Komatsu PC2000-8 BACKHOE Page 490 Operation & Maintenance Manual Download

Page: 490 / 504

MAINTENANCE

LOADING SHOVEL

7-16

(C): Injector installed on the boom

(D): Injector installed on the chassis

(19) Boom foot pin (RH)

(23) Arm cylinder head pin (RH)

(20) Boom foot pin (LH)

(24) Arm cylinder head pin (LH)

(21) Arm cylinder bottom pin (RH)

(F)

Grease fitting

(22) Arm cylinder bottom pin (LH)

(25) Boom cylinder bottom pin (RH)

(F)

Grease fitting

(26) Boom cylinder bottom pin (LH)

Summary of Contents for PC2000-8 BACKHOE

Page 1: ...death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all pe...

Page 2: ......

Page 3: ...FOREWORD 11...

Page 4: ...relevant personnel can read it at any time Storage location for the Operation and Maintenance Manual magazine box on the left side of the operator s seat If this manual is lost or damaged contact your...

Page 5: ...or death Follow the instructions in the safety message The following signal words are used to alert you to information that must be followed to avoid damage to the machine This signal word indicates...

Page 6: ...n for the earth moving machine transmitted from the opera tor s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096 The actual accelerati...

Page 7: ...weight and size of the operator q Wear seat belt q Inspect and maintain the seat suspension and adjustment mechanisms 5 Steer brake accelerate shift gears for wheeled machines and move the attachment...

Page 8: ...rk See the section RECOMMENDED APPLICATIONS 3 228 for further details DIRECTIONS OF MACHINE 1 In this manual the terms front rear left and right refer to the travel direction as seen from the operator...

Page 9: ...1 m from the outside surface of the machine at a height of 1 5 m is shown in the diagram below The hatched area A shows the area where the view is blocked by part of the machine when mirrors or other...

Page 10: ...diagram below The hatched areas B show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard Please be fully aware that there are places that cannot b...

Page 11: ...or ordering replacement parts please inform your Komatsu distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 This is at the bottom right of the room under th...

Page 12: ...top left of fuel filter 1 on the engine cylinder block as seen from the front of the machine Machine of poor fuel arrangement specification This is on top of the common rail cover on the engine cylin...

Page 13: ...AND DISTRIBUTOR 1 Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU LTD 2 3 6 Akasaka Minato ku 101 Tokyo Japan Authorised representative Address...

Page 14: ...SERIAL NUMBER PLATE according directive 2006 42 EC 1 A B C D E F G H A Machine designation type E Engine power B Serial Number F Product Identification Number C Year of construction G Manufacturer D O...

Page 15: ...clares that this machine PC2000 8 Fulfills all the relevant provisions of following EC Directives The manufacturer Authorized representative KOMATSU LTD 2 3 6 Akasaka Minato ku Tokyo 107 8414 Japan KO...

Page 16: ...ration according Directive 2006 42 EC Annex I point 1 7 4 2 c 1 13 SAFETY SAFETY 2 2 SAFETY LABELS 2 4 LOCATION OF SAFETY LABELS 2 5 SAFETY LABELS 2 6 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINT...

Page 17: ...OM 3 84 SWITCHES OUTSIDE OF MACHINE 3 87 LAMP INSIDE OPERATOR S CAB 3 97 LAMP OUTSIDE OF MACHINE 3 100 CONTROL LEVERS AND PEDALS 3 102 DOOR LOCK 3 104 EMERGENCY EXIT FROM OPERATOR S CAB 3 104 EMERGENC...

Page 18: ...ent 3 179 Seat Belt 3 184 Operations Before Starting Engine 3 185 STARTING ENGINE 3 189 AFTER STARTING ENGINE 3 192 Breaking in the New Machine 3 192 Engine Warm Up 3 193 Hydraulic Equipment Warm Up 3...

Page 19: ...ING MACHINE AFTER LONG TERM STORAGE 3 239 TROUBLES AND ACTIONS 3 240 RUNNING OUT OF FUEL 3 240 PHENOMENA THAT ARE NOT FAILURES 3 240 TOWING THE MACHINE 3 241 SEVERE JOB CONDITION 3 241 DISCHARGED BATT...

Page 20: ...ROM FUEL CIRCUIT 4 45 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 49 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4 60 INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR...

Page 21: ...4 107 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 108 REPLACE ACCUMULATOR IN OIL COOLER CIRCUIT 4 109 EVERY 5000 HOURS MAINTENANCE 4 110 CHANGE OIL IN HYDRAULIC TANK CLEAN STRAIN...

Page 22: ...RATIONS 7 2 OVERALL MACHINE VIEW 7 2 EXPLANATION OF COMPONENTS 7 3 SWITCHES 7 3 OPERATIONS 7 5 OPERATION OF WORK EQUIPMENT 7 5 PRECAUTIONS DURING OPERATION 7 7 EXCAVATOR WORK 7 11 PRECAUTIONS WHEN DIS...

Page 23: ...ING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine When operating or servicing the machine always follow these precau...

Page 24: ...S SEAT 2 152 PRECAUTIONS WHEN LEAVING MACHINE 2 162 EMERGENCY EXIT FROM OPERATOR S CAB 2 162 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 162 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 162 PROTECTION AG...

Page 25: ...MENTS 2 362 PRECAUTIONS WHEN WORKING AT HIGH PLACES 2 362 PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2 372 PROPER TOOLS 2 372 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 382 PRECAUTIONS...

Page 26: ...the correct place and always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off q There are also other labels in addition to the warning...

Page 27: ...SAFETY SAFETY LABELS 2 5 LOCATION OF SAFETY LABELS 2 9JH14979B...

Page 28: ...no one is on or near machine or in the swing area q Rotate cab for full view of travel path if it can be done safely q Use spotter if view is obstructed q Follow above even if the machine is equipped...

Page 29: ...peration confirm the machine motion and indicated operating pattern when operating machines Pay attention to the circumference and operate slowly when confirming the machine motion 6 Caution for high...

Page 30: ...t could cause injury q Read manual and adjusting track for safe and proper han dling 9 Caution for handling cable 09808 A0881 q Sign indicates an electric hazard from handling the cable q Read manual...

Page 31: ...ot attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire 15 Caution about high pressure for common rail 6218 81 2980 High Pr...

Page 32: ...tteries no sparks b Always wear safety glasses when working with batter ies c Keep children away from batteries d Caution battery acid e Read the operator s manual before working with batteries f Caut...

Page 33: ...al thoroughly If there are any places in this manual that you do not understand ask the person in charge of safety to give an explanation PREPARATIONS FOR SAFE OPERATION 2 PRECAUTIONS REGARDING SAFETY...

Page 34: ...pedal with mud or oil affixed to your shoes your foot may slip and this may cause a serious accident q Do not leave tools or a machine parts lying around inside the operator s compartment If tools or...

Page 35: ...oil q Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace q When washing parts with oil use a non flammable oil Do not use diesel oil or gasoline Th...

Page 36: ...ng operation and rub against other parts There is danger that this may lead to damage to the hoses and cause high pressure oil to spurt out leading to fire serious personal injury or death q Explosion...

Page 37: ...RSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel NO JUMPING ON OR OFF MACHINE q Never jump on or off the machine Never get on or off a moving machine...

Page 38: ...nd DO NOT GET CAUGHT IN WORK EQUIPMENT 2 The clearance in the area around the work equipment changes according to the movement of the link If you get caught you may suffer serious personal injury or d...

Page 39: ...here is no one except the operator in the surrounding area They may be hit by falling objects or flying objects q When carrying out demolition or breaker operations install a front guard and always ke...

Page 40: ...equipment side is broken there is a hazard that the operator may be directly hit or caught in the work equipment If the glass is broken stop operations immediately and replace the glass q The ceiling...

Page 41: ...ing fences around the worksite q When traveling or operating in water or on soft ground check the water depth speed of the current bedrock and shape of the ground beforehand and avoid any place that w...

Page 42: ...horn to warn people in the area When traveling or carrying out operations in places with poor visibility it is impossible to check for obstacles in the area around the machine and to check the conditi...

Page 43: ...ust masks q Do not allow other persons to approach during the opera tion q Always observe the rules and regulations for the work site and environmental standards This machine does not use asbestos but...

Page 44: ...re all at the Neutral position q Before starting the engine check that lock lever 1 is in LOCK position L q Adjust the mirrors so that the rear of the machine can be seen clearly from the operator s s...

Page 45: ...machine will move when the power is connected q For machines equipped with a battery isolator switch wait for at least 3 minutes after turning the starting switch OFF then turn the battery isolator sw...

Page 46: ...ard q Check the operating condition of the machine work equip ment arm boom travel and swing system q Check for any problem in the sound of the machine vibra tion heat smell or gauges check also that...

Page 47: ...e ground and the machine may be turned over q If the view to the right side is poor raise the boom to ensure better visibility q For machines equipped with an auto deceleration system always turn the...

Page 48: ...ator s cab facing uphill when travel down slopes set the operator s cab facing downhill Always check the firmness of the ground under the front of the machine when traveling q When traveling up a stee...

Page 49: ...the downhill side when the bucket is loaded This operation is dangerous and may cause the machine to tip over q If the machine has to be used on a slope pile the soil to make a platform A that will ke...

Page 50: ...broken materials or of the machine tipping over due to reaction from the impact q The not pass the bucket over the heads of other workers or over the operator s seat of dump trucks or other hauling e...

Page 51: ...er and objects placed beside the road are buried in the snow and cannot be seen There is a hazard of the machine tipping over or hitting covered objects so always carry out opera tions carefully PARKI...

Page 52: ...from moving out of position or coming off q Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove dirt from machine tracks On a rainy day in particular be extremely...

Page 53: ...ling wire rope q Never tow a machine on a slope q During the towing operation never stand between the tow ing machine and the machine being towed LIFTING OBJECTS WITH BUCKET 2 PRECAUTIONS FOR LIFTING...

Page 54: ...work equipment or swing to pull the load in any direction There is danger that the hook may break and the load come off causing the work equipment to move suddenly and cause personal injury q Do not...

Page 55: ...r touch the levers q If necessary put up signs around the machine also Warning tag part number 09963 A1640 When not using this warning tag keep it in the toolbox If there is no toolbox keep it in the...

Page 56: ...FOR INSPECTION AND MAINTENANCE q Stop the machine on firm level ground q Select a place where there is no hazard of landslides falling rocks or flooding STABILITY When dismantling or assembling the ma...

Page 57: ...ipment control lever back and forth left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit and then move lock lever 1 to the LOCK position...

Page 58: ...may contact the rotating parts and break or be sent flying q Release the residual pressure from the hydraulic system and place Lock lever 1 to its LOCK position For releasing of the residual oil pres...

Page 59: ...work equipment or the machine will suddenly drop This is extremely dangerous Never work under the work equipment or the machine q If it is necessary to raise the work equipment or the machine and the...

Page 60: ...lectrolyte level and add distilled water or commercially available battery filler solution to the UPPER LEVEL mark q Do not smoke or bring any flame close to the battery q Hydrogen gas is generated wh...

Page 61: ...r switch Then begin the cable removal at the ground negative cable side When installing the battery cables be sure to begin with the positive cable side and finish at the ground cable side Tighten the...

Page 62: ...rnal pressure in the circuit has been released If this is not done it may lead to serious personal injury or death Always do as follows q For details of the method of releasing the pressure see METHOD...

Page 63: ...posed reinforcement wire layer q Covering swollen in places q Twisted or crushed movable portion q Foreign material embedded in covering PRECAUTIONS FOR HIGH VOLTAGE When the engine is running and imm...

