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Komatsu PC360LC-11, Operation & Maintenance Manual

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Komatsu PC360LC-11 Operation & Maintenance Manual Download Page 18

OPERATION .................................................................................................................................................... 3-1

GENERAL VIEW....................................................................................................................................... 3-2

MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CAB EQUIPMENT NAMES................................................................................................................ 3-4
CONTROLS AND GAUGES NAMES................................................................................................. 3-5

EXPLANATION OF COMPONENTS ......................................................................................................... 3-9

EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................... 3-9
SWITCHES...................................................................................................................................... 3-88
CONTROL LEVERS AND PEDALS ................................................................................................. 3-96
OTHER EQUIPMENT ...................................................................................................................... 3-99

MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-141

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-141
METHOD FOR STARTING ENGINE.............................................................................................. 3-171
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-175
METHOD FOR STOPPING ENGINE ............................................................................................. 3-184
METHOD  FOR  STARTING  MACHINE  (TRAVEL  FORWARD  AND  REVERSE)  AND  STOPPING  MA-

CHINE ........................................................................................................................................ 3-186

METHOD FOR STEERING MACHINE........................................................................................... 3-189
METHOD FOR SWINGING MACHINE .......................................................................................... 3-191
METHOD FOR OPERATING WORK EQUIPMENT ....................................................................... 3-192
HANDLE WORKING MODE .......................................................................................................... 3-193
PROHIBITED OPERATIONS ......................................................................................................... 3-195
PRECAUTIONS FOR OPERATION ............................................................................................... 3-199
PRECAUTIONS FOR WORKING ON SLOPE ............................................................................... 3-201
METHOD FOR ESCAPING FROM MUD ....................................................................................... 3-202
RECOMMENDED APPLICATIONS................................................................................................ 3-203
EFFECTIVE USE OF HYDRAULIC EXCAVATOR.......................................................................... 3-204
METHOD FOR REPLACING AND INVERTING BUCKET.............................................................. 3-205
METHOD FOR PARKING MACHINE ............................................................................................. 3-208
METHOD FOR CHECKING AFTER FINISHING WORK................................................................ 3-210
LOCK ............................................................................................................................................. 3-210

HANDLE AIR CONDITIONER............................................................................................................... 3-217

EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-218
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-222

HANDLE RADIO ................................................................................................................................... 3-230

EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-230
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-232
STOW ANTENNA .......................................................................................................................... 3-235
SPACE FOR RADIO CASSETTE................................................................................................... 3-235

TRANSPORTATION.............................................................................................................................. 3-236

PRECAUTIONS FOR TRANSPORTING MACHINE ...................................................................... 3-236
SELECT TRANSPORTATION METHOD........................................................................................ 3-236
LOADING AND UNLOADING WITH TRAILER .............................................................................. 3-237
METHOD FOR LIFTING MACHINE ............................................................................................... 3-249

COLD WEATHER OPERATION............................................................................................................ 3-251

COLD WEATHER OPERATION INFORMATION ........................................................................... 3-251
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER................................ 3-252
AFTER COLD WEATHER SEASON .............................................................................................. 3-252

PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-254

PREPARATION FOR LONG-TERM STORAGE ............................................................................. 3-254
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-254
STARTING MACHINE AFTER LONG-TERM STORAGE............................................................... 3-254

TROUBLES AND ACTIONS ................................................................................................................. 3-256

ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-256
PHENOMENA THAT ARE NOT FAILURES ................................................................................... 3-257
PRECAUTIONS FOR TOWING MACHINE .................................................................................... 3-258
PRECAUTIONS FOR SEVERE JOB CONDITION......................................................................... 3-259
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-260

TABLE OF CONTENTS

FOREWORD

1-16

Summary of Contents for PC360LC-11

Page 1: ...se of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual UENAM01195 WARNING ORIGINAL INSTRUCTIONS ...

Page 2: ......

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

Page 4: ... Keep it in the magazine box on the left side of the operator s seat If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For details regarding the machine model name and the serial No see the machine serial No plate In order to arrange the proper Operation and Maintenan...

Page 5: ... safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used...

Page 6: ... the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used it is your responsibility to take th...

Page 7: ... of the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 Sound power level emitted by the machine measured ac cording to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European directive 2000 14 EC This value includes an uncertainty of 1 1 dB...

Page 8: ...ystems Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedule time to maintain terrain conditions 4 Use a seat that meets ISO 7096 and keep the seat maintained and adjusted Adjust the seat and suspens...

Page 9: ... Do not jump down from the cab or machine Do not repeatedly handle and lift loads FOREWORD VIBRATION LEVELS 1 7 ...

Page 10: ...to demolish cut loosen separate pick up transport and distribute component parts of buildings or civil engineering structures This machine is not prepared for use in Demolition Using this machine in demolition work gives an in creased risk of serious injury or death All Komatsu machines that are specifically designed and can be used for demolition work will display the Komatsu demolition decal If ...

Page 11: ...achine complies with the visibility standard ISO 5006 This machine maintains a proximity visibility of a height of 1 5 m at a point 1 m away from the outside surface of the machine and a visibility for a radius of 12 m Protective structures This machine is equipped with a structure to protect the operator ROPS conforming to ISO12117 2 For the location of the nameplate of the structure to protect t...

Page 12: ...l Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the reagent for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transpar...

Page 13: ...wing items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is located on the right bottom of the operator s cab The design of the nameplate differs according to the district LOCATION OF ENGINE NUMBER PLATE It is located on top of the engine cylinder head cover FOREWORD PRODUCT INFORMATION 1 11 ...

Page 14: ...ine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU UK Ltd Durham Road Birtley Chester le Street County Durham DH3 2QX United Kingdom Distributor name Address Service Personnel Phone Fax PRODUCT INFORMATION FOREWORD 1 12 ...

Page 15: ...SERIAL PLATE KS000853 A B D F G C E A MACHINE DESIGNATION TYPE E ENGINE POWER B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER C YEAR OF CONSTRUCTION G MANUFACTURER D WEIGHT FOREWORD SERIAL PLATE 1 13 ...

Page 16: ...ares that this machine PC360LC 11 PC360NLC 11 Fulfils all the relevant provisions of following EC Directives Machine Directive 2006 42 EC Electro Magnetic Compatibility Directive 2014 30 EU Outdoor Noise Directive 2000 14 EC amended by 2005 88 EC Radio Equipment Directive 2014 53 EU DECLARATION OF CONFORMITY FOREWORD 1 14 ...

Page 17: ...2 17 PREPARATIONS FOR SAFE OPERATION 2 17 PRECAUTIONS TO PREVENT FIRE 2 18 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 20 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 22 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 22 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 23 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2 23 UNAUTHORIZED MODIFICATION 2 23 PRECAUTIONS RELATED TO ATTACHMENTS AND...

Page 18: ...NG BUCKET 3 205 METHOD FOR PARKING MACHINE 3 208 METHOD FOR CHECKING AFTER FINISHING WORK 3 210 LOCK 3 210 HANDLE AIR CONDITIONER 3 217 EXPLANATION OF AIR CONDITIONER EQUIPMENT 3 218 METHOD FOR OPERATING AIR CONDITIONER 3 222 HANDLE RADIO 3 230 EXPLANATION OF RADIO EQUIPMENT 3 230 METHOD FOR CONTROLLING RADIO 3 232 STOW ANTENNA 3 235 SPACE FOR RADIO CASSETTE 3 235 TRANSPORTATION 3 236 PRECAUTIONS ...

Page 19: ...QUE FOR BOLTS AND NUTS 4 10 MAINTENANCE SCHEDULE 4 12 MAINTENANCE SCHEDULE TABLE 4 12 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 13 MAINTENANCE PROCEDURE 4 15 INITIAL 250 HOURS MAINTENANCE ONLY AFTER THE FIRST 250 HOURS 4 15 WHEN REQUIRED 4 15 CHECK AUTOMATIC GREASE SYSTEM 4 40 CHECKS BEFORE STARTING 4 42 EVERY 50 HOURS MAINTENANCE 4 42 4 42 EVERY 250 HOURS MAINTENANCE 4 43 EVERY 500 HOURS MAINT...

Page 20: ...28 WORKING MODES 6 29 METHOD OF WORK 6 30 WHEN TRAVELLING 6 31 TRANSPORT AND STORAGE OF SUPER LONG FRONT MACHINE 6 32 MAINTENANCE 6 32 SPECIFICATIONS SUPER LONG FRONT 6 33 HANDLE BUCKET WITH HOOK 6 36 PRECAUTIONS FOR OPERATION 6 36 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 37 EXPLANATION OF COMPONENTS ON MACHINE EQUIPPED WITH ATTACHMENT 6 37 METHOD FOR CHANGE OVER AND CONNECT HYDRAULIC...

Page 21: ...UBRICATION CHART 7 5 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 7 6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 8 INDEX 8 1 FOREWORD TABLE OF CONTENTS 1 19 ...

Page 22: ......

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

Page 24: ...1 ELECTROMAGNETIC INTERFERENCE 2 22 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 22 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 22 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 23 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2 23 UNAUTHORIZED MODIFICATION 2 23 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 23 PRECAUTIONS RELATED TO CAB GLASS 2 24 PRECAUTIONS WHEN RUNNING ENGINE INS...

Page 25: ...ONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2 46 USE PROPER TOOLS 2 46 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 46 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 46 PRECAUTIONS FOR WELDING 2 46 HANDLE BATTERY 2 47 PRECAUTIONS WHEN USING HAMMER 2 47 PRECAUTIONS FOR HIGH TEMPERATURE COOLANT 2 48 PRECAUTIONS FOR HIGH TEMPERATURE OIL 2 48 PRECAUTIONS FOR HIGH TEMPERATURE PARTS 2 48 PRECAUTIONS F...

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

Page 27: ...FETY LABELS a b c e d f g h KS001061 1 Combined safety information label a Warning for operation inspection and maintenance b Warning when leaving the operator s seat c Warning no passengers SAFETY SAFETY LABELS 2 5 ...

Page 28: ...quick coupler piping system 14 Warning when swinging and travelling in reverse 15 Caution for handling batteries 16 Caution when replacing fresh air filter 17 Caution for blast jobsite 18 Caution against high pressure fuel 19 Caution against high temperature 20 Warning for handling ROPS 21 Caution for overloading machine 22 Caution for handling DEF 23 Caution for handling DEF 24 Warning for operat...

Page 29: ...or s seat Lower the work equipment to the ground and move safety lock lever located near seat to lock position to avoid hit ting unlocked operation levers Sudden and unwanted machine movement can cause seri ous injury or death Warning no passengers c No passengers allowed to ride on the machine while it is moving Warning danger of falling objects d Do not operate where a danger of falling objects ...

Page 30: ...r lines Control levers operational function diagram f Control levers operating pattern In order to prevent an accident resulting in injury or death caused by error operation confirm the machine motion and in dicated operating pattern when operating machines Pay atten tion to the circumference and operate slowly when confirming the machine motion Caution when standing in operator cab g Take care wh...

Page 31: ...eversing To prevent SEVERE INJURY or DEATH do the following be fore moving machine or its attachments Sound horn to alert people nearby Be sure no one is on or near machine or in swing area Rotate cab for full view of travel path if it can be done safe ly Use spotter if view is obstructed Follow the above even if machine is equipped with travel alarm mirrors and rear view camera k k WARNING To ope...

Page 32: ...e personal injury and or burns Never remove the radiator cap or hydraulic tank oil filler cap when cooling water or hydraulic oil is at high tempera ture Caution for handling accumulator and gas spring 4 Caution for handling accumulator and gas spring 09659 A057B There is a hazard of explosion causing injury Do not disassemble the accumulator make holes in it weld it cut it roll it or bring it nea...

Page 33: ...manual for safe and proper handling Caution stop rotation during inspection and maintenance 7 Stopping rotation for inspection and maintenance 09667 A0481 Sign indicates a hazard of rotating parts such as belt fan etc Turn off before inspection and maintenance Emergency escape 8 Emergency escape 09844 00050 SAFETY SAFETY LABELS 2 11 ...

Page 34: ...ange 10 Prohibited to enter swing radius 09133 A3281 There is a danger of getting caught when upper structure swings Do not enter range of swing Caution for work equipment 11 Keeping out of working range area 09134 A1681 Sign indicates a hazard of being hit by the working device of the machine Keep away from the machine during operation SAFETY LABELS SAFETY 2 12 ...

Page 35: ...eration Warning when swinging or travelling in reverse 14 Warning when swinging or travelling in reverse 09833 A0881 k k WARNING When swinging or backing up excavator press button to change display mode on monitor so you can see rear and side of the machine Before moving look around and at mirror and monitor to confirm that no one is around the machine Failure to do so can result in serious injury...

Page 36: ...teries d Caution battery acid e Read the operator s manual before working with batteries f Caution explosive gases Caution when replacing fresh air filter 16 Caution when replacing fresh air filter 208 00 71261 After replacing fresh air filter remember to remove key from cover as the key may get damaged when cab door is opened SAFETY LABELS SAFETY 2 14 ...

Page 37: ...perature 19 Caution for high temperature 09817 K064B Warning for handling ROPS 20 Caution for machine with ROPS 09620 T2001 09620 A3001 If any modification is applied to the ROPS it may affect the strength and may not comply with the standard ROPS may provide less protection if it has been structural ly damaged or involved in roll over Always wear seat belt when moving Caution for overloading mach...

Page 38: ...ling DEF 23 Caution for handling DEF 09632 61480 To avoid engine damage or fire fill with Diesel Exhaust Fluid DEF only Never use diesel fuel Warning for operation inspection and maintenance 24 Warning for operation inspection and maintenance 09651 A0841 Read the manual before operating inspection maintenance disassembly assembly and transportation SAFETY LABELS SAFETY 2 16 ...

Page 39: ...ATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the safety related devices and use them properly Never remove any safety related devices Always keep them in good operating condition INSPECT MACHINE Check the machine before starting operations If ...

Page 40: ...may cause fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such as flammable or explosive items into the operator s compartment PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Observe the following precautions to prepare for action if any serious personal injury...

Page 41: ...el in the specified place and do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any flammable materials to a safe place before starting Fire caused by accumulation of combustible material Remove any dry leaves chips pieces of paper coal dust or any other combustible materials accumulated or affixed around the engine exhaust manifold muffler or ...

Page 42: ...ent personal injury caused by slipping or falling off the machine always observe the following Use the handrails and steps marked by arrows in the fig ure on the right when getting on and off the machine Always face the machine and maintain at least three point contact both feet and one hand or both hands and one foot with the handrails and steps to ensure that you sup port yourself Before getting...

Page 43: ...t it to LOCK position L and stop the engine If the control levers are touched by mistake there is danger that the machine may suddenly move and cause serious per sonal injury or death PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not taken when parking the machine the machine may suddenly move off by itself and this may lead to serious personal injury or death Always observe the fo...

Page 44: ...t mass exceeds the certified value shown on ROLL OVER PROTECTIVE STRUCTURE ROPS CERTIFICATION plate ROPS will not be able to fulfill its function Do not increase ma chine weight beyond the certified value by modifying the ma chine or by installing attachments to the machine Also if the function of the protective equipment is impeded the protective equipment will not be able to protect the operator...

Page 45: ... to the operator from falling objects flying objects and intruding objects as detailed in the previous section Operator cabin FOPS falling object protective structure Front window guard In the event any of the above parts become broken or damaged such that their function would be impaired they must be replaced with genuine Komatsu replacement parts No attempt should be made to repair these parts a...

Page 46: ...ss is broken during operations stop operations and repair the cab glass immediately If the cab glass on the work 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 operation immediately and replace the glass The ceiling window is made of plastic so if it is scratched the visibility will become poor and there ...

Page 47: ...l PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse under the weight or vibration of the machine there is a hazard that the machine may fall or tip over Remember that the soil is weak in these areas after heavy rain or blasting or after earthquakes Wh...

Page 48: ...prevent electric shock the operator should not leave the operator s compartment until it has been confirmed that the electricity has been shut off Also prohibit any other persons to come close to the machine ENSURE GOOD VISIBILITY To assist with job site organisation during use of this machine a visibility map is provided that shows an approxi mation of any masking to visibility between the 1m rec...

Page 49: ...Map with mirror and rear view camera visibility aids fitted SAFETY PRECAUTIONS FOR OPERATION 2 27 ...

Page 50: ...Map with mirror rear view camera side view camera visibility aids fitted For PC360LC 11 PC360NLC 11 2 Piece Boom PC390HRD 11 PRECAUTIONS FOR OPERATION SAFETY 2 28 ...

Page 51: ...Map with mirror rear view camera side view camera visibility aids fitted For PC360LC 11 17m Long Reach SAFETY PRECAUTIONS FOR OPERATION 2 29 ...

Page 52: ...Map with mirror rear view camera side view camera visibility aids fitted For PC360LC 11 Super Long Front PRECAUTIONS FOR OPERATION SAFETY 2 30 ...

Page 53: ...duty if there are areas where the visibility is poor Only one signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up additional lighting in the work area if necessary Stop operations if the visibility is poor because of mist snow rain or dust When checking the mirrors installed to the machine remove all dirt and adjust t...

Page 54: ...n Always observe the regulations for jobsite and environmental standards This machine does not contain asbestos but any part which is not the genuine part it has risk of containing asbestos Always use Komatsu genuine parts START ENGINE USE WARNING TAGS If there is a DANGER Do NOT operate warning tag dis played it means that someone is performing inspection and maintenance of the machine If the war...

Page 55: ...G OPERATOR S SEAT 3 155 Check that there are no persons or obstacles above below or in the area around the machine PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death Always observe the following Start the engine only while sitting down in the operator s seat When starting the engine sound the horn as a warning Prohibit other per...

Page 56: ...em When disconnecting the jumper cables take care not to bring the clips in contact with each other or with the machine For the starting procedure with the jumper cables see OPERATION START ENGINE WITH JUMPER CA BLES 3 262 PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly the machine will be unable to display its full perform ance It is dang...

Page 57: ...eople or obstacles in the surrounding area Before moving sound the horn to warn people in the surrounding area Check that the travel alarm and other alarms work properly If there is an area in the rear of the machine which cannot be seen position a signalman Be extremely careful not to hit any people or object and drive or swing slowly Always be sure to perform the above precautions even when the ...

Page 58: ...e machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine When passing over bridges or structures check first that the structure is strong enough to support the weight of the machine When passing on a public road check with authorities concerned and observe their instruction When operating in tunnels under bridges under electric w...

Page 59: ...gine stops move the control levers immediately to NEUTRAL position set the lock lever to LOCK position and then start the engine PRECAUTIONS WHEN OPERATING ON SLOPES When working on slopes there is a hazard that the machine may lose its balance and turn over when per forming swing or work equipment operations This may lead to serious personal injury or death Always pro vide a stable place when per...

Page 60: ...et may hit the dump truck and cause serious personal injury or death Generally speaking the machine is more liable to tip over when the work equipment is at the side than when it is at the front or rear of the machine Be extremely careful when swinging the work equipment from the front or rear to the side of machine while it is carrying a load It is dangerous that the machine may tip over When usi...

Page 61: ...bjects placed beside the road are buried in the snow and cannot be seen Be careful PRECAUTIONS WHEN PARKING MACHINE Unexpected move of the parked machine can cause serious personal injury or death Always observe the fol lowing Park the machine on a firm level ground Select a place where there is no hazard of landslides fall ing rocks or flooding Lower the work equipment to the ground When leaving ...

Page 62: ... ground only Avoid road edge or place near the cliff Never use the work equipment to load or unload the machine There is danger that the machine may fall or tip over Always use ramps of adequate strength Be sure that the ramps are wide long and thick enough to provide a safe loading slope Take suitable steps to prevent the ramps from moving out of position or coming off 1 Chocks 2 Ramp 3 Center of...

Page 63: ...ion Always wear leather gloves when handling the wire rope Never tow a machine on a slope During the towing operation never stand between the tow ing machine and the machine being towed LIFTING OBJECTS WITH BUCKETS SAFETY RULES FOR LIFTING OBJECTS Determine the signals to be used and place a signalman in position To prevent the machine from tipping over or falling carry out the operation on flat g...

Page 64: ...check carefully that the surrounding area is clear from objects structures or any persons working around the machine During the lifting operation reduce the engine speed and carry out the operation in L mode Never travel the machine while lifting the load If the load approaches the lifting limit of the machine a warning is shown on the monitor panel and an audible alarm sounds In this case lower t...

Page 65: ...ll over and injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and avoid use of organic solvents for cleaning An organic solvent like benzene toluene or methanol can invite a chemical reaction like dissolution and decomposition on the window glass deteriorating polycarbonate in use SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop th...

Page 66: ...g switch to ON position Operate the work equipment control lever back and forth right and left a few times fully to release the remaining internal pressure in the hydraulic circuit Then move lock lever 1 to LOCK posi tion L and turn the starting switch to OFF position Check that the battery relay is off and main power is not conducted After turning the starting switch to OFF posi tion wait for app...

