Komatsu Galeo PC800LC-8 Operation & Maintenance Manual Download | Manualshive

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CONTENTS

1-19

.................................................................................................................................................... 4-11

WEAR PARTS LIST.................................................................................................................................. 4-11

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

................................................................................. 4-12

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........................................................................................................................................... 4-14

TIGHTENING TORQUE SPECIFICATIONS

...................................................................................................... 4-15

TIGHTENING TORQUE LIST................................................................................................................... 4-15

SAFETY CRITICAL PARTS

............................................................................................................................... 4-16

SAFETY CRITICAL PARTS LIST ............................................................................................................. 4-16

MAINTENANCE SCHEDULE

............................................................................................................................. 4-17

MAINTENANCE SCHEDULE CHART...................................................................................................... 4-17

MAINTENANCE PROCEDURE

.......................................................................................................................... 4-19

INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) ................................... 4-19

INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) ................................... 4-19

WHEN REQUIRED ................................................................................................................................... 4-19

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-19

CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-24

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

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

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

REPLACE BUCKET TEETH (KMAX) .............................................................................................. 4-31

ADJUST BUCKET CLEARANCE .................................................................................................... 4-32

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .............................................................. 4-34

CHECK AND MAINTENANCE AIR CONDITIONER ....................................................................... 4-35

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

CHECK GAS SPRING..................................................................................................................... 4-36

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

CHECK BEFORE STARTING .................................................................................................................. 4-40

EVERY 10 HOURS MAINTENANCE........................................................................................................ 4-41

LUBRICATING................................................................................................................................. 4-41

EVERY 100 HOURS MAINTENANCE...................................................................................................... 4-43

LUBRICATING SWING CIRCLE ..................................................................................................... 4-43

EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-44

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-44

CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-44

CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS ............................... 4-46

CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST ............................................................ 4-47

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ..................................... 4-48

EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-49

REPLACE FUEL PRE-FILTER CARTRIDGE.................................................................................. 4-49

CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................................ 4-51

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL
COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH
AIR CONDITIONER) ....................................................................................................................... 4-52

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Summary of Contents for Galeo PC800LC-8

Page 1: ...ay cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personel who will come into contact with the machine Operation Maintenance Manual UEAM005400 WARNING ...

Page 2: ......

Page 3: ...FOREWORD 11 ...

Page 4: ...ughly and understand its contents fully Read the safety messages and safety labels given in this manual carefully so that they should be under stood fully Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically In case this manual should be lost or damaged immediately contact ...

Page 5: ...identally touch the control levers when they are not locked this may cause a serious injury or death Other signal words In addition to the above the following signal words are used to indicate precautions that should be followed to pro tect the machine or to give information that is useful to know Indicates an imminently hazardous situation which if not avoided will result in death or serious inju...

Page 6: ...nside a triangle and the method of avoiding the hazardous condition is shown inside a circle 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 a...

Page 7: ...ine q Sound pressure level at the operator s station measured according to ISO6396 Dynamic test method simulated working cycle q Sound power level emitted by the machine measured according to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European directive 2000 14 EC 73 108 ...

Page 8: ...de to Reduce Vibration Levels on Machine 1 The following guides can help an operator of this machine to reduce the whole body vibration levels 1 Use the correct equipment and attachments 2 Maintain the machine according to this manual q Tension of crawler for crawler machines q Brake and steering systems q Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and t...

Page 9: ... path as large as possible q Travel at low speed when traveling around sharp curves 7 Minimize vibrations for long work cycle or long distance traveling q Reduce speed to prevent bounce q Transport machines long distances between worksites 8 The following guidelines can be effective to minimize risks of low back pain q Operate the machine only when you are in good health q Provide breaks to reduce...

Page 10: ...100 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 idle 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 lo...

Page 11: ...rk q Demolition work See the section RECOMMENDED APPLICATIONS 3 121 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 A Front E Operator s seat B Rear F Sprocket C Left D Right ...

Page 12: ...area where the view is blocked by part of the machine when mirrors or other aids to visibility are installed as standard Please be fully aware that there are places that cannot be seen when operating the machine 12M CIRCUMFERENCE VISIBILITY 1 The visibility at a radius of 12 m from the machine is as shown in the diagram below The hatched areas B show the areas where the view is blocked when mirror...

Page 13: ...tsu distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 On the bottom right of the operator s cab The design of the nameplate differs according to the territory EPA REGULATIONS ENGINE NUMBER PLATE 1 On the upper side of the engine cylinder head cover EPA Environmental Protection Agency U S A ...

Page 14: ...he machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1 Machine serial No Engine serial No Product Identification Number Manufacturers name Address Distributor Address Phone KOMATSU UK Ltd Durham Road Birtley Chester Le street County Durham DH32QX United Kingdom ...

Page 15: ...o MANUFACT YEAR MASS ENGINE POWER Product Identification Number kg kW MANUFACTURER Manufactured by Komatsu UK Ltd for Komatsu Ltd Tokyo Japan MODEL SERIAL MANUFACTURING YEAR WEIGHT ENGINE POWER MANUFACTURER Komatsu UK Ltd Birtley Co Durham United Kingdom PRODUCT IDENTIFICATION NUMBER ...

Page 16: ...PRODUCT INFORMATION FOREWORD 1 14 ...

Page 17: ...10 PRODUCT INFORMATION 1 11 PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 11 EPA REGULATIONS ENGINE NUMBER PLATE 1 11 SERVICE METER LOCATION 1 12 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1 12 MACHINE SERIAL PLATE 1 13 SAFETY SAFETY INFORMATION 2 2 SAFETY LABELS 2 4 LOCATION OF SAFETY LABELS 2 5 SAFETY LABELS 2 6 SAFETY INFORMATION 2 13 SAFETY MACHINE OPERATION 2 22 STARTING ENGINE...

Page 18: ...CAB 3 49 DOOR LOCK 3 49 CAP WITH LOCK 3 49 HOT AND COOL BOX 3 51 MAGAZINE BOX 3 51 ASHTRAY 3 51 AIR CONDITIONER CONTROLS 3 52 AIR CONDITIONER CONTROL PANEL 3 52 METHOD OF OPERATION 3 56 USE AIR CONDITIONER WITH CARE 3 62 AIR CONDITIONER MAINTENANCE 3 63 OTHER FUNCTIONS 3 63 RADIO CASSETTE OPTION 65 USE RADIO WITH CARE 3 65 AUXILIARY ELECTRIC POWER 3 66 24V POWER SOURCE 3 66 12V POWER SOURCE 3 67 F...

Page 19: ...MACHINE 3 108 STEERING THE MACHINE 3 109 STEERING 3 109 SWINGING 3 111 WORK EQUIPMENT CONTROLS AND OPERATIONS 3 112 WORKING MODE 3 114 PROHIBITED OPERATIONS 3 115 GENERAL OPERATION INFORMATION 3 117 TRAVELING ON SLOPES 3 118 ESCAPE FROM MUD 3 120 TRACK ON ONE SIDE STUCK 3 120 TRACKS ON BOTH SIDES STUCK 3 120 RECOMMENDED APPLICATIONS 3 121 BACKHOE WORK 3 121 DITCHING WORK 3 121 LOADING WORK 3 121 B...

Page 20: ... MACHINE 3 144 SEVERE JOB CONDITION 3 145 DISCHARGED BATTERY 3 146 BATTERY REMOVAL AND INSTALLATION 3 146 BATTERY CHARGES 3 147 STARTING ENGINE WITH BOOSTER CABLES 3 148 OTHER TROUBLE 3 150 ELECTRICAL SYSTEM 3 150 CHASSIS 3 151 ENGINE 3 152 ELECTRONIC CONTROL SYSTEM 3 154 POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS 3 155 MAINTENANCE MAINTENANCE INFORMATION 4 2 OUTLINE OF SERVICE 4 4 HANDLING O...

Page 21: ...ACE BUCKET TEETH KMAX 4 31 ADJUST BUCKET CLEARANCE 4 32 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 4 34 CHECK AND MAINTENANCE AIR CONDITIONER 4 35 CLEAN LINE FILTER REMOVE DIRT 4 36 CHECK GAS SPRING 4 36 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 37 CHECK BEFORE STARTING 4 40 EVERY 10 HOURS MAINTENANCE 4 41 LUBRICATING 4 41 EVERY 100 HOURS MAINTENANCE 4 43 LUBRICATING SWING CIRCLE 4 43 EVERY 250 HOURS MA...

Page 22: ...HARGE PRESSURE IN ACCUMULATOR FOR BREAKER 4 68 EVERY 2000 HOURS MAINTENANCE 4 69 CHANGE OIL IN FINAL DRIVE CASE 4 69 CLEAN HYDRAULIC TANK STRAINER 4 70 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 71 CHECK ALTERNATOR 4 74 CHECK ENGINE VALVE CLEARANCE ADJUST 4 74 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS 4 74 EVERY 4000 HOURS MAINTENANCE 4 75 CHECK W...

Page 23: ...2 READ THE INSTRUCTION MANUAL THOROUGHLY 6 2 PRECAUTIONS WHEN REMOVING OR INSTALLING 6 2 PRECAUTIONS WHEN USING 6 3 ATTACHMENT GUIDE 6 4 COMBINATIONS OF WORK EQUIPMENT 6 5 WORKING RANGE DIAGRAM 6 6 TRACK SHOES SELECTION 6 7 HANDLING MACHINES EQUIPPED WITH KOMTRAX 6 8 BASIC PRECAUTIONS 6 8 INDEX COLOPHON ...

Page 24: ...CONTENTS 1 22 ...

Page 25: ...ING Please read and make sure that you fully understand the precautions discribed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precaustions strictly ...

Page 26: ...82 Attachment installation 2 182 Attachment combinations 2 192 Cab window glasses 2 192 Unauthorized modifications 2 192 Safety at jobsite 2 192 Working on loose ground 2 192 Distance to high voltage cables 2 202 Ensure good visibility 2 202 Ventilation for enclosed area 2 212 Signalman s signal and signs 2 212 Emergency exit from operator s cab 2 212 Asbestos dust hazard prevention 2 212 SAFETY M...

Page 27: ...is Running 2 342 Proper Tools 2 352 Accumulator Gas spring 2 352 Personnel 2 352 Attachments 2 362 Work Under the Machine 2 362 Noise 2 362 When Using Hammer 2 362 Welding Works 2 362 Removing Battery Terminals 2 372 Safety First when Using High pressure Grease to Adjust Track Tension 2 372 Do Not Disassemble Recoil Springs 2 372 Safety Rules for High pressure Oil 2 372 Precaution for High Fuel Pr...

Page 28: ...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 29: ...SAFETY SAFETY LABELS 2 5 LOCATION OF SAFETY LABELS 2 ...

Page 30: ...operation and maintenance can cause serious injury or death q Read the manual and labels before operation and mainte nance Follow instructions and warnings in manual and in labels on machine 1 Keep the manual in machine cab near operator If this manual is lost please contact your Komatsu distributor for a replacement ...

Page 31: ... leaving operator s seat 3 WARNING No passengers No passengers allowed to ride on machine while it is moving 4 WARNING DANGER OF FALLING OBJECTS Do not operate where a danger of falling objects exists Consult your dealer for fitting of FOPS protection ...

Page 32: ...r if machine or attachments are not kept safe distance away from electric lines 6 Control levers operational function diagram 7 Caution when stowing front window 09803 A0481 q Sign indicates a hazard from falling window q After raising window be sure to lock it in place with lock pins ...

