Komatsu PC450-8 Page 20 Operation & Maintenance Manual Download | Manualshive

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CONTENTS

1-18

FILTERS ............................................................................................................................................ 4-7

EXPLANATION OF LUBRICATION CHART DECAL

.................................................................................................................................................................... 4-8

ELECTRIC SYSTEM MAINTENANCE ..................................................................................................... 4-10

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

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

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

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

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

TIGHTENING TORQUE SPECIFICATIONS

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

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

SAFETY CRITICAL PARTS

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

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

MAINTENANCE SCHEDULE

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

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

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..................................................................... 4-19

MAINTENANCE PROCEDURE

.......................................................................................................................... 4-20

INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ............................... 4-20

WHEN REQUIRED ................................................................................................................................... 4-21

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ......................................................... 4-21

CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-27

CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-30

CHECK AND ADJUST TRACK TENSION....................................................................................... 4-31

REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ..................................................................... 4-33

REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................ 4-36

REPLACE BUCKET SIDE CUTTER, SHROUD .............................................................................. 4-38

ADJUST BUCKET CLEARANCE .................................................................................................... 4-39

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .............................................................. 4-40

CHECK AND MAINTENANCE AIR CONDITIONER ....................................................................... 4-41

WASH WASHABLE FLOOR............................................................................................................ 4-42

BLEEDING AIR FROM HYDRAULIC SYSTEM............................................................................... 4-45

CHECK BEFORE STARTING .................................................................................................................. 4-47

EVERY 50 HOURS MAINTENANCE........................................................................................................ 4-48

LUBRICATING................................................................................................................................. 4-48

EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-49

LUBRICATE SWING CIRCLE ......................................................................................................... 4-49

CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-50

CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST ..................................................... 4-52

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ..................................... 4-53

EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-54

LUBRICATING................................................................................................................................. 4-54

REPLACE FUEL PRE-FILTER CARTRIDGE.................................................................................. 4-55

CHECK SWING PINION GREASE LEVEL, ADD GREASE ............................................................ 4-58

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE .................... 4-59

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Summary of Contents for PC450-8

Page 1: ...nsafe use 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 personel who will come into contact with the machine Operation Maintenance Manual UEAM007200 WARNING ...

Page 2: ......

Page 3: ...FOREWORD 11 ...

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

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

Page 6: ...side a triangle and the method of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precau tions If any procedures or actions not specifically recommended or allowed in this manual ar...

Page 7: ...chine q Sound pressure level at the operator s station measured according to ISO6396 Dynamic test method simulated working cycle q Sound power level emitted by the machine measured according to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European directive 2000 14 EC 107 ...

Page 8: ...2 Maintain the machine according to this manual q Tension of crawler for crawler machines q Brake and steering systems q Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and traveling in good condition q Remove any large rocks or obstacles q Fill any ditches and holes q Site manager should provide machine operators with machine and schedule time to maintain te...

Page 9: ...ansport machines long distances between work sites 8 The following guidelines can be effective to minimize risks of low back pain q Operate the machine only when you are in good health q Provide breaks to reduce long periods of sitting in the same posture q Do not jump down from the cab or machine q Do not repeatedly handle and lift loads ...

Page 10: ...rk q Demolition work See the section RECOMMENDED APPLICATIONS 3 162 for further details DIRECTIONS OF MACHINE 1 In this manual the terms front rear left and right refer to the travel direction as seen from the operator s seat when the operator s seat is facing the front and the sprocket is at the rear of the machine A Front E Operator s seat B Rear F Sprocket C Left D Right ...

Page 11: ...rea where the view is blocked by part of the machine when mirrors or other aids to visibility are installed as standard Please be fully aware that there are places that cannot be seen when operating the machine 12M CIRCUMFERENCE VISIBILITY 1 The visibility at a radius of 12 m from the machine is as shown in the diagram below The hatched areas B show the areas where the view is blocked when mirrors...

Page 12: ... hours as indicated on the service meter Make sure that you fully understand the content of this manual and pay careful attention to the following points when breaking in the machine q Run the engine at idle for 15 seconds after starting it During this time do not operate the control levers or fuel control dial q Idle the engine for 5 minutes after starting it up q Avoid operation with heavy loads...

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

Page 14: ...tor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1 Machine serial No Engine serial No Product identification number PIN Manufacturers name KOMATSU UK LTD Address Durham Road Birtley Chester Le Street County Durham DH32QX United Kingdom Distributor name Address Service Personnel Phone Fax ...

Page 15: ...No MANUFACT YEAR MASS ENGINE POWER Product Identification Number kg kW MANUFACTURER Manufactured by Komatsu UK Ltd for Komatsu Ltd Tokyo Japan MODEL SERIAL MANUFACTURING YEAR WEIGHT ENGINE POWER MANUFACTURER Komatsu UK Ltd Birtley Co Durham United Kingdom PRODUCT IDENTIFICATION NUMBER ...

Page 16: ...0 PRODUCT INFORMATION 1 11 PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 11 EPA REGULATIONS ENGINE NUMBER PLATE 1 11 SERVICE METER LOCATION 1 12 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1 12 MACHINE SERIAL PLATE 1 13 SAFETY SAFETY INFORMATION 2 2 SAFETY LABELS 2 4 LOCATION OF SAFETY LABELS 2 4 SAFETY LABELS 2 5 SAFETY INFORMATION 2 13 SAFETY MACHINE OPERATION 2 22 STARTING ENGINE ...

Page 17: ... 78 WINDSHIELD 3 79 EMERGENCY ESCAPE HAMMER 3 84 DOOR LOCK 3 85 CAP WITH LOCK 3 85 DRINK BOX 3 87 MAGAZINE BOX 3 87 ASHTRAY 3 87 AIR CONDITIONER CONTROLS 3 88 Air Conditioner Control Panel 3 88 Method of Operation 3 92 Use Air Conditioner with Care 3 98 Inspection and maintenance of Air Conditioner Equipped Machine 3 99 RADIO 3 100 Control Panel 3 100 Controls of Radio 3 102 Use Radio with Care 3 ...

Page 18: ...43 Moving Machine Backward 3 144 Stopping Machine 3 145 STEERING THE MACHINE 3 146 Steering 3 146 SWINGING 3 148 WORK EQUIPMENT CONTROLS AND OPERATIONS 3 149 WORKING MODE 3 151 PROHIBITED OPERATIONS 3 153 GENERAL OPERATION INFORMATION 3 157 TRAVELING ON SLOPES 3 159 ESCAPE FROM MUD 3 161 Track on One Side Stuck 3 161 Tracks on Both Sides Stuck 3 161 RECOMMENDED APPLICATIONS 3 162 Backhoe Work 3 16...

Page 19: ...TIONS 3 189 RUNNING OUT OF FUEL 3 189 PHENOMENA THAT ARE NOT FAILURES 3 190 TOWING THE MACHINE 3 190 LIGHTWEIGHT TOWING HOLE 3 191 SEVERE JOB CONDITION 3 191 DISCHARGED BATTERY 3 192 Battery Removal and Installation 3 192 Battery Charges 3 193 Starting Engine with Booster Cables 3 194 OTHER TROUBLE 3 196 Electrical System 3 196 Chassis 3 197 Engine 3 198 Electronic Control System 3 199 Point of Co...