Page 67: ... before starting removal or installation operations for attachments Place attachments that have been removed from the ma chine in a stable condition so that they do not fall And take steps to prevent unauthorized persons from entering the storage area PRECAUTIONS FOR WORKING AT HIGH PLACES When working at high places use a step ladder or other stand to ensure that the work can be performed safely ...

Page 68: ...f the work equipment and machine are not supported they may come down and it may cause serious per sonal injury or death Never use concrete blocks for supports Concrete blocks may break under even light loads USE PROPER TOOLS Use the tools suited to the task and use them correctly Using damaged deformed or low quality tools or making improper use of the tools may cause serious personal injury or d...

Page 69: ...ulphuric acid Any mistake in handling may cause serious personal injury explosion or fire Always ob serve the following When handling the battery always wear protective eye glasses and rubber gloves If battery electrolyte gets into your eyes immediately wash your eyes with large amounts of fresh water After that get medical attention immediately If battery electrolyte gets on your clothes or skin ...

Page 70: ... cap or plug slowly to release the internal pressure and remove the cap or plug PRECAUTIONS FOR HIGH TEMPERATURE PARTS To prevent burns from touching high temperature parts when checking or performing maintenance after stop ping engine check the parts have been cooled down to touch with bare hand before checking or maintenance PRECAUTIONS FOR HIGH PRESSURE OIL The hydraulic system is always under ...

Page 71: ... loose or oil or fuel is found to be leaking from the mount stop operations and tighten to the specified torque If any damaged or deformed hoses or piping are found consult your Komatsu distributor Replace the hose if any of the following problems are found Damaged hose or deformed hydraulic fitting Frayed or cut covering or exposed reinforcement wire layer Covering swollen in places Twisted or cr...

Page 72: ...rful spring that acts to reduce the impact on the idler If it is disassembled by mistake the spring may shoot out and cause serious personal injury or death If it is necessary to disassemble it ask your Komatsu distributor to perform the work HANDLE ACCUMULATOR AND GAS SPRING This machine is equipped with an accumulator Even after the engine stops if the work equipment control lever is operated af...

Page 73: ...ISPOSING OF WASTE MATERIALS 2 51 and MAINTENANCE OF AIR CONDITIONER 2 51 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution pay full attention to the way to dispose of waste materials Always drain the oil from your machine in containers Nev er drain the oil and coolant directly onto the ground or dump into the sewage system rivers seas or lakes Obey appropriate laws and regulations ...

Page 74: ...il and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspection or the feeling when operating so always replace them at the specified interval Replace or repair defined life parts if any defect is found even when they have not reached the specified replacement time PRECAUTIONS FOR MAINTENANCE SAFETY 2 52 ...

Page 75: ...nly open containers in a well ventilated area For the method of storing see STORE DEF 4 8 When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is no...

Page 76: ......

Page 77: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 78: ...GENERAL VIEW MACHINE EQUIPMENT NAME 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Boom cylinder 7 Sprocket 8 Track frame 9 Track 10 Idler 11 Engine hood GENERAL VIEW OPERATION 3 2 ...

Page 79: ... B 12 Komatsu Closed Crankcase Ventilation hereafter KCCV ventilator 13 SCR 14 KDPF 15 Toolbox 16 Battery 17 Battery disconnect switch 18 System operating lamp 19 Fusible link 20 Grease pump holder OPERATION GENERAL VIEW 3 3 ...

Page 80: ...w 2 Ceiling window 3 Door lock release lever 4 Drink box 5 Fuse 6 Auxiliary electric power if equipped 7 Fire extinguisher if equipped 8 Emergency escape hammer 9 Magazine box 10 Cup holder 11 AUX 12 Ashtray GENERAL VIEW OPERATION 3 4 ...

Page 81: ...CONTROLS AND GAUGES NAMES KS001062 1 Radio 2 Lock lever 3 L H work equipment control lever 4 One touch power maximizing switch 5 Travel pedal 6 Travel lever OPERATION GENERAL VIEW 3 5 ...

Page 82: ...atic lock cancel switch 26 1st attachment proportional control switch 27 2nd attachment proportional control switch if equipped 28 Breaker switch 29 Spare switch 30 Spare switch 31 Quick coupler switch 32 Spare switch 33 Spare switch 34 Quick coupler switch 35 Lower wiper switch 36 Automatic grease system monitor if equipped 37 Additional lamps switch if equipped 38 AUX MACHINE MONITOR EQUIPMENT N...

Page 83: ... Swing lock pilot lamp 29 Engine preheating pilot lamp or One touch power maximizing pilot lamp 30 Auto deceleration pilot lamp 31 Working mode display 32 Travel speed display 33 Radiator coolant level caution lamp 34 Engine oil level caution lamp 35 Air cleaner clogging caution lamp 36 Charge level caution lamp 37 Water separator caution lamp 38 Engine oil pressure caution lamp 39 Function switch...

Page 84: ...witch 21 Engine oil pressure caution lamp 22 Charge level caution lamp 23 Radiator coolant level caution lamp 24 Seat belt caution lamp 25 Engine stop pilot lamp 26 Lock lever pilot lamp 27 Aftertreatment Devices Regeneration pilot lamp 28 Aftertreatment Devices Regeneration disable pilot lamp 29 Message display 30 Air conditioner pilot lamp 31 Wiper pilot lamp 32 Swing lock pilot lamp 33 Engine p...

Page 85: ...EMARK For the user menu used for setting various items of the machine on the machine monitor see USER MENU DISPLAY SWITCH 3 57 One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on the screen When there are fewer than 10 black or white spots this is not a failure or a defect If environmental temperatur...

Page 86: ...chine monitor see USER MENU DISPLAY SWITCH 3 57 One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on the screen When there are fewer than 10 black or white spots this is not a failure or a defect If environmental temperature of the machine monitor is high brightness may be automatically reduced to pro...

Page 87: ... travel mode display screen HH is displayed for 2 seconds the screen switches to standard screen AA If the working mode when the engine is started is B mode the opening screen GG is displayed for 2 sec onds and the screen then switches to the breaker mode confirmation screen II When starting with B mode press switch F6 If you do not want to start B mode press switch F5 In this case the system star...

Page 88: ...layed and engine does not start If engine shutdown secondary switch 1 is turned OFF nor mal the machine monitor switches to the standard screen and the engine can be started with usual starting switch key operation BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION When the starting switch is turned to OFF position end screen JJ or KK is displayed for 5 seconds then the d...

Page 89: ...is set the opening screen GG switches to ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting ID number for operator identification function without SKIP is set the opening screen GG switches to ID number input screen MM without SKIP when the starting switch is turned to ON position On the ID number input screen LL with SKIP or MM without SKIP input th...

Page 90: ... If inputting incorrect ID number for 3 times continuously you cannot input ID number for 5 minutes Wait for more than 5 minutes try inputting ID number again As long as ID number input screen is displayed the engine cannot be started If you forget the ID number and cannot start the engine ask the person in charge of the machine NOTICE Since the purpose of the operator identification function is n...

Page 91: ...starting screen BB for 2 seconds the screen changes to the maintenance time warning screen CC After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the stand ard screen AA After displaying the check before starting screen BB for 2 seconds the screen changes to the warning screen FF 1 or error screen EE After displaying warning screen FF 1 for 2 seconds the sc...

Page 92: ...top of switch F5 switch F5 Press switch F5 to check the detail of the current abnormality Current Abnormality screen is displayed BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE EXPLANATION OF COMPONENTS OPERATION 3 16 ...

Page 93: ...t Abnor mality screen is displayed WARNING DISPLAY NOTICE Appearance of any of action levels L01 to L04 on the machine monitor indicates presence of an ab normality the machine Take appropriate actions following the list of action level displays and remedies The caution lamp that lights up in red when an action level is displayed warns operator to stop the ma chine urgently stop or pause the curre...

Page 94: ...mps 2 and 3 When 3 types of caution are generated they are displayed on caution lamps 2 3 and 4 When 4 types or more of caution are generated they are displayed on caution lamps 2 3 and 4 alternately at intervals of 2 seconds Whole camera image display screen The current cautions are indicated by flashing of caution lamp 9 When 2 or more cautions are generated they are sequentially displayed start...

Page 95: ...on is generated it is displayed on caution lamp 2 When 2 types of caution are generated they are displayed on caution lamps 2 and 3 When 3 types or more of caution are generated they are displayed on caution lamps 2 and 3 alternately at intervals of 2 seconds Whole camera image display screen The current cautions are indicated by flashing of caution lamp 8 When 2 or more cautions are generated the...

Page 96: ...he machine to a safe place then ask your Komatsu distributor for inspection and mainte nance L02 Sounds inter mittently Lights up in red Stop the operation and run the engine at medium speed with no load or stop it If the condition is not improved ask your Komatsu distributor for inspection and maintenance L01 Does not sound Lights up in yellow Some functions may be restricted from use but the mac...

Page 97: ...bnormal L04 L03 Abnormal L01 Hydraulic system caution lamp Abnormal L04 L03 Abnormal L01 KDPF system caution lamp Abnormal L04 L03 Abnormal L01 KDPF soot accumulation caution lamp Abnormal L03 Accumulated L01 DEF level caution lamp Abnormal L04 L03 Sensing is disabled DEF system caution lamp Abnormal L04 L03 Abnormal L01 DEF system high tempera ture stop caution lamp Engine stopped at high tempera...

Page 98: ...on lamp Clogged L01 Overload caution monitor Overload KS001069 Quick coupler caution lamp Abnormal L03 Air conditioner system cau tion lamp Abnormal L01 Maintenance time caution lamp Due time is over Notice Seat belt caution lamp Seat belt is not fastened Engine overspeed Abnormal L02 Abrupt engine stop by AIS Excessive fre quency L03 Excessive fre quency L01 For the meaning of each caution lamp a...

Page 99: ...emedies according to the message displayed on the monitor Operation on the Current Abnormality screen On the Current Abnormality screen you can perform the follow ing operations with switches F1 F2 and F5 F1 Displays next page When on the last page it displays the first page F2 Displays the previous page When on the first page it dis plays the last page F5 Returns the screen to the standard screen...

Page 100: ... see METHOD FOR ENGINE WARM UP OPERATION 3 176 When temperature is correct The caution lamp lights up in blue HYDRAULIC OIL TEMPERATURE CAUTION LAMP The hydraulic oil temperature caution lamp warns about states of hydraulic oil temperature When abnormal The caution lamp lights up in red and indicates action level L02 The hydraulic oil temperature is abnormally high Stop operations and stop the eng...

Page 101: ...ellow Some functions may be restricted for use but the machine can operate When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for inspection and maintenance as needed HYDRAULIC SYSTEM CAUTION LAMP The hydraulic system caution lamp warns about abnormality in the hydraulic system When action level L04 is displayed The caution lamp lights up in re...

Page 102: ...113 KDPF SOOT ACCUMULATION CAUTION LAMP The KDPF soot accumulation caution lamp warns that soot is accumulated in KDPF or the filtering function of KDPF has low ered abnormally To cancel the alarm perform the manual stationary regenera tion of KDPF When abnormal The caution lamp lights up in red and indicates action level L03 The alarm buzzer sounds intermittently Large accumulation of soot in KDP...

Page 103: ...hen DEF is added after engine starting switch turn to OFF When DEF tank level sensor is detective REMARK For more information about the Inducement strategy and Inducement status concerning engine power deration see HANDLE UREA SCR SYSTEM WARNING 3 123 DEF SYSTEM CAUTION LAMP DEF system caution lamp alerts when abnormality in the sys tem are detected Whenever the caution lamp lights up in yellow or...

Page 104: ...d and the alarm buzzer sounds intermittently Stop the operation and move the machine to a safe place then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow Some functions may be restricted for use but the machine can operate When you finish the operation always have the inspection and maintenance performed Ask your K...

Page 105: ...il see METHOD FOR CHECKING OIL LEVEL IN EN GINE OIL PAN ADDING OIL 3 149 If the oil level drops again in a short time the engine oil may be leaking For the inspection and maintenance ask your Komatsu distributor ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp lights up when engine over run occurs Since overrun can damage the engine and hydraulic compo nents stop the work immediately an...

Page 106: ...or For detail see METHOD FOR CHECKING WATER SEPARA TOR DRAINING WATER AND SEDIMENT 3 145 REMARK The water separator forms one unit with the fuel prefilter The water separator is installed at the bottom of the fuel prefil ter as detachable condition AIR CLEANER CLOGGING CAUTION LAMP Air cleaner clogging caution lamp warns about clogging of the air cleaner When clogged The caution lamp lights up in ...

Page 107: ...n yellow The maintenance time is approaching Prepare necessary parts for the maintenance REMARK You can check maintenance items on the maintenance tab screen by pressing switch F6 on the maintenance time warning screen shown in the figure or on the standard screen The lighting time of maintenance time notice yellow has been initially set to 30 hours but it can be changed To change the setting ask ...

Page 108: ...ll sound intermittently during operation During abnormal operation Quick coupler caution lamp is illuminated when oil pressure in quick coupler system is low A warning buzzer will sound intermittently and an error mes sage L03 will appear on the monitor display For detail see QUICK COUPLER SYSTEM 6 4 PILOT DISPLAY AND METER DISPLAY Pilot display 1 Engine stop pilot lamp 2 Lock lever pilot lamp 3 A...

Page 109: ...s displayed For detail see CAMERA IMAGE SELECTOR SWITCH 3 52 Pilot display 1 Engine stop pilot lamp 2 Lock lever pilot lamp 3 Aftertreatment Devices Regeneration pilot lamp 4 Aftertreatment Devices Regeneration disable pilot lamp 5 Message display 6 Air conditioner pilot lamp 7 Wiper pilot lamp 8 Swing lock pilot lamp 9 One touch power maximizing pilot lamp 10 Preheating pilot lamp 11 Auto deceler...

Page 110: ... is being actuated When the swing lock switch is turned ON LOCK this lamp lights up When the swing parking brake cancel switch is turned to Can cel position this lamp flashes For the positions of the swing lock switch and swing parking brake cancel switch see CONTROLS AND GAUGES NAMES 3 5 REMARK The swing motor is equipped with a disc brake that mechanically stops the rotation When the swing lock ...

Page 111: ...ations of 2 way attachments like crusher in emphasis of fuel consumption For the location of the working mode selector switch see MACHINE MONITOR EQUIPMENT NAME 3 6 TRAVEL SPEED DISPLAY The travel speed display shows the set mode of the travel speed The travel speed is indicated as follows according to the setting of the travel speed selector switch Lo Low speed travel Mi Mid range speed travel Hi...

Page 112: ...eply is made OFF No messages ENGINE STOP PILOT LAMP The engine stop pilot lamp is displayed while the engine is stopped It goes out when the engine is started AFTERTREATMENT DEVICES REGENERATION PILOT LAMP k k CAUTION Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regeneration Stay away from the exhaust pipe outlet to prevent yourself from ge...

Page 113: ...accumulation caution lamp lights up If KDPF soot accu mulation caution lamp lights up cancel the regeneration disa ble setting and perform manual stationary regeneration For the procedures of cancellation of the regeneration disable setting and setting of manual stationary regeneration see HANDLE Komatsu Diesel Particulate Filter KDPF 3 113 LOCK LEVER PILOT LAMP The lock lever pilot lamp lights up...

Page 114: ...e Recommendation Guidance If light load work is continued for more than 10 minutes in P or ATT P mode E mode recommendation message is displayed When working on light load set the working mode to E to re duce unnecessary fuel consumption E mode recommendation message goes out more than 10 sec onds after or when switch F5 is pressed Reduce Travel Speed Recommended Guidance If the machine keeps trav...

Page 115: ... about engine stop operation during the after treatment devices regeneration goes out 10 seconds later or when switch F5 is pressed DEF low level guidance If the operable time estimated from the current DEF level and the latest average DEF consumption is shorter than 8 hours the low DEF level message is displayed The low DEF level message goes out more than 10 seconds after or when switch F5 is pr...

Page 116: ...ns it is normal When the indicator nears the red range A during operation the hydraulic oil temperature has exceeded 102 C Run the engine at low idle or stop it and wait for the oil temperature to drop A to B Red range A to C Green range C to D White range REMARK When the indicator reaches red range A the hydraulic oil temperature is as follows Red range A position 102 C or more Red range B positi...

Page 117: ...range B fuel level monitor D lights up in red The correct fuel level may not be displayed for a short time after the starting switch is turned to ON position but this is not abnormal SERVICE METER CLOCK The service meter clock shows the total hours of operation of the machine or the present time When the engine is running the service meter advances even when the machine is not moving The service m...

Page 118: ...level REMARK Although there is no abnormality on the machine when the gauge enters the yellow range for the conservation of global environment reduce the engine output to a point where there is no adverse effect on the operation Perform energy saving op erations within the green range Travel less frequently It also helps energy saving operations Consider the best way of oper ation for energy savin...

Page 119: ...s does not indicate abnormality In cold weather DEF level cannot be detected and DEF level caution lamp 1 lights up in white for approxi mately 1 hour However this does not indicate abnormality Even if DEF level caution lamp 1 does not light up in white it may take a long time for DEF level gauge to display the correct position Note that the following cases are not abnormal When DEF is added while...

Page 120: ...erate the function When the monitor display shows the standard screen the types of guidance icons and functions of function switches are as follows For the details of each function see the detailed explanation of each item A Switch F3 Camera image selector switch B Switch F4 Service meter clock display selector switch C Switch F5 Current Abnormality display switch Only while caution lamp is lit D ...

Page 121: ...dance icons and their functions not explained above see the pages where the control methods of re spective screens are explained WORKING MODE SELECTOR SWITCH Use working mode selector switch to set the movement or pow er of the work equipment The operation becomes easier by selecting the mode to match the content of the operation P mode For heavy duty operations E mode For operations with emphasis...

Page 122: ...ngine ask your Komatsu distributor to change the setting How to use working mode selector switch 1 When working mode selector switch 2 is pressed the Working Mode selector screen is displayed on the monitor 2 Press function switches F3 or F4 at the bottom of the screen or working mode selector switch 2 to change the mode selection one at a time If no switch is touched for more than 5 seconds the s...

Page 123: ...s on the function to reduce fuel consumption when the control levers are at NEUTRAL position Auto deceleration pilot lamp lights up Auto deceleration ON Auto deceleration pilot lamp goes off Auto deceleration OFF Each time the switch is pressed the auto deceleration is switched between ON and OFF Function of auto deceleration When the auto deceleration function is ON if the work equipment lever an...

Page 124: ...hine is traveling the machine may deviate to one side even when traveling in a straight line Stop the machine before switching the travel speed Travel speed selector switch is used to select the travel speed from 3 stages Lo lights up Low speed travel Mi lights up Mid range speed travel Hi lights up High speed travel When the engine is started the speed is automatically set to Lo Each time that th...

Page 125: ...per switch actuates the front window windshield wiper Each time the switch is pressed it changes INT ON stop monitor goes out Windshield wiper pilot lamp INT lights up Windshield wiper op erates intermittently Windshield wiper pilot lamp ON lights up Windshield wiper op erates continuously Windshield wiper pilot lamp off Windshield wiper stops OPERATION EXPLANATION OF COMPONENTS 3 49 ...

Page 126: ...r fluid is sprayed out At the same time the wiper is actuated continuously When releasing switch the wiper continues to operate for 2 cycles then stops If the wiper is moving intermittently and the switch is kept pressed continuously the window washer fluid is sprayed out At the same time the wiper is actuated continuously When releasing switch the wiper continues to operate for 2 cycles then retu...

Page 127: ... the warning AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches For explanation of each switch see HANDLE AIR CONDI TIONER FUNCTION SWITCHES The operation of the function switches in the standard screen OPERATION EXPLANATION OF COMPONENTS 3 51 ...

Page 128: ...tch F3 is pressed camera image full screen display MM is displayed Camera image full screen display MM is displayed on the entire screen When switch F3 is pressed on camera image full screen display MM message screen NN is displayed and no camera image is displayed On message screen NN when switch F3 is pressed or when no switch is operated for 10 seconds stand ard screen LL is displayed On messag...

Page 129: ...mage in full screen REMARK If the machine is equipped with No 1 camera only No 2 camera image to No 4 camera image are not dis played No 1 camera image only is displayed in full screen If the machine is not equipped with No 3 camera display is changed each time switch F1 is pressed but No 3 camera image is not displayed Press switch F3 and the screen returns to the standard screen Operation of ima...

Page 130: ... operation is performed for 5 seconds after the screen switches to the air conditioner control screen the screen automatically returns to the camera image screen For details of the air conditioner operation see HANDLE AIR CONDITIONER 3 217 It is possible to change the working mode by pressing the working mode selector switch For the working mode selector switch see WORKING MODE SELECTOR SWITCH 3 4...