Page 33: ... cap or hydraulic tank oil filler when cooling water or hydraulic oil is at high temperature 9 Caution for handling accumulator and gas spring 09659 A057B q There is the hazard of explosion causing injury q Do not disassemble the accumulator make holes in it weld it cut it hit it roll it or bring it near flame 10 Caution when adjusting track tension 09657 A0881 q Sign indicates a hazard of flying ...

Page 34: ...handling 12 Stopping rotation for inspection and maintenance 09667 A0481 q Sign indicates a hazard of rotating parts such as belt q Turn off before inspection and maintenance 13 Explanation of method for emergency escape 09844 00050 14 Caution against falling 09805 A0881 q There is the hazard of falling down q Do not go close to the edge of the machine by mistake ...

Page 35: ...d on this place here 16 Prohibited to enter swing radius 09133 A3281 q There is danger of getting caught when upper structure swings q Do not enter range of swing 17 Caution for operation 09134 A1681 q Sign indicates a hazard of being hit by the working device of the machine q Keep away from machine during operation ...

Page 36: ...ition of jump start 09842 A0481 q Start the engine only after sitting down in the operator s seat q Do not attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire ...

Page 37: ...e until the problem has been corrected 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 Always wea...

Page 38: ...ud and 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 driv...

Page 39: ...e 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 o...

Page 40: ...y Do not allow anyone to approach any rotating or telescoping part BURN PREVENTION Hot coolant q To prevent burns from hot water 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 radi ator cap by hand before starting the operation Even when the coolant has cooled down loosen the cap slowly to relieve the pressu...

Page 41: ...gasoline may catch fire so do not use them q Put greasy rags and other flammable materials into a safe container to maintain safety at the work place q Do not weld or use a cutting torch to cut 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...

Page 42: ...carrying out demolition or breaker operations install a front guard and use a laminated coating sheet on the front glass q When working in mines or quarries where there is a hazard of falling rock install FOPS Falling Objects Protective Structure and a front guard and use a laminated coating sheet on the front glass q When carrying out the above operations always close the front window In addition...

Page 43: ...als such as thatched roofs dry leaves or dry grass there is a hazard 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 operate 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 a...

Page 44: ...l it has been confirmed that the electricity has been shut off Also do not let anyone near the machine ENSURE GOOD VISIBILITY This machine is equipped with mirrors to improve the visibility but even with mirrors there are places which can not be seen from the operator s seat so always be careful when operating When operating or traveling in places with poor visibility if it is impossible to confir...

Page 45: ...for some reason the cab door does not open use the rear window as an emergency escape For details see EMERGENCY EXIT FROM OPERATOR S CAB 3 49 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 followi...

Page 46: ...sy to carry out operations and check that there is no dam age or wear to the seat belt or mounting clamps q Check the operation of the instruments and gauges check the angle of the mirror and check that the control levers are all at the Neutral position q Before starting the engine make sure that the lock lever is in the LOCK position q Adjust the mirrors so that the rear of the machine can be see...

Page 47: ... replace it immediately with the correct control pattern card q Check the operation of the work equipment traval system and swing system q Check for any problem in the sound of the machine vibration heat smell or gauges check also that there is no leakage of oil or fuel q If any problem is found carry out repairs immediately SAFETY RULES FOR CHANGING MACHINE DIRECTIONS q Always operate the machine...

Page 48: ...e its bal ance or may damage the machine or structures in the area q When traveling on rough ground or steep slopes if the machine is equipped with auto deceleration always turn the auto deceleration switch OFF cancel q Avoid traveling over obstacles when possible If the machine has to travel over an obstacle keep the work equipment close to the ground and travel at low speed Never travel over obs...

Page 49: ...eling q When traveling up a steep slope extend the work equip ment to the front to improve the balance keep the work equipment approximately 20 to 30 cm above the ground and travel at low speed q When traveling downhill lower the engine speed keep the travel lever close to the neutral position and travel at low speed q Always travel straight up or down a slope Traveling at an angle or across the s...

Page 50: ...is dangerous and may cause the machine to tip over q If the machine has to be used on a slope pile the soil to make a platform A that will keep the machine as horizon tal as possible PROHIBITED OPERATIONS q Never dig the work face under an overhang There is a hazard that rocks may fall or that the overhang may col lapse and fall on top of the machine q Do not excavate too deeply under the front of...

Page 51: ...work equipment or a hazard of serious personal injury being caused by flying pieces of broken materials or of the machine tipping over due to reaction from the impact q Generally speaking the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear q When using a breaker or other heavy work equipment there is a hazard of the machine losing its ...

Page 52: ...re buried in the snow and cannot be seen There is a hazard of the machine tipping over or hitting covered objects so always carry out opera tions carefully PARKING MACHINE q Park the machine on firm level ground q Select a place where there is no hazard of falling rocks or landslides or of flooding if the land is low q Lower the work equipment completely to the ground q When leaving the machine se...

Page 53: ...erate any lever except for the travel lever 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 ...

Page 54: ...a 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 othe...

Page 55: ...ys wear safety glasses and rubber gloves when start ing the engine with booster cables q When connecting a normal machine to a problem machine with booster cables always use a normal machine with the same battery voltage as the problem machine q For details of the starting procedure when using booster cables see Starting Engine with Booster Cables 3 148 in the OPERATION section TOWING 2 SAFETY RUL...

Page 56: ...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 57: ...EEP 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 claen and tidy there is the danger that you will trip slip or fall over and injure your self q When cleaning th...

Page 58: ...r 1 to the LOCK position L q Put blocks under the track to prevent the machine from moving 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 running carry out the operation with at least two workers and do as follows q One worker must always sit in the operator s seat and be r...

Page 59: ...gs is charged with high pres sure nitrogen gas When handling the accumulator careless procedure may cause an explosion which could lead to serious injury or property damage For this reason always observe the following precautions q Do not disassemble the accumulator q Do not bring it near flame or dispose of it in fire q Do not make holes in it weld it or use a cutting torch q Do not hit or roll t...

Page 60: ...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 61: ...e recoils spring assembly It contains a spring under high pressure which serves as a shock absorber for the idler If it is disassembled by mistake the spring will 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 replaci...

Page 62: ...m high pressure hoses it may cause fire or defective operation which may lead to serious injury If any loose bolts are found stop work and tighten to the specified torque If any damaged hoses are found stop operations immediately and contact your Komatsu distributor Replace the hose if any of the following problems are found q Damaged or leaking hydraulic fitting q Frayed or cut covering or expose...

Page 63: ...d by flying particles q When using compressed air to clean elements or the radiator always wear safety glasses dust mask gloves and other protective equipment PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS q For using the machine safely for an extended period of time replace safety critical parts like hoses and seat belts periodically Replacement of safety critical parts See SAFETY CRITICAL PARTS 4...

Page 64: ...SAFETY MAINTENANCE INFORMATION SAFETY 2 40 ...

Page 65: ...OPERATION 13 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 66: ...INE VIEW ILLUSTRATIONS 3 OVERALL MACHINE VIEW 3 1 Bucket 8 Sprocket 2 Bucket link 9 Track frame 3 Bucket cylinder 10 Track shoe 4 Arm 11 Idler 5 Arm cylinder 12 OPG Operator Protection Guard This is an option for the PC800 8 6 Boom 7 Boom cylinder ...

Page 67: ...d 14 Fuel control dial 3 Large capacity airflow air conditioner blower switch if equipped 15 Lamp switch 16 Swing lock switch 4 Air conditioner control switch 17 Machine push up switch 5 lock lever 18 Boom shockless control switch 6 Left work equipment control 19 Swing holding brake release switch 7 Travel pedals 20 Pump drive emergency switch 8 Travel levers 21 Step light switch 9 Cigarette light...

Page 68: ...ature monitor 21 Window washer switch 7 Engine oil pressure monitor 22 Windshield Wiper switch 8 Engine water temperature gauge 23 Maintenance switch 9 Charge level monitor 24 Travel speed selection switch 10 Radiator coolant level monitor 25 Auto deceleration switch 11 Working mode monitor 26 Hydraulic oil temperature monitor 12 Service meter 27 Hydraulic oil temperature gauge 13 Travel speed mon...

Page 69: ...le operations correctly and safely it is important to completely understand methods of operating the equipment and the meanings of the displays MONITORING SYSTEM 3 AA Screen with all lamps lighted up BB Screen for normal CC Maintenance time warning screen A Emergency monitors D Meter display portion B Caution monitors E Monitor switches portion C Basic check monitors ...

Page 70: ...terval warning screen CC warning screen FF or error screen EE q After displaying the check before starting screen DD for 2 seconds the screen changes to the maintenance interval warning screen CC q After displaying the maintenance interval warning screen CC for 30 seconds the screen returns to the normal screen BB q After displaying the check before starting screen DD for 2 seconds the screen chan...

Page 71: ...ality Occurs During Operation q If any abnormality occurs during operation the normal screen BB changes to warning screen FF 1 or the error screen EE q After displaying warning screen FF 1 for 2 seconds the screen automatically changes to warning screen FF 2 ...

Page 72: ... lights up When normal When abnormal At low temperature 1 Engine coolant temperature monitor Green Red White 2 Hydraulic oil temperature monitor Green Red White 3 Fuel level monitor Green Red 4 Radiator coolant level monitor OFF Red 5 Charge monitor OFF Red 6 Engine oil pressure monitor OFF Red 7 Engine oil level monitor OFF Red 8 Air cleaner clogging monitor OFF Red 9 Maintenance interval monitor...

Page 73: ...rform action immediately Engine Coolant Temperature Monitor Monitor 1 warns operator that the engine coolant temperature has risen If engine coolant temperature becomes abnormally high moni tor lights up red overheat prevention system is automatically actuated and the engine speed goes down Stop operations and run engine at low idle until monitor 1 changes to green Check for clogging of the radiat...

Page 74: ...e radiator grill or any other problem that will cause overheating Engine Oil Pressure Monitor Monitor 3 lights up red if the engine lubrication oil pressure goes below normal level If monitor lights up red stop the engine immediately check the lubrication system and level of oil in the engine oil pan REMARK While the starting switch is ON the lamp will remain lit and will go off once the engine is...

Page 75: ... Monitor 1 warns the operator of an abnormality in the charg ing system while the engine is running If the battery is not being charged properly while the engine is running monitor 1 lights up red If monitor lights up red check the V belt for looseness If any abnormality is found perform the necessary actions For details see OTHER TROUBLE 3 150 REMARK While the starting switch is ON the lamp will ...

Page 76: ... cleaner For details see CHECK CLEAN AND REPLACE AIR CLEANER ELEMENT 4 19 REMARK While the starting switch is ON the lamp will remain lit and will go off once the engine is started Engine Coolant Temperature Monitor If monitor 4 lights up white in low temperatures perform warming up operation For details see Engine Warm Up 3 95 Continue warming up operation until monitor 4 changes to green Hydraul...

Page 77: ... be checked before starting the engine If there is any abnormality monitor for the location of abnormality will light up Radiator Coolant Level Monitor Monitor 1 warns the operator that there has been a drop in the radiator coolant level If the radiator coolant is low the lamp lights up red so check coolant level in the radiator and subtank and add coolant REMARK While the starting switch is ON th...

