Galeo PC600-7 Operation & Maintenance Manual Download | Manualshive

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MAINTENANCE SCHEDULE

MAINTENANCE

4-16

MAINTENANCE SCHEDULE

4

If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For
details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (4-18)" to confirm the correct maintenance
schedule when carrying out maintenance.

MAINTENANCE SCHEDULE CHART

4

INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)

CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER ............................................................................. 4-59

INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)

CHANGE OIL IN SWING MACHINERY CASE................................................................................................. 4-63

CHANGE OIL IN P.T.O CASE .......................................................................................................................... 4-64

CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................. 4-69

WHEN REQUIRED

CHECK, CLEAN AND REPLACE AIR CREANER ELEMENT.......................................................................... 4-20

CLEAN INSIDE OF COOLING SYSTEM.......................................................................................................... 4-25

CHECK AND TIGHTEN TRACK SHOE BOLTS ............................................................................................... 4-27

CHECK AND ADJUST TRACK TENSION........................................................................................................ 4-28

CHECK ELECTRICAL INTAKE AIR HEATER .................................................................................................. 4-29

REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) ................................................................................. 4-30

ADJUST BUCKET CLEARANCE...................................................................................................................... 4-31

REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER......................................................... 4-32

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ............................................................................... 4-32

CHECK AND ADJUST AIR CONDITIONER ..................................................................................................... 4-33

CLEAN LINE FILTER, REMOVE DIRT............................................................................................................. 4-34

REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT ........................................................... 4-35

CLEAN PILOT LINE FILTER, REMOVE DIRT ................................................................................................. 4-36

BLEEDING AIR FROM HYDRAULIC SYSTEM ................................................................................................ 4-37

METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT ........................................... 4-40

CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit) .................................. 4-41

CHECKS BEFORE STARTING

EVERY 10 HOURS MAINTENANCE

LUBRICATING .................................................................................................................................................. 4-43

EVERY 100 HOURS MAINTENANCE

LUBRICATING SWING CIRCLE....................................................................................................................... 4-46

EVERY 250 HOURS MAINTENANCE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................... 4-47

CHECK LEVEL OF BATTERY ELECTROLYTE............................................................................................... 4-48

CHECK, CLEAN FUEL TANK STRAINER........................................................................................................ 4-50

CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS................................................. 4-50

CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST ............................................................................. 4-51

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES
EQUIPPED WITH AIR CONDITIONER) ........................................................................................................... 4-52

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Summary of Contents for PC600-7

Page 1: ... It is our policy to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously Due to this continuous program of research and development revisions may be made to this publication It is recommended that customers contact their distributor f...

Page 2: ...1 1 FOREWORD 11 ...

Page 3: ...erstand them fully Keep this manual at the storage location for the Operation and Maintenance Manual given below and have all personnel read it periodically If this manual has been lost or has become dirty and cannot be read request a replacement manual imme diately from Komatsu or your Komatsu distributor If you sell the machine be sure to give this manual to the new owners together with the mach...

Page 4: ...FOREWORD FOREWORD 1 3 ...

Page 5: ...FOREWORD FOREWORD 1 4 ...

Page 6: ...ous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or mod erate injury This word is used also to alert against unsafe practices that may cause prop erty damage Example of safety message using signal word WARNING When standing up from the operator s seat always place the lock lever in the LO...

Page 7: ...zardous condition is also displayed inside a triangle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precau tions If any procedures or actions not specifically recommended or allowed in this manual are used it is your responsi bility to t...

Page 8: ... q Ditching work q Loading work q Demolition work See the section RECOMMENDED APPLICATIONS 3 119 for further details DIRECTIONS OF MACHINE 1 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 ...

Page 9: ...hours as indicated on the service meter Make sure that you fully understand the content of this manual and pay careful attention to the following points when breaking in the machine q Run the engine at idling for 15 seconds after starting it During this time do not operate the control levers or fuel control dial q Idle the engine for 5 minutes after starting it up q Avoid operation with heavy load...

Page 10: ... PLATE 1 On the front bottom right of the operator s cab side of upper frame The design of the nameplate differs according to the territory ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1 This is at the side of the oil cooler housing on the left side face of the engine cylinder block The EPA restrictions plate is on the top surface of the intake manifold at the front of the chassis EPA Environmental...

Page 11: ...D 1 10 SERVICE METER LOCATION 1 On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1 Machine serial No Engine serial No Product identification number PIN Distributor name Address Service Personnel Phone Fax ...

Page 12: ...N 1 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1 10 SAFETY SAFETY INFORMATION 2 2 SAFETY LABELS 2 4 LOCATION OF SAFETY LABELS 2 5 SAFETY LABELS 2 6 SAFETY INFORMATION 2 12 SAFETY MACHINE OPERATION 2 21 STARTING ENGINE 2 21 OPERATION 2 23 TRANSPORTATION 2 30 BATTERY 2 31 TOWING 2 33 LIFTING OBJECTS WITH BUCKET 2 34 SAFETY MAINTENANCE INFORMATION 2 35 OPERATION MACHINE VIEW ILLUSTRATIONS 3 2 OVE...

Page 13: ... 3 47 Method Of Operation 3 52 Use Air Conditioner With Care 3 58 Inspection and maintenance of air conditioner equipped machine 3 58 Other Functions 3 59 RADIO 3 61 Control Panel 3 61 Controls Of Radio 3 62 Use Radio With Care 3 64 AUXILIARY ELECTRIC POWER 3 64 24V power source 3 64 12V power source 3 64 FUSE 3 65 CIRCUIT BREAKER 3 66 CONTROLLERS 3 67 TOOL BOX 3 67 GREASE PUMP 3 68 Method of Use ...

Page 14: ...ENERAL OPERATION INFORMATION 3 114 TRAVELING ON SLOPES 3 116 ESCAPE FROM MUD 3 118 Stuck One Side Of Track 3 118 Stuck Both Sides Of Tracks 3 118 RECOMMENDED APPLICATIONS 3 119 Backhoe Work 3 119 Ditching Work 3 119 Loading Work 3 119 BUCKET REPLACEMENT 3 120 Replacement 3 120 PARKING MACHINE 3 122 CHECK AFTER SHUT OFF ENGINE 3 123 LOCKING 3 124 TRANSPORTATION 3 125 PRECAUTIONS FOR TRANSPORTATION ...

Page 15: ... 3 149 Electronic Control System 3 151 Point Of Contact To Telephone When Error Occurs 3 152 MAINTENANCE MAINTENANCE INFORMATION 4 2 LUBRICANTS COOLANT AND FILTERS 4 4 HANDLING OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 4 Oil 4 4 Fuel 4 4 Cooling System Coolant 4 5 Grease 4 5 Carrying out KOWA Komatsu Oil Wear Analysis 4 5 Oil And Fuel Storage 4 6 Filters 4 7 ELECTRIC SYSTEM MAINTENANCE 4 7 WEAR...

Page 16: ...N ACCUMULATOR control circuit 4 41 CHECK BEFORE STARTING 4 42 EVERY 10 HOURS MAINTENANCE 4 43 LUBRICATING 4 43 EVERY 100 HOURS MAINTENANCE 4 46 LUBRICATING SWING CIRCLE 4 46 EVERY 250 HOURS MAINTENANCE 4 47 CHECK OIL LEVEL IN FINAL DRIVE CASE ADD OIL 4 47 CHECK LEVEL OF BATTERY ELECTROLYTE 4 48 CHECK CLEAN FUEL TANK STRAINER 4 50 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS 4 50 CHECK A...

Page 17: ...CE 4 72 CHECK WATER PUMP 4 72 CHECK VIBRATION DAMPER 4 72 CHECK FAN PULLEY AND TENSION PULLEY 4 72 REPLACE INJECTOR ASSEMBLY 4 72 CHECK FOR LOOSENESS OF HIGH PRESSURE CLAMP HARDENING OF RUBBER 4 73 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 74 EVERY 5000 HOURS MAINTENANCE 4 75 CHANGE OIL IN HYDRAULIC TANK 4 75 EVERY 8000 HOURS MAINTENANCE 4 77 REPLACE HIGH PRESSURE PIPING CL...

Page 18: ...2 1 SAFETY 12 ...

Page 19: ...ment Combinations 2 172 Cab Widow Glasses 2 182 Unauthorized Modifications 2 182 Safety at Jobsite 2 182 Working on Loose Ground 2 182 Distance to High Voltage Cables 2 192 Ensure Good Visibility 2 192 Ventilation for Enclosed Area 2 192 Signalman s Signal and Signs 2 202 Emergency Exit from Operator s Cab 2 202 Asbestos Dust Hazard Prevention 2 202 SAFETY MACHINE OPERATION 2 212 STARTING ENGINE 2...

Page 20: ...2 Proper Tools 2 372 Accumulator 2 372 Personnel 2 372 Attachments 2 382 Work Under the Machine 2 382 Noise 2 382 When Using Hammer 2 382 Welding Works 2 382 Removing Battery Terminals 2 392 Safety First when Using High pressure Grease to Adjust Track Tension 2 392 Do Not Disassemble Recoil Springs 2 392 Safety Rules for High pressure Oil 2 392 Precaution for High Fuel Pressure 2 402 Safety Handli...

Page 21: ...n the correct place and always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off q There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way q If the labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the labels see ...

Page 22: ...SAFETY SAFETY LABELS 2 5 LOCATION OF SAFETY LABELS 2 ...

Page 23: ...SAFETY LABELS SAFETY 2 6 SAFETY LABELS 2 1 Precautions for operation inspection and maintenance 09651 03001 2 Warning before moving 09802 03000 3 Warning when leaving operator s seat 09654 03001 ...

Page 24: ...SAFETY SAFETY LABELS 2 7 4 Warning for electric lines 09801 03001 5 Warning when opening front window 09839 03000 6 Warning when stowing front window 09803 03000 ...

Page 25: ...SAFETY LABELS SAFETY 2 8 7 Warning for hot oil 09653 03001 8 Warning for hot cooling water 09668 03001 9 Warning in handling accumulator 09659 53000 10 Warning when adjusting track tension 09657 03003 ...

Page 26: ...S 2 9 11 Warning for improper use of cables 09808 03000 12 Stop engine when performing inspection or maintenance 09667 03001 13 Emergency escape instruction 20Y 00 22880 14 Warning against falling off the edge 09805 23000 ...

Page 27: ...SAFETY LABELS SAFETY 2 10 15 Warning against falling 09805 13000 16 Keep off swing area 09133 23000 17 Warning when handling battery 09664 30082 18 Precautions for high voltage 7872 10 1600 ...

Page 28: ...SAFETY SAFETY LABELS 2 11 19 Jump start prohibited 09842 A0481 ...

Page 29: ...ne until the abnormality has been cor rected WORKING WEAR AND PERSONAL PROTECTIVE ITEMS q Do not wear loose clothing and accessories There is a hazard that they may catch on control levers or other protruding parts q If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful not to let it get caught q Alwa...

Page 30: ... oil from the soles of your shoes If you operate the pedal with mud or oil affixed to your shoes your foot may slip and this may cause a serious accident q Do not leave parts or tools lying around the operator s compartment q Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire q Do not use cellular telephones inside the operator s compartment when driving or...

Page 31: ... q To ensure safety always face the machine and maintain three point contact both feet and one hand or both hands and one foot with the handrails and steps including the track shoe to ensure that you support yourself q Do not grip the control levers or lock lever when getting on or off the machine q Never climb on the engine hood or covers where there are no non slip pads q Before getting on or of...

Page 32: ...r or steam spurting out when checking or draining the coolant wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation Even when the coolant has cooled down loosen the cap slowly to relieve the pres sure inside the radiator before removing the cap Hot oil q To prevent burns from hot oil spurting out when checking or draining t...

Page 33: ... any pipes or tubes that contain flammable liquids q Fire caused by accumulation of flammable material Remove any dry leaves chips pieces of paper dust or any other flammable materials accumulated or affixed around the engine exhaust manifold muffler or battery or inside the undercovers q Fire coming from electric wiring Short circuits in the electrical system can cause fire q Always keep electric...

Page 34: ... above operations always close the front window In addition always ensure that by standers are a safe distance away and are not in hazard from falling or fly ing objects q The above recommendations assume that the conditions are for standard operations but it may be necessary to add addi tional guards according to the operating conditions on the job site Always contact your Komatsu distributor for...

Page 35: ...ard of fire so be careful when operating q Check the terrain and condition of the ground at the worksite and determine the safest method of operation Do not carry out operations at places where there is a hazard of landslides or falling rocks q If water lines gas lines or high voltage electrical lines may be buried under the worksite contact each utility and identify their locations Be careful not...

