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Komatsu H75051, Operation & Maintenance Manual

The Komatsu H75051 Operation & Maintenance Manual is a comprehensive guide that provides users with essential information about efficiently operating and maintaining their equipment. Designed for easy access, this manual is available for free download on our website, ensuring hassle-free access to the valuable resource you need.

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METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT..................................................... 4-64

EVERY 2000 HOURS MAINTENANCE ......................................................................................................... 4-64

METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER... 4-64
METHOD FOR REPLACING HYDRAULIC OIL FILTER CARTRIDGE.................................................... 4-67
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ............................................. 4-68
METHOD FOR CHANGING OIL IN AXLE CASE .................................................................................... 4-69
METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC AIR FILTERS ................................ 4-71
METHOD FOR CLEANING BRAKE CIRCUIT STRAINER...................................................................... 4-71
METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT .................................................................. 4-72
METHOD FOR CHECKING FUNCTION OF PPC ACCUMULATOR ....................................................... 4-73
METHOD FOR CHECKING ALTERNATOR ............................................................................................ 4-74
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE ...................................... 4-74
METHOD FOR CHECKING VIBRATION DAMPER ................................................................................ 4-74
METHOD FOR REPLACING KCCV FILTER ELEMENT ......................................................................... 4-74
METHOD FOR REPLACING DEF FILTER.............................................................................................. 4-77
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT........................................................... 4-80

EVERY 4000 HOURS MAINTENANCE ......................................................................................................... 4-81

REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-81
METHOD FOR LUBRICATING DRIVE SHAFT ....................................................................................... 4-82
METHOD FOR CHECKING WATER PUMP............................................................................................ 4-83
METHOD FOR CHECKING STARTING MOTOR.................................................................................... 4-83
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR............................ 4-83
METHOD  FOR  CHECKING  FOR  LOOSENESS  OF  ENGINE  HIGH-PRESSURE  PIPING  CLAMP,  HARD-

ENING OF RUBBER ........................................................................................................................... 4-83

METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.

............................................................................................................................................................ 4-84

EVERY 4500 HOURS MAINTENANCE ......................................................................................................... 4-84

METHOD FOR CLEANING KDPF .......................................................................................................... 4-84
METHOD FOR CLEANING DEF TANK................................................................................................... 4-84

EVERY 8000 HOURS MAINTENANCE ......................................................................................................... 4-84

METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP............................................................ 4-84
METHOD FOR REPLACING STARTING MOTOR.................................................................................. 4-84

EVERY 9000 HOURS MAINTENANCE ......................................................................................................... 4-84

METHOD FOR REPLACING DEF HOSE ............................................................................................... 4-85
END OF SERVICE LIFE ......................................................................................................................... 4-85

MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS
USED

If the diesel fuel which does not include the bio-fuel is changed to the diesel fuel mixed with bio-fuel, set the
maintenance interval as follows.

Replace the fuel prefilter cartridge

When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed
with bio-fuel, and when the machine is operated further 250 hours.
After that, replace it within 500 hours as a periodic replacement by the service meter reading.

Replace the fuel main filter cartridge

When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed
with bio-fuel, and when the machine is operated further 250 hours.
After that, replace it within 1000 hours as a periodic replacement by the service meter reading.

MAINTENANCE

MAINTENANCE SCHEDULE TABLE

4-13

Summary of Contents for H75051

Page 1: ...is machine may be hazardous and cause injuries The operator and maintenance personnel must read this manual before commencing operation or maintenance Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals DANGER 2016 KOMATSU All Rights Reserved Printed in Europe 11 2016 ORIGINAL INSTRUCTIONS ...

Page 2: ... ...

Page 3: ...nuine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these recommendations could result in ineffective serv ice damage to the product or safety risks including personal injury or death 1 1 ...

Page 4: ...model name and the serial No see the machine serial No plate In order to arrange the proper Operation and Maintenance Manual you will need to provide the machine model name and the serial No This manual uses the International System of Units SI for units of measurement For reference units that have been used in the past are given in The explanations values and illustrations in this manual have bee...

Page 5: ... any subse quently installed electrical and electronic components comply with the EMV Directive 2014 30 EU in its current edition and bear the CE mark The following requirements also have to be met for subsequent installation of mobile communication systems e g radio telephone Only equipment approved by national legislation e g BZT approval for Germany may be used The unit must be fixed in positio...

Page 6: ... safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used...

Page 7: ... 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 precautions If any procedures or actions not specifically recommended or allowed in this manual are used it is your responsibility to take th...

Page 8: ...the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5 dB in accordance with ISO 11201 Sound power level emitted by the machine measured ac cording to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European di rective 2000 14 EC This value includes an uncertainty of 2 5 dB 1...

Page 9: ...rking and traveling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedule time to maintain terrain conditions 4 Use a seat that meets ISO 7096 and keep the seat maintained and adjusted Adjust the seat and suspension for the weight and size of the operator Wear seat belt Inspect and maintain the seat ...

Page 10: ...e machine front rear left right are determined according to the view from the operator s seat in the direction of travel front of the machine VISIBILITY FROM OPERATOR S SEAT This machine complies with the visibility standard ISO5006 This machine maintains a proximity visibility of a height of 1 5 m at a point 1 m away from the outside surface of the machine and a visibility for a radius of 12 m Pr...

Page 11: ...el Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the reagent for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transpa...

Page 12: ...IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE This is located at the center of the front frame on the right side of the machine The design of the nameplate differs according to the district LOCATION OF ENGINE NUMBER PLATE This is located at the right top of the engine rear part on the right side of the machine PRODUCT INFORMATION FOREWORD 1 10 ...

Page 13: ...This plate is located in travel direction front above the trans mission output g0047137 Komatsu Ltd Tokyo Japan SERIAL NO PART NO MODEL PRODUCED BY KOMATSU GERMANY GmbH HANNOVER FEDERAL REPUBLIC OF GERMANY FOR g0047138 Komatsu Ltd Tokyo Japan SERIAL NO PART NO MODEL PRODUCED BY KOMATSU GERMANY GmbH HANNOVER FEDERAL REPUBLIC OF GERMANY FOR FOREWORD PRODUCT INFORMATION 1 11 ...

Page 14: ...UORINATED GREENHOUSE GASES Product contains fluorinated greenhouse gases SERVICE METER LOCATION It is at the center bottom of the machine monitor HFC 134a GWP 1430 CO2 eq kg t 09971 10101 Product contains fluorinated greenhouse gases 1 0 1 43 g0027100 PRODUCT INFORMATION FOREWORD 1 12 ...

Page 15: ... Machine serial No Engine serial No Product identification number PIN Manufacturer name Address Komatsu Germany GmbH Hanomag Strasse 9 30449 Hannover Germany Distributor name Address Phone Fax Service personnel FOREWORD PRODUCT INFORMATION 1 13 ...

Page 16: ...Electro Magnetic Compatibility Directive 2004 108 EC until 19 April 2016 2014 30 EU after 20 April 2016 Outdoor Noise Directive 2000 14 EC amended by 2005 88 EC Radio Equipment and Telecommunications Terminal and Equipment Directive 1999 5 EC until 12 June 2016 Radio Equipment Directive 2014 53 EU after 13 June 2016 explanation of machine category Machine category Stand for WA Wheel loader DECLARA...

Page 17: ...icular the European Machi nery Directive lies with the customer who commissions retrofitting of the machine In the event of tools e g loading shovels being retrofitted by a third party supplier the technical specifications of the manufacturer must be taken into account For this purpose or for further information please be sure to consult Komatsu or your local Komatsu dealer FOREWORD RETROFITTING B...

Page 18: ...atsu Diesel Particulate Filter KVGT Komatsu Variable Geometry Turbo KCCV Komatsu Closed Crankcase Ventilation SCR Selective Catalytic Reduction DEF Diesel Exhaust Fluid ECSS Electrically Controlled Suspension System EXPLANATION OF ACRONYMS FOREWORD 1 16 ...

Page 19: ...CATION OF SAFETY LABELS 2 5 CONTENTS OF SAFETY LABELS 2 7 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2 15 PRECAUTIONS BEFORE STARTING OPERATION 2 15 PREPARATIONS FOR SAFE OPERATION 2 15 PRECAUTIONS TO PREVENT FIRE 2 17 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 18 DO NOT GET CAUGHT 2 20 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 20 UNAUTHORIZED MODIFICATION 2 21 PRECAUTIONS RELA...

Page 20: ...R CONDITIONER 3 211 EXPLANATION OF AIR CONDITIONER EQUIPMENT 3 212 METHOD FOR OPERATING AIR CONDITIONER 3 217 TRANSPORTATION 3 221 TRANSPORTATION PROCEDURE 3 221 LOADING AND UNLOADING WITH TRAILER 3 221 METHOD FOR LIFTING MACHINE 3 225 COLD WEATHER OPERATION 3 227 COLD WEATHER OPERATION INFORMATION 3 227 PRECAUTIONS AFTER DAILY WORK COMPLETION 3 228 PRECAUTIONS IN COLD WEATHER 3 228 AFTER COLD WEA...

Page 21: ...S MAINTENANCE 4 44 EVERY 100 HOURS MAINTENANCE 4 44 EVERY 250 HOURS MAINTENANCE 4 48 EVERY 500 HOURS MAINTENANCE 4 54 EVERY 1000 HOURS MAINTENANCE 4 59 EVERY 2000 HOURS MAINTENANCE 4 64 EVERY 4000 HOURS MAINTENANCE 4 81 EVERY 4500 HOURS MAINTENANCE 4 84 EVERY 8000 HOURS MAINTENANCE 4 84 EVERY 9000 HOURS MAINTENANCE 4 84 SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 SPECIFICATIONS WA270 8 5 2 ATTACHMENTS A...

Page 22: ...METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 7 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 8 INDEX 8 1 TABLE OF CONTENTS FOREWORD 1 20 ...

Page 23: ...ase read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions strictly 2 1 ...

Page 24: ... FROM OPERATOR S CAB 2 20 PRECAUTIONS FOR CLEANING CAB GLASS 2 20 DO NOT GET CAUGHT 2 20 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 20 UNAUTHORIZED MODIFICATION 2 21 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 21 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 21 PRECAUTIONS FOR OPERATION 2 22 PRECAUTIONS FOR JOBSITE 2 22 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2 22 PRECAUTIONS WHEN ...

Page 25: ... OR WORK EQUIPMENT 2 36 USE PROPER TOOLS 2 37 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 37 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 37 PRECAUTIONS FOR WELDING 2 37 HANDLE BATTERY 2 37 PRECAUTIONS WHEN USING HAMMER 2 38 PRECAUTIONS FOR HIGH TEMPERATURE COOLANT 2 38 PRECAUTIONS FOR HIGH TEMPERATURE OIL 2 39 PRECAUTIONS FOR HIGH TEMPERATURE PARTS 2 39 PRECAUTIONS FOR HIGH PRESSURE OIL 2 39 PREC...

Page 26: ...rly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the safety labels see this manual or the actual label and place an order to your Komatsu distributor There are also other labels in addition to the warning s...

Page 27: ...LOCATION OF SAFETY LABELS SAFETY SAFETY LABELS 2 5 ...

Page 28: ...12 Caution while engine is running 13 Caution for nearing machine 14 Prohibition of entering beneath work equipment 15 Caution for modification of ROPS FOPS 16 Prohibition of start by short circuiting 17 Caution for cleaning cooler core 18 Emergency escape 19 Caution when closing emergency escape right window 20 Caution for high temperature turbocharger 21 Caution for hot exhaust pipe 22 Caution f...

Page 29: ...eat 09654 C0481 Sign indicates a hazard of unexpected moving of stopped machine Lower working device to ground move safety lever to lock position and take engine key with you before leaving ma chine Caution when traveling in reverse 09802 D0880 Sign indicates a hazard of rear working and advancing be hind Read the operation and maintenance manual before oper ation SAFETY SAFETY LABELS 2 7 ...

Page 30: ... even if the machine is equipped with back up alarm and mirrors Caution for electric cables 09801 C0481 Sign indicates an electrocution hazard if machine is brought too near electric power lines Keep a safe distance from electric power lines Prohibition of trespassing 09162 C0641 Sign indicates a crush hazard between the articulating parts of the vehicle Keep away from the vehicle when it is movin...

Page 31: ...3 A0641 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool before removing cap Caution for high temperature oil and hydraulic oil 09653 A0641 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool bef...

Page 32: ...s an explosion hazard Never drill cut with gas hit or disassemble Also keep open flame away Prohibition of getting on or off fender Machines equipped with rear full length fender 09805 C0641 Sign indicates a hazard of falling Do not stand on this place here Caution while engine is running 09667 A0880 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance ...

Page 33: ... the working device is raised Caution for modification of ROPS 09620 A2001 09620 A3001 If any modification is applied to the ROPS or FOPS it may affect the strength and may not be comply with the stand ard Do not drill cut or weld on the ROPS or FOPS struc ture Any modification is prohibited ROPS or FOPS may provide less protection if it has been structurally damages or involved roll over Consult ...

Page 34: ...ttempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire Caution for cleaning cooler core 09667 A0481 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance Emergency escape 425 93 51110 SAFETY LABELS SAFETY 2 12 ...

Page 35: ...ed parts such as engine motor or muffler during or right after oper ation Never touch when hot Caution for high pressure common rail 6271 81 2981 Do not open high pressure fuel system with engine run ning Engine operation causes high fuel pressure High pressure fuel spray can cause serious injury or death Caution for blast site Machines equipped with KOMTRAX 09845 00480 Sign indicates an explosion...

Page 36: ...achine with rearview camera 09833 C0881 When backing up rear of machine is displayed on monitor Before moving look back and at mirror and monitor to con firm that no one is rear of machine Failure to do so can result in serious injury or death Caution for handling DEF 09632 61480 DEF only TO avoid engine damage or fire fill with DEF only Never use diesel fuel ᵎᵗᵔᵑᵐᵋᵔᵏᵒᵖᵎ SAFETY LABELS SAFETY 2 14 ...

Page 37: ...ATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the safety related devices and use them properly Never remove any safety related devices Always keep them in good operating condition INSPECT MACHINE Check the machine before starting operations If ...

Page 38: ... machine to move unexpectedly resulting in serious personal injury or death Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such as flammable or explosive items into the ...

Page 39: ...d surfaces or on parts of the electrical system After adding fuel or oil wipe up any spilled fuel or oil Put greasy rags and other combustible materials into a safe container to maintain safety at the workplace When washing parts with oil use a non flammable oil Do not use diesel fuel or gasoline There is danger that they may catch fire Do not weld or use a cutting torch to cut any pipes or tubes ...

Page 40: ...ipment When checking fuel oil battery electrolyte or coolant always use lighting with anti explosion specifica tions When taking the electrical power for the lighting equipment from the machine see POWER SUPPLY OUT LET 3 115 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine alwa...

Page 41: ...ine be used for the lifting of personnel PRECAUTIONS WHEN STANDING UP FROM OPERATOR S SEAT When standing up from the operator s seat to adjust the opera tor s seat be sure to lower the work equipment completely to the ground lock the work equipment by pressing work equip ment lock switch 1 pilot lamp lights up and stop the engine by setting parking brake switch 2 to ON operation position A If the ...

Page 42: ...AB GLASS Clean the cab glass to ensure visibility during operation Make sure to clean the glass with a mop from the ground DO NOT GET CAUGHT If the clearance at the articulating portion changes and you get caught in it you will suffer serious personal injury or death Do not allow anyone to come inside the articulation range The clearance in the area around the work equipment changes according to t...

Page 43: ... belt while operating the machine UNAUTHORIZED MODIFICATION Komatsu will not be responsible for any personal injuries product failures physical loss or damage or influ ence on the environment resulting from modifications made without authorization from Komatsu Any modification made without authorization from Komatsu can create hazards Before making a modifica tion consult your Komatsu distributor ...

Page 44: ...te so that there is no obstruction to travel operations PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse under the weight or vibration of the machine there is a hazard that the machine may fall or tip over Remember that the soil is weak in these area...

Page 45: ...places with poor visibility always observe the following Allocate a signalman for jobsite duty if there are areas where the visibility is poor Only one signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up additional lighting equipment in the work area if necessary Stop operations if the visibility is poor because of mi...

Page 46: ...re is a DANGER Do NOT operate warning tag dis played it means that someone is performing inspection and maintenance of the machine If the warning tag is ignored and the machine is operated the person performing inspection or maintenance may be caught in the rotating parts or moving parts It is dangerous and may cause serious personal injury or death Do not start the engine or touch the levers CHEC...

Page 47: ...ury or death Always observe the following Start the engine only while sitting down in the operator s seat When starting the engine sound the horn as a warning Prohibit other personnel to get on the machine Do not attempt to start the engine by short circuiting the engine starting circuit This may cause fire serious personal injury or death Check that the backup alarm alarm buzzer when machine trav...

Page 48: ...to bring the clips in contact with each other or with the machine For the starting procedure with the jumper cables see OPERATION START ENGINE WITH JUMPER CA BLES 3 237 PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly the machine will be unable to display its full perform ance It is dangerous and may cause serious personal injury or death W...

Page 49: ...gine stops de press the brake pedal immediately to stop the machine When driving the machine or performing operations always keep a safe distance from people structures or other machines to avoid coming into contact with them When traveling on a level ground keep the work equip ment approximately 30 cm above the ground If that height is not maintained between the work equipment and the ground the ...

Page 50: ...n drive it on to the slope again Drive the machine at low speed on the grass or fallen leaves Even with slight slopes there is a hazard that the machine may slip If the engine should stop on a slope depress the brake pedal immediately lower the bucket and apply the parking brake to stop the machine When driving the machine downhill drive it slowly at low speed Depress the brake pedal or use the en...

Page 51: ...e bucket is fully loaded do not start turn or stop the machine suddenly There is danger that the machine may tip over When handling unstable loads such as round and cylindri cal materials and stacked plates they may drop onto the operator s compartment if the work equipment is raised high and cause serious personal injury or death When handling unstable loads be careful not to raise the work equip...

Page 52: ... chine and do not perform abrupt lever operation Machine may slip even on a slight slope Be particularly careful when working on slopes Frozen road becomes soft when the temperature rises and the machine may tip over or be not able to es cape Be particularly careful when working on frozen road When traveling on snow covered roads always fit tire chains It is dangerous that the machine enters deep ...