Page 64: ...quipment to go down under its own weight After stopping the engine set the lock lever to the LOCK position The accumulator and gas spring are charged with high pressure nitrogen gas If the accumulator...

Page 65: ...lakes q Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters and batteries MERCURY CONTAINING COMPONENT S The monitor display backlight con...

Page 66: ...nd even when they have not reached the specified replacement time q The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the machine END OF SERVICE LIFE 2 For...

Page 67: ...OPERATION 13 WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 68: ...MACHINE VIEW ILLUSTRATIONS 3 OVERALL MACHINE VIEW 3 1 Bucket 9 Power container 2 Bucket cylinder 10 Hydraulic ladder 3 Arm 11 Sprocket 4 Arm cylinder 12 Track frame 5 Boom 13 Cab base 6 Boom cylinder...

Page 69: ...arette lighter 24V power supply socket 12 Travel pedals 4 AM FM Radio 13 Travel levers 5 Air conditioner control panel 2 14 Lock lever 6 Air conditioner control panel 1 15 Horn switch 7 Engine emergen...

Page 70: ...h 12 Fan reverse display lamp 4 Engine emergency stop switch 13 Rotating lamp switch if equipped 5 Room lamp switch 14 Greasing mode switch 6 Service center switch if equipped 15 Machine push up switc...

Page 71: ...1 Truck counter 1 6 Auto deceleration selector switch 22 Truck counter 2 7 Function switches F1 F6 23 ECO gauge 8 Engine water temperature monitor 24 Fuel gauge 9 Engine water temperature gauge 25 Fue...

Page 72: ...eck before starting screen Z Maintenance interval monitor screen 1 Engine oil pressure monitor 4 Engine oil temperature monitor 2 Charge level monitor 5 Air cleaner clogging monitor 3 Radiator coolant...

Page 73: ...tant to completely understand methods of operating the equipment and the meanings of the displays MONITORING SYSTEM 3 X 1 2 Normal operation screen 1 2 pilot screen all lights up Y Check before starti...

Page 74: ...ition opening screen S is displayed q After opening screen S has been displayed for 2 seconds the screen switches to Check before starting screen Y q After Check before starting screen Y has been disp...

Page 75: ...nds then the screen goes out If There Is Abnormality When Starting Engine q If there is any abnormality when the engine is started Check before starting screen Y switches to Mainte nance interval warn...

Page 76: ...ck before starting screen Y has been displayed for 2 seconds the screen switches to warning screen V or Error screen W If Any Abnormality Occurs During Operation q If any abnormality occurs during ope...

Page 77: ...starting items that must be checked before starting the engine If there is any abnormality monitor for the location of abnormality will light up Radiator Coolant Level Monitor Monitor 1 warns the ope...

Page 78: ...monitor screen goes out after 30 seconds and switches to the normal screen q For details of the method of confirming the maintenance interval see Maintenance Selector Switch 3 45 If it is desired to...

Page 79: ...ONTROLS AND GAUGES 3 13 Hydraulic oil level monitor This monitor 5 warns the operator that the hydraulic oil level has gone down If there is lack of hydraulic oil the lamp lights up red so check the o...

Page 80: ...ems which need to be repaired as soon as possible are displayed If there is any problem the appropriate monitor lamp will flash to indicate the location of the problem Displayed in center of screen in...

Page 81: ...aining amount of fuel in the tank goes down to approx 200 liter the monitor portion lights up red so add fuel quickly Air Cleaner Clogging Monitor Monitor 3 warns the operator of a clogged air cleaner...

Page 82: ...when condition is abnormal Monitor background D is red PTO Temperature Monitor When this monitor 6 is lighted up white in low temperatures carry out the warming up operation For details see Hydraulic...

Page 83: ...mount of grease is low add grease quickly If monitor 9 does not go out even when greasing is carried out or when there is ample grease but the monitor is lighted up red contact your Komatsu distributo...

Page 84: ...n then perform necessary actions These items should be observed while the engine is running If there is a problem the monitor for the abnormal location lights up red and buzzer sounds perform action i...

Page 85: ...or 2 warns the operator that the hydraulic oil tem perature has risen If the hydraulic oil temperature becomes abnormally high abnormality display C is shown Stop operations and stop the engine or run...

Page 86: ...has risen If the engine oil temperature becomes abnor mally high abnormal display C is given Stop operations and run the engine at low idling or stop the engine until the monitor changes to correct te...

Page 87: ...itor 12 Engine oil pressure gauge 4 Auto deceleration monitor auto lowidle monitor 13 ECO gauge 5 Working mode monitor 14 Idle stop guidance 6 Engine coolant temperature gauge 15 Truck counter display...

Page 88: ...cally actuated the preheating monitor lights up When the preheating is completed it goes out Automatic preheating is for a maximum of approx 30 seconds Swing Lock Monitor This monitor 2 informs the op...

Page 89: ...rmittent actuation of wiper both upper and lower ones OFF Wiper stopped q For details of the positions of the wiper switch see CONTROLS AND GAUGES 3 3 Auto deceleration Monitor Auto Low idle Monitor M...

Page 90: ...nitor 5 displays the mode for setting operations The monitor displays for the operation of the working mode switch are as follows P P mode heavy duty operation E E mode operation with emphasis on low...

Page 91: ...ormality display Red range B position Engine speed changes to low idling engine coolant temperature monitor 1 shows abnormality dis play alarm buzzer sounds at same time The overheat prevention system...

Page 92: ...raulic oil temperature The indicator should be in the green range during operations If the indicator starts to enter red range A during operations it shows that the hydraulic oil temperature is more t...

Page 93: ...ine has been operated or the present time The service meter advances if the engine is running even if the machine is not moving The meter advances by 1 for every hour of operation of the engine regard...

Page 94: ...carry out the warming up operation For details see Engine Warm Up 3 193 and Hydraulic Equipment Warm Up 3 195 Engine Oil Temperature Gauge This meter 11 shows the engine oil temperature The indica to...

Page 95: ...uel consump tion target is being achieved If the gauge is in green range A it shows that the fuel consumption is within the target If the gauge is in orange range B it shows that the fuel consumption...

Page 96: ...ck When truck counter switch b at the front as seen from the front of the machine on top of the left control lever is pressed the count advances Each time truck counter switch b is pressed the buzzer...

Page 97: ...mode in use when it was started the previous time q When switch 1 is pressed the working mode selection screen list is displayed For each setting mode P or E is displayed on the pilot monitor at the t...

Page 98: ...is automatically set as the working mode and the screen changes to Steps 3 and Steps 4 REMARK To return to the standard screen without changing the working mode press function switch F5 3 After selec...

Page 99: ...leration function is ON if the work equipment and travel levers are returned to the N posi tion the engine speed will drop after 4 seconds from the operating speed to idling speed This makes it possib...

Page 100: ...ds the engine speed drops from the work equipment speed to the idling speed In addition if the auto low idle function is ON after a further approx 30 seconds if the work equipment control levers and t...

Page 101: ...center of the monitor display and after 2 sec onds the display returns to the standard screen Wiper Switch This switch 4 actuates the front window wiper Each time the switch is pressed the wiper swit...

Page 102: ...iper A upper lower q Continuous operation of wiper top bottom B q Continuous operation of wiper top only C REMARK Each time wiper switch 4 is pressed the mode is displayed in the center of the monitor...

Page 103: ...e the wiper will be actuated continuously When switch 5 is released the wiper will continue to operate for 2 cycles then stop q If the wiper is moving intermittenly and switch 5 is kept pressed contin...

Page 104: ...tch when expanding function F2 Screen selector switch F3 Camera screen selector switch if equipped F4 Service meter clock display selector switch F5 Maintenance mode selector switch F6 User mode selec...

Page 105: ...Press switch A immediately below the guidance icon dis play to operate the function The operation of the function switches if the initial screen is the standard screen is as follows Camera Screen Sele...

Page 106: ...is pressed the whole screen shows the screen for the camera at the rear left of the machine q When function switch F2 is pressed the whole screen shows the screen for the camera at the rear center of...

Page 107: ...left of the machine and the screen for the camera at the rear right of the machine can be displayed at the same time q When two screens are displayed at the same time the dis play changes more slowly...

Page 108: ...creen returns to the standard screen To display the camera screen press function switch F3 again q Press the auto deceleration switch to turn the auto decel eration function ON OFF Even if the auto de...

Page 109: ...ayed at the top left of the screen and flashes q When the error monitor or warning monitor is displayed press function switch F5 to return to the standard screen and check the content of the error or...

Page 110: ...ES AND ACTIONS 3 240 Service Meter Clock Display Selector Switch 3 On the standard screen it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor disp...

Page 111: ...nce interval settings h c Time remaining until maintenance h a b Change engine oil 500 Replace engine oil filter 500 Replace fuel pre filter 500 Replace fuel main filter 1000 Replace hydraulic oil dra...

Page 112: ...reset the remaining time of a selected item highlighted in yellow REMARK When resetting the remaining time keep switch F6 pressed for at least 1 5 seconds If switch F6 is not kept pressed for at leas...

Page 113: ...list screen On the reset screen if no switch is operated for more than 30 seconds the screen automatically switches to the maintenance list screen 2 The reconfirmation screen shown on the right is di...

Page 114: ...down When on the last line it moves to the first line on the next page F4 Moves to previous item 1 line up When on the first line it moves to the last line on the previous page F5 Returns to standard...

Page 115: ...djustment d Language selection e Economy mode adjustment f Auto Low idle setting g Truck counter reset h Fan reverse mode The operation for setting a h is as follows Adjusting Screen Use this screen a...

Page 116: ...reen switches to the setting screen for the selected item a Standard screen adjustment b Camera screen adjustment only machines equipped with camera q On the mode selection screen shown on the right i...

Page 117: ...adjust the brightness of the monitor screen night mode q When the working lamp switch is in day position b or OFF position c if the standard screen is adjusted it is possible to adjust the brightness...

Page 118: ...ted item moves 1 segment to left F4 Indicator of selected item moves 1 segment to right F5 Returns to user menu F6 Accepts change and switches to next item setting ECO Display On this ECO display scre...

Page 119: ...53 2 Select ECO display selection on the user menu then press function switch F6 The screen switches to the tar get setting command screen 3 Select ECO Display Target Select then press function switch...

Page 120: ...on ment reduce the engine output to a point where there is no adverse effect on the operation Generally carry out energy saving operations in the green range Reducing the frequency of travel also help...

Page 121: ...lock displayed on the pilot monitor of the standard display 1 On the standard screen press switch F6 2 Select Clock Adjustment on the user menu then press switch F6 The screen switches to the time adj...

Page 122: ...s not necessary to change the hour setting press switch F6 F3 Time advances 1 hour F4 Time goes back 1 hour F5 Cancels change and returns to user menu F6 Accepts change and goes to setting for minutes...

Page 123: ...ighted in yellow press switch F6 to highlight 12h 24h Mode a in yellow 2 Change the 12h 24h mode with the switches as follows The selected display mode b or c is highlighted in green F3 Moves 1 item t...

Page 124: ...s change and returns to user menu F6 Accepts change and goes to setting for Time If the setting has been changed always press switch F6 REMARK Daylight saving time or summer time means moving the cloc...

Page 125: ...the language to use for the display then press switch F6 The screen display changes to the selected lan guage q On the language selection screen it is possible to carry out the following operations wi...