Page 36: ...If the machine should come too close or touch the electric cable to prevent electric shock the operator should not leave the operator s compartment until it has been confirmed that the electricity has been shut off Also do not let anyone come close to the machine ENSURE GOOD VISIBILITY q Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to en...

Page 37: ...ROM OPERATOR S CAB 3 43 in this manual ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste Always observe the following q Spray water to keep down the dust when cleaning Do not use compressed air for cleaning q If there is danger that ...

Page 38: ... fuel level and oil level in engine oil pan check for clogging of the air cleaner and check for dam age to the electric wiring q Adjust the operator s seat to a position where it is easy to carry out operations and check that there is no damage or wear to the seat belt or mounting clamps q Check that the gauges work properly check the angle of the lights and working lamps and check that the contro...

Page 39: ...ENGINE IN COLD WEATHER q Carry out the warming up operation thoroughly If the machine is not thoroughly warmed up before the control levers are operated the reaction of the machine will be slow and this may lead to unexpected accidents q If the battery electrolyte is frozen do not charge the battery or start the engine with a different power source There is a hazard that this will ignite the batte...

Page 40: ...hine vibration heat smell or gauges check also that there is no leakage of oil or fuel q If any abnormality is found carry out repairs immediately SAFETY RULES FOR CHANGING MACHINE DIRECTIONS q Before traveling position the upper structure so that the sprocket 1 is at the rear of the operator s cab If the sprocket 1 is at the front of the operator s cab the machine makes a movement reverse to the ...

Page 41: ...sed On jobsites where there is a hazard of flying objects or of objects entering the operator s compartment check that the door and windows are securely closed q If there is an area to the rear of the machine which cannot be seen position a signal person Take special care not to hit other machines or people when turning or swinging the machine Always be sure to carry out the above precautions even...

Page 42: ...eling or carrying out operations always keep a safe distance from people structures or other machines to avoid coming into contact with them q When passing over bridges or structures check first that the structure is strong enough to support the weight of the machine When traveling on public roads check first with the relevant authorities and follow their instructions q When operating in tunnels u...

Page 43: ...e machine may slip q If the engine stops when the machine is traveling on a slope move the control levers immediately to the neutral position and start the engine again OPERATIONS ON SLOPES q When working on slopes there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated This may lead to serious injury or property damage so always provide ...

Page 44: ...e strength and the structure before starting operations There is a hazard of the building collapsing and causing serious injury or damage q When carrying out demolition work do not carry out demoli tion above your head There is a hazard of broken parts fall ing or of the building collapsing and causing serious injury or property damage q Do not use the impact force of the work equipment for break ...

Page 45: ...amage OPERATIONS ON SNOW q Snow covered or frozen surfaces are slippery so be extremely careful when traveling or operating the machine and do not operate the levers suddenly Even a slight slope may cause the machine to slip so be particularly careful when working on slopes q With frozen ground surfaces the ground becomes soft when the temperature rises and this may cause the machine to tip over q...

Page 46: ...lock lever 1 to the LOCK position L then stop the engine q Always close the operator s cab door and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine Always remove the key take it with you and leave it in the specified place q If it is necessary to park the machine on a slope always do as follows q Set the bucket on the downhill side then dig...

Page 47: ...do not touch any other parts q Never correct your steering on the ramps If necessary drive off the ramps correct the direction then enter the ramps again q The center of gravity of the machine will change suddenly at the joint between the ramps and the track or trailer and there is danger of the machine losing its balance Travel slowly over this point q When loading or unloading to an embankment o...

Page 48: ...area with large amount of water q If acid gets into your eyes flush them immediately with large amount of water and seek medical attention q Before working with batteries turn the starting switch to the OFF position As there is a hazard that sparks will be generated always do as follows q Do not let tools or other metal objects make any contact between the battery terminals Do not leave tools or o...

Page 49: ...em machine There is a hazard that the machine will move when the power is connected q Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground side first when removing them q When removing the booster cables be careful not to let the booster cable clips touch each other or to let the clips touch the machine q Always wear safety goggles and...

Page 50: ...ire rope For towing see TOWING THE MACHINE 3 142 q Always wear leather gloves when handling wire rope q Fix the wire rope to the track frame q During the towing operation never stand between the towing machine and the machine being towed q Never tow a machine on a slope q Never use a wire rope which has cut strands A reduced diameter B or kinks C There is danger that the rope may break during the ...

Page 51: ...fied standard q Always observe the specified lifting load strictly q It is dangerous if the load hits any worker or structure Always check carefully that the surrounding area is safe before swinging or turning the machine q Do not start swing or stop the machine suddenly There is a hazard that the lifted load will swing q Do not pull the load to the side or in towards the machine q Do not leave th...

Page 52: ...KEEP WORK PLACE CLEAN AND TIDY q Do not leave hammers or other tools lying around in the work place Wipe up all grease oil or other sub stances that will cause you to slip Always keep the work place clean and tidy to enable you to carry out oper ations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self q When cleaning t...

Page 53: ...t the full stroke 2 to 3 times to eliminate the remaining internal pres sure in the hydraulic circuit and then push down lock lever 1 to the LOCK position L q Put blocks under the track to prevent the machine from mov ing TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury do not carry out maintenance with the engine running If maintenance must be carried out with the engine run n...

Page 54: ... tools or improper use of the tools could cause serious personal injury ACCUMULATOR The accumulator is charged with high pressure nitrogen gas When handling the accumulator careless procedure may cause an explosion which could lead to serious injury or property dam age For this reason always observe the following precautions q Do not disassemble the accumulator q Do not bring it near flame or disp...

Page 55: ...ent or the machine NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time wear ear cov ers or ear plugs while working If the noise from the machine is too loud it may cause temporary or permanent hearing problems WHEN USING HAMMER When using a hammer pins may fly out or metal particles may be scattered This may lead to serious injury Always do as fo...

Page 56: ...ll fly out and cause serious injury When it becomes necessary to disassemble it ask your Komatsu distributor to do the work SAFETY RULES FOR HIGH PRESSURE OIL The hydraulic system is always under internal pressure When inspecting or replacing piping or hoses always check that the pressure in the hydraulic circuit has been released If the circuit is still under pressure it will lead to serious inju...

Page 57: ...wollen in places q Twisted or crushed movable portion q Foreign material embedded in covering PRECAUTION FOR HIGH VOLTAGE q When the engine is running and immediately after it is stopped high voltage is generated inside the engine control ler and the engine injector and there is danger of electrocu tion Never touch the inside of the controller or the engine injector portion If it is necessary to t...

Page 58: ... critical parts like hoses and seat belts periodically Replacement of safety critical parts See SAFETY CRITICAL PARTS 4 14 q 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 injury or death It is difficult to judge the remaining life of these components ...

Page 59: ...3 1 OPERATION 13 ...

Page 60: ...ON 3 2 MACHINE VIEW ILLUSTRATIONS 3 OVERALL MACHINE VIEW 3 1 Bucket 7 Boom cylinder 2 Bucket link 8 Sprocket 3 Bucket cylinder 9 Track frame 4 Arm 10 Track shoe 5 Arm cylinder 11 Idler 6 Boom 12 OPG Operator Protection Guard if equipped ...

Page 61: ...blower 14 Starting switch switch If equipped 15 Fuel control dial 3 Revolving warning lamp switch option 16 Lamp switch 4 Air conditioner control switch 17 Alarm buzzer stop switch 5 Lock lever 18 Swing lock switch 6 L H work equipment control lever 19 Machine push up switch 7 One touch power max switch 20 Swing holding brake release switch 8 Travel pedals 21 Emergency pump drive switch 9 Travel l...

Page 62: ...itor 21 Window washer switch 7 Engine oil pressure monitor 22 Wiper switch 8 Engine water temperature gauge 23 Maintenance switch 9 Charge level monitor 24 Travel speed selector switch 10 Radiator coolant level monitor 25 Auto deceleration switch 11 Working mode monitor 26 Hydraulic oil temperature monitor 12 Service monitor 27 Hydraulic oil temperature gauge 13 Travel speed monitor 28 Maintenance...

Page 63: ...t suitable operations correctly and safely it is important to understand fully the methods of operating the equipment and the meanings of the displays MONITORING SYSTEM 3 1 All light up screen 3 Normal operation screen 2 Maintenance interval warning screen A Basic Check Items D Meter Display Portion B Caution Items E Monitor Switches Portion C Emergency Stop Items ...

Page 64: ...ce interval warning screen B warning screen D or error screen E q After displaying the check before starting screen A for 2 seconds the screen changes to the maintenance interval warning screen B q After displaying the maintenance interval warning screen B for 30 seconds the screen returns to the normal screen C q After displaying the check before starting screen A for 2 seconds the screen changes...

Page 65: ...ality Occurs During Operation q If any abnormality occurs during operation the normal operation screen A changes to warning screen B or the error screen D q After displaying warning screen B for 2 seconds the screen automatically changes to warning screen C ...

Page 66: ...ong the check before starting items that must be checked before starting the engine If there is any abnormality the monitor for the location of the abnormality will light up Radiator Coolant Level Monitor This monitor 1 warns the operator that there has been a drop in the radiator water level If the radiator water level is low the lamp lights up red so check the water level in the radiator and the...

Page 67: ... engine oil pan and add oil Maintenance interval Monitor This monitor 3 lights up to warning the operator that the set time has passed since the maintenance was last carried out This monitor screen goes out after 30 seconds and returns to the normal operation screen q For details of the method of checking the maintenance inter val see Maintenance Switch 3 22 If it is desired to change the setting ...

Page 68: ... is an abnormality in the charging system when the engine is running If the battery is not being charged properly while the engine is running it lights up red If it lights up red check for looseness of the V belt If any abnor mality is found take the necessary action For details see OTHER TROUBLE 3 147 REMARK While the starting switch is ON the lamp will remain lit and will go off when the engine ...

Page 69: ...ts up red stop the engine and check clean or replace the air cleaner For details see CHECK CLEAN AND REPLACE AIR CLEANER ELEMENT 4 20 Engine Water Temperature Monitor If this monitor 4 lights up white in low temperatures carry out the warming up operation For details see Warming Up Operation 3 94 Continue the warming up operation until monitor 4 changes to green Hydraulic Oil Temperature Monitor I...

Page 70: ...carry out action immediately Engine Water Temperature Monitor This monitor 1 warns the operator that the engine water temper ature has risen If the engine water temperature becomes abnormally high the monitor lights up red the overheat prevention system is automati cally actuated and the engine speed goes down Stop operations and run the engine at low idling until monitor 1 changes to green Check ...

Page 71: ...rication oil pressure goes below the normal level If it lights up red stop the engine and check the lubrication system and the level of oil in the oil pan REMARK The color when the monitor lights up for the basic check items caution items and emergency stop items is as fol lows Type of monitor Color when monitor lights up When normal When abnormal At low temperature Radiator coolant level monitor ...

Page 72: ...rature below 0 C 32 F The monitor lamp lights when the starting switch is turned to HEAT position and flashes after about 30 seconds to show that the pre heating is completed The monitor lamp will go off after about 10 seconds D 1 Engine pre heating monitor D 7 One touch power up monitor D 2 Swing lock monitor D 8 Engine water temperature gauge D 3 Wiper monitor D 9 Fuel gauge D 4 Auto deceleratio...

Page 73: ...splay when the wiper switch is operated is as fol lows When ON lights up Wiper moves continuously When INT lights up Wiper moves intermittently OFF Wiper stops Auto deceleration Monitor This monitor 4 shows if the auto deceleration function is being actuated The monitor display when the auto deceleration switch is oper ated is as follows Auto deceleration monitor ON Auto deceleration actuated Auto...

Page 74: ... goes out Power max function stopped Gauges and Meter 3 Engine Water Temperature Gauge This gauge 8 indicates the engine cooling water temperature During normal operation the indicator should be within the black range between A and C If the indicator enters the red range between A and B during operations the overheat prevention system is actuated The overheat prevention system acts as follows Red ...

Page 75: ... and C If the indicator enters the red range A during operation the hydraulic oil temperature has gone above 102 C 215 6 F Stop the engine or run it at low idling and wait for the hydraulic oil tem perature to go down REMARK Hydraulic oil temperature is as follows when the indicator enters the red range A A position in the red range 102 C 215 6 F or over Hydraulic oil temperature monitor will be i...