Page 78: ... lit and will go off once the engine is started Maintenance Interval Monitor Monitor 3 lights up to warn the operator that the set time has passed since maintenance was last performed This monitor screen goes out after 30 seconds and returns to the normal screen q For details of the method of checking the maintenance interval see Maintenance Switch 3 24 in the Detailed controls and gauges If it is...

Page 79: ...n the ambient temperature is low and the starting switch is set to the ON position the lamp lights up and when the preheating is completed it goes out The preheating time differs according to the ambient tempera ture Pilot display Gauges and Meter 1 Engine pre heating monitor 7 Engine coolant temperature gauge 2 Swing lock monitor 8 Fuel gauge 3 Wiper monitor 9 Hydraulic oil temperature gauge 4 Au...

Page 80: ...ed as follows When ON lights up Wiper moves continuously When INT lights up Wiper moves intermittently OFF Wiper stops Auto deceleration Monitor Monitor 4 shows if the auto deceleration is being actuated The monitor display when auto deceleration switch is operated as follows Auto deceleration monitor ON Auto deceleration actuated Auto deceleration monitor OFF Auto deceleration canceled Working Mo...

Page 81: ...ing operations the overheat prevention system is actuated A B Red range A C Black range The overheat prevention system acts as follows Red range position A Engine water temperature monitor D lights up red Red range position B Engine speed is reduced to low idling engine water temperature monitor D lights up red and the alarm buzzer sounds at same time The overheat prevention system remains actuate...

Page 82: ...switch is turned ON but this is not an abnormality Hydraulic Oil Temperature Gauge Meter 9 displays the hydraulic oil temperature During operations the indicator should be in the black range A to C If the indicator enters red range A during operations the hydraulic oil temperature as gone above 102 C Stop the engine or run it at low idle and wait for the hydraulic oil temperature to go down REMARK...

Page 83: ... The service meter advances by 1 for every hour of operation regardless of the engine speed Monitor Switches Portion 3 1 Working mode selector switch basic switch 8 Back switch 2 Auto deceleration switch selection switch 9 Up switch 3 Travel speed selector switch selection switch 10 Down switch 4 Wiper switch 11 Input confirmation switch 5 Window washer switch 12 Adjusting brightness and contrast ...

Page 84: ... on the monitor display portion 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 option setting have your Komatsu distributor change the setting REMARK When the mode selector switch is pressed the mode is dis played in the center of monitor display portion GG and the screen returns to normal screen BB after 2 seconds Dia gram on ...

Page 85: ...ch Selection Switch WARNING q When loading or unloading from a trailer always travel at low speed with travel speed selector switch 3 at the Lo position Never operate travel speed selector switch 3 while loading or unloading 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 b...

Page 86: ...ion GG and the screen returns to normal screen BB after 2 seconds Wiper Switch Switch 4 operates the wiper for the front glass Each time the switch is pressed it changes ON INT stop OFF Monitor display portion GG INT lighted up Wiper moves intermittently Monitor display portion GG ON lighted up Wiper moves continuously Monitor display portion GG OFF Wiper stops ...

Page 87: ...ased the spray stops q If switch 5 is kept pressed when the wiper is stopped the window washer fluid will spray out and at the same time the wiper will be actuated continuously When switch 5 is released the wiper will continue to operate for 2 cycles then stop q If the wiper is moving intermittenly and switch 5 is kept pressed continuously window washer fluid will spray out and at the same time th...

Page 88: ... confirming the mainte nance time perform the maintenance White display More than 30 hours remaining until mainte nance Yellow display Less than 30 hours remaining until mainte nance Red display Maintenance time has already passed NOTICE 1 If monitor display portion GG changes to the mainte nance timing warning screen when the engine is started or when the machine is being operated stop operations...

Page 89: ...tor item press input confirmation switch 11 Display screen will switch to the time remaining until maintenance Press back switch 8 to return to the previous screen Monitor No Maintenance item Default set screen H 01 Change engine oil 500 02 Replace engine oil filter 500 03 Replace fuel main filter 1000 41 Replace fuel pre filter 500 04 Replace hydraulic oil filter 1000 05 Replace hydraulic tank br...

Page 90: ...onfirma tion switch 11 The screen will switch 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 User Mode Adjustment Switch Press this switch 7 to set to fan reverse rotation and to adjust the set value for the economy mode Fan...

Page 91: ... the fan rotation is being changed the screen changes to the waiting screen The engine is automatically set to low idling and after approx 15 seconds the fan rotates in reverse After another approx 4 seconds the engine speed returns to normal NOTICE q The fan rotation speed is proportional to the engine speed When the engine is running at low idling the fan also rotates at minimum speed If it is d...

Page 92: ...just ment switch 7 9 When changing the fan rotation direction from reverse direction to the normal direction press input confirmation switch 11 Press Back switch 8 to return to the previous screen 10 When the fan rotation is being changed the screen changes to the waiting screen The engine is automatically set to low idling and after approx 15 seconds the fan rotates in the normal direction After ...

Page 93: ...reverse the work equipment makes almost no movement even when the levers are operated Rotating the fan in reverse is intended for use in cleaning the radiator so when carrying out operations and moving the work equipment switch the fan to the normal direction of rotation before starting operations Adjusting Set Value of Economy Mode 1 Press switch 7 and the monitor display screen changes to the fa...

Page 94: ...etails of productivity in each mode see Setting Econ omy Mode 3 114 REMARK The closer the selection is made to E3 the better the fuel con sumption becomes but the production is reduced accordingly Back Switch Press 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 display Up Switch Down Switch Press...

Page 95: ...justment Switch Press switch 12 to adjust the brightness or contrast of the dis play monitor Adjusting Brightness 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 2 Use the brightness contrast screen and press up switch 9 or down switch 10 to select brightness of the monitor The selected monitor is...

Page 96: ...e diagram on the right 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 con firmation switch 11 REMARK When the machine is...

Page 97: ...OPERATION DETAILED CONTROLS AND GAUGES 3 33 Alarm Buzzer Stop Switch Use this switch 13 to stop the alarm buzzer when it is sound ing during operation to indicate an abnormality in the warning item ...

Page 98: ...position This is the engine start position Keep the key at this position during cranking Immediately after starting the engine release the key It will automatically return to the ON position B 1 Starting switch 10 Emergency pump drive switch 2 Fuel control dial 11 Swing brake cancel switch 3 Cigarette lighter 12 Rotating lamp switch if equippedÅj 4 Lamp switch 13 Large capacity airflow air conditi...

Page 99: ...efore MAX but this does not indicate any abnormal ity Cigarette Lighter Lighter 3 is used to light cigarettes To use push the lighter in After a few seconds it will spring back Pull out the lighter and light your cigarette By removing the cigarette lighter the socket is available as a power source for the yellow flashing lamp Max current is 85 W 24V x 3 5 A Lamp Switch Switch 4 is used to turn on ...

Page 100: ...is operated in the downhill direction Switch 5 is used to lock the upper structure so it cannot swing a ON position actuated The swing lock is always applied and the upper structure will not swing even if the swing is oper ated In this condition the swing lock lamp lights up b OFF position canceled The swing lock is applied only when all the work equipment control levers are in neutral when any wo...

Page 101: ...ng The boom thrust force becomes more powerful so it is easy to twist and swing or escape from soft ground It is effective in performing digging operations using the bucket and weight of the machine in confined areas Boom Shockless Control Switch Switch 7 controls the shaking of work equipment when the boom is stopped Effect q The shaking and spillage of load from the bucket is reduced q Operator ...

Page 102: ...rm work for a short time when there is a failure in the pump control system It is necessary to repair the abnormal location as soon as possible This switch 10 makes it possible to do the work temporarily or start up the engine when there is something wrong with the network i e when the display shows E0E and with the pump control system i e when the display shows E07 a Emergency In abnormality Swit...

Page 103: ...temporarily perform operations should any abnormality occur in the swing brake system when monitor display shows E03 a Release Position for abnormality switch moved up b Normal Normal position switch moved down q When the monitor display is E03 move this switch up to make it possible to perform operations q When this switch is set to release position a the swing lock monitor flashes Rotating Lamp ...

Page 104: ... wiper turn switch 13 OFF When the wiper is under continuous operation at the ON posi tion if 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 moni tor the lower wiper both INT and ON and wiper will be actu ated in turn Step Light Switch Use...

Page 105: ...quipment 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 the lever 1 down to apply the lock This lock lever 1 is a hydraulic lock 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 swing ...

Page 106: ...the left and right directions will also be reversed q When operating the travel 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 This lever 2 is used to change the direction of travel between forward and reverse shows the pedal operation a FORWARD The lever is pushed forward The pedal is angled forward b REVERSE The ...

Page 107: ...re at the neutral position even if the fuel control dial is above midrange speed the engine speed will go down to a midrange speed If one of these levers is operated the engine speed will rise to the speed set by the fuel control dial If all the control levers are at the neutral position the engine speed goes down approx 100 rpm then after approx 4 seconds the engine speed goes down to the deceler...

Page 108: ...dow bottom window or door always set the lock lever 1 in the LOCK position L If the control levers are not locked and they are touched by accident this may lead to a serious acci dent q When opening or closing the window at the front of the cab stop the machine on horizontal ground lower the work equipment completely to the ground stop the engine then carry out the operation q When opening the fro...

Page 109: ...ground then stop the engine 2 Set the lock lever securely in the LOCK position L 3 Check that the wiper blade is stowed in the right stay 4 Grip handles A at the top right and left of the front win dow and pull lock lever B toward yourself to release the lock at the top of the front window The top of the front win dow will come out ...

Page 110: ...catch E at the rear of the cab securely to lock the window 6 Check that lock lever B is securely in 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 posi tion of the arrow on lock lever B the lock is not engaged Repeat the operation in Step 5 to engage the lock ...

Page 111: ...level ground lower the work equipment completely to the ground then stop the engine 2 Set the lock lever securely in the LOCK position L 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 112: ...the position of the arrow on lock lever B Check visually q If the arrow on lock case F does not match the posi tion 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 113: ...or 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 door in position after opening it 1 Push the door against catch 1 to lock it in position 2 To release the lock press knob 2 down at the left side of the operat...

Page 114: ...ting switch key counterclockwise align counter mark 3 on the cap with the groove of the rotor then turn the cap slowly until a click is heard This releases the lock and the cap can be opened Locking the Cap 1 Turn the cap until tight then insert the key into the key slot 2 Turn the key counterclockwise but for the B type turn clockwise and take the key out Opening and Closing Cover with Lock Openi...

Page 115: ...on ing is used MAGAZINE BOX 3 The cup holder is provided separately at the front of the magazine box Located on left side of the operator s seat Keep the Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary ASHTRAY 3 This is under the machine monitor at the front right of the oper ator s compartment Always make sure that you extinguish your cigarette...

Page 116: ... display on display monitor 7 the lamps above auto switch 5 and air conditioner 8 go out and opera tion stops REMARK When switch 1 is turned to the OFF position the lamp above FRESH RECIRC selector switch 6 does not go out but this is not a problem 1 OFF switch 6 FRESH RECIRC selector switch 2 Fan switch 7 Display monitor 3 Temperature control switch 8 Air conditioner switch 4 Vent selector switch...

Page 117: ...nitor display and air flow A Liquid crystal dispiay B Air flow a Air flow low b Air flow medium 1 c Air flow medium 2 d Air flow medium 3 e Air flow medium 4 f Air flow high Temperature Control Switch Switch 3 is used to control temperature inside the cab The temperature can be set between 18 C and 32 C q Press the switch to raise the set temperature press the switch to lower the set temperature q...