Page 126: ...s economy mode the engine output can be adjusted to improve the fuel consumption in E mode 1 On the standard screen press switch F6 2 Select Economy Mode Adjustment on the user menu then press switch...

Page 127: ...is shipped it is set to E0 q On the Economy Mode Adjustment menu screen it is possible to carry out the following operations with switches F3 F6 F3 Moves to item below F4 Moves to item above F5 Cance...

Page 128: ...the standard screen 2 Select Auto Low idle setting on the user menu then press function switch F6 The screen changes to the ON OFF screen for Auto Low idle setting 3 Select ON on the Auto Low idle set...

Page 129: ...screen the auto low idle monitor lights up q When the auto low idle function is ON after the work equipment control levers and travel levers are placed at Neutral the engine speed automatically goes d...

Page 130: ...1 to turn the auto decel eration function ON 2 When the auto deceleration function is turned ON the mode is displayed in the center of the monitor display and after 2 seconds the screen returns to the...

Page 131: ...nter Reset It is possible to correct or clear the truck counter 1 Press function switch F6 on the standard screen 2 Select Truck Counter Reset on the user menu then press function switch F6 The screen...

Page 132: ...F6 The screen switches to the selected item screen 01 TR1 CORRECT CLEAR Truck Counter Display 1 it is possible to correct or clear 02 TR2 CORRECT CLEAR truck counter Display 2 it is possible to correc...

Page 133: ...em screen operate function switches F3 or F4 to correct the counter value then press function switch F6 to confirm q After confirming press function switch F5 to return to the previous screen q If no...

Page 134: ...n switch F1 on the selected item screen then press function switch F6 to confirm The truck counter on the selected item screen is reset q After confirming press function switch F5 to return to the pre...

Page 135: ...on switch F6 The screen will switch to the ALL CLEAR screen When the ALL CLEAR screen is displayed press function switch F6 to confirm q After confirming press function switch F5 to return to the prev...

Page 136: ...ooler q Reverse rotation of the fan can be used for cleaning The fan blows the air to the outside to remove insects or dirt stuck to the net q After checking that no flammable or combustible material...

Page 137: ...n press function switch F6 The screen switches to Reverse FAN on the Fan Reverse Mode screen 4 To reverse the direction of the fan press function switch F6 The screen switches to Now Changing on the a...

Page 138: ...ine speed q When rotating the cooling fun in reverse while the engine is not running switch the display to this screen with the engine starting switch in ON position and then turn the switch to the ST...

Page 139: ...tion switch F6 The screen switches to Now Changing on the action screen q If function switch F5 is pressed the screen returns to the previous screen 9 When the screen changes to Now Changing in the op...

Page 140: ...n reverse press function switch F5 to switch to the initial screen then run the engine at low idling or stop the engine to carry out warming up or cooling operation On the initial screen if the coolan...

Page 141: ...lamp switch if equipped 3 Engine emergency stop switch 12 Greasing mode selector switch 4 Service center switch if equipped 13 Machine push up switch 5 Room lamp switch 14 Boom shock less limit switch...

Page 142: ...ctric current flows through the charging and lamp circuits Keep starting switch key in the ON position while the engine is running C START position This is the engine start position Keep the key at th...

Page 143: ...he OFF position and the emergency stop is cancelled When this happens indicator lamp L goes out REMARK It is possible to judge the status ON OFF of the engine emer gency stop switch by checking the co...

Page 144: ...position do not forget to turn it off Use this switch 5 to light up the room lamp a ON position Lights up b OFF position Goes out This lamp lights up even if the starting switch is at the OFF positio...

Page 145: ...nation of monitor screen is at normal level Step Light Switch This switch 8 lights up the step to ensure safety at night when getting on or off the machine q If the switch is set to ON position a the...

Page 146: ...ll it out and light your cigarette If the cigarette lighter is removed the socket can be used as the power source for the yellow flashing lamp The capacity of the cigarette lighter is 85W 24V x 3 5A 1...

Page 147: ...boom thrust force to push up the chassis when moving down from a bench there is dan ger that the machine may suddenly go down and turn over so set to the high pressure setting With this switch 13 it...

Page 148: ...is at the ON position q If the swing control lever is operated immediately after setting the swing lock switch to the ON posi tion swing drag may occur To avoid danger wait for approx 5 seconds after...

Page 149: ...switch 2 q When switch 16 is pressed the buzzer emits a peep at the same time so it is possible to check that the switch 16 has been pressed q In addition when switch 16 is kept pressed for approx 3...

Page 150: ...switch is in the OFF position do not forget to turn it off Use this switch 18 to light up the room lamp inside the cab base ON position Lights up OFF position Goes out 18 Room lamp switch cab base ro...

Page 151: ...ed slightly slower than normal q When starting up the engine with E0E or E07 showing on the display and the engine does not run move this switch to position c Then the engine may be started After the...

Page 152: ...soon as possible This switch 22 makes it possible to carry out operations for a short time when there is an abnormality in the emergency stop switch system but no monitor lights up and the engine cann...

Page 153: ...mp switch pump room 32 Step light switch 26 Engine emergency stop switch front of power container 33 Step light switch 27 Engine emergency stop switch rear of power container 34 Nighttime maintenance...

Page 154: ...engine room NOTICE It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position do not forget to turn it off Use this switch 24 to light up the room lamp insid...

Page 155: ...will make an emergency stop When this happens indi cator lamp L lights up green to indicate that the engine emer gency stop switch has been actuated b OFF normal operation position When the engine em...

Page 156: ...will make an emergency stop When this happens indi cator lamp L lights up green to indicate that the engine emer gency stop switch has been actuated b OFF normal operation position When the engine eme...

Page 157: ...rgencies q When carrying out an emergency stop of the engine If engine emergency stop indicator lamp L is off pull down rope R Indicator lamp L will light up green and the engine will make an emergenc...

Page 158: ...stop indicator lamp L is off pull down rope R Indicator lamp L will light up green and the engine will make an emergency stop q Cancelling engine emergency stop When indicator lamp L is lighted up pul...

Page 159: ...d it immediately returns to the OFF condition but the step light continues to remain lighted up for approx 90 seconds q Use this switch at night when moving between the ground and the operator s cab w...

Page 160: ...hted up until switch 34 is turned manually to OFF position b q Use this switch at night for maintenance work when it is desired to keep the steps or the passage lighted up q It is possible to light up...

Page 161: ...iately after the fan stops rotating in reverse power is supplied to the fan reverse rotation solenoid for a short time in order to protect the hydraulic motor Before turning the battery isolator switc...

Page 162: ...ecomes possible to start the engine Before starting the engine check that this switch is at the ON position b OFF position When the switch is turned counterclockwise from the ON posi tion the flow of...

Page 163: ...mp Lighted up Green Engine emergency stop switch is at ON emergency stop position Light off Engine emergency stop switch S is at OFF normal operation position 1 Engine emergency stop Indicator lamp 5...

Page 164: ...he OFF normal operation position before starting the engine again If lamp 2 is off when the starting switch is turned to the ON posi tion the engine can be started Fan Reverse Rotation Display Lamp Th...

Page 165: ...he lamp goes off For more details see Engine Emergency Stop Cancel Switch 3 86 Ladder Warning Lamp This lamp 7 lights up red when any of the following devices have been lowered q Hydraulic ladder q Se...

Page 166: ...ACHINE 3 9JH14996A 1 Proximity switch warning lamp 4 Engine emergency stop Indicator lamp 2 Proximity switch warning lamp 5 Engine emergency stop Indicator lamp if equipped 3 Engine emergency stop Ind...

Page 167: ...these lamps light up red it is necessary to check the cause and carry out repairs so please ask your Komatsu distributor to carry out inspection Engine Emergency Stop Indicator Lamp These lamps 3 to 6...

Page 168: ...lock the work equipment swing travel and attachment if equipped control levers Push the lever 1 down to apply the lock This lock lever 1 is a hydraulic lock even if it is in the lock position L the wo...

Page 169: ...avel levers check if the track frame is facing the front or the rear If the sprocket is at the rear the track frame is facing the front With this lever 2 the travel direction of the machine is changed...

Page 170: ...Neutral The boom and bucket are held in position and do not move DOOR LOCK 3 Use the door lock to fix the door in position after opening it 1 Push the door into catch 1 to lock it in position 2 When r...

Page 171: ...them Take care not to slip on the broken and scattered pieces Hammer A is provided to help the operator get out of the cab in emergency when the cab door or window will not open q Hammer A is install...

Page 172: ...rail and steps to ensure that you sup port yourself In particular the rope ladder will tend to swing and there is danger of falling off so be particularly careful to support yourself securely when cli...

Page 173: ...pper 2 2 Remove snap hook 3 from the hook of escape door 1 then lower rope ladder 4 to the ground 3 Using handrails 5 and 6 support yourself and step on to fixed ladder 7 4 Climb down fixed ladder 7 W...

Page 174: ...pe ladder 4 to the ground When doing this use handrail 8 and the rungs of fixed ladder 7 PRECAUTION WHEN STORING ROPE LADDER 3 When storing rope ladder 4 put a step of rope ladder 4 on installation br...

Page 175: ...ree other places where additional fire extinguishers can be installed If you wish to have additional fire extinguishers please consult your Komatsu distributor The three places where additional fire e...

Page 176: ...he Cap 1 Turn the cap until tight then insert the key into the key slot 2 Turn the starting switch key counterclockwise clockwise for the B type and remove the key Opening and Closing Cover with Lock...

Page 177: ...sure that you extinguish the cigarette before clos ing the lid CUP HOLDER 3 There are 2 cup holders at the rear left of the operator s seat MAGAZINE BOX 3 This is on the left side of the operator s s...

Page 178: ...DETAILED CONTROLS AND GAUGES OPERATION 3 112 HOOK 3 This is at the rear of the operator s compartment UTILITY BOX 3 This is under the assistant s seat...

Page 179: ...temperature and air flow displays on display monitor 6 and air conditioner switch 7 go out and operation stops REMARK Even if switch 1 is turned OFF the lamp at the top of FRESH RECIRC selector switc...

Page 180: ...ch to raise the set temperature press the switch to lower the set temperature q The temperature is generally set at 25 C q The temperature can be set in stages of 0 5 C q The sensors for the temperatu...

Page 181: ...vents displayed q During automatic operation the vents are automatically selected A Rear vents top x 2 bottom x 2 B Face vents left x 1 right x 1 C Foot vents front x 1 rear x 1 D Defroster vents left...

Page 182: ...ES OPERATION 3 116 q Rear vents A A1 Rear vents top 2 places A2 Rear vents bottom 2 places q Face vents B B1 Face vent left 1 place B2 Face vent right 1 place q Foot vents C C1 Foot vent front 1 place...

Page 183: ...to the set temperature q When auto switch 8 is pressed the lamp above the auto switch lights up q Press switch 5 then use temperature control switch 3 to set the temperature and run the air conditione...

Page 184: ...h 1 is pressed the display of tempera ture setting a and air flow b goes out and operation stops Air Conditioner Switch Use this switch 7 to start or stop the air conditioner cooling dehumidifying hea...

Page 185: ...ir volume b are also shown on the monitor display 2 Use temperature set switch 3 to set to the desired tem perature The air flow combination of vents and selection of fresh or recirculated air is auto...

Page 186: ...he lamps above auto switch 8 and air conditioner switch 7 go off stopping the operation of the air conditioner Manual Operation 1 Press fan switch 2 and adjust the air flow When doing this check that...

Page 187: ...select the desired vents When this is done the display for vent c of the display monitor changes according to the selection 5 Press RECIRCL A or FRESH B on air source selector switch 5 Stopping Manual...