Page 20: ...YSTEM 4 27 CHECK AND TIGHTEN TRACK SHOE BOLTS 4 30 CHECK AND ADJUST TRACK TENSION 4 31 REPLACE BUCKET TEETH VERTICAL PIN TYPE 4 33 REPLACE BUCKET TEETH HORIZONTAL PIN TYPE 4 36 REPLACE BUCKET SIDE CUTTER SHROUD 4 38 ADJUST BUCKET CLEARANCE 4 39 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 4 40 CHECK AND MAINTENANCE AIR CONDITIONER 4 41 WASH WASHABLE FLOOR 4 42 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 45 ...

Page 21: ...AINTENANCE 4 75 CHANGE OIL IN FINAL DRIVE CASE 4 75 CLEAN HYDRAULIC TANK STRAINER 4 76 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 76 CHECK ALTERNATOR 4 79 CHECK ENGINE VALVE CLEARANCE ADJUST 4 79 CHECK VIBRATION DAMPER 4 79 EVERY 4000 HOURS MAINTENANCE 4 80 CHECK WATER PUMP 4 80 CHECK STARTING MOTOR 4 80 REPLACE ACCUMULATOR FOR CONTROL CIRCUIT 4 80 CHECK FOR LOOS...

Page 22: ...Using Breaker 6 21 Operation When Using General Attachment 1 e g Crusher 6 23 Working Mode Selection 6 24 Operation When Using Attachment 2 e g clamshell rotation crusher rotation 6 25 LONG TERM STORAGE 6 25 SPECIFICATIONS 6 25 ATTACHMENT GUIDE 6 26 ATTACHMENT COMBINATIONS 6 26 SELECTION OF TRACK SHOES 6 28 METHOD OF SELECTING SHOES 6 28 RECOMMENDED ATTACHMENT OPERATIONS 6 29 HYDRAULIC BREAKER 6 2...

Page 23: ...SHER CONTROL FOR OPENING AND CLOSING 7 11 TILTING CAB MECHANISM OPERATION 7 12 BOOM ANGLE ALARM BUZZER CANCEL SWITCH 7 13 CEILING WINDOW WIPER SWITCH 7 14 MACHINE OPERATIONS AND CONTROLS 7 15 BEFORE STARTING ENGINE 7 15 FUNCTION CHECK 7 16 PRECAUTIONS WHEN OPERATING 7 16 PROHIBITON OF WORK OUTSIDE SPECIFIED WORKING RANGE 7 17 PROHIBITION OF WORK AT THE STROKE END OF A CYLINDER 7 20 PROHIBITION OF ...

Page 24: ...gh reach demolition equipment fitted 7 45 PROCEDURE FOR LOADING ON TO TRAILER 7 45 TRANSPORTATION demolition digging equipment fitted 7 46 PROCEDURE FOR LOADING ON TO TRAILER 7 46 TRANSPORTATION high reach demolition equipment alone 7 46 PROCEDURE FOR LOADING ON TO TRAILER 7 46 SPECIFICATIONS 7 51 WORKING RANGE PC450LCD HIGH REACH 7 51 WORKING RANGE PC450LCD MEDIUM REACH 7 52 WORKING RANGE PC450LC...

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

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

Page 27: ...nce when Engine is Running 2 362 Proper Tools 2 372 Accumulator Gas spring 2 372 Personnel 2 372 Attachments 2 382 Work Under the Machine 2 382 Noise 2 382 When Using Hammer 2 382 Welding Works 2 382 Removing Battery Terminals 2 392 Safety First when Using High pressure Grease to Adjust Track Tension 2 392 Do Not Disassemble Recoil Springs 2 392 Safety Rules for High pressure Oil 2 392 Precaution ...

Page 28: ...nd always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off q There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way q If the labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the labels see this manual or the ac...

Page 29: ...ce q Improper operation and maintenance can cause serious injury or death q Read the manual and labels before operation and mainte nance Follow instructions and warnings in manual and in labels on machine q Warning q a Read the manual before operating maintenance disas sembly assembly and transportation ...

Page 30: ...leaving operator s seat q c WARNING No passengers No passengers allowed to ride on machine while it is moving q d WARNING DANGER OF FALLING OBJECTS Do not operate where a danger of falling objects exists Consult your dealer for fitting of FOPS protection ...

Page 31: ...l function diagram WARNING In order to prevent an accident resulting in injury or death caused by error operation confirm the machine motion and indicated operating pattern when operating machines Pay attention to the circumference and operate slowly when confirming the machine motion 2 Caution for operation inspection and maintenance 20E 00 K1120 q Read the manual before operation maintenance dis...

Page 32: ...or or hydraulic tank will cause personal injury and or burns q Never remove the radiator cap or hydraulic tank oil filler when cooling water or hydraulic oil is at high temperature 5 Caution for handling accumulator 09659 A057B q There is the hazard of explosion causing injury q Do not disassemble the accumulator make holes in it weld it cut it hit it roll it or bring it near flame 6 Caution when ...

Page 33: ...an electric hazard from handling the cable q Read manual for safe and proper handling 8 Stop rotating parts when inspection and maintenance 09667 A0481 q Sign indicates a hazard of rotating parts such as belt q Turn off before inspection and maintenance 9 Emergency escape 09844 00050 ...

Page 34: ...wn q Do not go close to the edge of the machine by mistake 11 Caution against falling 09805 C0481 q Sign indicates a hazard of falling q Do not step here 12 Prohibited to enter within swing range 20E 00 K1150 q There is danger of getting caught when upper structure swings q Do not enter range of swing ...

Page 35: ...by fall ing attachment q Read the manual for safe operation 14 206 00 K1010 q Pump Control override switch and swing lock override switch q Read the operation manual before operation 15 Keeping out of working range area 20E 00 K1140 q Sign indicates a hazard of being hit by the working device of the machine q Keep away from the machine during operation ...

Page 36: ...e a serious bodily injury or fire 17 Caution when swinging or traveling in reverse WARNING When swinging or backing up excavator press button to change display mode on monitor so you can see rear and side of 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 or death 18 Overload caution 208 00 76910...

Page 37: ...ne until the problem has been corrected WORKING WEAR AND PERSONAL PROTECTIVE ITEMS q Do not wear loose clothing and accessories There is a hazard that they may catch on control levers or other protruding parts q If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful not to let it get caught q Always we...

Page 38: ...rious accident q Do not leave parts or tools lying around the operator s compartment q Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire q Do not use cellular telephones inside the operator s compartment when driving or operating the machine q Never bring any dangerous objects such as flammable or explosive items into the operator s compartment LEAVING OPE...

Page 39: ...or steps including the track shoe wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts q Do not get on or off the machine while holding tools in your hand PRECAUTIONS WHEN WORKING IN HIGH PLACES When working at high places use a step ladder or other stand to ensure that the work can be carried out safely MOUNTING AND DISMOUNTING q Never jump on or off...

Page 40: ...antifreeze and window washer liquid are particu larly flammable and can be hazardous To prevent fire always observe the following q Do not smoke or use any flame near fuel or oil q Stop the engine before refueling q Do not leave the machine while adding fuel or oil q Tighten all fuel and oil caps securely q Do not spill fuel on overheated surfaces or on parts of the electrical system q Use well ve...

Page 41: ... loose they may vibrate during operation and rub against other parts This may lead to damage to the hoses and cause high pressure oil to spurt out leading to fire damage or serious injury q Explosion caused by lighting equipment When checking fuel oil battery electrolyte window washer fluid or coolant always use lighting with anti explosion specifications If such lighting equipment is not used the...