Page 53: ...ending on the work equipment installed the machine weight transportation height and overall length differ Check beforehand that all bridges and other structures on the transportation route are strong enough to withstand the combined weight of the transporter and the machine being transported This machine needs to be divided into components for transportation depending on the regulation When transp...

Page 54: ...nes equipped with a cab always lock the door after loading the machine To prevent the door from opening during transportation When it is necessary to remove handrails and steps take care not to lose removed handrails and steps Install the removed handrails and steps securely TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method Any ...

Page 55: ...ce clean the tidy to enable you to perform operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop the machine on a firm level ground Select a place where there is no hazard of landslides falling rocks or flooding ONLY AUTHORIZED PERSONNEL As long as mainte...

Page 56: ...o the ground and stop the en gine before performing any inspection and maintenance Stop the engine work equipment is lowered to the ground and turn the starting switch to ON position Press the work equipment lock switch 2 to release the work equipment lock the pilot lamp goes off then operate the multifunction mono lever 1 to RAISE and LOWER posi tion fully 2 to 3 times to release the remaining pr...

Page 57: ... may contact the rotating parts and break and be scattered It is dangerous If the automatic active regeneration of KDPF starts during maintenance work surroundings of KDPF become high temperature When performing maintenance work perform the after treatment devices regeneration disable according to HAN DLE Komatsu Diesel Particulate Filter KDPF 3 124 Lower the work equipment to the ground and press...

Page 58: ...ENT Machine or work equipment may fall and it is dangerous that serious personal injury or death may occur Al ways observe the following Do not perform inspection and maintenance under the work equipment which is not lowered to the ground Always lower the work equipment to the ground when performing inspection and maintenance Make sure the hoists or hydraulic jacks you use are in good repair and s...

Page 59: ...ied person to perform welding HANDLE BATTERY Before inspecting or handling the battery turn the key in the starting switch to OFF position and check that the system operating lamp is off Then set the battery disconnect switch to OFF position and remove the switch key Danger of battery exploding When the battery is being charged flammable hydrogen gas is generated and may explode In addition the ba...

Page 60: ...able negative cable first When installing con nect the positive cable first then connect the ground Tighten the battery cable terminals securely Secure the battery firmly in the specified position PRECAUTIONS WHEN USING HAMMER When using a hammer pins may come out or metal particles may be scattered It is dangerous and may cause serious personal injury or death Always observe the following When hi...

Page 61: ...ipment such as protective eyeglasses and leather gloves High pressure oil leaking from small holes is dangerous that may penetrate your skin and cause loss of sight if it contacts your skin or eyes directly If a jet of high pressure oil hit your skin or eyes and suffer injury wash the place with clean water and consult a doctor immediately for medical attention The oil pressure in the ECSS circuit...

Page 62: ...disassemble Do not bring it near flame or dispose of it in fire Do not make holes in it weld it nor use a cutting torch Do not hit or roll the accumulator or subject it to any im pact When disposing of the accumulator the gas must be re leased Ask your Komatsu distributor to perform this work PRECAUTIONS FOR COMPRESSED AIR When performing cleaning with compressed air there is a hazard of serious p...

Page 63: ...t these components may fail and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspection or the feeling when operating so always replace them at the specified interval Replace or repair the defined life parts if any defect is found even when they have not reached the speci fied replacement time TIRES HANDLE TIRES If tires or ri...

Page 64: ...rtially to release the air from the tire gradually then remove the tire PRECAUTIONS FOR STORING TIRES Tires for construction equipment are extremely heavy it may lead to serious personal injury or death To maintain safety al ways observe the following As a basic rule store the tires in a warehouse which unau thorized persons cannot enter If the tires must be stored outside always erect a fence and...

Page 65: ...n tainer for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is non flammable however in...

Page 66: ......

Page 67: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 68: ...n signal lamp 6 Headlamp 7 Rearview mirror 8 Front working lamp 9 ROPS cab 10 Auto greasing if equipped 11 Rear wheel 12 Stepladder 13 Lift cylinder 14 Boom 15 Rear working lamp 16 Rearview camera 17 Rear combination lamp 18 Rear full length fender 19 Chock if equipped GENERAL VIEW OPERATION 3 2 ...

Page 69: ...d range selector switch 6 Machine monitor 7 Steering wheel 8 Horn switch 9 Lamp switch 9 Turn signal lever 9 Dimmer switch 10 Parking brake switch 11 Monitor switch 12 Cigarette lighter 13 Rearview monitor brightness adjustment switch 14 Rearview monitor 15 Work equipment lock switch 16 R H switch panel OPERATION GENERAL VIEW 3 3 ...

Page 70: ...mergency HST pump drive switch SWITCH PANEL Front switch panel 1 Front working lamp switch 2 Rear working lamp switch 3 Beacon lamp switch if equipped 4 Monitor brightness selector switch 5 ECSS switch 6 Quick coupler attachment switch if equipped R H switch panel 7 Travel speed control dial 8 Traction control switch 9 Directional selector switch actuation switch 10 Attachment selector switch if e...

Page 71: ...ilot lamp 10 Turn signal pilot lamp L H 11 Headlamp high beam pilot lamp 12 Turn signal pilot lamp R H 13 Brake oil pressure caution lamp 14 Clearance lamp pilot lamp 15 Engine tachometer 16 Speedometer 17 Fuel level caution lamp 18 Fuel gauge 19 Variable speed display 20 DEF level gauge 21 R H meter Select the fuel consumption gauge service meter odometer or clock 22 L H meter Select the service ...

Page 72: ...ft indicator position display 34 Work equipment lock pilot lamp 34 Remote positioner pilot lamp 35 Steering low oil pressure caution lamp 36 Emergency HST pump drive pilot lamp 37 Preheating pilot lamp 38 Fan reverse rotation display 39 Secondary steering pilot lamp 40 Aftertreatment devices regeneration display 41 Guidance display 42 Maintenance time caution lamp 43 Guidance icon 44 Seat belt cau...

Page 73: ...iew monitor 3 Ashtray 4 Open knob for alternate exit of cab 5 Cool box 6 Cup holder 7 Open lock for cab L H door 8 Cab door handle 9 Fuse 10 AUX 11 Unlock knob for slide window of cab 12 Open handle for cab L H door 13 12 V power supply OPERATION GENERAL VIEW 3 7 ...

Page 74: ...Outside of cab 1 Slow blow fuse 2 Frame lock bar GENERAL VIEW OPERATION 3 8 ...

Page 75: ...DPF 6 DEF injector 7 SCR assembly 8 Dust indicator 9 Komatsu Closed Crankcase Ventilation hereafter KCCV ventilator 10 Battery disconnect switch 11 System operating lamp 12 DEF pump 13 DEF filter 14 DEF tank OPERATION GENERAL VIEW 3 9 ...

Page 76: ... operations correctly and safely it is important to completely understand methods of operat ing the equipment and the meanings of the displays EXPLANATION OF MACHINE MONITOR EQUIPMENT FF Failure display screen A Warning display B Pilot display C Meter display D Monitor switch area EXPLANATION OF COMPONENTS OPERATION 3 10 ...

Page 77: ...n BB 3 The pointer of engine tachometer D swings once 4 Speedometer E displays 88 for 2 seconds 5 The alarm buzzer sounds for 2 seconds then stops under the normal condition NOTICE If the lamps alarm buzzer etc do not work the machine monitor may be failed or the electric wiring may have breakage In this case ask your Komatsu distributor for repair REMARK When the engine is started the battery vol...

Page 78: ...n be started with usual starting switch opera tion BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION When starting switch is turned to OFF position the screen goes out In the following case the end screen is displayed for 5 seconds and then screen goes out End screen with message If there is any message from your Komatsu distributor it is displayed on end screen DD for 5...

Page 79: ...ting screen BB If you input an incorrect ID number press RETURN switch 2 and clear an input character at a time On the ID number input screen LL with SKIP press menu switch 3 and the screen changes to the Check Be fore Starting screen BB without inputting ID number REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identification functio...

Page 80: ...chine has trou ble starting screen AA is displayed for 2 seconds and then it is changed to the failure display screen FF When ENTER switch displayed in guidance icon 1 is pressed the Current Abnormality screen is displayed When the machine monitor is started if the time to the next maintenance of any item is 30 hours or less starting screen AA is displayed for 2 seconds and then it is changed to m...

Page 81: ... The machine has a trouble if any of the action levels L01 to L04 is displayed on the machine moni tor Take appropriate actions following List of action level displays and required actions These caution lamps do not guarantee the condition of the machine Do not simply rely on the monitor when performing checks before starting daily inspection Al ways get off the machine and check each item directl...

Page 82: ...l caution lamp ACTION LEVEL DISPLAY Action level display indicates the degree of urgency of the ab normality currently generated on the machine by L01 to L04 The larger the number in the table is the more serious effects the abnormality may have on the machine if it is left with no ac tion When the machine monitor displays an action level take ap propriate actions according to List of action level...

Page 83: ...d display avoid a long time usage of the secondary steer ing If the condition is not improved check the failure code and ask your Komatsu distributor for in spection and maintenance L01 OFF Does not sound Lights up in yellow Some functions may be restricted from use but the machine can operate When you finish the operation always have the inspection and main tenance performed Ask your Komatsu dist...

Page 84: ...vel C Failure code Code to indicate the content of the failure Notify it when calling your Komatsu distributor D Failure name E Message Take appropriate remedies according to the displayed message F Contact telephone number The telephone number of the contact such as your Komatsu distributor is displayed If no point of contact telephone number is registered no telephone number is displayed Ask you...

Page 85: ...ERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about over heating of the engine coolant If the engine coolant temperature is abnormally high the cau tion lamp lights up in red and action level L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Stop the machine in a safe place set the directional lever and directional ...

Page 86: ...the engine low idle speed under the low ambient temperature is available For details see 2 STAGE LOW IDLE SWITCH BRAKE OIL PRESSURE CAUTION LAMP The brake oil pressure caution lamp warns that the brake oil pressure is below the specified value When action level L03 is displayed If the brake oil pressure drops below the specified value while the engine is running the caution lamp lights up in red A...

Page 87: ...nds intermittently Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for inspection and maintenance as needed BRAKE OIL TEMPERATURE CAUTION ...

Page 88: ... advancing to the next Inducement status With No Action level display Warning starts Inducement status is Warning Need to add DEF immediately When Lightning in white When fluctuation of DEF tank level is large frozen or not limited to tank level sensing is not performed correct ly When DEF is added after engine starting switch turn to OFF When DEF tank level sensor is defective SEATBELT CAUTION LA...

Page 89: ...move the machine to a safe place stop the engine then ask your Komatsu distributor for the inspection and maintenance HST SYSTEM CAUTION LAMP HST system caution lamp warns about abnormality in the HST system When action level L03 is displayed The caution lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Stop the operation move the ...

Page 90: ...perature of the aftertreatment devices may increase abnormally For the aftertreatment devices see HANDLE Komatsu Diesel Particulate Filter KDPF 3 124 KDPF SOOT ACCUMULATION CAUTION LAMP The KDPF soot accumulation caution lamp warns that soot is accumulated in KDPF or the filtering function of KDPF has low ered abnormally When action level L03 is displayed The caution lamp lights up in red if much ...

Page 91: ...Komatsu distributor to go off this caution lamp When stopping the engine stop it after running it at low idle for approximately 5 minutes For details see METHOD FOR STOPPING ENGINE 3 181 When stopping the engine during the aftertreatment devices re generation stop the regeneration first according to PROCE DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING 3 130 then stop the en gine afte...

Page 92: ...p the engine then ask your Komatsu distributor for inspection and maintenance ENGINE OIL LEVEL CAUTION LAMP Engine oil level caution lamp warns about drop of engine lubri cating oil level It displays only while the engine is stopped If the caution lamp lights up in yellow and action level L01 is displayed inspect the oil level in the oil pan and add oil See METHOD FOR CHECKING OIL LEVEL IN ENGINE ...

Page 93: ...N LAMP The water separator caution lamp warns that water is accumu lated in the water separator When water is accumulated in the water separator the caution lamp lights up in red Stop the engine and drain water from the water separator For details see METHOD FOR CHECKING WATER SEPARA TOR DRAINING WATER AND SEDIMENT 3 152 REMARK The water separator forms one unit with the fuel prefilter The water s...

Page 94: ...ecome worse and the machine life will be shortened Perform necessary maintenance as soon as possible When lamp lights up in yellow The maintenance time is approaching Prepare the necessary parts for the maintenance REMARK To check the items that need maintenance see Maintenance menu screen On the standard screen when the menu switch is pressed while the caution lamp is lit the screen changes direc...

Page 95: ...off When the directional lever and directional selector switch are not in NEUTRAL position N while the parking brake is applied When the speed range selector switch is operated to the speed range of 1st or 2nd during the travel at the speed range of 3rd or 4th When the directional change operation is per formed during the high speed travel at the speed range of 3rd or 4th When the directional leve...

Page 96: ... lamp 10 2 stage low idling pilot lamp 11 Clearance lamp pilot lamp 12 Work equipment lock pilot lamp 12 Remote positioner display 13 Shift lever position display 14 Steering low oil pressure caution lamp 15 Emergency HST pump drive pilot lamp 16 Preheating pilot lamp 17 Fan reverse rotation display 18 Secondary steering pilot lamp 19 Aftertreatment devices regeneration display 20 ECO guidance 21 ...

Page 97: ...LAMP The turn signal pilot lamp flashes synchronously with the turn signal lamp when it is turned on HEADLAMP HIGH BEAM PILOT LAMP The headlamp high beam pilot lamp lights up when the head lamps are set to high beam CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lights up when the clearance lamps are turned on OPERATION EXPLANATION OF COMPONENTS 3 31 ...

Page 98: ... the display pops up 2 STAGE LOW IDLING PILOT LAMP The 2 stage low idling pilot lamp lights up when the 2 stage low idling is effective REMOTE POSITIONER PILOT LAMP The remote positioner pilot lamp lights up in green when the re mote positioner is effective When the remote positioner function is changed from OFF to ON the display pops up The remote positioner does not operate when the boom detent ...

Page 99: ... RADIATOR FAN AUTOMATIC REVERSE MODE 3 61 PREHEATING PILOT LAMP The preheating pilot lamp lights up when the automatic pre heating function of the engine is actuated and goes out when preheating is completed This lamp also lights up during manual preheating The electri cal heater for engine preheating is actuated while this lamp is lit AIR CONDITIONER DISPLAY The air conditioner display shows the ...

Page 100: ...F is set to regeneration disable REMARK The lighting cycle becomes shorter when the ambient tem perature is lower or working load is smaller Even if the aftertreatment devices regeneration is disabled when the manual stationary regeneration is necessary KDPF soot accumulation caution lamp lights up If KDPF soot accumulation caution lamp lights up cancel the re generation disable setting and perfor...

Page 101: ...e engine is stopped the steering pressure is low and the steering low pressure pilot lamp lights up but this does not indicate any abnormality TRACTION LEVEL DISPLAY The traction control operating state is displayed at the traction level display SHIFT LEVER POSITION DISPLAY The shift lever position display shows the position of the direc tional lever or directional selector switch in enlarged lett...

Page 102: ...consumption The details of the guidance are as follows REMARK Display Non display of ECO guidance can be switched For the method of switching the display see SWITCH DISPLAY NON DISPLAY OF ECO GUIDANCE 3 57 EXCESSIVE IDLING GUIDANCE If the engine continues running idle for more than 5 minutes the excessive idling message is displayed on the monitor When waiting for work or taking short break stop t...

Page 103: ...or Limit the accelerator operation in order to reduce the fuel con sumption The notification of accelerator pedal depressing limit goes out automatically after 10 seconds TRACTION CONTROL RECOMMENDATION GUIDANCE When Fuel consumption improves when traction control is se lected is displayed on the monitor using the traction control is recommended to restrain the fuel consumption For using method of...

Page 104: ...ES REGEN ERATION GUIDANCE Immediately after starting the aftertreatment devices regeneration the information about the engine stop opera tion during the aftertreatment devices regeneration is displayed When stopping the engine during regeneration of the aftertreat ment devices stop the regeneration first according to PROCE DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING 3 130 then sto...

Page 105: ...r indicates the travel speed of the machine ENGINE TACHOMETER The engine tachometer indicates the engine speed If the engine speed is higher than the allowable range during operation the engine overrun caution lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Operate the machine with moderate engine speed and travel speed OPERATION...

Page 106: ...vel L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Stop the machine in a safe place set the directional lever and directional selector switch to NEUTRAL position N and run the engine at a medium speed with no load until the HST oil temperature caution lamp goes out If the HST oil temperature becomes less than 10 C the caution lamp is...

Page 107: ... operation ways accelerator operation travel speed speed range etc and the given load during travel load weight slope ground condition etc As the gauge is higher the fuel consumption is higher Reduce the graduation of the gauge to a point where there is no ad verse effect on the operation leading to energy saving opera tion to reduce the fuel consumption REMARK Even if the gauge is in orange range...

Page 108: ...ng hour regardless of the en gine speed Odometer display Indicates the total distance that machine has traveled in kilo meters Clock display Indicates the current time A 12 hour display B 24 hour display REMARK If the battery is disconnected for a long period for storage etc the time information may be lost For the method of setting and correcting the time and changing the display of the clock see...

Page 109: ...ights up in red the engine output and engine speed are limited For detail see HANDLE UREA SCR SYSTEM WARNING 3 133 When remaining level of DEF cannot be detected DEF level caution lamp 1 lights up in white REMARK Immediately after turning the starting switch to ON position and during the engine is running DEF level cau tion lamp 1 lights up in white However this does not indicate abnormality In co...

Page 110: ... keypad 3 Menu switch 4 ENTER switch 5 RETURN switch 6 DOWN switch 7 Guidance icon REMARK The switches available on each screen can be checked with the guidance icon This function is not available when you press a switch not marked by the guidance icon or you press the guidance icon itself EXPLANATION OF COMPONENTS OPERATION 3 44 ...

Page 111: ... the Message display menu screen When the menu switch is pressed on the user menu screen the menu screen changes ENTER SWITCH Pressing ENTER switch on the user menu screen decides any selection and changes and proceeds to the next screen When ENTER switch is pressed on the standard screen with a warning message displayed the Current Abnormality screen is displayed For the Current Abnormality scree...