Page 118: ...ent 1 place D Front window glass vent 2 place B2 Front window glass vent 1 place Note 1 Air blows from vents marked O Monitor display C Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to set temperature 32 0 Max heating Liqiud crystal display Vent mode Vent Remarks A B C D Front vents O Cannot be selected for auto matic operation Front and rear vents O O Front rear and...

Page 119: ...e air flow is always set to High but this is not a problem FRESH RECIRC Selector Switch Switch 6 is used to switch the air source between recircula tion of air inside the cab and intake of from the outside q When switch 6 is pressed the lamp above 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 ...

Page 120: ...and the air conditioner stops q Air conditioner cannot be operated while the fan is off Sunlight Sensor This sensor 9 automatically adjusts the flow of air from the vents to match the strength of the sun s rays In addition it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun s rays before hand and automatically adjusts the temperature Meth...

Page 121: ... and the air conditioner is oper ated automatically to provide the set temperature REMARK When vent display monitor c displays d or e and engine coolant temperature is low the air flow is automatically limited to prevent cold air from blowing out Stopping Automatic Operation Press OFF switch 1 The displays for temperature setting a and air flow b on monitor 7 and lamps above auto switch 5 and air ...

Page 122: ...and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Turn air conditioner switch 8 ON Check that the lamp above air conditioner switch lights up 3 Press temperature setting switch 3 and adjust tempera ture inside the cab ...

Page 123: ...hanges according to the selection 5 Press RECIRC FRESH selector switch 6 and select recir culation 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 monitor 7 and lamps above auto switch 5 and air conditioner switch 8 go out the operation stops ...

Page 124: ...r flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 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 above air conditioner switch lights up 4 Adjust fan switch 2 temperature setting switch 3 and RECIRC FRESH selector swi...

Page 125: ...st the air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display on the display monitor to f or g as shown in diagram on the right 3 Press RECIRC FRESH selector switch 6 and set it to take in fresh air ...

Page 126: ...unning at high speed It will cause failure of the air conditioner q If water gets into the control panel or sunlight sensor it may lead to unexpected failure be careful not to let water get on these parts In addition never bring any flame near these parts q For the auto function of the air conditioner to work properly always keep the sunlight sensor clean and do not leave anything around the sunli...

Page 127: ...ONDITIONER COMPRESSOR BELT TENSION ADJUST 4 48 CLEAN FRESH RECIRC AIR FILTERS OF AIR CONDITIONER ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER 4 53 and carry out inspection according to the table Other Functions 3 Self diagnostic Function It is possible to perform troubleshooting of various sensors and equipment used on the air conditioner 1 Turn the starting switch key to the ON B position 2 Pr...

Page 128: ...d Celsius It is possible 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 Display Failure mode E No failure E11 Disconnection in RECIRC sensor E12 Short circuit in RECIRC sensor...

Page 129: ... and store the antenna at position A 2 Tighten bolt 1 Use Radio with Care 3 q To ensure safety always keep the sound to a level where it is possible to hear outside sounds during opera tion q If water gets into the speaker case or radio it may lead to an unexpected failure so be careful not to get water on the equipment q Do not wipe the scales or buttons with benzene thinner or any other solvent ...

Page 130: ...UXILIARY ELECTRIC POWER 3 24V power source 3 NOTICE Do not use this as the power source for 12 V equipment Pull out the connector plug for taking out electric power from the rear side of the panel Maximum usable electric power is 85 W 24 V x 3 5 A ...

Page 131: ...OPERATION DETAILED CONTROLS AND GAUGES 3 67 12V power source 3 if equipped This power source can be used up to a capacity of 60W 12V x 5A ...

Page 132: ...ames NO Fuse Capacity Circuit Name 1 10A Redundancy Swing holding brake solenoid 2 10A Solenoid valve 3 10A PPC lock solenoid Starting motor cut out relay 4 20A Window washer Cigarette lighter 5 10A Horn flashlight OPT 6 10A Ribbon heater relay 7 10A Revolving warning lamp OPT 8 10A Overload caution 9 10A Left knob switch 10 20A Monitors Buzzer 11 25A Air conditioner unit 12 10A Lower wiper 13 20A...

Page 133: ... circuit breaker is a circuit protection device installed to cir cuits where large current flows It protects the electrical com ponents 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 start...

Page 134: ... there is no problem if rain gets on it but do not spray it with water when washing the machine q If any abnormality occurs in the controller do not disassemble it yourself Contact your Komatsu dis tributor for repairs q Engine controller Open the engine hood It is under the engine oil filter q Pump controller This is on the right side at the rear of the operator s seat TOOL BOX 3 Cloth bag This i...

Page 135: ...ide of the chassis Method of Use 3 1 When the engine is started and the power switch 1 and remote switch 2 are turned to the ON position pump 3 is actuated and grease is sent under pressure to grease gun 4 2 When the lever of grease gun 4 is pulled it is set to the greasing condition and grease is discharged ON OFF ...

Page 136: ...ch 2 to prevent pressure from building up inside grease gun 1 q Set so the nipple and nozzle at the tip of grease gun are perpendicular q When removing the nozzle at tip of the grease gun from the nipple carefully angle the tip of nozzle slightly and remove it q When there is only a small amount of grease left in the grease can the pump will not pump out grease so move grease to the center or fill...

Page 137: ...y to hold in position 6 After fitting grease pump holder bracket 1 into the head of the grease pump install with 2 bolts 2 q The pump will operate for a short time and then stop but the first grease includes air inside the pump so it is cloudy white and not suitable for use 7 Loosen check valve 7 and pump out all the grease which has air in it from hole a at the bottom of check valve 7 8 After ble...

Page 138: ...DETAILED CONTROLS AND GAUGES OPERATION 3 74 REMARK Keep spare grease in grease can storage location in the grease pump chamber ...

Page 139: ...uit can be oper ated for a short time even after the engine is stopped There fore if the control lever is moved in the direction to lower the work equipment it is possible for the work equipment to move under its own weight The accumulator is installed to the position shown in the dia gram on the right RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN ACCUMULATOR 1 Place the w...

Page 140: ...linkage hoses Check for cracks excessive wear play in wotk equipment cylinders linkage and hoses If any problem is found repair it 2 Remove dirt and debris from around the engine battery and radiator Check for dirt accumulated around the engine and radiator Also check for flammable material dry leaves twigs etc around the battery engine muffler turbocharger or other high temperature engine parts I...

Page 141: ... Add Coolant WARNING q Do not open the radiator cap unless necessary Wait for the engine to cool down before checking the coolant in the sub tank q Immediately after the engine is stopped the coolant is at a high temperature and the radiator is under high internal pressure If the cap is removed to check the coolant level in this condition there is a hazard of burns Wait for the temperature to go d...

Page 142: ...ls of the procedure in cold weather see COLD WEATHER OPERATION 3 137 Check Oil Level in Engine Oil Pan Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns Wait for the oil temperature to go down before performing this operation 1 Open the front cover in the center of the engine hood 2 Remove dipstick G and wipe the oil off with ...

Page 143: ...t up com pletely Never bring flames near fuel because it is highly flammable and dangerous 1 Open fuel filler cap F of the fuel tank 2 When fuel filler cap F is opened float gauge G comes up in proportion to the remaining fuel level in the tank Check that the fuel tank is full Inspect the fuel level both visually and with float gauge G 3 If fuel is found to be low unscrew fuel filler cap F on the ...

Page 144: ...e fuel pre filter 1 Open up the front left side cover of the engine hood 2 It is possible to judge the water level and amount of sedi ment by looking through transparent cap 2 If there is any water or sediment collected at the bottom set a container to catch the drain water under drain hose 3 3 Loosen drain valve 1 and drain the water 4 When fuel comes out from drain hose 3 tighten drain valve 1 i...

Page 145: ...ck sight gauge G The oil level should be between the H and L marks 5 If the level is below the L mark add oil through oil filler F at the top of the hydraulic tank REMARK The oil level will vary depending upon the oil temperature Accordingly use the following as a guide Before starting operation Between H and L levels Oil temperature 10 to 30 C Normal operation Around H level Oil temperature 50 to...

Page 146: ... a cloth 2 Fully insert dipstick G into the filler pipe A Front Swing machinery at front of machine Swing machinery at rear of machine 3 When dipstick G is pulled out if oil level is between the H and L marks of the gauge oil level is proper 4 If oil does not reach the L mark on dipstick G add oil through the filler pipe F 5 If oil is above the H mark on the oil level gauge loosen drain plug P and...

Page 147: ...arts and oil are at high temperature immediately after the engine is stopped and may cause serious burns Wait for the oil temperature to go down before performing this operation NOTICE Park the machine on flat ground and stop the engine After waiting for more than 30 minutes after stop ping the engine check the oil level 1 Open up the front left side cover of the engine hood and check the oil leve...

Page 148: ...e of the battery clean and check the breather hole in the battery cap If it is clogged with dirt or dust wash the battery cap to clean the breather hole Check for 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 wiring Also check for loose terminals and tighten any loose termi nals found Be sure to ...

Page 149: ...seat is moved backward So return the seat to its upright position before moving the seat to the rear Pull up lever 2 and set the backrest to a position that is com fortable for operation then release the lever Sit with your back against the seat backrest when adjusting If your back is not against the backrest the backrest may sud denly move forward C Adjusting seat tilt q Forward tilt Push lever 3...

Page 150: ...seat back is tipped to the front armrest 5 cannot be adjusted by turning dial 6 When adjusting the angle of armrest 5 set the seat back to a position where it is easy to carry out operations then adjust the armrest E Overall fore and aft adjustment of seat Move lever 7 to right set to the desired position then release the lever In this case the operator s seat left and right control levers and loc...

Page 151: ...ust the mirror mount so that it is possible to see any person or object of height 1 m and diameter 30 cm 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 position X1 220mm X2 75mm X3 100mm Range of view Y right side 2000mm Range of view Z left side 3700mm Range of ...

Page 152: ...ear the seat belt during operations q Fit the seat belt so that it is not twisted Fastening and Removing This seat belt has a wind in device so it is not necessary to adjust the length Fastening Seat Belt Hold grip 2 and pull the belt out from wind in 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 pr...

Page 153: ...pedal are touched when the engine is started the machine may move unexpectedly and this may lead to serious personal injury 1 Check that lock lever 1 is at the LOCK position L 2 Check that each control lever and control pedal is at the Neutral position If the control levers and control pedal are not being touched they will be at the Neutral position 3 Insert key into starting switch 2 turn the key...

Page 154: ...level monitor 5 q Charge level monitor 6 q Fuel level monitor 7 q Engine coolant temperature monitor 8 q Engine oil pressure monitor 9 q Engine coolant temperature gauge 10 q Fuel gauge 11 q Air cleaner clogging monitor 12 If the monitors do not light up or the buzzer does not sound there is probably a failure in the monitor so contact your Komatsu distributor for repairs 2 After approx 3 seconds ...

Page 155: ...tely for the item which is lighted up red 4 If there are any items where the maintenance time has passed maintenance interval monitor 16 lights up for 30 seconds Press maintenance switch 17 check the item then perform maintenance immediately For details of the method of checking the maintenance interval see Maintenance Switch 3 24 in the Detailed controls and gauges ...