Page 131: ...screen or return to the standard screen display It is possible to stop the alarm buzzer for the warning item where there is an abnormality by pressing the buzzer can cel switch Even if the buzzer cancel switch is pressed the camera image display screen does not switch to another screen or return to the standard screen Depending on the warning alarm buzzer does not stop sounding by pressing the buz...

Page 132: ... is flashing if no lever is operated for 10 seconds or more the screen automatically returns to the standard screen When the screen returns to the standard screen the cau tion lamp at the top left of the screen goes out and the caution lamp and action level are displayed on the center of the screen If a caution lamp is displayed move the machine to set it in a safe posture then have inspection per...

Page 133: ...tment Devices Regeneration d SCR Information e Maintenance f Monitor Setting g Mail Check These menus a to g are for setting and confirming the fol lowing items For operations in each menu see the detailed explanation pa ges of respective items a Energy Saving Guidance Check of Operation Records Check of ECO Guidance Records Check and reset of Average Fuel Consumption Record Configurations b Machi...

Page 134: ... d SCR Information Check of DEF level Information on DEF system e Maintenance Check and reset of various maintenance times f Monitor Setting Screen Adjustment Screen Adjustment camera Clock Adjustment Language Operator ID g Mail Check Check of mail contents and reply to mail EXPLANATION OF COMPONENTS OPERATION 3 58 ...

Page 135: ... the previous item 1 line above When it is on the first line it moves to the last line F5 Returns the screen to the standard screen F6 Displays the setting screen for selected item If no switch is operated for 30 seconds on the user menu screen the screen automatically returns to the previous screen ENERGY SAVING GUIDANCE Each item of Energy Saving Guidance menu a is used for displaying and settin...

Page 136: ... F3 Displays the next page When on the last page it displays the first page F4 Displays the previous page When on the first page it dis plays the last page F5 Returns the screen to the Energy Saving Guidance menu screen CHECK ECO GUIDANCE RECORD Select the ECO Guidance Records 2 on the Energy Saving Guidance menu screen then press switch F6 On the ECO Guidance Records menu display the frequency of...

Page 137: ...ring the last 12 hours or the graph of daily fuel consumption during the last 1 week Operation on the Average Fuel Consumption Record screen Press switch F1 F2 or F5 on the Average Fuel Consumption Record screen to perform the following operations F1 Clears the graph data F2 Switches graphical displays of the average fuel consump tion F5 Returns the screen to the Energy Saving Guidance menu screen...

Page 138: ...on during the last 1 week Switching be tween them is available Deleting the average fuel consumption records 1 When switch F1 CLEAR is pressed the reconfirmation screen shown in the figure is displayed 2 When the switch F6 is pressed graphs of data of the last 12 hours and the last 1 week are both deleted and the screen returns to the Average Fuel Consumption Record screen REMARK Press switch F5 t...

Page 139: ...OFF Operations on the Configurations screen Press switches F3 to F6 to perform the following operations on the Configurations screen F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Returns the screen to the Energy Saving Guidance menu screen F6 Displays the setting...

Page 140: ...moves to the last line on the previous page F5 Cancels the setting and returns to Configurations screen F6 Changes the setting and returns to Configurations screen 2 The Average Fuel Consumption Display screen appears 1 Day Displays the average fuel consumption from 0 00 a m of the day to 0 00 a m of the next day Split Time Displays the average fuel consumption during the split measurement period ...

Page 141: ...or ECO Guidance Records 2 screen then press the measure ment stop switch F1 STOP SWITCH DISPLAY NON DISPLAY OF ECO GAUGE It is possible to change the setting of Display Non display of ECO gauge 7 1 Select the ECO Gauge display 8 from the Configurations screen then press switch F6 2 ECO Gauge Display setting screen appears ON Displays the ECO gauge 7 on the standard screen OFF Does not display ECO ...

Page 142: ...to change the target fuel consumption value the upper limit value of the green range of the ECO gauge 1 Select the ECO Gauge Target Value 9 from the Configu rations screen then press switch F6 2 ECO Gauge Display Fuel Target Value appears On this screen it is possible to perform the following oper ations with switches F3 to F6 F3 Decreases the target fuel consumption value by 1 ℓ h F4 Increases th...

Page 143: ...st line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting change and returns to Configurations screen F6 Changes the setting and returns to Configurations screen SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF It is possible to change the setting of Display Non d...

Page 144: ... Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting change and returns to Configurations screen F6 Changes the setting and returns to Configurations screen MACHINE SETTINGS Each item of Machine Setting menu b is used for setting items of machine Economy Mode Adjustment Breaker Setting Attachment Setting Auto Idle Sto...

Page 145: ...On the Breaker Setting menu you can change the name of breaker displayed on the monitor and the breaker oil flow setting For machines that have no attachment the Breaker Setting menu is not displayed 1 Select Breaker Setting menu 2 on the Machine Setting menu b screen then press switch F6 2 On the Breaker Setting screen shown in the figure select breaker and press switch F6 On the Breaker Setting ...

Page 146: ...phabet numeral or symbol F5 Returns the screen to the Breaker Setting screen without changing the name F6 Enters the change and returns the screen to the Breaker Setting screen Changing Breaker Oil Flow Rate Setting 1 On the Breaker Setting screen select a setting to change its oil flow then press switch F2 2 The Breaker Oil Flow Rate Setting screen is displayed On the Breaker Oil Flow Rate Settin...

Page 147: ...to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels the selection and returns the screen to the Machine Setting menu screen F6 Allocates the selected setting to that of ATT P or ATT E mode Changing Attachment Setting name It is possible to change the attachment setting name as you like You can use alphabet letters A to Z Arabic n...

Page 148: ...out changing the oil flow rate F6 Enters the oil flow setting and returns to the Attach ment Setting screen X Present oil flow setting Y Min adjusted oil flow Z Max adjusted oil flow It is not possible to change the oil flow for No Attachment setting ATTACHMENT SETTING 2 If installing 2nd attachment lines as a field kit ask your Komatsu distributor to change the monitor setting to allow 2 attachme...

Page 149: ...d on the at tachment 1 oil flow setting screen and the guidance icon ATT1 d is displayed on the attachment 2 oil flow setting screen It is not possible to change the oil flow for No Attachment setting AUTO IDLE STOP TIMER SETTING The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with the lock lever in LOCK position for a set time The auto i...

Page 150: ...than that specified in the Service Menu 3 When the idling time reaches 30 seconds before the set time the monitor returns to the standard screen and changes to the countdown screen If you set the lock lever to FREE position countdown stops and the screen returns to the standard screen 4 When countdown reaches 0 the engine stops and the screen changes to the Auto Idle Stop in Operation screen 5 To ...

Page 151: ...ICES REGENERATION Each item of Aftertreatment Devices Regeneration menu c is to make settings for the aftertreatment devices regeneration For details of the aftertreatment devices regeneration see HANDLE Komatsu Diesel Particulate Filter KDPF 3 113 SCR INFORMATION Each item of SCR information menu d is for displaying infor mation related to SCR and DEF For details of SCR information see HANDLE URE...

Page 152: ...Cleaning 4500 DEF Tank Washing 4500 Fuel Doser Cleaning 4500 Hydraulic Oil Change 5000 a Maintenance items b Default maintenance interval settings h c Time remaining until maintenance h 1 When using engine oil for cold district the maintenance interval setting must be changed For details of the oil see RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 On Maintenance menu screen it is possible to perform ...

Page 153: ...ime Reset screen On the Maintenance menu screen if switch F6 is kept pressed for at least 1 5 seconds the screen changes to the Maintenance Due Time Reset screen Reset the remaining time to the maintenance on this screen 1 Press switch F6 when the Maintenance Due Time Reset screen is in the condition shown in the figure The screen switches to the reconfirmation screen REMARK When canceling the res...

Page 154: ... light switch is at day mode ON and the screen is adjusted it is possible to adjust the brightness of the monitor screen day mode As long as mark is displayed in the upper right cor ner of the screen brightness is automatically restrict ed by the machine monitor to protect the liquid crystal Screen adjustment may not change the screen bright ness as long as mark is displayed However it is not an e...

Page 155: ...een then press switch F6 The screen switches to the selection menu for the clock adjustment The following 5 items can be changed a GPS Synchronization b Calendar c Time d 12h 24h Mode e Daylight Saving Time REMARK b Calendar and c Time need to be readjusted since they are reset after a long term storage When the GPS Synchronization is set to ON they can be automatically readjusted 2 Perform the fo...

Page 156: ... switch F6 F3 Calendar goes back 1 year F4 Calendar advances 1 year F5 Cancels change and returns the screen to Clock Ad justment screen F6 Proceeds to setting for month 3 When month display B is highlighted in yellow operate the switches as follows to change month display B If it is not necessary to change the month press switch F6 F3 Calendar goes back 1 month F4 Calendar advances 1 month F5 Can...

Page 157: ... the screen to Clock Ad justment screen F6 Proceeds to setting for the minute 3 When minute display E is highlighted in yellow operate the switches as follows to change minute display E If it is not necessary to change the minute press switch F6 F3 The time goes back 1 minute F4 The time advances 1 minute F5 Cancels change and returns to the time setting screen F6 Accepts change and returns the sc...

Page 158: ...F3 Moves to the next item 1 line below Moves to the top line when on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when on the top line F5 Cancels change and returns to Clock Adjustment screen F6 Accepts change and returns the screen to Clock Ad justment screen REMARK Daylight saving time or summer time means moving the clock forward an hour to take advantage ...

Page 159: ...eck and change the Operator ID which is under identification on the Operator ID menu The Operator ID menu is not displayed when the operator identification function is disabled REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identi fication function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch ...

Page 160: ... the screen returns to the Monitor Setting menu screen On the Monitor Setting menu screen as the same way when the starting switch is ON and SKIP is se lected is displayed in the column of Operator ID In this case the operator ID is not identified When you press switch F6 after inputting the ID which is not registered to the Operator ID Change screen a message is displayed below and the screen ret...

Page 161: ... screen and press F6 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen When you press switch F6 after inputting the ID which is not registered to the Operator ID Change screen a message is displayed below and the screen returns to the Monitor Setting menu screen In this case the identified ID is not changed On the Operator ...

Page 162: ...essage to your Komatsu distributor Reply to the message according to the replying method mentioned below If the starting switch is turned to OFF position when there is any unread message the message will be displayed on the end screen and when the monitor is started next time the message will change to a read message the message display lights up in blue B The message will be deleted when it becom...

Page 163: ...ing the monitor switch Each switch corresponds to the value shown on the right side below the switch If you input an incorrect number press switch F5 and you can clear an input character at a time If switch F5 is pressed when the input column is blank the screen returns to the standard screen 2 After inputting a selected item number press switch F6 3 When the message Do you send Numeric Input is d...

Page 164: ...h if equipped 9 Ceiling window wiper switch if equipped 10 Cigarette lighter 11 Room lamp switch 12 Seat heater switch if equipped 13 Engine shutdown secondary switch 14 Pump secondary drive switch 15 Swing parking brake cancel switch 16 Lock lever automatic lock cancel switch 17 Quick coupler switch 18 1st attachment proportional control switch EXPLANATION OF COMPONENTS OPERATION 3 88 ...

Page 165: ...Fuel control dial is used to control the engine speed and out put a Low idle MIN The position where the dial is turned fully to the left b High idle MAX The position where the dial is turned fully to the right CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes When the cigarette lighter is pushed in it will return to its origi nal position after a few seconds so pull it out to use...

Page 166: ...mps light up and monitor illumination is set to day mode c OFF position Lamps go out The monitor illumination is set to day mode HORN SWITCH Horn switch is located on R H work equipment control lever When switch is pressed the horn sounds ONE TOUCH POWER MAXIMIZING SWITCH One touch power maximizing switch is used to actuate the one touch power maximizing function Press once single click and keep t...

Page 167: ...control system Do not use it except for emergency Repair the problem as soon as possible If this switch is moved to Emergency position by mistake while the machine is operating normally L03 appears in the display If L03 is displayed during operation press the moni tor function switch F5 to check whether the current failure code includes any of the hydraulic system er rors DXA9KB DXA8KB DXA9KA or D...

Page 168: ...03 a Cancel When abnormal switch is set up b Normal When normal switch is pushed down When the upper structure does not swing but the display does not show L03 move this switch to Cancel position a and operation can be performed When the switch is moved to Cancel position a the swing lock pilot lamp flashes LOCK LEVER AUTOMATIC LOCK CANCEL SWITCH NOTICE The lock lever automatic lock cancel switch ...

Page 169: ...monitor display and after 2 seconds the screen returns to the standard screen After moving the machine or work equipment temporarily by operating this switch stop the engine return the switch to normal position b and then ask your Komatsu distribu tor for repair REVOLVING LAMP SWITCH if equipped Revolving lamp switch is used to light up the yellow revolving lamp on top of the cab a ON Lights up b ...

Page 170: ...ndary switch only in an emergency Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch If the engine shutdown secondary switch is moved to the stop engine position by mistake while the machine is operating normally Engine Shutdown Secondary SW In Operation is displayed on the machine monitor If Engine Shutdown Secondary SW In Operation is displayed o...

Page 171: ...eat heating and the seat becomes warm QUICK COUPLER SWITCHES To operate the quick coupler circuit switches 23 on RHS console 17 on LH PPC lever must be operated to gether Refer to PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS 6 2 for an explanation of these switches operation 1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH The 1st attachment proportional control switch is a roller proportional control s...

Page 172: ...ircuit to 2 stages a Low pressure set Since the bracing force of the boom is decreased the machine is less moved up during digging work and the operator can dig smoothly Use this position for the general normal operation for ordinary soil soft rocks blasted rocks etc b High pressure set Since the bracing force of the boom is increased the machine can easily escape from soft ground CONTROL LEVERS A...

Page 173: ...equipped REMARK The lock lever is of hydraulic lock type Accordingly when it is in LOCK position L the control levers or control pedals move but the machine does not move Automatic lock function of lock lever k k WARNING The lock lever automatic lock function assists the operator in judgment to reduce damage caused by accident It does not stop the work equipment or machine in all situations Even i...

Page 174: ...u perform operations with your foot on the pedal the machine may suddenly start if you de press the pedal by mistake and this may lead to serious personal injury or death Be extremely careful when using the pedal for travel and steering operations and do not put your foot on the pedal when it is not necessary When the track frame is facing the rear the direction of operation of the steering lever ...

Page 175: ...alling objects OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING CAB FRONT WINDOW k k WARNING When opening or closing the front window bottom window or door always set the lock lever to LOCK position If the control lever or control pedal is touched by mistake when the lock lever is in FREE position it may cause serious personal injury or death When opening or closing the front window stop the machine...

Page 176: ...wed in the right stay If the wiper blade is stowed in wrong stowing position b lift it to move to the correct stowing position a or ask your Komatsu distributor for repair a Correct stowing position The wiper blade is on the cab b Wrong stowing position The wiper blade is on the glass 3 Hold handles A 2 places on the right and left top sides of the front window and pull levers B 2 places to re lea...

Page 177: ...the front win dow are not for pulling up the front window Do not pull up the front window with the handles A 5 Check that lever B is securely at LOCK position If the arrow on lock case F matches the position of the arrow on lever B the lock is engaged Check vis ually If the arrow on lock case F does not match the posi tion of the arrow on lever B the lock is not engaged Repeat the operation in ste...

Page 178: ... the machine on a level ground lower the work equip ment to the ground then stop the engine Operate the control grip g of the lock lever 1 to set it se curely to LOCK position L 2 Check that the wiper blade is stowed in the right stay If the wiper blade is stowed in wrong stowing position b lift it to move to the correct stowing position a or ask your Komatsu distributor for repair a Correct stowi...

Page 179: ... down the front window with the handles A 5 When the bottom of the window reaches the top of lower side window push the top of the window to the front to push it against right and left lock catches G and engage the lock 6 Check that lever B is securely at LOCK position If the arrow on lock case F matches the position of the arrow on lever B the lock is engaged Check vis ually If the arrow on lock ...

Page 180: ...ck position B to hold it securely in position 3 When removing it set lever 2 to release position C hold the glass with both hands and pull it up EMERGENCY ESCAPE HAMMER k k CAUTION If it is necessary to break the window glass with the hammer be extremely careful not to get injured with scattered pieces of broken glass To prevent injury remove the broken pieces of glass remaining in the frame befor...

Page 181: ...ne or do not put your hands on the door frame The door may suddenly close and cause injury 1 Use the door lock to keep and fix the door opened 2 Push the door against catch 1 to lock it in position When closing the door push down lever 2 on the left side of the operator s seat and the catch is released 3 When keeping the door open fix it securely to the catch CAB DOOR HINGE The cab door hinge has ...

Page 182: ...not inserted all the way to the end it may break DRINK BOX It is provided on the rear right side of the operator s seat to store drinks Air according to the setting of the air conditioner blows into the drink box MAGAZINE BOX Located on the left side of the operator s seat Keep Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary CUP HOLDER The cup h...

Page 183: ...er supply for 12 V equipment This will cause failure of the equipment When cigarette lighter is removed the lighter socket can be used as a power source The capacity of the cigarette lighter is 85 W 24 V x 3 5 A REMARK Use 24 V power source while engine is running 12 V power source This power source can be used up to a capacity of 144 W 12 V x 12 A When it is used at 1 place 144 W 12 V x 12 A When...

Page 184: ...o protect the electrical component and wiring from burning out If the fuse becomes corroded or looks white powdery or the fuse is loose in the fuse holder replace the fuse Replace the fuse with the one of the same capacity KS000913 EXPLANATION OF COMPONENTS OPERATION 3 108 ...

Page 185: ...at with heater 13 5 A Air conditioner ECU power source 14 5 A Key ACC signal 15 20 A Working lamp 16 10 A Radio backup room lamp system operating lamp 17 20 A Monitor Pump controller 18 30 A Engine controller 19 5 A Air conditioner ECU backup 20 10 A Optional power source continuous power supply 21 10 A CAB headlamp 1 22 10 A CAB Rear lamp 23 10 A Lower window wiper 24 10 A Quick coupler 25 15 A R...

Page 186: ...e starting switch key is turned to START position fusible link 1 2 places may be broken Open the cover on the left side of the machine to check the fusible links and replace them REMARK A fusible link refers to the large sized fuse wiring installed in the high current flow portion of the circuit It protects electrical components and wiring from burning in the same way as an ordinary fuse TOOL BOX ...

Page 187: ...arelessly this is extremely dangerous NOTICE Keep battery disconnect switch in ON position except the following cases When the machine is stored for a long time more than a month When repairing the electrical system When performing electric welding When handling the battery When replacing fuse etc Do not turn battery disconnect switch to OFF position while the system operating lamp is lit If it is...

Page 188: ...erating lamp 1 indicates that the controller mount ed on the machine is turned ON Lamp 1 lights up in green when the controller is turned ON and goes out in 2 to 6 minutes after the starting switch is turned to OFF position Before operating the battery disconnect switch check that lamp 1 is not lit NOTICE If the battery disconnect switch is turned OFF while this lamp is lit the data in the control...

Page 189: ... regardless of the quantity of the accumulat ed soot During the KDPF regeneration the aftertreatment devices regeneration pilot lamp 1 stays lit on the machine monitor REMARK Even if aftertreatment devices regeneration pilot lamp 1 lights up the machine does not need to be stopped and the work can be continued unless the caution lamp is displayed at the cen ter of the monitor The KDPF regeneration...

Page 190: ...ease but this is not a fail ure Even just after the regeneration is completed the soot ac cumulation level may not be 0 This is caused by the ac cumulated noncombustible material in the exhaust gas and is not a failure Since noncombustible matter which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals For detail...

Page 191: ...screen A is displayed first The action level goes out 2 seconds after and the screen changes to standard screen B If the lock lever is set to LOCK position or all the work equipment control levers are set in NEUTRAL the screen changes to Aftertreatment Devices Regeneration screen C after 3 seconds only the first time If the manual sta tionary regeneration is not performed the screen returns to sta...

Page 192: ...al stationary regeneration PROCEDURE FOR MANUAL STATIONARY REGENERATION k k CAUTION Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regen eration Avoid getting near the exhaust pipe outlet and around the Aftertreatment devices to prevent being burnt Also keep combustible materials away from the exhaust pipe outlet and around the Aftertreatment...

Page 193: ...step 6 the screen shown in the figure may be displayed This indicates that the opera tions in steps 1 to 4 were not performed correctly or there is trouble other than KDPF soot accumulation abnormality Check that the engine is running normal the lock lever is in LOCK position L and the fuel control dial is in Low idle MIN position then repeat the procedure from step 6 If the manual stationary rege...

Page 194: ...ration dis appears and the screen returns to the standard screen At this time to display the explanation of the manual stationary regeneration again press switch F6 on the standard screen to display the Aftertreatment Devices Regeneration screen 7 This screen is displayed during the manual stationary re generation It may take more than 40 minutes to complete the manual stationary regeneration Do n...

Page 195: ...en repeat the procedure from step 6 If the machine needs to be moved during the manual stationary regeneration stop the regeneration tempo rarily and move the machine referring to the after treatment devices regeneration disable and cancel procedures described below When restarting the manual stationary regeneration secure the safety of the machine and around it then cancel the regeneration disabl...