Page 112: ...itch For details of other switch functions see the explanation for each screen in USER MENU 3 46 The confirmation sound is heard when the switch is pressed but a reaction is taken the switch function is operated when the switch is released USER MENU When menu switch 1 is pressed on the standard screen while the machine is stopped the user menu screen is displayed to enable you to configure and con...

Page 113: ...ection Setting for Traction Selection Hold Setting for Eco Traveling mode Setting for Reverse Travel Speed Range Limit Setting for Boom Raise Detent Setting Setting for PZ Auto Tilt in Selection Display and resetting of Trip Meter Auto Idle Stop Timer Setting C Aftertreatment Devices Regeneration Setting for Regeneration Disable Operation of Manual Stationary Regeneration D SCR Information Check o...

Page 114: ...N switch Moves to the item below When on the last item moves to the first item 3 ENTER switch Enters any selection or changes and proceeds to the next screen 4 RETURN switch Cancels a selection or changes and returns to the previous screen or the standard screen REMARK If no switch is operated for 30 seconds on the user menu screen the screen automatically returns to the previous screen or the sta...

Page 115: ...ays the following informa tion on a daily basis or during the split measurement period Working Hours Engine On The time during which the engine is running Average Fuel Consumption Average of the fuel con sumed while the engine is running Actual Working Hours The time spent for traveling oper ation of work equipment and operation of accelerator Ave Fuel Consumption Actual Working Average of the fue...

Page 116: ...measurement is stopped D Dates and times when the measurement is started and stopped To start the split time measurement see the guidance icon and press ENTER switch 1 When the measurement is started the previous split time measurement results Average Fuel Consumption Display Operation Records and ECO Guidance Records are reset When the confirmation screen is displayed press ENTER switch 1 again t...

Page 117: ... GUIDANCE 3 36 In the Operational Advice section the advice to the ECO guidance that appeared most frequently is displayed The ECO guidance count increases when display condi tions are satisfied even if the ECO guidance is not dis played When Average Fuel Consumption Display is set to 1 Day 1 Day is displayed on the place shown with arrow in the right figure When Average Fuel Consumption Display i...

Page 118: ...tion Records and ECO Guidance Records are reset When the confirmation screen is displayed press ENTER switch 1 again to start the split measurement or press RE TURN switch 2 to cancel the start FUEL CONSUMPTION RECORD The Average Fuel Consumption Record screen alternately displays the following graphs Average fuel consumption for the Last 12 hours Average fuel consumption for the Last 7 days Selec...

Page 119: ...ance icon and press ENTER switch 1 When the confirmation screen is displayed press ENTER switch 1 again to clear or press RETURN switch 3 to cancel clearing REMARK If clearing is performed while the graph of the Last 12 hours is displayed only the graph of the Last 12 hours is cleared If clearing is performed while the graph of the Last 7 days is displayed both graphs of the Last 12 hours and Last...

Page 120: ...guidance Switching ON OFF of ECO Guidance Display at Key OFF Select Configurations from Energy Saving Guidance menu screen then press ENTER switch 1 SET DISPLAY OF FUEL CONSUMPTION GAUGE The display of the fuel consumption gauge can be set to the value on daily basis or during split measurement period 1 Select Average Fuel Consumption Display from Configu rations menu then press ENTER switch 1 EXP...

Page 121: ...umption during the split measurement period after the measurement is started until it is finished Select Split Time to start the split measurement automatically REMARK Setting of 1 Day or Split Time is also applied to the display of the Operation Records and ECO Guidance Records SWITCH DISPLAY NON DISPLAY OF ECO GAUGE Display non display of ECO gauge can be switched 1 Select ECO Gauge Display from...

Page 122: ...CO Gauge Display is set to OFF the items of ECO Gauge Display Fuel Target Value is not displayed SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE ECO Gauge Target Value A the upper limit value of the green range can be changed 1 Select ECO Gauge Display Fuel Target Value from Con figurations menu then press ENTER switch 1 EXPLANATION OF COMPONENTS OPERATION 3 56 ...

Page 123: ...increased the fuel consumption indi cated when the ECO gauge is at the maximum is also in creased in proportion If the target fuel value is decreased the fuel consumption indi cated when the ECO gauge is at the maximum is also de creased in proportion SWITCH DISPLAY NON DISPLAY OF ECO GUIDANCE Display non display of ECO guidance displayed on the stand ard screen can be switched 1 Select ECO Guidan...

Page 124: ...dance Display at Key OFF and ECO Guidance Records are not displayed ECO Guidance Records however is not reset SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF Display non display of the Operational Advice indicated on the end screen when the key is turned to OFF position can be switched 1 Select ECO Guidance Display at Key OFF from Configu rations menu then press ENTER switch 1 EXPLANATION O...

Page 125: ...e Operational Ad vice indicated on ECO GUIDANCE RECORD 3 51 MACHINE SETTING AND INFORMATION In each item of Machine Setting and Information menu B setting and information of the machine are checked or changed RADIATOR FAN MANUAL REVERSE MODE k k CAUTION When rotating the fan in the reverse direction beware extremely that dirt will not fly out and cloth etc will not be wound in the fan Dust may be ...

Page 126: ...s less than 100 C It has been 20 seconds or more since the engine was started 3 Press ENTER switch 1 to rotate the fan in the reverse di rection or press RETURN switch 2 to cancel If the fan reverse operation is performed without satisfying the condition for reversing the fan the screen shown in the figure is displayed and the fan rotation direction cannot be switched In this case press RETURN swi...

Page 127: ...verse 10 minutes elapses after the fan rotation direction is re versed Stop the engine The coolant temperature boost temperature or HST oil temperature overheat the caution lamp of the oil tempera ture gauge or coolant temperature gauge on the machine monitor lights up in red then action level L02 is dis played while the fan is rotating in reverse RADIATOR FAN AUTOMATIC REVERSE MODE k k CAUTION Wh...

Page 128: ...e direction for 4 minute once for every 0 5 hours The default is Mode A When you want other than above settings for the duration and cycle of the automatic fan reverse rotation consult your Komatsu distributor REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met Other than OFF is set in Automatic Fan Reverse Mode The ...

Page 129: ...he fan rota tion returns from reverse direction to normal direction Turn off the automatic fan reverse mode The set duration time for the automatic fan reverse mode has elapsed Stop the engine The coolant temperature boost temperature or HST oil temperature overheat the caution lamp of the oil temperature gauge or coolant temperature gauge on the machine monitor lights up in red then action level ...

Page 130: ...work load is performed and it can re strain the fuel consumption When the Eco Traveling mode is set to ON the fuel consumption during traveling at 3rd or 4th can be re duced Level 1 to Level 5 Most suitable setting can be selected in accordance with the specific gravity of handled material operating condition and application Initially Auto is selected TRACTION LEVEL SELECTION HOLD You can decide w...

Page 131: ... OFF The traction mode at key OFF is returned to Auto OFF is set as default Accordingly Auto which is effec tive to reduce the fuel consumption and tire wear is select ed at key OFF ECO TRAVELING MODE The fuel consumption during traveling at 3rd or 4th can be reduced while the traction level is set to Auto by setting Eco Traveling mode to ON position OPERATION EXPLANATION OF COMPONENTS 3 65 ...

Page 132: ...turns to the normal mode ON Reduces the fuel consumption during traveling at 3rd or 4th while the traction level is set to Auto The default is ON REVERSE TRAVEL SPEED RANGE LIMITATION Even when the speed range selector switch is at 3rd or 4th the speed range in reverse travel can be limited to 2nd or below EXPLANATION OF COMPONENTS OPERATION 3 66 ...

Page 133: ...speed range is not limited ON Even when the travel speed range is set in 3rd or 4th the reverse travel speed range is limited to 2nd or below The default is OFF BOOM RAISE DETENT SETTING With the boom RAISE detent function the multifunction mono lever can be stopped in the position where it is pulled further from RAISE position OPERATION EXPLANATION OF COMPONENTS 3 67 ...

Page 134: ...om RAISE detent is disabled The default is ON REMARK When the boom RAISE detent is disabled the remote position er function is disabled as well For details see REMOTE POSITIONER 3 199 PZ AUTO TILT IN SELECT With PZ auto tilt in function the spillage of the loaded material can be prevented by tilting the bucket automati cally while the boom is raised EXPLANATION OF COMPONENTS OPERATION 3 68 ...

Page 135: ... and press ENTER switch 1 OFF PZ auto tilt in function is disabled Light Sets the compensation angle of auto tilt in to smaller val ue Normal Sets the compensation angle of auto tilt in to standard val ue Heavy Sets the compensation angle of auto tilt in to larger value Initially Normal is selected OPERATION EXPLANATION OF COMPONENTS 3 69 ...

Page 136: ...ETTING It is used to stop the engine automatically when the idle state continued for a predetermined time The auto idle stop works only when all of the following conditions are met The engine is running normally The parking brake works properly The accelerator pedal is not depressed The directional lever and directional selector switch are in NEUTRAL position N The machine is stopped The engine co...

Page 137: ...ngine speed or set the directional lev er or directional selector switch to any position other than NEUTRAL N at this point the countdown is stopped and the screen returns to the standard screen 4 If the idle state is further continued and the countdown reaches 0 seconds the engine stops The work equipment is locked as well after the engine is stopped Turn the unnecessary switches to OFF position ...

Page 138: ...DLE UREA SCR SYSTEM WARNING 3 133 MAINTENANCE SCREEN SETTING Each item on Maintenance menu screen E is used for dis playing and setting the notification relevant to maintenance On the Maintenance menu screen the following maintenance items their replacement intervals and their remaining times to the next replacement are displayed Maintenance item Interval h Default Air Cleaner Cleaning or Change C...

Page 139: ... negative symbol If any item is displayed in red perform the maintenance for it immediately REMARK The replacement intervals in Air Cleaner Cleaning or Change and Coolant Change are not set initially If you want to change the setting for the maintenance interval and the maintenance notice time consult your Komatsu distrib utor When the maintenance time caution lamp 2 is lit on the stand ard screen...

Page 140: ... using the nu meric keypad then press ENTER switch 1 REMARK For the setting changing or canceling the password ask your Komatsu distributor 2 The screen changes to Maintenance Due Time Reset screen When ENTER switch 1 is pressed the following reconfir mation screen is displayed To cancel press RETURN switch 2 3 On the reconfirmation screen shown in the figure when ENTER switch 1 is pressed again t...

Page 141: ...e rearview monitor Select Rearview Monitor Setting on the Monitor Setting menu screen and press ENTER switch 1 Reference line display The is used to change ON OFF of the reference line on the rearview monitor 1 Select Guide Line Display Mode from the Rearview Monitor Setting menu and press ENTER switch 1 OPERATION EXPLANATION OF COMPONENTS 3 75 ...

Page 142: ...s ON REVERSE INTERLOCK ENABLED MODE In this mode display method of rear view monitor can be changed by switching ON OFF 1 Select Reverse interlock Selection mode on the Rear view Monitor Setting menu then press ENTER switch 1 2 Select ON or OFF then press ENTER switch 1 ON Displays images on the rear view monitor only when trav eling in reverse OFF Always displays images on the rear view monitor R...

Page 143: ...n L H meter display A or R H meter display B Select Meter Display Selection on the Monitor Setting menu screen then press ENTER switch 1 SELECT L H METER DISPLAY This is used for the selection of the items to be displayed on the L H meter display OPERATION EXPLANATION OF COMPONENTS 3 77 ...

Page 144: ...TER switch 1 The following 3 items can be selected SMR Service Meter ODO Odometer CLK Clock REMARK For details of each item see L H AND R H METER 3 41 The default of L H meter is SMR Service Meter SELECT R H METER DISPLAY This is used for the selection of the items to be indicated on the R H meter display EXPLANATION OF COMPONENTS OPERATION 3 78 ...

Page 145: ...Average Fuel Consumption SMR Service Meter ODO Odometer CLK Clock REMARK For details of each item see L H AND R H METER 3 41 The default of R H meter is FUEL Average Fuel Consump tion SCREEN ADJUSTMENT This function is used for the adjustment of brightness of the machine monitor 1 Select Screen Adjustment on the Monitor Setting screen then press ENTER switch 5 OPERATION EXPLANATION OF COMPONENTS 3...

Page 146: ... the brightness in the night mode can be adjusted The brightness of night illumination for the switch panel and op eration switches are adjusted synchronously with the bright ness of the machine monitor CLOCK ADJUSTMENT On the clock adjustment menu you can change the setting of the clock displayed on the standard screen The following items can be changed GPS Synchronization Calendar Time 12hour or...

Page 147: ...be set manually REMARK This setting is held even if the starting switch is turned to OFF position The default is OFF When the machine is in the environment where the radio waves from GPS cannot be received the automatic setting function might be disable Turning the GPS Synchronization ON disables selecting the Calendar and Time CALENDAR SETTING Adjust the date of the machine monitor OPERATION EXPL...

Page 148: ...alendar one year 2 DOWN switch Puts calendar back one year 3 RETURN switch Cancels the change and returns the screen to Clock Adjustment menu 4 ENTER switch Proceeds to setting for month 3 When month display B is highlighted in yellow operate the switches as follows to change month display When it is not necessary to change the month setting press ENTER switch 4 1 UP switch Advances calendar one m...

Page 149: ...he machine monitor clock 1 Select Time from the Clock Adjustment menu and press ENTER switch 4 REMARK If ON is selected for the setting of GPS Synchroniza tion you cannot select the Time 2 The Time screen is displayed When time display D is highlighted in yellow operate the switches as follows to change time display When it is not necessary to change the time setting press ENTER switch 4 1 UP swit...

Page 150: ... the screen to the Clock Adjustment screen 12 HOUR AND 24 HOUR DISPLAY MODE Choose either a 12 hour display am pm or a 24 hour display 1 Select 12hour or 24hour Mode from the Clock Adjust ment menu then press ENTER switch 1 2 Select 12hour or 24hour then press ENTER switch 1 12hour Select 12H display AM PM 24hour Select 24 hour display REMARK This setting is held even if the starting switch is tur...

Page 151: ...n rises early in summer in our daily life This setting is held even if the starting switch is turned to OFF position The default is OFF LANGUAGE SETTINGS The language displayed on the machine monitor can be selected The languages that can be selected are as follows English Japanese French Spanish Portuguese Italian German Swedish Dutch Danish Norwegian Fin nish Icelandic Czech Hungarian Polish Slo...

Page 152: ...fication on the Operator ID menu The Operator ID menu is not displayed when the operator identification function is disabled REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identi fication function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted the identified ID is displa...

Page 153: ... for 1 second 2 The Operator ID Change screen is displayed Input the already registered ID on the Operator ID Change screen and press ENTER switch 1 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen On the Monitor Setting menu screen the inputted ID is displayed in the column of Operator ID OPERATION EXPLANATION OF COMPONEN...

Page 154: ...he screen returns to the Monitor Setting menu screen In this case the identified ID is not changed On the Operator ID screen if no switch is operated for more than 30 seconds the screen automatically changes to the Monitor Setting menu screen In this case the identified ID is not changed WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is av...

Page 155: ...e identified ID is not changed On the Operator ID screen if no switch is operated for more than 30 seconds the screen automatically changes to the Monitor Setting menu screen In this case the identified ID is not changed MESSAGE DISPLAY On machines equipped with KOMTRAX you can see the mes sages from your Komatsu distributor on this User Message menu G When there is any message message display 1 o...

Page 156: ... is dis played B Serial No of message C Validity D Text E Reply field In case of a message requesting for reply the Numeric Input is displayed Make any reply to the message REPLY TO MESSAGE 1 When replying to a message input the selected item num ber shown in the text of the message by using the switch panel Each switch of the switch panel corresponds to the number shown on the lower right of the ...

Page 157: ...itch key is set to OFF position The service meter and odometer can be displayed even if the machine monitor is not turned ON 1 Press UP switch 2 while holding down DOWN switch 1 when the starting switch is in OFF position Service meter A and odometer B are displayed while both switches are held down NOTICE If the monitor screen is displayed during other operations while the starting switch is at O...

Page 158: ...SWITCHES g0032100 1 ECSS switch 2 Front working lamp switch EXPLANATION OF COMPONENTS OPERATION 3 92 ...

Page 159: ...y can be removed from the starting switch the electrical current to the electrical system is cut and the engine stops In addition the parking brake is applied automatically B ON position Electric current flows through the charging and lamp circuits Keep the switch at this position while the engine is running When the ambient temperature is low during engine startup the engine preheating pilot lamp...

Page 160: ...chine monitor light up Position c Headlamps light up together with the lamps lit in position b REMARK The lamp switch can be operated regardless of the turn signal lever position DIMMER SWITCH The dimmer switch is used to switch the headlights between high and low beams Position L Low beam Position H High beam TURN SIGNAL LEVER The turn signal lever is used to operate the turn signal lamp Position...

Page 161: ...and rear view monitor while lamp switch is turned ON When operating the machine with the headlamp lighting up dur ing the day if this switch is set to Day mode monitor screen does not loose the brightness A Day position The monitor screen is set to the day mode B Night position The monitor screen is set to the night mode REMARK When the lamp switch is turned to OFF position operating this switch d...

Page 162: ...ke is applied and the parking brake pilot lamp lights up on the monitor Position B OFF released The parking brake is released REMARK When the parking brake has been applied the machine does not move even if the directional lever is operated When the directional lever is shifted to F forward or R re verse position while the parking brake is applied the cen tralized warning lamp lights up and the al...

Page 163: ... If the room lamp is left to be turned on the batteries may be exhausted Always turn the switch to OFF position after using room lamp The room lamp switch illuminates the room lamp Position A OFF goes out Position B Lights up when cab door opens Position C ON lights up REMARK The room lamp lights up even when the starting switch is at OFF position When leaving the operator s seat set to position A...

Page 164: ...ce lower the work equipment to the ground first press the ECSS switch to OFF position then start the work Keep the ECSS switch turned off during leveling work The ECSS switch is used to turn on and off the ECSS Position A ON The pilot lamp lights up and the ECSS operates Position B OFF The ECSS does not operate REMARK The ECSS absorbs the machine vibration during travel with the hydraulic spring e...