Page 42: ...INSTALLATION q When installing optional parts or attachments there may be problems with safety or legal restrictions Therefore contact your Komatsu distributor for advice q Any injuries accidents or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu q When installing and using optional attachments read the instruction manual for t...

Page 43: ...ge electrical lines may be buried under the work site contact each utility and iden tify their locations Be careful not to sever or damage any of these lines q Take action to prevent unauthorized people from approach ing the job site When working on public roads position flagmen and erect barriers to ensure the safety of passing traffic and pedestri ans q When traveling or operating in shallow wat...

Page 44: ...ility but even with mirrors there are places which can not be seen from the operator s seat so always be careful when operating When operating or traveling in places with poor visibility if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine there is danger that the machine may suffer damage or the operator may suffer serious personal injury When...

Page 45: ... glass Be careful also not to slip on the broken pieces of glass on the ground ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on job sites handling demolition work or work handling industrial waste Always observe the following q Spray water to keep down the dust when cleaning Do not use compressed ai...

Page 46: ... electric wiring q Adjust the operator s seat to a position where it is easy to carry out operations and check that there is no dam age or wear to the seat belt or mounting clamps q Check the operation of the instruments and gauges check the angle of the mirror and check that the control levers are all at the Neutral position q Before starting the engine check that lock lever 1 is in LOCK position...

Page 47: ...oughly If the machine is not thoroughly warmed up before the control levers or control pedals are operated the reaction of the machine will be slow or the machine may move in a way not expected by the operator Particularly in cold weather be sure to carry out the warming up operation thoroughly q If the battery electrolyte is frozen do not charge the battery or start the engine with a different po...

Page 48: ...tor to ride on the machine q Check that the travel alarm works properly q Always lock the door and windows of the operator s compart ment in position open or closed On job sites where there is a hazard of flying objects or of objects entering the operator s compartment check that the door and windows are securely closed q If there is an area to the rear of the machine which cannot be seen position...

Page 49: ...und and travel at low speed Never travel over obstacles which make the machine tilt strongly to one side q When traveling or carrying out operations always keep a safe distance from people structures or other machines to avoid coming into contact with them q When passing over bridges or structures check first that the structure is strong enough to support the weight of the machine q When operating...

Page 50: ...ne then travel on to the slope again q Travel on grass fallen leaves or wet steel plates with low speed Even with slight slopes there is a hazard that the machine may slip OPERATIONS ON SLOPES q When working on slopes there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated This may lead to serious injury or property damage so always provi...

Page 51: ... to the road shoulder or cliff with the sprocket at the rear when carrying out operations q Do not carry out demolition work under the machine There is a hazard that the machine may become unstable and tip over q When working on or from the top of buildings or other struc tures check the strength and the structure before starting operations There is a hazard of the building collapsing and causing ...

Page 52: ...ct the boom cylinder There is a hazard that impact will cause the machine to tip over q Do not pass the bucket over the head of other workers or over the operator s seat of dump trucks or other haul ing equipment The load may spill or the bucket may hit the dump truck and cause serious injury or property damage OPERATIONS ON SNOW q Snow covered or frozen surfaces are slippery so be extremely caref...

Page 53: ...lock lever 1 to the LOCK position L then stop the engine q Always close the operator s cab door and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine Always remove the key take it with you and leave it in the specified place q If it is necessary to park the machine on a slope always do as follows q Set the bucket on the downhill side then dig...

Page 54: ...te any lever except for the travel lever q Never correct your steering on the ramps If necessary drive off the ramps correct the direction then enter the ramps again q The center of gravity of the machine will change suddenly at the joint between the ramps and the track or trailer and there is danger of the machine losing its balance Travel slowly over this point q When loading or unloading to an ...

Page 55: ...them immediately with large amount of water and seek medical attention q Before working with batteries turn the starting switch to the OFF position As there is a hazard that sparks will be generated always do as follows q Do not let tools or other metal objects make any contact between the battery terminals Do not leave tools or other metal objects lying around near the battery q When disconnectin...

Page 56: ...roblem machine There is a hazard that the machine will move when the power is connected q Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground side first when removing them q When removing the booster cables be careful not to let the booster cable clips touch each other or to let the clips touch the machine q Always wear safety glasses...

Page 57: ...s ample strength for the weight of the machine being towed q Always wear leather gloves when handling wire rope q Fix the wire rope to the track frame q During the towing operation never stand between the tow ing machine and the machine being towed q Never tow a machine on a slope q Operate the machine slowly and be careful not to apply any sudden load to the wire rope q Never use a wire rope whic...

Page 58: ...de the area q It is dangerous if the raised load hits any person or structure When swinging or operating the work equipment check carefully that the surrounding area is safe q Do not swing or operate the work equipment suddenly There is danger that this may cause the load to sway and the machine to tip over q Do not leave the operator s seat when there is a raised load q Do not use the work equipm...

Page 59: ...EEP WORK PLACE CLEAN AND TIDY q Do not leave hammers or other tools lying around in the work place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean and tidy to enable you to carry out operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self q When cleaning the ...

Page 60: ...ox one minute after turning off the engine starting switch key and press the horn switch If the horn does not sound it is not activated q Put blocks under the track to prevent the machine from mov ing TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury do not carry out maintenance with the engine running If maintenance must be carried out with the engine running carry out the oper...

Page 61: ...cumulator and gas springs is charged with high pres sure nitrogen gas When handling the accumulator careless procedure may cause an explosion which could lead to serious injury or property damage For this reason always observe the following precautions q Do not disassemble the accumulator q Do not bring it near flame or dispose of it in fire q Do not make holes in it weld it or use a cutting torch...

Page 62: ...nt or the machine NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time wear ear cov ers or ear plugs while working If the noise from the machine is too loud it may cause temporary or permanent hearing problems WHEN USING HAMMER When using a hammer pins may fly out or metal particles may be scattered This may lead to serious injury Always do as fol...

Page 63: ...ever attempt to disassemble the recoils spring assembly It contains a spring under high pressure which serves as a shock absorber for the idler If it is disassembled by mistake the spring will fly out and cause serious injury When it becomes necessary to disassemble it ask your Komatsu distributor to do the work SAFETY RULES FOR HIGH PRESSURE OIL The hydraulic system is always under internal press...

Page 64: ...om high pressure hoses it may cause fire or defective operation which may lead to serious injury If any loose bolts are found stop work and tighten to the specified torque If any damaged hoses are found stop operations immediately and contact your Komatsu distributor Replace the hose if any of the following problems are found q Damaged or leaking hydraulic fitting q Frayed or cut covering or expos...

Page 65: ...d by flying particles q When using compressed air to clean elements or the radiator always wear safety glasses dust mask gloves and other protective equipment PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS q For using the machine safely for an extended period of time replace safety critical parts like hoses and seat belts periodically Replacement of safety critical parts See SAFETY CRITICAL PARTS 4...

Page 66: ...SAFETY MAINTENANCE INFORMATION SAFETY 2 42 ...

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

Page 68: ...INE VIEW ILLUSTRATIONS OPERATION 3 2 MACHINE VIEW ILLUSTRATIONS 3 OVERALL MACHINE VIEW 3 1 Bucket 6 Boom cylinder 2 Bucket cylinder 7 Sprocket 3 Arm 8 Track frame 4 Arm cylinder 9 Track shoe 5 Boom 10 Idler ...