Page 196: ...dard screen Press switch F6 on the standard screen 2 Operate switches F1 and F2 to select Aftertreatment De vices Regeneration menu C to display Aftertreatment Devices Regeneration screen 3 Select the regeneration disable and press switch F6 then the regeneration function is disabled and the regeneration cannot be performed EXPLANATION OF COMPONENTS OPERATION 3 120 ...

Page 197: ...lamp 3 may light up but this does not indicate abnormality Also during the regeneration to protect the system the regener ation disable cannot be operated When the regeneration is performed to protect the system the exhaust temperature is lower than that of when the re generation is performed to burn soot and is almost the same level as the normal exhaust gas temperature While regeneration is bein...

Page 198: ... After treatment Devices Regeneration screen is displayed If the screen is not displayed operate switches F1 and F2 to display Aftertreatment Devices Regeneration screen 2 Select Cancel of the regeneration disable and press switch F6 and the regeneration disable is canceled If soot accumulation level 4 is lit 3 or more the regenera tion is started automatically REMARK When canceling the regenerati...

Page 199: ...a NH3 and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water The Komatsu Urea SCR System continuously monitors its operation conditions and stores information on inap propriate operations including malfunctions The information is used for system diagnostics and also for Induce ment required by the authorities on engine systems that use Urea SCR systems Ind...

Page 200: ...es in the engine system If DEF out of the standard is filled or used by mistake contact your Komatsu dis tributor About the operation of Urea SCR system The Urea SCR System automatically starts operating as soon as the engine is started Even after the engine starting switch is turned to the OFF position the devices will still be in operation for sever al minutes to purge any DEF in the lines the i...

Page 201: ... in 4 levels from Warning Continuous Warning Low level Inducement and Severe Inducement The DEF level caution lamp 1 on the machine monitor will light up audible alert will start then Action level will be dis played on the machine monitor and engine power will be derat ed in steps In Action Level L03 Low level Inducement and L04 Severe Inducement engine power will be derated When Action Level 03 o...

Page 202: ...e 2 gradations of the DEF level gauge light up in the red range DEF level caution lamp 1 lights up in red No Action level is displayed Press F6 to display the SCR Information screen Inducement status 4 2 Without treatment engine power will be derated Add DEF to the DEF tank immediately Low level Inducement The audible alert sounds in short and sharp beeps 1 gradation of the DEF level gauge light u...

Page 203: ...estoration function to move the machine to a safe place and add DEF Inducement strategy when abnormalities are detected in the Urea SCR System devices Except abnormalities in the KDPF and the EGR system If any abnormality is detected in the DEF quality or in the Urea SCR system the Inducement strategy is activat ed The inducement strategy progresses in 4 levels Warning Continuous Warning Low level...

Page 204: ...n Level L01 once shows up in yellow on the machine monitor 2 for two seconds and goes out Press F6 to display the SCR Information screen SCR Information screen message 4 1 Please inspect and maintain SCR system Move the machine to the safe place and contact your Ko matsu Distributor If operation continues for 5 hours after Warning started without taking any actions instructed by the Action Level t...

Page 205: ...gine power deration capability of the ma chine will be limited Move the machine to the safe place and contact your Ko matsu Distributor The duration of Low level Inducement is 10 hours The remaining time Hours and Minutes to Severe Induce ment is displayed in the column 5 of the SCR Informa tion screen In Severe Inducement engine power will be derated fur ther Severe Inducement The audible alert s...

Page 206: ...p 1 DEF system caution lamp 2 and Action Level displayed on the machine monitor 3 au dible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine power deration starts with Action Level L03 Warning Continuous Warning and Low level Inducement and advances to further deration when L04 Severe Inducement is displayed Once the sys tem advances to Sever...

Page 207: ...n red The DEF system caution lamp 2 lights up in yellow The action level L03 lights up in red at action level dis play 3 Press F6 to display the SCR Information screen SCR Information screen message 5 2 Without treat ment engine power will be derated Move the machine to the safe place and contact your Ko matsu Distributor The duration time of Continuous Warning is 5 hour The remaining time Minutes...

Page 208: ... engine power restoration works only when the Inducement status is Severe Induce ment and relieves back temporarily to the power deration of Low level Inducement The operator can re store engine power through the machine monitor For the engine power restoration procedure refer to the section of Temporary Restoration from Inducement in this manual If Inducement advances to Severe In ducement and it...

Page 209: ...tem is in Inducement SCR Information screen displays remaining time to the next Inducement status in the column 6 and information on the Urea SCR System condition 4 and the current status of In ducement 5 Warning The audible alert sounds in short and sharp beeps The Engine system caution lamp 1 lights up in red The action level L03 lights up in red at action level dis play 3 Press F6 to display th...

Page 210: ...sharp beeps The Engine system caution lamp 1 lights up in red DEF system caution lamp 2 lights up in red The action level L03 lights up in red at action level dis play 3 Press F6 to display the SCR Information screen SCR Information screen message 5 3 Engine power is under deration Due to the reduction of engine power the machine normal operation will be limited The duration time of Low level Indu...

Page 211: ...ncluded in Urea SCR systems In case the Urea SCR system advances to Severe Inducement engine power is derated heavily This may cause difficulties of moving the machine to a safe place for adding DEF or troubleshooting and correcting abnor malities of the Urea SCR system For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of Low leve...

Page 212: ...s displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Low level Inducement for the maximum of 30 minutes The remaining time minutes seconds of Temporary Re storation from Inducement is displayed in the column 2 on the SCR Information screen If it is decided NOT to activate Temporary Restoration from Inducement after having progresse...

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

Page 214: ...taminate DEF pump and DEF injector which will cause the failure of the machine Never reuse the DEF filter KOMTRAX KOMTRAX equipment may not be mounted on machines for some countries or regions OUTLINE OF KOMTRAX KOMTRAX is a system that remote controls machines equipped with the KOMTRAX device by using satellite communication or portable radio communication Each customer can check the machine info...

Page 215: ...e starting switch to OFF position and turn the battery dis connect switch key to OFF position Then remove the key When the battery disconnect switch is turned to OFF position it is possible to prevent power consumption of the battery but the functions of KOMTRAX stop at the same time For operation of the battery disconnect switch see BATTERY DISCONNECT SWITCH 3 111 Contact your Komatsu distributor...

Page 216: ...utor judges that it is necessary to suspend KOMTRAX com munication If you do not observe the above rules neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages EXPLANATION OF COMPONENTS OPERATION 3 140 ...

Page 217: ... turbocharger or other high temperature engine parts If any dirt or combustible materials are found remove them For removal of dirt from the radiator see METHOD FOR CHECKING AND CLEANING RADIATOR FINS OIL COOLER FINS AFTERCOOLER FINS AND AIR CONDITIONER CONDENSER FINS 4 53 3 Check around the engine for coolant and oil leakage Check for oil leakage from the engine and coolant leakage from the cooli...

Page 218: ...evices and also KDPF connections for leakage of exhaust gas and deposition of soot If any problem is found ask your Komatsu distributor for repair 16 Check around SCR for exhaust gas leakage Check the pipe between the KDPF and SCR and also the SCR connections for leakage of exhaust gas and urea deposit If any problem is found ask your Komatsu distributor for repair METHOD FOR CHECKING BEFORE START...

Page 219: ...d in the right hand rear pump compartment of the machine 2 Remove the refuel hose which is stored in tray 3 from the machine Unscrew the strainer valve cap H to open position J Place the fuel hose 2 into the fuel barrel placed next to the machine Remove the fuel cap F 3 Refuel Pump with Auto Shut off Refuel System 9JH02623AA 3 2 5 OPERATION MACHINE OPERATIONS AND CONTROLS 3 143 ...

Page 220: ...tank Releasing switch 5 will stop the refuel pump in this over ride condition When using this override the level of the tank must be monitored to prevent overfilling and fuel spillage If fuel is allowed to overflow stop refuelling immediately by turning off the master switch 4 After finishing refuelling make sure the master switch 4 is returned to the OFF position Refuel Pump without Auto Shut off...

Page 221: ...n O to drain all the sediment and water accumulated at the bottom together with fuel 3 When only the clean fuel flows out turn drain valve 2 to CLOSE position S METHOD FOR CHECKING WATER SEPARATOR DRAINING WATER AND SEDI MENT 1 Open the door on the right side of the machine 2 Check for water and sediment It is possible to judge the water level and amount of sedi ment by looking through transparent...

Page 222: ...gine is started as the temperature around fuel prefilter 1 increases the frozen water will melt and the water separator caution lamp may suddenly light up In cold season even if the water separator caution lamp is not lit drain the water frequently REMARK If transparent cup 2 is dirty and it is difficult to see the inside clean transparent cup 2 when replac ing fuel prefilter cartridge 1 When the ...

Page 223: ... OIL LEVEL IN HYDRAULIC TANK ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully 1 Set the machine in the posture shown in the...

Page 224: ...he right and left tracks Stop the engine After the hydraulic oil has been cooled down remove cover 1 and drain the excess oil through drain plug P to the container for receiving the oil REMARK The oil level vary with the oil temperature Accordingly use the following as a guide Before starting operation Between H and L levels Oil temperature 10 to 30 C Normal operation Around H Level Oil temperatur...

Page 225: ... checking repair any abnormality im mediately REMARK If the inside of sub tank is so dirty that you cannot check the coolant level see METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4 20 2 Check sub tank 1 If the coolant level is within the range between FULL and LOW the coolant amount is at a proper level If the coolant level is below LOW add coolant to FULL lev el through the filler port of sub ta...

Page 226: ... the dipstick pipe then remove it 4 Check if the oil is sticking up to between marks H and L on dipstick G It is appropriate if the oil level is between marks H and L If the oil level is below the L mark add oil through oil filler port F 5 If the oil level is higher than H decrease it to a proper level according to the following procedure 1 Remove cover 1 2 Take out hose 2 from the toolbox and ins...

Page 227: ...o damage to the coating Perform inspection to confirm that there is no loose terminals and tighten any loose parts if found Always check if there is any accumulation of combustible material around the battery and remove such combustible material METHOD FOR CHECKING FUEL LEVEL ADDING FUEL k k WARNING When adding fuel never spill the fuel or let it overflow It may cause a fire If any fuel has spille...

Page 228: ...rely METHOD FOR CHECKING DEF LEVEL ADDING DEF k k WARNING Do not put fluid other than DEF into DEF tank When opening the cap of DEF tank of the machine the ammonia vapour may escape Keep your face away from the filler port Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder operation of the devices Before removing the filler cap wipe off the dirt from ar...

Page 229: ...ontainer Do not use a funnel when to add DEF The strainer may be broken When using a portable DEF refill container use up DEF each time If any of DEF is left remove for eign material if there is any Do not wash the adding nozzle in city water Minerals may clog the devices Do not dilute DEF with water If you add fluid other than DEF diesel fuel low concentration DEF etc by mistake the caution lamp ...

Page 230: ...90 REMARK It is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop function to add DEF When the specified nozzle is used the magnet installed inside the filler port of the tank cancels the wrong fluid addition prevention device and you can add DEF This mechanism prevents addition of DEF into the fuel tank addition of fuel into DEF tank and spill of...

Page 231: ...does not sound ask your Komatsu distributor for repair METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR S SEAT k k WARNING When adjusting the position of the operator s seat always set the lock lever to LOCK position to pre vent any malfunction due to accidental contact with the control levers NOTICE If the seat position is adjusted while the parts tools or empty cans are left around the operato...

Page 232: ...le for operation then release the lever REMARK Sit with your back against the backrest when adjusting If your back is not touching the backrest the backrest may suddenly move forward METHOD FOR TILTING SEAT Pull up the tilt adjustment lever and adjust the front angle of the seat To raise the front of the seat apply your weight to the rear of the seat while pulling up lever To lower the front of th...

Page 233: ...Height of the armrest can be adjusted up or down by using the knob at the rear of the armrest Armrest height adjustment 43 mm 1 Loosen knob 1 at the rear of the armrest 2 Pull plunger 2 3 Adjust the height of armrest 3 while pulling plunger 2 4 Push back plunger 2 after aligning it to the height adjust ment hole of armrest 3 5 Tighten knob 1 at the rear of the armrest METHOD FOR ADJUSTING ARMREST ...

Page 234: ...SPENSION SEAT HARDNESS Air suspension seat if equipped Operate the suspension switch to adjust the hardness of the suspension If you press the suspension switch the suspension be comes hard If you pull the suspension switch the suspension becomes soft Air release sound is heard Weight adjustment range 60 to 150 kg METHOD FOR HEATING SEAT Heated seat if equipped Turn the seat heater switch ON a OFF...

Page 235: ... operate it so that the shaft of the headrest becomes straight If it is forcibly twisted the installation part may be broken METHOD FOR ADJUSTING MIRRORS k k WARNING Be sure to adjust the mirrors before starting work If they are not adjusted properly you cannot secure the visibility and may be injured or may lead to a serious personal injury or death k k CAUTION To prevent the machine from moving ...

Page 236: ...ee a person at the rear left end of the machine 3 If you cannot adjust loosen mounting bolts 1 of the mir ror and stay and adjust the angles If the mirror is adjusted by loosening the mounting bolts be sure to adjust the mirror to its specified position For the adjustment method see PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR A 3 160 PROCEDURE FOR ADJUSTING REGULAR POSITI...

Page 237: ...que of mounting bolt 6 6 0 to 7 0 Nm 0 61 to 0 71 kgm Mounting position 7 166 mm NOTICE Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L become equal If the mirror and stay mounting bolts are tightened excessively the bracket may be damaged Be sure to tighten bolts to the specified torque OPERATION MACHINE OPERATIONS AND CONTROLS 3 161 ...

Page 238: ...d The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Adjust the mirror so that you can see a person at the rear right of the machine 1 Adjust the mirror with your hand so that the side of the ma chine is reflected in the mirror as shown in the figure 2 Check that you can see a person at the rear right of the machine 3 If you canno...

Page 239: ...evel ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped When returning the mirror to its regular position perform the following adjustment Adjust mirror 1 Tightening torque of mounting bolt 2 6 0 to 7 0 Nm 0 61 to 0 71 kgm Mounting position 3 120 mm Mounting angle 4 30 NOTICE Tighten the right and left bolts of each bracket...

Page 240: ... during the work make sure that the following conditions are met before starting the work The machine is placed on a firm level ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Adjust it so that people within 1 m around the machine can be seen from the operator s seat W 1 m MACHINE OPERATIONS AND CONTROLS OPERATION 3 164 ...

Page 241: ...ways adjust the camera before starting work If it is not adjusted properly you cannot secure the visibility and a serious personal injury or death may result When adjusting the angle of the camera prepare a scaffold first in order to provide a safe working plat form If you try to work standing on the counterweight there is a danger of serious injury or death due to falling off from the machine OPE...

Page 242: ... on the monitor is not aligned correctly adjust mounting angle A of the rearview camera in the following pro cedure Angle A can be adjusted within the range from 32 to 53 1 Insert a flat head screwdriver or the like into hole 3 of cover 2 and push inside tooth B to remove the cover 2 Remove bolts 4 2 places 3 Remove cover 1 MACHINE OPERATIONS AND CONTROLS OPERATION 3 166 ...

Page 243: ...ording to the record Take care of shim 6 since it comes off together with cover 1 4 Loosen camera mounting bolts 5 3 places and adjust camera mounting angle A so that corner D of mounting bracket C is aligned with horizontal line E 5 After adjusting tighten bolts 5 Tightening torque 11 8 to 14 7 Nm 1 2 to 1 5 kgm REMARK A part of the machine is shown on the monitor screen OPERATION MACHINE OPERATI...

Page 244: ...ear period It is not the start of the 3 year period of actual usage This seat belt has a retractable device so it is not necessary to adjust the length METHOD FOR FASTENING SEAT BELT 1 Hold grip 2 and pull out the belt from retractable device 1 2 Check that the belt is not twisted and then inset tongue 3 into buckle 4 securely 3 Pull the belt lightly to check that it is properly locked METHOD FOR ...

Page 245: ...on L 3 Check that all control levers and control pedals are at NEUTRAL position If the control levers and control pedals are released they return to NEUTRAL position 4 Insert the key into starting switch 2 and turn it to ON posi tion B DO NOT touch the left D or right E proportion al control slide switches otherwise the Neutral Detection System will recognise the wrong position as Neutral and this...

Page 246: ...rge level caution lamp 5 Engine oil pressure caution lamp 6 Engine oil level caution lamp 7 Air cleaner clogging caution lamp 8 Water separator caution lamp 9 If any caution lamp does not light up or the buzzer does not sound there is probably a failure in the caution lamp so ask your Komatsu distributor for repair 2 After approximately 2 seconds the screen changes to the working mode travel speed...

Page 247: ...that there are no persons or obstacles in the surrounding area then sound the horn and start the engine Never use starting aid fluids as they may cause explosions Exhaust gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Before starting the engine check that fuel control dial 2 is at Low idle MIN position If the fuel control dial is ...

Page 248: ... automatic preheating is performed Keep the key in starting switch 3 at ON position B until the pre heating pilot lamp goes out The time that the preheating pilot lamp stays lit depends on the ambient temperature as shown in the table Ambient temperature Lighting time 4 C to 20 C 5 seconds to 40 sec onds 20 C and below 40 seconds If a password has been set the input display screen will be indicate...

Page 249: ... engine immedi ately Check the oil level oil leakage etc and take proper measures REMARK White smoke may be discharged for a short time immedi ately after the engine is started or during the aftertreatment devices regeneration in the cold season but this is not a failure REMARK Urea SCR system has the function of heating and keeping itself warm to prevent freezing of DEF If DEF is frozen DEF syste...

Page 250: ... started When the turbo protect function is actuated the engine speed is held at approximately 1000 rpm or less regardless of the position of the fuel control dial When the turbo protect function is actuated the engine speed is held at approximately 1000 rpm or less even if the fuel control dial is operated When the turbo protect function is canceled the engine speed is set to the speed for the po...

Page 251: ...on the environment the method of performing the warm up operation may differ so perform the warm up operation according to the descriptions given in the appropriate section The hydraulic equipment is not warmed by simply performing engine warm up operation Perform the warm up operations for the hydraulic equipment and engine separately Warm up of the hydraulic equipment thoroughly ensures that the...

Page 252: ...on for 5 minutes after the engine is started Avoid operation with heavy loads or at high speeds Immediately after starting the engine avoid sudden starts sudden acceleration unnecessary sudden stops and sudden changes in direction of the machine METHOD FOR ENGINE WARM UP OPERATION NOTICE Do not accelerate the engine abruptly until it is warmed up Do not run the engine at low idle or high idle unde...

Page 253: ...lamp background C is white If the engine coolant temperature caution lamp displays the proper temperature the engine warm up operation is completed Then perform the warm up operation for the hydraulic components METHOD FOR CANCELLING AUTOMATIC WARM UP OPERATION If it becomes necessary in an emergency to cancel the auto matic warm up operation or to lower the engine speed to low idle do as follows ...

Page 254: ...s no person or obstacle in the surrounding area then sound the horn and start the operation Perform the warm up operation for the hydraulic equipment until the hydraulic oil temperature caution lamp displays the proper temperature When the hy draulic oil temperature is low the low temperature dis play shown in the figure is given Display A when temperature is proper Caution lamp background C is bl...

Page 255: ...re For detail see METHOD FOR ENGINE WARM UP OPERATION 3 176 2 Set swing lock switch 2 to ON position and check that the swing lock pilot lamp is lit 3 Set the working mode to P mode heavy duty operation mode The hydraulic component is warmed up quickly For the details of the working mode setting procedure see WORKING MODE SELECTOR SWITCH 3 45 4 Move lock lever 3 slowly to FREE position F then rais...

Page 256: ...draulic oil temperature caution lamp 7 displays proper temperature If the hydraulic oil temperature caution lamp is not displaying the proper temperature it is displaying low temperature repeat steps 6 to 7 until the monitor displays the proper temperature Display A when temperature is proper Caution lamp background C is blue Display B when temperature is low Caution lamp background C is white 9 C...

Page 257: ...ny problem is found contact your Komatsu distributor NOTICE In cold temperatures ambient temperature below 0 C even when the hydraulic oil temperature caution lamp displays the proper temperature perform the Hydraulic system warm up operation in cold weath er to warm up all the hydraulic equipment 12 Hydraulic system warm up operation in cold weather 1 Turn fuel control dial 4 to High idle MAX pos...

Page 258: ...following operation 3 to 5 times Circulate warm hydraulic oil through all control circuits Boom operation RAISE E LOWER F Arm operation IN B OUT A Bucket operation CURL D DUMP C Swing operation LEFT G RIGHT H When performing swing operations release swing lock switch 2 check that the swing lock pilot lamp is OFF then operate the swing Travel Lo operation FORWARD A REVERSE B For attachment operatio...