Page 156: ...ed MAX position the engine will accelerate suddenly and cause damage to the engine parts q Do not keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes then start again from the beginning q After the engine starts wait for the engine oil pressure monitor to go out Do not touch the control levers or con...

Page 157: ...ble on the right 4 If the preheating monitor does not light up or it lights up and then goes out to inform that the engine preheating has been completed turn the key in starting switch 3 to the START position C and start the engine REMARK If the ambient temperature is low the engine may not start even when the key in the starting switch 3 is kept at the START position for 20 seconds If this happen...

Page 158: ...on 2 The preheating monitor starts lighting about 30 seconds after preheating starts and then goes off in about 10 seconds 3 After the preheating monitor goes off turn the key in starting switch 3 to START position C The engine will start If the engine cannot be started with the above procedure wait for at least two minutes then start again from Step 1 REMARK The relationship between the turbochar...

Page 159: ...operation for the hydraulic equipment separately from the warm up operation for the engine Warm up the hydrau lic equipment thoroughly ensures that the hydraulic oil is warmed up and that warm hydraulic oil circulates in all the control circuits Engine Warm Up 3 NOTICE q Do not accelerate the engine suddenly until the warm up operation has been completed q Do not run the engine at low idling or hi...

Page 160: ...onitor 1 displays green If the engine water temperature monitor displays green the engine warm up operation is completed After checking that the engine water temperature monitor displays green carry out the warming up operation for the hydraulic equipment NOTICE Canceling automatic warm up operation If it becomes necessary in an emergency to cancel the automatic warm up operation or to lower the e...

Page 161: ...lays green q The warm up operation for the hydraulic equipment is necessary not only for the circuit between the pump and cylinders and between the pump and motor but also for all the control circuits Do not carry out the operation just for one cylinder or motor or the operation just in one direction Carry out the operation in both directions for the work equipment boom arm bucket swing travel and...

Page 162: ... or ground 6 Move right work equipment control lever 5 slowly in the direction to pull in the bucket D Operate the lever to the end of its travel and hold it in position for 30 seconds 7 Move right work equipment control lever 5 slowly in the direction to push out the bucket C Operate the lever to the end of its travel and hold it in position for 30 seconds 8 Next move left work equipment control ...

Page 163: ...he machine monitor our in the following status q Radiator coolant level monitor 8 OFF q Charge level monitor 9 OFF q Engine oil pressure monitor 10 ON q Engine oil level monitor 11 OFF q Air cleaner clogging monitor 12 OFF q Engine pre heating lamp 13 OFF q Engine water temperature gauge 14 Indicator in green range q Engine water temperature monitor 1 Green display q Hydraulic oil temperature gaug...

Page 164: ...until hydraulic oil temperature monitor 7 displays green For both normal temperatures and cold temperatures carry out the following operation 16 Check that fuel control dial 4 is at a point midway between low idling MIN and full speed MAX If it is not at the midway position set it to the midway posi tion and run the engine at a mid range speed before oper ating 17 Before starting operations repeat...

Page 165: ...on Left G Right H q Travel Lo operation FORWARD A REVERSE B 18 Check that hydraulic oil temperature monitor 7 is display ing green If the hydraulic oil temperature monitor is not displaying green it is displaying white repeat Steps 6 to 10 until the display is green If the hydraulic oil temperature monitor displays green the hydraulic equipment warm up operation is completed After confirming that ...

Page 166: ... Operation 3 1 Check that hydraulic oil temperature monitor 7 displays green 2 Push working mode selector switch 19 of the machine monitor to select the working mode to be used For details of the procedure for selecting the working mode see Working Mode Selector Switch Basic Switch 3 20 ...

Page 167: ...or display 1 P mode For heavy duty operations 2 E mode For operations with emphasis on fuel economy 3 Heavy duty lift Boom lifting power increased when raising boom indepen dently 4 Swing priority mode Priority given to swing when operating boom and swing simultaneously ...

Page 168: ...d Do not stop the engine abruptly except in an emergency If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Run the engine at low idle 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 Remove the key from starting switch 1 ...

Page 169: ...horn q Do not allow anyone to enter the area around the machine q Clear any obstacles from the travel path q There is a blind spot at the rear of the machine so be particularly careful when traveling in reverse q If the control lever is operated when the auto deceleration is being actuated the engine speed will suddenly rise so be careful when operating q Before starting the machine off check that...

Page 170: ...f the pedals 6 to move the machine forward q When sprocket A is at the front of the machine Slowly pull the levers 5 backward or slowly depress the rear part of the pedals 6 to move the machine forward 3 Check that the travel alarm sounds properly If the travel alarm does not sound please contact your Komatsu distributor for repair REMARK In cold temperatures if the machine travel speed is not nor...

Page 171: ...6 as follows q When sprocket A is at the rear of the machine Slowly pull the levers 5 backward or slowly depress the rear part of the pedals 6 to move the machine backward q When sprocket A is at the front of the machine Slowly push the levers 5 forward or slowly depress the front part of the pedals 6 to move the machine backward 3 Check that the travel alarm sounds properly If the travel alarm do...

Page 172: ... OPERATIONS AND CONTROLS OPERATION 3 108 Stopping Machine 3 Avoid stopping suddenly Give yourself ample room when stopping 1 Put the left and right travel levers 1 in the neutral position then stop the machine ...

Page 173: ... levers to change direction Avoid sudden changes of direction as much as possible Espe cially when performing counter rotation spin turn stop the machine 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 trav eling forward and pull it back to turn left when traveling in rever...

Page 174: ...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 175: ...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 176: ...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 if less than 15 seconds has passed since the engine was stopped when the starting switch is turned to the ON position even with the engine stopped it is pos sible to operate the levers to lower work equipment to the ground In ad...

Page 177: ...ONS AND CONTROLS 3 113 q Boom control Move the right work equipment control lever to the front or rear to operate the boom q Bucket control Move the right work equipment control lever to the left or right to operate the bucket ...

Page 178: ...carry out that operation without problem q Work possible can carry out operation with some minor problems U Work possible can carry out operation but there are many problems Work impossible too many problems cannot carry out operation Working mode Applicable operations P mode Normal digging loading operations Operations with emphasis on productivity E mode Normal digging loading operations operati...

Page 179: ...force to compact soil or break objects This is not only dangerous but will also drastically 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 cylinde...

Page 180: ...gging 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 will make for better econ omy Sudden Lever Shifting High Speed Travel 1 Never carry out sudden lever shifting as this may cause sudden starting 2 Avoid sudden lever shiftin...

Page 181: ...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 with the Work Equipment in the Same Posture Precautions when carrying out operations continually with the work equipment in the same posture When oper...

Page 182: ...e a platform A on the slope so the machine is kept horizontal during operation q Do not travel up or down steep slopes There is danger that the machine may turn over q When traveling raise the bucket approx 20 to 30cm from the ground Do not travel downhill in reverse q Never turn on slopes or travel across slopes Always go down to a flat place to perform these opera tions It may be longer but it w...

Page 183: ...is will cause the brake to be automatically applied Engine 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 q If the engine stops when the machine is on a slope never use the left work equipment control lever to carry out swing operations The upper...

Page 184: ...m of the bucket 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 stuck in mud use the bucket to raise the track then lay boards or logs and drive the machine out Tracks on Both Sides Stuck 3 When the tracks on both sides are stuck in mud and they slip making it impossibl...

Page 185: ... 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 operat ing 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 paralle...

Page 186: ...ot under the bucket while standing at the side for the work q When removing or inserting pins be extremely careful not to get 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 lead and follow that person s instructions and signals Replacement 3 1 Place the bucke...

Page 187: ...nd B into hole 1 and hole 2 respectively REMARK Carry out installation in the reverse order to removal When installing bucket 6 it is easy to damage the O ring 7 so fit O ring 7 to bucket 6 in the position shown in diagram on the right After inserting pin fit the O ring correctly in the groove Install the stopper bolts and nuts for each pin then grease the pin Add fresh grease sufficiently until i...

Page 188: ...pe insert 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 machine may move suddenly and this may lead to a serious accident Before leaving the operator s compartment always set the lock lever securely to LOCK position 1 Put left and right travel levers 1 in the neutral position The machine stops 2...

Page 189: ...coolant temperature gauge is in the red range allow it to cool until the indicator enters the black range then stop the engine For details of the inspec tion and action to take see TROUBLES AND ACTIONS 3 143 q If the engine oil pressure monitor lights up stop the engine immediately For details of the inspection and action to take see TROUBLES AND ACTIONS 3 143 6 Stop the engine For details on the ...

Page 190: ...k the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove any mud affixed to the undercarriage LOCKING 3 Always lock the following places 1 Door of operator s cab Always remember to close the window 2 Fuel tank filler port 3 Engine hood 3 places 4 Battery box cover 2 places 5 Left side door of the machine 2 places 6 Tool box side cover 7 Hydraulic...

Page 191: ...gth for the weight of this machine When lifting keep the machine horizontal When carrying out lifting operations set the lock lever to the LOCK position to prevent the machine from moving unexpectedly Never enter the area under or around a raised machine Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting equipment other than in the pro...

Page 192: ...f gravity in the condition shown in the diagram on the right d Distance between centers horizontal measurement 4507mm 3 Combination of wire rope cable length The length of wire rope cable is the length from the pin to center of the hole q When using the following wire rope use wire rope with more length than given in chart below q In addition select a wire rope length that will bring the lifting p...

Page 193: ... Set all the control levers securely at LOCK position L with lock lever 1 2 Stop the engine and pull out the starting switch key 3 Lock the window glass roof window front window opera tor s seat door side cover engine hood and battery box cover securely 4 When transporting the machine place a retangular block under the front and rear track shoes to prevent the machine from moving Furthermore faste...

Page 194: ...n be divided into three or four units for transportation When transporting contact your Komatsu distributor Three Units for Transportation Four Units for Transportation Upper structure undercarriage Work equipment Others Upper structure Undercarriage Work equipment Others ...

Page 195: ...on the work equipment control lever do not start the engine Item Unit PC800 8 PC800LC 8 Overall width mm 3 490 3 490 A1 mm 3 770 3 770 A2 mm B mm 6 840 7 100 Weight kg 46 900 50 600 Item Unit PC800 8 PC800LC 8 Overall width mm 3 195 A1 mm 2 840 A2 mm B mm 5 970 Weight kg 25 600 Item Unit PC800 8 610mm SHOE PC800LC 710mm SHOE Q ty 2 2 A mm 1 305 1 305 B mm 5 810 6 330 C mm 1 445 1 445 Weight kg 11 ...

Page 196: ...A mm 7 430 8 370 B mm 2 465 2 600 Overall width mm 1 500 1 500 Weight kg 6 640 7 488 Item Unit 2 9m 3 6m A mm 4 220 4 900 B mm 1 640 1 310 Overall width mm 753 753 Weight kg 4 450 4 400 Item Unit PC800 8 PC800LC 8 A mm 2 200 2 365 B mm 1 950 1 850 Overall width mm 2 105 1 850 Weight kg 3 420 2 960 Item Unit PC800 PC800LC 8 Q ty 2 A mm 3 235 Weight kg 775 x 2 ...

