 130 EXPLANATION OF COMPONENTS OPERATION (c) Aftertreatment Devices Regeneration • Setting for Regeneration Disable • Operation of Manual Stationary Regeneration (d) SCR Information • Check of DEF level • Urea SCR system information (e) Maintenance • Check and reset of various Maintenance Times (f) Monitor Setting •...
Page 131 OPERATION EXPLANATION OF COMPONENTS On the user menu screen, it is possible to perform the following operations with switches F1 to F6. F1: Moves to the left menu. When on the left end menu, it moves to the right end menu. F2: Moves to the right menu.
Page 132 EXPLANATION OF COMPONENTS OPERATION 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 133 OPERATION EXPLANATION OF COMPONENTS 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. For details, see “ECO GUIDANCE (3-37)”. CHECK FUEL CONSUMPTION RECORD Select the Average Fuel Consumption Record (3) from the En- ergy Saving Guidance menu screen, then press switch F6.
Page 134 EXPLANATION OF COMPONENTS OPERATION 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 135 OPERATION EXPLANATION OF COMPONENTS 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 136 EXPLANATION OF COMPONENTS OPERATION 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 137 OPERATION EXPLANATION OF COMPONENTS 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 138 EXPLANATION OF COMPONENTS OPERATION 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 139 OPERATION EXPLANATION OF COMPONENTS 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 140 EXPLANATION OF COMPONENTS OPERATION 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 141 OPERATION EXPLANATION OF COMPONENTS On the “Economy Mode Adjustment ”menu, you can adjust the engine output in E mode. In the economy mode, the higher the selected number starting from E0 becomes, the lower the engine output becomes. In the meantime, the better the fuel efficiency becomes.
Page 142 EXPLANATION OF COMPONENTS OPERATION Changing the “Breaker Setting” name You can change the breaker setting name as you like. You can use alphabet letters A to Z, Arabic numerals 0 to 9, symbols #, *, +, -, and /, and the space. On the “Breaker Setting”...
Page 143 OPERATION EXPLANATION OF COMPONENTS ATTACHMENT SETTING On machines ready for installation of attachment, you can adjust the oil flow rate in ATT/P mode and ATT/E mode to match the attachment on the “Attachment Setting” menu. For machines that have no attachment, the “Attachment Setting” menu is not displayed. Select “Attachment Setting”...
Page 144 EXPLANATION OF COMPONENTS OPERATION F5: Returns to the attachment setting screen without changing the name. F6: Enters the change and returns to the attachment setting screen. It is not possible to change the name for "No Attachment" setting. Changing “2-Way Attachment Oil Flow Rate Setting” Select an attachment setting to change its oil flow rate on the “Attachment Setting”...
Page 145 “HANDLE Komatsu Diesel Partic- ulate Filter (KDPF) (3-115)” until the aftertreatment de- vices regeneration pilot lamp or the KDPF soot accu- mulation caution lamp goes out.
Page 146 EXPLANATION OF COMPONENTS OPERATION When the fan rotates in reverse, the screen shown in the figure is displayed automatically. This screen is kept displayed while the fan is rotating in re- verse. NOTICE If the fan rotation direction cannot be reversed, the caution lamp lights up.
Page 147 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 148 EXPLANATION OF COMPONENTS OPERATION Select the set time on the “Auto Idle Stop Timer Setting” screen shown in the figure, and then press switch F6. On the “Auto Idle Stop Timer Setting” screen shown in the figure, you can perform the following operations with switches F3 to F6.
Page 149 Each item of Aftertreatment Devices Regeneration menu (c) is to make settings for the aftertreatment devices regeneration. For details of the aftertreatment devices regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-115)”. SCR INFORMATION Each item in SCR information menu (d) is for displaying infor- mation related to SCR and DEF.
Page 150 EXPLANATION OF COMPONENTS OPERATION MAINTENANCE SCREEN SETTING Each item of setting menu (e) on maintenance screen is used for displaying and setting the notification relevant to mainte- nance. The items on the maintenance display are as follows. Air Cleaner Clean and Change Coolant Change Hydraulic Oil Additional Filter Change Hydraulic Oil Pilot Filter Change...
Page 151 • 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 the maintenance time reset screen On the maintenance menu screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the maintenance time reset screen.
Page 152 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 153 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 154 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 155 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 156 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 157 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 158 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 159 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 160 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 161 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. Make a reply to the message. REMARK • (3) is the subject of the received message. When no message is received, “No message”...
Page 162: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES KS000854 (1) One-touch power maximizing switch (10) Cigarette lighter (2) Horn switch (11) Room lamp switch (3) Starting switch (12) Seat heater switch (4) Fuel control dial (13) Engine shutdown secondary switch (5) Lamp switch (14) Pump secondary drive switch (6) Swing lock switch (15) Swing parking brake cancel switch...
Page 163 OPERATION EXPLANATION OF COMPONENTS (19) 2nd attachment proportional control switch (if (22) Lower wiper switch (if equipped) equipped) (23) Quick coupler switch (20) Breaker switch (21) Additional lamps switch (if equipped) STARTING SWITCH Starting switch is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn.
Page 164 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 165 OPERATION EXPLANATION OF COMPONENTS Use room lamp switch to light up the room lamp. (a) ON position Lights up (b) OFF position The room lamp lights up even when the starting switch is at OFF position. PUMP SECONDARY DRIVE SWITCH CAUTION When pump secondary drive switch (1) is being used or immediately after it is used, the temperature of resistor (2)
Page 166 EXPLANATION OF COMPONENTS OPERATION 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. Do not use it except for emergency. Repair the problem as soon as possible.
Page 167 • 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 168 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 169 OPERATION EXPLANATION OF COMPONENTS • When the starting switch is turned to ON position while the engine shutdown secondary switch is in the engine stopped position (a), “Engine Shutdown Sec- ondary SW In Operation” is displayed on the machine monitor. If this screen is displayed, return the engine shutdown secondary switch to the normal position (b).
Page 170: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION The additional lamps switch is used to turn on the cab front lamps, cab rear lamps and extra boom lamps (If fitted by cus- tomer) (a) ON Lamps light up. (b) OFF Lamps go out. 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 171 • 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 172 To cancel the lock, return the lock lever to LOCK position (L), check that each control lever and the attachment switch are in neutral, and then release the lock lever again. For the genuine hydraulic oils which Komatsu recommends, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-5)”.
Page 173: Other Equipment
OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT CONTROL LEVER The L.H. work equipment control lever is used to operate the arm and upper structure. Arm control (a): Arm OUT (b): Arm IN Swing control (c): Swing RIGHT (d): Swing LEFT N (NEUTRAL) The upper structure and arm are held in position and do not move.
Page 174 EXPLANATION OF COMPONENTS OPERATION Push up lock (A) in the front centre of the roof window and check that the lock is released. Then hold handle (B) and push up the roof window. When closing Hold grip (B), lower the roof window, and apply lock (A). If the lock cannot be applied, “open” the roof window, then pull it in again and apply the lock.
Page 175 OPERATION EXPLANATION OF COMPONENTS Hold handles (A) (2 places) on the right and left top sides of the front window, and pull levers (B) (2 places) to re- lease the locks at the top of the front window. The top of the front window will come out.
Page 176 EXPLANATION OF COMPONENTS OPERATION Hold lower handle (C) with your left hand from inside the operator's cab, and with your right hand, grip top handle (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window. REMARK Handles (A) on the right and left top sides of the front win- dow are not for pulling up the front window.
Page 177 OPERATION EXPLANATION OF COMPONENTS When closing CAUTION When closing the window, lower it slowly and be careful not to get your hand caught. Stop the machine on a level ground, lower the work equip- ment to the ground, then stop the engine. Set lock lever (1) securely to LOCK position (L).
Page 178 EXPLANATION OF COMPONENTS OPERATION When the bottom of the window reaches the top of lower side window, push the top of the window to the front to push it against right and left lock catches (G) and engage the lock. Check that lever (B) is securely at LOCK position.