Page 259: ...temperature the hydraulic equipment warm up operation is completed After checking that the hydraulic oil temperature caution lamp displays the proper temperature perform the op eration after completion of the warm up operation METHOD FOR OPERATION AFTER COMPLETION OF WARM UP OPERATION 1 Check that hydraulic oil temperature caution lamp displays proper temperature Display A when temperature is prop...

Page 260: ...ting operations B mode For breaker operations ATT P mode For operations of 2 way attachments like crusher ATT E mode For operations of 2 way attachments like crusher fuel economy conscious operations METHOD FOR STOPPING ENGINE k k WARNING Keep away from the exhaust pipe immediately after stopping the engine MACHINE OPERATIONS AND CONTROLS OPERATION 3 184 ...

Page 261: ...during the aftertreatment devices regeneration the components may be damaged When stopping the engine stop the aftertreatment devices regeneration first and run the engine at low idle for ap proximately 5 minutes Then stop the engine Stop the engine according to the following procedure 1 Operate the control grip g of the lock lever to set it se curely to LOCK position L 2 Run the engine at low idl...

Page 262: ...devices are operating to purge After the purge is completed the devices stop automatically METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND STOPPING MACHINE k k WARNING Before operating the travel levers or travel pedals check the direction of the track frame If the track frame is facing the rear if the sprocket is at the front the machine moves in the opposite direction to the direction...

Page 263: ...fficult to travel safely raise the work equipment further 2 Operate right and left travel levers 5 or right and left trav el pedals 6 as follows 3 Check the position of the sprocket When sprocket A is at the rear of the machine Start the machine either by pushing levers 5 forward slowly or by depressing the front parts of pedals 6 slowly When sprocket A is at the front of the machine Start the mac...

Page 264: ...s follows 3 Check the position of the sprocket When sprocket A is at the rear of the machine Start the machine either by pulling levers 5 backward slowly or by depressing the rear parts of pedals 6 slowly When sprocket A is at the front of the machine Start the machine either by pushing levers 5 forward slowly or by depressing the front parts of pedals 6 slowly 4 When travelling check that the ala...

Page 265: ...he sprocket When the sprocket is at the front the directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine Use the travel levers to change direction Avoid sudden changes of direction to travel as much as possible Especially when performing counter rotation turn spin turn stop the machine before turning Operate 2 travel levers 1 as...

Page 266: ...ION OF MACHINE When turning LEFT during straight travel A Forward left turn Return the left travel lever from FORWARD to NEUTRAL position The machine turns forward LEFT B Reverse left turn Return the left travel lever from REVERSE to NEUTRAL position The machine turns in reverse LEFT REMARK When turning to the forward RIGHT return the right travel lever from FORWARD to NEUTRAL position When turnin...

Page 267: ...R SWINGING MACHINE k k WARNING The tail of the machine extends outside the tracks Check that there is no one around the machine before operating the swing If the travel levers are operated when the engine speed is decreased by the auto deceleration function the en gine speed will suddenly increase Operate the levers carefully When swinging the upper structure do as follows 1 Before swinging turn s...

Page 268: ...ecreased by the auto deceleration function the en gine speed will suddenly increase Operate the levers carefully Use the R H and L H work equipment control levers to operate the work equipment When the levers are released they return to NEUTRAL position and the work equipment is held in that position Arm control Move the L H work equipment control lever back and forth You can operate the arm Swing...

Page 269: ...be used for releasing the remaining pressure in the hydraulic cylinder circuits or for lowering the boom after loading the machine onto a trailer HANDLE WORKING MODE METHOD FOR SELECTING WORKING MODE Use working mode selector switch 1 to select the working mode that matches the operating conditions or purpose This will make it possible to perform operations efficiently Use the following procedure ...

Page 270: ...owing procedure 1 Press working mode selector switch 1 The screen changes to the working mode selection screen 2 Press working mode selector switch 1 or function switch F3 or F4 to select the appropriate mode 3 After selecting the desired mode press function switch F6 to accept the change The screen returns to the standard screen If function switch F5 is pressed the screen returns to the standard ...

Page 271: ...e operating power increases as long as the switch is press ed REMARK However the increased power is automatically stopped after 8 5 seconds This function is not actuated when the working mode is set to L mode or B mode PROHIBITED OPERATIONS k k WARNING Do not operate the work equipment control lever when the machine is traveling If any lever is operated when the auto deceleration is being actuated...

Page 272: ...y extended PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging nor use the dropping force of the bucket as a mattock breaker or pile driver This will drastically reduce the life of the machine PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig This can apply an excessive force ...

Page 273: ... large vibration occurs in the machine and can crack the work equipment or frame If the bucket blade slides and collides with a rock an excessive impact load occurs in the work equipment and frame and can shorten the service life of the machine PROHIBITION OF DIGGING OPERATION ON HARD ROCKY GROUND Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavat...

Page 274: ...d damage the undercover and frame In the worst case the hydraulic components are dam aged and a serious accident can result During operation keep checking the track top for crushed stones soil and sand PROHIBITION OF SUDDEN LEVER OR PEDAL SHIFT DURING HIGH SPEED TRAVEL 1 Do not operate the levers and pedals suddenly nor take any other action to move the machine quickly 2 Do not operate the levers ...

Page 275: ...t may break the undercarriage parts When driving the machine for a long time check the track ten sion every 1 5 hours and adjust any looseness For the adjustment see MAINTENANCE METHOD FOR CHECKING AND ADJUSTING TRACK TENSION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELLING Travelling over boulders tree stumps or other obstacles will cause a big shock to the chassis and in particular to the un...

Page 276: ...ar of the upper structure will go under water and water will be thrown up by the cooling fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in water or soil or sand deeper than the center of upper carrier roller 1 After the job be sure to supply grease to the parts which have been under water for a long time until the used grease...

Page 277: ...y Always operate or travel in such a way that it is possi ble to stop safely at any time if the machine slips or becomes unstable When travelling uphill if the shoes slip or it is impos sible to travel uphill using only the force of the tracks do not use the pulling force of the arm to help the ma chine travel uphill There is danger that the machine may tip over Accordingly don t travel uphill wit...

Page 278: ...hen start the engine again Pay attention to DEF level Before working on a slope or travelling on a rough ground check DEF tank and add sufficient amount of DEF as necessary If the remaining DEF level becomes low sudden drop of its level or abnormality in urea SCR system may be detected If DEF level caution lamp or DEF system caution lamp lights up in red move the machine to a level place immediate...

Page 279: ...set the travel lever to FORWARD position to drive the machine out RECOMMENDED APPLICATIONS In addition to the following it is possible to further increase the range of applications by using various attach ments DIGGING WORK BACKHOE WORK It is suitable for excavating areas that are lower than the machine When the condition of the machine is as shown in the figure angle between bucket cylinder and l...

Page 280: ...ace easily visi ble to the operator Loading is easier and capacity greater if you begin from the rear of the dump truck body than if loading is done from the side EFFECTIVE USE OF HYDRAULIC EXCAVATOR Operation for reducing fuel consumption Carbon dioxide emissions reducing operation The operating methods for reducing fuel consumption are as follows Avoiding unnecessary engine idle running Avoiding...

Page 281: ...es Stop the machine on a firm and flat surface and do the work When performing joint work appoint a leader and follow that person s instructions and signals METHOD FOR CHANGING BUCKET Replace the bucket according to the following procedure 1 Lower the bucket to the flat surface of the ground NOTICE After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at bot...

Page 282: ...f pin and cause abnormal wear of the pin METHOD FOR INVERTING BUCKET Invert the bucket according to the following procedure 1 Lower the bucket to the flat ground REMARK When removing the pins place the bucket so that it is in light contact with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to re move the pins NOTICE After remov...

Page 283: ...l the next use 6 Install the stopper bolts and nuts for each pin then grease the pins REMARK Lubricate with grease thoroughly until the grease comes out from the end faces When replacing the bucket replace the dust seal with a new one if it is damaged If a damaged one is used without being replaced sand and dirt may enter the part of pin and cause abnormal wear of the pin OPERATION MACHINE OPERATI...

Page 284: ...ndard machines METHOD FOR PARKING MACHINE k k WARNING Avoid a sudden stop Stop the machine gradually Place the machine on a firm and level place Do not park the machine on a slope If it is unavoidably necessary to park the machine on a slope block the tracks from movement As an addi tional safety measure thrust the work equipment into the ground If the control lever is touched by accident the mach...

Page 285: ...MIN position and lower the engine speed 3 Make the undercarriage and upper structure point to the same direction and lower the bucket to the ground with its bottom face horizontal 4 Operate the control grip g of the lock lever 3 to set it se curely to LOCK position L OPERATION MACHINE OPERATIONS AND CONTROLS 3 209 ...

Page 286: ...ing 1 Walk around the machine and check the work equipment machine exterior and undercarriage also check for any leakage of oil or coolant If any problems are found repair them 2 Fill the fuel tank 3 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove mud etc from the undercarriage if any LOCK Lock position Always lock the following plac...

Page 287: ... key to CLOSE position B then remove the key METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pulling the cover handle Position A OPEN Position B LOCK METHOD FOR LOCKING COVER WITH LOCK 1 Close the cover and insert the key into the key slot 2 Turn the starting switch key to CLO...

Page 288: ...cause of its weight If the engine hood is not locked it may close suddenly because of wind etc Immediately after the engine is stopped the engine hood and aftertreatment devices are still hot Accordingly wait until they have cooled down before opening or closing the engine hood METHOD FOR OPENING ENGINE HOOD 1 Stop the machine on a level ground lower the work equipment to the ground then stop the ...

Page 289: ...LOCKING ENGINE HOOD 1 Hold knob 5 and support the engine hood 2 Push stay 6 in the direction of the arrow and remove stay 6 from LOCK position 7 3 Check that stay 6 is set in guide groove 8 and then lower the engine hood k k CAUTION Do not lower the engine hood forcibly while stay 6 is not set in guide groove 8 If you do so stay 6 may be deformed Do not release knob 5 until the engine hood is low ...

Page 290: ...ng it do not release the handle until the stay is set in the lock position securely When closing it hold the handle securely since the DEF tank filler cap cover may move down be cause of its own weight If it is not locked it may close suddenly because of wind etc METHOD FOR OPENING DEF TANK FILLER CAP COVER 1 Insert the key into the key slot 2 Turn the key counterclockwise and remove it Position A...

Page 291: ...ower the cover 3 Turn the key clockwise to lock and remove it Position A OPEN Position B CLOSE LOCK METHOD FOR OPENING AND CLOSING CAB DOOR When opening the door locked door 1 Insert the key into the key slot 2 Turn the key clockwise to unlock the key then open the door handle Position A OPEN OPERATION MACHINE OPERATIONS AND CONTROLS 3 215 ...

Page 292: ...n B CLOSE LOCK When locking the door 1 Close the door and insert the key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key MACHINE OPERATIONS AND CONTROLS OPERATION 3 216 ...

Page 293: ...ab is low the air conditioner may not work In this case circulate recirculation air to warm the inside of the cab After that turn the air conditioner switch ON the air conditioner will work If any abnormality is detected in any equipment or sensor used on the air conditioner the air conditioner system caution lamp lights up on the monitor screen If the air conditioner system caution lamp lights up...

Page 294: ...s used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH You can adjust the air flow by using the fan switch The air flow can be adjusted to 6 levels Press the switch to increase the air flow press the switch to decrease the air flow During auto operation the air flow is automati...

Page 295: ... 5 C Monitor display and function Monitor display C Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to set temperature 32 0 Max heating REMARK If the mode is set to auto mode and the temperature setting is set to 18 0 C or 32 0 C the air flow from the fan is always set to HIGH and does not change even when the temperature reaches the set value VENT SELECTOR SWITCH The ...

Page 296: ... mode AUTO SWITCH Use the auto switch for automatic selection of the air flow vents and air source FRESH RECIRC according to the set temperature Press this switch then use temperature control switch 1 to set the temperature and run the air conditioner under automatic control When switching from automatic operation to manual oper ation it is possible to use the switches to select the vents and air ...

Page 297: ...setting to take in fresh air or to demist the window glass DISPLAY MONITOR This monitor display indicates the status of temperature setting a air flow rate b and vents c When OFF switch 1 is pressed the display of temperature setting a and air flow rate b go out and operation stops AIR CONDITIONER SWITCH Use air conditioner switch for turning the air conditioner cool ing dry heating ON or OFF Pres...

Page 298: ...e the cab caused by changes in the strength of the sun s rays beforehand and automatically adjusts the temperature METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of operation as desired METHOD FOR AUTOMATIC OPERATION 1 Turn auto switch 1 ON Set temperature a and air flow b are displayed HANDLE AIR CONDITIONER OPERATION 3 222 ...

Page 299: ...o the set temperature and the air conditioner is operated auto matically to provide the set temperature REMARK When vent monitor c displays d or e and engine coolant temperature is low the air flow is automatically limited to pre vent cold air from blowing out METHOD FOR STOPPING AUTOMATIC OPERATION Press OFF switch 1 The air conditioner stops OPERATION HANDLE AIR CONDITIONER 3 223 ...

Page 300: ...adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Turn air conditioner switch 2 ON 3 Use temperature control switch 3 to set to the desired temperature HANDLE AIR CONDITIONER OPERATION 3 224 ...

Page 301: ...e monitor changes according to the selection 5 Press FRESH RECIRC air selector switch 5 and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH METHOD FOR STOPPING MANUAL OPERATION Press OFF switch 1 The air conditioner stops OPERATION HANDLE AIR CONDITIONER 3 225 ...

Page 302: ...ir blow ing to the feet set as follows 1 Press fan switch 1 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch 2 and set the vent display on the monitor to the display shown in the figure HANDLE AIR CONDITIONER OPERATION 3 226 ...

Page 303: ...3 Turn on the air conditioner switch 3 4 Adjust fan switch 1 temperature control switch 4 and FRESH RECIRC selector switch 5 to the desired posi tions OPERATION HANDLE AIR CONDITIONER 3 227 ...

Page 304: ... and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch 2 and set vent display on the monitor to f or g as shown in drawing HANDLE AIR CONDITIONER OPERATION 3 228 ...

Page 305: ...2 0 of maximum heating 5 Adjust vents A B1 and B2 so that the air blows onto the window glass Vents C and D are fixed and cannot be adjusted 6 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air turn on the air conditioner switch 5 OPERATION HANDLE AIR CONDITIONER 3 229 ...

Page 306: ... button 5 Preset button 6 Display selector button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX on it Press the button again to turn the power off BAND AUX SELECTOR BUTTON Press band AUX selector button to select the desired band or AUX Each time the button...

Page 307: ...t will be canceled For the sound adjusting method see METHOD FOR CONTROLLING RADIO 3 232 DISPLAY A Band name AUX frequency clock and other character numeric information are displayed B Frequencies are displayed at steps of 50 kHz in certain areas C Lights up when a stereo broadcasting is heard while a FM station is selected D Lights up at the time of balance adjustment in the sound adjusting condi...

Page 308: ...djust the fre quency Press the button and the frequency increases press the button and the frequency decreases Hold down the button and the frequency increases continuously hold down the button and the fre quency decreases continuously Hold down the button and release it then the fre quency increases continuously Hold down the but ton and release it them the frequency decreases continuously as an ...

Page 309: ...While a frequency is displayed press button 1 of preset button 2 and the preset number P 1 appears on the display The preset number is shown for 0 5 seconds and then the frequency is displayed METHOD FOR REGISTERING PRESET Hold down one of 1 to 6 of preset button 1 while listening to the radio The currently received frequency is registered to the preset number corresponding to the pressed button E...

Page 310: ...W REGISTER RANGE BASS 1 Press sound control button 1 to light up BAS on the dis play You can adjust the low register range bass of the sound 2 Press tuning time adjustment button 2 to adjust the low register range bass Press the button and the low register range bass level increases by 1 Maximum 7 Press the button and the low register range bass level decreases by 1 Minimum 7 METHOD FOR ADJUSTING ...

Page 311: ...of antenna 1 and stow the antenna 1 to the bottom part 2 After stowing the antenna 1 tighten the bolt 2 to fix it SPACE FOR RADIO CASSETTE The radio cassette is not factory fitted If fitment is required 1 Remove front cover 1 2 Connect speakers and aerial to radio cassette Please contact your Komatsu distributor for a fitting instruction REMARK If radio is fitted in this location do not operate ra...

Page 312: ... that the weight and dimension given in SPECIFICATIONS weight and dimension may differ accord ing to the type of track shoe or arm or other attachments Consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard installed for the operator s cab Consult your Komatsu distributor for handling of the handrails when transporting the machine TRANSPORTA...

Page 313: ...he work equipment for loading and unloading operations Always use ramps The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer and it is dangerous that the machine loses its balance Accordingly pass this point slowly If it is necessary to swing the upper structure on the trailer platform the footing is unstable so be extreme ly careful that the machine ...

Page 314: ...mps to prevent them from bending 4 Push travel speed selector switch 5 to set the travel speed to low Lo lights up The travel speed Lo Mi Hi is displayed on travel speed display 6 5 Turn auto deceleration switch 7 OFF and operate the fuel control dial to set the engine to low speed Each time auto deceleration switch 7 is pressed it switches OFF to ON to OFF in turn When auto deceleration switch 7 ...

Page 315: ... the trailer 9 Set the travel direction toward the ramps and drive slowly Lower the work equipment as far as possible without caus ing interference On the ramps operate only the travel lever Do not operate any other lever 10 When loading a machine with the work equipment instal led at the point where the tracks are on both the ramps and the ground surface turn the swing lock switch OFF 11 Swing th...

Page 316: ...see STOW ANTENNA 3 235 For stowing mirror see PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR A 3 160 To prevent damage to the bucket cylinder during transportation put a wooden block under the tip of the bucket link to prevent the bucket cylinder from touching the floor Check that the engine hood catcher is locked Hold the handle of the engine hood and raise it slight ly If it does not open the...

Page 317: ...able doors covers and caps Select the way of secure the machine according to the transportation form of each territory from the following METHOD FOR SECURING MACHINE WITH TIE DOWN POINT Tie one end of each chain or wire rope of appropriate strength to the tie down holes 1 on the track frame X 50 to100 mm Keep the chains off the track frame OPERATION TRANSPORTATION 3 241 ...

Page 318: ...ETHOD FOR REMOVING AND INSTALLING MIRROR If they are to be removed for shipment or are to be installed again perform the following procedure After installation of mirror always adjust it For details see METHOD FOR ADJUSTING MIRRORS 3 159 METHOD FOR REMOVING MIRROR Mirrors A B 1 Loosen mounting bolt 2 then remove mirror 1 from sup port 3 2 Loosen bolt 4 and remove support 3 and clamp 5 from the han...

Page 319: ...e inspection and maintenance Use the crane etc for carrying the handrails There is a danger of rolling over or falling from high place that can lead to serious personal injury or death Check the scaffolding and ensure your safety before starting the work If installation or removal work of the handrail is improper there is a hazard that someone may fall from the machine during the installation or r...

Page 320: ...Install handrail B and cover 4 then tighten them with bolts 3 3 Install handrail A and cover 2 then tighten them with bolts 1 Tightening torque 98 to 123 Nm 10 0 to 12 5 kgm METHOD FOR REMOVING AND INSTALLING CLIMBING HANDLE When removing and installing handle A for transportation of the machine etc perform the operation according to the fol lowing procedure METHOD FOR REMOVING CLIMBING HANDLE Rem...

Page 321: ...llowing procedure 1 Remove connector A of the revolving lamp When removing the connector pull it out while pressing the claw in the center of the connector 2 Place the connector for wiring B in a clean vinyl bag or the like to protect it from water etc during transportation and fix it to the operator s cab with sealing tape or the like 3 Tilt down lock D of revolving lamp bracket C OPERATION TRANS...

Page 322: ...m the claw of base bracket E k k CAUTION When removing and installing the revolving lamp be sure to hold grip G instead of lamp itself to prevent damage 7 Remove revolving lamp bracket C from fixing claw F of base bracket E METHOD FOR INSTALLING REVOLVING LAMP 1 Hold grip G and turn it counterclockwise seeing it from the rear of the machine TRANSPORTATION OPERATION 3 246 ...

Page 323: ...e bracket E 3 Raise the lever of lock D REMARK If the reaction force of lock D is large try it again by shift ing bracket C 4 Insert connector A Securely insert the connector until it clicks PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm level ground Maintain a safe distance from the road shoulder OPERATION TRANSPORTATION 3 247 ...

Page 324: ...e engine up fully in cold weather 6 Set the lock lever to FREE position F 7 Push travel speed selector switch 5 to set the travel speed to low Lo lights up The travel speed Lo Mi Hi is displayed on travel speed display 6 8 Turn auto deceleration switch 7 OFF and operate the fuel control dial to set the engine to low speed Each time auto deceleration switch 7 is pressed it switches OFF to ON to OFF...