Page 188: ...doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display c on the display monitor to mode display M3 as shown in the di...

Page 189: ...flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display c on the display monitor to the following mode q To...

Page 190: ...agram on the right 3 Press FRESH RECIRC selector switch 5 to set to intake of outside air 4 Press temperature setting switch 3 and set temperature on the display 7 monitor to maximum heating In wet or...

Page 191: ...entilation and cooling Temperature Control When the cooler is on set the temperature so that it feels slightly cool when entering the cab 5 or 6 C lower than the outside temperature This temperature d...

Page 192: ...an one failure is detected press the or portion of temperature setting switch 3 to dis play the failures in turn q After completing the troubleshooting press OFF switch 1 again to return to the normal...

Page 193: ...t the same time for more than 5 seconds while the fan is running the temperature display will switch between F and C Note that the unit is not displayed RADIO 3 Control Panel 3 s Liquid crystal displa...

Page 194: ...ay For details of the method of adjusting the time see Setting Correct Time 3 131 AS PS button This button 5 actuates the auto store and preset scan functions q Auto store If this button is kept press...

Page 195: ...s for tuning auto tuning and manual tuning 3 With the display 7 showing the desired frequency keep the desired Preset button No pressed for at least 1 5 sec onds The reception sound will disappear but...

Page 196: ...o tuning will be cancelled and the setting will return to the fre quency in use before the button was pressed Method of Operating Mode q BAS Bass adjustment When button 2 is pressed BAS is displayed o...

Page 197: ...by one hour M button Adjusts the minute each time the button is pressed the time advances by one minute q If the H or M button is kept pressed the time will advance continuously until the button is re...

Page 198: ...to hear outside sounds during opera tion q If water gets into the speaker case or radio it may lead to an unexpected failure so be careful not to get water on the equipment q Do not wipe the scales o...

Page 199: ...e equipment Pull out the connector plug for taking out electric power from the rear side of the panel Maximum usable electric power is 85 W 24 V x 3 5 A 12V Power Source 3 This power source can be use...

Page 200: ...o first turn the starting switch to the OFF position wait over one minute then switch off the battery isolator switch The fuses protect the electrical equipment and wiring from burning out If the fuse...

Page 201: ...enoid valve Starting motor cut relay 4 10A Cigarette lighter 5 20A Horn Flash light 6 10A Bottom dump solenoid valve 7 10A Rotating lamp 8 20A Spare lamp 9 10A Radio 10 30A Wipper Window washer 11 20A...

Page 202: ...ng out When restoring the electrical circuit that has been shut off push in the reset button that sprang out when the circuit was cut off If the electric circuit is working properly the reset button w...

Page 203: ...s circuit breaker is a large size breaker installed to circuits where a large capacity current is flowing In the same way as normal fuses and circuit breakers installed to the power board inside the c...

Page 204: ...troller 2 VHMS controller Bottom dump solenoid valve Rotating lamp Rear and side lamp Radio Wiper Window washer 2 60A Swing holding brake solenoid valve Machine push up Boom anti vibration solenoid va...

Page 205: ...r switch The fuses protect the electrical equipment and wiring from burning out If the fuse becomes corroded or white powder can be seen or the fuse is loose in the fuse holder replace the fuse Replac...

Page 206: ...ve the negative terminal of the battery For machines equipped with the optional battery isolator switch turn the starting switch OFF then wait for at least 3 minutes before turning the battery isolato...

Page 207: ...oolbox placed in the cab base room in the machine s front direction HANDLING GREASE PUMP AND GREASE GUN 3 The grease pump is stored under the center maintenance floor right side of machine The grease...

Page 208: ...r s seat inside the cab room to the MANUAL position 2 Remove grease gun 1 from holder 2 then move to the greasing posture 3 Pull lever 3 of grease gun 1 with your finger When lever 3 is pulled the gre...

Page 209: ...ere is only a small amount of grease left in the grease can the pump will not pump out grease so move the grease to the center or fill the can with new grease Supplying Grease When replacing grease ca...

Page 210: ...oosening hexagonal screw 11 of the grease level sensor lift up limit switch 12 remove cap 13 then remove spring 14 4 Remove 2 wing nuts 15 5 Lift up grease can cover 16 vertically to remove it 6 Remov...

Page 211: ...ll it to the new grease can that will replace the old grease can NOTICE Be careful not to drop clamp 19 when lifting the grease can up and tighten it securely REMARK If grease can is equipped with ref...

Page 212: ...he shafts 11 Insert wire 23 of the grease level sensor through hole C in grease can cover 16 12 Be careful not to drop wire 23 into the grease can when inserting it Insert grease can cover 16 until it...

Page 213: ...e remove the connection hose from the grease pressure feed pump A From grease pressure feed pump B To grease can q Komatsu does not handle grease pressure feed pumps but if the charging port is necess...

Page 214: ...osing of the accumulator the gas must be released Contact your Komatsu distributor for proper disposal This machine is equipped with an accumulator in the control circuit The accumulator is a device t...

Page 215: ...the engine starting switch to the ON position 4 Move the lock lever 1 to the free position F and oper ate the work equipment control lever and the attachment operation pedal optional back and forth a...

Page 216: ...r operate the work equip ment If this happens the ladder warning lamp inside the opera tor s cab lights up red For details see Ladder Warning Lamp 3 99 This lock is cancelled when the ladder is stowed...

Page 217: ...ep ladder lowering switch 3 on switch box 1 pressed until the ladder automatically stops REMARK The hydraulic ladder can be lowered also when the engine is not running but its move is not as fast as w...

Page 218: ...on chain to the hook on the machine If the angle when the ladder comes down under its own weight is within 5 when the engine is started the ladder will automatically return to the stowing position so...

Page 219: ...orking properly so adjust as follows to make actuating display lamp L light up cor rectly q If actuation display lamp L does not light up There is probably a problem with proximity switch 1 so change...

Page 220: ...iately and ask for repairs to be carried out The machine can move so this is extremely dangerous For this reason when carrying out this operation always set the hydraulic ladder to the stowing positio...

Page 221: ...connector b to connector D and connect con nector d to connector B 6 Connect the negative terminal of the battery start the engine then check that it is possible to operate the travel swing and work...

Page 222: ...e KOMTRAX Plus equipment or the machine itself REMARK There is absolutely no need to inspect or operate the KOMTRAX Plus but if any abnormality is found please con tact your Komatsu distributor KOMTRA...

Page 223: ...he machine equipped with this device is used such restriction or law has a priority than this warning KOMTRAX Plus specifications are as follows Rated horsepower 5 10 W Operating frequency 148 150 MHz...

Page 224: ...ent cylinders linkage hoses Check for cracks excessive wear play in wotk equipment cylinders linkage and hoses If any problem is found repair it 2 Remove dirt and debris from around the engine battery...

Page 225: ...If any problem is found repair it Tighten any loose bolts 9 Check for problem in gauges monitor Check for problem in the gauges and monitor in the operator s cab If any problem is found replace the pa...

Page 226: ...the engine is stopped the coolant is at high temperature In addition pressure has accumulated inside the radiator If the cap is opened under these conditions it will cause burns Wait for the temperatu...

Page 227: ...ant 4 After adding coolant tighten cap 5 securely then lower the cap lever to secure cap 3 in place 5 If the reserve tank 2 becomes empty there is probably water leakage After checking repair any abno...

Page 228: ...o open cover 6 2 After removing cover 8 loosen radiator cap 9 slowly to release the pressure then push cap 9 in and loosen it further to remove it 3 Check that the coolant is in the hatched portion in...

Page 229: ...machines equipped with a service center option see Method of Draining Adding Engine Oil 6 20 1 Open the door of the power container at the front of the machine 2 Remove dipstick G and wipe the oil of...

Page 230: ...he oil level after the engine has been operated wait for at least 15 minutes after stopping the engine before checking If the machine is at an angle make it horizontal before checking Check Fuel Level...

Page 231: ...ork equipment is not in the condition shown in the diagram on the right start the engine run the engine at low speed retract the arm and bucket cylinders lower the boom put the bucket teeth in contact...

Page 232: ...the correct oil level is in blue range a1 on the gauge label shown in the diagram on the right q When the hydraulic oil is at high temperature 50 80 C the correct oil level is in red range b1 on the...

Page 233: ...elow the correct line add oil through filler port F at the top of the hydraulic tank NOTICE Do not add oil above the correct level This may damage the hydraulic circuit and cause the oil to spurt out...

Page 234: ...P2 q When using drain plugs P3 at bottom of hydraulic sub tank Loosen 2 drain plugs P3 at the bottom of the hydraulic sub tank and drain the oil The outlet port for draining the oil is drain tube B Wh...

Page 235: ...or the oil temperature to go down before performing this operation NOTICE When checking the oil level park the machine on the level ground and start checking more than 15 min utes after the engine has...

Page 236: ...ing monitor on the monitor panel does not light up 2 If it lights up immediately clean or replace the element For details of method of cleaning the element see CHECK CLEAN AND REPLACE AIR CLEANER ELE...

Page 237: ...lso for loose terminals and tighten if necessary Be particularly careful to check the battery starting motor and alternator wiring Always check that no flammable materials are accumulated around the b...

Page 238: ...d water from splashing and making the surrounding area dirty 2 Open drain valve 1 at the rear of the revolving frame and drain the sediment and water accumulated at the bottom of the water separator t...

Page 239: ...d and may cause seri ous burns Wait for the temperature to go down before starting the operation q Fuel is highly flammable and dangerous Never bring flames near fuel The water separator is installed...

Page 240: ...looking through transparent cap 1 If there is any water or sediment collected at the bottom set a container to catch the drain water under drain hose 3 3 Pull up fuel shut off lever A installed at the...

Page 241: ...6 Push down fuel shut off lever A to open the fuel supply circuit 7 After completing the water drain operation bleed the air Use the same procedure as when replacing the fuel filter cartridge q For de...

Page 242: ...Do not bring any fire or flame close The water separator serves to separate moisture mixed in the fuel NOTICE If float 1 goes above level line 2 there is danger that the separated water may be sucked...

Page 243: ...water will drain from plug 4 4 When fuel starts to come out tighten plug 4 immediately Tightening torque 1 5 2 5 Nm 0 15 0 25 kgm 5 If the inside of filter case 6 is dirty with the sediment wash it F...

Page 244: ...r defective operation of the buzzer 1 Before starting the engine turn the starting switch to the ON position and check that all monitors and gauges light up for approx 3 seconds and that the alarm buz...

Page 245: ...lever 3 operated continuously for more than 1 minute A Fore and aft adjustment Pull lever 1 up set the seat to the desired position then release the lever Fore and aft adjustment 170 mm 10 mm x 17 sta...

Page 246: ...nt range REMARK When the seat is pushed down the air is discharged The air makes a sound when it is discharged but this does not indicate any failure When lever 3 is pushed down the seat height may su...

Page 247: ...rest portion as desired Push Tension becomes stronger Push Tension becomes weaker J Adjustment of armrest angle Armrest 8 can spring up to an angle of approx 90 In addi tion it is possible to rotate d...

Page 248: ...nd screws 3 holding the mir ror then adjust to a position which gives the best view from the operator s seat In particular adjust so that people to the left and right side at the rear of the machine c...

Page 249: ...t the angle of C2 mirror the way a view in the rear of the counterweight left portion can be seen D1 Adjust the angle of D1 mirror the way a view of the fuel tank right lower portion can be seen D2 Ad...