Page 179 OPERATION EXPLANATION OF COMPONENTS EMERGENCY ESCAPE HAMMER CAUTION • If it is necessary to break the window glass with the hammer, be extremely careful not to get injured with scattered pieces of broken glass. • To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through the window.
Page 180 EXPLANATION OF COMPONENTS OPERATION CAB DOOR HINGE The cab door hinge has 2 rotation axes with stoppers (S). REMARK When opening and closing the cab door, hitting sound of stop- per (S) is heard, but this is not a failure. CAP AND COVER WITH LOCK Use the starting switch key to open and close the locks on the caps and covers.
Page 181 OPERATION EXPLANATION OF COMPONENTS 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. CUP HOLDER The cup holder is located on the left side of the operator's seat. ASHTRAY This is on top of the console box on the left side of the opera- tor's seat.
Page 182 EXPLANATION OF COMPONENTS OPERATION POWER SUPPLY OUTLET 24 V power source NOTICE Do not use it as a power supply for 12 V equipment. This will cause failure of the equipment. When cigarette lighter is removed, the lighter socket can be used as a power source.
Page 183 OPERATION EXPLANATION OF COMPONENTS Fuse 1 - Fuse capacities and circuit names Fuse ca- Name of circuit pacity Relay for lamp, emergency switch 30 A Solenoid valve PPC hydraulic lock solenoid 10 A Window washer, cigarette lighter 10 A Horn Auto preheater relay 10 A Revolving lamp...
Page 184 EXPLANATION OF COMPONENTS OPERATION (12) 10 A Sensor power supply relay (2) (13) 10 A DEF line heater relay (1) (14) 20 A DEF line heater relay (2) REMARK • Spare fuses are installed in the back of the fuse holder lid at the rear of the operator's seat.
Page 185 OPERATION EXPLANATION OF COMPONENTS GREASE PUMP HOLDER This is installed in the battery box at front right of the machine. Keep the grease pump hooked on this holder while it is not used. FIRE EXTINGUISHER (if equipped) A fire extinguisher is provided at the rear part inside the opera- tor's cab.
Page 186 Even if the starting switch is in OFF position, the controller may operate. The lamp lights up in this situation, but it is not a failure. • After the starting switch has been turned OFF, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. 3-114...
Page 187 OPERATION EXPLANATION OF COMPONENTS HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
Page 188 "L04" lights up. In this case, the machine needs to be repaired by your Komatsu distributor. Also, the maximum engine output and maxi- mum engine speed are limited to protect the engine and KDPF system.
Page 189 • 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 190 EXPLANATION OF COMPONENTS OPERATION 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 monitor “L03” may be displayed. However, this does not indicate abnormality.
Page 191 OPERATION EXPLANATION OF COMPONENTS When the degree of emergency is high • If KDPF soot accumulation caution lamp (2) lights up in red (action level (3): L03), screen (D) is displayed. • 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 screen (C) after 3 seconds.
Page 192 EXPLANATION OF COMPONENTS OPERATION 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 193 OPERATION EXPLANATION OF COMPONENTS 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 194 EXPLANATION OF COMPONENTS OPERATION REMARK • The progress of the manual stationary regeneration performed when soot is accumulated can be checked by the number of lighting lamps of 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 195 OPERATION EXPLANATION OF COMPONENTS 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 196 EXPLANATION OF COMPONENTS OPERATION 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 197 OPERATION EXPLANATION OF COMPONENTS 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 198 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. 3-126...
Page 199 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 200 EXPLANATION OF COMPONENTS OPERATION ambient temperature drops further than a temperature where the heating system is capable of maintaining fluidi- ty of DEF, the DEF system automatically starts purging the remaining DEF back to the tank and stops pumping and injection while heating continues. Once the ambient temperature rises above a temperature where DEF system becomes functional, it resumes operation automatically.
Page 201 OPERATION EXPLANATION OF COMPONENTS • 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. Inducement status (4): “1 DEF low level warning appears.”...
Page 202 EXPLANATION OF COMPONENTS OPERATION Inducement status (4): “3 Engine power is under deration.” Add DEF to the DEF tank immediately. • Severe Inducement: The audible alert sounds in continuous beep. No gradation of the DEF level gauge lights up . The DEF level caution lamp (1) lights up in red.
Page 203 OPERATION EXPLANATION OF COMPONENTS Perform the following procedure. Press F6 on the standard screen to display the “SCR Informa- tion” screen of the user menu. If either the lock lever is set to LOCK position or the travel lever and control levers are in NEUTRAL position for over 3 sec- onds, “SCR Information”...
Page 204 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (4): “2 Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu Distributor. The duration of “Continuous Warning” is 5 hours. The re- maining time (Hours and Minutes) to “Low level Induce- ment”...
Page 205 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 206 EXPLANATION OF COMPONENTS OPERATION • Warning: The audible alert sounds in short and sharp beeps. 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 on the user menu screen when the Standard screen is on.
Page 207 Komatsu distributor. Inducement strategy when abnormality is found in the EGR Valve System by the...
Page 208 “Severe Inducement”, the engine power will be further derated. 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 209 OPERATION EXPLANATION OF COMPONENTS • Continuous Warning: The audible alert sounds in repetition of “three beeps and a pause”. The Engine system system caution lamp (1) lights up in red. The DEF system caution lamp (2) lights up in yellow. The action level “L03”...
Page 210 “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In- ducement” 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. Temporary Restoration from Inducement Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 211 OPERATION EXPLANATION OF COMPONENTS Press F6 while the pop-up menu screen B is displayed. The “Engine power Recovery” window pops up. 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 is displayed in the column (1) of the pop-up menu window B.
Page 212 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and contact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
Page 213 The machine information you can check with KOMTRAX includes the following; “Machine position”, “service me- ter”, “working hours”, “fuel consumption”. Your Komatsu distributor uses the above machine information for supply of service to the customers, improve- ment of our products and service, etc.
Page 214 Komatsu may suspend KOMTRAX communication in the following cases. • When Komatsu judges that KOMTRAX is used by an unregistered customer. • When Komatsu judges that KOMTRAX is used in a country or region where its use is not authorized. 3-142...
Page 215 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 216: 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 217 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 218 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR REFUELLING PUMP When the machine is operated on sites with no fuel container and pump, the machine may be refuelled from fuel barrels. The refuelling pump is located in the right hand rear pump compartment of the machine. Remove the refuel hose which is stored in tray (3) from the machine.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS Refuelling will continue automatically until the tank has reached capacity (float switch (6) will reach its limit and the pump will stop). It is important to ensure the machine is parked on level ground and monitor refuelling to avoid fuel overfill or spill- age.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT Open the engine hood. The water separator forms one unit with fuel pre-filter (1). Check for water and sediment. It is possible to judge the water level and amount of sedi- ment by looking through transparent cup (2).
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When bleeding air, see “METHOD FOR REPLACING FUEL PRE-FILTER CARTRIDGE (4-51)” or “METH- OD FOR REPLACING FUEL MAIN FILTER CARTRIDGE (4-61)”. 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.
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK The oil level vary with the oil temperature. Accordingly, use the followings as a guide: • Before starting operation: Between H and L levels (Oil temperature: 10 to 30 °C) • Normal operation: Around H Level (Oil temperature: 50 to 80 °C) METHOD FOR INSTALLING HYDRAULIC TANK OIL FILLER CAP CAUTION...
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS Open the engine hood. NOTICE If the sub-tank is empty, leakage of coolant should be suspected. After checking, repair any abnormality im- mediately. REMARK If the inside of sub-tank is so dirty that you cannot check the coolant level, see “METHOD FOR CLEANING INSIDE OF COOLING SYSTEM (4-20)”.
Page 224 • 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 225 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL WARNING When adding fuel, never spill the fuel or let it overflow. It may cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
Page 226 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 227 OPERATION MACHINE OPERATIONS AND CONTROLS 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 (3) counterclockwise. The caps of DEF tanks are blue, as required by emission regulations.