Page 76: ...s started the working mode is set automatically to A mode When the switch is pressed it is possible to select the other modes The monitor display on the monitor display portion A changes for each mode q If it is desired to have the working mode set to start automatically in E L or B mode default options setting please ask your Komatsu distributor to change the setting E 1 Working mode selector swi...

Page 77: ... reduce fuel consump tion Monitor display portion A ON Auto deceleration actuated Monitor display portion A OFF Auto deceleration canceled Each time that the switch is pressed the auto deceleration switches between actuated and canceled q Auto deceleration function When the auto deceleration function is ON if the work equipment levers and travel lever are returned to the N position the engine spee...

Page 78: ...ng operation q If the travel speed is switched between Hi and Lo when the machine is traveling the machine may deviate to one side even when traveling in a straight line Stop the machine before switching the travel speed This switch 3 is used to set the travel speed to 3 stages Lo lights up Low speed travel Hi lights up Hi speed travel When the engine is started the speed is automatically set to L...

Page 79: ...changes ON INT stop OFF Monitor display portion A ON lighted up Wiper moves continu ously Monitor display portion A INT lighted up Wiper moves intermit tently Monitor display portion A OFF Wiper stops REMARK Each time that the wiper switch is operated the mode is displayed in the center of the monitor display portion A The screen returns to the normal screen after 2 seconds If the wiper does not w...

Page 80: ...ittent operation Maintenance Switch q This switch 6 is used to check the time remaining to mainte nance q When this switch 6 is pressed the screen on the monitor display changes to the maintenance screen shown in the dia gram on the right The time remaining to maintenance is indicated by the color of each monitor display After confirming the maintenance time carry out the maintenance White display...

Page 81: ...or for the selected item is inverted to black 2 After selecting the monitor item press input confirmation switch 11 The display screen will switch to the time remain ing to maintenance Press back switch 8 to return to the previous screen Monitor No Maintenance item Initial setting display H 01 Engine oil change 500 02 Replace engine oil filter 500 03 Replace fuel filter 500 04 Replace hydraulic oi...

Page 82: ...ch to the default setting screen 4 After checking the time on the default setting screen press input confirmation switch 11 The screen will return to the maintenance screen Press back switch 8 to return to the previous screen Back Switch Press this switch 8 when in the maintenance mode brightness contrast adjustment mode or select mode The screen will return to the previous screen on the monitor d...

Page 83: ...this switch 12 to adjust the brightness and contrast of the monitor display screen Adjusting brightness and contrast 1 When monitor adjustment switch 12 is pressed the monitor display screen changes to the brightness contrast screen shown in the diagram on the right q Adjusting brightness 2 Use the brightness contrast screen and press up switch 9 or down switch 10 to select the brightness monitor ...

Page 84: ... contrast 2 Use the brightness contrast screen and press up switch 9 or down switch 10 to select the contrast monitor The selected monitor is inverted to black 3 When the screen changes to the contrast adjustment screen press up switch 9 or down switch 10 to adjust the contrast 4 After completing adjustment of the contrast press input confir mation switch 11 REMARK When the machine is shipped from...

Page 85: ...eat position When starting the engine in winter set the key to this position When the key is set to the HEAT position D the pre heating monitor lightsup Keep the key at this position until the monitor lamp flashes Immediately after the pre heating monitor flashes release the key The key automatically returns to the OFF position A Then start the engine by turning the key to the START position C 1 S...

Page 86: ...ng lamp Max current is 85 W 24V x 3 5 A Swing Lock Switch WARNING q When not using the swing operation e g in traveling put the swing lock switch to the ON position a q On slopes even when the swing lock switch is at the ON position a the weight of the work equipment may cause the upper structure to swing if the swing control lever is operated in the downhill direction Switch 4 is used to lock the...

Page 87: ...g the boom thrust force to push up the chassis when moving down from a bench there is dan ger that the machine may suddenly go down and turn over so set to the high pressure setting This switch 7 is used to switch the safety valve set pressure at the head end of the boom cylinder to two levels a Low pressure setting The boom thrust force is weak so the swaying of the chassis is small during diggin...

Page 88: ...t will also light up even when the engine is not running Pump Drive Emergency Switch NOTICE The emergency pump driving switch is provided to make it possible to carry out work for a short time when there is a failure in pump control system It is necessary to repair the abnormal location as soon as possible This switch 10 is used to make it possible to carry out operations temporarily if any abnorm...

Page 89: ...sible to carry out operations temporarily if any abnormality should occur in the swing brake system when the display shows E03 a Release Position for abnormality switch moved up b Normal Normal position switch moved down q When the display is E03 move this switch up to make it possible to carry out operations q When the switch is set to the Release a position the swing lock monitor flashes Revolvi...

Page 90: ... ON position and is operating continuously and the lower wiper switch is turned ON the wiper and lower wiper will be actuated in turn If the lower wiper switch is at the ON position and is operating continuously and the wiper is actuated with the machine monitor the lower wiper both INT and ON and wiper will be actuated in turn When the wiper switch monitor is turned ON if the lower wiper is actua...

Page 91: ...seconds q Even if the starting switch key is at the OFF position the step light will light up for approx 60 seconds when the switch is pressed One Touch Power Max Switch This switch 15 on the left work equipment control lever is used to actuate the power max and slow down functions Press once single click and keep the switch pressed The one touch power max function is actuated for a maximum of 8 5...

Page 92: ...k equipment control levers when pulling lock lever 1 up or pushing it down This lever 1 is a device to lock the work equipment swing travel and attachment if equipped control levers Push lever 1 down to apply the lock This lock lever 1 is a hydraulic lock so even if it is in the lock position L the work equipment control lever and travel lever will move but the work equipment travel motor and swin...

Page 93: ...vel levers check if the track frame is facing the front or the rear If the sprocket is at the rear the track frame is facing the front Lever 2 is used to change the direction of travel between for ward and reverse shows the pedal operation a FORWARD The lever is pushed forward The pedal is angled forward b REVERSE The lever is pulled back The pedal is angled back N Neutral The machine stops REMARK...

Page 94: ...ment and attachment affect the engine speed as follows When the travel lever and the work equipment control lever are in the neutral position the engine will slow down to a medium speed even if the fuel control dial is above the medium speed position When operating either of these levers the engine speed will go up to the one adjusted by the fuel control dial When all the control levers are in the...

Page 95: ...and the control lever is touched by mistake this may lead to a serious acci dent Opening 3 1 Set lock lever 1 securely to the LOCK position L 2 Check for any ceiling window movement by pulling lock knob A located on front side then push up and open the ceiling window grasping grip B Closing 3 Hold grip B lower the ceiling window and apply lock A If the lock cannot be applied open the ceiling windo...

Page 96: ...nt completely to the ground stop the engine then carry out the operation q When opening the front window hold the grip securely with both hands pull up and do not let go until the auto matic lock catch is locked q When closing the front window the window will move quicker under its own weight Hold the grips securely with both hands when closing it It is possible to stow pull up the front window in...

Page 97: ... CONTROLS AND GAUGES 3 39 4 Grip handles A at the top right and left of the front window and pull lock lever B toward yourself to release the lock at the top of the front window The top of the front window will come out ...

Page 98: ... catch E at the rear of the cab securely to lock the window 6 Check that lock lever B is securely at the LOCK position q The lock is engaged if the arrow on lock case F matches the position of the arrow on lock lever B Check visually q If the arrow on lock case F does not match the position of the arrow on lock lever B the lock is not engaged Repeat the operation in Step 5 to engage the lock ...

Page 99: ... level ground lower the work equipment completely to the ground then stop the engine 2 Set lock lever 1 to the LOCK position L securely 3 Grip left and right handles A and pull down lock lever B to release the lock 4 Grip handle C at the bottom of the front window with your left hand and handle D at the top with your right hand push to the front then lower slowly ...

Page 100: ...the position of the arrow on lock lever B Check visually q If the arrow on lock case F does not match the position of the arrow on lock lever B the lock is not engaged Repeat the operation in Step 5 to engage the lock Removing Lower Windshield 1 Open the front window then hold grip A pull up and remove the bottom window 2 After removing the bottom window store it at the rear of the operator s cab ...

Page 101: ... an emergency exit DOOR LOCK 3 WARNING q Before the releasing the door lock always stop the machine on flat ground Never release the door lock on a slope The door may suddenly close and cause injury q When releasing the door lock do not extend your body or hands outside the machine and do not put your hands on the door frame The door may suddenly close and cause injury Use the door lock to fix the...

Page 102: ...y counterclockwise align the key slot with the match mark 3 on the cap then open the cap 1 Open 2 Lock REMARK B type is used for the fuel tank cap and hydraulic tank cap With A type if the cap rotates freely it is locked In this condition the cap cannot be removed from the tank Turned the starting switch key counterclockwise align counter mark 3 on the cap with the groove of the rotor then turn th...

Page 103: ...nd insert the key into the key slot 2 Turn the key clockwise and take the key out HOT AND COOL BOX 3 This is on the right side at the rear of the operator s seat It is interconnected with the air conditioner it stays warm when the heating is used and stays cool when the cooling is used MAGAZINE BOX 3 with cup holder This is on the left side of the operator s seat Keep the Operation and Maintenance...

Page 104: ...S AND GAUGES OPERATION 3 46 ASHTRAY 3 This is under the machine monitor at the front right of the opera tor s compartment Always make sure that you extinguish your cigarette then put it in the ashtray and close the lid ...

Page 105: ...used to stop the fan and air conditioner q When OFF switch 1 is pressed the set temperature and air flow display on display monitor 7 and the lamps above auto switch 5 and air conditioner switch 8 go out and operation stops 1 OFF switch 6 RECIRC FRESH selector switch 2 Fan switch 7 Display monitor 3 Temperature control switch 8 Air conditioner switch 4 Vent selector switch 9 Defroster selector lev...

Page 106: ...4 4 F and 32 C 89 6 F q Press the switch to raise the set temperature press the switch to lower the set temperature q The temperature is generally set at 25 C 77 F q The temperature can be set in stages of 0 5 C 0 9 F Monitor display and the function REMARK If the mode is set to auto mode and the temperature setting is set to 18 0 C 64 4 F and 32 0 C 89 6 F the air flow from the fan is always set ...

Page 107: ...ssed the display on monitor display 7 switches and air blows out from the vents displayed q During automatic operation the vents are automatically selected A Rear vents 4 places B Face vent 1 place C Foot vent 1 place D1 Front window vent 1 place D2 Front window vent 1 place q Front window vent D2 can be opened or closed by hand ...

Page 108: ...witch This switch 6 is used to switch the air source between recircula tion of the air inside the cab and intake of air from the outside q When switch 6 is pressed the lamp at the top of the selector switch lights up to show that air is being blown out q During automatic operation the selection of inside air RECIRC and outside air FRESH is carried out automati cally REMARK Even when the switch is ...

Page 109: ...shows b and air conditioner switch 8 is pressed the air conditioner is switched ON the lamp at the top of the air conditioner switch lights up and the air conditioner starts When it is pressed again to the OFF position the lamp at the top of the air condi tioner switch goes out q The air conditioner cannot be operated while the fan is stopped Defroster Selector Lever This lever 9 is used in cold o...

Page 110: ...ir flow b are displayed on the monitor 2 Use temperature set switch 3 to set to the desired tempera ture 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 REMARK When vent display monitor c displays d or e and the engine water tempe...

Page 111: ...tor and the lamps above auto switch 5 and air conditioner switch 8 go out and the operation stops Manual Operation 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Turn air conditioner switch 8 ON Check that the lamp at the top of the air conditioner switch lights up ...

Page 112: ...vent c of the display mon itor changes according to the selection 5 Press RECIRC FRESH selector switch 6 and select recircu lation of the air inside the cab RECIRC or intake of fresh air from outside FRESH Stopping Manual Operation Press OFF switch 1 The displays for temperature setting a and air flow b on the display monitor and the lamps above auto switch 5 and air conditioner switch 8 go out an...

Page 113: ...doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Press vent selector switch 4 and set the vent display on the display monitor to the display shown in the diagram on the right 3 Turn air conditioner switch 8 ON Check that the lamp at the top of the air conditioner switch lights up 4 Adjust fan switch 2 temperature setting switch 3 and FRESH RECIRC s...

Page 114: ...When doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Press vent selector switch 4 and set the vent display on the display monitor to the display shown in f or g in the dia gram on the right 3 Press FRESH RECIRC selector switch 6 and set it to take in fresh air ...

Page 115: ...play monitor to the maximum heating temperature of 32 0 5 Adjust vents A B and D2 so that the air blows onto the window glass Vents C and D1 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 the air turn air conditioner switch 8 ON ...