Page 250: ...seat belt so that it is not twisted REMARK The date of seat belt manufacture attached to the seat belt is the start of the 5 year period It is not the start of the 3 year period of actual usage Faste...

Page 251: ...pedal are touched when the engine is started the machine may move unexpectedly and this may lead to serious personal injury 1 Check that battery isolator switch 1 and starting motor isolator switch 2...

Page 252: ...buzzer does not sound there is probably a failure in the monitor so ask your Komatsu distributor to carry out repairs 2 After approx 2 seconds the screen switches to the work ing mode display monitor...

Page 253: ...h 3 45 in the explanation for each component 5 Check that engine emergency stop lamp 26 is out If it is lighted up the monitor goes out and even if the starting switch is turned to the START position...

Page 254: ...tch front of power container Engine emergency stop switch rear of power container Engine emergency stop switch left side of the machine if equipped Engine emergency stop switch right side of the machi...

Page 255: ...d MAX position the engine will accelerate suddenly and cause damage to the engine parts q Do not keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the en...

Page 256: ...ating has been completed turn the key in starting switch 3 to the START position C and start the engine REMARK If the ambient temperature is low the engine may not start even when the key in the start...

Page 257: ...After the preheating monitor goes off turn the key in starting switch 3 to START position C The engine will start If the engine cannot be started with the above procedure wait for at least two minute...

Page 258: ...n the environment the method of carrying out the warm up operation may differ so carry out the warm up operation according to the items given in the appropriate section When only the engine is warmed...

Page 259: ...ine warm up operation starts automatically When the engine automatic warm up operation starts the engine speed is maintained at a speed higher than the normal low idling speed If the engine water temp...

Page 260: ...ecking that the engine coolant temperature monitor displays the correct temperature carry out the warm up operation for the hydraulic equipment NOTICE Canceling automatic warm up operation If it becom...

Page 261: ...itor back ground C is blue B Display when temperature is low Monitor back ground C is white q The warming up operation for the hydraulic equipment is necessary not only for the circuit between the pum...

Page 262: ...g mode to P mode heavy duty mode For details of the procedure for setting the working mode see Working Mode Selector Switch 3 31 4 Move lock lever 3 slowly to the FREE position F then raise the bucket...

Page 263: ...mperature monitor 7 is display ing the correct temperature If the hydraulic oil temperature monitor is not displaying the correct temperature it is displaying low temperature repeat Steps 6 to 10 unti...

Page 264: ...17 Display is correct level 2 2 monitor screen q PTO temperature gauge 18 Displays green range q PTO oil temperature monitor 19 Displays correct temper ature q Engine oil temperature gauge 20 Displays...

Page 265: ...ow Monitor background C is white For both normal temperatures and cold temperatures carry out the following operation 16 Check that fuel control dial 4 is at a point midway between low idling MIN and...

Page 266: ...lic oil temperature monitor displays the correct temperature the hydraulic equipment warm up opera tion is completed After confirming that the hydraulic oil temperature monitor displays the correct te...

Page 267: ...TION MACHINE OPERATIONS AND CONTROLS 3 201 q Working mode monitor display 1 P mode For heavy duty operations 2 E mode For operations with emphasis on fuel economy 3 Heavy lift mode For assisting opera...

Page 268: ...ncy If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Run the engine at low idle for about 5 minutes to cool...

Page 269: ...he starting switch is turned to the START position the engine will not start q Even when the key in the starting switch is turned to the ON position the machine monitor does not give a display q Indic...

Page 270: ...the engine emergency stop switch at the OFF normal operation position Press engine emergency stop switch S installed at the front or rear of the power container and set it to engine stop position a q...

Page 271: ...llows 1 Turn the head of engine emergency stop switch S to the right The switch will spring out slightly and will be reset to OFF normal operation position b When doing this check set indicator lamp L...

Page 272: ...the engine emergency stop switch is pulled while the engine is running the engine stops and the machine monitor goes out q Even when the key in the starting switch is turned to the START position the...

Page 273: ...ncelled 2 Turn the starting switch key to the ON position 3 Check that engine emergency stop warning lamp C on the console panel to the left of the operator s seat inside the cab is off 4 Start the en...

Page 274: ...Ground Pull down fuel shut off lever 1 installed at the front right of the machine The engine will stop after approx 3 5 minutes q When starting the engine again after it has stopped move fuel shut o...

Page 275: ...r This makes it possible to prevent the fuel inside the fuel tank from flowing out even if the fuel piping hoses are burned Fuel shut off valve 3 is connected to fuel shut off lever 1 and fuel shut of...

Page 276: ...safe and sound the horn q Do not allow anyone to enter the area around the machine q Clear any obstacles from the travel path q There is a blind spot at the rear of the machine so be particularly car...

Page 277: ...art the machine either by pushing lever 5 forward slowly or by stepping on the front part of pedal 6 slowly q When sprocket is situated at the front of the machine Start the machine either by pulling...

Page 278: ...press the rear part of the pedals 6 to move the machine backward q When sprocket A is at the front of the machine Slowly push the levers 5 forward or slowly depress the front part of the pedals 6 to m...

Page 279: ...OPERATION MACHINE OPERATIONS AND CONTROLS 3 213 1 Put the left and right travel levers 1 in the neutral position then stop the machine...

Page 280: ...movement of the machine Use the travel levers to change direction Avoid sudden changes of direction as much as possible Espe cially when performing counter rotation spin turn stop the machine before t...

Page 281: ...Forward left turn B Reverse left turn REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left...

Page 282: ...auto deceleration function the engine speed will suddenly rise operate the levers carefully 1 Before starting the swing operation turn swing lock switch 1 OFF and check that swing lock monitor 2 has...

Page 283: ...ontrol levers to operate the work equipment Note that when the levers are released they return to the HOLD position and the work equipment is held in that position q Arm control Move the left work equ...

Page 284: ...g to the function of the auto deceleration device even if the fuel control dial is in the FULL position REMARK This machine is equipped with an accumulator in the operation circuit For this reason the...

Page 285: ...the starting switch is turned to the ON position the work ing mode is automatically set to P mode Use the working mode selector switch to set to the most effi cient working mode for the type of job W...

Page 286: ...orce to compact soil or break objects This is not only dangerous but will also drastically reduce the life of the machine Operations Using Travel Force Do not dig the bucket into the ground and use th...

Page 287: ...the rock behind the principle of the lever will bring excessive force to bear on the machine or work equip ment and there is danger that this may lead to breakage or damage of the machine In such situ...

Page 288: ...nt and frame and this will reduce the service life of the machine Digging Hard Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it af...

Page 289: ...ine travels over rough parts of the ground sur face the thrusting load on the machine will increase and reduce the service life of the machine To protect the machine when traveling on rough ground or...

Page 290: ...ravel speed keep the work equipment close to the ground and try to travel so that the center of the track passes over the obstacle Permissible Water Depth NOTICE When driving the machine out of water...

Page 291: ...the bucket approx 100 to 150 cm from the ground Do not travel downhill in reverse q Never turn on slopes or travel across slopes Always go down to a flat place to perform these opera tions It may be l...

Page 292: ...ine again q An accumulator is provided in the operation control circuit For this reason the work equipment can go down of its own weight for some time after the engine has stopped if the work equipmen...

Page 293: ...tom of the bucket in contact with the ground Never push with the teeth The angle between the boom and arm should be 90 to 110 The same applies when using the inverted bucket When only one side is stuc...

Page 294: ...orce of each cylinder When excavating use this angle effectively to optimize your working efficiency The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle toward...

Page 295: ...foot under the bucket while standing at the side for the work q When removing or inserting pins be extremely careful not to get your fingers caught q Never insert your fingers into the pin holes when...

Page 296: ...t and right NOTICE After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at both ends of the bushings be careful not to damage them 3 Align the arm with hole A...

Page 297: ...s an additional safety measure thrust the bucket into the ground q If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accide...

Page 298: ...ality is found in any of them take proper action after stopping the engine and in reference to TROUBLES AND ACTIONS 3 240 MACHINE INSPECTION AFTER DAILY WORK 3 1 Walk around the machine and check the...

Page 299: ...ose the window 2 Door of cab base room 3 Fuel tank filler port 4 Hydraulic tank filler port 5 Power container front door 5 places 6 Power container rear door 3 places 7 Battery case cover 2 places 8 A...

Page 300: ...sembled for transportation When transporting the machine please consult your Komatsu distributor METHOD OF LIFTING UNITS FOR TRANSPORTATION 3 WARNING q Never raise the machine with any worker on it q...

Page 301: ...with large amounts of fresh water and see a doctor at once q When changing the coolant or when handling the coolant containing coolant that has been drained during repair of the radiator please conta...

Page 302: ...so drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 Insulate it against cold temperature to ensure the machine can be...

Page 303: ...ground and allow the machine to be moved the next morn ing q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing q Fill the fuel tank to capacity This mi...

Page 304: ...or switch to the OFF position Put a cover on the battery during storage q Lock each control lever and pedal with the lock lever and pedal lock q To prevent rust fill with coolant to give a density of...

Page 305: ...rease at all lubrication points q When the machine is stored for a long period moisture in the air will mix with the oil Check the oil before and after starting the engine If there is water in the oil...

Page 306: ...ification machines if equipped see Bleeding air from fuel circuit with the electric priming pump 4 47 PHENOMENA THAT ARE NOT FAILURES 3 Note that the following phenomena are not failures q When the ar...

Page 307: ...or this machine is 1 079 kN 110 027 kg Always carry out towing operations within the maximum towing capacity q If the machine sinks in mud and cannot get out under its own power or if the drawbar pull...

Page 308: ...lling install the positive terminal first If a tool touches the positive terminal and the chassis there is danger that it will cause a spark so be extremely careful q If the terminals are loose there...

Page 309: ...egative termi nal of the battery Be sure to attach the clips securely q Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than...

Page 310: ...it is not a good conductor q When removing the booster cable exercise good care so that the booster cable clips may not contact each other or they contact the chassis NOTICE q The starting system for...

Page 311: ...he problem machine Starting the Engine WARNING Always check that the lock lever is set to the LOCK position regardless of whether the machine is work ing normally or has failed Check also that all the...

Page 312: ...the ON position The hydraulic tank strainer is not installed normally The starter isolator switch is in the OFF position The battery isolator switch is in the OFF position Check repair Replace Charge...

Page 313: ...track shoe Does not swing Swing lock switch still applied Turn swing lock switch OFF Swing travel work equipment can not be operated Hydraulic ladder is not stowed Abnormal proximity switch for hydrau...

Page 314: ...ECK BEFORE STARTING Clean or repair see EVERY 500 HOURS SERVICE Change cooling water clean inside of cooling system see WHEN REQUIRED Replace engine water level sensor Replace engine water temper atur...

Page 315: ...ce See WHEN REQUIRED Check repair See adjustment of clearance above Check replace Check replace repair Engine hunts Air entering suction side of fuel line Clogged fuel strainer Drain water of fuel pre...

Page 316: ...have inspection carried out immediately E14 Abnormality in throttle abnormality in fuel control dial Move machine to a safe posture and carry out inspection immediately E15 Abnormality in electronic...

Page 317: ...the monitor the telephone number for the point of contact is displayed at the bottom of the error screen REMARK If no point of contact telephone number has been registered no telephone number is disp...

Page 318: ...TROUBLES AND ACTIONS OPERATION 3 252...

Page 319: ...MAINTENANCE 14 WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 320: ...lubrication of the machine use the Komatsu genuine lubricants Moreover use oil of the specified viscosity according to the ambient temperature Windshield Washer Fluid Use ethyl alcohol window washer f...