Page 325: ... losing its balance NOTICE This method of lifting applies to the standard specification machine The method of lifting differs depending on the attachments and options installed For details of the procedure for machines other than the standard specification machine consult your Komatsu distributor For the weight see SPECIFICATIONS 5 1 When lifting the machine perform the operation on flat ground as...

Page 326: ...rollers pass the wire ropes under the tracks When the wire rope contacts with the edge of the machine put wooden block or backing metal between them 8 Set the lifting angle A of the wire rope to 30 to 40 then sling the machine slowly 9 After the machine comes off the ground check the hook condition and the lifting posture and then sling the ma chine upward slowly TRANSPORTATION OPERATION 3 250 ...

Page 327: ...TICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break the devices in the tank The parts inside the tank may be affected Add DEF to the specified amount for cold weather below the level of when DEF may freeze For the specified amount of DEF see METHOD FOR CHECKING DEF LEVEL ADDING DEF 3 152 If DEF or the machine equipped with DEF system cannot be stored at the outside temperatu...

Page 328: ...d by mud dirt or drops of water on the rod from getting inside the seal Place the machine on a firm dry ground If this is impossible park the machine on boards The boards prevent the tracks from freezing to the ground and allow the machine to move the next morn ing Open the drain valve and drain any water collected in the fuel system to prevent it from freezing Fill up the fuel tank This minimizes...

Page 329: ...ied viscosity For details see RECOM MENDED FUEL COOLANT AND LUBRICANT 7 5 If the machine is parked for long time in the cold weather condition quality of DEF may be affected by repeated freeze ask your Komatsu distributor to inspect OPERATION COLD WEATHER OPERATION 3 253 ...

Page 330: ... set the stop valve to the LOCK position Install the blind plugs to the elbows For explanation of LOCK and FREE states of the stop valve see METHOD FOR REMOVING AND IN STALLING ATTACHMENT 6 44 To prevent rust fill the cooling circuit with Non Amine Engine Coolant AF NAC to give a density of at least 30 for the engine coolant MAINTENANCE DURING LONG TERM STORAGE k k WARNING If it is necessary to pe...

Page 331: ... according to the procedure in METHOD FOR ENGINE WARM UP OPERATION 3 176 If the machine has been stored for more than 2 months perform the following procedure Before starting the engine replace DEF filter and fill up DEF tank according to the procedure in METHOD FOR REPLACING DEF FILTER 4 73 Start the engine and check correctly If SCR system has any abnormality warning is displayed on the monitor ...

Page 332: ...dangerous Bleed air according to the following procedure 1 Fill the fuel tank until full to FULL mark on the fuel gauge with fuel 2 Insert the key into the starting switch 3 Turn the starting switch key to ON position B The fuel feed pump operates 4 Hold the starting switch key at ON position B for 60 sec onds and then return it to OFF position A and hold it there for 10 seconds 5 Repeat above ste...

Page 333: ...s before trying again Perform this operation a maximum of 4 times PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures When the arm is operated IN from a high position for dig ging under no load the arm speed drops momentarily at the vertical position When performing bucket CURL operation from a high posi tion for digging under no load the bucket speed drops mo mentar...

Page 334: ...e towed machine Move the machine slowly and be careful not to apply any sudden load to the wire rope Do not use the holes for towing light objects or tie down holes when towing the machine NOTICE The maximum towing capacity for this machine is 16800 N 17100 kg Do not tow any load greater than this If the machine sinks in mud and cannot get out under its own power or if the machine tows a heavy obj...

Page 335: ...not to apply any sudden load to the wire rope Do not use the tie down holes for towing the machine There is a hole in the track frame to fit the shackle when towing light objects Permissible towing load Max 108000 N 11000 kg PRECAUTIONS FOR SEVERE JOB CONDITION When performing digging operations in water if the work equipment mounting pin goes into the water per form greasing every time the operat...

Page 336: ...ling batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the ground normally the negative terminal When installing first connect the cable to the positive terminal If a tool touches the positive terminal and the chassis it is dangerous that it may cause a spark Be extremely careful If the terminals are loose it is dangerous that ...

Page 337: ...ative charger clip of the charger to the nega tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or the battery cells will dry up and this may cause the battery to catch...

Page 338: ... a 24 V battery The sizes of the jumper cables and clips should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected Check that the lock levers and parking brake levers if equipped of both machine are in LOCK posi tion Che...

Page 339: ...ct the jumper cables in the reverse of the order in which they were con nected 1 Remove the clip of jumper cable B from the revolving frame E of the failed machine 2 Remove the clip of jumper cable B from the negative terminal of battery D on the normal machine 3 Remove the clip of jumper cable A from the positive terminal of battery D on the normal machine 4 Remove the clip of jumper cable A from...

Page 340: ...ot light up Defective wiring Check repair Defective heater relay Replace Defective monitor Replace Oil pressure caution lamp does not light up when engine is stopped starting switch is at ON position Defective monitor Replace Defective oil pressure caution switch Replace When startability at low temperature is poor if you touch the outside of the electric heater by hand after pre heating it is not...

Page 341: ...switch to ON position temporarily PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS For the remedies indicated with in the remedy column always contact your Komatsu distributor In cases of problems or causes which are not listed below ask your Komatsu distributor for repairs Problem Main causes Remedy Engine oil pressure caution lamp lights up Lowered oil level in engine oil pan sucking in air Set it...

Page 342: ...VERY 500 HOURS MAINTENANCE Defective thermostat Replace thermostat Loosened radiator filler cap in high altitude operation Tighten cap or replace packing Defective coolant level sensor Replace sensor Defective monitor Replace monitor Starting motor turns but engine does not start Lack of fuel Add fuel See CHECKS BEFORE STARTING Air in fuel system Repair place where air is sucked in See EVERY 500 H...

Page 343: ... 91 After that immediately ask your Komatsu distributor for in spection and repair When the machine has not run out of fuel if CA2249 or CA559 appears on the current abnormality screen re place both fuel main filter and fuel prefilter immediately For details of replacement see METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 4 49 and METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE 4 61 If CA2249 or C...

Page 344: ......

Page 345: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 346: ...o not remove the strainer while adding DEF WELDING INSTRUCTIONS When performing welding turn the starting switch to OFF position check that the system operating lamp is not lit Turn the battery disconnect switch to OFF position and remove the key Do not apply a voltage higher than 200 V continuously Connect grounding cable within 1 m of the area to be welded If grounding cable is connected near in...

Page 347: ...YDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with new parts When doing this be careful not to forget to assemble O rings and gaskets When installing the hoses do not twist them or bend them sharply If they are installed so their service life will be extremely shortened and they may be damaged CHECKS AFTER INSPEC...

Page 348: ...n closing the engine hood after inspection or maintenance make sure that the catch is securely locked If the engine hood catch is not locked there is a danger that the engine hood may open PRECAUTIONS FOR MAINTENANCE MAINTENANCE 4 4 ...

Page 349: ...dy always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures 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 Never mix oils of different grades or brands Always add the specified amount of oil Having too much oil or too little oil a...

Page 350: ...lant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu recommends the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious problems such as corrosion of the engine and aluminum parts of the cooling system When using antifreeze always observe the preca...

Page 351: ...under heavy duty conditions Komatsu recommends using the recom mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual Grease fittings not included in the periodic maintenance section are the grease fittings for overhaul so they do not need grease If any part becomes stiff after being used for long time add grease Alway...

Page 352: ...o protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first STORE DEF Completely seal up its container for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container Make sure that transfer equip ment and tank must meet DEF compatible ...

Page 353: ...ke It is dangerous that causes an electric shock For the operation of the battery disconnect switch see BATTERY DISCONNECT SWITCH 3 111 It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is damaged This will cause an electrical leakage and may lead to malfunction of the machine Do not wash the inside of the operator s cab with water When washing the mac...

Page 354: ...s the part that is removed Thread diame ter of bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 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 3 90 0 235 285 320 400 455 565 610 765 ...

Page 355: ...arget value Allowable range Nm kgm Nm kgm 02 19 44 4 5 35 to 54 3 5 to 5 5 03 22 74 7 5 54 to 93 5 5 to 9 5 04 27 103 10 5 84 to 132 8 5 to 13 5 05 32 157 16 0 128 to 186 13 0 to 19 0 06 36 216 22 0 177 to 245 18 0 to 25 0 10 41 215 22 0 176 to 234 18 0 to 24 0 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4 11 ...

Page 356: ... METHOD FOR CHECKING GAS SPRING 4 37 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 4 38 CHECK AUTOMATIC GREASE SYSTEM 4 40 PERIODIC CHECKS 4 40 REFILLING GREASE 4 40 GREASING PROCEDURE 4 40 SYSTEM TEST 4 41 CHECKS BEFORE STARTING 4 42 EVERY 50 HOURS MAINTENANCE 4 42 4 42 METHOD FOR LUBRICATING WORK EQUIPMENT 4 42 EVERY 250 HOURS MAINTENANCE 4 43 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 4 43 ...

Page 357: ...ILTER 4 73 EVERY 4000 HOURS MAINTENANCE 4 75 REPLACE DEFINED LIFE PARTS 4 75 METHOD FOR CHECKING WATER PUMP 4 76 METHOD FOR CHECKING VIBRATION DAMPER 4 76 METHOD FOR CHECKING STARTING MOTOR 4 76 METHOD FOR REPLACING ACCUMULATOR FOR CONTROL CIRCUIT 4 77 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 78 EVERY 4500 HOURS MAINTENANCE 4 78 METHOD FOR CLEANING KDPF 4 78 ...

Page 358: ...AKER 6 54 Replace pilot filter element if equipped Use a guideline of 250 hours for use of the breaker operating ratio of the breaker 50 or more and replace the element ac cording to the table For detail see METHOD FOR REPLACING ADDITIONAL PI LOT FILTER ELEMENT FOR BREAKER 6 55 X Breaker operating ratio Y Replacement interval H A Hydraulic tank element pilot filter element B Hydraulic oil C Elemen...

Page 359: ...able to display its performance fully and the cleaning efficiency will also go down In addition during the cleaning operation more dirt stuck to the element will fall inside the inner element If any dirt enters the engine it can damage the engine Be sure to stop the engine before checking cleaning or servicing the air cleaner Do not check clean or service the air cleaner when strong wind is blowin...

Page 360: ...ent dirt or dust from entering 5 Clean dusts in inside and on cover 3 of air cleaner body 7 by using a clean cloth or brush 6 If any dust is attached to vacuator valve 4 installed to cover 3 remove it 7 When the outer element has been cleaned 6 times or used for 1 year replace it When the element needs to be replaced Replace the inner and outer elements with new ones For details see METHOD FOR REP...

Page 361: ... cleaner element face where no hole is drilled B C comes to cover 3 end If it is installed in wrong direc tion it may cause breakage of the air cleaner element or serious damage to the engine When inserting the element into the body if the rubber at the tip is swollen or the outer element is not pushed in straight and cover 3 is installed by force with hook 2 there is a danger that the hook and ai...

Page 362: ...or panel If it light up just after cleaning of the elements has been finished replace the inner and outer elements METHOD FOR CHANGING AIR CLEANER ELEMENT Replace the outer element in the following procedure 1 Open the door at the rear right side of the machine re move hooks 2 3 places and remove cover 3 2 Hold the outer element 5 rock it lightly up and down and to the right and left and pull the ...

Page 363: ...eads to damage of the engine Do not use such improper part 6 Remove inner element 6 then quickly install the new inner element Install the inner element securely so that it does not move 7 Push new outer element 5 in straight with your hand into the air cleaner body Hold the element and rock it lightly up and down and to the right and left while pushing it in the element can be inserted easily 8 I...

Page 364: ... inside of cooling system and re placement of coolant Non Amine Engine Coolant AF NAC Every 2 years or 4000 hours whichever comes sooner The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of coolant is essential Komatsu machines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Cool...

Page 365: ...Amine Engine Coolant AF NAC is already diluted with distilled water so it is not flammable Check the density with a coolant tester Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant Clean the inside of the cooling system according to the following procedure 1 Place the machine on a level ground then stop the engine 2 Open engine hood 1 3 Check t...

Page 366: ...CHECKS BEFORE STARTING ENGINE 3 169 and METHOD FOR START ING ENGINE 3 171 10 Set the swing lock switch to ON position a and check that the swing lock pilot lamp is lit 11 To complete the warm up operation of the hydraulic equipment more quickly set the working mode to P mode heavy duty mode For the details of the working mode setting procedure see METHOD FOR SELECTING WORKING MODE 3 193 12 Move th...

Page 367: ...he end of its travel and hold it in position for 30 seconds 3 Move the L H work equipment control lever slowly in the direction to the arm IN side B Operate the lever to the end of its travel and hold it in position for 30 seconds 4 Move the L H work equipment control lever slowly in the direction to the arm OUT side A Operate the lever to the end of its travel and hold it in position for 30 secon...

Page 368: ...struction for the de tergent liquid 18 Close drain valve 4 19 Install cover 3 20 Add Non Amine Engine Coolant through the coolant filler port up to the mouth of the port For details of the coolant density see coolant density ta ble 21 Run the engine at low idle for 5 minutes to remove the air from the coolant then run at high idle for a further 5 minutes Keep radiator cap 2 removed during the abov...

Page 369: ...ng tighten a further 120 10 METHOD FOR CHECKING AND ADJUSTING TRACK TENSION 1 Run the engine at low idle then move the machine forward for a distance equal to the track length on ground and slowly stop the machine 2 Place straight wooden square bar 3 which reaches from idler 1 to carrier roller 2 on the track 3 Measure the maximum deflection a between the bottom surface of the wooden bar and top s...

Page 370: ... If it is loosened more than 1 turn there is a danger of plug 1 flying out under the high internal pressure of the grease Never loosen any part other than plug 1 Never put your face in the mounting direction of plug 1 1 Loosen plug 1 gradually to release the grease 2 If the grease does not come out smoothly move the machine forward and backward a short distance 3 Tighten plug 1 4 To check if the t...

Page 371: ...e bucket and make the bottom of the bucket horizontal 2 Check that the work equipment is in a stable condition then operate the control grip g of the lock lever to set it to LOCK position L 3 Use a hammer and drift to knock out lock pin 2 If the drift is set against rubber pin lock 3 when it is hit the rubber pin lock may break Set it against the back of the pin 4 After removing lock pin 2 and rub...

Page 372: ... to it or if there are protrusions the teeth 1 will not enter adapter 4 properly and there will not be proper contact at the mating portion 9 Fit tooth 1 to adapter 4 and check that when tooth 1 is pressed strongly the rear face of the hole for the pin of teeth 1 is at the same level as the rear face of the hole for the pin of adapter 4 If the rear face of the pin hole of tooth 1 protrudes in fron...

Page 373: ...When replacing the tooth replace the rubber pin lock and lock pin with new parts at the same time This will prevent the tooth from falling out METHOD FOR REPLACING BUCKET TEETH HORIZONTAL PIN TYPE Replace the bucket teeth before the adapter starts to wear k k WARNING It is dangerous if the work equipment moves by mistake when the tooth is being replaced Set the work equipment in a stable condition...

Page 374: ...t with a hammer to install the tooth to the bucket METHOD FOR REPLACING BUCKET SIDE CUTTER AND SHROUD k k WARNING It is dangerous if the work equipment moves by mistake when replacing the side cutter and shroud of the bucket Set the work equipment in a stable condition and stop the engine Then set the lock lever securely to LOCK position L As the pin is driven out with strong force it is dangerous...

Page 375: ...his method ask your Komatsu distributor to have the replacement performed METHOD FOR ADJUSTING BUCKET CLEARANCE k k WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance Lower the work equipment to the ground set it in a stable condition stop the engine and set the lock lever securely to LOCK position L 1 Set the work equipment in the position shown in ...

Page 376: ...rt or dust get in when adding fluid Mixture ratio of pure washer fluid and water The proper mixing proportion varies with the ambient temperature Add washer fluid diluted with water at the following proportion Area season Mixing proportion Freezing temperature Normal Washer fluid 1 3 water 2 3 10 C Winter in cold district Washer fluid 1 2 water 1 2 20 C Winter in extremely cold district Pure washe...

Page 377: ...mage When required Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of the compressor CHECK LEVEL OF REFRIGERANT GAS k k WARNING If the refrigerant used in the air conditioner gets into your eyes or is splashed on your hands it may cause loss of sight or frostbite Never touch the refrigerant Do not loosen any part of the r...

Page 378: ...ecurely to LOCK position L before leaving the operator s seat Select a firm flat place for work When setting the machine at an angle use strong blocks to stabilize the base of the machine and be extremely care ful when performing the work METHOD FOR CLEANING WASHABLE FLOOR MAT 1 Stop the machine on a level ground lower the bucket to the ground stop the engine and then perform the cleaning 2 When w...

Page 379: ...le by using blocks 2 Swing the upper structure slowly so that water drain holes 3 in the cab floor are at a low position 3 Lower the work equipment to the ground and set the ma chine in a stable condition 4 Operate the control grip g of the lock lever 1 to set it se curely to LOCK position L and stop the engine MAINTENANCE MAINTENANCE PROCEDURE 4 35 ...

Page 380: ...ojections 2 into the holes METHOD FOR SETTING MACHINE AT ANGLE You can set the machine at an angle by using a slope or blocks Consider the condition of the machine and select the safe method METHOD FOR USING SLOPE k k WARNING Select a solid and smooth slope Always block the tracks from movement and thrust the work equipment into the ground 1 Stop the machine with the work equipment on the downhill...

Page 381: ...en doing this check that the machine is always stable METHOD FOR CHECKING GAS SPRING k k WARNING The gas spring is charged with high pressure nitrogen gas so improper handling may cause an explo sion resulting in serious personal injury or death When handling always observe the following Do not disassemble Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling ...

Page 382: ...than the level of the oil in the hydraulic tank 3 After completing the air bleed operation tighten air bleeder 1 and install the drain hose METHOD FOR STARTING ENGINE Start the engine according to OPERATION METHOD FOR STARTING ENGINE and run it at low idle for 10 minutes and then start the following work METHOD FOR BLEEDING AIR FROM CYLINDER NOTICE If the engine runs at high speed immediately afte...

Page 383: ...ght and left sides REMARK When rotating the track at idle rotate equally both forward and in reverse METHOD FOR BLEEDING AIR FROM ATTACHMENT WHEN ATTACHMENT IS EQUIPPED NOTICE If the method of air bleeding from the attachment is specified by the manufacturer bleed the air ac cording to the specified procedure After completing the air bleeding operation stop the engine and leave the machine for 5 m...

Page 384: ... high pressure wash directly on the pump 9 Replace or clean the pump filler filter behind the connector on the reservoir every 500 hours REFILLING GREASE If the yellow lamp 5 on the in cab display 2 illuminates the minimum grease level in the reservoir has been reached The grease reservoir must be refilled as soon as possible GREASING PROCEDURE 1 Remove the dust cap from the filler coupling 7 2 Ca...

Page 385: ...er cleaning the machine or to vent the system a continuous lubrication cycle run can be performed 1 Move the starter switch to the ON position B 2 Depress the test button 9 on the pump for more than six seconds The system will perform a continuous lubrication test During this run the green LED 4 of the selected interval on the in cab display 2 will flash 02 sec on 0 2 sec off 3 The continuous test...

Page 386: ...ng fuel level adding fuel Method for checking DEF level adding DEF Method for checking working lamp Method for checking horn EVERY 50 HOURS MAINTENANCE METHOD FOR LUBRICATING WORK EQUIPMENT NOTICE If any abnormal noise is generated from any greasing point perform greasing regardless of the greas ing interval Perform greasing every 10 hours for the first 50 hours operation on a new machine After th...

Page 387: ...not bring any open flame near the battery Battery electrolyte is dangerous object If it gets in your eyes or on your skin wash it off with a large amount of water and consult a doctor NOTICE Do not add the electrolyte to the battery exceeding UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts If there is a fear that the ba...

Page 388: ...TROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO CHECK FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery or there is no UPPER LEVEL line on the side of the battery check as follows 1 Remove cap 2 at the top of the battery and check the electrolyte level through electrolyte filler port 3 2 If the electrolyte does not reach the sleeve 4 always add the purifie...

Page 389: ...tween compressor pulley A and fan pulley B with a finger approximately 58 8 N 6 0 kg If deflection C is 13 to 15 mm the belt tension is normal If the deflection is out of the standard adjust it to the standard value METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 1 Loosen bolt 2 and nut 3 REMARK Loosening bolts 2 and 3 allows compressor 4 to move around the mounting position of bolt 2 2 Adjus...

Page 390: ...o the grease fit tings marked by arrows 2 places 3 After greasing wipe off any old grease that is pushed out EVERY 500 HOURS MAINTENANCE Maintenance for every 50 and 250 hours should be performed at the same time METHOD FOR LUBRICATING NOTICE If any unusual noise is generated from any greasing point perform greasing regardless of the greasing interval Perform greasing every 10 hours for the first ...