Page 69: ...r switch 6 Travel levers 23 Roof wiper switch if equipped 7 Horn switch 24 Quick coupler switch 8 Machine monitor 25 Additional lamp switch 9 Cigarette Lighter 26 2nd attachment proportional control switch 10 Right work equipment control lever 27 Quick coupler switch 11 Starting switch 28 Spare 12 Fuel control dial 29 Spare back of lever 13 Lamp switch 30 1st attachment proportional control switch...

Page 70: ...t temperature gauge 20 Radiator coolant level monitor 6 Hydraulic oil temperature gauge 21 Air conditioner monitor 7 Service meter Clock 22 Wiper monitor 8 Hydraulic oil temperature monitor 23 Swing lock monitor 9 Working mode monitor 24 Engine pre heating monitor or One touch power max monitor 10 Travel speed monitor 11 Fuel gauge 25 Auto deceleration monitor 12 ECO gauge 26 Engine oil level moni...

Page 71: ...splays MONITORING SYSTEM 3 AA Screen for standard BB Screen with all lamps lighted up CC Maintenance time warning screen REMARK 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 lighted up on the screen If there are fewer than 10 black or white spots this is not a failure or a defect A Emergency monitors ...

Page 72: ...starting screen DD is displayed for 2 seconds the screen switches to the working mode travel mode display screen HH q After the working mode travel mode display screen HH is displayed for 2 seconds the screen switches to stan dard screen BB q If the working mode when the engine is started is B mode the opening screen GG is displayed for 2 seconds and the screen then switches to the breaker mode co...

Page 73: ... the temperature and the battery condition If this happens the display on the machine monitor may momentarily go out but this does not indicate any abnormality Stopping Engine When Situation is Normal q When the starting switch is turned to the ON position ending screen JJ is displayed for 5 seconds then on the display goes out ...

Page 74: ...en CC warning screen FF or error screen EE q After displaying the check before starting screen DD for 2 seconds the screen changes to the maintenance interval warning screen CC q After displaying the maintenance interval warning screen CC for 30 seconds the screen returns to the standard screen BB q After displaying the check before starting screen DD for 2 seconds the screen changes to the warnin...

Page 75: ...lity Occurs During Operation q If any abnormality occurs during operation the standard screen BB changes to warning screen FF 1 or the error screen EE q After displaying warning screen FF 1 for 2 seconds the screen automatically changes to warning screen FF 2 ...

Page 76: ...ning screen Type of monitor Color when monitor lights up When normal When abnormal At low temperature 1 Engine coolant temperature monitor Blue Red White 2 Hydraulic oil temperature monitor Blue Red White 3 Fuel level monitor Blue Red 4 Radiator coolant level monitor OFF Red 5 Charge level monitor OFF Red 6 Engine oil pressure monitor OFF Red 7 Engine oil level monitor OFF Red 8 Air cleaner cloggi...

Page 77: ...tor 1 warns operator that the engine coolant temperature has risen If the engine coolant temperature becomes abnormally high the monitor shows abnormal display C The overheat preven tion system is automatically actuated and the engine speed drops Stop operations and run the engine at low idling until monitor 1 shows normal display B Display A at low temperatures Monitor background D is white Displ...

Page 78: ...n it at low idling until the monitor changes to normal display B Display A at low temperatures Monitor background D is white Display B at correct temperatures Monitor background D is blue Display C when condition is abnormal Monitor background D is red Engine Oil Pressure Monitor Monitor 3 lights up red if the engine lubrication oil pressure goes below normal level If monitor lights up red stop th...

Page 79: ...monitor for the abnormal location lights up red Engine Coolant Temperature Monitor If this monitor 1 shows low temperature display A carry out the warm up operation For details see Engine Warm Up 3 131 Monitor 1 will show normal display B so carry out the warm up operation for the engine Display A at low temperatures Monitor background D is white Display B at correct temperatures Monitor backgroun...

Page 80: ...fuel tank is low When the remaining fuel level reaches approx 80 liters the monitor lamp lights up red so add fuel as soon as possible Charge Level Monitor This monitor 4 warns the operator that there is an abnormality in the charging system when the engine is running If the battery is not being charged properly while the engine is running monitor 1 lights up red If monitor lights up red check the...

Page 81: ...GAUGES 3 15 OVERLOAD CAUTION When lifting This monitor 7 warns that the machine is close to tipping due to the load an audible warning is also given if the warning is given lower the load Refer the lifting capacity chart for safe load ...

Page 82: ...tems among the check before starting items that must be checked before starting the engine If there is any abnormality monitor for the location of abnormality will light up Radiator Coolant Level Monitor Monitor 1 warns the operator that there has been a drop in the radiator coolant level If the radiator coolant is low the lamp lights up red so check coolant level in the radiator and subtank and a...

Page 83: ...mains lighted after the maintenance time has already passed q Lighted yellow The maintenance time is due within 30 hours q Lighted red The maintenance time has already passed This monitor lights up when the starting switch is turned to the ON position It goes off after 30 seconds and the display changes to the normal screen REMARK For details of the method of confirming the maintenance inter val s...

Page 84: ...is actuated When the ambient temperature is low and the starting switch is set to the ON position the lamp lights up and when the preheating is completed it goes out The preheating time differs according to the ambient tempera ture Pilot display Gauge and Meter 1 Engine pre heating monitor 10 Engine coolant temperature gauge 2 Swing lock monitor 11 Hydraulic oil temperature gauge 3 Wiper monitor 1...

Page 85: ...ing lock monitor is lighted up the brake remains applied Wiper Monitor Monitor 3 indicates operating status of the wiper The monitor display when wiper switch is operated as follows When ON lights up Wiper moves continuously When INT lights up Wiper moves intermittently OFF Wiper stops q For details of the positions of the wiper switch see CON TROLS AND GAUGES 3 3 Auto deceleration Monitor Monitor...

Page 86: ...tor switch Lo Low speed travel Mi Mid range speed travel Hi High speed travel q For details of the positions of the travel speed selector switch see CONTROLS AND GAUGES 3 3 One Touch Power Max Monitor This monitor 7 shows if the one touch power max function is being actuated The monitor display when the knob switch on the left control lever is operated is as follows The actual monitor display is s...

Page 87: ...meter 10 shows the engine coolant temperature During normal operations the indicator should be in the green range If the indicator goes beyond red range A during opera tions the overheat prevention system is actuated q A B Red range q A C Green range q C D White range The overheat prevention system is actuated as follows Red range A position Engine coolant temperature monitor E shows abnormality d...

Page 88: ...own q A B Red range q A D Green range q D C 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 position 105 C or more When the indicator is in red range A B hydraulic oil temperature monitor E shows the abnormality display When the engine is started if the indicator is at position C and the hydraulic ...

Page 89: ...EMARK When the indicator reaches red range B there is less than 80 liters of fuel remaining When the indicator is in the red range B fuel level monitor D lights up red The correct fuel level may not be displayed for a short time when the starting switch is turned ON but this is not an abnormality Service Meter Clock This meter 13 shows the total hours of operation of the machine or the present tim...

Page 90: ...CO Gauge This gauge 14 shows the working load status When the gauge is in green range A the work load is light to medium When the gauge is in orange range B the load is heavy q When the gauge enters the orange range there is no abnor mality on the machine but to protect the environment reduce the engine output to a point where there is no adverse effect on the operation Generally carry out energy ...