Page 197: ... for all models Item Unit PC800 8 PC800LC 8 Q ty 2 A mm 2 590 Weight kg 481x2 Item Unit PC800 8 PC800LC 8 OPT A mm 1 530 1 530 B mm 3 195 3 195 C mm 830 830 Weight kg 12 040 12 040 Item Unit PC800 8 PC800LC 8 A mm 1 820 B mm 250 C mm 980 Weight kg 55 Item Unit PC800 PC800LC 8 A mm 1 790 B mm 70 C mm 1 790 Weight kg 81 ...

Page 198: ...models q Catwalk 1 same for all models q Catwalk 2 same for all models Item Unit PC800 PC800LC 8 Q ty 2 A mm 1 175 B mm 315 C mm 995 Weight kg 120x2 Item Unit PC800 PC800LC 8 A mm 3 200 B mm 495 Weight kg 50 Item Unit PC800 PC800LC 8 A mm 1 900 B mm 495 Weight kg 30 ...

Page 199: ...the track frame 3 Set blocks B 20 to 30 cm wooden blocks towards the outside of track frame A then use the boom cylinder 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 Tightening torque 2452 3040 N m 250 310 kgf m 5 Follow the same procedure to retract the tr...

Page 200: ... 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 20 bolts and tighten to specified torque Tightening torque 2452 3040 N m 250 310 kgf m 5 Follow the same procedure to retract the track frame on the other side q Stop the machine on firm level ground when extending or retracting the track fram...

Page 201: ... that has been drained when repairing the radiator please contact your Komatsu distributor or request a specialist company to carry out the operation Antifreeze is toxic Do not let it flow into drainage ditches or spray it onto the ground surface q Antifreeze is flammable Do not bring any flame close Do not smoke when handling antifreeze NOTICE q Use Komatsu Supercoolant AF NAC wherever available ...

Page 202: ...ne can be started easily the next morning REMARK Measure the specific gravity and calculate the charging rate from the following conversion table q As the battery capacity drastically drops in low temperatures cover or remove the battery from the machine store the battery in a warm place and install it again the next morning q If the electrolyte level is low add distilled water in the morning befo...

Page 203: ...OPERATION COLD WEATHER OPERATION 3 139 Brightness Contrast Guideline for bar display for brightness and contrast in cold weather Ambient temperature Brightness Contrast 10 C 7 max 5 4 20 C 7 7 6 ...

Page 204: ...e ground and allow the machine to be moved the next morn ing q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing q Fill the fuel tank to capacity This minimizes moisture condensation in the tank when the temperature drops q After operation in water or mud remove water from undercarriage as described below to extend undercarriage service life 1 Swing ...

Page 205: ...This prevents moisture from collecting q Lubricate and change the oil before storage q Coat the exposed portion of the hydraulic cylinder piston rod with grease q Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it sepa rately q Lock each control lever and pedal with the lock lever and pedal lock q Set the stop valve to the LOCK position on mach...

Page 206: ...hine is equipped with an air conditioner operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner compressor Always run the engine at low idle when doing this In addition check the refrigerant level twice a year AFTER STORAGE 3 NOTICE If the machine has been stored without carrying out the monthly rust prevention operation consult your Komatsu distr...

Page 207: ... off com pletely Be careful when opening the air bleed plug at the fuel filter head The system is still under pressure and fuel may spurt out 1 Loosen air bleed plug A at the fuel main filter head 1 2 Loosen wing nut 4 holding lever 3 of priming pump 2 3 Push in lever 3 repeatedly Check that bubbles come out with the fuel from air bleed plug A 4 Tighten air bleed plug A Tightening torque 4 9 to 6 ...

Page 208: ...q When going down a steep slope at low speed a noise will be emitted from the travel motor brake valve TOWING THE MACHINE 3 WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope Always check that the wire rope used for towing has ample strength for the weight of the machine being towed Never ...

Page 209: ...k frame q When towing a machine travel at a speed of less than 1 km h for a distance of only a few meters to a place that is suitable for carrying out repairs This is for use only in emergencies 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 ope...

Page 210: ...en removing the battery first disconnect the cable from the ground normally the negative terminal When installing 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 defective contact may generate sparks that will cause an explosion q When...

Page 211: ...he charger to the positive terminal of the battery then connect the negative charger clip of the charger to the negative terminal of the battery Be sure to attach 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...

Page 212: ...ot as far away from the battery as possi ble 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 NOTICE q The starting system for this machine uses 24V For the normal machine also use a 24V battery q The size of the booster cable and clip shoul...

Page 213: ...at the HOLD or neutral position 1 Make sure the clips are firmly connected to the battery terminals 2 Start engine of the normal machine and run it at high idle 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 after 2 minutes or so Booster Cable Disconnection After the engine has started disconnect boo...

Page 214: ... Starting switch is turned 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 215: ...e Clogged element in hydraulic tank strainer Loose suction hose Lack of hydraulic oil Clean see EVERY 2000 HOURS SERVICE Retighten Add oil to specified Excessive rise in hydraulic oil tem perature Dirty oil cooler Lack of hydraulic oil 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 WHEN REQUIRED Abnorm...

Page 216: ...leakage CHECK BEFORE STARTING Check fan belt tension see EVERY 500 HOURS SERVICE Replace water level sensor Change coolant 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 coolant level monitor lights up Engine w...

Page 217: ...r liner Defective compression Defective turbocharger Defective injector Clean or replace See WHEN REQUIRED Check repair See adjustment of clearance above Check replace Check adjust repair Engine hunts Air entering suction side of fuel line Check repair Abnormal noise generated combustion or mechanical Low grade fuel being used Overheating Change to specified fuel Refer to Radiator water level moni...

Page 218: ...l possible with the machine but ask your distributor for an inspection E10 Abnormality in electronic governor system engine stopped Carry out inspection immediately E11 E14 Abnormality in electronic governor system abnormality in engine protection output Abnormality in throttle abnormality in fuel control dial It is possible to carry out normal working operations but have inspection carried out im...

Page 219: ...ch 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 regis tered screen B is not displayed If it is necessary to register the point of contact telephone num ber ask your Komatsu distributor to register it ...

Page 220: ...TROUBLES AND ACTIONS OPERATION 3 156 ...

Page 221: ...MAINTENANCE 14 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 222: ...articles or foreign materials are found always report to the person in charge and carry out suitable action 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 200 V continuously q Connect grounding cable within 1 m of the area to be welded If grounding cable is connected n...

Page 223: ...ls see BLEEDING 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 sharply If they are installed so their service life will be ...

Page 224: ...water metal particles dirt etc from getting in The majority of problems with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil q Never mix oils of different grades or brands q Always add the specified amount of oil Having too much oil or too little oil are both causes of problems q If the oil in the work equipmen...

Page 225: ...lity is used the durabil ity may drop markedly COOLANT AND WATER FOR DILUTION 4 q The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of antifreeze coolant is essential Komatsu machines are supplied with Komatsu Supercoolant AF NAC Komatsu Supercoolant AF NAC has excellent anticorrosion antifreeze an...

Page 226: ...YING OUT KOWA Komatsu Oil Wear Analysis 4 KOWA is a maintenance service that makes it possible to prevent machine failures and downtime With KOWA the oil is periodically sampled and analyzed This enables early detection of wear of the machine drive parts and other problems We strongly recommend you to use this service The oil analysis is carried out at actual cost so the cost is low and the result...

Page 227: ...take other measures to protect them q To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first FILTERS 4 q Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace all filters periodically For details see the Ope...

Page 228: ...system is checking fan belt tension checking damage or wear to the fan belt and checking battery fluid level q Never install any electric components other than those specified by Komatsu q External electro magnetic interference may cause malfunction of the control system controller before install ing a radio receiver or other wireless equipment contact your Komatsu distributor q When working at th...

Page 229: ...MAINTENANCE OUTLINE OF SERVICE 4 9 EXPLANATION OF LUBRICATION CHART DECAL Interval of service Change filter Lubrication by greasing G Amount of oil required at change liters Check oil level change EO ...

Page 230: ... shovel cylinder Grease N A 13 Boom arm Bucket cylinder foot Arm cylinder rod pin Grease 4 41 14 Swing circle Grease 4 43 15 Hydraulic oil filter Change element 4 62 16 Fuel pre filter Change element 4 49 17 Engine oil filter Change element 4 56 18 Engine oil change Change oil 4 56 19 Corrosion resistor Change element 4 66 20 Pilot filter Change element 4 54 21 Fuel main filter Change element 4 58...

Page 231: ...lot filter 21T 60 31410 Filter 1 Every 500 hours Engine oil filter 600 211 1340 Cartridge 2 Every 500 hours Fuel main filter 600 319 3520 Cartridge 1 Every 1000 hours Fuel pre filter 600 319 3440 Cartridge 1 Every 500 hours 600 319 3400 Cartridge with transparent cap 1 Corrosion resistor if equipped 600 411 1171 Cartridge 1 Every 1000 hours Air conditioner RECIRC filter 20Y 979 6261 Filter 1 Every...

Page 232: ...in temperatures below 0 C be sure to use the recommended multi grade oil even if the ambient temperature may become higher during the course of the day q If the machine is operated at a temperature below 20 C a separate device is needed so consult your Komatsu distributor q When the fuel sulfur content is less than 0 2 change the engine oil according to the period inspection table given in this Op...

Page 233: ...W30 25 C 40 C Note 1 Komatsu EOS5W40 20 C 40 C Komatsu EO10W30DH 15 C 50 C Komatsu EO15W40DH 0 C 40 C Komatsu EO30DH Swing machinery case Final drive case Power train oil Note 2 30 C 50 C TO10 Coupling case Power train oil 30 C 10 C TO30 0 C 40 C TO30 Hydraulic system Power train oil 20 C 45 C TO10 Hydraulic oil 20 C 50 C HO46 HM Grease fitting Hyper grease Note 3 20 C 45 C G2 TE Lithium EP grease...

Page 234: ...zing is not an issue the use of antifreeze coolant is essential Komatsu machines are supplied with Komatsu Supercoolant AF NAC Komatsu Supercoolant AF NAC has excel lent anticorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu Supercoolant AF NAC is strongly recommended wherever available 2 For details of the ratio when diluting super coolant w...

Page 235: ...torque N m kgf m Target value 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...

Page 236: ...ective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the critical parts SAFETY CRITICAL PARTS LIST 4 NO Safety critical parts for periodic replacement Q ty Replacement interval 1 Fuel hose fuel tank to Fuel Cutoff ValveÅj 1 Every 2 years or 4000 hours whichever comes sooner 2 Fuel hose Fuel Cutoff V...

Page 237: ...NG 4 364 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 374 CHECKS BEFORE STARTING EVERY 10 HOURS MAINTENANCE LUBRICATING 4 414 EVERY 100 HOURS MAINTENANCE LUBRICATING SWING CIRCLE 4 434 EVERY 250 HOURS MAINTENANCE CHECK OIL LEVEL IN FINAL DRIVE CASE ADD OIL 4 444 CHECK LEVEL OF BATTERY ELECTROLYTE 4 444 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS 4 464 CHECK ALTERNATOR DRIVE BELT TENSION ADJUST...

Page 238: ...NANCE CHANGE OIL IN FINAL DRIVE CASE 4 694 CLEAN HYDRAULIC TANK STRAINER 4 704 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 714 CHECK ALTERNATOR 4 744 CHECK ENGINE VALVE CLEARANCE ADJUST 4 744 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS 4 744 EVERY 4000 HOURS MAINTENANCE CHECK WATER PUMP 4 754 REPLACE ACCUMULATOR FOR CONTROL CIRCUIT 4 754 CHECK FOR LO...