Page 116: ...with its sensor function Ventilation q If you smoke when the cooler is on the smoke may start to hurt your eyes so turn the lever to FRESH to remove the smoke while continuing the cooling q When running the air conditioner for a long time turn the lever to the FRESH position once an hour to carry out ventilation and cooling Temperature Control q When the cooler is on set the temperature so that it...

Page 117: ...ure setting switch 3 to dis play the failures in turn q After completing the troubleshooting press OFF switch 1 again to return to the normal display If any abnormality is detected by the self diagnostic function ask your Komatsu distributor to carry out inspection and repair Display Failure mode E No failure E11 Disconnection in recirculated air sensor E12 Short circuit in recirculated air sensor...

Page 118: ...e to switch the set temperature display between F and C If the and portions of temperature setting switch 3 are pressed at the same time for more than 5 seconds while the fan is running the temperature display will switch between F and C Note that the unit is not displayed Liquid crystal display range C 18 0 to 32 0 F 64 4 to 89 6 ...

Page 119: ...it to the left to increase the sound from the left speaker After adjusting the left and right balance push the knob lightly to return it to its original position If the knob is left pulled out the volume cannot be adjusted Tone Control Knob TONE If this knob 2 is turned to the right from the center position the high tone is emphasized if it is turned to the left the high tone is reduced FM AM Sele...

Page 120: ...ting see Controls Of Radio 3 62 Display This display 7 shows the reception band frequency preset No and time Time Reset Button This button 8 is used to correct the time H Hour M Minute SET Sets to start of hour 00 minutes Stereo Indicator ST This indicator 9 lights up when a stereo broadcast is received from the FM station Controls Of Radio 3 Preset Station Buttons 1 Press power switch 1 and displ...

Page 121: ... the point where it is canceled will be picked up Setting Correct Time 1 Press display selector button 4 to display the time After 5 seconds the display will return to the frequency dis play and the time cannot be corrected If this happens press display selector button 4 again 2 Press time adjustment button 8 and adjust the hour and minute H button Adjusts hour advances one hour each time it is pr...

Page 122: ...water on the equipment q Do not wipe the scales or buttons with benzene thinner or any other solvent Wipe with a soft dry cloth Use a cloth soaked in alcohol if the equipment is extremely dirty q When the battery is replaced the settings for the preset buttons are all cleared so set again AUXILIARY ELECTRIC POWER 3 24V power source 3 NOTICE Do not use this as the power source for 12V equipment Pul...

Page 123: ...No Fuse Circuit name 1 10A Prolix circuit 2 10A Solenoid valve 3 10A PPC oil pressure lock solenoid 4 20A Window washer cigarette lighter 5 10A Horn flashlight if equipped 6 10A Spare fuse 7 10A Revolving warning lamp if equipped 8 10A Spare fuse 9 10A Radio Left knob switch 10 20A Monitors buzzer 11 25A Air conditioner unit 12 20A Spare fuse 13 20A Spare fuse 14 10A OPT power supply 1 15 10A OPT ...

Page 124: ...it breaker is a circuit protection device installed to cir cuits where large current flows It protects the electrical compo nents and wiring from damage caused by an abnormal current in the same way as a normal fuse After repairing and restoring the location of the abnormality there is no need to replace the breaker It can be used again If the starting motor does not work even when the starting sw...

Page 125: ... to get water mud or juice on the controller This will cause failure q If any abnormality occurs in the controller do not disassemble it yourself Contact your Komatsu dis tributor for repairs Controller installed TOOL BOX 3 Cloth bag This is inside the toolbox at the rear of the cab ...

Page 126: ...turned on pump 3 is actuated and grease is sent under pressure to grease gun 2 2 Grease is discharged when lever for grease gun 2 is pulled It is possible to check the greasing condition by looking at pressure gauges 4 and 5 4 green low pressure 5 red high pressure 3 When the lever of grease gun 2 is released the supply of grease stops 4 After using turn power switch 1 OFF ...

Page 127: ...ase so move the grease to the center or fill the can with new grease Supplying Grease 3 1 Remove 3 wing bolts 2 from grease can 1 then remove cover 3 from the pump 2 Remove follow plate 4 inside the grease can 3 Fill grease can 1 with new grease then set follow plate 4 on top of the grease q Fill the hollow in the center of the follow plate with grease before setting the following plate on top of ...

Page 128: ... air inside the hose and grease gun q When filling with grease be extremely careful not to let sand or dirt stick to the follow plate or pump suc tion portion q If there is ample grease but the pump does not pump out any grease the follow plate may not be correctly set in position so set it in position again correctly q The standard grease can contains 16 liters 4 23 US gal If an 18 liters 4 76 US...

Page 129: ... not bring it near flame or dispose of it in fire Do not make holes in it or weld it Do not hit it roll it or subject it to any impact When disposing of the accumulator the gas must be released Please contact your Komatsu distributor to have this work carried out This machine is equipped with an accumulator in the control circuit The accumulator is a device to store oil pres sure for the control c...

Page 130: ...to release the pressure in the control circuit 5 Start the engine again stop the engine after 2 3 seconds then carry out the operation in Step 3 6 Continue the operation in Step 4 until the hissing noise of pressure oil can no longer be heard Approx 2 3 times 7 Set lock lever 1 to the LOCK position L and lock the work equipment levers and attachment control pedal Note that the pressure cannot be c...

Page 131: ... any abnormality is found repair it 2 Remove the dirt from around the engine battery and radiator Check that there is no dirt accumulated around the engine or radiator Check also that there is no flammable material dry leaves twigs etc around the battery engine muffler turbocharger or other high temperature parts of the engine If any dirt or flammable materials are found remove them 3 Check for le...

Page 132: ...rear view mirror If it is damaged replace it with a new mirror Clean the surface of the mirror and adjust the angle so that the area at the rear can be seen from the operator s seat 10 Seat belt and mounting clamps Check that there is no abnormality in the seat belt or mounting clamps If there is any damage replace with new parts 11 Check bucket with hook if equipped for damage Check that there is...

Page 133: ...slowly to release the pressure before removing it 1 Open the cover of the engine hood check that the coolant is between the FULL and LOW lines on sub tank 1 Add water through the water filler of sub tank 1 to the FULL line if the level is low 2 After adding coolant tighten the cap securely 3 If sub tank 1 is empty check for water leakage then check the water level in the radiator If the water leve...

Page 134: ... filler pipe then take it out again 4 The oil level should be between the H and L marks on dipstick G If the oil level is below the L mark add engine oil through oil filler F 5 If the oil is above the H mark drain the excessive engine oil from drain plug P at the bottom of the engine oil pan then check the oil level again 6 If the oil level is correct tighten the oil filler cap securely and close ...

Page 135: ...tank capacity 880 liters 232 50 US gal Position of tip of float gauge G when fuel tank is full Approx 50 mm 2 in from top surface of fuel tank 4 After adding fuel push float gauge G straight down with fuel filler cap F Be careful not to get float gauge G caught in the tab of fuel filler cap F and tighten fuel filler cap F securely REMARK If breather hole 1 in the cap becomes clogged the pressure i...

Page 136: ...sition and operate the control levers work equipment travel fully in each direction to release the internal pressure 3 Open cover 1 on the left side of the machine and check sight gauge G The oil level should be between the H and L marks NOTICE Do not add oil if the level is above the H line This will dam age the hydraulic equipment and cause the oil to spurt out WARNING If the oil is above the H ...

Page 137: ...er the engine is stopped and may cause serious burns Wait for the temperature to go down before starting the operation 1 Remove dipstick G and wipe the oil from the dipstick with a cloth 2 Insert dipstick G fully in the guide 3 When dipstick G is pulled out if the oil level is between the H and L marks of the gauge oil level is proper 4 If the oil does not reach the L mark on dipstick G add engine...

Page 138: ...e engine After waiting for more than 30 minutes after stop ping the engine check the oil level 1 Open the left side cover and use dipstick 1 to check the oil level 2 The oil level should be between the L and H marks If neces sary add engine oil at the dipstick guide hole Check Air Cleaner For clogging 1 Confirm that the air cleaner clogging monitor does not flash 2 If it flashes immediately clean ...

Page 139: ...ed with dirt or dust wash the battery cap to clear the breather hole Check that there is no damage to the fuse that a fuse of the specified capacity is being used that there are no signs of any disconnection breakage or short circuit in the electric wiring check for any loose terminals and tighten any loose terminals that are found Be particularly careful to check the wiring for the battery starti...

Page 140: ...he backrest A Fore and aft adjustment Pull lever 1 up set the seat to the desired position then release the lever Fore and aft adjustment 160 mm 6 3 in 16 stages B Adjusting reclining NOTICE The seat can be reclined to a large angle when the seat is pushed fully forward but the reclining angle is reduced when the seat is moved back so when moving the seat to the rear return the seat back to its or...

Page 141: ...mrest 5 can be made to spring up by hand approx 90 In addition by turning the bottom 6 of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle Armrest adjustment angle 25 REMARK If the seatback is pushed forward without armrest 5 being raised the armrest will automatically rise If the cable at the rear of the armrest 5 is tense the seatback is pushed forward ar...

Page 142: ...ing the mirror then adjust the position to give the best view from the operator s seat q Adjust the mirror mount so that it is possible to see any per son or object of height 1 m 3 ft 3 in and diameter 30 cm 11 8 in at the rear left and right of the machine q Install the mirror to the mounting position and dimensions shown The values given below are reference values for the range of view Mounting ...

Page 143: ... wear the seat belt during operations q Fit the seat belt so that it is not twisted Fastening and Removing This seat belt is retractable so it is not necessary to adjust the length Fastening seat belt Hold grip 2 and pull the belt out from retraction device 1 check that the belt is not twisted then insert tongue 3 into buckle 4 securely When doing this pull the belt lightly to check that it is pro...

Page 144: ...rious accident 1 Check that lock lever 1 is at the LOCK position L 2 Check the position of each levers Set the control lever to the neutral position 3 Insert the key in starting switch 2 turn the key to the ON position B then carry out the following checks q If a password has been set the input display screen is shown on the monitor screen After inputting the password press input confirmation swit...

Page 145: ...nitors do not light up or the buzzer does not sound there is probably a failure in the monitor so con tact your Komatsu distributor for repairs 5 After approx 3 seconds the screen switches to the working mode travel speed display monitor Then it switches to the normal screen q Fuel level monitor 7 q Engine water temperature monitor 8 q Engine water temperature gauge 10 q Fuel gauge 11 q Hydraulic ...

Page 146: ...enance switch 17 check the item then carry out maintenance immediately For details of the method of checking the maintenance inter val see Maintenance Switch 3 22 in the Explanation of components 8 Press lamp switch 18 and check that the front lamp lights up If it does not light up there is probably a blown bulb or discon nection so contact your Komatsu distributor for repairs ...

Page 147: ...the low idling MIN position If the fuel control dial is at the FULL position the engine will accelerate suddenly and cause damage to the engine parts q Do not crank the starting motor continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes before trying again REMARK If the engine is stopped when it is not fully warmed up and it is started again a few minutes ...

Page 148: ...r the engine starts release the key in starting switch 3 The key will automatically return to the ON position B 5 Even after the engine is started do not touch the work equip ment control levers and the travel pedals while the engine hydraulic pressure monitor lamp is still lighted NOTICE If the engine oil pressure monitor does not go out even after 4 to 5 seconds have passed stop the engine immed...

Page 149: ... careful to ensure good ventilation NOTICE q Before starting the engine check that fuel control dial 2 is at the low idling MIN position If the fuel control dial is at the FULL position the engine will accelerate suddenly and cause damage to the engine parts so set it to an intermediate or low speed position q Do not keep the starting motor rotating continuously for more than 20 seconds If the eng...

Page 150: ...but this is not an abnormality If the temperature is low the monitor screen may become dark or it may take time for the display to appear but this is not an abnor mality 4 When preheating monitor 4 flashes turn the key in starting switch 3 to the START position C to start the engine 5 After the engine starts release the key in starting switch 3 The key will automatically return to the ON position ...

Page 151: ...al is operated within the time shown below the engine speed will not change q In cold weather the turbo protect function is actuated so the engine speed is maintained below 1000 rpm for several seconds After that the automatic warming up function raises the engine speed to 1200 rpm Cooling water temperature Turbo protect time sec Above 10 C 50 F 0 10 to 10 C 50 to 14 F Change 0 to 5 below 10 C 14 ...

Page 152: ...s will help to extend the machine life Do not suddenly accelerate the engine before the warm ing up operation is completed q Do not run the engine at low idling or high idling continu ously for more than 20 minutes This will cause leakage of oil from the turbocharger oil supply piping If it is nec essary to run the engine at idling apply a load from time to time or run the engine at a mid range sp...