Page 91: ...ttachment ready machines q When the monitor first appears it is automatically set to the mode in use when it was started the previous time q Press switch 1 to display the working mode selection screen For each set mode the pilot monitor at the top right of the monitor display shows P E L B ATT q For machines ready for attachment the attachment mode is added to the display For details of the method...

Page 92: ... default setting please ask your Komatsu distributor to change the setting Procedure for operation 1 If working mode selector switch 1 is pressed the Working Mode screen is displayed on the monitor 2 Press function switches F3 or F4 at the bottom of the screen or working mode selector switch 1 to change the mode selection one at a time q If no switch is touched for more than five seconds the selec...

Page 93: ... to the standard screen The monitor display highlighted in orange in Steps 4 returns to blue REMARK When setting the working mode to B mode to ensure safety the buzzer sounds and at the same time the message in the illustration on the right is displayed When setting to the breaker mode always press function switch F6 q If function switch F5 is pressed the breaker mode is not set and the screen ret...

Page 94: ...ment and travel levers are returned to the N position the engine speed will drop after 4 seconds from the operat ing speed to idling speed This makes it possible to reduce fuel consumption If any lever is operated when the machine is in this condi tion engine speed will return to the previous operating speed to make it possible to perform operations 1 When auto deceleration switch 2 is pressed and...

Page 95: ...s up Low speed travel Mi lights up Medium speed travel Hi lights up Hi speed travel When the engine is started the speed is automatically set to Lo Each time that the switch is pressed the display changes Lo J Mi J Hi J Lo in turn Even if the travel speed is set to high speed Hi or a mid range speed Mi when traveling on soft ground or uphill and travel power is needed the system automatically shif...

Page 96: ...it changes ON INT stop OFF Wiper monitor INT lighted up Wiper operates intermittently Wiper monitor ON lighted up Wiper operates continuously Wiper monitor OFF Wiper stops REMARK Each time wiper switch 4 is pressed the mode is displayed in the center of the monitor display and after two seconds the screen returns to the standard screen ...

Page 97: ...e the wiper will be actuated continuously When switch 5 is released the wiper will continue to operate for 2 cycles then stop q If the wiper is moving intermittently and switch 5 is kept pressed continuously window washer fluid will spray and at the same time the wiper will be actuated continuously When switch 5 is released the wiper will continue to oper ate for 2 cycles then return to intermitte...

Page 98: ...the func tions are displayed as follows F3 Camera screen selector switch if equipped F4 Service meter time display selector switch F5 Maintenance mode switch F6 User mode switch F1 and F2 are auxiliary switches for expanded functions For explanation of each switch see Handling Function Switches 3 33 Air Conditioner Switch The air conditioner switches 8 consist of 9 switches For explanation of each...

Page 99: ...en if guidance icon B is pressed it will not function Press switch A immediately below the guidance icon dis play to operate the function The operation of the function switches if the initial screen is the standard screen is as follows Camera Screen Selector Mode Switch 3 On machines with a camera press switch F3 to switch to the camera screen display q On machines not equipped with a camera the g...

Page 100: ...h F3 is pressed the image display screen is displayed q Press switch F1 to display all the screens for images from the No 1 camera q Press switch F2 to display all the screens for images from the No 2 camera q Press switch F3 to display all the screens for images from the No 3 camera REMARK If the machine is not equipped with a No 2 camera or No 3 camera guidance icons a b and c are not displayed ...

Page 101: ...e the dis play changes more slowly than when only one screen is dis played q Press switch F5 to return to the standard screen Other Mode Operations When Displaying Camera Image q Even during the camera display it is possible to operate other modes q The air conditioner can be operated If the air conditioner switch is operated the screen switches to the air conditioner control screen If the screen ...

Page 102: ...return to the camera image display q Press the travel speed selector switch to change the travel speed mode For details of the travel speed selector switch see Travel Speed Selector Switch 3 29 When the travel speed mode is changed the screen returns to the standard screen To display the camera image press switch F3 again q Press the auto deceleration switch to turn the auto decelera tion function...

Page 103: ...tion When Warning is Generated When Displaying Camera Image q If an error or alarm occurs while the camera image is being displayed the error monitor or alarm monitor is displayed at the top left of the screen and flashes q If the error monitor or alarm monitor is displayed press switch F6 return to the standard screen and check the con tent of the error or alarm display When the error monitor is ...

Page 104: ... 3 16 Caution Monitors 3 13 Emergency Monitors 3 11 and TROUBLES AND ACTIONS 3 189 Service Meter Clock Display Selector Switch 3 On the standard screen it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor display q When the time is being displayed press switch F4 to switch to the service meter display When the service meter is being displayed pr...

Page 105: ...ance items b Default maintenance interval settings h c Time remaining until maintenance h a b Engine oil change 500 Engine oil filter change 500 Fuel main filter change 1000 Fuel pre filter change 500 Hydraulic oil filter change 1000 Hydraulic tank breather change 500 Corrosion resistor change Machines equipped with corrosion resistor 1000 Damper case service 1000 Final drive oil change 2000 Swing...

Page 106: ...esetting the remaining time for the selected item item highlighted in yellow REMARK When resetting the remaining time keep switch F6 pressed for at least 1 5 seconds If switch F6 is not kept pressed for at least 1 5 seconds the switch operating sound can be heard but the screen does not switch to the screen for resetting the remain ing time q If no switch is operated for 30 seconds on the maintena...

Page 107: ...ancel the reset press switch F5 The screen returns to the maintenance list screen On the reset screen if no switch is operated for more than 30 seconds the screen automatically switches to the maintenance list screen 2 The reconfirmation screen shown on the right is displayed 3 If switch F6 is pressed again the remaining time is reset and the screen switches to the maintenance list screen REMARK I...

Page 108: ...owing operations with switches F3 to F6 F3 Moves to next item 1 line down When on the last line it moves to the first line on the next page F4 Moves to previous item 1 line up When on the first line it moves to the last line on the previous page F5 Returns to standard screen F6 Switches to setting screen for selected item q If no switch is operated for 30 seconds on the user menu screen the screen...

Page 109: ...can be set a Breaker attachment setting machines ready for installation of attachment b Message display machines equipped with KOMTRAX c Screen adjustment d Clock adjustment e Language selection f Economy mode adjustment The operation for setting a to f is as follows ...

Page 110: ...l flow in B mode and ATT mode to match the attachment For machines that have no attachment the breaker attach ment setting mode is not displayed Changing Breaker Mode Setting 1 On the standard screen press switch F6 2 Select Breaker Attachment Settings on the user menu then press switch F6 Screen for machine with 1 Attachment Line Screen for machine with 2 Attachment Lines 2 A ...

Page 111: ...h switches F3 to F6 F3 Moves to next item 1 line down F4 Moves to previous item 1 line up F5 Returns to user menu screen F6 Switches to setting screen for selected item 4 The screen switches to the Breaker Select Menu q Breaker setting selection menu In breaker Select a the oil flow to be set in B mode can be set to one of two set values q Breaker flow setting menu In the breaker flow setting b th...

Page 112: ...on 1 Select breaker setting selection a on the breaker setting menu screen then press switch F6 2 On the Breaker Select screen select one of the two set values for the oil flow then press switch F6 q The default values for the flow setting are both set to 300 liter min as shown in the illustration on the right To select the oil flow setting follow the procedure given in Changing breaker flow setti...