Page 239: ...NT 4 WARNING q When using compressed air there is danger of dirt flying and causing personal injury Always wear protective glasses dust mask or other protective equipment q When removing the outer element from the air cleaner body it is dangerous to pull it out by force When working in high places or where the foothold is poor be careful not to fall because of the reac tion when pulling out the ou...

Page 240: ...light 1 Open the engine hood at the front side of the machine remove 6 hooks 2 then remove cover 3 NOTICE q Never remove the inner element 6 It will allow dirt to enter and cause failure of the engine q Do not use a screwdriver or other tool 2 Hold the outer element 5 rock it lightly up and down and to the left and right and rotate the element to the left and right to pull it out 3 When the outer ...

Page 241: ...r element even though it has not been cleaned 6 times 8 If small holes or thinner parts are found on the element when it is checked by shining a light through it after clean ing replace the element 9 Remove the cloth or tape covering inner element 6 NOTICE q Do not use an element whose folds or gasket or seal are damaged q If the element or O ring are cleaned and used again after they have been us...

Page 242: ...r cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks in turn on opposite sides top bottom left right in the same way as when tightening bolts 4 Always install cover 3 so that the evacuator 4 is facing the ground A 5 When cover 3 is installed check that the clearance between the air cleaner body and cover 3 is not too large If it is too large install again 13 Wh...

Page 243: ...must not be cleaned and used again When replacing the outer element replace the inner element at the same time q If the inner element is not installed properly and the outer element and cover are installed there is danger that the outer element will be damaged q The seal portion on imitation parts lacks precision and allows the entry of dust which leads to dam age of the engine Do not use such imi...

Page 244: ...r body and cover 3 is not too large If it is too large install again 10 After replacing the element press reset button 9 of the dust indicator to return the yellow display to its original position CLEAN INSIDE OF COOLING SYSTEM 4 WARNING q Immediately after the engine is stopped the coolant is at a high temperature and the radiator is under high internal pressure If the cap is removed to drain the...

Page 245: ...rcoolant AF NAC always keep the density of Supercoolant between 30 and 68 When deciding the ratio of antifreeze to water check the lowest temperature in the past and decide from the mix ing table given below It is actually better to estimate and temperature about 10 C lower when deciding the mixing ratio The mixing ratio depends on the ambient temperature but it should always be a minimum of 30 by...

Page 246: ...nes equipped with corrosion resistor 2 Remove the cover and turn radiator cooling water filler cap 3 slowly to take it off 3 Open drain valves 6 and 7 to drain cooling water 4 Remove covers 4 and 5 and place a container to receive antifreeze mixed cooling water under drain valve 6 located in the lower part of the radiator and also under engine cooling water drain valve 7 located in the upper part ...

Page 247: ...then run at high idling for 5 min utes Leave radiator cap 3 removed when doing this 13 After draining off the coolant of sub tank 8 clean the inside of the sub tank and refill the water between FULL and LOW level 14 Stop the engine wait for 3 minutes add city water until the water level reaches near the water filler port then tighten the cap 3 CHECK AND TIGHTEN TRACK SHOE BOLTS 4 If the machine is...

Page 248: ...rder to maintain the standard tension Stop the machine on firm horizontal ground when carrying out the inspection and maintenance Checking 1 Run the engine at low idle then move the machine forward for a distance equal to the track length on ground and slowly stop the machine 2 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 botto...

Page 249: ...rned or replaced Contact your Komatsu distributor for repairs B Grease cylinder Loosening Track Tension WARNING It is extremely dangerous to release the grease by any method except the procedure given below If track tension is not relieved by this procedure contact your Komatsu distributor for repairs 1 Loosen plug 1 gradually to release the grease 2 Turn plug 1 a maximum of one turn 3 If the grea...

Page 250: ...s a hazard that fragments will fly during the replacement work so always wear protective equip ment like safety glasses and gloves 1 Set the bucket with the bottom of the bucket on block 3 so that pin 1 can be removed then stop the engine 2 Check that the work equipment is in a stable condition then set the lock lever to the LOCK position L 3 Place a bar on the head of pin 1 hit the bar with a ham...

Page 251: ...only with strong force so there is a hazard that the pin may fly out Check that there is no one in the surrounding area q There is a hazard that fragments will fly during the replacement work so always wear protective equip ment like safety glasses and gloves 1 Set the bucket with the bottom of the bucket on block 3 so that pin 1 can be removed then stop the engine 2 Check that the work equipment ...

Page 252: ...e adapter insert pin 1 then tighten 90 clockwise with the box wrench to lock the pin and complete the installation ADJUST BUCKET CLEARANCE 4 WARNING It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance Set the work equipment in a stable condition stop the engine then set safety lock lever securely to the LOCK position L ...

Page 253: ... easy and accurate measure ment 3 Loosen 4 plate mounting bolts 2 and loosen plate 3 The shim is a split type so the operation can be carried out without removing the bolts 4 Remove shim 4 corresponding to the amount of play a measured above Example In the case of play of 3 mm remove two 1 0 mm shims and one 0 5 mm shim Play becomes 0 5 mm For shim 4 two types of 1 0 mm and 0 5 mm are used When pl...

Page 254: ...r 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 general use and 30 C cold area use select according to the area and season Operation area and season Mixture ratio Freezing temperature Normal Pure washer fluid 1 3 water 2 3 10 ...

Page 255: ...rant C Colorless transparent No refrigerant REMARK When there are bubbles the refrigerant gas level is low so contact your Komatsu distributors 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 to 5 minutes once a month to maintai...

Page 256: ...1 after washing it q Tightening torque for plug 2 181 18 1 N m 18 5 1 85 kgf m After assembling the line filter again bleed the air For details see BLEEDING AIR FROM HYDRAULIC SYS TEM 4 37 CHECK GAS SPRING 4 WARNING The gas spring is charged with high pressure nitrogen gas so mistaken operation may cause an explo sion which will lead to serious injury or damage When handling the gas spring always ...

Page 257: ...ration before starting NOTICE q Bleed the air as follows 1 Pump work equipment swing 2 Work equipment circuit q Run the engine at less than 1000 rpm and operate the cylinders slowly q Do not suddenly stop and cause the cylinder pressure to rise or operate to the end of the stroke q When operating the cylinder for the first stroke extending and retracting operate particularly slowly q When operatin...

Page 258: ...n go on to the next operation 3 Bleeding air from cylinders 1 Run the engine at low idle and extend and retract each cylinder 4 to 5 times taking care that a cylinder is not moved to the end of its stroke Stop the cylinder approx 100 mm short of its stroke end 2 Next operate each cylinder 3 to 4 times to the end of its stroke 3 Finally operate each cylinder 4 to 5 times to the end of its stroke to...

Page 259: ... in the oil inside the hydraulic cylinders q Check that there is no leakage of oil and wipe off any oil that has been spilled 6 Bleeding air from travel motor circuit If the piping has been removed from the travel motor cir cuit bleed the air after reassembling To bleed the air run the engine at low idling and do as follows 1 Start the engine and run at low idling 2 Remove travel motor cover 1 the...

Page 260: ... 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 for water and sediment in water separator drain water q Check oil level in hydraulic tank add oil q Check oil level in swing machinery case add oil q Check oil level in coupling case add oil q Check working lamp switch q Check electric wiring q Check function of horn ...

Page 261: ...h 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 2 Boom foot pin 2 places 3 Boom cylinder rod end pin 2 places 4 Arm cylinder foot pin 5 Arm cylinder foot pin 6 Boom Arm coupling pin 1 place 7 Bucket cylinder foot pin 1 place 8 Arm cylinder rod pin 9 Arm cylinder rod pin 10 Arm Link coupling pin 1 place 11 Arm Buck...

Page 262: ...MAINTENANCE PROCEDURE MAINTENANCE 4 42 12 Link coupling pin 2 places 13 Bucket cylinder rod pin 1 place 14 Bucket Link coupling pin 1 place ...

Page 263: ...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 fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out ...

Page 264: ...ottom edge of the plug hole 3 If the oil level is low check again Install plug F operate the travel lever travel in FORWARD or REVERSE and rotate the sprocket one turn Perform inspection for Proce dure 2 again 4 If the oil level is low add engine oil through plug hole F until the oil overflows from plug hole F 5 After checking install plug F CHECK LEVEL OF BATTERY ELECTROLYTE 4 Perform this check ...

Page 265: ...an the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL U L and LOWER LEVEL L L lines If the battery is wiped with a dry cloth static electricity may cause a fire or explosion 2 If the electrolyte level is below the midway point between the UPPER LEVEL U L and LOWER LEVEL L L lines remove cap 2 and add distilled water to the U L line 3 After a...

Page 266: ... After adding distilled water tighten cap 2 securely REMARK If distilled water is added to above the bottom of the sleeve use a syringe to lower the level to the bottom of the sleeve Neutralize the removed fluid with baking soda sodium bicar bonate then flush it away with a large amount of water or con sult your Komatsu distributor or battery maker When it is Possible to Use Indicator to Check Ele...

Page 267: ...tor q If nut 6 is tightened the belt tension will increase if nut 6 is loosened the belt will become loose 2 After adjusting the belt tighten bolts and nuts 3 5 in reverse number order from 5 to 3 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 is elongated and there is no mor...

Page 268: ...order and move the compressor q If nut 9 is tightened the belt tension will increase if nut 9 is loosened the belt will become loose 2 After adjusting the belt tighten bolts and nuts 6 8 in reverse number order from 8 to 6 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 is elo...

Page 269: ...ny fire or flame close NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing the filter cartridge always use a genuine Komatsu part q The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle If any part other than a genuine Komatsu filter cartri...

Page 270: ...he new filter cartridge with clean fuel coat the packing surface thinly with oil then install to the filter holder NOTICE q When adding fuel do not remove cap B Always add fuel from the 8 small holes A on the dirty side q After adding fuel remove cap B and install the fuel fil ter q Always fill with clean fuel Be careful not to let any dirt or dust get into the fuel In particular center portion is...

Page 271: ...ion swing 2 times to the right or left then lower the work equipment to the ground and stop the engine 2 Open the grease pump box at the right side of the machine then remove spare grease can holder cover 1 and spare grease can 3 Remove 3 bolts 2 then remove cover 3 REMARK When cover 3 does not come off easily insert removed bolt 2 into tapped bolt hole 4 and then remove cover 3 4 Insert a scale i...

Page 272: ...ant leakage or overheating On dusty jobsites check the fins daily irrespective of the maintenance interval 1 Open the cover 1 2 Open duct 2 at the machine s rear right side Duct 2 opens when ten bolts 3 are removed 3 Use compressed to blow off mud dust or leaves clogging the radiator fins oil cooler fins fuel cooler fins 2 and after cooler fins 3 At the same time clean the net in front of the oil ...

Page 273: ...er 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 Replace the filter with a new part every year If the clog ging of the filter cannot be removed by blowing with air or washing in water replace the filter immediately CLEAN FRESH AIR FILTER 1 Use the starting switch key to open cover 2 at the rear left of the operator ...

Page 274: ...he filter case first If the short S end is installed first cover 2 will not close REPLACE PILOT FILTER 4 WARNING Start the engine run it for approx 10 minutes at low idling and check for any leakage of fuel from the filter seal mounting surface 1 Loosen drain plug 1 to drain fuel 2 Remove filter 2 and replace it with a new one Tightening torque 20 25 N m 2 04 2 55 kgf m ...