Page 321: ...frequently q When checking and replacing the oil or filters move the machine to a place where there is no dust and take care to prevent dust from entering the system Avoid Mixing Lubricants If a diff...

Page 322: ...nance items been performed correctly q Have any tools or parts been dropped inside the machine It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage...

Page 323: ...ticles dirt etc from getting in The majority of problems with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil q...

Page 324: ...sity fuel with low lubricating ability is used the durabil ity may drop markedly COOLANT AND WATER FOR DILUTION 4 q Komatsu genuine Supercoolant AF NAC has the important function of preventing corrosi...

Page 325: ...hyper white grease as it hardens CARRYING OUT KOWA Komatsu Oil Wear Analysis 4 KOWA is a maintenance service that makes it possible to prevent machine failures and downtime With KOWA the oil is period...

Page 326: ...being sucked in If drums have to be stored outside cover them with a waterproof sheet or take other measures to protect them q To prevent any change in quality during long term storage be sure to use...

Page 327: ...ystem is checking fan belt tension checking damage or wear to the fan belt and checking battery fluid level q Never install any electric components other than those specified by Komatsu q External ele...

Page 328: ...r 21T 04 31170 q For details of the loading specification machine see WEAR PARTS 7 21 Item Part No Part Name Q ty Replacement fre quency Engine oil filter 600 211 1340 Cartridge 4 Every 500 hours serv...

Page 329: ...below 0 C be sure to use the recommended multi grade oil even if the ambient temperature may become higher during the course of the day q If the machine is operated at a temperature below 20 C a separ...

Page 330: ...C TO30 Hydraulic system Power train oil 20 C 50 C TO10 Hydraulic oil 20 C 50 C HO46 HM Grease fitting Note 3 Hyper grease Note 4 20 C 50 C GT2 T G2 TE Lithium EP grease 20 C 50 C G2 LI Cooling system...

Page 331: ...lubricating ability of the grease in order to prevent squeaking of pins and bushings the use of G2 T or G2 TE is recommended Note 5 Coolant 1 Komatsu genuine Supercoolant AF NAC has the important func...

Page 332: ...17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 11 8 14 7 27 34 59 74 98 123 153 190 1 2 1 5 2 8 3 5 6 0 7 5 10 0 12 5 15 5 19 5 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 0 52 3 70...

Page 333: ...r condition after a certain period of usage This is impor tant to ensure that these parts maintain their full performance at all times Furthermore should anything abnormal be found on any of these par...

Page 334: ...hose engine to heater 12 16 Swing line hose 4 17 Boom cylinder line hose backhoe 4 18 Arm cylinder line hose backhoe 7 19 Bucket cylinder line hose backhoe 7 20 Pump suction coupling 2 21 Fuel hose f...

Page 335: ...NG AIR FROM FULE CIRCUIT 4 454 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 494 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4 604 INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASIN...

Page 336: ...MERGENCY LADDER 4 1024 GREASING HYDRAULIC LADDER 4 1034 EVERY 2000 HOURS MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE 4 1044 CHECK GREASE LEVEL IN SWING PINION ADD GREASE 4 1054 CHECK ALTERNATOR STARTIN...

Page 337: ...ER THE FIRST 500 HOURS 4 Carry out the following maintenance only after the first 500 hours of operation on new machines q Change oil in swing machinery case q Change oil in PTO case q Change oil in f...

Page 338: ...q Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel light up If the element is cleaned frequently before the air cleaner clogging monitor light up the ai...

Page 339: ...after it has been cleaned replace external ele ment 5 internal element 6 and O ring 8 REMARK Use dust indicator 4 as a guideline for the cleaning interval for the air cleaner element If tip D of the y...

Page 340: ...at an angle insert your hand and push it in straight 4 After removing the outer element 5 cover the inner ele ment 6 with a clean cloth or tape to prevent dirt or dust from entering 5 Wipe off or brus...

Page 341: ...or oil stuck to the seal portion of the new element or cleaned element Wipe off any dirt or oil 10 Push the outer element in straight with your hand when installing it to the air cleaner body If the o...

Page 342: ...2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks in turn on opposite sides top bottom left right in the same way as when tig...

Page 343: ...installed there is danger that the outer element will be damaged q The seal portion on imitation parts lacks precision and allows the entry of dust which leads to dam age of the engine Do not use such...

Page 344: ...as follows 1 Align cover 3 with the element 2 Hook the tip of hook 2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks in turn o...

Page 345: ...anticorrosion anti freeze and cooling properties and can be used continuously for two years or 4000 hours As a basic rule we do not recommend the use of any coolant other than Supercoolant AF NAC If y...

Page 346: ...hines equipped with a service center option see Method of Draining Adding Coolant 6 26 Coolant is already diluted with distilled water so it is not flammable For details of the distilled water see COO...

Page 347: ...14 Start the engine and run for approx 10 minutes at low idling 15 Stop the engine and open drain valves 6 and 7 to drain the water 16 After draining the water use a detergent to wash the tank For de...

Page 348: ...h the link mating surface CHECK AND ADJUST TRACK TENSION 4 WARNING q For details of the method of starting the engine and operating the work equipment see BEFORE STARTING ENGINE 3 158 STARTING ENGINE...

Page 349: ...easure the maximum deflection between bottom surface of the wooden bar and top surface of the track shoe Deflection a should be 10 30 mm Adjustment If the track tension is not at the standard value ad...

Page 350: ...r rectly 4 Check that protrusion A of hydraulic cushion cylinder plunger 3 is within the specified value on both the left and right 5 If protrusion A is not within the specified value carry out Step 3...

Page 351: ...on of the hydraulic cushion cylinder again after pump ing in grease If it is not within the correct range loosen the plug 1 one turn to release the grease and adjust If that protrusion of hydraulic cu...

Page 352: ...track link does not become loose ask your Komatsu distributor to carry out repairs 1 Loosen plug 1 a little at a time to release the grease 2 Loosen plug 1 a maximum of 1 turn 3 If the grease does no...

Page 353: ...sure to ask your Komatsu distributor for the replacement NOTICE q When replacing the bucket teeth be sure to replace all of them at once Should all the bucket teeth be not replaced at a time the bucke...

Page 354: ...e adapter insert new pin 1 then tighten 90 clockwise with the socket wrench to lock the pin and complete the installa tion REMARK Turn the tooth upside down and rotate the installation positions Such...

Page 355: ...the tooth pins cannot be removed in this procedure for safety s sake be sure to ask your Komatsu distributor for the replacement Prepare for a socket wrench for 16 mm width across flats 1 Set the buc...

Page 356: ...e and mounting hole 7 7 Install new wear cap 6 by fitting it in adapter mounting hole 7 8 Clean the tooth mounting face fit tooth 2 in the adapter insert pin 1 and then lock the pin by turning a socke...

Page 357: ...loop are sent flying around q Never hit the tooth against a boulder for the purpose of removing the slinging loop There is the danger that the broken slinging loop will be sent flying around in piece...

Page 358: ...p 4 adapter 5 side shroud 6 NOTICE When cutting the slinging loop at each part of the bucket cut at the following cutting positions A A or B B according to the shape of the loop In addition when doing...

Page 359: ...Fluid and Water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the following proportions before adding There are two types depending on the freez...

Page 360: ...s appear there is lack of refrigerant gas so have your service shop add refrigerant immediately If the air condi tioner is run when there is lack of refrigerant gas it will cause damage to the compres...

Page 361: ...Remove cover 1 2 Install a bolt 10 mm in bolt hole A of element 2 then hold the bolt and pull out element 2 3 Clean element 2 q When cleaning the element clean the dirt and dust stuck to side surface...

Page 362: ...ICE If there is a change to high water temperature when operating the engine over several days when there is no change in the ambient temperature a possible reason is peeling of the sealing material a...

Page 363: ...f the supply pump or the air bleed plug at the top of the fuel filter head is opened the residual pressure may spray out fuel Loosen the plug and breather slowly before open ing NOTICE The common rail...

Page 364: ...es come out with the fuel tighten air breather 6 One place each on left and right sides of engine Tightening torque 4 9 6 9 Nm 0 5 0 7 kgm 4 Pump priming pump lever 4 again several times until it beco...

Page 365: ...e first time after replacing the supply pump or modifying the piping or any other parts WARNING q After the engine is stopped all parts are at high temperature so there is danger of suffering burns Wa...

Page 366: ...s in the instance that the engine stops due to fuel exhaustion or in the instance that the fuel hose tube or priming pump has been maintained or replaced In that case tilt the electric priming pump sw...

Page 367: ...those for pilot selector valve circuit and main valve PPC circuit 6 Work equipment circuit Run the engine at less than 1000 rpm and operate the cylinders slowly Do not use sudden stopping and starting...

Page 368: ...n hose from the pump case and fill the pump case with hydraulic oil through drain port 2 Oil will come out from the drain hose when it is removed so fix the mouthpiece of the hose at a position higher...

Page 369: ...IRCUIT After the removal and installation of the swing motor and the disconnection and connection of the swing holding brake circuit piping bleed air from the brake circuit in the following manner CAU...

Page 370: ...ts up BLEEDING AIR FROM IDLER CUSHION CIRCUIT Bleed the air from the idler cushion circuit before pumping grease into the hydraulic charge grease cylinder 1 Loosen plug 1 of the grease cylinder 1 turn...

Page 371: ...flow out of air bleeding plug 3 and out of the plug 6 hole 7 Tighten air bleeding plugs 7 and 3 Left and right 2 places 8 Install plug 6 9 Finally tighten grease cylinder plug 1 Left and right 2 plac...

Page 372: ...or valve and the disconnection and connection of the pilot selector valve circuit bleed air from the pilot selector valve circuit in the following manner REMARK If air is not bled at all or bled but i...

Page 373: ...il free of air bub bles begins to flow out of bleeder A and then tighten bleeder A Tightening torque 8 8 9 8 Nm 0 9 1 0 kgm 3 Turn the swing lock switch to the ON position 4 Operate boom RAISE and SWI...

Page 374: ...eration or an abnor mal noise from the PPC lever so be sure to follow the air bleeding instructions 1 Start up the engine and loosen bleeder A The bleeder is provided at the joint of the main valve sp...

Page 375: ...INTENANCE PROCEDURE 4 57 Rear Side of Main Valve R Machine s rear side 1 Arm DUMP 4 locations 2 Boom LOWER 2 locations 3 Bucket DUMP 4 locations 4 Left travel forward 2 locations 5 Right travel forwar...

Page 376: ...RE MAINTENANCE 4 58 Front side of main valve F Machine s front side 1 Arm DIGGING 3 locations 2 Boom RAISE 3 locations 3 Bucket DIGGING 4 locations 4 Right travel backward 2 locations 5 Left travel ba...

Page 377: ...ork equip ment will not move for more than 10 seconds Do not oper ate the lever fully to make the work equipment move 2 Keep the engine running at low idling and operate each cylinder from a point 100...

Page 378: ...mes 3 Screw in the hydraulic tank cap 4 Start up the engine and stop it after approx 10 seconds q Do not raise the engine rotation above 1000 rpm q Hold the work equipment control lever to the N posi...

Page 379: ...lic tank and release the internal pressure inside the tank 2 Slowly loosen drain valve 1 installed inside the axle and let the remaining pressure inside the circuit to be released After more than 1 mi...