Page 165: ...rk the ma chine on a road due to machine failure or during emergency only Position A The turn signal lamps and the turn signal pilot lamp flash Position B The lamps go out DIRECTIONAL SELECTOR SWITCH The directional selector switch is used to set the travel direction to FORWARD NEUTRAL and REVERSE Position F FORWARD Position N NEUTRAL Position R REVERSE The directional selector switch operates onl...

Page 166: ...hen position A is pressed the pilot lamp lights up to turn it on WORK EQUIPMENT LOCK SWITCH k k WARNING When leaving the operator s seat be sure to lock the work equipment by pressing the work equip ment lock switch the pilot lamp lights up If the work equipment is not locked and the multifunc tion mono lever A is touched by mistake it may lead to serious accident If the work equipment is not secu...

Page 167: ...on B the machine starts to travel at the same time Take care The emergency HST pump drive switch is used to enable driving the machine temporarily if the machine cannot travel due to the trouble in the pump control system the HST system caution lamp lights up in red and action level L03 is displayed When you release your hand from the switch it returns auto matically to position A Keep the switch ...

Page 168: ...y goes out To turn on the traction control or the S mode again press the Max traction switch or change the directional lever position REMARK Use this switch to increase the rim pull further for the scrape up work PCS PROPORTIONAL CONTROL SWITCH if equipped PCS Proportional Control Switch is used to operate the at tachment Position A Extend the left cylinder retract the right cylinder Position B HO...

Page 169: ...ned Moreover the machine may start smoothly and a sudden start at forward travel may not occur REMARK Select the traction level Auto for loading work The rim pull is automatically adjusted to the optimum one to reduce the fuel consumption and decrease the slipping of tires as well If you select the most suitable maximum rim pull for the work condition by using the traction control switch and with ...

Page 170: ...target material Suitable for light target material Suitable on the ground not slip pery Suitable on the slippery ground Level 3 Level 2 Level 1 Low Use this to keep the rim pull at small level for a particular purpose C Tires will not easily slip and operation on a slippery ground such as a snow removal work can be per formed easily because an appropriate driving force is obtained Moreover the mac...

Page 171: ... selector switch can be enabled by setting the directional selector switch actuation switch to enable Position A Directional selector switch is enabled Position B Directional selector switch is disabled REMARK When setting the directional selector switch actuation switch to disable set the directional lever and the direc tional selector switch to NEUTRAL position The direction al selector switch a...

Page 172: ...larm buzzer is can celed Return the speed range selector switch to 3rd or 4th ENGINE SHUTDOWN SECONDARY SWITCH NOTICE The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to OFF position but the engine does not stop Use the engine shutdown secondary switch only in an emergency Contact your Komatsu distributor for repair immediately when there is any ab...

Page 173: ... automatically returns to NORMAL position b When the starting switch is turned to ON position while the engine shutdown secondary switch is in STOP ENGINE position a Engine Shutdown Sec ondary SW in Operation is displayed on the machine monitor If this screen is displayed return the engine shutdown secondary switch to NORMAL position CONTROL LEVERS AND PEDALS 1 Steering tilt lock lever 2 Direction...

Page 174: ...ns F and N or between po sitions N and R MULTIFUNCTION MONO LEVER The multifunction mono lever is used to operate the boom and bucket NOTICE Do not use FLOAT position when lowering the bucket Use FLOAT for leveling work Position a RAISE When the multifunction mono lever is pulled further from the RAISE position the lever stops in that position When the remote boom positioner is enabled the boom st...

Page 175: ...on The steering wheel is allowed to move back and forth and up and down L LOCK position The steering wheel is fixed in the position The adjustable range is shown below Vertical adjust ment When 0 mm Top to 40 mm Tilt adjustment 0 to 129 mm 0 to 162 mm NOTICE Do not operate the steering tilt lock lever repeatedly with an excessive force The lever can be loosened or its angle can be displaced In suc...

Page 176: ...approaches the dump truck while raising the boom REMARK When performing the work by decelerating and stopping the machine with the brake pedal and accelerator pedal use the L H brake pedal because it is more convenient ACCELERATOR PEDAL The accelerator pedal is used to adjust the speed and output of the engine It freely controls the engine from low idle to high idle OTHER COMPONENTS METHOD FOR OPE...

Page 177: ... the door opens to the full open posi tion OPEN LOCK FOR CAB L H DOOR Use this to fix the door in position after opening it or when getting on and off the operator s cab 1 Push the door against catch 1 to lock it in position 2 When keeping the door open fix it securely to the catch 3 When getting on or off the machine hold the inside hand rail 4 When closing the door push down knob 2 to release th...

Page 178: ...ous Never operate the machine with the door open Always operate the machine while the door is fully closed or locked half open Alternate exit door closed fully or locked half open When door knob 1 is pressed down completely the door is locked with fully closed state When cooling or heating the cab keep the door locked and fully closed with this function If the door knob 1 is pulled up the door is ...

Page 179: ...ide door wide and go out To return the door knob to the locked state grip door knob 1 and pull it toward the rear of the machine Match the guide rail of the door knob with the guide pin on the guide cab side and push in the door knob toward the front Check that the guide pin is inserted into the guide rail securely and push in and fix door knob 1 to the lock position OPERATION EXPLANATION OF COMPO...

Page 180: ...cap with lock and cover see LOCK 3 206 Insert the key as far as it will go to the shoulder A and turn it If the key is turned when it is not inserted all the way to the end it may break COOL BOX Drink hand towel etc can be kept cold during the cooling op eration They can be kept warm during the heating operation Do not put things which smell or break easily or leak water etc in this box Do not use...

Page 181: ...ot use this as a power supply for 12 V equipment This will cause failure of the equipment When the cigarette lighter 1 is removed its socket can be used as a 24 V power supply The maximum capacity is 85 W 24 V x 3 5 A REMARK Use 24 V power supply while the engine is running 12 V power supply Power supply take out port 2 at the rear left of operator s seat can be used as a 12 V power supply The max...

Page 182: ...by using an commer cially available audio cable 3 Press the band AUX selector button and select AUX FUSE NOTICE When replacing the fuse be sure to turn the starting switch to OFF position and after confirming that the system operating lamp is not lit set the battery disconnect switch key to OFF position The fuses protect the electrical component and wiring from burning out If the fuse is corroded ...

Page 183: ... brake lamp 12 15 A HST control 13 10 A Boom 14 20 A Wiper 15 20 A Radio Fuse box B No Fuse capacity Name of circuit 1 20 A Air conditioner blower 2 5 A Air conditioner compressor 3 20 A Revolving lamp 4 20 A Heated wire glass 5 10 A Load meter 6 20 A Auxiliary power supply 7 10 A DC converter 8 10 A Parking brake 9 20 A Horn 10 10 A L H clearance lamp 11 10 A R H clearance lamp 12 20 A Front work...

Page 184: ...side of the machine as shown in the figure Remove the cover 1 open the cover 2 and check the slow blow fuse If any trouble occurs on the slow blow fuse replace the slow blow fuse by referring to MAINTENANCE METHOD FOR REPLACING SLOW BLOW FUSE Slow blow fuse A 80 A Machine s power supply 1 B 120 A Machine s power supply 2 C 120 A Engine preheater power supply D 80 A Battery power supply starting sw...

Page 185: ...ce and transportation The front frame and the rear frame are locked so that the ma chine body is not articulated F FREE position It is used for normal operation The machine body is articulated METHOD OF USING TOWING PIN 1 Position the protrusion 2 of towing pin 1 with groove 3 of the counterweight and insert it 2 Turn the handle 4 of towing pin 1 by 180 OPERATION EXPLANATION OF COMPONENTS 3 119 ...

Page 186: ...e battery disconnect switch in ON position except the following cases When the machine is stored for a long time more than a month When repairing the electrical system When performing the electric welding When handling the battery When replacing the fuse etc Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit If the battery disconnect switch is turned o...

Page 187: ...nnect switch is turned to OFF position every electric system of the machine becomes inoperable The memory of the clock of the monitor is lost Set them again when using Immediately after the starting switch is turned to OFF posi tion data is saved on each controller Before turning the battery disconnect switch to OFF posi tion make sure that the system operating lamp 4 below the battery disconnect ...

Page 188: ...ghts up to return DEF to the tank Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit BACKUP ALARM NOTICE If water directly hits the backup alarm during the high pressure machine washing the water gets in it and the sound pressure decreases Do not jet the water over the backup alarm This alarm sounds as soon as the machine moves in reverse to warn the p...

Page 189: ...ear view monitor 1 is set in operation a monitor screen enables the operator to check the rear for safety REMARK The screen may be hard to see in the dark place at night but it is not a trouble The luminance of the rear view monitor can be adjusted with rearview monitor brightness adjustment switch 2 For the adjustment method see REAR VIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH 3 95 If the object of...

Page 190: ...s to burn the soot is performed automatically to keep the filtering performance of KDPF high This purification process is called the regeneration If operations which lower the purification function of KDPF con tinues for long hours the regeneration is performed to protect the KDPF system regardless of the quantity of the accumulat ed soot During the KDPF regeneration aftertreatment devices regener...

Page 191: ...up in red and the KDPF soot accumulation caution lamp 2 lights up in red engine power deration is activated To restore engine power it is necessary to perform PROCE DURE FOR MANUAL STATIONARY REGENERATION If soot accumulated in the KDPF exceed the defined level without performing PROCEDURE FOR MANUAL STA TIONARY REGENERATION the Action level L04 lights up in red Stop the machine immediately and as...

Page 192: ...ng interval of KDPF filters adversely affect the engine such as deteriorated oil may reduce lubricating function and it may cause failure In addition the regeneration interval may be shortened and the fuel consumption may increase If the mixing ratio of the bio fuel in the diesel fuel is high the regeneration of KDPF may become more fre quent When the degree of emergency is low If KDPF soot accumu...

Page 193: ...OR MANUAL STATIONARY REGENERATION k k CAUTION Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regen eration Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt Also keep combustible materials away from the exhaust pipe outlet and around the aftertreatment devices to pre vent a fire The manual...

Page 194: ... After ENTER switch is pressed in step 6 the screen shown in the figure may be displayed This indicates that the operations in steps 1 to 3 were not performed correctly or there is trouble other than KDPF soot accumulation ab normality Check operation of the engine make sure you are not depressing the accelerator pedal and check the position of the directional lever and parking brake switch then r...

Page 195: ...regenera tion is not displayed and the screen returns to the standard screen At this time to display the explana tion of the manual stationary regeneration again press ENTER switch on the standard screen to dis play Aftertreatment Devices Regeneration screen 7 This screen is displayed during the manual stationary re generation It may take more than 30 minutes to complete the manual stationary rege...

Page 196: ... regeneration disable and cancel of regeneration disable procedures described in the following When restarting the manual stationary regeneration secure the safety of the machine and around it then cancel the regeneration disable 8 After the manual stationary regeneration is completed the screen automatically returns to the standard screen PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE ...

Page 197: ... the engine During the regeneration to protect the system even if the regeneration disable is set aftertreatment devices regen eration pilot lamp 2 may light up but this does not indi cate abnormality Also during the regeneration to protect the system the regeneration disable cannot be operated When the regeneration is performed to protect the system the exhaust temperature is lower than that of w...

Page 198: ...generation screen is not displayed display it by pressing the menu switch several times 2 Select Cancel of Regeneration Disable and press EN TER switch and the regeneration disable is canceled If soot accumulation level 1 lights up 3 or more the re generation may be started automatically REMARK When canceling the regeneration disable release the ac celerator pedal set the directional lever in NEUT...

Page 199: ...uously monitors its operation conditions and stores information on inap propriate operations including malfunctions The information is used for system diagnostics and also for Induce ment required by the authorities on engine systems that use Urea SCR systems Inducement is intended for the operator to take prompt actions to maintain and correct inappropriate behaviors of Urea SCR systems by utiliz...

Page 200: ...tem automatically starts operating as soon as the engine is started Even after the engine starting switch is turned to the OFF position the devices will still be in operation for sever al minutes to purge any DEF in the lines the injector and the supply pump back to the DEF tank It does not indicate any abnormality When DEF has been returned to the tank the devices stop Do not turn OFF the battery...

Page 201: ...vel caution lamp 1 on the ma chine monitor will light up audible alert will start then Action level will be displayed on the machine monitor and engine power will be derated in steps In Action Level L03 Low level Inducement and L04 Severe Inducement engine power will be derated When Action Level 03 or 04 is displayed move the machine to a safe place and add DEF The content of the warning can be ch...

Page 202: ...e SCR Information screen Inducement status 4 2 Without treatment engine power will be derated Add DEF to the DEF tank immediately Low level Inducement The audible alert sounds in Intermittent alarm 1 gradation of the DEF level gauge light up in red The DEF level caution lamp 1 lights up in red Action Level L03 is displayed in red 5 Press the menu switch to display the SCR Information screen Induce...

Page 203: ...chine to a safe place and add DEF Inducement strategy when abnormalities are detected in the Urea SCR System devices Except abnormalities in the KDPF and the EGR system If any abnormality is detected in the DEF quality or in the Urea SCR system the Inducement strategy is activa ted The inducement strategy progresses in 4 levels Warning Continuous Warning Low level Inducement and Severe In ducement...

Page 204: ...actions instructed by the Action Level table Inducement advances to Continuous Warning Continuous Warning The audible alert sounds in Intermittent alarm The DEF system caution lamp 1 lights up in yellow If operation continues for 5 hour after Warning started without taking any actions instructed by the Action Level table Inducement advances to Continuous Warning Press the menu switch to display th...

Page 205: ...gine power is under heavy deration Due to the further deration of engine power capability the machine will be limited further Severe Inducement is the final status of Inducement Unless all the SCR system abnormalities are corrected engine performance will be kept derated Engine power can be restored temporarily from power derate If Inducement advances to Severe Induce ment and it becomes necessary...

Page 206: ...ve the machine to a safe place and contact your Komatsu distributor The content of the warning can be checked on the SCR Information screen of the user menu Perform the following procedure Press the menu switch on the standard screen to display the SCR Information screen of the user menu After a lapse of 3 seconds to stop the machine SCR Informa tion screen is displayed SCR Information screen disp...

Page 207: ...e duration time of Continuous Warning is 5 hour The remaining time Hours and Minutes to Low level Induce ment is displayed in the column 6 of SCR Information screen In Low level Inducement engine power will be derated Low level Inducement The audible alert sounds in Intermittent alarm The KDPF system caution lamp 1 lights up in red The DEF system caution lamp 2 lights up in red The action level L0...

Page 208: ...ucement in this manual If Inducement advances to Severe Inducement and it be comes necessary to restore engine power use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor Inducement strategy when abnormality is found in the EGR Valve System by the Urea SCR system If any abnormality is detected in the EGR Valve System through the Urea SCR...

Page 209: ... dis play 3 Press the menu switch to display the SCR Information screen SCR Information screen message 5 1 Please inspect and maintain SCR system Engine power is derated Move the machine to the safe place and contact your Ko matsu Distributor If operation continues for 5 hour after Warning started without taking any actions instructed by the Action Level table Inducement advances to Continuous War...

Page 210: ... of engine power the machine normal operation will be limited The duration time of Low level Inducement is 10 hour The remaining time Hours and Minutes to Severe In ducement is displayed in the column 6 of SCR Informa tion screen In Severe Inducement engine power will be derated fur ther Move the machine to the safe place and contact your Ko matsu Distributor Severe Inducement The audible alert so...

Page 211: ... machine to a safe place for adding DEF or troubleshooting and correcting abnor malities of the Urea SCR system For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of Low level Inducement through the machine monitor Note that Tempo rary Restoration from Inducement does not regain full engine power Temporary Restoration from Induceme...

Page 212: ...e the Engine power Recov ery window is displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Low level Inducement for the maximum of 30 minutes The remaining time minutes seconds of Temporary Re storation from Inducement is displayed in the column 4 on the SCR Information screen If it is decided NOT to activate Temporary Restoration f...

Page 213: ...han the amount of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the previous Inducement and whether the new abnormality abnormalities is the same as the previous ones or not it is judged as a recurrence If a recurrence occurs Severe Inducement will be activated Inducement in the recurrence...

Page 214: ...using satellite communication or portable radio communication The GPS Global Positioning System receiver and communication system are equipped in the vehicle man agement system The machine information such as the machine maintenance maintenance management operating situation management and machine location management is gathered from the inside network of the machine It can be useful for you to pe...

Page 215: ...her high temperature engine parts If any dirt or combustible materials are found remove them 4 Check around the engine for leakage of coolant oil and exhaust gas Check the engine for leakage of oil and exhaust gas and check the cooling system for coolant leakage If any problem is found repair it 5 Check the fuel line for leakage Check for leakage of fuel or damage to the hoses and tubes If any pro...

Page 216: ...When cleaning the stains deposited on the monitor surface such as dusts brush them off using a clean soft and dry cloth For sticky dirt such as oil remove it with glass cleaner for family use on the market weakly acid to weakly alkaline containing no abrasive and then finish wipe with a clean soft and dry cloth 16 Check the rearview mirrors Check the rear view mirror for trouble If it is damaged r...

Page 217: ...y do not use the following tires Wear Tires with a tread grooves of less than 15 of that of a new tire Tires with extreme uneven wear or with stepped type wear Damage Tires with damage that has reached cords 1 or with cracks in the rubber Tire with cut or broken cords 1 When tires are peeled separated Tires with damaged bead 2 Leaking or improperly repaired tubeless tires Deteriorated deformed or ...

Page 218: ...ngine has run high pressure is generated in the engine fuel piping When draining the water or removing the transparent cup wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting the work Do not bring any open flame close 1 Open the engine side cover 1 on the right side of the machine Water separator 2 is integrated with the fuel prefilter and lo...

Page 219: ...ghts up in red on the machine monitor it indicates that water is accumulated in transparent cup 4 In this case as well use the procedure above to drain the water When only the water separator caution lamp lights up it lights up at position 6 If other caution lamps also light up at the same time the water separator caution lamp lights up at a different position REMARK If drain plug 3 is hard to tur...

Page 220: ...nt is insufficient add the coolant to FULL level through the filler port of the reservoir tank 2 4 Tighten the cap securely after the refilling If reservoir tank 2 is empty leakage of coolant is suspect ed After checking repair any abnormality immediately If no abnormality is found check the level of the coolant in the radiator If it is low add coolant of the same density in radiator according to ...