Page 228 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 229 OPERATION MACHINE OPERATIONS AND CONTROLS • 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 230 MACHINE OPERATIONS AND CONTROLS OPERATION 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 twisted, the installation part may be broken.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION Pull the fore-aft adjustment lever 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 232 MACHINE OPERATIONS AND CONTROLS OPERATION 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 233 OPERATION MACHINE OPERATIONS AND CONTROLS PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) CAUTION To prevent the machine from moving during the work, make sure that the following conditions are met before starting the work. • The machine is placed on a firm, level ground. •...
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION When returning the mirror to its regular position, perform the following adjustment. Adjust stay (1). Mounting position (2): 69 mm Mounting angle (3): 81 ° Mounting angle (4): 110 ° Adjust mirror (5). Tightening torque of mounting bolt (6): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting position (7): 74 mm NOTICE...
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the mirror so that the side of the machine is reflect- ed in the mirror as shown in the figure. PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) CAUTION To prevent the machine from moving during the work, make sure that the following conditions are met before starting the work.
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION If the mirror is adjusted by loosening the mounting bolts, be sure to adjust the mirror to its regular position. For the adjustment method, see the “Procedure for adjusting regular position of machine right front mirror (B)”. PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) CAUTION...
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the mirror so that the side of the machine is reflected in the mirror as shown in the figure. PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) CAUTION To prevent the machine from moving during the work, make sure that the following conditions are met before starting the work.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION • The regular position of the mirror is as follows: Adjust mirror (1). Tightening torque of mounting bolt (2): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting angle (3): 15 ° Mounting position (4): 15 mm METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE WARNING •...
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the angle of the rearview camera so that people within 1 m away from the machine's rear part (W) can be seen in the machine monitor at the operator's seat. If the image on the monitor is not aligned correctly, adjust mounting angle (A) of the rearview camera in the following pro- cedure.
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • Shim (6) may be inserted in the cover mounting bolts to adjust the clearance in the rim of the cover. When removing cover (1), record the places and quantities of the shims. When installing the cover, insert the shims according to the record.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the lock lever is se- curely at LOCK position. Perform the check before starting the engine according to the following procedure. Check that battery disconnect switch (S) is in ON position (I).
Page 243 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. Perform the following inspection on the machine monitor.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION • Engine coolant temperature gauge (9) • Engine coolant temperature caution lamp (10) • Fuel gauge (11) • Fuel level caution lamp (12) • Hydraulic oil temperature gauge (13) • Hydraulic oil temperature caution lamp (14) •...
Page 245: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING ENGINE WARNING • Start the engine only while sitting down in the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a serious personal injury or death or fire. •...
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION 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 247 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK White smoke may be discharged for a short time immediately after the engine is started or during the after- treatment devices regeneration in the cold season, but this is not a failure. REMARK Urea SCR system has the function of heating and keeping itself warm to prevent freezing of DEF. If DEF is frozen, DEF system is heated and thawed automatically after the engine starts.
Page 248: Method For Operations And Checks After Starting Engine
Check that there is no abnormal noise when the engine is idling or when the engine speed rises slightly. When there is an abnormal noise at the engine startup and if that condition continues, the engine may be dam- aged. In that case, ask your Komatsu distributor to check the engine as soon as possible. 3-176...
Page 249 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION Check that engine coolant temperature caution lamp (1) displays the proper temperature. If it displays low temperature, perform additional warm-up of the engine according to step 2 until it displays the prop- er temperature. • Display (A) when temperature is proper: Caution lamp background (C) is blue.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Turn fuel control dial (2) to High idle (MAX) position and hold it for 3 seconds or more. Turn fuel control dial (2) to Low idle (MIN) position. The engine automatic warm-up is cancelled, and the en- gine speed is lowered.
Page 252 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 on, check on the monitor that the swing lock is actuated, then start the warm-up operation.
Page 253 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 (3-45)”. Move lock lever (3) slowly to FREE position (F), then raise the bucket from the ground.
Page 254 Hydraulic oil temperature caution lamp (7): Displays proper temperature • 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. 3-182...
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS 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 cold weath- er" to warm up all the hydraulic equipment. 12.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION When performing swing operations, release swing lock switch (2), check that swing lock pilot lamp (18) is not lit, then operate the swing. • Travel (Lo) operation: FORWARD (A) ←→ REVERSE • For attachment operations (if equipped), change the working mode to the attachment mode.
Page 257 OPERATION MACHINE OPERATIONS AND CONTROLS • Display (A) when temperature is proper: Caution lamp background (C) is blue. • Display (B) when temperature is low: Caution lamp background (C) is white. If the hydraulic oil temperature caution lamp displays the proper temperature, the hydraulic equipment warm-up operation is completed.
Page 258: Method For Stopping Engine
MACHINE OPERATIONS AND CONTROLS OPERATION Display of working mode P mode E mode For heavy-duty operations For fuel economy conscious operations L mode B mode For operations requiring fine control and lifting operations For breaker operations ATT/P mode ATT/E mode For operations of 2-way attachments like crusher For operations of 2-way attachments like crusher (fuel economy conscious operations)
Page 259 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE If the engine is stopped abruptly, the service lives of com- ponent parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency. Do not stop the engine abruptly except the case in an emergency.
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • When engine 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 a time lag provided for the controller to memo- rize the operation status and then terminate the sys- tem.
Page 261: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE WARNING • Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction to the direction of the operation of the travel levers or travel pedals (front and rear travel are reversed, right...
Page 262 (6) slowly. When travelling, check that the 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 263 (6) slowly. When travelling, check that the alarm sounds normally. If the travel alarm does not sound, contact your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warm-up operation.
Page 264: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine.
Page 265: Method For Swinging Machine
OPERATION MACHINE OPERATIONS AND CONTROLS • (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 266: Method For Operating Work Equipment
MACHINE OPERATIONS AND CONTROLS OPERATION 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 267: Handle Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS • 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 268 MACHINE OPERATIONS AND CONTROLS OPERATION 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) Aligning position (fine control operations and lift- L mode ing operations) B mode Breaker operations Operations of double-acting attachment on crush-...
Page 269: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS • If a working mode is selected, and nothing is done for 5 seconds, the selected working mode is auto- matically accepted and the screen returns to the standard screen. • If a working mode is selected and working mode selector switch (1) is kept pressed, the selected mode is accepted and the screen returns to the standard screen.
Page 270 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING TRAVEL FORCE Do not use the travel force to perform excavation by digging the bucket into the ground. This damages the machine or work equipment. PROHIBITION OF OPERATIONS USING HYDRAULIC CYLINDERS TO STROKE If the work equipment is used with the cylinder rod operated to its stroke end, and given impact by some external force, the hy- draulic cylinders may be damaged, causing personal injury.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF OPERATIONS USING MACHINE DROPPING FORCE Do not use the dropping force of the machine for digging. PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces.
Page 272 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS WHEN MACHINE IS NOT STABLE If the machine is operated while its undercarriage is unstable, torsional loads occur in the frames and can shorten the service life of the machine. In this case, prepare an embankment, etc. in front of the track to stabilize the machine.
Page 273: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF HIGH-SPEED TRAVEL OPERATIONS ON ROUGH GROUND If the machine travels on rough ground (rock-bed, etc.) at high speed, large push-up loads are applied to the chassis, thus the service life of the chassis is shortened. When driving on rough ground (rock-bed, etc.), direct the idler (1) having the cushion mechanism in the travel direction and drive the machine at low speed.
Page 274 MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS FOR HIGH SPEED TRAVEL On uneven roadbeds such as rock beds or uneven roads with large rocks, drive the machine at Lo-speed. When driving the machine at Hi-speed, set the idler in the forward direction. •...
Page 275: Precautions For Working On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR WORKING ON SLOPE WARNING • Swinging operations or operating the work equipment on slopes machine may lose its balance and turn over. Avoid such operations as much as possible. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 276: 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 277: 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 278: 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. 3-206...