Page 153: ...ased earlier E Left swing F Right swing 6 After carrying out the warming up operation check that all the gauges on machine monitor 6 and the caution lamps are in the following conditions q Radiator water level monitor 7 OFF q Engine oil level monitor 8 OFF q Charge monitor 9 OFF q Fuel level monitor 10 Green display q Engine water temperature monitor 11 Green display q Engine oil pressure monitor ...

Page 154: ...clogging monitor 16 is lighted up clean or replace the element immediately For details of the method of cleaning the element see CHECK CLEAN AND REPLACE AIR CLEANER ELE MENT 4 20 9 Use working mode switch 19 on machine monitor 6 to select the working mode to be used ...

Page 155: ... areas carry out the automatic warming up operation after starting the engine When the engine is started if the engine water temperature is low below 30 C the warming up operation is car ried out automatically The automatic warming up operation is canceled if the engine water temperature reaches the specified tempera ture 30 C or if the warming up operation is continued for 10 minutes If the engin...

Page 156: ...n until the work equipment monitor display is green This will extend the service life of the machine REMARK If the hydraulic oil temperature is low the hydraulic oil temperature monitor display will be white 1 Turn the fuel control dial 2 to the medium speed position a 2 Set lock lever 1 to the FREE position F and raise the bucket from the ground 3 Operate bucket control lever 3 and arm control le...

Page 157: ...at there is no abnormal exhaust gas color noise or vibration If any abnormality is found contact your Komatsu distributor 7 If air cleaner clogging monitor 16 is lighted up clean or replace the element immediately For details of the method of cleaning the element see CHECK CLEAN AND REPLACE AIR CLEANER ELE MENT 4 20 8 Turn fuel control dial 2 to the full speed MAX position and carry out the operat...

Page 158: ...conomy 13 Heavy duty lift Boom lifting power increased when raising boom indepen dently NOTICE Canceling automatic warming up operation If it becomes necessary in an emergency to cancel the automatic warming up operation or to lower the engine speed to low idling do as follows 14 Turn fuel control dial 2 to the full speed MAX position and hold it for 3 seconds ...

Page 159: ...t parts of the engine may be considerably reduced Hence do not stop the engine abruptly except in an emergency If the engine has overheated do not try to stop it abruptly Run it at low idling to allow it to cool down gradually and then stop it 1 Run the engine at low idling for about 5 minutes to cool down gradually 2 Turn the key in starting switch 1 to the OFF position A and stop the engine 3 Re...

Page 160: ...t allow anyone in the area around the machine q Remove all obstacles from the travel path of the machine q The rear of the machine is a blind spot so be particularly careful when travel in reverse q If the lever is moved inside the deceleration range engine speed will rise suddenly Operate the levers care fully q Before starting the machine off check that the alarm sounds normally 1 Set swing lock...

Page 161: ...nt part of pedals 6 slowly to move the machine off q When the sprocket A is at the front of the machine Pull levers 5 backward slowly or depress the rear part of pedals 6 slowly to move the machine off 3 Check that the alarm sounds properly If the alarm does not sound please contact your Komatsu distributor for repair REMARK In cold temperatures if the machine travel speed is not normal carry out ...

Page 162: ...t and left travel pedals 6 as follows q When the sprocket A is at the rear of the machine Pull levers 5 backward slowly or depress the rear part of pedals 6 to move the machine off q When the sprocket A is at the front of the machine Push levers 5 forward slowly or depress the front part of pedals 6 to move the machine off 3 Check that the alarm sounds properly If the alarm does not sound please c...

Page 163: ...RATIONS AND CONTROLS 3 105 Stopping Machine 3 Avoid stopping suddenly Give yourself ample room and return the lever slowly when stopping 1 Put the left and right travel levers 1 in the neutral position then stop the machine ...

Page 164: ...el levers to change direction Avoid sudden changes of direction as far as possible In particu lar when carrying out counter rotation spin turn stop the machine first before turning Operate two travel levers 1 as follows Steering the Machine when Stopped When turning to the left Push the right travel lever forward to turn to the left when traveling forward and pull it back to turn left when traveli...

Page 165: ...eft A Forward left turn B Reverse left turn REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left pull the left travel lever back and push the right travel lever forward REMARK When using counter rotation to turn right pull the right travel lever back and push the left travel lever forward ...

Page 166: ...hat the area around the machine is safe 1 Before starting the swing operation turn swing lock switch 1 OFF and check that swing lock monitor 2 has gone out 2 Operate left work equipment control lever 3 to swing the upper structure A Left swing B Right swing 3 When not using the swing turn swing lock switch 1 ON Check that swing lock monitor 2 lights up ...

Page 167: ...rn to the neutral position and the work equipment is held in place q If the work equipment control levers are returned to the neutral position when the machine is stopped even if the fuel control dial is set to FULL the auto deceleration mechanism will act to reduce the engine speed to a mid range speed REMARK With this machine an accumulator is installed in the operating circuit so if less than 1...

Page 168: ...MACHINE OPERATIONS AND CONTROLS OPERATION 3 110 Boom operation Bucket operation ...

Page 169: ... starting switch is turned ON the working mode is set to A mode digging Use the working mode switch to set the mode to the most efficient mode to match the type of work Working mode Applicable operation A mode Normal digging loading operations operations with emphasis on productivity E mode Normal digging loading operations operations with emphasis on fuel economy Heavy duty lift mode Normal diggi...

Page 170: ... force to compact soil or break objects This is not only dangerous but will also markedly reduce the life of the machine Operations Using Travel Force Do not dig the bucket into the ground and use the travel force to carry out excavation This will damage the machine or work equipment Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends If the work equipment is used with the cylinder ...

Page 171: ...igging Digging Hard Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it after breaking up by some other means This will not only save the machine from damage but make for better economy Sudden Lever Shifting High Speed Travel 1 Never carry out sudden lever shifting as this may cause sud den starting 2 Avoid sudden lever shifting fr...

Page 172: ...f the track passes over the obsta cle High Speed Travel On uneven roadbeds such as rock beds or uneven roads with large locks travel at Lo speed When traveling at high speed set the idler in the forward direction q To switch the travel speed press travel speed selector switch 1 The travel speed is displayed as Lo Mi or Hi on the monitor display Precautions when carrying out operations continually ...

Page 173: ... go under water and water will be thrown up by the radiator fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in water deepen than of the center of carrier roller 1 Supply grease to the parts which have been under water for a long time until the used grease is projected out of the bearings around the bucket pin in particular ...

Page 174: ...opes or travel across slopes Always go down to a flat place to perform these opera tions It may be longer but it will ensure safety q Always operate or travel in such a way that it is possible to stop safely at any time if the machine slips or becomes unstable q When traveling uphill if the shoes slip or it is impossible to travel uphill using only the force of the tracks do not use the pulling fo...

Page 175: ...ne Stopped on Slope If the engine stops when traveling uphill move the travel levers to the neutral position lower the bucket to the ground stop the machine then start the engine again Cab Doors on Slope WARNING Do not open or close the door when the machine is on a slope The operating effort may suddenly change Always keep the door locked in position when it is open and when it is closed q If the...

Page 176: ...t in contact with the ground The angle between the boom and arm should be 90 to 110 The same applies when using the bucket installed in the reverse direction When only one side is affixed in mud use the bucket to raise the track then lay boards or logs and drive the machine out Stuck Both Sides Of Tracks 3 When the tracks on both sides are stuck in mud and they slip making it impossible for the ma...

Page 177: ...ith the arm is from a 45 angle away from the machine to a 30 angle towards the machine There may be some differences depending on the excavation depth but try to stay within the above range rather than operating the cylinder to the end of its stroke Ditching Work 3 Ditching work can be performed efficiently by attaching a bucket which matches the digging operation and then setting the tracks paral...

Page 178: ... your fingers caught q Never insert your fingers into the pin holes when aligning the holes Stop the machine on a firm and flat surface and do the work When performing joint work appoint a conductor and follow that person s instructions and signals Replacement 3 1 Place the bucket in contact with a flat surface NOTICE When removing the bucket set the bucket cylinder 3 facing down as shown in the d...

Page 179: ...o damage the O ring 7 so fit the O ring 7 to the arm 4 in the position shown in the dia gram on the right After inserting the pin fit the O ring correctly in the groove Install the stopper bolts and nuts for each pin then grease the pin Lubricate with grease thoroughly until the grease comes out from the end face When replacing the bucket replace the dust seal if it has been damaged If a damaged s...

Page 180: ...ert blocks underneath the track shoes As an additional safety measure thrust the bucket into the ground q If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accident Before leaving the opera tor s compartment always set the lock lever securely to LOCK position L 1 Put left and right travel levers 1 in the neutral position ...

Page 181: ... AFTER SHUT OFF ENGINE 3 Check the engine water temperature engine oil pressure and fuel level on the machine monitor REMARK After stopping the engine if the starting switch is turned within approx 10 seconds to the ON or START position to start the engine again the monitor display is not reset and the screen before the starting switch was turned OFF is displayed ...

Page 182: ...oor of operator s cab Always remember to close the window 2 Fuel tank filler port 3 Engine hood 4 Battery box cover 5 Left side door of the machine 2 places 6 Tool box side door 7 Hydraulic tank filler port 8 Spare pail cover REMARK Use the starting switch key to open and close all these places ...

Page 183: ...posture given in the procedure below There is danger that the machine may lose its balance q When lifting the machine pay careful attention to the center of gravity to maintain the balance When lifting the machine carry out the operation on flat ground as follows 1 When lifting the machine choose level ground and do as follows Pass the wire ropes between the 1st and 2nd track rollers from the fron...

Page 184: ...hine on the specified position of the trailer secure it according to the following procedure 1 Set all the control levers securely at LOCK position L with lock lever 1 2 When transporting the machine place wooden blocks under the front and rear track shoes to prevent the machine from moving Also hold it down with chains or wire rope of a suit able strength Be particularly careful to ensure that th...

Page 185: ...hree units or four units for transportation When transporting the machine please contact your Komatsu distributor Three units for transportation A Upper structure Undercarriage B Work equipment C Other Four units for transportation A Upper structure B Undercarriage C Work equipment D Others ...

Page 186: ...7 Overall width mm ft in 3 195 10 6 3 195 10 6 A mm ft in 3 330 10 11 3 330 10 11 B mm ft in 6 170 20 3 6 340 20 10 Weight kg lb 33 200 73 206 34 200 75 411 Unit PC600 7 PC600LC 7 Overall width mm ft in 3 195 10 6 A mm ft in 2 500 8 2 B mm ft in 4 970 16 4 Weight kg lb 16 800 37 044 Unit PC600 7 PC600LC 7 Quantity 2 2 A mm ft in 1 260 4 2 1 260 4 2 B mm ft in 5 340 17 6 5 690 18 8 C mm ft in 875 2...

Page 187: ...rall width mm ft in 1 190 3 11 Weight kg lb 4 820 10 628 Unit PC600 7 PC600LC 7 A mm ft in 4 870 15 12 B mm ft in 1 270 4 2 Overall width mm ft in 480 1 7 Weight kg lb 3 240 7 144 Unit PC600 7 PC600LC 7 A mm ft in 2 040 6 8 B mm ft in 1 870 6 2 Overall width mm ft in 1 790 5 10 Weight kg lb 2 510 5 535 Unit PC600 7 PC600LC 7 Quantity 2 A mm ft in 2 672 8 9 Weight kg lb 1 040 520 x 2 2 293 1147 x 2...

Page 188: ...7 A mm ft in 3 108 10 2 Weight kg lb 770 1 698 Unit PC600 7 PC600LC 7 A mm ft in 1 320 4 4 B mm ft in 3 195 10 6 C mm ft in 680 2 3 Weight kg lb 10 750 23 704 Unit PC600 7 PC600LC 7 A mm ft in 1 816 5 11 B mm ft in 215 8 5 C mm ft in 980 3 3 Weight kg lb 55 121 Unit PC600 7 PC600LC 7 A mm ft in 500 1 8 B mm ft in 1 910 6 3 Weight kg lb 32 71 ...

Page 189: ...OPERATION TRANSPORTATION 3 131 q Catwalk 2 same for all models Unit PC600 7 PC600LC 7 A mm ft in 2 310 7 7 B mm ft in 500 1 8 Weight kg lb 37 82 ...