Page 221: ... oil filler cap F secure ly 7 Close the engine side cover 1 REMARK Wait for at least 15 minutes after stopping the engine after the engine has been operated and check the oil level If the machine is inclining make it level before check ing When the ambient temperature is low water or emul sified matter may stick to the dipstick fuel filler cap etc or the drained oil may be milky white because of w...

Page 222: ...nd their capacity is proper Perform inspection to confirm that there is no disconnection or trace of short circuiting in the electric wiring and no damage to the coating Perform inspection to confirm that there is no loose terminals and tighten any loose parts if found Always check if there is any accumulation of combustible material around the battery and remove such combustible material METHOD F...

Page 223: ...DEF LEVEL AND ADDING DEF k k WARNING Do not put fluid other than DEF into DEF tank When opening the cap of DEF tank of the machine the ammonia vapor may escape Keep your face away from the filler port Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder operation of the devices Before removing the filler cap wipe off the dirt from around the filler port B...

Page 224: ...fer it to another container Do not use a funnel when to add DEF The strainer may be broken When using a portable DEF refill container use up DEF each time If any of DEF is left remove for eign material if there is any Do not wash the adding nozzle in city water Minerals may clog the devices Do not dilute DEF with water If you add fluid other than DEF diesel fuel low concentration DEF etc by mistak...

Page 225: ...ulations 7 By sight gauge 5 add DEF through the filler port until float 6 reaches line F 7 Line 8 in the sight gauge indicates approximately 5 ℓ be low line F and line 10 indicates approximately 10 ℓ Line 9 is the max adding line when DEF may freeze in cold weather 8 After adding align claw 11 of the cap with groove 12 of the filler port and close the cap securely by turning it clock wise by 90 OP...

Page 226: ... wear check the hub nuts bolts for loosening Proper inflation pressure varies with the contents of work etc For detail see TIRE PRESSURE METHOD FOR CHECKING WINDOW WASHER FLUID SPOUTING OUT Operate the window washer and check that the washer fluid spouts out normally If the fluid does not spout out normally clean the washer nozzle hole with a fine wire such as a safety pin If the condition does no...

Page 227: ...bnormality ask your KOMATSU distributor for testing and repair METHOD FOR CHECKING LOCKS Check that all places can be locked properly For the locations of the locks see LOCK 3 206 If there is any abnormality ask your KOMATSU distributor for testing and repair METHOD FOR CHECKING ALTERNATE EXIT OF CAB Operate the open knob for alternate exit of cab and check that the exit opens and closes properly ...

Page 228: ...ward Sit with your back against the backrest when adjusting If your back is not on the backrest it may suddenly return to the original position Adjustment amount Forward tilt 21 any degree is acceptable if it is greater than 21 Backward tilt 33 2 After adjusting release the lever METHOD FOR TILTING SEAT Pull the lever up and move the front side of the seat cushion up and down to the desired positi...

Page 229: ... is low or when the machine has not been used for a while it takes time to raise the seat to desired height since no air is in the suspension You can adjust the seat to desired height more quickly by pressing the switch while reducing the load on the seat METHOD FOR ADJUSTING SEAT CUSHION IN FORE AFTER DIRECTION Operate the lever upward set the seat cushion to the desired position then release the...

Page 230: ...rmrest angle Amount of adjustment 35 Forward tilt 12 backward tilt 23 REMARK You can flip up the armrest METHOD FOR ADJUSTING LUMBAR SUPPORT Turn the knob to the right or left and give proper tension to the waist part METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS By operating the knob the damping force of the suspension damper can be adjusted MACHINE OPERATIONS AND CONTROLS OPERATION 3 164 ...

Page 231: ...ust the knob to 2nd stage position d or 1st stage position c The damper becomes softer METHOD FOR WARMING UP SEAT When the switch is operated in the A direction the heater in side the seat cushion is activated When it is operated in the B direction the heater is turned off Turn off the switch when the temperature of cushion becomes correct k k CAUTION Using the heater for a long time may cause low...

Page 232: ...headrest METHOD FOR ADJUSTING MIRRORS k k WARNING Be sure to adjust the mirrors before starting work If they are not adjusted properly you cannot secure the visibility and may be injured or may lead to a serious personal injury or death NOTICE Tighten the mirror mounting bolts securely to prevent the mirrors from coming off due to loosening of the bolt Tightening torque of mirrors A and B 2 0 to 2...

Page 233: ...range are as follows Visibility range left 2500 mm Visibility range right 2500 mm Mirror A Hatched area a must be in view Mirror B Hatched area b must be in view METHOD FOR ADJUSTING REAR VIEW CAMERA METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE k k WARNING Be sure to adjust the camera before starting work If it is not adjusted properly you cannot secure the visibility and a serious personal injury ...

Page 234: ...1 m away from the machine s rear part W is displayed in the monitor at the operator s seat If the image on the monitor is not aligned correctly adjust mounting angle A of the rear view camera Angle A can be adjusted within the range from 37 to 52 deg MACHINE OPERATIONS AND CONTROLS OPERATION 3 168 ...

Page 235: ... Loosen mounting bolts 1 3 places and adjust angle A REMARK A part of the machine is shown on the monitor screen 2 After adjusting tighten bolts 1 3 places OPERATION MACHINE OPERATIONS AND CONTROLS 3 169 ...

Page 236: ...ening the seat belt check that there is no problem in the belt mounting bracket or belt If it is worn or damaged replace it Even if no problem can be seen in the belt replace the seat belt every 3 years from starting usage or 5 years after manufacture whichever comes sooner The date of manufacture of the belt is shown on the back of the belt Before operating fasten the seatbelt Be sure to use the ...

Page 237: ...nd make sure that the work equipment is locked the pilot lamp in the switch is lit If the multifunction mono lever is touched by accident when adjusting the lever stand the work equip ment may move unexpectedly and cause a serious personal injury or death METHOD FOR ADJUSTING ARMREST HEIGHT AND ANGLE Adjust the height and angle of the armrest 1 according to the following procedure 1 Set the lock l...

Page 238: ...ono lever is touched by accident when starting the engine the work equipment may move unexpectedly and this may lead to a serious injury or death Perform the check before starting the engine according to the following procedure 1 Check that the battery disconnect switch S is in ON posi tion I 2 Check that the parking brake switch 1 is in ON position A MACHINE OPERATIONS AND CONTROLS OPERATION 3 17...

Page 239: ...e the directional selector switch actuation switch 3 is in ON position A 5 Check that the bucket is lowered to the ground If not lower the bucket to the ground in the following procedure 1 Check that the multifunction mono lever is in HOLD position 2 Turn the starting switch 5 to ON position 3 Cancel the work equipment lock the pilot lamp in the switch 6 goes out 4 Operate the multifunction mono l...

Page 240: ...e by short circuiting the engine starting circuit Doing so may cause a fire or serious personal injury or death Check that there is no person or obstacle in the area around the machine then sound the horn and start the engine Exhaust gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not accelerate the engine abruptly until it is w...

Page 241: ...on C after the engine preheating has been completed The starting motor keeps running to start the engine Keep the key in starting switch 1 at position C to keep running the starting motor until the engine starts REMARK When the ambient temperature is low fuel is not supplied to the engine for 3 seconds to ensure lubrication of the en gine and to improve the durability after the key in starting swi...

Page 242: ...of KCCV and blowby piping may be frozen and blocked To prevent freeze stop the engine or if it is necessary to run the engine at idle apply the load from time to time When the engine is started after it has been left at temperature of approximately 20 C for more than a half day it takes time to attain perfect combustion Operate the starting switch according to the following proce dure 1 Turn the k...

Page 243: ... is thawed and supplied but this does not indicate any abnormality When the ambient temperature decreases to a level where DEF may freeze while the machine is in opera tion DEF system is warmed automatically to prevent freezing When the ambient temperature decreases to a level where freezing of DEF is not preventable the devices stop automatically but this does not indicate any abnormality If DEF ...

Page 244: ...TING CONDITION AND UNUSUAL NOISE OF ENGINE When starting the engine check that the engine causes no abnormal noise and that it starts up easily and smoothly Check that there is no abnormal noise when the engine is idling or when the engine speed rises slightly When there is an abnormal noise at the engine startup and if that condition continues the engine may be dam aged In that case ask your Koma...

Page 245: ...en thoroughly adjusted and tested before shipment from the factory However operating the machine under full load before running in the machine can adversely affect the performance and shorten the machine life Be sure to run in the machine for the initial 100 hours as indicated on the service meter Make sure that you fully understand the descriptions in this manual then run in the machine while pay...

Page 246: ... work equipment lock switch after the warm up op eration 3 Operate the multifunction mono lever to TILT position e and to HOLD position b repeatedly to warm up the hy draulic oil Duration of relieving at TILT position e should be within 10 seconds Oil reaches the relief pressure through the above opera tions and hydraulic oil gets warmer in a shorter time 4 Turn the steering wheel slowly approxima...

Page 247: ...ed varies according to the following conditions but it is not abnormal The cooling fan speed increases when the hydraulic oil temperature or engine coolant temperature is high The cooling fan rotates at a fixed speed in proportion to the engine speed regardless of any oil or coolant temper ature while it is rotating in reverse METHOD FOR STOPPING ENGINE k k WARNING Keep away from the exhaust pipe ...

Page 248: ... turned to OFF position A while the engine is still hot guidance 2 may be displayed on the machine monitor To cool down the engine before stopping run it at low idle the next time and after because it may cause damage to the devi ces METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND SHIFTING GEAR AND STOPPING MACHINE METHOD FOR MOVING MACHINE k k WARNING Always disengage the frame lock ba...

Page 249: ...n HOLD position 3 Cancel the work equipment lock the pilot lamp in the switch goes out with the work equipment lock switch 3 4 Operate the multifunction mono lever 2 to set the work equipment to the travel posture as shown in the figure A 30 cm OPERATION MACHINE OPERATIONS AND CONTROLS 3 183 ...

Page 250: ...7 Set the directional lever 6 to the desired position Position F FORWARD Position N NEUTRAL Position R REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE If the backup alarm does not sound ask your Komatsu dis tributor for repair REMARK You can also use the directional selector switch 7 to set the travel direction to FORWARD NEUTRAL and RE VERSE Position F FORW...

Page 251: ...ped in between speed ranges the centralized warning lamp may light up and the alarm buzzer may sound This is not a failure in this case Operate the speed range selector switch so that the selec tion of the speed range is completed within 2 seconds When the machine is traveling at high speed if the speed range selector switch is operated to a slower speed range such as from 4th to 3rd and from 4th ...

Page 252: ...irectional selection while the machine is traveling at a high speed when 3rd or 4th speed is used the centralized warning lamp lights up and alarm buzzer sounds if the travel speed and engine speed are in hatched area of the table If the alarm buzzer sounds depress the brake pedal immedi ately to reduce the travel speed sufficiently then make a direc tional selection X Travel speed km h Y Engine s...

Page 253: ...n reverse in accordance with the directional lever 1 regardless of the position of the directional selec tor switch 2 Be careful to operate because the operation of the direc tional lever 1 is prior 1 Set the directional lever 1 to NEUTRAL N position 2 Set the directional selector switch 2 to NEUTRAL posi tion N 3 Turn the directional selector switch actuation switch 3 to ON position A OPERATION M...

Page 254: ...ccordance with the directional lever 1 posi tion Set the directional lever 1 to NEUTRAL N position When the directional selector switch 2 is in FORWARD F or REVERSE R position when starting the engine The directional selector pilot lamp lights up in yellow the centralized warning lamp lights up and the alarm buzzer start sounding intermittently at the same time The engine does not start under this...

Page 255: ...brake after the machine is stopped 1 Release the accelerator pedal 1 then depress the brake pedal 2 to stop the machine 2 Set the directional lever 3 and the directional selector switch 4 to NEUTRAL N position 3 Set the parking brake switch 5 to ON position A and apply the parking brake OPERATION MACHINE OPERATIONS AND CONTROLS 3 189 ...

Page 256: ...he machine is traveling turn the steering wheel 1 to the desired direction then the machine turns to the di rection Front and rear frames of this machine is articulated around the connection pin center pin at which the 2 frames are connected with each other and the rear wheels follow the trace of the front wheels Turn the steering wheel lightly as it follows the turning of machine NOTICE When stee...

Page 257: ...ering oil pressure caution lamp red 3 and the centralized warning lamp 4 light up and the alarm buzzer sounds intermittently The steering oil pressure caution lamp red 3 lights up to in form the operator that there is a failure in the steering system If the steering oil pressure caution lamp red 3 lights up move the machine immediately to a safe place and stop it there Do not operate the machine u...

Page 258: ...that position When the remote boom positioner is enabled the boom stops at the preset position and the lever returns to HOLD position at the same time The boom stops at the highest position and the lever returns to HOLD position at the same time when the remote boom posi tioner is disabled Position b HOLD The boom remains in the position where it was stopped Position c LOWER Position d FLOAT The b...

Page 259: ...If the machine is not stopped by depressing the brake pedal use the parking brake to stop the machine NOTICE If the parking brake was used as a secondary brake ask your Komatsu distributor to inspect the park ing brake system for any trouble PRECAUTIONS WHEN TRAVELING ON SLOPES LOWER CENTER OF GRAVITY WHEN STEERING MACHINE When turning the machine on a slope lower the work equipment to lower the c...

Page 260: ...bruptly to prevent the radiator coolant temperature from rising sharply Cool the radiator coolant down gradually before stopping the engine Always travel with the bucket empty Never travel with calcium chloride or dry ballast in the tires PAY ATTENTION TO DEF LEVEL Before working on a slope or traveling on a rough ground check DEF tank and add sufficient amount of DEF as necessary If the remaining...

Page 261: ...ng the multifunction mono lev er to the bucket TILT position from time to time Try to scoop the material in the center of the bucket so that the load does not become uneven 3 When it is hard to thrust the bucket into the stockpile move the bucket edge upward and downward by shifting the multifunction mono lever to the right and left DIG AND LOAD ON HORIZONTAL SURFACE When digging the ground in dig...

Page 262: ...t is unavoidable to drive the machine forward for the leveling work do not set the bucket dumping angle to more than 20 The work equipment may be damaged Keep ECSS switch turned OFF during leveling work 1 Scoop earth and sand into the bucket and then while driv ing the machine in reverse tilt the bucket forward to dump earth and sand bit by bit to spread them 2 When leveling the ground tilt the bu...

Page 263: ...opper glory hole etc Maintain the travel road constantly in good condition LOADING WORK Select an efficient loading method which minimizes the number of turns and travel distance according to the job site k k WARNING Maintain the ground of job site level Do not perform sudden steering or braking while the boom is being raised with the bucket loaded This is dangerous Never thrust the work equipment...

Page 264: ... load the soils onto the dump truck The smaller the turning angle of the wheel loader is the more efficient the operation becomes Before raising the boom to the maximum height after filling the bucket with load shake the bucket near the ground to stabilize the load then raise the bucket This will prevent the load from spilling to the rear PRECAUTIONS FOR FORKING WORK When scooping soils up onto a ...

Page 265: ...unction mono lever Do not enter under the work equipment while the boom is raised The bucket can be stopped automatically at the desired height with the remote boom positioner the boom must be higher than the boom horizontal position and at the desired digging angle with the bucket positioner The bucket is adjustable to the desired position according to the operating condition REMOTE POSITIONER Th...

Page 266: ... boom rises and then stops at the moment when the multifunction mono lever returns from the RAISE detent position to HOLD position REMARK When the multifunction mono lever is set to RAISE detent position if the boom is very close to the position specified by the positioner approximately within 2 the lever is not stopped at the RAISE detent position For the boom RAISE detent function see BOOM RAISE...

Page 267: ...osition where it is pulled further than RAISE position to HOLD position near the maximum height the boom stops If the remote positioner is effective the remote positioner pilot lamp lights up on the machine monitor METHOD FOR ADJUSTING BUCKET POSITIONER 1 Lower the bucket to the ground 2 Return the multifunction mono lever to HOLD position ac cording to the desired digging angle 3 Press the work e...

Page 268: ...he switch to the bucket position A 6 Loosen the nut 1 and adjust the position of proximity switch 3 so that the rear end A of the bar 2 is matched to the center of sensory surface B of the proximity switch 3 MACHINE OPERATIONS AND CONTROLS OPERATION 3 202 ...

Page 269: ...u can check the bucket angle during the operation with the indicator at the top right side corner of the bucket A Top face of indicator Top face A of the indicator is in parallel with the cutting edge B Side face of indicator Side face B of the indicator is at a right angle to the cutting edge PZ AUTO TILT IN This machine employs the structure to keep the tilt angle parallel to the ground while ra...

Page 270: ...RNING Stop the machine gradually Avoid a sudden stop Do not park the machine on a slope If it is unavoidable to place the machine on a slope place the machine at a right angle to the slope face chock the tires and then lower the bucket to the ground The machine may move suddenly if the control lever is touched by accident This may lead to a serious per sonal injury or death Before leaving the oper...

Page 271: ... 3 Set the parking brake switch 4 to ON position A to apply the parking brake 4 Operate the multifunction mono lever 5 to lower the bucket 5 Check that the multifunction mono lever 5 is in HOLD position 6 Press the work equipment lock switch 6 and lock the work equipment the pilot lamp in the switch is lit OPERATION MACHINE OPERATIONS AND CONTROLS 3 205 ...

Page 272: ...ge If oil or coolant leakage or any abnormality is detected repair it 2 Check DEF tank pump injector hose and joint for leakage If any abnormality is found ask your Komatsu distributor for repair 3 Fill the fuel tank 4 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 5 Remove any mud affixed to the undercarriage LOCK Position to be locked Alwa...

Page 273: ... PROCEDURES FOR LOCKING FUEL FILLER PORT CAP 1 Screw in the oil filler cap 2 Insert the starting switch key into the key slot 3 Turn the starting switch key to LOCK position B and then align the key slot with match mark 1 of the cap Position A OPEN Position B LOCK 4 Remove the starting switch key METHOD FOR OPENING AND CLOSING HYDRAULIC OIL FILLER PORT CAP PROCEDURES FOR OPENING HYDRAULIC OIL FILL...