Page 279: 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 280 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK When installing the bucket, for arm pin part (A), fit O-ring (5) to bucket (6) in the position shown in the figure. After inserting the pin, fit it in the regular groove. For link pin part (B), install the bucket with O-ring (5) fitted in the regular groove.
Page 281 OPERATION MACHINE OPERATIONS AND CONTROLS Invert the removed bucket. Align the pin hole of arm (1) with replacement bucket hole (2), then align the pin hole of link (3) with hole (4), and in- stall pins (A) and (B) which are coated with grease. REMARK When inverting, do not install O-rings.
Page 282: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION • Machines with Automatic Grease System require one time lubrication each time the bucket is changed. Lubricate at the bucket linkage and at the grease metering valve as indicated until grease comes out from the end faces. It will be necessary to replace the plug at the grease metering valve with a grease nipple during lubrication.
Page 283 OPERATION MACHINE OPERATIONS AND CONTROLS Put right and left travel levers (1) in NEUTRAL position. The machine stops. Turn fuel control dial (2) to Low idle (MIN) position and lower the engine speed. Lower the bucket horizontally until the bottom touches the ground.
Page 284: Method For Checking After Finishing Work
MACHINE OPERATIONS AND CONTROLS OPERATION 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. Then, inspect and take necessary remedy according to “TROUBLES AND ACTIONS (3-257)”.
Page 285 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key clockwise, align the matching marks (1) of the key groove and the cap, then open the cap. Position (A): OPEN Position (B): CLOSE (LOCK) PROCEDURE FOR CLOSING CAP WITH LOCK Screw in the cap until it becomes tight, then insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key.
Page 286 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING ENGINE HOOD CAUTION • When opening or closing the engine hood, place the machine on a level ground, lower the work equipment to the ground, stop the engine, then perform the operation. •...
Page 287 OPERATION MACHINE OPERATIONS AND CONTROLS 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 288 MACHINE OPERATIONS AND CONTROLS OPERATION Set stay (3) securely in position (4) to lock it. METHOD FOR LOCKING DEF TANK FILLER CAP COVER Pull 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...
Page 289 OPERATION MACHINE OPERATIONS AND CONTROLS Position (B): CLOSE (LOCK) When locking the door Close the door and insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key. 3-217...
Page 290: 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 291: 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 292 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 293 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 294 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 295: 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 296 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 297 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 298 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 299 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 300 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. 3-228...
Page 301 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 302 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 303: 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 304 HANDLING RADIO OPERATION PRESET BUTTON If you register desired stations to the preset button beforehand, you can select each station by touching this but- ton once. It is possible to preset 6 stations each for both AM and FM. For the presetting method, see “METHOD FOR CONTROLLING RADIO (3-233)”. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display.
Page 305: 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 306 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 307 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 308: Stow Antenna
The radio cassette is not factory fitted. If fitment is required: Remove front cover (1) . Connect speakers and aerial to radio cassette. Please contact your Komatsu distributor for a fitting instruction. REMARK If radio is fitted in this location, do not operate radio in LH con- sole.
Page 309: 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 with a protective guard installed for the operator's cab. •...
Page 310: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER WARNING Always observe the following when loading or unloading the machine from a trailer. • Select the firm, level ground when loading or unload- ing the machine. Maintain a safe distance from the road shoulder •...
Page 311 OPERATION TRANSPORTATION PROCEDURES FOR LOADING MACHINE Load on a firm and level ground. Maintain a safe distance from the road shoulder Apply the brake of the trailer securely. Set chocks (1) to the wheels to secure the trailer. Set right and left ramps (2) parallel to each other and equally spaced to the right and left of center (3) of the trail- er.
Page 312 TRANSPORTATION OPERATION If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it; if it has no work equipment, travel in reverse to load it. Follow instructions and signals of a conductor particularly when traveling in reverse.
Page 313 OPERATION TRANSPORTATION When the machine passes over the rear wheels, it inclines backward. Carefully travel in reverse to the specified point, and then stop. METHOD FOR SECURING MACHINE NOTICE Stow the radio antenna. Retract the mirrors so that they are within the width of the machine. For stowing radio antenna, see “STOW ANTENNA (3-236)”.
Page 314 TRANSPORTATION OPERATION METHOD FOR SECURING MACHINE WITH TIE-DOWN POINT Tie one end of each chain or wire rope of appropriate strength to the tie-down holes (1) on the track frame. X: 50 to 100 mm (Keep the chains off the track frame.) METHOD FOR SECURING MACHINE WITHOUT TIE-DOWN POINT Place blocks under both ends of the tracks to prevent the ma- chine from moving during transportation, and secure the ma-...
Page 315 OPERATION TRANSPORTATION After installation of mirror, always adjust it. For details, see “METHOD FOR ADJUSTING MIRRORS (3-160)”. METHOD FOR REMOVING MIRROR Mirrors (A), (B) Loosen mounting bolt (2), then remove mirror (1) from sup- port (3). Loosen bolt (4) and remove support (3) and clamp (5) from the handrail.
Page 316 TRANSPORTATION OPERATION Install mirror (1) to support (3), then tighten it with lock bolt (2). METHOD FOR REMOVING AND INSTALLING HANDRAIL WARNING • After the machine is transported, be sure to install the handrails before inspection and mainte- nance. • Use the crane, etc.
Page 317 OPERATION TRANSPORTATION Remove bolts (3), then remove handrail (B), cover (4), and plate (5). METHOD FOR INSTALLING HANDRAIL When performing the installation, install handrail (B) first. Install handrail (B), cover (4) and plate (5), then tighten them with bolts (3). Install handrail (A) and cover (2), then tighten them with bolts (1).
Page 318 TRANSPORTATION OPERATION Release lock (D) of bracket (C) of the revolving warning lamp to remove it by shifting from claw (F) of mounting por- tion (E). REMARK When removing and installing the revolving warning lamp, be sure to hold grip (G) instead of lamp itself to prevent damage.
Page 319 OPERATION TRANSPORTATION Set the lock lever to FREE position (F). Push travel speed selector switch (5) to set the travel speed to low (Lo lights up). The travel speed (Lo, Mi, Hi) is displayed on travel speed display (6). Turn auto-deceleration switch (7) OFF and operate the fuel control dial to set the engine to low speed.
Page 320: Method For Lifting Machine
TRANSPORTATION OPERATION 12. Lower the bucket to the ground. NOTICE Do not hit the bucket against the ground to prevent damage to the hydraulic cylinders. 13. With the bucket lowered to the ground, move to the ramps slowly from the rear end of the trailer. 14.
Page 321: Spread And Narrow Track Frame Gauge
OPERATION TRANSPORTATION Set the lock lever securely to LOCK position (L). Stop the engine. Check that there is nothing around the operator's seat, and then get off the machine. Close the cab door and front window securely. Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear.
Page 322 TRANSPORTATION OPERATION Remove centre frame mounting bolts (1) (9 pieces each on the front and rear side) on one side. Swing the upper structure to a right angle to track frame (2) to be moved in. Connect track frames (2) and (3) on right and left sides with chain block (4).
Page 323 OPERATION TRANSPORTATION Swing the upper structure to a right angle to track frame (2) to be moved out. Connect bucket (3) and track frame (2) to be moved out by chain block (4). Raise track frame (2) to be moved out by using the work equipment.
Page 324: 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 325: Precautions After Daily Work Completion
OPERATION COLD WEATHER OPERATION When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be started easily in the next morning.
Page 326: After Cold Weather Season
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM- MENDED FUEL, COOLANT, AND LUBRICANT (7-5)”. 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. 3-254...
Page 327: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. 3-255...
Page 328 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 drained DEF according to the local regulations and rules.
Page 329: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill 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 330: Phenomena That Are Not Failures
TROUBLES AND ACTIONS OPERATION 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: • When the arm is operated IN from a high position for dig- ging under no load, the arm speed drops momentarily at the vertical position.