Page 380: ...et in If there is any dirt of dust around the fuel system clean it off thoroughly with fuel before starting the operation q To prevent dirt or dust from getting into the fuel circuit remove all dirt a...

Page 381: ...so dirty that the position of float 6 cannot be checked replace case 4 9 Install screen 5 to the water separator holder 10 Replace O ring 7 with a new part 11 Tighten plug 1 insert case 4 so that flo...

Page 382: ...fuel level add fuel q Check oil level in hydraulic tank add oil q Check oil level in PTO case add oil q Check air cleaner for clogging q Check working lamp switch q Check electric wiring q Check funct...

Page 383: ...lug slowly to release the pressure q Prepare a handle 1 Set so that plug 1 on the outside of the machine is at the bottom position 2 Using a handle remove plug G and check the oil level The oil level...

Page 384: ...te to go above the UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts q When adding distilled water in cold weather add it b...

Page 385: ...s 1 Remove cap 2 at the top of the battery look through the water filler port 3 and check the electrolyte surface If the electrolyte does not reach the sleeve 4 add purified water e g commercially ava...

Page 386: ...hem q Tightening torque 4658 245 Nm 475 25 kgm CHECK ALTERNATOR DRIVE BELT TENSION ADJUST 4 WARNING When carrying out inspection and adjustment set to the engine stop position as follows Press engine...

Page 387: ...ve the alternator q If nut 9 is tightened the belt tension is increased if nut 9 is loosened the belt tension is reduced 2 After adjusting the belt tighten bolts and nuts 5 8 in the reverse order from...

Page 388: ...engine stop position as follows Press engine stop switch 1 installed at the front of the power container on the left side of the machine or engine stop switch 2 installed at the rear of the power cont...

Page 389: ...and move the compressor q If nut 10 is tightened the belt tension is increased if nut 10 is loosened the belt tension is reduced 2 After adjusting the belt tighten bolts and nuts 6 9 in the reverse or...

Page 390: ...se serious burns Wait for the oil temperature to go down before performing this operation NOTICE After the machine has been operated for 6 months even if it has not been operated for 500 hours change...

Page 391: ...ain valves P1 and P2 q Press drain valves P1 and P2 then turn them to open or close them and carry out the drain operation 4 If the filter cartridge is removed immediately after the engine is stopped...

Page 392: ...here is danger of personal injury Always wear protective glasses dust mask and other protective equipment NOTICE When using compressed air to prevent damage to the fins keep a distance from the fins I...

Page 393: ...the radiator side right side of machine and oil cooler side left side of machine then open door 1 Each door is installed with 6 bolts 2 A Oil cooler B Radiator 2 Remove dustproof nets 3 installed in f...

Page 394: ...peration If steam cleaning high pres sure machine wash is carried out at close range there is danger that the internal fins of the heat exchange equipment may be deformed and this will cause early clo...

Page 395: ...hind the assistant s seat then open box cover 1 Recirculated air filter 3 is inserted at the rear of box cover 1 2 Pull out recirculated air filter 3 to the front 3 Clean the recirculated air filter 3...

Page 396: ...t is extremely dirty wash the filter in a neu tral detergent After washing dry it thoroughly before using it again If it is impossible to remove the clogging from the filter with compressed air or by...

Page 397: ...ing 2 cartridges 1 Hydraulic pump drain filter cartridges 3 places 2 Swing travel motor drain filter cartridges 2 places REPLACE SWING TRAVEL MOTOR DRAIN FILTER CARTRIDGE 4 2 places 1 Using the filter...

Page 398: ...iron particles or foreign material stuck to the bottom of the fil ter case or the outside of the cartridge If such materials are stuck to the cartridge of filter case there is probably an abnormality...

Page 399: ...in the fuel filter head It is still under pressure so fuel may spurt out NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacin...

Page 400: ...lever A installed to the front of the main pump inside the pump room and close the fuel supply cir cuit from the fuel tank S Shut off O Open 2 Set a container under the fuel pre filter cartridge to ca...

Page 401: ...c priming pump 4 47 NOTICE q When adding fuel do not remove cap B Always add fuel from the 8 small holes A on the dirty side q After adding fuel remove cap B and install the fuel fil ter q Always fill...

Page 402: ...ee REPLACE FUEL MAIN FILTER CARTRIDGE 4 85 12 Push down fuel shut off lever A installed to the front of the main pump inside the pump room so that it can supply fuel S Shut off O Open 13 Start the eng...

Page 403: ...ose q Be careful when opening the air bleed plug in the fuel filter head It is still under pressure so fuel may spurt out NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has...

Page 404: ...supply cir cuit from the fuel tank S Shut off O Open 2 Set the container to catch the fuel under the filter cartridge 3 Using a filter wrench turn filter cartridge 2 counterclock wise to remove it 4...

Page 405: ...el q Remove cap B and install the fuel filter 5 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it 3 4 of a turn If the filter cartridge i...

Page 406: ...quipped see Bleeding air from fuel circuit with the electric priming pump 4 47 8 Add fuel to the fuel tank until full to FULL mark on the fuel gauge 9 After replacing filter cartridge 2 loosen air ble...

Page 407: ...face of the fuel tank then remove cover 3 2 Replace breather element 4 with a new part 3 Install cover 3 and nut 2 NOTICE q For machines equipped with the optional service cen ter see REPLACE FUEL TAN...

Page 408: ...Adding Swing Machinery Case Oil Front 6 22 Method of Draining Adding Swing Machinery Case Oil Rear 6 23 q Oil refill capacity 60 liter 30 liter x 2 15 9 US gal 7 9 US gal x 2 1 Set a container under...

Page 409: ...tick G If the oil does not reach the L mark add oil through oil filler port F 6 If the oil level is above the H mark loosen drain valve P to drain excess oil from the power train and check the oil lev...

Page 410: ...inutes after stop ping the engine check the oil level REMARK For details of the method of draining and adding PTO case oil to machines equipped with a service center option see Method of Draining Addi...

Page 411: ...MAINTENANCE MAINTENANCE PROCEDURE 4 93 2 Add a specified amount of power train oil from oil filler port F...

Page 412: ...blown up and cause serious injury Always use safety glasses dust mask or other protective equipment 1 Open the door of the power container at the front of the machine then take out filter case 1 2 Ta...

Page 413: ...stributor 4 Clean the removed parts in flushing oil 5 Install the new element in the place where old element 4 was installed 6 Set valve 3 strainer 5 and spring 2 on top of the ele ment 7 Set cover 1...

Page 414: ...l filler port When releasing cap F oil may spurt out so turn it slowly to release the internal pressure then remove it 1 Remove nut 2 of breather assembly 1 at the top of the hydraulic tank then remov...

Page 415: ...MAINTENANCE MAINTENANCE PROCEDURE 4 97...

Page 416: ...ecified q Position of clamps q Detail of clamp portion A and portion B Tightening torques Clamp 1 24 0 25 0 Nm 2 45 2 55 kgm Clamp 2 10 0 11 0 Nm 1 02 1 12 kgm Clamp 3 24 0 25 0 Nm 2 45 2 55 kgm Clamp...

Page 417: ...CTURE 4 Color check It is easy to use a color check to check visibly for cracks in welded structures After the first 4000 hour inspection check the revolving frame center frame boom and arm every 1000...

Page 418: ...MAINTENANCE PROCEDURE MAINTENANCE 4 100 q Revolving frame A Important check points q Center frame A Important check points...

Page 419: ...MAINTENANCE MAINTENANCE PROCEDURE 4 101 q Boom A Important check points q Arm A Important check points...

Page 420: ...4 Check that there is no wear damage or other abnormality If any problem is found replace with genu ine parts NOTICE With a rope ladder 1 even if there is no visual wear or damage the rope will deter...

Page 421: ...owered position as shown in the diagram on the right then pump in grease with a grease gun through grease fittings 1 to 4 REMARK Destination for grease pumped in through each grease fitting 1 Ladder c...

Page 422: ...maining inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure q Oil refill capacity 85 liter each left and right q Prepare a handle 1 Set so that plug 1 on the out...

Page 423: ...d the grease is extremely milky white remove bolt 3 under the track frame remove cover 4 then remove the inside cover Drain the grease and replace it completely with new grease Total grease capacity 8...

Page 424: ...uld be carried out at the same time GREASE ENGINE MOUNT 4 if equipped Add grease with a grease gun through grease fitting 2 on engine mount 1 CHECK WATER PUMP 4 Check that there is no leakage of water...

Page 425: ...any rubber parts If any problem is found the part must be replaced In this case please ask your Komatsu distributor to carry out the replacement NOTICE If the engine continues to be used when there ar...

Page 426: ...installed to prevent fire if any fuel leaks and sprays into contact with high temperature parts of the engine Check visually and touch by hand to check that there are no missing caps no loose mountin...

Page 427: ...time has not reached 4000 hours if the machine has been used for 2 years replace the accumulator 1 Remove the cap from oil filler port F at the top of the hydraulic tank to release the internal press...

Page 428: ...ts gradually REMARK For details of the method of draining and adding hydraulic oil to machines equipped with a service center option see Method of Draining Adding Hydraulic Oil 6 25 q Oil refill capac...

Page 429: ...il be careful not to get oil over yourself q After draining the oil tighten drain plugs P1 and P2 6 Remove cover 1 at the top of the hydraulic tank pull the top of rod 3 up from the top and take out s...

Page 430: ...t Check that the hydraulic oil is at the correct level as follows q When the hydraulic oil is at normal temperature 15 30 C the correct oil level is in blue range a1 or a2 on the gauge label shown in...

Page 431: ...ng posture is 2 in the diagram on the right the correct oil level on the gauge label is range a2 at normal tem perature and b2 at high temperature 10 After changing the hydraulic oil and cleaning the...

Page 432: ...at the same time REPLACE INJECTOR NOZZLE ASSEMBLY 4 Please ask your Komatsu distributor to replace the injector assembly REPLACE HIGH PRESSURE PIPING CLAMP 4 Contact your Komatsu distributor to have t...

Page 433: ...SPECIFICATIONS 15...

Page 434: ...f engine Komatsu SAA12V140E 3 diezel engine Engine power kW rpm 713 1 800 ISO 9249 728 1 800 ISO 14396 A Overall length mm 17 030 B Overall height mm 7 135 C Overall width 1 mm 7 490 D Track width mm...

Page 435: ...specification machine see SPECIFICATION 7 19 Working ranges Unit PC2000 8 A Max digging reach mm 15 780 B Max digging depth mm 9 235 C Max digging height mm 13 410 D Max vertical wall depth mm 2 710...

Page 436: ...SPECIFICATIONS SPECIFICATIONS 5 4...

Page 437: ...ATTACHMENTS AND OPTIONS 16 WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 438: ...ls for the machine and the attachment or option q If you lose the instruction manual or it is damaged always obtain an new copy from the attachment manufac turer or your Komatsu distributor PRECAUTION...

Page 439: ...nstalled the working range becomes larger q If heavy work equipment is installed pay careful attention to the following precautions q The swing overrun the distance the work equipment moves before com...

Page 440: ...f unauthorized attachments or options will not be the responsibility of Komatsu COMBINATIONS OF WORK EQUIPMENT 6 WARNING Depending on the type or combination of work equipment there is danger that the...

Page 441: ...ts and attachments to suit the application The recommendations are given as a guide only based on typical conditions Select the combination of boom arm and bucket from the combinations shown in the ta...

Page 442: ...t an oil filler pump unit and nozzle Wiggins made ZZ9A1 or an equiv alent are required X Position for stowing fuel quick charge lever 4 Lock plate Y Position for adding fuel to fuel quick charge lever...