Page 113: ...etting screen for selected item Changing breaker flow setting 1 Select breaker flow setting b on the Breaker Select Menu screen then press switch F6 2 On the Breaker Oil Flow Setting screen select one of the two set values for the oil flow then press switch F6 q The default values for the oil flow setting are both set to 300 liter min as shown in the illustration on the right The present oil flow ...

Page 114: ...o previous screen F6 Switches to setting screen for selected item 3 On the Breaker Oil Flow Setting screen change the set oil flow q After using switches F3 or F4 to change to a suitable oil flow press switch F6 to accept the change in the oil flow and return to the previous screen q When switch F5 is pressed no change is made in the oil flow and the screen returns to the previous screen X Present...

Page 115: ... 49 Changing Attachment Mode Setting 1 On the standard screen press switch F6 2 Select Breaker Attachment Settings on the user menu then press switch F6 Screen for machine with 1 Attachment Line Screen for machine with 2 Attachment Lines 2 A ...

Page 116: ... item 1 line up F5 Returns to user menu screen F6 Switches to setting screen for selected item 4 The screen switches to the 2 Way Attachment Select menu q 2 Way Attachment Select In 2 Way Attachment Select a the oil flow to be set in ATT mode can be set to one of two set values q 2 Way Attachment Oil Flow Setting menu In 2 Way Attachment Oil Flow Setting b it is possible to change the oil flow set...

Page 117: ...llowing operations with switches F3 F6 F3 Moves to next item 1 line down F4 Moves to previous item 1 line up F5 Returns to previous screen F6 Switches to setting screen for selected item Changing attachment setting selection 1 Select attachment setting selection a on the attachment setting menu screen then press switch F6 ...

Page 118: ... mode is marked with ATT in front of the item name as shown in the illustra tion on the right q If No 2 Way Attachment is selected it becomes impos sible to select the attachment mode on the working mode selection screen On the working mode selection screen it is not possible to select No 2 Way Attachment q On the 2 Way Attachment Select Menu screen and 2 way attachment select menu it is possible ...

Page 119: ...values for the oil flow setting are both set to 550 liters min as shown in the illustration on the right The present oil flow set for ATT mode is marked with ATT in front of the item q No 2 Way Attachment cannot be selected q On the 2 Way Attachment Select Menu screen and 2 Way Attachment Select Menu screen it is possible to carry out the following operations with switches F3 F6 F3 Moves to next i...

Page 120: ... as a field kit ask distribu tor to change monitor setting to allow 2 attachments as shown below On machines equipped with 2 attachment lines it is possible on the attachment 2 settings menu to adjust the oil flow in ATT mode to match the attachment installed Changing Attachment 2 Mode Setting 1 On the standard screen press switch F6 2 Select Attachment 2 settings on the user menu then press switc...

Page 121: ...attachment setting selection a on the attachment setting menu screen then press switch F6 2 On the 2 Way Attachment Select Menu select one of the two set values for the oil flow then press switch F6 Q The default values for the oil flow setting are both set to 40 l min as shown in the illustration on the right To change the oil flow setting follow the procedure given in See Changing attachment 2 f...

Page 122: ...witch F6 Q The default values for the oil flow setting are both set to 40 l min as shown in the illustration on the right The present oil flow set for ATT mode is marked with ATT in front of the item q On the 2 Way Attachment Select Menu screen and 2 Way Attachment Select Menu screen it is possible to carry out the following operations with switches F3 F6 F3 Moves to next item 1 line down F4 Moves...

Page 123: ...After using switches F3 or F4 to change to a suitable oil flow press switch F6 to accept the change in the oil flow and return to the previous screen Q When switch F5 is pressed no change is made in the oil flow and the screen returns to the previous screen X Present oil flow setting Y Min adjusted oil flow Z Max adjusted oil flow 20 120 2 A ...

Page 124: ...re is no territory where it is possible to the use the message service In territories where it is not possible to use the message service the message display menu functions as follows 1 On the standard screen press switch F6 2 Select User Message on the User Menu then press switch F6 q If you press switch F5 the screen returns to the user menu screen 3 No message is displayed on the screen Press s...

Page 125: ...ack light of the screen 1 On the standard screen press switch F6 2 Select screen adjustment on the user menu then press switch F6 The screen switches to the selection menu screen for screen adjustment q On machines equipped with cameras it is possible to adjust the brightness contrast and back light of the cameras screen on this menu ...

Page 126: ...or screen adjustment is not displayed If screen adjustment is selected from the user menu the adjustment screen in Step 4 is displayed 4 Use switches F2 to F6 to adjust the brightness contrast and back light of the selected screen 1 Adjustment screen for standard screen q If the light switch is at night mode ON and the stan dard screen is adjusted it is possible to adjust the brightness of the mon...

Page 127: ...djusted values to default value F3 Indicator of selected item moves 1 segment to left F4 Indicator of selected item moves 1 segment to right F5 Returns to user menu F6 Accepts change and switches to next item setting Clock Adjustment On this clock adjustment menu it is possible to change the set ting of the clock displayed on the pilot monitor of the standard display ...

Page 128: ...ser menu then press switch F6 The screen switches to the time adjustment selection menu screen q The following three items can be changed a Clock setting b 12 24 hour display mode c Daylight saving time 3 On the clock adjustment selection screen it is possible to carry out the following operations with switches F3 to F6 ...

Page 129: ...F3 Time advances 1 hour F4 Time goes back 1 hour F5 Cancels change and returns to user menu F6 Accepts change and goes to setting for minutes 2 When minute display c is highlighted in orange operate the switches as follows to adjust minute display c If it is not necessary to change the minute setting press switch F6 If the time has been changed always press switch F6 F3 Time advances 1 minute F4 T...

Page 130: ...lighted in yellow press switch F6 to highlight 12h 24h Mode a in yellow 2 Change the 12h 24h mode with the switches as follows The selected display mode b or c is highlighted in green F3 Moves 1 item to left F4 Moves 1 item to right F5 Cancels change and returns to user menu F6 Accepts change and goes to setting for Daylight Saving Time If the setting has been changed always press switch F6 ...

Page 131: ...eturns to user menu F6 Accepts change and goes to setting for Time If the setting has been changed always press switch F6 REMARK Daylight saving time or summer time means moving the clock forward 1 hour to take advantage of the fact that the sun rises early in summer This system is used in many countries during the summer Language Selection On this language selection menu it is possible to select ...

Page 132: ... the language to use for the display then press switch F6 The screen display changes to the selected lan guage q On the language selection screen it is possible to carry out the following operations with switches F3 to F6 F3 Moves to item below F4 Moves to item above F5 Cancels change and returns to user menu screen F6 Accepts change and returns to user menu screen ...

Page 133: ...is economy mode the engine output can be adjusted to improve the fuel consumption in E mode 1 On the standard screen press switch F6 2 Select Economy Mode Adjustment on the user menu then press switch F6 The screen switches to the economy mode adjustment selection menu screen ...

Page 134: ... 3 q The higher the selection is made from E0 to E3 the better the fuel consumption becomes but the produc tion is reduced accordingly q When the machine is shipped it is set to E0 q On the Economy Mode Adjustment menu screen it is possible to carry out the following operations with switches F3 F6 F3 Moves to item below F4 Moves to item above F5 Cancels change and returns to user menu screen F6 Ac...