Page 331: Precautions For Severe Job Condition
OPERATION TROUBLES AND ACTIONS NOTICE The maximum towing capacity for this machine is 303030 N {30900 kg} . Do not tow any load greater than this. • 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.
Page 332: Precautions For Discharged Battery
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 333 OPERATION TROUBLES AND ACTIONS • Tightening torque of battery terminal fixing nut (A): 9.8 to 11.8 Nm {1.0 to 1.2 kgm} • When replacing the battery, secure it with the battery hold- down fittings. Tightening torque of mounting bolt (B): 9.8 to 19.6 Nm {1.0 to 2.0 kgm} PRECAUTIONS FOR CHARGING BATTERY WARNING...
Page 334 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 335: 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 336 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 337 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 338 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Radiator coolant level caution lamp Lowered coolant level, leakage of Check, add coolant, repair. See lights up. coolant CHECKS BEFORE STARTING. Dirt or scale accumulated in cooling Change coolant, flush inside of cool- system ing system.
Page 339 For details of replacement, see “METHOD FOR REPLACING FUEL PRE-FILTER CARTRIDGE (4-51)” and “METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE (4-61)”. 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 341: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 342: 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 343: 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 344: 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 345: 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 346 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 347 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 348 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 349: 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 350: 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 351 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Tighten the hoses by the following torque shown in the table. Tightening torque Width Nominal No. of across Target value Allowable range hose flats "b" (mm) Nm kgm Nm kgm 35 to 54 3.5 to 5.5 54 to 93 5.5 to 9.5...
Page 352: Maintenance Schedule
250 hours. For details, see the oil part number and note in “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-5)”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE WHEN REQUIRED ............................4-15 METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER ..........
Page 353: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE TABLE METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR BREAKER) ........................4-63 METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ..........4-63 METHOD FOR REPLACING DEF TANK BREATHER ELEMENT............4-64 METHOD FOR CHECKING ALTERNATOR BELT TENSION AND REPLACING ALTERNATOR BELT .. 4-64 EVERY 2000 HOURS MAINTENANCE ......................
Page 354 MAINTENANCE SCHEDULE TABLE 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 355: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING • When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear protective eyeglasses, dust mask, or other protective equipment. •...
Page 356 MAINTENANCE PROCEDURE MAINTENANCE Open the door at the rear left side of the machine, remove hooks (2) (6 places) and remove cover (3). Hold outer element (5), rock it lightly up and down and to the right and left, and twist to pull it out. When outer element (5) is removed, check that the inner element does not come out of position and is not at an an- gle.
Page 357 MAINTENANCE MAINTENANCE PROCEDURE NOTICE • Do not use the element with damaged pleats or a damaged gasket or seal. • If the element and O-ring are cleaned and used again after they are used for more than one year, it will cause problems.
Page 358 MAINTENANCE PROCEDURE MAINTENANCE Always install cover (3) so that vacuator (4) faces the ground (A). When cover (3) is installed, check that the clearance between the air cleaner body and cover (3) is not too large. If the clearance is too large, remove cover (3), and then install it again.
Page 359 MAINTENANCE MAINTENANCE PROCEDURE NOTICE • Do not clean and reuse the inner element. When replacing the outer element, replace the inner ele- ment with a new one at the same time. • If the outer element and cover are installed while the inner element is not installed properly, the out- er element may be damaged.
Page 360: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4,000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 361 MAINTENANCE MAINTENANCE PROCEDURE Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant. Clean the inside of the cooling system according to the following procedure. Place the machine on a level ground, then stop the engine. Remove bolts (A) (2 pieces), then open cover (1).
Page 362 MAINTENANCE PROCEDURE MAINTENANCE Place containers under drain valve (5) on the radiator side and drain valve (6) on the engine side to receive the cool- ant. Open drain valves (5) and (6) to drain the coolant. After draining the coolant, close drain valves (5) and (6) and fill with city water.
Page 363 MAINTENANCE MAINTENANCE PROCEDURE 13. Turn the fuel control dial to a point midway between Low idle (MIN) and High idle (MAX). NOTICE When the work equipment is operated, take care that it does not interfere with the machine or ground. 14.
Page 364 MAINTENANCE PROCEDURE MAINTENANCE 15. Stop the engine and open drain valves (5) and (6) to drain the coolant. 16. Open the engine hood, drain the coolant from sub-tank (7), clean the inside of the sub-tank, then fill with Non-Amine Engine Coolant to the middle between FULL and LOW marks.
Page 365 MAINTENANCE MAINTENANCE PROCEDURE 18. Close drain valves (5) and (6). 19. Install covers (3) and (4). 20. Add Non-Amine Engine Coolant through the coolant filler port up to the mouth of the port. For details of the coolant density, see “Coolant density ta- ble”.
Page 366: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS NOTICE If the machine is used with track shoe bolts loose, they will break. If any looseness of the shoe bolt is found, retighten it. Check for looseness of the shoe bolt (1). If any looseness of the bolt is found, tighten it in order shown in the figure.
Page 367: Method For Replacing Bucket Teeth (Vertical Pin Type)
Check the track tension again, and if the tension is not correct, adjust it again. If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. METHOD FOR REPLACING BUCKET TEETH (VERTICAL PIN TYPE) Replace the bucket teeth before the adapter starts to wear.
Page 368 MAINTENANCE PROCEDURE MAINTENANCE To make it possible to drive out a pin of tooth (1), put block (5) under the bottom of the bucket, and make the bottom of the bucket horizontal. Check that the work equipment is in a stable condition, then set the lock lever to LOCK position (L).
Page 369 MAINTENANCE MAINTENANCE PROCEDURE • The steel ball sinks. The rubber of the rubber pin lock is deteriorated and steel ball (7) sinks into it when you press it. Remove the soil stuck to adapter (4) by using a knife. Use your hand or a hammer to push rubber pin lock (3) in- to the hole of adapter (4).
Page 370: Method For Replacing Bucket Teeth (Horizontal Pin Type)
MAINTENANCE PROCEDURE MAINTENANCE • After the lock pin (2) is driven in completely, its tip sur- face is flush with the surface of tooth (1). • Lightly hit lock pin (2) in the reverse direction from which it was hit in. •...
Page 371: Method For Replacing Bucket Side Cutter And Shroud
(2). REMARK If it cannot be removed by this method, ask your Komatsu distributor to have the replacement performed. 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.
Page 372: Method For Adjusting Bucket Clearance
Insert pin (1) half way, then drive it in fully with a hammer. Install it to the bucket. REMARK If it cannot be removed by this method, ask your Komatsu distributor to have the replacement performed. METHOD FOR ADJUSTING BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance.
Page 373: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE Use a clearance gauge for easy and accurate measure- ment. Loosen plate mounting bolts (2) (4 pieces) and loosen plate (3). The shim is a split type, so the work can be performed without removing the bolts. Remove shim (4) corresponding to the amount of play "a".
Page 374 MAINTENANCE PROCEDURE MAINTENANCE Check mainte- Content of check and maintenance Guideline for maintenance interval nance items conditioner con- Clogged fins Every 500 hours denser “METHOD FOR CHECKING AND CLEANING RADIATOR FINS, OIL COOLER FINS, AFTER- COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (4-53)”...
Page 375: Method For Washing Washable Floor
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributor to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 376 MAINTENANCE PROCEDURE MAINTENANCE Referring to “METHOD FOR SETTING MACHINE AT ANGLE”, select a safe method, depending on the state of the machine. In this example, the machine is set at angle by using blocks. Swing the upper structure slowly so that water drain holes (3) in the cab floor are at a low position.
Page 377 MAINTENANCE MAINTENANCE PROCEDURE Pull out projections (2) (6 places) on the back of the floor mat and remove the floor mat. Remove the cap from water drain hole (3). Flush out the dirt on the floor directly with water through water drain hole (3).
Page 378: Method For Checking Gas Spring
Do not perform drilling, welding or flame-cutting. • 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. 4-38...
Page 379: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE PROCEDURE The gas springs are located at the engine hood (2 places on right and left sides). In the following cases, ask your Komatsu distributor for inspection, repair, and replacement. • The engine hood is heavy to open. •...