Page 443: ...t caught by the fuel quick charge lever or lever operating handle and this may cause injury q When operating the stopper be careful not to get a finger pinched NOTICE q After completing the fuel filli...

Page 444: ...ur left hand to hold lever operating handle 1 then use both hands to lower lever operating handle 1 3 Check that the stopper 4 is at the LOCK position com pletely open as shown in the diagram on the r...

Page 445: ...ing handle 1 slightly towards the front of the machine then push up until lock bar 3 enters the oblong hole in lock plate 2 q Do not touch lock plate 2 when doing this 8 Push lock plate 2 slightly to...

Page 446: ...ferent from the breather on the machine is not equipped with the fuel quick charge Use the following procedure to replace the fuel tank breather element every 1000 hours 1 Open breather cover 1 on top...

Page 447: ...B position 3 Lower the fuel quick charge to the fuel filling position For details see PROCEDURE FOR OPERATING FUEL CHARGE 6 7 4 Cover the front of proximity switch 1 installed to the fuel quick charge...

Page 448: ...is change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place After moving the machine contact your Komatsu distributor immediately and ask fo...

Page 449: ...lts 1 and 2 of the clamp holding the connec tor cable 4 Interchange connector a and connector c Connect connector a to connector C and cover connec tor c and connector A with cap X 5 Interchange conne...

Page 450: ...onnect the negative terminal of the battery start the engine then check that it is possible to operate the travel swing and work equipment If they cannot be operated there is probably some other cause...

Page 451: ...Coolant coupler 2 Service panel 13 Engine oil coupler 3 Service arm cylinder 14 Fuel coupler 4 Proximity switch 15 Grease coupler 5 Detector plate 16 Grease full indicator 6 Service arm lowering switc...

Page 452: ...operate the work equip ment If this happens the ladder warning lamp inside the opera tor s cab lights up red For details see Ladder Warning Lamp 3 99 This lock is cancelled when the service arm is st...

Page 453: ...swing circle until the service arm automatically stops REMARK When the lock lever is in the FREE position the service arm cannot be operated It is possible to lower the service arm even when the engi...

Page 454: ...ys set the service to the switch to the LOCK position If it is at the FREE position it becomes possible to operate the service arm from the ground so there is danger that this may lead to a serious ac...

Page 455: ...le force feed pumps but if a force feed pump coupler is needed please consult your Komatsu distributor NOTICE q Before connecting the service center coupler and force feed pump coupler wipe off all di...

Page 456: ...temperature immediately after the engine is stopped and may cause serious burns Wait for the oil temperature to go down before performing this operation q Refill capacity for oil pan 122 liter 1 Open...

Page 457: ...ine oil 6 After completing the draining and adding of engine oil remove the force feed pump coupler 7 Install the cap to the coupler 8 Set drain valve P of the oil pan to shut position S 9 Run the eng...

Page 458: ...e cap of swing machinery oil front coupler 1 and connect the force feed pump coupler securely 4 Start to drain and add swing machinery oil 5 After completing the draining and adding of swing machin er...

Page 459: ...e cap of swing machinery oil rear coupler 1 and connect the force feed pump coupler securely 4 Start to drain and add swing machinery oil 5 After completing the draining and adding of swing machin ery...

Page 460: ...t for the oil temperature to go down before performing this operation NOTICE Park the machine on flat ground and stop the engine After waiting for more than 30 minutes after stop ping the engine check...

Page 461: ...re starting the operation q When removing the cap from the oil filler oil may spurt out so turn it slowly to release the internal pressure then remove it q When removing holder cover of the strainer t...

Page 462: ...down then open the cap slowly to release the pressure q When cleaning the cooling system with the engine running set the lock lever to the LOCK position to prevent the machine from moving q For detail...

Page 463: ...be touched by hand then raise cap lever 4 of cap 3 at the top of the reservoir tank and release the pressure inside the reservoir tank 4 Remove water filler cap 5 5 Set drain valve P under the machin...

Page 464: ...nder the machine to shut position S 12 Push down cap lever 4 of cap 3 at the top of the sub tank then install water filler cap 5 13 Check that the coolant in the reserve tank is in the range between t...

Page 465: ...l the cap to the coupler Method of Adding Grease 6 1 Remove the cap of grease coupler 1 and connect the force feed pump coupler securely 2 Open force feed pump basic pressure valve 2 or start the grea...

Page 466: ...urs Set the service center to the lowered position as shown in the diagram on the right then pump in grease with a grease gun through grease fittings 1 to 3 REMARK Destination for grease pumped in thr...

Page 467: ...rent from the breather on the machine is not equipped with the service center Use the following procedure to replace the fuel tank breather element every 1000 hours 1 Open breather cover 1 on top of t...

Page 468: ...the ON B position 3 Lower the service arm For details see When Lowering Service Arm Setting to Position for Use 6 17 4 Cover the front of proximity switch 1 installed to the ser vice arm with steel p...

Page 469: ...center This change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place After moving the machine contact your Komatsu distributor immediately...

Page 470: ...ts 1 and 2 of the clamp holding the connec tor cable 4 Interchange connector a and connector c Connect connector a to connector C and cover connec tor c and connector A with cap X 5 Interchange connec...

Page 471: ...nect the negative terminal of the battery start the engine then check that it is possible to operate the travel swing and work equipment If they cannot be operated there is probably some other cause s...

Page 472: ...IONS 6 CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE 6 1 Check that the starting switch key is at OFF position A 2 Set the battery isolator switch to OFF position b q For details of the battery isolato...

Page 473: ...power source cable through external power source insertion port 2 5 Remove the cap of jump start receptacle 3 then connect the external power source cable to jump start receptacle 3 6 Close cover 1 of...

Page 474: ...t is possible to send machine data without stopping the machine by using the satellite communications functions of ORBCOMM communications company Please ask your Komatsu distributor to make the initia...

Page 475: ...G SHOVEL 17 WARNING When using a loading shovel specification the method for operation is different in some way from the standard machine This section gives the explanation for the parts that are diff...

Page 476: ...ATIONS LOADING SHOVEL 7 2 MACHINE VIEW ILLUSTRATIONS 7 OVERALL MACHINE VIEW 7 1 Bucket 7 Sprocket 2 Bottom dump cylinder 8 Track frame 3 Bucket cylinder 9 Track shoe 4 Arm 10 Idler 5 Arm cylinder 11 B...

Page 477: ...OPERATOR S CAB 3 75 1 Starting switch 11 Rotating lamp switch if equipped 2 Fuel control dial 12 Greasing mode selector switch 3 Engine emergency stop switch 13 Machine push up switch 4 Service center...

Page 478: ...ox 5 seconds to give a signal to the dump truck and others in the surrounding area Bottom Dump Switch Press switches 18 and 19 on the work equipment control lever to open and close the front bucket If...

Page 479: ...r and the movement of the work equipment is as shown in the diagram on the right When the lever is released it returns to the HOLD position and the work equipment is held in position q If the work equ...

Page 480: ...OPERATIONS LOADING SHOVEL 7 6 Boom operation A Boom RIASE B Boom LOWER Bucket operation A Bucket DUMP B Bucket CURL Bottom dump operation A OPEN B CLOSE...

Page 481: ...uch operations have to be per formed pile soil to make a platform A on the slope so the machine is kept horizontal during operation q Do not travel up or down steep slopes There is danger that the mac...

Page 482: ...se the Dropping Force of the Bucket for Operations Do not use the dropping force of the bucket as a pickaxe breaker or pile driver This will bring excessive force to bear on the rear of the machine an...

Page 483: ...force to bear on the work equipment so do not use the rear bucket in this way Be Careful not to Spill the Load When the bucket is fully loaded do not raise the boom fully If the boom is raised fully...

Page 484: ...achine from damage but will make for better econ omy Phenomena that do not Indicate Failure Note that the following phenomena are not failures q When starting or stopping the swing noise will be emitt...

Page 485: ...ly A simple method of seeing the angle of the bucket teeth to the ground surface is to use the teeth and the part of the rear bucket shown in the diagram on the right Check that the part of the rear b...

Page 486: ...e before removing the cap 1 Stop the machine on firm horizontal ground lower the work equipment to the ground as shown in the diagram on the right then stop the engine q Set the lock lever to FREE pos...

Page 487: ...d counterweight When transporting the machine please consult your Komatsu distributor MACHINE CONFIGURATION FOR TRANSPORT 7 WARNING q Never raise the machine with any worker on it q When carrying out...

Page 488: ...ock lever securely to the LOCK position Greasing of the work equipment is normally carried out automatically but if any abnormal noise is heard from the pins carry out greasing manually through the gr...

Page 489: ...linder bottom pin LH 3 Bottom dump cylinder head pin RH F Grease fitting 4 Bottom dump cylinder head pin LH 7 Arm top pin RH1 14 Bucket cylinder bottom pin LH 8 Arm top pin LH1 15 Boom top pin RH 9 Ar...

Page 490: ...installed on the chassis 19 Boom foot pin RH 23 Arm cylinder head pin RH 20 Boom foot pin LH 24 Arm cylinder head pin LH 21 Arm cylinder bottom pin RH F Grease fitting 22 Arm cylinder bottom pin LH 25...

Page 491: ...LOADING SHOVEL MAINTENANCE 7 17 q Greasing point chart...

Page 492: ...in RH1 8 Arm top pin LH1 9 Arm top pin RH2 10 Arm top pin LH2 11 Arm cylinder head pin RH 12 Arm cylinder head pin LH 13 Bucket cylinder bottom pin RH 14 Bucket cylinder bottom pin LH 15 Boom top pin...

Page 493: ...Engine power kW rpm 713 1 800 ISO 9249 728 1 800 ISO 14396 A Overall length mm 13 075 B Overall height mm 8 180 C Overall width 1 mm 7 490 D Track width mm 810 E Height of cab mm 7 030 F Tail swing r...

Page 494: ...ING SHOVEL Working ranges Unit PC2000 8 A Max digging reach mm 13 170 B Max reach at ground level mm 11 940 C Max digging height mm 14 450 D Max digging depth mm 3 190 E Min reach at ground level mm 7...

Page 495: ...orms one unit with the cap Part number 21T 04 31170 Item Part No Part Name Q ty Replacement frequency Engine oil filter 600 211 1340 Cartridge 4 Every 500 hours service Fuel pre filter 1 600 319 3440...

Page 496: ...e check before starting if there is any danger of interference and operate with caution COMBINATION OF WORK EQUIPMENT 7 Select the combination of boom arm and bucket from the combinations shown in the...

Page 497: ...INDEX 18...

Page 498: ...INDEX 8 2...

Page 499: ...18 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 16 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 14 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 18 PREPARATIONS FOR SAFE OPERATION 2 11 PROTECTI...

Page 500: ...PRECAUTIONS FOR MAINTENANCE 2 33 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2 33 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 38 PRECAUTIONS FOR OPERATION 2 19 LIFTING OBJECTS WITH BUCKET...

Page 501: ...ration levels 1 4 VISIBILITY FROM OPERATORSSEAT 1 7 W WEAR PARTS 4 10 7 21 WEAR PARTS LIST 4 10 7 21 WORK EQUIPMENT CONTROLS AND OPERATIONS 3 217 WORKING MODE 3 219 Y YOUR MACHINE SERIAL NUMBERS AND D...

Page 502: ...INDEX 8 6...

Page 503: ...COLOPHON 19...

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Komatsu PC2000-8 BACKHOE, Operation & Maintenance Manual

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