Page 135: ...s position during cranking Immediately after starting the engine release the key It will automatically return to the ON position B 1 Starting switch 12 Cigarette lighter 2 Fuel control dial 13 Room lamp 3 Lamp switch 14 Emergency pump drive switch 4 Swing lock switch 15 Swing parking brake release switch 5 Machine push up switch 16 Quick coupler switch 6 Lower wiper 17 Quick coupler switch 7 Heate...

Page 136: ...mination is set to day mode Swing Lock Switch WARNING q When not using the swing operation e g when traveling put the swing lock switch to the OFF posi tion q On slopes even when the swing lock switch is at the ON position the weight of the work equipment may cause the upper structure to swing if the swing control lever is operated in the downhill direction This switch 4 is used to lock the upper ...

Page 137: ... switch 6 is pressed the lower wiper is turned on a ON Lower wiper operates b OFF Lower wiper stops Heated Seat When the switch 7 is pressed the heater will operate pro vided the ambient temperature is sufficiently low c ON Heater operates see Note below d OFF Heater stops Note There is a temperature thermostat fitted in the seat cushion the heater only operates when the temperature is low approx ...

Page 138: ...stem Press it once single click and keep it pressed In P and E modes the power max function can be actuated for a maxi mum of only 8 5 seconds q This function is not activated when the working mode is set to L mode B mode or ATT mode Cigarette Lighter This switch 11 is used when lighting cigarettes When the cigarette lighter is pushed in it will return to its origi nal position after several secon...

Page 139: ...the pump control system Do not use it except in emergency Furthermore remove the cause of the problem immediately q If this switch is depressed and moved to the EMERGENCY position by mistake thereby engaging the machine in the work while the machine is in normal condition an E02 mark is shown in the display If E02 is displayed during the work check that the switch is in the NORMAL position This sw...

Page 140: ...he RHS console and 17 on the LH PPC lever must be operated together Refer to Hydraulic Quick Coupler OPERATION 6 5 for an explanation of these switches operation 1st Attachment Proportional Control Switch This switch 18 is a roller proportional control switch used to operate the 1st attachment circuit e g crusher clam shell open close Refer to MACHINE READY FOR ATTACHMENT 6 9 for warnings and expl...

Page 141: ... not to touch the work equipment control lever This lever 1 is a device to lock the work equipment swing travel and attachment if equipped control levers L LOCK position Even when levers or attachment control pedal if equipped are operated machine does not move F FREE position Machine moves according to operation of levers or attachment control panel if equipped REMARK This lock lever is of hydrau...

Page 142: ... operating the travel levers check if the track frame is facing the front or the rear If the sprocket is at the rear the track frame is facing the front This lever 2 is used to change the direction of travel between forward and reverse shows the pedal operation a FORWARD The lever is pushed forward The pedal is angled forward b REVERSE The lever is pulled back The pedal is angled back N Neutral Th...

Page 143: ...ROLS AND GAUGES 3 77 Right work equipment control lever 4 is used to operate the boom and bucket Boom operation a RAISE b LOWER Bucket operation c DUMP d CURL N Neutral The boom and bucket are held in position and do not move ...

Page 144: ...ntrol pedals is touched by mistake this may lead to a serious accident Opening 1 Set the lock lever 1 securely to the LOCK position L 2 Push up lock A in the front center of the roof window and check that the lock is released Then hold grip B and push up the roof window Closing Hold grasping grip B lower the ceiling window and apply lock A If the lock cannot be applied open the ceiling window then...

Page 145: ...ground stop the engine then carry out the operation q When opening the front window hold the grip securely with both hands pull up and do not let go until the automatic lock catch is locked q When closing the front window the window will move quicker under its own weight Hold the grips securely with both hands when closing it It is possible to stow pull up the front window in the roof of the opera...

Page 146: ...OLS AND GAUGES OPERATION 3 80 4 Hold 2 grips A on the left and right top sides of the front window and pull the 2 levers B to release the locks at the top of the front window The top of the front window will come out ...

Page 147: ...t lock catch E at the rear of the cab securely to lock the window 6 Check that lever B is securely at the LOCK position q The lock is engaged if the arrow on lock case F matches the position of the arrow on lever B Check visually q 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 Step 5 to engage the lock ...

Page 148: ...n level ground lower the work equipment completely to the ground then stop the engine 2 Set the lock lever 1 securely to the LOCK position L 3 Grip left and right handles A and pull down lever B to release the lock 4 Grip handle C at the bottom of the front window with your left hand and handle D at the top with your right hand push to the front then lower slowly ...

Page 149: ...n of the arrow on lever B Check visually q 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 Step 5 to engage the lock Removing Lower Windshield 1 Open the front window then hold grip 1 pull up and remove the bottom window q If sand or dust is collected at the bottom of the front window it will be difficult to remove th...

Page 150: ... break the window glass with the hammer be extremely careful not to injure yourself on the flying pieces of broken glass To prevent injury remove the broken pieces of glass remaining in the frame before escaping through the window Be careful also not to slip on the broken pieces of glass If it should become impossible to open the cab door for any reason and it is necessary to make an emergency esc...

Page 151: ...e injury Use the door lock to fix the door in position after opening it 1 Push the door against catch 1 to lock it in position 2 When closing the door push down the lever 2 on the left of the operator s seat to release the catch 3 When attaching the door in position lock it firmly to the catch CAP WITH LOCK 3 Use the starting switch key to open and close the locks on the caps and covers For detail...

Page 152: ...g the Cap 1 Turn the cap until tight then insert the key into the key slot 2 Turn the starting switch key to LOCK position B then remove the key Opening and Closing Cover with Lock Opening the Cover Locked Cover 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pull ing the cover grip A Open B Lock Locking the Cover 1 Close the cover and insert the key into t...

Page 153: ... air conditioner MAGAZINE BOX 3 The cup holder is provided separately at the front of the magazine box Located on left side of the operator s seat Keep the Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary ASHTRAY 3 This is on top of the console box on the left side of the opera tor s seat Always put out your cigarette before putting it in the ash...

Page 154: ...o stop the fan and air conditioner REMARK Even if this switch 1 is pressed the monitor screen does not switch to the air conditioner adjustment screen 1 OFF switch 6 FRESH RECIRC selector switch 2 Fan switch 7 Display monitor 3 Temperature control switch 8 Air conditioner switch 4 Vent selector switch 9 Sunlight sensor 5 Auto switch ...

Page 155: ...re Control Switch Switch 3 is used to control temperature inside the cab The temperature can be set between 18 C and 32 C q Press the E switch to raise the set temperature press the R switch to lower the set temperature q The temperature is generally set at 25 C q The temperature can be set in stages of 0 5 C Monitor display and the function REMARK If the mode is set to auto mode and the temperatu...

Page 156: ...A Rear vent 4 places B1 Face vent 1 place C Foot vent 1 place D Front window glass vent 2 place B2 Front window glass vent 1 place Note 1 Air blows from vents marked O Liquid crystal display Vent mode Vent Remarks A B C D Front vents O Cannot be selected for auto matic operation Front and rear vents O O Front rear and foot vents O O O Foot vent O Foot vent Defroster vent O O Cannot be selected for...

Page 157: ...igh but this is not a problem FRESH RECIRC Selector Switch Switch 6 is used to switch the air source between recircula tion of the air inside the cab and intake of fresh air from the out side q During automatic operation the selection of inside air RECIRC and outside air FRESH is performed automati cally Display Monitor Monitor 7 displays the status of temperature setting a air flow b and vents c ...