Page 380 If oil does not ooze out, stop the engine, remove port S hose (3), and fill the motor case with hydraulic oil. When replacing the travel motor safety valve, ask your Komatsu distributor for the replacement and the air bleeding.
Page 381: Check Automatic Grease System
MAINTENANCE MAINTENANCE PROCEDURE If a breaker or other attachment is installed, perform the air bleeding procedure until the air is completely bled from the attachment circuit. Turn the fuel control dial to Low idle (MIN) position. Repeat operating the attachment approximately 10 times to bleed air. Check that there is no leakage of oil and wipe off any oil that is spilled.
Page 382: Refilling Grease
MAINTENANCE PROCEDURE MAINTENANCE REFILLING GREASE If the yellow lamp (5) on the in-cab display (2) illuminates, the minimum grease level in the reservoir has been reached. The grease reservoir must be refilled as soon as possible. KS000880 GREASING PROCEDURE Remove the dust cap from the filler coupling (7). Carefully clean the filter coupling (7) and the filler coupling on the filler hose.
Page 383: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE Move the starter switch to the ON position (B). Depress the test button (9) on the pump for three to five seconds. The system will run a run a single test. During this test the green LED (4) of the selected interval on the in-cab display (2) will flash (2 sec.
Page 384: Every 50 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE • Method for checking oil level in engine oil pan, adding oil • Method for checking electric wiring • Method for checking fuel level, adding fuel • Method for checking DEF level, adding DEF • Method for checking working lamp •...
Page 385: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 50 hours service should be performed at the same time. METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL Perform this procedure before operating the machine. Inspect the battery electrolyte level according to the standard at least once a month. WARNING Do not use the battery if the battery electrolyte level is below LOWER LEVEL line.
Page 386: Method For Checking And Adjusting Air Conditioner Compressor Belt Tension
If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed electrolyte with baking soda (sodium bicarbon- ate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 387 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT Open cover (1). Open the engine food and remove guard (2). Press the centre between crankshaft pulley (A) and com- pressor pulley (B) with a finger (approximately 58.8 N {6.0 kg} ). If deflection (C) is 14 to 16 mm, the belt tension is normal. If the deflection is out of the standard, adjust it to the standard value.
Page 388: Every 500 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE Check each pulley for damage, wear of the V-groove, and the wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks of the belt.
Page 389: Method For Lubricating
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR LUBRICATING NOTICE • If any unusual noise is generated from any greasing point, perform greasing regardless of the greasing interval. • Perform greasing every 10 hours for the first 50 hours of operation on a new machine. •...
Page 390 MAINTENANCE PROCEDURE MAINTENANCE (7) Boom foot pin (2 places) After greasing, wipe off any old grease that is pushed out. 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. Accordingly, wait until they have cooled down before starting the work.
Page 391: Method For Replacing Fuel Pre-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 392 MAINTENANCE PROCEDURE MAINTENANCE Turn valve (1) at the bottom of the fuel tank to CLOSE po- sition (S). Open the engine hood. Place a container under fuel pre-filter cartridge (2) to re- ceive the fuel. Loosen drain valve (3) and drain water and sediments from transparent cup (4), and also drain all the fuel from fil- ter cartridge (4).
Page 393: Method For Checking Swing Pinion Grease Level, Add Grease
Total amount of grease: 33 ℓ (29.7 kg) If the grease is milky white, it needs to be replaced. Ask your Komatsu distributor to replace it. Install cover (2) with bolt (1). METHOD FOR CHECKING AND CLEANING RADIATOR FINS, OIL COOLER FINS,...
Page 394 MAINTENANCE PROCEDURE MAINTENANCE NOTICE When using compressed air for cleaning, blow it keeping some distance to avoid damaging the fins. Damage on the fins can cause water leakage and overheating. In a dusty job site, check the fins every day, regardless of the maintenance interval. Open cover (1).
Page 395: Method For Cleaning Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE If the rubber hose is cracked or become fragile, ask your Komatsu distributor for replacement. If the hose clamp is loose, tighten it. Remove undercover (10) and blow out the mud, dirt, and leaves to the outside.
Page 396 MAINTENANCE PROCEDURE MAINTENANCE While holding cover (4) open, remove filter (5) inside it. REMARK • When removing, insert your finger into dent (D) of duct and pull it toward you. If you grasp the filter with excessive force, it may be deformed or damaged.
Page 397: Method For Checking Oil Level In Swing Machinery Case, Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE 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. Accordingly, wait until they have cooled down before starting the work. Open the cover.
Page 398: Every 1000 Hours Maintenance
Check structures for cracks. If any cracks are found contact your Komatsu distributor. If the structure is welded, or holes are drilled in it, or it is repaired in any other way, its strength may be reduced.
Page 399 MAINTENANCE MAINTENANCE PROCEDURE Park the machine on a level and firm ground, lower the work equipment to the ground in the posture shown in the figure, and stop the engine. Remove the cap for oil filler (F), and release the internal pressure.
Page 400: Method For Change Oil In Swing Machinery Case
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGE OIL IN SWING MACHINERY CASE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. Refill capacity: 20 ℓ...
Page 401: 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 402 MAINTENANCE PROCEDURE MAINTENANCE Turn filter cartridge (2) counterclockwise by using the filter wrench, and remove it. After removing the filter cartridge, fuel drops fall down from the filter head. In order to prevent flow out of the fuel, be sure not to leave the machine without the filter cartridge.
Page 403: Method For Checking All Tightening Points Of Engine Intake Pipe Clamps
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 404: Method For Replacing Def Tank Breather Element
Close DEF tank cover at the right of the machine. METHOD FOR CHECKING ALTERNATOR BELT TENSION AND REPLACING AL- TERNATOR BELT Special tools are required for inspection and replacement of the alternator belt. Ask your Komatsu distributors for inspection and replacement. REMARK As the auto alternator belt tensioner is installed, no belt tension adjustment is required.
Page 405: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time. METHOD FOR CHANGING OIL IN FINAL DRIVE CASE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 406: 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 407 MAINTENANCE MAINTENANCE PROCEDURE • When the control lever is operated in the direction to lower the work equipment, the work equipment goes down under its own weight. • Release the pressure from the hydraulic circuit. The accumulator is installed to the position shown in the figure. METHOD FOR CHECKING ACCUMULATOR FUNCTION CAUTION When performing the inspection, check first that there is no person or obstacle in the surrounding area.
Page 408 If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulator for the hy- draulic circuit has probably dropped. Ask your Komatsu distrib- utor for inspection. This completes the inspection. After completion of the inspection, set the lock lever to LOCK position and turn the starting switch to OFF position.
Page 409 MAINTENANCE MAINTENANCE PROCEDURE If an attachment is installed, set the lock pin of the attach- ment control pedal to position (c) where you can operate the pedal. Perform the following procedure within 15 seconds. After the engine stops, the accumulator pressure decreas- es gradually.
Page 410: 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 of the parts are still very hot.
Page 411 MAINTENANCE MAINTENANCE PROCEDURE By using the special wrench, loosen ring (3) of KCCV ven- tilator (1). After ring (3) comes off, remove case (4) from body (2) and remove element (5). There may be oil accumulated or sticking in the case and element.
Page 412: Method For Replacing Def Filter
MAINTENANCE PROCEDURE MAINTENANCE Align the position of ◇ mark (13) on the case with that of ◇ mark (8) of the filter body label, then install the case to the filter body. The case can be installed only when its claws (14) are cor- rectly inserted in grooves (10) of the filter body.
Page 413 Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine.
Page 414 MAINTENANCE PROCEDURE MAINTENANCE Insert filter removal tool (3) into the bottom of the DEF pump and thrust in with hand. Check that filter removal tool (3) is fully inserted to the end. Insert the filter removal tool to the end where you cannot thrust it in any further.
Page 415: Every 4000 Hours Maintenance
Accumulator for additional attachment 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. METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked.