Page 190: ...k frame A to be retracted then use the work equipment to jack up the track frame 3 Set blocks B 20 to 30 cm 8 to 12 in wooden blocks towards the outside of track frame A then use the boom cyl inder to lower the machine slowly The track frame A will slide and stop when it contacts the stopper 4 Lower the machine carefully and install bolts 2 one side front rear 8 bolts out of bolts 1 5 Tightening t...

Page 191: ...storted 3 Using the arm pull the machine to the front The track frame will slide 4 Extend the track frame until it comes into contact with the stopper then lower the machine slowly to the ground Install bolts 1 one side front rear 16 bolts and tighten to speci fied torque 5 Tightening torque 1960 2450 N m 200 250 kgf m 1450 1810 lbft 6 Follow the same procedure to retract the track frame on the ot...

Page 192: ...o not smoke when handling antifreeze NOTICE q Never use methanol ethanol or propanol based antifreeze q Never use any water leakage prevention agent or any antifreeze containing such an agent q Do not mix different types of antifreeze For details of the antifreeze mixture when changing the coolant see CLEAN INSIDE OF COOLING SYSTEM 4 25 Use a Permanent Antifreeze ethylene glycol mixed with corrosi...

Page 193: ...e drops the capacity of the battery will also drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 and insulate it against cold temperature so that the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the rate of charge from the following conversion table q As the battery c...

Page 194: ...eezing q Fill the fuel tank to the full in order to prevent moisture from forming dew in the tank room as the ambient tem perature goes down q After operation in water or mud remove water from undercarriage as described below to extend undercarriage service life 1 Swing 90 with engine at low idling and bring the work equip ment to the side of the track 2 Jack up the machine until the track is rais...

Page 195: ...remove it from the machine and store it sepa rately q Lock each control lever and pedal with the lock lever q Set the stop valve to the lock position on machines ready for attachments Install the blind plugs to the elbows q Set the selector valve to the When not use position on machines ready for attachments DURING STORAGE 3 WARNING If it is unavoidably necessary to carry out the rust preventive o...

Page 196: ...machine is stored for a long period moisture in the air will get into the oil Check the oil before and after starting the engine If there is water in the oil change the oil STARTING MACHINE AFTER LONG TERM STORAGE 3 When starting the engine after the machine has been in storage for a long time carry out the automatic warming up operation If the engine is started according to the starting procedure...

Page 197: ...e precise parts than the conventional injection pump and nozzle so problems may be caused by dust or dirt getting in When carrying out inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt is stuck to any part use fuel to wash it off completely q If no clean fuel is available bleed the air with priming pump 3 without removing the fuel cartridge NO...

Page 198: ... the side of the supply pump and pump priming pump 3 approx 90 100 times With this operation fuel will start to overflow from air breather 4 When no more bubbles come out with the fuel tighten air breather 4 Tightening torque 4 9 to 6 9 N m 0 5 to 0 7 kgf m 3 6 to 5 1 lbft 5 Pump the knob again several tens of times until it becomes stiff then push in the knob of priming pump 3 and tighten it 6 If...

Page 199: ...momentarily when the arm is more or less at the vertical position q When the bucket control lever is operated to the CURL posi tion and the work equipment is lowered under no load from a high position the bucket speed will drop momentarily when the bucket teeth are more or less at the horizontal position q When starting or stopping the swing noise will be emitted from the brake valve q When going ...

Page 200: ...wire rope as shown in the diagram on the right Place pieces of wood between wire ropes and body to prevent damage to ropes and body At this time never use the hole for light weight towing SEVERE JOB CONDITION 3 q When carrying out digging operations in water if the work equipment mounting pin goes into the water carry out greasing every time the operation is carried out q For heavy duty operations...

Page 201: ...ling install the positive terminal first If a tool touches the positive terminal and the chassis there is danger that it will cause a spark so be extremely careful q If the terminals are loose there is danger that the defec tive contact may generate sparks that will cause an explosion Terminals should be connected firmly q When removing or installing the terminals check which is the positive termi...

Page 202: ...egative terminal of the battery Be sure to fix the clips securely q Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or dry up and this may cause the battery to catch fire and explode q If the battery electrolyte is frozen do not ch...

Page 203: ...e a mistake when connecting a booster cable In the last connection to the upper struc ture frame a spark will be caused so connect the cable to a spot as far away from the battery as possible Avoid the work equipment however because it is not a good conductor q When removing the booster cable exercise good care so that the booster cable clips may not contact each other or they contact the chassis ...

Page 204: ...work ing normally or has failed Check also that all the control levers are at the HOLD or neutral position 1 Make sure the clips are firmly connected to the battery terminals 2 Start the engine of the normal machine and keep it to run at high idling speed 3 Turn the starting switch of the problem machine to the START position and start the engine If the engine doesn t start at first try again afte...

Page 205: ...tarting switch is turned to ON Defective wiring Defective starting motor Insufficient battery charge Defective safety relay Defective engine controller Check repair Replace Charge Replace Replace Pinion of starting motor keeps going in and out Insufficient battery charge Defective safety relay direct start ing motor Charge Replace Starting motor turns engine slug gishly Insufficient battery charge...

Page 206: ...ged element in hydraulic tank strainer Loose suction hose Clean see EVERY 2000 HOURS SERVICE Retighten Excessive rise in hydraulic oil tem perature Loose fan belt Dirty oil cooler Lack of hydraulic oil Check fan belt tension see EVERY 500 HOURS SERVICE Clean see EVERY 500 HOURS SERVICE Add oil to specified level see CHECK BEFORE STARTING Track comes off Track too loose Adjust track tension see WHE...

Page 207: ...ORE STARTING Check fan belt tension see EVERY 500 HOURS SERVICE Change cooling water clean inside of cooling system see WHEN REQUIRED Clean or repair see EVERY 500 HOURS SERVICE Replace engine water temperature gauge Replace thermostat Replace thermostat seal Tighten cap or replace packing Repair connect wiring Radiator water level monitor lights up Engine water temperature gauge is in red range E...

Page 208: ...Worn piston ring cylinder liner Defective compression Defective turbocharger Defective exchaust brake Defective injector Clean or replace See WHEN REQUIRED Check repair See adjustment of clearance above Check replace Check replace repair Check adjust repair Engine hunts Air entering suction side of fuel line There is knocking combustion or mechanical Poor quality fuel being used Overheating Error ...

Page 209: ...ion immediately E11 E14 Abnormality in electronic governor system abnormality in engine pro tection output Abnormality in throttle abnormality in fuel control dial It is possible to carry out normal working operations but have inspection carried out immediately Move machine to a safe posture and carry out inspection immedi ately E15 Abnormality in electronic governor system It is possible to carry...

Page 210: ...ach time input confirmation switch 1 is pressed Error screen screen A screen B screen C error screen Check the point of contact telephone number on screen B REMARK If the point of contact telephone number has not been registered screen B is not displayed If it is necessary to register the point of contact telephone number ask your Komatsu distributor to register it ...

Page 211: ...4 1 MAINTENANCE 4 ...

Page 212: ...n charge and take the necessary action When replacing the engine oil filter fill the new filter with fresh clean specified oil before installing Fuel Strainer If your machine is equipped with a fuel strainer do not remove it while fueling Welding Instructions q Turn off the engine starting switch q Do not apply more than 200V continuously q Connect grounding cable within 1m 3 3 ft from the area to...

Page 213: ...G AIR FROM HYDRAULIC SYSTEM 4 37 Hydraulic Hose Installation q When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace with new parts When doing this be careful not to forget to assemble the O rings and gaskets q When installing the hoses do not twist them or bend them into loops with a small radius This will cause damage to the hose and mark...

Page 214: ...h cases please contact your Komatsu distributor q When changing the oil always replace the related filters In particular when replacing the engine oil filter fill the new filter with fresh clean specified oil before installing q We recommend you have an analysis made of the oil periodically to check the condition of the machine For those who wish to use this service please contact your Komatsu dis...

Page 215: ... and will also cause problems with corrosion from the air in the coolant Grease 4 q Grease is used to prevent twisting and noise at the joints q This construction equipment is used under heavy duty conditions Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual q The nipples not included in the MAINTEN...

Page 216: ...ake sure that the oil is well mixed before sampling q Carry out sampling regularly at fixed intervals q Do not carry out sampling on rainy or windy days when water or dust can get into the oil For further details of KOWA please contact your Komatsu distributor Oil And Fuel Storage 4 q Keep indoors to prevent any water dirt or other impurities from getting in q When keeping drum cans for a long per...

Page 217: ... 4 q It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged This will cause an electrical short circuit and may lead to malfunction of the machine Do not wash the inside of the operator s compartment with water When washing the machine or when washing the floor inside the operator s compartment be careful not to let water get into the electrical ...

Page 218: ...0 Cartridge 1 Every 500 hours Fuel filter 600 319 3310 Cartridge 1 Every 500 hours Additional fuel filter If equipped 600 319 3440 600 311 3230 600 311 3220 1 Element seal cup 1 1 1 Every 500 hours Hydraulic oil filter 209 60 77530 07000 05180 Element O ring 1 1 Every 1 000 hours Hydraulic tank breather 20Y 60 21470 Element 1 Every 500 hours Corrosion resistor 600 411 1151 Cartridge 1 Every 1 000 ...

Page 219: ...iesel fuel The engine mounted on this machine employs electronic control and a high pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics For this reason it requires high precision for the parts and good lubrication If kerosene or other fuel with low lubricating ability is used there will be a big drop in durability ...

Page 220: ...oil that matches the temperature range in the table We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications Specified capacity Total amount of oil including oil for components and oil in piping Refill capacity Amount of oil needed to refill system during normal inspection and maintenance ASTM American Society ...

Page 221: ...se LS EP2 Antifreeze 6 CALTEX RPM delo 400 RPM delo 450 Universal thuban Universal thuban EP Marfak all purpose 2 Ultra duty grease 2 AF engine coolant 7 CASTROL Turbomax RX super CRD EP EPX Hypoy Hypoy B Hypoy C MS3 Spheerol EPL2 Anti freeze 8 CHEVRON Delo 400 Universal gear Ultra duty grease 2 9 CONOCO Fleet motor oil Universal gear lubricant Super sta grease 10 ELF Multiperformance 3C Performan...

Page 222: ... freeze and summer coolant 15 PETRO FINE FINA kappa TD FINA potonic N FINA potonic NE FINA marson EPL2 FINA tamidor 16 SHELL Rimura X Spirax EP Spirax heavy duty Albania EP grease 17 SUN Sunoco GL5 gear oil Sunoco ultra prestige 2EP Sun prestige 742 Sunoco antifreeze and summer cool ant 18 TEXACO Ursa super plus Ursa premium Multigear Multifak EP2 Starplex 2 Coda 2055 startex antifreeze coolant 19...

Page 223: ...e Permissible range 6 8 10 12 14 10 13 17 19 22 13 2 1 35 31 3 2 66 6 7 113 11 5 177 18 0 11 8 14 7 1 2 1 5 27 34 2 8 3 5 59 74 6 0 7 5 98 123 10 0 12 5 157 196 16 0 20 0 16 18 20 22 24 24 27 30 32 36 279 28 5 382 39 0 549 56 0 745 76 0 927 94 5 245 309 25 0 31 5 343 425 35 0 43 5 490 608 50 0 62 0 662 829 67 5 84 5 824 1030 84 0 105 0 27 30 33 36 39 41 46 50 55 60 1320 135 0 1720 175 0 2210 225 0...

Page 224: ...ess of their condition after a certain period of usage This is impor tant to ensure that these parts maintain their full performance at all times Furthermore should anything abnormal be found on any of these parts replace it with a new one even if the peri odic replacement time for the part has not yet arrived If any of the hose clamps show deterioration like deformation or cracking replace the cl...

Page 225: ...4 000hours which ever come first Option Water separator equipped machines 10 Fuel hose water separator to priming pump 1 11 Water separatorís case O ring plug 1 12 Front pump outlet hose 2 Every 2 years or 4 000 hours whichever come first 13 Rear pump outlet hose 2 14 Pump branch hose 2 15 In line filter to valve hose 2 16 Swing hose 4 17 Suction hose 4 18 Boom cylinder line hose B H 4 19 Arm cyli...

Page 226: ...4 REPLACE BUCKET TEETH HORIZONTAL PIN TYPE 4 304 ADJUST BUCKET CLEARANCE 4 314 REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER 4 324 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 4 324 CHECK AND ADJUST AIR CONDITIONER 4 334 CLEAN LINE FILTER REMOVE DIRT 4 344 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT 4 354 CLEAN PILOT LINE FILTER REMOVE DIRT 4 364 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 ...