Page 274: ...ch key into the key slot 3 Turn the starting switch key to LOCK position B Position A OPEN Position B LOCK 4 Remove the starting switch key 5 Install the cover 2 with bolt 1 METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pull ing the cover handle Position A position OPEN Posi...

Page 275: ...und on a tubeless tire Do not install the tire protector mesh chain to rear wheels Do not to use tires such as urethane tires that weigh remarkably more than the standard tires since the ma chine can be damaged due to an unexpected load If a tire not specified by Komatsu is used rim dis placement may occur between the tire and rim Opera tor comfort may be degraded as well 1 Side wall 2 Shoulder 3 ...

Page 276: ...ing much digging force Low end of range in the following table If the deflection of the tire is excessive raise the inflation pressure within the limits given in the following table to give a appropriate deflection see deflection ratio Tire size Pattern H Free height mm Air pressure kPa kg cm2 Ground sandy ground Normal road When shipped from the plant Stock pile Digging 20 5 R25 L3 Rock Front whe...

Page 277: ...d maintenance When the air conditioner is not used every day to prevent loss of the film of oil at various parts run the air conditioner with the engine at low speed from time to time and perform cooling or dry heating for several minutes To prevent leakage of the refrigerant from the air conditioner cooling circuit operate the air conditioner for several minutes 2 or 3 times a month during the of...

Page 278: ...mbol OFF SWITCH The OFF switch is used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH Use the fan switch to adjust the air flow from the fan in the manual operation When switch A is pressed while the air conditioner power supply is OFF the electric power for the air conditione...

Page 279: ...raise the set temperature press the switch to lower the set temperature The set temperature is indicated on the display monitor The temperature is generally set at 25 C The temperature can be set in stages of 0 5 C Monitor display and function Monitor display Set temperature 18 C Max cooling 18 5 to 31 5 C Adjusts temperature inside cab to set temperature 32 C Max heating REMARK If the mode is set...

Page 280: ...t from the vents displayed When this switch is pressed in the defroster mode the vents right before being switched to DEF is selected During automatic operation the vents are automatically selected A FACE 2 places B FOOT 2 places C DEF 2 places D DEF 2 places Monitor display Vent mode Vent Remarks A B C D Face vent Face and foot vents Foot vent Foot and defroster vents Defroster vent Cannot be sel...

Page 281: ...to the environment If the environment changed suddenly by leaving cab door open for a long time etc the control of air conditioner may change temporarily but this is not a failure Even if the control changes it returns automatically to control the air according to the environment after certain period of time elapses FRESH RECIRC AIR SELECTOR SWITCH Use FRESH RECIRC air selector switch to switch th...

Page 282: ...ir conditioner switch to start and stop the cooling heating or drying function When the air conditioner switch is pressed while the main power switch is turned ON the air conditioner is turned ON and the air conditioner operation symbol is indicated on the display monitor If the switch is pressed again it is turned OFF and the op eration symbol on the display monitor goes out HANDLE AIR CONDITIONE...

Page 283: ...r from the vents to match the strength of the sun s rays Only in automat ic operation mode In addition it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun s rays beforehand and automatically adjusts the temperature METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of opera...

Page 284: ...s set do not operate the temperature control switch unnecessarily It may take longer time to reach the set temperature To heat or cool air quickly set the temperature display to 18 0 C max cooling or 32 0 C max heating If any switch is operated during automatic operation the function of that switch is applied first and AUTO on the air conditioner monitor goes out and the man ual operation is selec...

Page 285: ...ax heating 4 Press vent selector switch and select the desired vents At this time the display for the vent of the display monitor changes according to the selection 5 Press the FRESH RECIRC air selector switch and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH REMARK To heat or cool the air quickly set the temperature dis play to 18 0 C max cooling ...

Page 286: ... to Hi METHOD FOR OPERATING DEMIST Dew condensation adhered to the inside of the window glass can be removed by demist operation 1 Press the defroster switch to set the vents in DEF mode 2 Press air conditioner switch and perform the cooling or dry heating operation To remove the dew condensation quickly press the fan switch to set the air flow to Hi REMARK Do not decrease the set temperature too ...

Page 287: ...tion return to the ground or to the bed of the trailer then change the travel direction The center of gravity of the machine shifts suddenly at the joint of the ramps and the trailer so there is a danger of the machine losing its balance Accordingly pass this point slowly When loading or unloading always use ramps or a platform Proceed as follows PROCEDURES FOR LOADING MACHINE Load on a firm and l...

Page 288: ...om the starting switch 6 Set the frame lock bar to LOCK position L to lock the front and rear frames 7 Set chocks at the front and rear of the tires to prevent the machine from moving during transportation 8 Tie one end of each chain or wire rope of appropriate strength to the tie down holes as shown in the figure and secure the machine Secure the machine so that it will not move during transporta...

Page 289: ...Securing position Fixing angle A 69 B 59 C 33 D 46 Expected trailer width E 2990 mm OPERATION TRANSPORTATION 3 223 ...

Page 290: ...er securely 2 Set the chocks 1 to the front and rear of the tires to se cure the trailer 3 Set the right and left ramps 2 parallel to each other and equally spaced to the right and left of center 3 of the trail er Make the installation angle 4 at maximum of 15 If the ramps bend a large amount under the weight of the machine put blocks 5 under the ramps to prevent them from bending 4 Remove the cha...

Page 291: ...the machine from moving unexpected ly Set the parking brake switch to ON position Lock the work equipment the pilot lamp in the switch is lit Set the frame lock bar to the LOCK position Never enter the area under or around a lifted machine There is a danger of the machine losing its balance Use the procedure below to set the machine in the proper posture and use the sling when lifting the machine ...

Page 292: ... lifting tools such as the wire rope and sling suita ble for the weight of the machine as shown in the figure of the lifting position Reeve the wire rope to the lifting posi tions of the machine NOTICE Use protectors etc so that the wire ropes will not be broken at sharp edges or narrow places Width of the threader and bar must be sufficient for preventing the lifting equipment and wire rope from ...

Page 293: ... interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR CLEANING INSIDE OF COOLING SYSTEM 4 20 DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break the devices in the tank The parts inside the tank may be affected Add DEF to the specified amount for cold weather below the level of when DEF may freeze For the specified amount of DEF see METHOD FOR CH...

Page 294: ...ards prevent the tracks from freezing to the ground and allow the machine to move the next morn ing Open the drain valve and drain any water collected in the fuel system to prevent it from freezing Fill up the fuel tank This minimizes moisture condensation in the tank when the temperature drops In cold weather condition add DEF to the defined level strictly If adding more than the defined level it...

Page 295: ...hat a new film of oil will coat moving parts At the same time charge the battery as well When operating the work equipment wipe off all the grease from the hydraulic cylinder rods If the machine 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...

Page 296: ...tem has any abnormality stop the engine and then start it again If SCR system still has abnormality after the engine is restarted contact your Komatsu distributor If DEF is kept in DEF tank for more than 1 year ask your Komatsu distributor for replacement Dispose of drained DEF according to the local regulations and rules Aged DEF may have smell of ammonia Replace DEF in a well ventilated place an...

Page 297: ... the towing operation never stand between the towing machine and the machine being towed Operate the machine slowly and be careful not to ap ply any sudden load to the wire rope If there is a failure in the brake system the brakes will not work so be extremely careful NOTICE Tow the machine only for a short distance such as to a place for inspection and maintenance Do not tow the machine for a lon...

Page 298: ...ible to determine beforehand the re quired traction force Towing on flat level roads will require the minimum rim pull while towing on slopes or on uneven road surfaces will require the maximum rim pull Connect a wire rope to the part indicated with the arrow in the drawing For the towing pin see METHOD OF USING TOWING PIN 3 119 TOW THE MACHINE WHOSE ENGINE CAN BE STARTED If the transmission and s...

Page 299: ...tem so remove the front and rear drive shafts If necessary chock the tires to prevent the machine from moving 2 The steering cannot be operated so remove the steering cylinder Even if the brakes are in good condition the brakes can only be used a limited number of times There is no change in the operating force for the brake pedal but the braking force is reduced each time the pedal is depressed 3...

Page 300: ...il they stop evenly The parking brake is released A Plug mounting hole M14 O ring boss B Releasing screw hole M10 METHOD FOR OPERATING MACHINE IN EMERGENCY The speed range is selected by electric signals in normal operation If there should be a failure in the electrical system and the machine does not move ask your Komatsu distributor The machine may be able to travel temporarily by operating the ...

Page 301: ... first connect the cable to the positive terminal If a tool touches the positive terminal and the chassis it is dangerous that it may cause a spark Be extremely careful If the terminals are loose it is dangerous that the de fective contact may generate sparks and it may cause an explosion Install the cable terminals securely When removing or installing the cable terminals check which is the positi...

Page 302: ...tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or the battery cells will dry up and this may cause the battery to catch fire and explode If the battery electrolyte i...

Page 303: ...bles and clips are firmly connected Check that the work equipments of both machines are locked the pilot lamps are lit or the parking brake switches are in LOCK position Check that each lever is in NEUTRAL position To prevent damage of the electric devices of the failed machine turn the starting switch of the failed machine to OFF position check that the system operating lamp is not lit and then t...

Page 304: ...Remove the clip of jumper cable A from the positive terminal of battery C on the failed machine OTHER TROUBLE PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM For the remedies indicated with in the remedy column always contact your Komatsu distributor In cases of problems or causes which are not listed below ask your Komatsu distributor for repairs Problem Main causes Remedy Lamp does not glow brightly...

Page 305: ...pair PHENOMENA AND ACTIONS FOR CHASSIS Contact your Komatsu distributor for the remedies indicated with in the remedy column Ask your Komatsu distributor for repairs for problems or causes which are not listed below Problem Main causes Remedy HST Engine runs but machine does not move Parking brake is applied Release the parking brake Directional lever is not shifted in posi tion completely Set the...

Page 306: ...g Play in steering cylinder pin Lubricate the bearing Change the pins and bushings Lack of oil in the hydraulic tank Add oil to specified level by referring to EVERY 100 HOURS MAINTE NANCE Parking brake Braking effect is poor Disc has worn Replace the disc Brake drags or remains applied Lack of oil in the hydraulic tank Add oil to specified level by referring to EVERY 100 HOURS MAINTE NANCE Hydrau...

Page 307: ...is im proper Replace oil See USE OF FUEL METHOD FOR USING FUEL COOL ANT AND LUBRICANTS ACCORD ING TO AMBIENT TEMPERATURE Clogged oil filter cartridge Replace cartridge See EVERY 500 HOURS MAINTENANCE Oil leakage due to improper connec tion or breakage of oil pipe or pipe joint Check repair Defective engine oil pressure sensor Replace sensor Defective monitor Replace monitor Steam spurts out from t...

Page 308: ... or bluish Water entry in the aftertreatment de vices Check repair Breakage of the aftertreatment devi ces Replace the aftertreatment devices Excessive oil in oil pan Set oil to specified level See CHECKS BEFORE STARTING Improper fuel Replace with specified fuel Exhaust gas turns black from time to time Breakage of the aftertreatment devi ces Replace the aftertreatment devices Clogged air cleaner ...

Page 309: ...r the re placement the machine still can perform normal operation but ask your Komatsu distributor for inspection immediate ly When failure code CA4166 SCR Temperature Sensor ECU High Temperature Error is displayed raise the cool ing fan speed by raising the engine speed to emit the heat inside the engine room Telephone number for the point of contact when an error occurs When an error screen is d...

Page 310: ......

Page 311: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 312: ...e the strainer while adding DEF WELDING INSTRUCTIONS When conducting weld repair turn the starting switch to OFF position and after confirming that the system operating lamp is turned off set the battery disconnect switch key to OFF position and pull it out Do not apply a voltage higher than 200 V continuously Connect grounding cable within 1 m of the area to be welded If grounding cable is connec...

Page 313: ...aced or the hydraulic piping is disconnected the air must be bled from the circuit For bleeding air see METHOD FOR CHANGING OIL IN HYDRAULIC TANK CLEANING HY DRAULIC TANK STRAINER 4 64 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with new parts When doing this be careful not to forge...

Page 314: ... according to the ambient temperature For detail see RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 CLOSE ENGINE SIDE COVER SECURELY When closing the engine side cover after inspection and maintenance lock it securely with the catcher If the engine side cover is not locked with the catcher the engine side cover may open PRECAUTIONS FOR MAINTENANCE MAINTENANCE 4 4 ...

Page 315: ...cular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too much oil or too little oil are both causes of failures If the oil in the work equipment is not clear there is probably water or air getting into the circuit In such cases consult your Komatsu distributor When changing the oil always r...

Page 316: ...rts of the cooling system When using antifreeze always observe the precautions given in Operation and Maintenance Manual Non Amine Engine Coolant AF NAC is already diluted with distilled water so it is not flammable The coolant density needs to be changed according to the ambient temperature For the coolant density see METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4 20 Even in areas where it is not...

Page 317: ...r overhaul so they do not need grease If any part becomes stiff after being used for long time add grease Always wipe off all of the old grease that is pushed out when greasing Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts PERFORM KOWA Komatsu Oil Wear Analysis KOWA is a maintenance service that makes i...

Page 318: ...ner Make sure that transfer equip ment and tank must meet DEF compatible material specification If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container The relationship between the upper limit of storage temperature and the storage period of DEF is shown in the table Temperature of storage area Storage period Max 10 C Up to 36 month...

Page 319: ... connectors of electrical components after washing the machine or in the rain wipe off the water drop stuck around connectors before removing the connectors and keep the water drop away from inside of the connectors Checking and maintenance items are checking fan belt tension checking damage of the fan belt and checking battery fluid level Komatsu recommends installing electric components specifie...

Page 320: ...f bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 3 31 67 111 172 1 35 3 2 6 8 11 3 17 5 11 8 to 14 7 27 to 34 59 to 74 98 to 123 153 to 190 1 2 to 1 5 2 8 to 3 5 6 0 to 7 5 10 0 to 12 5 15 5 to 19 5 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 52 3 70 3 90 235 to 285 320 to 400 455 to 565 610 to 765 785 to ...

Page 321: ...77 to 245 18 0 to 25 0 10 33 41 216 22 0 177 to 245 18 0 to 25 0 Face seal Nominal No of hose Nominal size thereads per inch a Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 02 9 16 18UN 19 44 4 5 34 to 54 3 5 to 5 5 03 11 16 16UN 22 74 7 5 54 to 93 5 5 to 9 5 04 13 16 16UN 27 103 10 5 84 to 132 8 5 to 13 5 05 1 14UNS 32 157 16 0 128 to 186 13 0 to 19 0 06 1 3...

Page 322: ...CTION OF ECSS ACCUMULATOR 4 39 METHOD FOR CHECKING FUNCTION OF BRAKE ACCUMULATOR 4 39 SELECT AND CHECK TIRES 4 40 METHOD FOR CLEANING AND REPLACING FUEL TANK BREATHER ELEMENT 4 41 CHECKS BEFORE STARTING 4 43 EVERY 50 HOURS MAINTENANCE 4 44 METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK 4 44 EVERY 100 HOURS MAINTENANCE 4 44 METHOD FOR LUBRICATING WORK EQUIPMENT 4 44 METHOD FOR LUBRICATING RE...

Page 323: ...RESSURE PIPING CLAMP HARD ENING OF RUBBER 4 83 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 84 EVERY 4500 HOURS MAINTENANCE 4 84 METHOD FOR CLEANING KDPF 4 84 METHOD FOR CLEANING DEF TANK 4 84 EVERY 8000 HOURS MAINTENANCE 4 84 METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP 4 84 METHOD FOR REPLACING STARTING MOTOR 4 84 EVERY 9000 HOURS MAINTENANCE 4 84 METHOD FOR ...

Page 324: ...urs after chang ing Every 500 hours Every 1000 hours Within 500 operating hours after changing After 500 op erating hours after chang ing Within 500 operating hours after changing After 500 op erating hours after chang ing Fuel prefilter cartridge Replace Replace Replace Replace Replace Fuel main fil ter cartridge Replace Replace Replace Replace MAINTENANCE SCHEDULE TABLE MAINTENANCE 4 14 ...

Page 325: ...use of the re action when pulling out the outer element NOTICE Do not clean the element before the yellow piston shown in dust indicator 2 display enters the red 7 5 kPa 0 08 kg cm2 position If the element is cleaned frequently before the yellow piston of the dust indicator enters the red 7 5 kPa 0 08 kg cm2 position the air cleaner will not be able to display its performance fully and the cleanin...

Page 326: ...ters the red 7 5 kPa 0 076 kg cm2 position soon after the cleaning the element must be re placed For the replacement of the element see METHOD FOR REPLACING AIR CLEANER ELEMENT 4 18 METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT 1 Open the engine side cover 1 on the right side of the ma chine 2 Remove the clips 2 4 places and remove the cover 3 3 Pull out the outer element 4 NOTICE Never remove the...

Page 327: ...in a dry place 5 Blow dry compressed air 0 2 MPa 2 1 kg cm2 or less from the inside of the outer element along the pleats 6 Blow along the pleats from the outside then blow again from the inside 7 Peel off a seal after cleaning the element each time 8 After the cleaning illuminate the inside of the element with an electric bulb to check If it has a small hole or thin part replace it k k CAUTION Wh...

Page 328: ...on after the cleaning replace both the inner and outer elements METHOD FOR REPLACING AIR CLEANER ELEMENT 1 Open the engine side cover 1 on the right side of the ma chine 2 Remove the clips 2 4 places and remove the cover 3 3 Pull out the outer element 4 Do not remove the inner element 5 at this time 4 Clean the interior of the air cleaner body cover 3 and va cuator valve 6 with a clean cloth a whi...

Page 329: ...reakage of the air cleaner element or serious damage to the engine 6 Install the cover 3 according to the following procedure 1 Set the new outer element 4 2 Replace the O ring 7 with a new one 3 Install the cover 3 and fix it with clip 2 7 Push the button of dust indicator The yellow piston returns 8 Replace the seal 8 on the cover 3 with a new one 9 Close the engine side cover 1 on the right sid...

Page 330: ...r comes sooner 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 coolant is essential Komatsu machines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000...

Page 331: ...lled water so it is not flammable For dilution water see COOLANT AND WATER FOR DILUTION 4 6 Check the density with a coolant tester Items to be prepared A container whose capacity is enough to receive the specified capacity of coolant A hose to add coolant 1 Place the machine on a level ground then stop the engine 2 Remove the radiator top cover 1 3 Check that the coolant temperature is low enough...