Page 391: ...p in grease through the grease fittings shown by arrows 1 Boom cylinder rod pin 2 places 2 Arm cylinder foot pin 1 place 3 Boom and arm connection pin 1 place 4 Arm cylinder rod end 1 place 5 Bucket cylinder foot pin 1 place 6 Boom cylinder foot pin 2 places 7 Boom foot pin 2 places 3 After greasing wipe off any old grease that is pushed out MAINTENANCE MAINTENANCE PROCEDURE 4 47 ...

Page 392: ...e not to get splashed with the drained oil 5 After draining the oil raise the lever to close the valve 6 Open the door on the rear right side of the machine 7 Turn filter cartridge 3 counterclockwise by using the filter wrench and remove it 8 Clean the filter holder fill the new filter cartridge with clean engine oil coat the thread and packing surface of the new filter cartridge with clean engine...

Page 393: ...il all of parts cool down before starting the work High pressure is generated inside the engine fuel piping system when the engine is running When replacing the filter wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter Do not bring any open flame close NOTICE Komatsu genuine fuel filter cartridges use a special filter that has hi...

Page 394: ...urn filter cartridge 4 counterclockwise by using the filter wrench and remove it 10 Install currently removed transparent cup 3 to the bottom of the new filter cartridge At this time be sure replace O ring 6 with a new one REMARK When installing the transparent cup thinly apply oil to the packing surface and screw the cup After it touch es the sealing surface of filter cartridge 4 tighten it 1 4 t...

Page 395: ... If the filter cartridge is fastened too much the packing will be damaged and this leads to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing Therefore be sure to observe the tight ening angle When tightening with a filter wrench be extremely careful not to dent or damage the filter 13 Check that drain valve 2 is closed securely 14 Remove the plastic bag wra...

Page 396: ...nd left and stop the machine 2 Remove bolts 1 2 pieces on the top of the revolving frame and remove cover 2 3 Insert ruler 3 into the grease through inspection and ad justment hole A Check that the height of grease S in the area where the pinion passes is at least 20 mm Add grease if the grease amount S is less than 20 mm 4 Check that the grease is not milky white Total amount of grease 33 ℓ 29 7 ...

Page 397: ...gh pressure water or steam there is a danger of personal injury Always wear protective equipment such as protective eyeglasses and dust mask NOTICE When using compressed air for cleaning blow it keeping some distance to avoid damaging the fins Damage on the fins can cause water leakage and overheating In a dusty job site check the fins every day regardless of the maintenance interval 1 Open engine...

Page 398: ...ernal fins of the heat exchange equipment may be deformed and this will cause early clogging and breakage of the equipment 6 Visually check the rubber hose connected to the heat ex change equipment Check the hose clamp for looseness as well If the rubber hose is cracked or become fragile ask your Komatsu distributor for replacement If the hose clamp is loose tighten it 7 Remove undercover 10 and b...

Page 399: ...he inspection window at the bottom rear left inside the operator s cab 2 Take out the recirculation air filter 3 Clean the filter with compressed air If there is oil on the filter or if the filter is extremely dirty wash it in a neutral detergent After rinsing it in water dry it thoroughly before using it again Replace the filter with a new one every year If the clog ging of the filter cannot be r...

Page 400: ...ning return filter 5 REMARK The fresh air filter must be installed facing it in the cor rect direction When installing insert long end L of filter 5 into duct 6 first If short end S is inserted first filter 5 will get stuck with protrusion B of the sheet metal Keep the filter away from protrusion B of the sheet metal and insert it from the top first If the insertion is not enough or the filter is ...

Page 401: ...oil container to receive oil under hose 2 then open the drain valve 7 After checking oil level or adding oil insert dipstick G into the hole and install air bleeding plug 1 METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down befor...

Page 402: ...URES FOR CRACKS Before checking be sure to remove any excessive dirt e g from undercarriage and excessive grease e g around area of articulating joint pins from areas of the machine to be checked Check structures for cracks If any cracks are found contact your Komatsu distributor If the structure is welded or holes are drilled in it or it is repaired in any other way its strength may be reduced Co...

Page 403: ...irt or other materi al and remove any if found Take extreme care that the dirt does not fall into the hy draulic tank 6 Clean the removed parts by using cleaning oil 7 Install the new element in the place where old element 5 was installed 8 Place strainer 4 valve 3 and spring 2 onto the element 9 Set cover 1 in position press it down by hand and install the cover with the mounting bolts 10 Install...

Page 404: ...oil may not flow out easily REMARK If the oil becomes thin thread condition there is no problem in stopping the draining operation To reduce the oil draining time swing the upper struc ture to slightly increase the temperature of the machi nery oil then drain the oil However never swing the upper structure while draining the oil This may cause breakage of the swing machinery 4 Remove dipstick G an...

Page 405: ... is running When replacing the filter wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter Do not bring any open flame close When opening the air bleeding plug of the fuel filter head take care There may be remaining pres sure and fuel may spout out NOTICE Komatsu genuine fuel filter cartridges use a special filter that has highly ...

Page 406: ...nt flow out of the fuel be sure not to leave the machine without the filter cartridge 6 Clean the filter head Thinly apply oil to the packing of the new filter cartridge and install the cartridge to the filter head NOTICE Do not fill the new filter cartridge with fuel Remove cap B at center and install the filter car tridge 7 When installing the cartridge tighten it until the packing surface conta...

Page 407: ...ecking the tightening of the clamps between the air cleaner turbocharger aftercooler engine METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRES SURE IN ACCUMULATOR FOR BREAKER if equipped A special tool is needed for checking and charging of nitrogen gas Ask your Komatsu distributor to perform this work METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT k k WARNING Immediately after the e...

Page 408: ...ine parts Do not flush DEF tank breather element Flushing or regenerating of it will degrade the performance of element and will cause the breakage of DEF tank Never reuse the DEF element Always stop the engine and clean around DEF tank before replacing After the engine is stopped DEF system devices automatically purge DEF in DEF injector and DEF pump and return it to DEF tank to prevent malfuncti...

Page 409: ...atsu distributor to perform this work REMARK As the auto alternator belt tensioner is installed to this machine no belt tension adjustment is required EVERY 2000 HOURS MAINTENANCE Maintenance for every 50 250 500 and 1000 hours service should be performed at the same time METHOD FOR CHANGING OIL IN FINAL DRIVE CASE k k WARNING Immediately after the engine is stopped its parts and oil are still ver...

Page 410: ...its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pres sure then remove it carefully 1 Remove the cap for oil filler F and release the internal pressure 2 Remove the bolts 6 pieces and remove cover 1 The cover 1 may be jum...

Page 411: ...en gas charge pressure in the accumulator is low and operations are continued it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma chine FUNCTION OF ACCUMULATOR The accumulator has function of storing pressure of the control circuit in it Even if the engine is stopped the control circuit can be operated as long as the accumulator functi...

Page 412: ... the ground If the work equipment goes down under its own weight and contacts the ground the accumulator is normal If the work equipment does not go down or stops in midway the charged pressure of the gas in the accumulator for the hy draulic circuit has probably dropped Ask your Komatsu distrib utor for inspection This completes the inspection After completion of the inspection set the lock lever...

Page 413: ... check only just after the engine stops 1 Turn the starting switch to OFF position A and then stop the engine 2 Turn the starting switch to ON position B 3 Operate the control grip g of the lock lever to set it securely to FREE position F then operate the work equipment control levers and the attachment control pedal if equipped fully to forward backward right and left to release the pressure in t...

Page 414: ...is operated without the filter element the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil Therefore do not start the engine without the filter element The filter element cannot be flushed Flushing or regenerating of the filter element will degrade per formance of the filter As a result the turbo...

Page 415: ...EMARK When the ambient temperature is low water or emulsified matter may stick to the inside of KCCV because of con densation of water vapor in the blowby gas However if the coolant level is normal it is not a problem 3 Remove used O ring 6 sticking to case 4 and install a new O ring contained in the service kit Apply engine oil to the new O ring 4 While matching marks 7 of the new element with ma...

Page 416: ...4 are cor rectly inserted in grooves 10 of the filter body When in serting take extreme care so that protrusion 15 in the case is joined together with rubber lip 16 of the element 6 Fit ring 3 to the threaded part of the body and tighten it with the hand firmly until it stops 7 By using the special wrench further tighten the ring 1 15 to 2 15 turns 1 to 2 ridges of the ring If the engine is operat...

Page 417: ...ing or regenerating of it will degrade the performance of filter and will cause the breakage of equipment Never reuse the filter Improper assembly of DEF filter may cause leakage of DEF Replace the DEF filter in the correct pro cedure After the engine is stopped DEF system devices automatically purge DEF in DEF injector and DEF pump and return it to DEF tank to prevent malfunction of the devices c...

Page 418: ... Insert the filter removal tool to the end where you cannot thrust it in any further 6 Turn filter removal tool 3 in reverse and remove filter 6 Filter 6 is removed and you can take it out together with filter removal tool 3 If filter 6 cannot be removed from DEF pump grip filter removal tool 3 pull it down then it will be removed 7 Slide filter 6 down and remove spacer 5 from filter re moval tool...

Page 419: ...hey are likely to wear out or deteriorate Replace them every 2 years or every 4000 hours whichever comes sooner DEFINED LIFE PARTS LIST No Periodical replacement parts Replacement interval 1 Fuel system Fuel hose Every 2 years or 4000 hours whichever comes sooner 2 Engine lubrication system Turbocharger lubrication hose Engine oil filter hose 3 Work equipment hydraulic system Main pump delivery ho...

Page 420: ...damp hub and inertia member Match marks 1 are stamped on the damp hub and inertia member to indicates misalignment between them If this misalignment is 1 6 mm or more or if dent 2 from the damper metal surface is 3 2 mm or more ask your Komatsu distributor for parts replacement METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked If the engine is start...

Page 421: ...e it Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disposing of it the gas must be released Ask your Komatsu distributor to have this work per formed NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued it becomes impossible to r...

Page 422: ... Komatsu distributor for cleaning of the KDPF METHOD FOR CLEANING DEF TANK Ask your Komatsu distributor for cleaning of the DEF tank EVERY 5000 HOURS MAINTENANCE Maintenance for every 50 250 500 and 1000 hours service should be performed at the same time METHOD FOR CHANGING OIL IN HYDRAULIC TANK k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause ...

Page 423: ... the drain plug under the ma chine When removing drain plugs P and A be careful not to get oil on yourself Almost the same amount of oil can be drained from 2 pla ces by removing plug P from the tank bottom first and then plug A from the suction tube 7 Remove drain plug P from the tank bottom to drain the oil Check the installed O ring for damage Replace O ring with a new one if necessary 8 Remove...

Page 424: ...3 Install undercovers 1 and 2 EVERY 8000 HOURS MAINTENANCE Maintenance for every 50 250 500 1000 2000 and 4000 hours service should be performed at the same time METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps EVERY 9000 HOURS MAINTENANCE Maintenance for every 50 250 500 1000 and 4500 hours service should be performed at...

Page 425: ...SPECIFICATIONS 5 1 ...

Page 426: ...0 600 E Cab height mm 3160 F Tail swing radius mm 3445 G Overall length of track mm 4955 4955 H Distance between tumbler centres mm 4030 4030 I Height of handrail mm 3255 Min ground clearance mm 498 Travel speed Lo Mi Hi km h 3 2 4 5 5 5 Swing speed rpm 9 5 Working ranges Unit PC360LC 11 PC360NLC 11 A Max digging reach mm 11100 B Max digging depth mm 7380 C Max digging height mm 10100 D Max vertic...

Page 427: ...ntre B Bucket hook height OF Lifting capacity rating overfront OS Lifting capacity rating overside LEGEND 1 Position of lifting point 2 Arm length 3 Boom length 4 Hydraulic pressure WORKING CONDITIONS WITH BUCKET 1014 kg IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE SPECIFICATIONS SPECIFICATIONS 5 3 ...

Page 428: ...BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND Loads do not exceed 87 of hydraulic capacity or 75 of tipping capacity load limited by hydraulic capacity rather than tipping PC360LC 11 SPECIFICATIONS SPECIFICATIONS 5 4 ...

Page 429: ...PC360NLC 11 SPECIFICATIONS SPECIFICATIONS 5 5 ...

Page 430: ......

Page 431: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1 ...

Page 432: ... leader and follow his her instructions Use a crane when handling heavy objects 25 kg or more The crane must be operated by a qualified operator Never go under a load raised by the crane Do not perform operations with the load kept raised by the crane Always use a stand to prevent the load from falling When removing a heavy part consider the machine balance after it is removed To prevent the machi...

Page 433: ...ts the mass of the bucket see the following EXPLANATION OF LIFT CAPACITY CHART 1 PIECE BOOM 5 3 should be taken into consideration For an attachment not intended to bear a load for example a breaker it should not exceed the minimum lift capacity of the machine as shown on the related lift capacity charts see SPECIFICATIONS section Chapter 5 For attachments intended to bear a load for example clams...

Page 434: ...ommendations If in doubt about the installation or operation consult your Komatsu distributor Pressure regulation valves 5 and 6 allow the attachment pressure and the release pressure for the quick coupler to be limited according to the coupler manufacturer s recommendation respectively Maximum cir cuit pressure 34 3 MPa 350 kg cm2 Ensure that the quick coupler is installed by a suitably qualified...

Page 435: ...Operation switch REMARK The switch has a safety lock mechanism to prevent acci dental operation Slide the lock towards you then rock the switch The lamp on the switch will come on and a warning buzzer will sound NOTICE Operation will only take place if button 2 is also pressed A When depressed at this point quick coupler deactivat ed Lock bucket attachment B When depressed at this point quick coup...

Page 436: ... Komatsu distributor for inspection and maintenance TO PICK UP A NEW BUCKET OR ATTACHMENT k k WARNING Check daily that the hoses and fittings in the quick coupler piping system are in good condition Pay particular attention to the hoses and fittings at the arm end as these can be damaged easily In case of damage or leakage of oil stop work Loss of oil could lead to the bucket or attachment fall in...

Page 437: ... bucket cylinder arm and boom as necessary Follow the quick coupler manufacturer s instructions 5 Release button 2 If the bucket or attachment needs a connection to the hydraulic system of the machine follow all instruc tions in ATTACHMENT REMOVAL AND INSTALLATION The quick coupler will lock onto the bucket or attachment if necessary operate one of the machine control levers to raise the system pr...

Page 438: ...and components In order to keep your machine in the best condition for long periods of time it is essential to follow the instructions in this Operation and Maintenance Manual Commercially available grease additives may be good for the machine but they may also cause harm Komatsu does not recommend any commercially available grease additive Refer also to section RECOMMENDED FUEL COOLANT AND LUBRIC...

Page 439: ...y not be available with some specifica tions SYSTEM OPERATION The system performs all operations automatically When the starting switch is in the ON position the grease pump will at pre defined intervals supply measured quantities of grease to all the points connected to the sys tem Within 60 seconds after switching the starting switch to the ON position the in cab display 2 shows the select ed gr...

Page 440: ...cessary Yellow lamp 5 flashing Minimum level in the reservoir has been reached Reset by filling the reservoir Red lamp 6 flashing System out of order Immediate action required Possible causes Insufficient grease pressure during 10 consecutive cycles or 10 consecutive times in the same main line Check for cause and reset by depressing the test button at the pump for at least one second while the ig...

Page 441: ...p unit and its surroundings Attention avoid using high pressure wash directly on the pump 9 Replace or clean the pump filler filter behind the connector on the reservoir every 500 hours REFILLING GREASE If the yellow lamp 5 on the in cab display 2 illuminates the minimum grease level in the reservoir has been reached The grease reservoir must be refilled as soon as possible GREASING PROCEDURE 1 Re...

Page 442: ...ning the machine or to vent the system a continuous lubrication cycle run can be performed 1 Move the starter switch to the ON position B 2 Depress the test button 9 on the pump for more than six seconds The system will perform a continuous lubrication test During this run the green LED 4 of the selected interval on the in cab display 2 will flash 02 sec on 0 2 sec off 3 The continuous test cycle ...

Page 443: ...cles if necessary Every time a test cycle is carried out grease is added to the grease points This will increase grease usage and can cause excessive greasing of the grease points ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM 6 13 ...

Page 444: ...t B C D 3 First Boom Raise Cylinder 7 Grease Nipple Second Boom Raise Cylinder 4 Second Boom Raise Cylinder 8 Grease Nipple Second Boom Raise Cylinder OPERATION Explanation of Components 2 piece boom control pedal The control pedal to the left of the travel levers controls the operation of the second boom adjust cylinder Press ing down on the front of the pedal pushes the second boom away from the...

Page 445: ...ntrol pedal A Extend second boom raise cylinder B Retract second boom raise cylinder A Press the front of the pedal B Press the rear of the pedal 9JH02584E A B KS001257 9JH02586F ATTACHMENTS AND OPTIONS 2 PIECE BOOM 6 15 ...

Page 446: ...t preparation of machine for long term storage 2 When leaving the machine for a short time INSPECTION AND MAINTENANCE To use the machine safely and to prevent failures before they occur always carry out checks before starting and periodic maintenance The locations for periodic inspection are as shown in the diagram below P KS001260 A A B B R A Cracks at end of weld checks before starting KS001258 ...

Page 447: ...ired is the same as mono boom machine SPECIFICATIONS 2 PIECE BOOM Item Unit PC360LC 11 PC360NLC 11 Operating weight kg 37290 36810 Bucket capacity m3 1 01 Engine model KOMATSU SAA6D114E 6 diesel engine Engine power kW rpm 192 1900 ISO 9249 202 1900 ISO 14396 A Overall length mm 11145 B Overall height work equipment mm 3710 to hoses 3420 to top of boom C Overall width mm 3290 2990 D Shoe width mm 7...

Page 448: ...ing reach mm 11285 B Max digging depth mm 6435 C Max digging height mm 12515 D Max vertical wall digging depth mm 5410 E Max dumping height mm 9195 F Min dumping height mm 4100 G Max reach at ground level mm 11100 2 PIECE BOOM ATTACHMENTS AND OPTIONS 6 18 ...

Page 449: ...ength 4 Hydraulic pressure WORKING CONDITIONS WITH BUCKET 1014 kg IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND WITH 600 mm WIDTH SHOE Loads do not exceed 87 of hydraulic capacity or 75 of tipping capacity load limited by hydraulic c...

Page 450: ...PC360LC 11 2 Piece Boom PC360NLC 11 2 Piece Boom 2 PIECE BOOM ATTACHMENTS AND OPTIONS 6 20 ...

Page 451: ...long reach machine and to identify any damage to the equipment early car ry out the following checks before starting the machine Check daily for any loose nuts or bolts and tighten any that are found Check daily for any oil leakage Check all parts of the work equipment for any cracks bending buckling and play of the boom and arm If any abnormality is found contact your Komatsu distributor immediat...

Page 452: ... R Recommended work C Work requiring caution N Work that is not permitted Applicable operations 1 Dredge rivers specific gravity max 1 8 R 2 Hauling loading dry sand specific gravity max 1 8 R 3 Digging hauling piled soil specific gravity max 1 8 R 4 Digging clay layers C 5 Digging bank R 6 Quarry work or digging bedrock N 17M LONG REACH BOOM AND ARM ATTACHMENTS AND OPTIONS 6 22 ...

Page 453: ... be used Item Unit PC360LC 11 17m Max digging radius mm 1100 General Purpose Bucket material density 1 8 t m3 Capacity ISO m3 0 93 Maximum Width mm 1000 Maximum Weight kg 780 General Purpose Bucket material density 1 2 t m3 Capacity ISO m3 1 11 Maximum Width mm 1200 Maximum Weight kg 890 Bucket Maximum weight at the end of the arm kg 2454 Ditching Bucket material density 1 1 t m3 Maximum Width mm ...

Page 454: ... the bucket k k CAUTION Attachments like breakers and fork grabs may not be used k k CAUTION Use with engine throttle at 70 80 for ease of use and safety k k CAUTION Do not operate the 17m Long Reach machine control levers in the same way as a standard excavator The 17m Long Reach equipment has a higher inertia and will achieve higher velocities causing wear and damage WHEN TRAVELLING Lower the bo...

Page 455: ... it to the arm with the pin D and snap ring E When doing this raise the boom slightly and retract the arm cylinder slightly from the end of the stroke 5mm 10mm to align the holes correctly 4 It is dangerous to carry out this operation with the arm raised from the ground MAINTENANCE SPECIAL SERVICE REQUIREMENTS FOR 17M LONG REACH WORK EQUIPMENT k k CAUTION When working in water or in wet sand use m...

Page 456: ...ions are subject to change without notice Unit PC360LC 11 17m Long Reach A Maximum digging height mm 14595 B Maximum dumping height mm 11490 C Maximum digging depth mm 12300 D Maximum wall digging depth mm 9445 E Maximum digging depth for 2400mm level mm 12200 F Minimum digging reach mm 17000 G Maximum reach at ground level mm 16880 H Minimum swing radius mm 5970 I Maximum height of minimum swing ...