Page 227: ...4 644 CHECK PLAY TURBOCHARGER ROTOR 4 64 REPLACE CORROSION RESISTOR CARTRIDGE 4 654 GREASE FAN PULLEY AND TENSION PULLEY 4 654 CHECK WELDED STRUCTURE 4 664 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR for breaker 4 684 EVERY 2000 HOURS MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE 4 694 CLEAN HYDRAULIC TANK STRAINER 4 704 CLEAN ENGINE BREATHER 4 714 CLEAN CHECK TURBOCHARGER 4 714 CHECK ALTERNATO...

Page 228: ...AULIC OIL FILTER ELEMENT q On new machines replace the element after the first 100 to 150 hours then carry out further replacement of the element according to the table on the right CHANGE OIL IN HYDRAULIC TANK q Change the oil according to the table on the right REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER q Use a guideline of 250 hours for use of the breaker operating ratio for the breaker 50 o...

Page 229: ...ERY 500 HOURS MAINTENANCE INITIAL 500 HOURS MAINTENANCE ONLY AFTER THE FIRST 500 HOURS 4 Carry out the following maintenance only after the first 500 hours q Change oil in swing machinery case q Change oil in P T O case q Change oil in final drive case Special tools are needed for the inspection and maintenance so please contact your Komatsu distributor to have this work carried out For details of...

Page 230: ...el flashes immediately after the element is cleaned replace the outer element inner element and O ring q Replacing evacuator valve Replace it if it is damaged or the rubber is markedly deformed NOTICE Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel flashes If the element is cleaned frequently before the clogging monitor flashes the air cleaner will ...

Page 231: ...crewdriver or other tool 3 After removing the outer element 6 cover the air connector inside the air cleaner body with a clean cloth or tape to pre vent dirt or dust from entering 4 Wipe off or brush off the dirt stuck to cover 3 and the inside of the air cleaner body 7 5 Remove any dirt or dust that is accumulated to evacuator valve 4 installed to cover 3 ...

Page 232: ...ter elements when the monitor 1 flashed soon after installing the cleaned outer element even though it has not been cleaned 6 times 10 Check that there is no play in the inner element If any play is found push it in properly 11 Remove the cloth or tape cover installed in Step 3 12 If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleani...

Page 233: ...h it in straight 3 Push the outer element in straight with your hand when installing it to the air cleaner body If the element is held and rocked lightly up and down and to the left and right while pushing it in the element can be inserted easily NOTICE When inserting the element if the rubber at the tip is swollen or the outer element is not pushed in straight and cover 3 is assembled by force to...

Page 234: ...ntake port in Step 2 4 Install the new inner element to the body then tighten the nut Do not clean the inner element and use it again NOTICE The inner element must not be used again even after its cleaning When replacing the outer element replace the outer element at the same time 5 Set the outer element in position then lock cover 3 with hooks 2 6 After replacing the element press reset button 4 ...

Page 235: ...taining ethylene glycol The ratio of antifreeze to water depends on the ambient temperature but to obtain the corrosion resistance effect a minimum ratio of 30 by volume is necessary When deciding the ratio of antifreeze to water check the lowest temperature in the past and decide from the mix ing rate table given below It is actually better to estimate a temperature about 10 C 18 F lower when dec...

Page 236: ...of the muffler and coolant drain valve 5 at the bottom of the radiator 4 Open drain valves 5 and 7 and drain the water 5 After draining the antifreeze solution close drain valves 5 and 7 then fill with clean water After the radiator is filled with water start and run the engine at low idling speed After the water temperature rises above 90 C 194 F run the engine for about 10 minutes 6 Stop the eng...

Page 237: ... tighten to a tightening torque of 784 78 N m 80 8 kgf m 578 6 57 9 lbft then check that the nut and shoe are in tight contact with the link mating surface 2 After checking further tighten to the tightening torque of 120 10 Order for tightening Tighten the bolts in the order shown in the diagram on the right After tightening check that the nut and shoe are in close contact with the link mating sur...

Page 238: ... Place wooden bar 3 on top of the track from No 2 roller 1 to No 3 roller 2 3 Measure the maximum deflection between the bottom sur face of the wooden bar and the top surface of the track shoe Deflection a should be 10 to 30 mm 0 8 to 1 2 in Adjustment WARNING Grease inside the adjusting mechanism is under high pressure Grease coming from plug 1 under pres sure can penetrate the body causing injur...

Page 239: ...se 2 Turn plug 1 a maximum of one turn 3 If the grease does not come out smoothly move the machine forwards and backwards a short distance 4 Tighten plug 1 5 To check that the tension is correct move the machine slowly forward 6 Check the track tension again and if the tension is not cor rect adjust it again CHECK ELECTRICAL INTAKE AIR HEATER 4 Before the start of the cold season once a year conta...

Page 240: ... other protec tive equipment 1 Set a block 3 under the bottom face of the bucket so that pin 1 can be removed Turn the starting switch to the ON posi tion within 15 seconds after stopping the engine operate the control levers fully check that the work equipment is stable then set the safety lock lever to the LOCK position L Set so that the bottom face of the bucket is horizontal 2 Place a bar on t...

Page 241: ...d arm adjust the bucket clearance in the following man ner 1 Set the work equipment to the position shown in the diagram on the right then stop the engine and set lock lever 1 to the LOCK position L 2 Loosen 3 bolts 2 6 bolts 3 plate 1 and plate 5 3 Take out shims 4 equivalent in size to free play a Thickness of shim 4 is 0 5 mm or 1 0 mm 0 02 or 0 04 in When free play a is less than a thickness o...

Page 242: ...ful not to let any dust get in Mixture ratio of pure washer fluid and water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the following proportions before adding There are two types depending on the freezing temperature 10 C 14 F general use and 30 C 22 F cold area use so select according to the area and season Operation area and season Mixtur...

Page 243: ...rant C Colorless transparent No refrigerant REMARK When there are bubbles the refrigerant gas level is low so con tact your refrigerant dealer to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor Inspection During Off Season Even during the off season operate the air conditioner for 3 5 minutes once a month to maintain th...

Page 244: ...URE IN HYDRAULIC CIRCUIT 4 40 1 Remove 4 bolts 1 then remove flange 2 2 After removing 4 bolts 3 temporarily screw 2 of them into cover 4 3 Remove cover 4 and wash filter 5 When washing the fil ter remove plug 6 and clean out all the dirt stuck to the side face of the case 4 After washing filter 5 install it again When installing the fil ter cover and flange again replace backup ring 7 and O rings...

Page 245: ...on q Prepare a container to catch the oil 1 Place a container under the filter element to catch the oil 2 Turn filter case 1 to the left to remove it then take out ele ment 2 3 Remove plug 3 from filter case 1 4 Clean the removed parts then install new element 2 and O ring 4 5 When installing bring the case into contact with the filter holder then tighten a further 1 2 turns NOTICE For details of ...

Page 246: ... to catch the oil 2 Remove plug 1 3 Remove strainer 2 and wash it 4 Replace O ring 3 with new one 5 Install the washed strainer 2 Tightening torque for a strainer 8 83 to 9 81 N m 0 9 to 1 0 kgf m 6 5 to 7 2 lbft Fix two positions of the cylinder 6 Install the O ring 3 and the plug 1 Tightening torque for a plug 108 0 to 147 0 N m 11 to 15 kgf m 79 6 to 108 5 lbft ...

Page 247: ... or above when filling the pump Be sure to use a clean oil can Carry out Steps 1 3 below to bleed the air If necessary carry out Steps 4 6 in addition 1 Bleeding air from pump 2 Loosen air bleed plug 1 and check that oil oozes out from the air bleeder 3 3 If oil 4 does not ooze out remove the pump case drain hose and elbow then fill the inside of the pump case with hydraulic oil through drain port...

Page 248: ... does not ooze out stop the engine remove drain hose 1 then fill the motor case with hydraulic oil 14 After completion of bleeding air install drain hose 1 15 Run the engine at low idling and slowly swing the upper structure at least 2 times uniformly to the left and right NOTICE q If the air is not bled from the swing motor the motor bearings may be damaged q When replacing the travel motor safet...

Page 249: ...turn NOTICE Do not loosen plug 2 more than one turn 20 Carry out fine operation of the travel lever and set to FOR WARD and REVERSE 4 5 times 21 When no more cloudy white oil comes out from air bleed plug 2 tighten air bleed plug 2 22 Install the travel motor cover 23 Operation 24 After completing the air bleed operation stop the engine and wait for at least 5 minutes before starting opera tions T...

Page 250: ... the work equipment to the ground as shown in the diagram on the right then stop the engine q Set the lock lever at the FREE position F 2 Operate each work equipment control lever to the full stroke within 5 6 seconds after stopping the engine q Leave the starting switch at the ON position 3 Remove the cap of the hydraulic tank 4 Start the engine run for approx 10 seconds then stop the engine agai...

Page 251: ...pressure inside the hydraulic circuit in a failure occurs on the machine Check the nitrogen gas charge pressure as follows 1 Set the work equipment to maximum reach as shown in the diagram on the right 2 Stop the engine and carry out the LOWER operation for the boom 3 Check that the tip of the bucket drops at least 1m If the tip of the bucket drops less than 1m the charge pressure inside the accum...

Page 252: ...evel add water q Check oil level in engine oil pan add oil q Check fuel level add fuel q Drain water and sediment from fuel tank q Check oil level in hydraulic tank add oil q Check oil level in swing machinery case add oil q Check oil level in P T O case add oil q Check air cleaner for clogging q Check working lamp switch q Check electric wirings q Check function of horn ...

Page 253: ...ING 4 1 Set to the greasing posture below lower the work equipment to the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Boom cylinder foot pin 2 places ...

Page 254: ...oot pin 2 places 3 Boom cylinder rod end pin 2 places 4 Arm cylinder foot pin 1 place 5 Boom Arm coupling pin 1 place 6 Bucket cylinder foot pin 1 place 7 Arm cylinder rod pin 1 place 8 Arm Link coupling pin 1 place 9 Arm Bucket coupling pin 1 place ...

Page 255: ...MAINTENANCE MAINTENANCE PROCEDURE 4 45 10 Link coupling pin 2 places 11 Bucket cylinder rod pin 1 place 12 Bucket Link coupling pin 1 place ...

Page 256: ...or every 10 hours service should be carried out at the same time LUBRICATING SWING CIRCLE 4 4 points 1 Lower the work equipment to the ground 2 Using a grease pump pump in grease through the grease fit tings shown by arrows 3 After greasing wipe off any old grease that was pushed out ...

Page 257: ...e oil or plug may fly out Loosen the plug slowly to release the pressure q Prepare a handle 1 Set the TOP mark at the top with the UP mark and plug P perpendicular to the ground surface 2 Using a handle remove plug F and check that the oil level is within a range of 10 mm 0 4 in below the bottom edge of the plug hole 3 If the oil level is low check again Install plug F operate the travel lever tra...

Page 258: ...y electrolyte to go above the UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts NOTICE When adding distilled water in cold weather add it before starting operations in the morning to prevent the electrolyte from freezing Inspect the battery electrolyte level at least once a month and follow the basic safety procedures giv...

Page 259: ...stributor or battery maker When it is impossible to check electrolyte level from side of battery If it is impossible to check the electrolyte level from the side of the battery or there is no display of the UPPER LEVEL line on the side of the battery check as follows 1 Remove cap 1 at the top of the battery look through the water filler port and check the electrolyte surface If the elec trolyte do...

Page 260: ...te level If it is possible to use and indicator to check the electrolyte level follow the instructions given CHECK CLEAN FUEL TANK STRAINER 4 Tighten the valve of the fuel tank remove cap 1 of the strainer case under the oil pan then take out the strainer and wash the strainer and strainer case After doing this replace the strainer O ring CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS 4 B...

Page 261: ...belt tension with nut 9 as follows TIGHTEN to INCREASE tension LOOSEN to DECREASE tension 2 After adjusting the belt tighten the bolts and nuts 3 to 8 in the order of 8 to 3 the opposite order from loosening Finally tighten nut 9 q Check each pulley for damage wear of the V groove and wear of the V belt Check in particular that the V belt does not contact the bottom of the V groove q If the V belt...

Page 262: ...ove compressor q Adjust the belt tension with nut 9 as follows TIGHTEN to INCREASE tension LOOSEN to DECREASE tension 2 After adjusting the belt tighten the bolts and nuts 5 to 8 in the order of 8 to 5 the opposite order from loosening Finally tighten nut 9 q Check each pulley for damage wear of the V groove and wear of the V belt Check in particular that the V belt does not contact the bottom of ...