Page 332: ...otation has become smoother then press the work equipment lock switch 6 to release the work equipment lock pilot lamp goes out 12 Operate the multifunction mono lever 7 to TILT position e and to HOLD position b repeatedly to warm up the hydraulic oil Oil reaches the relief pressure through the above opera tions and hydraulic oil gets warmer in a shorter time 13 Turn the steering wheel slowly appro...

Page 333: ...und the center of scale A after that continue the above operations for approxi mately 10 seconds 14 Stop the engine 15 Open the drain valve 4 to drain the coolant 16 Close the drain valve 4 17 Add the Non Amine Engine Coolant through the coolant filler port up to the mouth of the port For the concentration of Non Amine Engine Coolant see Coolant density table NOTICE Add less than 12 ℓ min of the N...

Page 334: ...ediately after the engine is stopped parts and oil are still very hot Wait for the temperature to go down and then start the work If ooze of oil is recognized on the transfer case perform the checks 1 Start the engine 2 Perform the warm up operation of the transfer After finishing the warm up operation keep running the engine at low idle for 5 minutes or longer REMARK The completion of the warm up...

Page 335: ...pstick G into the dipstick pipe and tighten the cap NOTICE The oil level changes according to the oil temperature Check the oil level after completing the warming up operation of the transfer If the oil temperature of the transfer is low the oil level at low idling becomes lower than the mark B on HOT IDLE side If the oil volume is correct the oil level is between the marks A and B on HOT IDLE sid...

Page 336: ...to prevent entry of dusts through the mounting location of the breather METHOD FOR CHECKING OIL LEVEL IN AXLE CASE AND ADDING OIL k k WARNING When checking the oil level apply the parking brake and fix the front and rear frames using the frame lock bar Immediately after the engine is stopped parts and oil are still very hot Wait for the temperature to go down and then start the work If ooze of oil...

Page 337: ...hat the amount of the lubricating oil for the axle with Limited Slip Differential may be different Always use the specified lubricating oil 5 If the oil level exceeds the upper groove H drain the ex cessive oil through drain plug P and then check the oil level again 6 If the oil level is appropriate install plug 1 Tightening torque 93 to 123 Nm 9 5 to 12 5 kgm METHOD FOR CLEANING AXLE BREATHER k k...

Page 338: ...r the cleaning since it is dangerous as the condenser is heated If the pressurized water hits a person directly or dirt scatters by use of it there is a danger of per sonal injury Wear the protective equipment such as the protective eyeglasses and dust mask If dirt or dust is stuck to the condenser clean them by using water If water pressure is excessive the fin may be deformed So cleaning by usin...

Page 339: ...FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE NOTICE When rotating the fan in the reverse direction beware extremely that dirt will not fly out and cloth etc will not be wound in the fan Since dust may be blown up check that there is no people around while the fan is rotating in reverse On the job site where the dirt sticks easily to radiator or cooler set the automatic cooling fan to rotat...

Page 340: ...until the oil and coolant temperature goes down before operating the switch In a cold circumstance perform the cleaning by Fan Reverse Mode within less than 5 minutes If the fan reverse rotation is performed for a long time DEF hose may freeze METHOD FOR CLEANING FIN WITH COMPRESSED AIR k k WARNING When opening fan guard stop the engine and display warning tag on multifunction mono lever METHOD FO...

Page 341: ...s a danger that the in ternal fins of the heat exchange equipment may be de formed and this will cause early clogging and break age of the equipment 4 Check the rubber hoses If any hose is cracked or hardened by age replace it with a new one Also check and tighten all the loose hose clamps 5 After cleaning close the fan guard 3 and rear grille 1 METHOD FOR CLEANING FIN WITH ENGINE SIDE COVER OPEN ...

Page 342: ...ing re placed Set the work equipment in a stable condition stop the engine then lock the work equipment the pilot lamp in the switch lights up Turn or replace the cutting edge before the wear reaches the edge of the bucket 1 Raise the bucket to a suitable height then put a block A under the bucket to prevent the bucket from lowering Raise the bucket to make its bottom surface level 2 Remove bolts ...

Page 343: ...the bolts and nuts 1 and 2 and remove the bucket teeth 3 5 Clean the mounting surface of bucket teeth 3 6 Install a new teeth to the bucket Eliminate the clearance between the teeth and top face of the bucket by inserting shims Continue the adjustment with shims until the insertion of 0 5 mm thick of shim becomes impossible If the wear extends to the mounting surface repair the mounting surface be...

Page 344: ...136 kgm 5 814 to 912 Nm 83 to 93 kgm 10 After operating several hours check that the pin does not come out METHOD FOR REPLACING KMAX TEETH if equipped Replace the tooth before the wear reaches to the adapter Items to be prepared Socket wrench with 11 mm of width across flats and torque wrench REMARK The wear will become uniform by rotating the mounting position of the tooth This will extend the se...

Page 345: ...ate the shaft from the lock state 90 to free state 0 3 Check that the maximum torque is 11 Nm 1 12 kgm and above If the torque value is low replace the pin with a new one T1 Torque Nm T2 Turning angle degree REMARK The torque value increases gradually and reaches to the maximum at approximately 45 and it decreases gradually after 45 7 Clean the mounting surface of tooth 2 8 Fit new tooth 2 to the ...

Page 346: ... the cover 1 METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING LEVEL OF REFRIGERANT GAS k k WARNING If the refrigerant used in the air conditioner gets into your eyes or is splashed on your hands it may cause loss of sight or frostbite Never touch the refrigerant Do not loosen any part of the refrigerant circuit Do not bring any open flame close to any point where the refrige...

Page 347: ...ate B After the air conditioner switch is turned on bubbles are seen continuously Insufficient Condition viewed through the sight glass State of refrigerant flow Bubbles are seen Gaseous and liquid refrigerants are mixed No bubble All refrigerant becomes liquid and transparent Milky white Oil and refrigerant are separated and their mixture is milky white MAINTENANCE AND SCHEDULE OF AIR CONDITIONER...

Page 348: ...operating lamp is not lit set the battery disconnect switch key to OFF position Replace the slow blow fuse with the one of the same capacity Should the slow blow fuse is blown investigate the cause and take necessary actions The slow blow fuse is on the side of the engine on the left side of the machine 1 Remove the cover 1 2 Open the cover 2 of the slow blow fuse box and check it 3 Turn the start...

Page 349: ...on of the machine during travel 2 Compare the vertical motion of the machine when the ECSS switch is turned to ON position and OFF posi tion If there is no change in the vertical motion the accumulator gas pressure has probably dropped Ask your Komatsu distributor for inspection REMARK Perform the inspection while the travel speed is 10 km h or higher ECSS Electronically Controlled Suspen sion Sys...

Page 350: ...ding to the conditions of use and the weight of the attachments of the machine Use the tires shown in the following table The travel speed displayed varies with the tire size NOTICE For usability of tires consult your Komatsu distributor Do not install the tire protector mesh chain to rear wheels Do not to use tires such as urethane tires that weigh remarkably more than the standard tires since th...

Page 351: ...at high speed or operating under heavy load Check the tire inflation pressure before starting work while the tires are cold When inflating a tire use an air chuck which can be fixed to the air valve of the tire as shown in the figure Do not work in front of the rim but work on the tread side of the tire 1 Measure the inflation pressure with a tire inflation pressure gauge 2 Adjust the inflation pr...

Page 352: ...low the dry compressed air from the inside of the ele ment 6 After cleaning install the element to the breather body At that time install the element in correct direction Direct the surface having the mark shown by 7 toward up to install 7 Install the cover 5 8 Tighten the nut 4 Tightening torque 10 to 14 Nm 1 0 to 1 4 kgm 9 Close the engine side cover 1 and rear grille 2 NOTICE If the element is ...

Page 353: ...ar and check the mounting bolts and nuts for looseness Check the handrails and steps for breakage and loose bolts Check the gauges and monitor for problem Check the rear view mirror Check the air cleaner mounting bolts for looseness Check the battery terminals for looseness Check the seat belt and mounting hardware Clean the cab windows Check the tires Check the rims Check the rear view monitor ME...

Page 354: ...t side of the fuel tank and drain the sediment and water accumulated at the bottom together with fuel 3 When only the clean fuel flows out close drain valve 1 EVERY 100 HOURS MAINTENANCE Maintenance for every 50 hours service should be performed at the same time METHOD FOR LUBRICATING WORK EQUIPMENT 1 By using a grease pump pump in grease through the grease fittings shown by arrows Pump in grease ...

Page 355: ...n 2 places Grease bucket pin 1 bell crank pin 3 and boom pivot pin 6 with the work equipment in the posture shown in the figure Lower the bucket to the with its bottom parallel to the ground METHOD FOR LUBRICATING REAR AXLE PIVOT PIN 2 places 1 By using a grease pump pump in grease through the grease fittings 1 MAINTENANCE MAINTENANCE PROCEDURE 4 45 ...

Page 356: ...ler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully NOTICE If the oil is added to above H mark stop the engine and wait for the hydraulic oil to cool down Then drain the excessive oil through the drain plug It may damage the oil circuit and cause the oil to spurt out Lower the bucket to the ground and stop the engine Wait for 5 minutes before che...

Page 357: ...IR FILTER k k WARNING When using compressed air there is a danger that dirt may scatter and cause personal injury Wear the protective equipment such as the protective eyeglasses and dust mask When the air conditioner is used clean the air conditioner fresh air filter Before cleaning the filter stop the air conditioner 1 Insert the starting switch key into key slot 1 and release the lock 2 Loosen t...

Page 358: ...e reduced and there will be a rumbling sound from the air conditioner unit EVERY 250 HOURS MAINTENANCE Maintenance for every 50 hours service should be performed at the same time METHOD FOR LUBRICATING STEERING CYLINDER PIN 1 By using a grease pump pump in grease through the grease fittings shown by arrows Pump in grease until new grease A comes out through the gaps on the right and left or top an...

Page 359: ...t If it gets in your eyes or on your skin wash it off with a large amount of water and consult a doctor Do not use a dry wipe to clean the battery A wet wipe will prevent fire or explosion from static elec tricity NOTICE Do not add the electrolyte to the battery exceeding UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts ...

Page 360: ...s tributor or a battery manufacturer METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO CHECK FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery or there is no UPPER LEVEL line on the side of the battery check according to the following procedures 1 Open the cover of the battery box One each of the battery box is provided on both sides ...

Page 361: ...he instructions given METHOD FOR TESTING PARKING BRAKE 1 On a dry slope downhill turn the parking brake switch from OFF position B to ON position A 2 Check that the machine is stopped and held at the current position If any problem is found ask your Komatsu distributor for adjustment METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION k k WARNING When checking and adjusting t...

Page 362: ...OD FOR TESTING WHEN AIR CONDITIONER COMPRESSOR BELT IS RE PLACED Press the middle point between the compressor pulley and crankshaft pulley with your thumb approximately 98 N 10 kg The standard deflection is 8 to 11 5 mm When you use a belt tension gauge the tension is normal if it is in the range of 530 to 745 N 54 to 76 kg REMARK When the belt is replaced with a new one the above value is employ...

Page 363: ...s not touching the bottom of the V groove Replace the belt with a new one if the belt is stretched and has no allowance for adjustment or has slipping sound or squeak because of cuts or cracks of the belt When the new V belt is installed readjust it after operating for 1 hour METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS RETIGHTEN ING BOLTS Loosening of wheel hub bolt 1 accelerates the wear of ...

Page 364: ...g travel the brake can be operated with the oil pressure in the accumulator temporarily 1 Park the machine on a level ground and lower the work equipment to the ground 2 Apply the parking brake 3 Start the engine and run it at medium speed for 1 minute and then stop it 4 Turn the starting switch to ON position and repeat depressing the brake pedal If the brake oil pressure caution lamp does not li...

Page 365: ... to release the internal pres sure then remove it carefully Refill capacity 23 ℓ Items to be prepared Container to catch drained oil Filter wrench 1 Open the engine side cover 1 on the right side of the ma chine 2 Open engine oil filler F 3 Place an oil container right under drain plug P to catch the drained oil 4 Remove drain plug P and drain the oil Check the drained oil If it contains much meta...

Page 366: ...G 11 Run the engine at low idle for a time then stop the engine and check that the oil level is between H and L marks on the dipstick For details see METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN ADDING OIL 3 154 REMARK When the ambient temperature is low water or emulsified matter may stick to the dipstick oil filler cap etc or the drained oil may be milky white because of water vapor in the bl...

Page 367: ...e the fuel 3 Loosen the drain valve 2 and drain the water and sedi ments from transparent cup 3 and also drain all the fuel from filter cartridge 4 4 Disconnect the connector 5 5 Wrap the connector 5 with a plastic bag etc so that fuel oil and water do not get onto the disconnected connector 6 Remove the clip 6 of sensor harness 7 Turn the transparent cup 3 counterclockwise by using the filter wre...

Page 368: ...onnect the connector 5 REMARK If water gets on the connector 5 the sensor may malfunction and the water separator caution lamp may flash When removing the connector 5 be extremely careful not to let water get on the connector If water gets on the connector 5 dry it completely before connecting it 16 After completing the replacement of the filter cartridge 4 bleed air from the circuit Bleed the air...

Page 369: ...that has highly efficient filtering ability When replacing parts Komatsu recommends using Komatsu genuine parts The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system...

Page 370: ...loose fuel will also leak from the packing clearance Be sure to observe the tightening angle When tightening with a filter wrench be extremely careful not to dent or damage the filter 7 After completing the replacement of filter cartridge 2 bleed air from the circuit Bleed the air as follows 1 Fill up the fuel tank with fuel to the level where the float is at the highest position 2 Loosen the knob...

Page 371: ... spontaneously METHOD FOR CLEANING TRANSFER CASE BREATHER 1 Loosen the bolts 1 3 pieces and remove the cover 2 2 After removing dirt and dusts around the breather 3 re move the breather 3 and immerse it in detergent liquid to clean While the breather is removed use care to prevent entry of dusts through the mounting location of the breather METHOD FOR CHANGING OIL IN TRANSFER CASE AND CLEANING TRA...

Page 372: ... out the strainer 4 6 Remove the dirt etc from the strainer 4 then wash it in the clean diesel fuel or flushing oil If the strainer 4 is damaged replace it with a new one 7 Install the strainer 4 to the case Replace the O ring 5 of cover 2 with a new one and in stall the tube 3 8 Add the refill capacity of oil through the oil filler port F 9 After adding oil check that the oil level is correct by ...

Page 373: ...an the filter head and install the new filter cartridge When installing the cartridge tighten it until the packing surface contacts the seal surface of the filter holder then tighten it 1 2 of a turn by using the filter wrench Tightening torque 29 to 39 Nm 3 0 to 4 0 kgm 4 Run the engine at low idle for 5 minutes to bleed air from the HST circuit 5 Check the hydraulic oil level After adding oil ch...

Page 374: ...METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT Special tools are required for the replacement of the belt Ask your Komatsu distributor to perform this work Since the auto tensioner is installed tension adjustment is not required If alternator drive belt shows the following conditions it must be replaced Ask your Komatsu distributor to replace it When vertical flaw 2 that crosses horizontal flaw...

Page 375: ...f oil filler port F 4 Place a container under the drain plug 3 to catch the drained oil 5 Remove the drain plug 3 6 Open the drain valve 4 gradually to drain the oil 7 After draining the oil close the drain valve 4 and tighten the drain plug 3 Tightening torque Drain plug 3 29 4 4 9 Nm 3 0 0 5 kgm Drain valve 4 63 7 14 7 Nm 6 5 1 5 kgm 8 Remove the bolts 5 2 pieces and remove the cover 6 MAINTENAN...

Page 376: ...h of the steering bucket and boom cylinders 4 to 5 times taking care not to move them to the stroke end stop them approximately 100 mm short of the stroke end NOTICE If the engine is run at high speed immediately after the startup or a cylinder is pushed up to its stroke end air taken inside the cylinder may cause damage to the piston packing etc 18 Extend and retract each of the steering bucket a...

Page 377: ... bolts 1 2 pieces METHOD FOR REPLACING HYDRAULIC OIL FILTER CARTRIDGE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully Items to be prepared Cont...

Page 378: ... 4 places 7 Check the hydraulic oil level Check that it is at the specified level by referring to METHOD FOR CHECKING OIL LEVEL IN HYDRAUL IC TANK ADDING OIL 4 46 8 Check the hydraulic oil filter for oil leakage METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temper...

Page 379: ...nd 4 with bolts 1 2 pieces and bolts 2 2 pieces METHOD FOR CHANGING OIL IN AXLE CASE k k WARNING When changing the oil apply the parking brake and secure the front and rear frames with the frame lock bar Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work If the plug is removed oil may s...

Page 380: ... dipstick G installed to plug 1 by using a piece of cloth 6 Set dipstick G as shown in the figure 2 Axle 3 Spot facing surface 7 Check the oil level The oil level is appropriate if it is between 2 grooves H and L of the dipstick 8 If the oil does not reach the lower groove L supply the axle oil from plug hole 1 9 If the oil level exceeds the upper groove H drain the ex cessive oil through the drai...

Page 381: ...t and may cause burn in jury Wait for the temperature to go down and then start the work When removing the rubber hose the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully Items to be prepared Container to catch the drained oil 1 Remove the bolts 1 3 pieces and remove the rear frame cover 2 2 Remove the bolts 3 3 pieces and remove the washer tank cover 4 ...

Page 382: ...ectors 6 12 Install the washer tank cover 4 with bolts 3 3 pieces 13 Install the rear frame cover 2 with bolts 1 3 pieces METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT k k WARNING When checking the condition apply the parking brake and fix the front and rear frames by using the frame lock bar Perform this check when the brake oil temperature is 60 C or below If the disc wear approaches the wear limit...

Page 383: ...eration with 2 workers One worker depres ses the brake pedal and the other pushes in the inspection gauge 2 3 Install the inspection plug 1 Tightening torque 127 to 177 Nm 13 to 18 kgm METHOD FOR CHECKING FUNCTION OF PPC ACCUMULATOR For handling of the accumulator see HANDLE ACCUMULATOR AND GAS SPRING 2 40 When you cannot restart the stopped engine while the work equipment is raised you can use as...