Page 275: ...k 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 REPLACE DRAIN FILTER CARTRIDGE 4 1 Using a filter wrench turn the filter cartridge 1 to the left to remove it 2 Fill the new filter cartridge with hydraulic oil coat the pack ing surface with oil then install it When installing it bring the packing s...

Page 276: ...valve down slowly and drain the oil After draining the oil move the lever up to close the valve q Never loosen plug a Even if it is not loosened the oil will come out when the lever is operated q When not using hose 2 keep it in the toolbox 3 Open the front cover of the engine hood use a filter wrench from the top of the engine turn filter cartridge 4 to the left and remove it 4 Clean the filter h...

Page 277: ...ning be extremely careful not to damage the filter or cause dents 6 After replacing the filter cartridge add 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 Oil 3 78 8 In...

Page 278: ... bleed plug in the fuel filter head It is still under pressure so fuel may spurt out NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing the filter cartridge always use a genuine Komatsu part q The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and...

Page 279: ...ap B and install the filter cartridge 6 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it 3 4 of a turn If the filter cartridge is tightened too far the packing will be damaged and this will lead to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing so always tighten the correct amount 7 Turner va...

Page 280: ...wing nut 6 securely to lock lever 5 in position Target tightening torque 11 8 N m 1 2 kgf m 15 After replacing the filter cartridge start the engine and run it at low idling for 10 minutes Check for leakage of oil from the filter seal surface If any oil is leaking check the tightening of the filter car tridge If there is still oil leakage repeat Steps 1 4 to remove the filter cartridge and if any ...

Page 281: ...perature immediately after the engine is stopped and may cause burns Wait for the temperature to go down before starting the work q When removing the oil filler cap turn it slowly to release the internal pressure then remove it 1 Remove the cap of oil filler F at the top of the hydraulic tank 2 Replace element 1 inside the cap ...

Page 282: ...sembly 1 at the top of the hydraulic tank then remove cover 3 2 Replace filter element 4 with a new element 3 Install cover 3 and snap ring 2 REPLACE HYDRAULIC OIL FILTER ELEMENT 4 WARNING q The parts and oil are at high temperature immediately after the engine is stopped and may cause burns Wait for the temperature to go down before starting the work q When removing the oil filler cap turn it slo...

Page 283: ... position push it down by hand and install the cover with the mouning bolts 9 Install the cap of oil filler port F 10 To bleed the air start the engine according to Engine Warm Up 3 95 and run the engine at low idle for 10 min utes 11 Stop the engine REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank 12 Check for oil leakage and wipe of...

Page 284: ...stick G into filler pipe F then remove it 7 The oil level should be between H and L marks on the dip stick G If the oil does not reach the L mark add oil through oil filler port F 8 If the oil is above the H mark pull drain hose 1 out then loosen plug P After draining the excess oil check the oil level again If the oil level is correct wind in drain hose 1 and store it inside the hole 9 Immediatel...

Page 285: ...ming this operation NOTICE Park the machine on flat ground and stop the engine After waiting for more than 30 minutes after stop ping the engine check the oil level q Refill capacity 7 liters 1 Loosen drain plug 1 at the bottom of the Coupling case drain the oil then tighten the plug again 2 Refill the specified quantity of oil through oil filler F NOTICE If excess oil is supplied drain it to the ...

Page 286: ...the gap in the gasket so always keep the proper tightening angle 6 Turn valve 1 of corrosion resistor 2 to the OPEN stopper position 7 After replacing the cartridge run the engine and check for any leakage of water from the filter seal surface If any water leakage is found check the tightening of the filter cartridge CHECK WELDED STRUCTURE 4 Color check Cracks in welded structures can be seen easi...

Page 287: ...MAINTENANCE MAINTENANCE PROCEDURE 4 67 A Important check points F Front q Revolving frame q Center frame ...

Page 288: ...portant check points q Boom 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 Have your Komatsu distributor inspect and charge the accumulator ...

Page 289: ...ay fly out Loosen the plug slowly to release the pressure q Refill capacity Each 20 liters 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 ones 3 Tighten plug P 4 Add oil through the hole of plug F ...

Page 290: ... q When removing 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 ...

Page 291: ...n 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 NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued it will become impossible to release the remaining pressure inside the hydraulic circuit if a failure occur...

Page 292: ...the work equipment in the maximum reach posture arm fully out bucket fully dumped at a height A 1 5 m from the ground Carry out Steps 3 5 within 15 seconds When the engine is stopped the pressure in the accumulator gradually goes down For this reason the check can only be carried out immediately after the engine is stopped 3 Keep the work equipment at the maximum reach turn the starting switch to ...

Page 293: ...nspection After completion of the inspection set the lock lever to the LOCK position and turn the starting switch to the OFF position METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT 4 WARNING q The hydraulic system is always under internal pressure so when inspecting or replacing the piping or hoses always release the pressure in the circuit before starting If the pressure is not released high p...

Page 294: ... 1000 rpm q Set the work equipment control levers to the HOLD position 5 Operate each work equipment control lever to the full stroke within 5 6 seconds after stopping the engine q Repeat Steps 4 5 three times CHECK ALTERNATOR 4 Contact your Komatsu distributor to have the alternator checked If the engine is started frequently have this inspection carried out every 1000 hours CHECK ENGINE VALVE CL...

Page 295: ...raulic circuit cannot be completely removed When removing the hydraulic equip ment do not stand in the direction that the oil spurts out when carrying out the operation In addition loosen the bolts slowly when carrying out the operation Do not disassemble the accumulator Do 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 an...

Page 296: ...se bolts or hardened rubber please contact your Komatsu distributor for replacement CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 Check for any missing fuel spray prevention caps 1 to 11 or fuel spray prevention cover 12 and check also for any hardened rubber portions If there are any missing caps or cover or the rubber is hardened please contact your Komatsu distributor for re...

Page 297: ...ONDITION OF COMPRESSOR 4 Ask your Komatsu distributor to carry out the inspection CHECK STARTING MOTOR 4 Contact your Komatsu distributor to have the starting motor checked If the engine is started frequently have this inspection carried out every 1000 hours ...

Page 298: ... to go down before starting the work q When removing the oil filler cap turn it slowly to release the internal pressure then remove it q Refill capacity 470 liters q Prepare a handle for the socket wrench 1 Swing the upper structure so that hydraulic tank drain plug P3 and drain plug P1 at the bottom of the pump suction tube are in the middle between the left and right tracks 2 Retract the arm and...

Page 299: ...f any replace the defective O ring with a new one After draining oil tighten drain plugs P1 P2 P3 and P4 q Tightening torque P1 and P2 152 24 5 N m 15 5 2 5 kgf m P3 and P4 68 6 9 8 N m 7 1 kgf m q When removing drain plug P3 P4 be careful not to get oil on yourself 7 Add the specified amount of new and clean oil through oil filler port F Check that the oil level is between H and L on the sight ga...

Page 300: ... 1000 2000 and 4000 hours of service should be performed at the same time REPLACE HIGH PRESSURE PIPING CLAMP 4 Contact your Komatsu distributor to have the engine high pressure clamps replaced REPLACE FUEL SPRAY PREVENTION CAP 4 Contact your Komatsu distributor to have the fuel spray prevention cap replaced ...

Page 301: ...SPECIFICATIONS 15 ...

Page 302: ... horsepower HP rpm 487 1 800 487 1 800 A Overall length mm 13 030 13 895 B Overall height mm 4 615 4 850 C Overall width mm 4 110 4 210 D Track shoe width mm 710 810 E Height of cab mm 3 640 3 640 F Radius of upper structure mm 4 300 4 300 G Length of track mm 5 810 6 330 H Tumbler center distance mm 4 500 5 020 Min ground clearance mm 840 840 Travel speed Low High km h 2 8 4 2 2 8 4 2 Swing speed...

Page 303: ...A Maximum digging radius mm 12 265 13 740 B Maximum digging depth mm 7 130 8 600 C Maximum digging height mm 11 330 11 840 D Maximum vertical wall dig ging depth mm 4 080 5 575 E Maximum dumping height mm 7 525 8 145 F Maximum digging reach at ground level mm 11 945 13 460 ...

Page 304: ...SPECIFICATIONS SPECIFICATIONS 5 4 ...

Page 305: ...ATTACHMENTS AND OPTIONS 16 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 306: ...ne itself and for the attachment or optional device thoroughly 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 r...

Page 307: ...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 308: ...may be problems with safety so please contact your Komatsu distributor before installing q Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety but may also have an adverse effect on the operation of the machine and the life of the equipment q Any injuries accidents or damage resulting from the use of unauthorized attachments or opti...

Page 309: ...inations shown in the table below Note The figure shown in for the bucket shows the CECE bucket capacity z This shows the general operations This shows the light work X This shows that the impossible to use Model PC800 8 PC800LC 8 Work equipment Boom Boom 7 1m Boom 8 2m Bucket width mm Arm Arm 2 9m Arm 3 6m With side cutter excluding side shroud With side cutter including side shroud Bucket Narrow...

Page 310: ... 9m arm PC800LC 8 3 6m arm A Maximum digging reach mm 12 265 13 740 B Maximum digging depth mm 7 130 8 600 C Maximum digging height mm 11 330 11 840 D Maximum vertical wall dig ging depth mm 4 080 5 575 E Maximum dumping height mm 7 525 8 145 F Maximum digging reach at ground level mm 11 945 13 460 ...

Page 311: ...ry 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 Normal soil soft ground These shoes cannot be used on rough ground where there are large obstacles such as boulders or fallen trees Travel at Hi or Mi speed only on flat ground and if it is impossible to avoid going over obstacles shift down...

Page 312: ...fire on the KOMTRAX equipment or the machine itself Your Komatsu distributor will carry out removal and installation of KOMTRAX q Do not allow cables or cords to become caught do not damage or pull cables or cords by force Short circuits or disconnected wires may cause failure or fire on the KOMTRAX equipment or the machine itself q For anyone wearing a pacemaker make sure that the communications ...

Page 313: ...INDEX 17 ...

Page 314: ...INDEX 7 2 ...

Page 315: ... 2 Precautions when Selecting 6 2 Precautions when Using 6 3 Read the Instruction Manual Thoroughly 6 2 Grease Pump 3 71 H Handling Machines Equipped With KOMTRAX 6 8 Basic Precautions 6 8 Handling Oil Fuel Coolant and Performing Oil Clinic 4 4 Hot and cool box 3 51 I Introduction 1 9 L Locking 3 126 Long term storage 3 141 After Storage 3 142 Before Storage 3 141 During Storage 3 142 Starting mac...

Page 316: ...ce Information 2 33 Service Meter Location 1 12 Specifications 5 2 Sun Roof 3 43 Swinging 3 111 Switches 3 34 T Tightening Torque Specifications 4 15 Tightening Torque List 4 15 Tool Box 3 70 Transportation 3 127 Lifting Machine 3 127 Procedure for Increasing or Reducing Track Frame Gauge 3 135 Shipping Machine Information 3 129 Transportation Posture 3 130 Transportation Procedure 3 127 Traveling...

Page 317: ...COLOPHON 18 ...

Page 318: ...COLOPHON 8 2 PC800 800LC 8 GALEO HYDRAULIC EXCAVATOR Form No UEAM005400 2006 KOMATSU All Rights Reserved Printed in Belgium 01 06 ...

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