Page 263: ...onal injection pump and nozzle If any part other than a genuine Komatsu filter cartridge is used dust or dirt may get in and cause problems with the injection system Always avoid using substitute parts q When carrying out inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt is stuck to any part use fuel to wash it off completely q Container to ca...

Page 264: ...f the replacement of fuel filter cartridge 1 bleed the air Bleed the air as follows 6 Add fuel to the fuel tank until full to FULL mark on the fuel gauge 7 After replacing filter cartridge 1 loosen air bleed plug 2 8 Loosen the knob of priming pump 3 move it up and down and continue until no more bubbles come out with the fuel 9 Tighten air bleed plug 2 push in the knob of priming pump 3 then tigh...

Page 265: ...h of the grease is approx 60 mm 2 4 in Add grease if necessary Insert the scale A in the position shown in the diagram on the right when measuring If the grease is particularly milky due to ingress of water etc then remove bolts 3 and cover 4 from the bottom of the track frame and remove the grease Replace all of the grease with new grease The total amount of grease is 31 liters 28 kg 8 2 US gal 6...

Page 266: ...t a distance of at least 300 mm 11 8 in Never blow the compressed air at right angles to the core If the fins are damaged it may cause water leakage or overheating On dusty jobsites check the fins daily regardless of the maintenance interval 1 Open the engine hood and rear duct 1 on the right side of the machine 2 Direct compressed air to radiator fins 9 oil cooler fins 8 and condenser fins 4 to b...

Page 267: ... tioner unit CLEAN INTERNAL AIR FILTER 1 Remove wing bolts 1 from the inspection window at the bot tom rear left on the inside of the operator s cab then take out the recirculated air filter 2 Clean the filter with compressed air If there is oil on the filter or if the filter is extremely dirty wash it in a neutral agent After rinsing it in water dry it thoroughly before using it again If the clog...

Page 268: ...lter case 3 again open the cover at the bottom left of the operator s cab by hand return the filter case to its original position then close the cover When doing this check that the lock is applied REPLACE BREATHER ELEMENT IN HYDRAULIC TANK 4 WARNING q The parts and oil are at high temperature after the engine is stopped and may cause burns Wait for the temperature to go down before starting the w...

Page 269: ...ut the strainer remove any dirt stuck to the strainer then wash it in flushing oil If the strainer or O ring are damaged replace with a new part 3 Install the strainer and filter case 1 CHECK FAN BELT 4 Check the V belt and when the following conditions exist replace the V belt q When the V belt makes contact with the bottom of the groove in each pulley q When the V belt is worn and its surface is...

Page 270: ... oil 2 Be careful not to get oil on yourself Move lever 3 of the drain valve down slowly to drain the oil and after draining the oil raise the lever to close it 3 Open the cover of the engine hood use a filter wrench from the top of the engine turn filter cartridge 3 to the left and remove it 4 Clean the filter holder fill the new filter cartridge with clean engine oil coat the thread and packing ...

Page 271: ...tightening be extremely careful not to damage the filter or cause dents 6 After replacing the filter cartridge add engine oil through oil filler port F so that the oil level is between the H and L marks on dipstick G 7 Run the engine for a short time at low idling then stop the engine Check that the oil level gauge is between the H and L marks For details see Check Oil Level In Engine Oil Pan Add ...

Page 272: ...olts then remove cover 1 When doing this the cover may fly out under the force of spring 2 so hold the cover down when removing the bolts 4 After removing spring 2 valve 3 and strainer 5 take out element 4 q If there are metal particles or foreign material inside strainer 5 please contact your Komatsu distributor 5 Clean the removed parts in diesel oil 6 Install the new element in the place where ...

Page 273: ...again 3 Remove dipstick G and air bleding plug 1 then add the specified amount of engine oil through filler port F of the dip stick guide 4 After adding oil install air bleed plug 1 5 Wipe off the oil on the dipstick with a cloth 6 Insert dipstick G fully in the oil filler pipe then take it out again 7 The oil level should be between H and L marks on the dipstick G If the oil does not reach the L ...

Page 274: ... the engine check the oil level q Refill capacity 6 liters 1 6 US gal 1 Loosen drain plug 1 at the bottom of the PTO case drain the oil then tighten the plug again 2 Refill the specified quantity of engine oil through oil filler F NOTICE If excess oil is supplied drain it to the specified amount to avoid overheating CHECK ALL TIGHTENING PARTS OF TURBOCHARGER 4 Please contact your Komatsu distribut...

Page 275: ...ace into contact with the seal surface of the filter holder then tighten a further 2 3 times If the filter cartridge is tightened too far the gasket will be damaged and water will leak If it is too loose water will leak from the gap in the gasket so always keep to the proper tightening angle 6 Turn valve 1 of corrosion resistor 2 to the OPEN stopper position 7 After replacing the cartridge run the...

Page 276: ... the color check Detergent penetrating agent developing solution 2 Spray with detergent and wash to remove all the dirt and oil from the place to be checked 3 After washing dry the area then spray with penetrating agent and leave for 5 20 minutes 4 Spray with detergent then clean the surface with a cloth 5 Clean the surface again then spray with developing solution 6 Leave for 15 20 minutes then c...

Page 277: ...MAINTENANCE MAINTENANCE PROCEDURE 4 67 q Center frame A Important check points q Boom ...

Page 278: ...ROCEDURE MAINTENANCE 4 68 q Arm CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR for breaker 4 If equipped A special tool is needed for inspecting and charging with nitrogen gas Please ask your Komatsu distributor ...

Page 279: ...re remaining inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure q Refill capacity each 10 liters 2 6 US gal q Prepare a handle 1 Set the TOP mark at the top with the TOP mark and plug P perpendicular to the ground surface 2 Remove plugs P and F with the handle and drain the oil REMARK Check the O rings in the plugs for damage If necessary replace with new on...

Page 280: ... cover 1 the cover may fly off under the force of spring 2 so loosen the 4 bolts slowly 1 Remove the cap from oil filler F on top of the hydraulic tank 2 Remove cover 1 and lift up the top of rod 3 from above to take out spring 2 and strainer 4 3 Remove any dirt stuck to strainer 4 then wash it in clean diesel oil or flushing oil If strainer 4 is damaged replace it with a new part 4 When installin...

Page 281: ...w O ring with engine oil set it then install breather 1 CLEAN CHECK TURBOCHARGER 4 Contact your Komatsu distributor for cleaning and inspection CHECK ALTERNATOR STARTING MOTOR 4 The brushes may be worn or the bearing may have run out of grease so contact your Komatsu distributor for inspection or repair When the engine is frequently started ask for inspection every 1000 hours or every 6 months whi...

Page 282: ...d contact your Komatsu distributor for disassembly and repair or replacement CHECK VIBRATION DAMPER 4 There may be leakage from the damper dents or face runout so please contact your Komatsu distributor for replacement CHECK FAN PULLEY AND TENSION PULLEY 4 Inspect the pulley for play and grease leakage If any fault is detected ask Komatsu distributor to disassemble and repair or replace REPLACE IN...

Page 283: ...r to check that the rubber has not hardened If there is any problem the problem part must be replaced In such a case please contact your Komatsu distributor NOTICE If the engine continues to be used when there are loose bolts hardened rubber or missing parts there is danger of damage or breakage occurring due to vibration and wear at the connections of high pressure piping Always check that the pr...

Page 284: ... are protective parts installed to prevent fire caused by fuel leaking and spraying out on to high temperature parts of the engine Check visually that there are no missing caps or loose bolts and feel with your finger to check that the rubber has not hardened If there is any problem the problem part must be replaced In such a case please contact your Komatsu distributor ...

Page 285: ... capacity 360 liters 95 1 US gal q Prepare a handle for socket wrench set 1 Swing the upper structure so that the drain plug under the hydraulic tank will be between both tracks 2 Retract the arm and bucket cylinders then lower the boom and put the teeth in contact with the ground 3 Set the safety lock lever to the LOCK position and stop the engine 4 Remove the cap of oil filler F at the top of th...

Page 286: ... and install cover 2 When loosening drain plug P2 be careful not to get oil on yourself 8 Tighten the bolts to install cover 2 9 Add the specified amount of new and clean engine oil for hydraulic system through oil filler port F Check that the oil level is between H and L on the sight gauge 10 Bleed the air from the circuit after cleaning or replacing the filter element or strainer or after changi...

Page 287: ...2000 and 4000 hours service should be carried out at the same time REPLACE HIGH PRESSURE PIPING CLAMP 4 Please contact your Komatsu distributor to have the engine high pressure clamp replaced REPLACE FUEL SPRAY PREVENTION CAP 4 Please contact your Komatsu distributor to have the fuel spray prevention cap replaced ...

Page 288: ...5 1 SPECIFICATIONS 15 ...

Page 289: ...ll length mm ft in 12 810 42 0 12 810 42 0 B Overall height mm ft in 4 300 14 1 4 300 14 1 C Overall width mm ft in 3 900 12 10 3 900 12 10 D Track shoe width mm ft in 600 1 12 600 1 12 E Height of cab mm ft in 3 290 10 10 3 290 10 10 F Radius of upper structure mm ft in 3 675 12 1 3 675 12 1 G Overall length of track mm ft in 5 340 17 6 5 690 18 8 H Tumbler center distance mm ft in 4 250 13 11 4 ...

Page 290: ...in 13 020 42 9 13 020 42 9 B Max digging depth mm ft in 8 490 27 10 8 490 27 10 C Max digging height mm ft in 11 880 38 12 11 880 38 12 D Maximum vertical wall digging depth mm ft in 7 510 24 8 7 510 24 8 E Max dumping height mm ft in 7 960 26 1 7 960 26 1 F Max digging reached at ground level mm ft in 12 800 41 12 12 800 41 12 ...

Page 291: ...6 1 ATTACHMENTS AND OPTIONS 16 ...

Page 292: ... for the machine and the attachment or option q If you lose the instruction manual or it is damaged always obtain an new copy from the attachment manufac turer or your Komatsu distributor PRECAUTIONS WHEN REMOVING OR INSTALLING 6 When removing or installing the attachment or option obey the following precautions and take care to ensure safety during the operation q Carry out the removal and instal...

Page 293: ...installed the working range becomes larger q If heavy work equipment is installed pay careful attention to the following precautions q The swing overrun the distance the work equipment moves before completely stopping after the swing brake is applied will be greater There is danger of hitting objects if the swing overrun is miscalculated so allow extra space to the swing position when swinging q T...

Page 294: ...r combination of work equipment there is danger that the work equipment may hit the cab or machine body When using unfamiliar work equipment for the first time check before starting if there is any danger of interference and operate with caution Select the combination of boom arm and bucket from the combinations shown in the table below q for standard operations Q Possible to use only light work I...

Page 295: ... 740 45 1 14 630 47 12 11 550 37 11 B Max digging depth mm ft in 8 490 27 10 9 275 30 5 10 255 33 8 7 060 23 2 C Max digging height mm ft in 11 880 38 12 12 180 39 12 12 560 41 2 11 140 36 7 D Maximum vertical wall digging depth mm ft in 7 510 24 8 8 375 27 6 9 275 30 5 5 630 18 6 E Max dumping height mm ft in 7 960 26 1 8 245 27 1 8 600 28 3 7 210 23 8 F Max digging reached at ground level mm ft ...

Page 296: ...n and ground contact pressure If wider shoes than necessary are used the load on the track shoe will increase so this may cause problems such as bending of the shoe cracking of the link damage of the pin and looseness of the shoe bolts Category Use Precautions when using A Rocky ground riverbeds normal soil On rough ground with large obstacles such as boulders or fallen trees travel at low speed B...

Page 297: ...cautions For Safety 6 2 Precautions When Removing Or Installing 6 2 Precautions When Selecting 6 2 Precautions When Using 6 3 Read The Instruction Manual Thoroughly 6 2 Grease Pump 3 68 H Handling Oil Fuel Coolant And Performing Oil Clinic 4 4 Hot and cool box 3 45 I Introduction 1 7 L Locking 3 124 Long term storage 3 137 After Storage 3 138 Before Storage 3 137 During Storage 3 137 Starting mach...

Page 298: ...ervice Meter Location 1 10 Specifications 5 2 Sun Roof 3 37 Swinging 3 108 Switches 3 27 T Tightening Torque Specifications 4 13 Tightening Torque List 4 13 Tool Box 3 67 Transportation 3 125 Lifting Machine 3 125 Precautions for Transportation 3 125 Procedure for Increasing or Reducing Track Frame Gauge 3 132 Shipping Machine Information 3 126 Transportation Posture 3 127 Traveling On Slopes 3 11...

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