Page 384: ... Special tools are necessary for inspection and maintenance Ask your Komatsu distributor to perform this work METHOD FOR CHECKING VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber If any cracks or peeling are found contact your Komatsu distributor to have the parts replaced METHOD FOR REPLACING KCCV FILTER ELEMENT k k WARNING Immediately after the engi...

Page 385: ... in the fig ure For the use of the special wrench see the figure 1 Remove the bolt 1 then remove the fixing clip 2 of the KCCV drain hose 2 By using the special wrench loosen the ring 5 of the KCCV ventilator 3 3 After the ring 5 comes off remove the case 6 from body 4 and remove the element 7 MAINTENANCE MAINTENANCE PROCEDURE 4 75 ...

Page 386: ...all a new O ring contained in the service kit Apply the engine oil to the new O ring 5 While matching the mark 9 of the new element with the mark 10 of the body label insert the element firmly into the end of the body The element can be installed only when its claws 11 are correctly inserted in grooves 12 of the filter body Bases 13 and 14 are oval When inserting take extreme care so that those ba...

Page 387: ...very hot Do not replace the filter immediately Wait until all of parts cool down before starting the work NOTICE Komatsu recommends using Komatsu genuine parts for replacement parts If the machine is operated without DEF filter attached or with the filter other than Komatsu genuine parts foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine Never operat...

Page 388: ...minutes Before replacing the filter clean around the DEF pump first after DEF system devices stop Items to be prepared DEF filter removal tool Torque wrench 1 Remove the bolts 1 5 pieces to remove cover 2 The DEF filter is located at the positions shown in the fig ure 2 Remove filter cap 3 at the bottom of DEF pump and re move equalizing element 4 3 Turn cap 6 of filter removal tool 5 and remove i...

Page 389: ...out together with filter removal tool 5 If filter 8 cannot be removed from DEF pump grip filter removal tool 5 pull it down then it will be removed 8 Slide filter 8 down and remove spacer 7 from filter re moval tool 5 9 Pull filter 8 up while pushing in the tip of filter removal tool 5 and remove it 10 Return the removed spacer 7 to filter removal tool 5 and keep them 11 Insert a new filter and a ...

Page 390: ...e element other than Komatsu genuine parts Do not flush DEF tank breather element Flushing or regenerating of it will degrade the performance of element and will cause the breakage of DEF tank Never reuse the DEF element Always stop the engine and clean around DEF tank before replacing After the engine is stopped DEF system devices automatically purge DEF in DEF injector and DEF pump and return it...

Page 391: ...cover 5 and nut 4 5 Install cover 2 with bolt 1 EVERY 4000 HOURS MAINTENANCE Maintenance for every 50 100 250 500 1000 and 2000 hours service should be performed at the same time REPLACE DEFINED LIFE PARTS Material quality of these parts can change as time passes and they are likely to wear out or deteriorate Replace them every 2 years or every 4000 hours whichever comes sooner MAINTENANCE MAINTEN...

Page 392: ...uipment hose Lift cylinder hose Bucket cylinder bottom hose Bucket cylinder head hose Main valve hose Quick coupler hose 6 Others PPC accumulator METHOD FOR LUBRICATING DRIVE SHAFT Use the special grease for drive shaft and perform greasing every 4000 hours or every 2 years If the special grease is not used but common lithium base grease is used perform greasing every 1000 hours after then Part No...

Page 393: ...eplacement METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked If the engine is started frequently have this inspection performed every 1000 hours METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR Ask your Komatsu distributor to perform the work METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIP ING CLAMP HARDENING OF RUBBER MAIN...

Page 394: ...bber portion is hardened If there are any problems the related parts must be replaced Ask your Komatsu distributor for replacement EVERY 4500 HOURS MAINTENANCE Maintenance for every 50 100 250 and 500 hours service should be performed at the same time METHOD FOR CLEANING KDPF Contact your Komatsu distributor for cleaning of the KDPF METHOD FOR CLEANING DEF TANK Ask your Komatsu distributor for cle...

Page 395: ...HOSE Ask your Komatsu distributor for replacement of the DEF hose END OF SERVICE LIFE For safe dismantling of the machine at the end of service life please contact your Komatsu distributor MAINTENANCE MAINTENANCE PROCEDURE 4 85 ...

Page 396: ......

Page 397: ...SPECIFICATIONS 5 1 ...

Page 398: ...ent mm 3200 C Overall height with bucket lifted up mm 5230 D Overall width mm 2505 E Min ground clearance mm 465 F Bucket width mm 2540 G Dumpling clear ance 1 Cutting edge BOC tip mm 3020 2960 H Dumpling reach 1 Cutting edge BOC tip mm 930 910 I Bucket dump angle max height 48 Min turning radi us Cutting edge BOC tip mm 5990 6020 Center of out side tire mm 5175 Permissible towing load kN kg 92 5 ...

Page 399: ... 1 Value when bucket dump angle is 45 B I A G E H F D C 9 J W0 1 4 5 6 SPECIFICATIONS SPECIFICATIONS 5 3 ...

Page 400: ......

Page 401: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1 ...

Page 402: ...ntained ground 20 5R25 L2 Traction Soft ground 20 5 25 12PR L2 Traction Loading of products and blasted rock Excavating bucket with BOC 1 9 m3 General ground 20 5 25 12PR L3 Rock Hard ground 20 5 25 12PR L3 Rock BOC Abbreviation for Bolt On Cutting edge You need to change the travel speed display on the machine monitor according to the tire size If you are instal ling the optional tires ask your K...

Page 403: ...ITH QUICK COUPLER 1 Quick coupler attachment switch 2 Quick coupler lock release pilot lamp QUICK COUPLER ATTACHMENT SWITCH Use the quick coupler switch to install or remove the attach ment Position a Release Push the switch in to the position a then pull lock A in the direction of the arrow b and release the connection While the quick coupler switch is pushed the quick coupler lock release pilot ...

Page 404: ...ion METHOD FOR REMOVING ATTACHMENT 1 Tilt the attachment 2 Pull lock A of the quick coupler switch in the direction of the arrow b and push in to RELEASE position a Keep the quick coupler attachment switch pressed un til the work of the step 6 is completed When you release the quick coupler the quick coupler lock release pilot lamp 1 lights up and the alarm buzzer sounds intermittently 3 Operate t...

Page 405: ...ck coupler switch The switch returns to its original position the pilot lamp 1 for releasing quick coupler goes out and the alarm buzzer stops sounding 8 Drive the machine in reverse slowly to separate the ma chine from the attachment METHOD FOR INSTALLING ATTACHMENT 1 Set the coupler tilted forward posture on a level ground stop the machine at the position just before attachment hook and the coup...

Page 406: ...ttently 3 Operate the lever from HOLD position B to TILT posi tion e while the quick coupler attachment switch is press ed into a Retract the coupler plunger while keeping it at TILT position e from the state that the coupler contacts to the tilt end stopper 4 Check that the lock pins have been removed The lock pin indicators 3 may not be visible 5 Operate the lever from HOLD position B to DUMP po...

Page 407: ...ilted fully 9 Put your hand off the quick coupler attachment switch The switch returns to its original position the pilot lamp 1 for releasing quick coupler goes out and the alarm buzzer stops sounding 10 Operate the lever from HOLD position B to TILT posi tion e and keep it in TILT position e Pull out the cou pler plunger to lock the attachment 11 Check that the lock pin indicators 3 on left and ...

Page 408: ...WITH FORK 1 Multifunction mono lever 2 Attachment selector switch MULTIFUNCTION MONO LEVER The multifunction mono lever is used to operate the boom and fork NOTICE Do not use FLOAT position when lowering the fork HANDLE FORK ATTACHMENTS AND OPTIONS 6 8 ...

Page 409: ...from the TILT position the lever stops in that position As soon as the fork reaches the position preset by the fork positioner the lever returns to the HOLD position Position f DUMP ATTACHMENT SELECTOR SWITCH The attachment selector switch is used to switch the bucket po sitioner and fork positioner When using the fork set it to B position A Bucket positioner Set to this position when using the bu...

Page 410: ...l 2 Return the multifunction mono lever to HOLD position 3 Press the work equipment lock switch and lock the work equipment the pilot lamp lights up 4 Stop the engine 5 If the attachment selector switch is equipped turn the switch to fork position B HANDLE FORK ATTACHMENTS AND OPTIONS 6 10 ...

Page 411: ...ity switches 3 so that it is within 3 to 5 mm and fix it Tightening torque 14 7 to 19 6 Nm 1 5 to 2 0 kgm 9 After adjustment run the engine to raise the boom Check that the lever automatically returns to HOLD position at the point where the fork becomes horizontal when tilting back the fork after fork DUMP opera tion LOADING AND UNLOADING OPERATION The following is the explanation how to operate t...

Page 412: ...ll be stable 2 Set the forks horizontal drive the machine forward slowly and insert the forks under the load so that the load can be loaded on the center of the forks 3 Keep driving forward until the forks are inserted completely under the load and the load comes to contact with the car riage back 4 Raise the fork approximately 15 cm off from the ground or the another one under the load Tilt the f...

Page 413: ...n carrying the load Use the 3rd or 4th in the speed range when traveling without load The appropriate speed for carrying the load varies depend ing on the conditions Think safety first always when driv ing the machine Drive the machine at low speed when carrying the load on the rough ground or slopes Tilt the load to the mountain side when carrying the load on the slopes Drive the machine in rever...

Page 414: ...4 Drive the machine in reverse slowly and pull the fork off from the load 5 Lower the fork HANDLE FORK ATTACHMENTS AND OPTIONS 6 14 ...

Page 415: ...ation even if the switch operation is stopped This action is called the detent control Use this control when the installed attachment requires contin uous hydraulic oil flow The detent control operation pilot lamp D lights up during the detent control The detent control is canceled by any of the following opera tions Operate the switch again Turn the work equipment lock switch to ON position Turn ...

Page 416: ...RTIONAL OIL FLOW MODE Oil flow control mode display lamp proportional oil flow mode lights up when the flow control mode of PCS is in the propor tional oil flow mode DETENT OPERATION PILOT LAMP The detent operation pilot lamp lights up when the detent con trol is performed in the fixed oil flow mode 1 to 4 are displayed in order at intervals of 0 5 seconds PCS PROPORTIONAL CONTROL SWITCH ATTACHMEN...

Page 417: ...trol METHOD FOR SETTING PCS 1 Press the menu switch 1 and enter the setting mode 2 Select Attachment Setting on Machine Setting and Infor mation menu and press ENTER switch 2 If the flow rate mode and the maximum flow rate are set al ready select an arbitrary setting and the setting is com pleted If you press the menu switch 1 at this time you can change the setting of the selected attachment You ...

Page 418: ... the default value 4 Select Flow Control Mode and press ENTER switch 2 You can select Proportional Control Mode or Continuous Flow Rate Mode 5 Select Attachment Oil Flow Rate Setting and press EN TER switch 2 You can set the maximum oil flow at the switch full stroke and the flow during the detent control in the fixed oil flow mode Change the flow with UP or DOWN switches and then press ENTER swit...

Page 419: ...rations consult your Komatsu distrib utor Method for operating the auto greasing system The pump with grease tank is located at the position as shown in the figure For details see CHECKING AUTO GREASING AND OPERA TION METHOD FOR FILLING GREASE 6 23 Turn the starting switch to ON position B The power supply to the grease pump is turned on The auto greasing pilot lamp is lit for 2 seconds Display an...

Page 420: ...operating one of the two push buttons It is used for displaying current values and preset parameters In addition the display is used for operator prompting during setting of operating parameters Display Denotation Explanation Control function t TIMER PA PAUSE The control unit operates as a time controlled contact maker TIMER and is in the PAUSE state Part of lubrication cycle Input and display val...

Page 421: ... in the FAULT mode The sequence of opera tions is stopped Fault Cycle Switch No signal from cycle switch during pump running time The control unit is in the FAULT mode The sequence of opera tions is stopped Operation Hour Meter The subsequently displayed values are the operating hours of the con trol unit Fault Hour Meter The values displayed in the following are the fault hours which are the time...

Page 422: ...layed fill up with grease and reset the fault with button B Fault message Display Denotation Explanation Control function Fault Low Level The minimum level in the grease tank has been reached The control unit is in the FAULT mode The sequence of opera tions is stopped Fault Cycle Switch No signal from cycle switch during pump running time The control unit is in the FAULT mode The sequence of opera...

Page 423: ...e the manual greasing 2 Check the function of the control unit and system components Check the system components for leakage and damage Perform the check periodically Check the bearings visually Check that the bearings have been lubricated properly Before reaching min mark refill the grease tank with grease to max mark The grease amount between the marks min and max is approximately 1 6 ℓ By the f...

Page 424: ......

Page 425: ...REPLACEMENT PARTS 7 1 ...

Page 426: ... the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses and replace defective 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 defined life parts DEFINED LIFE PARTS LIST No Periodical replacement parts Replacement interval...

Page 427: ...efilter 600 319 3610 Cartridge 1 Fuel main filter 600 319 3750 Cartridge 1 Every 1000 hours HST oil filter 418 18 34160 Cartridge 1 Transfer strainer 124 15 51740 Strainer 1 07000 73042 O ring 1 Every 1000 hours DEF tank breather 421 60 35170 Element 1 Every 2000 hours KCCV filter 600 331 2900 Element 1 Hydraulic oil filter 418 60 55150 Cartridge 1 Hydraulic tank breather 285 62 17320 Element 1 Ai...

Page 428: ...nsult your Komatsu distributor NOTICE The fuel used must be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high precision parts and ...

Page 429: ...Meaning of the symbol Read the Operation and Maintenance Manual Lubricating with grease Change the engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil Change power train oil filter REPLACEMENT PARTS RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 ...

Page 430: ...gine oil filter Change hydraulic oil filter Change breather element in hydraulic tank Change fuel filter Change KCCV filter breather element Change axle oil Change DEF tank breather element Change DEF filter RECOMMENDED FUEL COOLANT AND LUBRICANT REPLACEMENT PARTS 7 6 ...

Page 431: ... C TOS0W30 KES 30 C 50 C TOS5W30 KES Bio oil 15 C 40 C BO46 G4 Engine oil 20 C 50 C EO10W30 DH Axle Axle oil 30 C 50 C AXO80 KES Note 3 Power train oil 40 C 50 C TO50 KES Note 4 Pin Bushing Grease fitting Hyper grease 20 C 50 C G2 TE KES Note 6 Lithium EP grease 10 C 50 C G2 LI KES Note 5 Cooling system Non Amine Engine Coolant AF NAC 30 C 50 C AF NAC KES Note 7 Fuel tank Diesel fuel 30 C 20 C EN ...

Page 432: ...e 6 Hyper grease G2 TE has high performance When it is necessary to improve the lubricating performance of the grease in order to prevent squeaking of pins and bushings the use of G2 TE is recommended Note 7 Non Amine Engine Coolant AF NAC 1 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 cool...

Page 433: ...4 53 Air conditioner recirculation air filter and fresh air filter Replace 4 71 Air conditioner switch 3 216 Air conditioner switch and numeric keypad 3 46 Air conditioner system caution lamp 3 28 Alternate exit of cab Check 3 161 Alternator Check 4 74 Alternator belt Check Replace 4 64 Always use clean washer fluid 4 2 Appoint leader when working with others 2 33 Armrest angle Adjust 3 164 Armres...

Page 434: ...k 3 194 DEF level caution lamp 3 22 DEF level gauge 3 43 DEF low level guidance 3 37 DEF system caution lamp 3 25 DEF system high temperature stop caution lamp 3 25 DEF tank Clean 4 84 DEF tank breather element Replace 4 80 Defined life parts list 4 82 7 2 Defroster Operate 3 220 Defroster function Check 3 161 Defroster switch 3 217 Demist Operate 3 220 Detent operation pilot lamp 6 16 Dig and loa...

Page 435: ...of components 3 10 Explanation of components on machine with fork 6 8 Explanation of components on machine with quick coupler 6 3 Explanation of machine monitor equipment 3 10 F Fan Operate in reverse manually 4 29 Fan control system caution lamp 3 27 Fan reverse rotation display 3 33 Fan switch 3 212 Filter 4 8 Fin Clean by rotating cooling fan in reverse 4 29 Fin Clean with compressed air 4 30 F...

Page 436: ...mp switch 3 94 Language settings 3 85 LCD unit 6 15 Leveling work 3 196 Lever stand Adjust 3 171 Lifting of personnel prohibited 2 19 Load and carry operation 3 197 Loading and unloading operation 6 11 Loading work 3 197 Location of engine number plate 1 10 Location of product identification number PIN ma chine serial number plate 1 10 Location of safety labels 2 5 Lock 3 206 Lock inspection cover...

Page 437: ...king brake Check 3 179 4 51 Parking brake Release 3 234 Parking brake pilot lamp 3 36 Parking brake switch 3 96 PCS Set 6 17 PCS Proportional Control Switch 3 102 6 15 Perform KOWA Komatsu Oil Wear Analysis 4 7 Periodic replacement of defined life parts 2 41 Permissible water depth 3 193 Phenomena and actions for electrical system 3 238 Phenomena and actions for engine related parts 3 241 Pick up ...

Page 438: ...cooler fin Clean 4 29 Raise remote boom positioner Operate 3 199 Raise remote boom positioner Release 3 200 Read this manual 1 2 Rear axle pivot pin Lubricate 4 45 Rear heated wire glass switch 3 100 Rear view camera guide line Check 3 170 Rear view monitor brightness adjustment switch 3 95 Rear wiper switch 3 97 Rear working lamp switch 3 97 Rearview camera Adjust 3 167 Rearview camera angle Adju...

Page 439: ...and actions 3 231 Turbocharger protection function 3 177 Turn battery disconnect switch to off position 2 37 Turn off ecss switch before performing inspection and maintenance 2 36 Turn signal lever 3 94 Turn signal pilot lamp 3 31 Two workers for maintenance when engine is running 2 35 U Unauthorized modification 2 21 Understanding the machine 2 15 Unlock knob for slide window of cab 3 112 Up swit...

Page 440: ...WA270 8 WHEEL LOADER Form No VENAM31500 2016 KOMATSU Hanomag GmbH All Rights Reserved Printed in Europe 12 2016 ...

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