Page 416: Method For Replacing Accumulator (For Control Circuit)
• Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 417: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
Check clamps (1) to (14) visually and with your fingers that there are no loose bolts or hardening of the rubber. If there is any problem, the replacement must be performed. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,...
Page 418: Every 4500 Hours Maintenance
Check fuel spray prevention caps (1) and (2) visually or with a finger to see if any of them has slipped off, or the rubber portion is hardened. If there is any problem, the replacement must be performed. Ask your Komatsu distributor for replacement. EVERY 5000 HOURS MAINTENANCE Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time.
Page 419 MAINTENANCE MAINTENANCE PROCEDURE • Socket wrench handle Swing the upper structure so that drain plug (P) of the hy- draulic tank and drain plug (A) at the bottom of the pump suction tube are placed in between the right and left tracks.
Page 420: Every 8000 Hours Maintenance
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. 4-80...
Page 421: Specifications
SPECIFICATIONS...
Page 422 Machines that are designated as Heavy Duty specification are supplied with arm length of 2.4m, 2.9m or 3.4m. These machines are not recommended for use with arm lengths of 4.0m and 4.8m. Please contact your Komatsu distributor for further information if required.
Page 423 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC490-11, PC490LC-11 A Max. digging reach mm 12030 B Max. digging depth mm 7755 C Max. digging height mm 10980 D Max. vertical wall digging depth mm 6805 E Max. dumping height mm 7630 F Min. dumping height mm...
Page 424: Explanation Of Lift Capacity Chart (6.7M Boom)
SPECIFICATIONS SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART (6.7M BOOM) 6.7m Boom - PC490-11, PC490-11 LEGEND A: Reach from swing centre B: Bucket hook height OF: Lifting capacity (rating overfront) OS: Lifting capacity (rating overside) LEGEND (1) Position of lifting point (2) Arm length (3) Boom length Hydraulic pressure: 37.3 MPa...
Page 425 SPECIFICATIONS SPECIFICATIONS 6.7m Boom - PC490-11...
Page 426 SPECIFICATIONS SPECIFICATIONS 6.7m Boom - PC490LC-11...
Page 427: Explanation Of Lift Capacity Chart (7.1M Boom)
SPECIFICATIONS SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART (7.1M BOOM) 7.1m Boom - PC490-11, PC490LC-11 LEGEND A: Reach from swing centre B: Bucket hook height OF: Lifting capacity (rating overfront) OS: Lifting capacity (rating overside) LEGEND (1) Position of lifting point...
Page 428 SPECIFICATIONS SPECIFICATIONS 7.1m Boom - PC490-11...
Page 429 SPECIFICATIONS SPECIFICATIONS 7.1m Boom - PC490LC-11...
Page 431: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 432: 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 433 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 434: Quick Coupler System
Maximum cir- cuit pressure 34.3 MPa (350 kgf/cm • Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu dealer. LOCATIONS (1) Switch - Quick Coupler...
Page 435 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM (1) Operation switch REMARK The switch has a safety lock mechanism to prevent acci- dental operation. Slide the lock towards you then rock the switch. The lamp on the switch will come on and a warning buzzer will sound.
Page 436 This machine has a system installed to give a warning if there is a failure to maintain pressure in the quick coupler system. If the buzzer sounds in the cab make sure that the cause is clarified be- fore continuing work. In particular check for leaks in the system. If in doubt call your Komatsu dis- tributor.
Page 437: Automatic Grease System
If in doubt please consult your Ko- matsu distributor. Komatsu genuine grease is provided to maintain reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best condition for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 438: Diagram Of Automatic Greasing Points
AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS DIAGRAM OF AUTOMATIC GREASING POINTS DIAGRAM OF AUTOMATIC GREASING POINTS Part/Location Swing circle Boom cylinder foot pin Boom foot pin Boom cylinder rod end Arm cylinder foot pin Boom arm coupling Arm cylinder rod end Bucket cylinder foot pin Bucket cylinder rod end (may not be available with some...
Page 439: Indication On The In-Cab Display
ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM Select the interval by pushing button (3) on the in-cab dis- play (2). KS000879 INDICATION ON THE IN-CAB DISPLAY Indication Meaning The red lamp (6) flashes as soon as the ignition has been 1. The pump is not powered. Check fuses and connec- switched on.
Page 440: Check Automatic Grease System
AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS A green lamp is flashing continuously (0.2 sec. on/0.2 Continuous test run being executed (see System Test). sec. off) CHECK AUTOMATIC GREASE SYSTEM PERIODIC CHECKS Check the grease level in the reservoir, but do not refill the reservoir before minimum level is reached. Check the in-cab display is functioning.
Page 441 ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM REMARK Do not fill the reservoir before you have a low level indica- tion (5) on the in-cab display. KS000880 SYSTEM TEST In order to check the system a single lubrication cycle can be performed as follows: Move the starter switch to the ON position (B).
Page 442 AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS NOTICE Only use grease tests cycles if necessary. Every time a test cycle is carried out grease is added to the grease points. This will increase grease usage and can cause excessive greasing of the grease points.
Page 443: Handle Bucket With Hook
If the bucket with hook is turned 180 deg. and used for opera- tions, 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. Refer also to GENERAL PRECAUTIONS FOR LIFTING OP-...
Page 444: Handle Machine Ready For Installation Of Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS ON MACHINE EQUIPPED WITH AT- TACHMENT KS000877 (1) Stop valve (2) Selector valve (3) Attachment control pedal (4) Lock pin (5) Additional filter for breaker (6) Accumulator (7) 1st Attachment proportional control switch...
Page 445 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (F) FREE Hydraulic oil flows. (L) LOCK Hydraulic oil stops. When removing or installing attachments, set this valve to LOCK position. SELECTOR VALVE The selector valve switches the flow of the hydraulic oil. It is automatically switched according to the selected working mode.
Page 446 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS LOCK PIN NOTICE Before changing the position of the lock pin, stop the engine. If you depress the pedal to (D) side with lock pin at (c) position when using the breaker, it may cause malfunction and breakage of breaker.
Page 447 • 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 To the machine equipped with a breaker you need to install an accumulator whose model number matches to that of the breaker manufacturer to the breaker piping .
Page 448: Method For Change-Over And Connect Hydraulic Circuit For Machine Ready For Installation Of Attachment
B mode set at the shipment from the plant and it becomes 27.4 MPa {280 kg/cm } when ATT/P or ATT/E mode is selected. Depending on the attachment, it may be necessary to adjust the pres- sure. Ask your Komatsu distributor for the adjustment. SWITCHING THE HYDRAULIC CIRCUIT •...
Page 449 Connect the attachment piping (2) provided by the attach- ment manufacturer to the part from where the plug is re- moved. 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. 6-19...
Page 450 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 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 figure. •...
Page 451: Method For Removing And Installing Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Hydraulic oil flowing through crusher circuit does not pass through additional filter for breaker. Relief valve is set to high pressure. Maximum oil flow can be adjusted in user mode. Set pressure of safety valve of service valve (when shipped from plant): 24.5 MPa {250 kg/cm Crusher circuit (2-way circuit) is formed.
Page 452 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Loosen oil filler cap (F) slowly on the top of the hydraulic tank to release the internal pressure in the hydraulic tank. Check that the hydraulic oil temperature is low. Turn the rotor of the stop valve installed to the piping for the inlet port and the outlet port on the side face of the arm to LOCK position (L).
Page 453 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Turn the starting switch to ON (B) position. 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 454: Method For Operating Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Loosen oil filler cap (F) slowly on the top of the hydraulic tank to release the internal pressure in the hydraulic tank. Check that the hydraulic oil temperature is low. 10.
Page 455 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (2) Attachment Control Pedal Set the working mode to B mode. Insert the lock pin in front-only FREE position (b). Press the front of the pedal to operate the breaker. The breaker operates.
Page 456 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS If you enter the selection of the breaker mode, the confir- mation message is displayed. WARNING When a special attachment is installed, if the mode is switched to the breaker mode by mistake, it may lead to serious danger, such as sudden drop of the work equipment.