Page 457: ...ATTACHMENTS AND OPTIONS 17M LONG REACH BOOM AND ARM 6 27 ...

Page 458: ...per long front machine and to identify any damage to the equipment early carry out the following checks before starting the machine Check daily for any loose nuts or bolts and tighten any that are found Check daily for any oil leakage Check all parts of the work equipment for any cracks bending buckling and play of the boom and arm If any abnormality is found contact your Komatsu distributor immed...

Page 459: ...R Recommended work C Work requiring caution N Work that is not permitted Applicable operations 1 Dredge rivers specific gravity max 1 8 R 2 Hauling loading dry sand specific gravity max 1 8 R 3 Digging hauling piled soil specific gravity max 1 8 R 4 Digging clay layers C 5 Digging bank C 6 Quarry work or digging bedrock N ATTACHMENTS AND OPTIONS SUPER LONG FRONT BOOM AND ARM 6 29 ...

Page 460: ...rm to this table must not be used Item Unit PC360LC 11 22m Max digging radius mm 1100 General Purpose Bucket material density 1 8 t m3 Capacity ISO m3 0 47 Maximum Width mm 955 Maximum Weight kg 575 General Purpose Bucket material density 1 2 t m3 Capacity ISO m3 0 63 Maximum Width mm 955 Maximum Weight kg 650 Powered attachment Maximum Weight at the end of the arm kg 800 Ditching Bucket material ...

Page 461: ...CAUTION Do not bring any shock loading on the work equipment k k CAUTION Do no apply any side load to the bucket k k CAUTION Attachments like breakers and fork grabs may not be used k k CAUTION Use with engine throttle at 70 80 for ease of use and safety k k CAUTION Do not operate the Super Long Front control levers in the same way as a standard excavator The Super Long Front equipment has a highe...

Page 462: ...g this raise the boom slightly and retract the arm cylinder slightly from the end of the stroke 5mm 10mm to align the holes correctly 4 It is dangerous to carry out this operation with the arm raised from the ground MAINTENANCE SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT k k CAUTION When working in water or in wet sand use molybdenum LM P for the grease k k WARNING NEVER slew ...

Page 463: ...FRONT Item Unit PC360LC 11 22m Super Long Front A Overall shipping height mm 3470 B Overall shipping length mm 17220 C Transport length mm 15963 D Track length mm 4955 E Track length on ground mm 4030 F Tail swing radius mm 3770 H Overall height of cab mm 3164 Track shoe mm PC360LC 11 22m Super Long Front Operating weight kg Ground pressure kg cm2 700mm 41300 0 68 800mm 41680 0 60 850mm 41870 0 57...

Page 464: ...Front A Maximum digging height mm 16260 B Maximum dumping height mm 13480 C Maximum digging depth mm 17485 D Maximum wall digging depth mm 14275 E Maximum digging depth for 2400mm level mm 17410 F Minimum digging reach mm 22010 G Maximum reach at ground level mm 21915 H Minimum swing radius mm 7350 I Maximum height of minimum swing mm 13445 SUPER LONG FRONT BOOM AND ARM ATTACHMENTS AND OPTIONS 6 3...

Page 465: ...ATTACHMENTS AND OPTIONS SUPER LONG FRONT BOOM AND ARM 6 35 ...

Page 466: ...e speed and perform the operation in L mode The wire or sling may come off the hook depending on the working posture Pay sufficient attention to the hook angle so that the sling does not come off Never drive the machine while lifting a load If the bucket with hook is turned 180 and used for operations it will hit the arm during the bucket DUMP operation Be careful when using it If you are planning...

Page 467: ...al 4 Lock pin 5 Additional filter for breaker 6 Accumulator for low pressure 7 1st line attachment proportional switch 8 2nd line attachment proportional switch 9 Breaker mode switch STOP VALVE The stop valve 1 stops the flow of the hydraulic oil a FREE Hydraulic oil flows b LOCK Hydraulic oil stops ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 37 ...

Page 468: ...m operations with your foot on the pedal the attachment may suddenly move if you de press the pedal by mistake and this may lead to serious personal injury or death Lock the pedal with the lock pin when pedal operation is not necessary Control pedal is used to control the attachment When the front center neutral and rear of the pedal are depressed the movement of the attachment is as follows Hydra...

Page 469: ...ing the breaker use the working mode selector switch on the monitor switch portion to set the working mode to B mode and set the lock pin to position b when using the pedal When using the crusher use the working mode selector switch on the monitor switch portion to set the working mode to ATT mode and set the lock pin to position c when using the pedal ADDITIONAL FILTER FOR BREAKER NOTICE Always i...

Page 470: ...rformed without having an accumulator installed the service life of the machine will be reduced Contact your Komatsu distributor for further information regarding the breaker This accumulator is installed to reduce the peak pressure in the hydraulic circuit when the breaker is used Do not touch it usu ally When inspecting the accumulator see METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PR...

Page 471: ...HINE READY FOR INSTALLATION OF ATTACHMENT NOTICE The return circuit when a breaker is installed must return directly to the return filter so do not use it in the mode other than B mode The standard set pressure of the safety valve of the service valve is 21 6 MPa 220 kg cm2 if you select B mode set at the shipment from the plant and it becomes 24 5 MPa 250 kg cm2 when ATT P or ATT E mode is select...

Page 472: ...uit is formed 2 Hydraulic oil flowing through crusher circuit does not pass through additional filter for breaker 3 Relief valve is set to high pressure When shipped from factory 24 5 MPa 250 kg cm2 4 Maximum oil flow can be adjusted in user mode METHOD FOR CONNECTING HYDRAULIC CIRCUIT When installing the attachment connect the hydraulic circuit as follows 1 Check that stop valve 1 is located at L...

Page 473: ...ft side of the work equipment Depress the rear side of pedal The oil flows into piping of the right side of the work equipment REMARK When a breaker is installed depress only the front side of pedal METHOD FOR SWITCHING HYDRAULIC CIRCUIT Depending on the type of attachment set the working mode on the monitor as follows The hydraulic circuit and the set pressure of the safety valve in the service v...

Page 474: ...ional attachment and set the working mode to ATT P or ATT E mode Hydraulic oil flowing through crusher circuit does not pass through additional filter for breaker Relief valve is set to high pressure Maximum oil flow can be adjusted in user mode Set pressure of safety valve of service valve when shipped from plant 24 5 MPa 250 kg cm2 Crusher circuit 2 way circuit is formed METHOD FOR REMOVING AND ...

Page 475: ...ulic oil flows direction of arrow is parallel to longitudinal direction of arm b LOCK Hydraulic oil does not flow direction of arrow is at right angle to longitudinal direction of arm When setting FREE or LOCK position of the stop valve remove bolt 1 and washer 2 fit lever 3 and refit bolt 1 and washer 2 rotate valve to furthest po sition clockwise or anti clockwise After setting re move lever 3 a...

Page 476: ...RAULIC TANK ADDING OIL 3 147 METHOD FOR INSTALLING ATTACHMENT 1 Remove the bucket For the removal procedure of the bucket see METHOD FOR INVERTING BUCKET 3 206 2 Place the attachment on a horizontal place install pin A and then pin B in this order to the arm 3 Lower the attachment to the ground and stop the engine 4 Turn the starting switch to ON B position 5 Set the lock lever to FREE position F ...

Page 477: ...f the hydraulic tank to release the internal pressure in the hydraulic tank 9 Check that the hydraulic oil temperature is low 10 Remove the plugs 2 places at the outlet and inlet Be careful not to get any dirt or mud on the hose fitting If an O ring is damaged replace it with a new one 11 Connect the hose on the attachment side Check the direction of flow of the oil and be careful not to make any ...

Page 478: ...s are operated when the engine speed is decreased by the auto decel eration function the engine speed will suddenly increase Be careful If you perform operations with your foot on the pedal the attachment may suddenly move if you de press the pedal by mistake and this may lead to serious personal injury or death Do not rest your foot on the pedal except when you operate the pedal When the attachme...

Page 479: ... enter the selection 1 To keep working mode selector switch 1 pressed 2 To press switch F6 3 To leave as it is for 5 seconds If you enter the selection of the Breaker Mode the confir mation message is displayed k k WARNING When a special attachment is installed if the mode is switched to the Breaker Mode by mistake it may lead to serious danger such as sudden drop of the work equipment 4 Press swi...

Page 480: ...ntact the attachment manufacturer and then decide When handling the breaker follow the instruction manual from the breaker manufacturer and use the break er correctly METHOD FOR OPERATING GENERAL ATTACHMENT SUCH AS CRUSHER ETC 1 Set the working mode to ATT P or ATT E mode 2 Set both front and rear lock pins to FREE position c 3 Depress the front or rear side of the pedal The attachment operates ME...

Page 481: ...ATT E For the oil passage route see METHOD FOR CHANGE OVER AND CONNECT HYDRAULIC CIRCUIT FOR MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 41 When handling the attachment follow the instruction manual from the manufacturer and use the attachment correctly METHOD FOR OPERATION WHEN USING GENERAL ATTACHMENT 1 E G CRUSHER k k WARNING When operating the attachment using rolling switch lock the pedal ...

Page 482: ...ions see WHEN USING GENERAL ATTACHMENTS SUCH AS CRUSHER LONG TERM STORAGE NOTICE If there is no breaker or general attachment installed operating the pedal may cause overheating and other problems If the equipment is not to be used for a long time do as follows Set the stop valve in LOCK condition Install the plugs to the piping end of the stop valve Set the lock pin in LOCK position MAINTENANCE O...

Page 483: ...g switch to ON B position 3 Set the lock lever to FREE position F 4 Operate each work equipment control lever and attach ment control pedal fully to the front rear right and left a few times within 15 seconds to release the internal pres sure in the hydraulic circuit ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 53 ...

Page 484: ...l container 4 After checking that the hydraulic oil temperature has drop ped turn filter case 2 counterclockwise remove it then remove element 3 5 Clean the removed parts then install new element 3 REMARK Element 3 must be installed facing in the correct direc tion Set direction Y with the holes in it up and fit the hole in element 3 on the protruding part inside filter head 4 6 Fit new O ring 5 t...

Page 485: ...has drop ped turn filter case 1 counterclockwise remove it then remove element 2 4 Clean the removed parts then install new element 2 REMARK Element 2 must be installed facing in the correct direc tion Set direction Y with the holes in it up and fit the hole in element 2 on the protruding part inside filter head 4 5 Install a new O ring 3 to filter case 1 then tighten filter case 1 Tightening torq...

Page 486: ...g pressure of service valve Port A 24 5 MPa 250 kg cm2 other than B mode Port B 24 5 MPa 250 kg cm2 other than B mode Safety valve relief set pressure of service valve Port A 29 9 MPa 305 kg cm2 B mode Port B 24 5 MPa 250 kg cm2 B mode Safety valve cracking pressure of service valve Port A 24 5 MPa 250 kg cm2 B mode Port B 20 1 MPa 205 kg cm2 B mode HANDLE MACHINE READY FOR INSTALLATION OF ATTACHM...

Page 487: ...ARM PIN INFORMATION A A B B 2 4 1 3 A A B B KS001081 PC360LC NLC 11 1 345 mm 0 0 5 3 343 mm 0 5 0 5 2 90 mm 0 036 0 090 4 90 mm 0 036 0 090 ATTACHMENTS AND OPTIONS ARM PIN INFORMATION 6 57 ...

Page 488: ...ment there is a danger that the work equipment may hit the cab or machine body When using unfamiliar work equipment for the first time check before starting if there is any danger of interference and operate it with care Categories of use Select a proper attachment for each use General digging Digging or loading sand gravel clay etc Light duty digging Digging and loading dry and loose sandy soil o...

Page 489: ... may hit the cab or machine body When using unfamiliar work equipment for the first time check before starting if there is any danger of interference and operate it with care Categories of use Select a proper attachment for each use General digging Digging or loading sand gravel clay etc Light duty digging Digging and loading dry and loose sandy soil or muddy soil Loading Loading of dry and loose ...

Page 490: ...0 1 13 1000 Values shown are in accordance with EN474 5 2006 A1 2009 E TOOL CONTROL SYSTEM SYSTEM OVERVIEW The machine may be equipped with a tool control system the system limits 1st attachment line flow and pres sure and 2nd attachment line flow The system can store settings for up to 16 different attachments to adjust attachment settings please contact your Komatsu distributor The tool control ...

Page 491: ...breaker operations are performed in a mode other than the breaker mode there is a danger of breakage of the hydraulic equipment Do not perform operations in any mode except the breaker mode see METHOD FOR SE LECTING WORKING MODE 3 193 NOTICE When this tool control system is fitted the factory flow set ting on the machine will be set to minimum do not adjust this value as doing so will have no effe...

Page 492: ...gh ground where there are large obstacles such as boulders or fallen trees Travel at Hi or Mi speed only on flat ground and if it is impossible to avoid trav elling over obstacles shift down and travel at half speed in Lo C Extremely soft ground swampy ground Use the shoes only in places where the machine sinks and it is impossible to use A or B shoes These shoes cannot be used on rough ground whe...

Page 493: ...tration is needed such as when working with crushed rocks after blasting or rip ping Jobsites where heavy duty operations are performed such as hitting or pulling up rocks with the tips of the teeth SELF SHARPENING TOOTH HORIZONTAL PIN TYPE VERTICAL PIN TYPE Jobsites requiring penetration such as digging and loading sandy or clayey soil SELECTION GUIDE FOR VERTICAL OR HORIZONTAL PIN TYPE TOOTH App...

Page 494: ...he attachments or the models consult your Komatsu distributor HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows Crushing rock Road construction This attachment can be used for a wide range of applications including breaking up road surfaces or slag tunnel work rock crushing and breaking operations in quarries Precautions when performing breaking operati...

Page 495: ... of the chisel gradually deviates from the direction of the breaker body Adjust the direction with the bucket cylinder so that it keeps the proper direction Always keep the chisel pressed against the impact surface properly not to strike at the air Prohibited operations To ensure that the machine has a long life and to ensure that operations are performed in safety do not operate the machine in an...

Page 496: ...Do not work by using the swing force Do not move the chisel while performing breaking operation Do not perform breaker operation in horizontal or upward direc tion Do not work under water RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS 6 66 ...

Page 497: ...ith any cylinder at the stroke end Posture of hydraulic breaker to be greased NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use Be sure to grease the breaker keeping it in the right posture ATTACHMENTS AND OPTIONS RECOMMENDED ATTAC...

Page 498: ...holding it in the right posture shown below Lower the chisel perpendicularly to the ground Insert the grease gun perpendicularly to the greasing point Wrong posture RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS 6 68 ...

Page 499: ...REPLACEMENT PARTS 7 1 ...

Page 500: ...mps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Retighten all loose hoses and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the defined life parts DEFINED LIFE PARTS LIST No Parts for periodic repla...

Page 501: ...0 Cartridge 1 Every 500 hours Fuel prefilter 600 319 3610 Cartridge including O ring 1 Every 500 hours Breather of hydraulic tank 421 60 35170 Element 1 Every 1000 hours Hydraulic oil filter 207 60 71183 07000 15195 Element O ring 1 1 Every 1000 hours Fuel main filter 600 319 3750 Cartridge 1 Every 1000 hours DEF tank breather 421 60 35170 Element 1 Every 1000 hours KCCV filter 600 331 2900 Elemen...

Page 502: ... 5 5 5 Horizontal pin type 207 70 14151 09244 02516 Tooth Pin 5 5 Side cutter type 207 70 34160 207 70 34170 Side cutter left Side cutter right 1 1 Shroud type 208 934 7132 113 78 21170 209 939 7110 209 939 7120 Shroud Pin Shim Shim 2 4 8 8 Rock bucket 207 70 14280 09244 02516 Tooth Pin 5 5 CONSUMABLE PARTS REPLACEMENT PARTS 7 4 ...

Page 503: ... be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high precision parts and lubrication if low viscosity fuel with low lubricating a...

Page 504: ...ydraulic oil level Change power train oil Check power train oil level Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter Replace DEF tank breather element Replace DEF filter USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Reservoir Fluid Type Ambient Temperature degrees Celsius Recommended Komat...

Page 505: ...uel 30 C 20 C EN590 10 C 50 C DEF tank DEF tank 30 C 50 C DEF Note 6 Engine oil pan Swing machi nery case Final drive case each of right and left Damper case Hydraulic oil sys tem Cooling system Fuel Tank DEF tank Speci fied ca pacity ℓ 39 5 16 9 1 3 365 41 605 60 Refill ca pacity ℓ 38 5 14 9 1 3 188 37 39 REMARK Specified capacity means the total amount of oil including the oil in the tank and th...

Page 506: ...UPERCOOLANT AF NAC SUPERCOOLANT AF NAC has excellent anticorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours SUPERCOOLANT AF NAC is strongly recommended wherever available 2 For the SUPERCOOLANT AF NAC density see METHOD FOR CLEANING INSIDE OF COOLING SYS TEM 4 20 SUPERCOOLANT AF NAC is supplied in diluted state so always fill up with diluted coolant ...

Page 507: ...ner fresh recirc filter Clean 4 55 Air conditioner pilot lamp 3 36 Air conditioner recirculation air filter Clean 4 55 Air conditioner switch 3 51 3 221 Air conditioner system caution lamp 3 30 Air suspension seat hardness Adjust 3 158 Alternator Check 4 70 Alternator belt tension Check Replace 4 65 Always use clean washer fluid 4 2 Ambient temperature range for operation and storage 3 174 Antenna...

Page 508: ...edals 6 38 Controls and gauges names 3 5 Coolant 3 251 Coolant Check level Add 3 149 Coolant and water for dilution 4 6 Cooling system Clean inside 4 20 Counter rotation turn 3 191 Cover with lock Lock 3 211 Cover with lock Open 3 211 Cover with lock Open Close 3 211 Cup holder 3 106 Current Abnormality display switch 3 23 Cylinder Bleed air 4 38 D Damper case Check oil level Add oil 4 60 Daylight...

Page 509: ...ntenance 4 78 Every 50 hours maintenance 4 42 Every 500 hours maintenance 4 46 Every 5000 hours maintenance 4 78 Every 8000 hours maintenance 4 80 Every 9000 hours maintenance 4 80 Explanation of air conditioner equipment 3 218 Explanation of components 3 9 Explanation of components on machine equipped with attachment 6 37 Explanation of machine monitor equipment 3 9 Explanation of radio equipment...

Page 510: ...oduction 1 8 Investigate and confirm jobsite conditions 2 25 J Jumper cable Connect 3 262 Jumper cable Disconnect 3 263 K KCCV filter element Replace 4 70 KDPF Clean 4 78 KDPF Handle 3 113 KDPF soot accumulation caution lamp 3 26 KDPF system caution lamp 3 26 Keep machine clean 2 17 Keep work place clean and tidy 2 43 Komatsu Closed Crankcase Ventilation KCCV 3 123 Komatsu genuine lubricants 4 2 K...

Page 511: ...ble 4 12 Maintenance screen Set 3 76 Maintenance time caution lamp 3 31 Manual operation Stop 3 225 Manual stationary regeneration Operate 3 116 Message Check 3 86 Message Reply 3 87 Message display 3 36 3 86 Meter display 3 39 Method for adjusting 3 155 Method for checking before starting 3 142 6 21 6 28 Method for operation when using general attachment 1 e g crusher 6 51 Method for operation wh...

Page 512: ... hole 3 259 Precautions for welding 2 46 Precautions for working at high places 2 45 Precautions for working on slope 3 201 Precautions for working under machine or work equipment 2 46 Precautions related to attachments and options 2 23 Precautions related to cab glass 2 24 Precautions related to protective structure 2 22 Precautions to prevent fire 2 18 Precautions when installing hydraulic hoses...

Page 513: ...h 3 95 Seat height Adjust 3 156 Seat reclining Adjust 3 156 Seat tilt Adjust 3 156 Seat unit fore and aft direction Adjust 3 158 Seatbelt caution lamp 3 32 Select suitable place for inspection and maintenance 2 43 Selector valve 6 38 Self sharpening tooth horizontal pin type vertical pin type Use 6 63 Serial plate 1 13 Service meter Clock 3 41 Service meter location 1 12 Shovel work 3 204 Sound ba...

Page 514: ...al or horizontal pin type tooth Select 6 63 Vertical pin type tooth Use 6 63 Vibration damper Check 4 76 Vibration levels 1 6 Visibility from operator s seat 1 9 Volume control button 3 230 W Warning display 3 17 Washable floor Wash 4 34 Washable floor mat Clean 4 34 Water pump Check 4 76 Water separator Check Drain water and sediment 3 145 Water separator caution lamp 3 30 Wear well fitting cloth...

Page 515: ......

Page 516: ...PC360LC 11 PC360NLC 11 HYDRAULIC EXCAVATOR Form No UENAM01195 2017 KOMATSU All Rights Reserved Printed in Belgium 07 2017 ...

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