Page 457 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Press the working mode selector switch (1). The screen changes to working mode selection screen. Press working mode selector switch (1) or switch F3 or F4 to select attachment mode ATT/P or ATT/E. With Attachment Mode ATT/P or ATT/E highlighted in yel- low, enter the selection by either of the following opera- tions.
Page 458: Long-Term Storage
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 1. Proportional Control Rolling Switch With the working mode set to ATT/P or ATT/E mode, rolling the switch up produces movement of the attachment, rolling down produces opposite movement of the attachment. Slight move- ment of the roller will give slight movement of the attachment;...
Page 459: Maintenance Of Additional Filter For Breaker
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT MAINTENANCE OF ADDITIONAL FILTER FOR BREAKER WARNING • Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in- jury. Accordingly, wait until they have cooled down before starting the work. •...
Page 460 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 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 461 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Remove plug (1) and drain the hydraulic oil accumulated in filter case (2) into the prepared oil container. After checking that the hydraulic oil temperature has drop- ped, turn filter case (2) counterclockwise, remove it, then remove element (3).
Page 462: Specifications
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS After checking that the hydraulic oil temperature has drop- ped, turn filter case (1) counterclockwise, remove it, then remove element (2). Clean the removed parts, then install new element (2). REMARK Element (2) must be installed facing in the correct direc- tion.
Page 463: Arm/Pin Information
ATTACHMENTS AND OPTIONS ARM/PIN INFORMATION ARM/PIN INFORMATION A - A B - B KS000370 +0.2 +1.0 370 mm 370 mm -0.7 -0.0 PC490/LC-11 -0.036 -0.036 100 mm 100 mm -0.090 -0.090 6-33...
Page 464: 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 465: Rock Bucket Selection
Material 2.99 / 2250 2.74 / 2159 2.76 / 2175 2.56 / 2100 2.30 / 2000 1.69 / 1650 1.34 / 1450 / kg 1.8 t/m PC490LC-11 (6.7 m Boom) PC490LC-11 (7.1 m Boom) 1-Piece Boom 1-Piece Boom Bucket Volume/ 2.4 m...
Page 466: Tool Control System
2nd attachment line flow. The system can store settings for up to 16 different attachments, to adjust attachment settings please contact your Komatsu distributor. The tool control system monitor is located in the operator cab on the door pillar.
Page 467: Track Shoes Selection
The system automatically monitors for system abnormalities, in the event of an error the monitor display screen (7) will display ERR and an audible intermittent buzzer will sound. In the event of a system error, stop work im- mediately, move the machine to a safe place and contact your Komatsu distributor for support. TRACK SHOES SELECTION Select the appropriate track shoe to match the operating conditions.
Page 468 Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid travelling • over obstacles, shift down and travel at half speed in Lo. Table 2 PC490, PC490LC-11 Specifications Category Option 600 Triple...
Page 469: Recommended Attachment Operations
Select the optimum attachment model for the hydraulic excavator body. The attachments and models ready for installation differ according to the machine body. For details of the selection of the attachments or the models, consult your Komatsu distributor. HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows.
Page 470 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm off the ground. Do not raise it off the ground unnecessarily. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 471 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not use the mount to gather in pieces of rock. Do not work by using the swing force. Do not move the chisel while performing breaking operation. Do not perform breaker operation in horizontal or upward direc- tion.
Page 472 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Do not perform the operation with bucket cylinder rod extended fully to raise the machine off the ground. Do not perform the breaker work with any cylinder at the stroke end.
Page 473 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Grease the breaker while holding it in the right posture shown below. • Lower the chisel perpendicularly to the ground. • Insert the grease gun perpendicularly to the greasing point. Wrong posture 6-43...
Page 475: Replacement Parts
REPLACEMENT PARTS...
Page 476: 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 477: 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 478 CONSUMABLE PARTS REPLACEMENT PARTS Replacement in- Item Part No. Part Name Q'ty terval Vertical pin type 208-70-34211 Tooth (208-70-34220) (Pin) (208-70-34191) (Lock) Horizontal pin type 208-70-14152 Tooth (09244-03036) (Pin) Bucket Side cutter type 208-70-34160 Side cutter (left) 208-70-34170 Side cutter (right) Shroud type 208-934-7132 Shroud...
Page 479: 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 480: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter Replace DEF tank breather element Replace DEF filter USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient Temperature, degrees Celsius Recommended Komatsu Reservoir Fluid Type Fluids...
Page 481 250 hours. For changing maintenance time of machine monitor, ask your Komatsu distributor to perform the work. Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Page 482: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
Page 483: Index
INDEX INDEX Symbols Alternator - Check..........4-70 Alternator belt tension - Check / Replace..... 4-64 12H24H display mode - Switch......3-83 Always use clean washer fluid........ 4-2 1st attachment proportional control switch....3-97 Ambient temperature range for operation and storage 1st-line attachment proportional switch....6-17 ..............3-176 2nd attachment proportional control switch..
Page 484 INDEX Breaker - Check points when using ..... 6-26 Coolant and water for dilution......... 4-6 Breaker - Operate..........6-24 Cooling system - Clean inside......4-20 Breaker - Set............3-69 Counter-rotation turn...........3-193 Breaker mode switch..........6-18 Cover with lock - Lock.........3-213 Breaker switch............3-97 Cover with lock - Open........3-213 Bucket - Invert.............3-208 Cover with lock - Open / Close......
Page 485 INDEX Every 8000 hours maintenance......4-80 Every 9000 hours maintenance......4-80 ECO gauge............3-42 Explanation of air conditioner equipment....3-219 ECO guidance............3-37 Explanation of components........3-9 ECO guidance record - Check......3-60 Explanation of components on machine equipped Economy mode - Adjust........3-68 with attachment..........6-14 Effective use of hydraulic excavator....
Page 486 Keep machine clean..........2-18 Guards..............2-42 Keep work place clean and tidy......2-41 Guide to reduce vibration levels on machine..1-6 Komatsu Closed Crankcase Ventilation (KCCV) 3-126 Komatsu genuine lubricants........4-2 Komatsu genuine replacement parts...... 4-2 Handle oil, fuel, coolant, and performing oil clinic...4-5 KOMTRAX............
Page 487 INDEX Machine - Set at angle.......... 4-37 Mirror - Install............3-243 Machine - Start (Travel forward and reverse) / Stop..Mirror - Remove..........3-243 ..............3-189 Mirror - Remove / Install........3-242 Machine - Start after long-term storage....3-255 Mirrors - Adjust............3-160 Machine - Steer (Change the direction)....
Page 488 INDEX Precautions before starting inspection and mainte- Precautions when leaving machine...... 2-22 nance............. 2-41 Precautions when loading and unloading..... 2-38 Precautions before starting operation....2-18 Precautions when operating on snow or frozen surfa- Precautions for adding.......... 2-51 ces..............2-37 Precautions for adding DEF........4-2 Precautions when parking machine......
Page 489 INDEX Sound balance - Adjust........3-235 Sound control button...........3-232 Radiator coolant level caution lamp...... 3-29 Space for radio cassette........3-236 Radiator fin / Oil cooler fin / Aftercooler fin / Air condi- Specifications..........5-2,6-32 tioner condenser fin - Check / Clean..... 4-53 Spread and narrow track frame gauge....
Page 490 INDEX Tuning/time adjustment button......3-231 Turbocharger protection function......3-175 Turn battery disconnect switch to off position..2-44 Two workers for maintenance when engine is running ...............2-42 Unauthorized modification........2-24 Understanding the machine........2-18 Urea SCR system warning - Handle....3-126 Use handrails and steps when getting on or off ma- chine..............

This manual is also suitable for:

Pc490-11

Komatsu PC490LC Installation And Instruction Manual

Table of Contents

Maintenance Schedule

Quick Links

Chapters

Related Manuals for Komatsu PC490LC

Summary of Contents for Komatsu PC490LC