Page 158: ...ot be operated while the fan is off Sunlight Sensor This sensor 9 automatically adjusts the flow of air from the vents to match the strength of the sun s rays In addition it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun s rays before hand and automatically adjusts the temperature Method of Operation 3 The air conditioner can be operate...

Page 159: ...lated air is automatically selected accord ing to the set temperature and the air conditioner is oper ated automatically to provide the set temperature REMARK When vent display monitor c displays d or e and engine coolant temperature is low the air flow is automatically limited to prevent cold air from blowing out Stopping Automatic Operation Press OFF switch 1 Operation stops ...

Page 160: ...eration 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Turn air conditioner switch 8 ON 3 Press temperature setting switch 3 and adjust tempera ture inside the cab ...

Page 161: ...ts When this is done the display for vent c of the display monitor changes according to the selection 5 Press RECIRC FRESH selector switch 6 and select recir culation of the air inside the cab RECIRC or intake of fresh air from outside FRESH Stopping Manual Operation Press OFF switch 1 Operation stops ...

Page 162: ...an switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set the vent display on the display monitor to the display shown in the diagram on the right 3 Turn air conditioner switch 8 ON 4 Adjust fan switch 2 temperature setting switch 3 and RECIRC FRESH selector switch 6 to the desired posi tion...

Page 163: ...st the air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display on the display monitor to f or g as shown in diagram on the right 3 Press RECIRC FRESH selector switch 6 and set it to take in fresh air ...

Page 164: ...d failure be careful not to let water get on these parts In addition never bring any flame near these parts q For the auto function of the air conditioner to work properly always keep the sunlight sensor clean and do not leave anything around the sunlight sensor that may interfere with its sensor function Ventilation q When running the air conditioner for a long time turn the lever to the FRESH po...

Page 165: ...g used every day to pre vent loss of the film of oil at various parts run at the engine at low speed from time to time and carry out cooling or dehu midifying heating for several minutes q If the temperature inside the cab is low the air conditioner may not work In this case circulate fresh air to warm the inside of the cab When the air conditioner switch is turned ON the air conditioner will work...

Page 166: ...0 VOL 40 SEL button Each time this button 2 is pressed the mode changes as follows VOL volume J BAS bass J TRE treble J BAL balance The mode is displayed on display 7 For details of each mode see Method of Operating Mode 3 103 FM AM Selection Button AM FM Press this button 3 to select the desired band Each time the button is pressed the band changes FM J AM J FM 1 Power switch Volume control knob ...

Page 167: ... pressed within 2 seconds it is possible to select one of the already preset stations Wait for 6 sec after pressing the button and then press the button again to select the next preset station If it is impossible to receive the preset frequency the selection advances after 1 second to the next preset station Preset Station Buttons 1 2 3 4 5 6 If this button 6 has been used to decide which stations...

Page 168: ...nnel each for AM and FM can be preset to each Preset button REMARK It is also possible to save to the Preset button by using the auto store button Method of Tuning 1 Press power switch 1 and display the frequency on display 7 2 Use tuning button 9 to set to the desired frequency There are two methods for tuning auto tuning and man ual tuning q Manual tuning Press tuning button 9 until the frequenc...

Page 169: ...h each mode the display is returned automatically to its original setting after 5 seconds Setting Correct Time 1 Press display selector button 4 to display the time After 5 seconds the display will return to the frequency dis play and the time cannot be corrected If this happens press display selector button 4 again 2 Press time adjustment button 8 to select Hour or Minute H button Adjusts the hou...

Page 170: ... may lead to an unexpected failure so be careful not to get water on the equipment q Do not wipe the scales or buttons with solvent such as benzene or thinner Wipe with a dry soft cloth If the dirt cannot be removed easily soak the cloth with alcohol q When the battery is replaced the settings for the preset buttons are all cleared so set them again Space for radio cassette 3 The radio cassette is...

Page 171: ...s as the power supply for 12V equipment It will cause failure of the equipment Pull out the connector plug for taking out electric power from the rear side of the panel Maximum usable electric power is 85 W 24 V x 3 5 A 12V Power Source 3 If equipped This power source can be used up to a capacity of 60W 12V x 5A ...

Page 172: ... hazard switch 2 30A Solenoid valve 3 10A PPC hydraulic lock solenoid 4 10A Window washer cigarette lighter 5 10A Horn 6 10A Auto pre heater lower wiper 7 10A Rotating lamp heated mirror if fitted 8 20A Working lamp rear lamp 9 10A Radio speaker L H lever power max quick coupler switch hydraulic ladder quick coupler solenoid 10 10A Refuel pump 11 20A Air conditioner unit 12 20A Rear worklamp 13 20...

Page 173: ...o the large sized fuse wiring installed in the high current flow portion of the circuit to protect electrical components and wiring from burning in the same way as an ordinary fuse CONTROLLER 3 Controller installed NOTICE q Be careful not to get water mud or juice on the controller This will cause failure q The engine controller has been given moisture prevention treatment so there is no problem i...

Page 174: ... they do not contact the battery This may cause damage to the battery GREASE PUMP HOLDER 3 This is inside the door at the rear right of the machine When not using the grease gun fit it in this holder FIRE EXTINGUISHER 3 If equipped A fire extinguisher is prepared at the rear part inside the opera tor s cab The directions are described on the nameplate affixed to it Just in case carefully read and ...

Page 175: ...s The refuelling pump is located under the air cleaner at the right hand side of the machine 2 Place the fuel hose 2 which is stored in tray 3 into the fuel barrel placed next to the fuel tank 3 Switch on refuelling pump using switch 1 on the pump assembly when adding fuel never let the fuel overflow This may cause a fires NOTICE q This pump is protected by a fuse 2 If pump fails to function check...

Page 176: ...ped with an accumulator in the control circuit The accumulator is a device to store oil pressure for the control circuit and when it is installed the control circuit can be actuated for a short time even after the engine is stopped Due to this device the work equipment lowers under its own weight if the control lever is moved in the lowering direction The accumulator is installed to the position s...

Page 177: ...inders linkage hoses Check for cracks excessive wear play in work equipment cylinders linkage and hoses If any problem is found repair it 2 Remove dirt and debris from around the engine battery and radiator Check for dirt accumulated around the engine and radiator Also check for flammable material dry leaves twigs etc around the battery engine muffler turbocharger or other high temperature engine ...

Page 178: ...at belt and mounting clamps If there is any damage replace with new parts 10 Check bucket with hook if equipped for damage Check for damage to the hook guide and hook mount If any problem is found contact your Komatsu distrib utor for repairs 11 Check clean rear view monitor Check that there is no problem with the rear view monitor If any problem is found contact your Komatsu dis tributor and ask ...

Page 179: ...nds after stopping the engine move each control lever for work equipment and travel to the full stroke in all directions to release the internal pressure 4 Check sight gauge G The oil level should be between the H and L marks 5 If the level is below the L mark add oil through oil filler F at the top of the hydraulic tank REMARK The oil level will vary depending upon the oil temperature Accordingly...

Page 180: ...en remove it 4 The oil level should be between the H and L marks on dip stick G If the oil level is below the L mark add oil through oil filler F 5 If the oil is above the H mark on the gauge remove cover 1 drain the excess oil from drain valve P at the bottom of the engine oil pan then check the oil level again 6 If oil level is correct securely tighten the oil filler cap and close the engine hoo...

Page 181: ...1 3 It is possible to judge the water level and amount of sedi ment by looking through transparent cap 2 If there is any water or sediment collected at the bottom set a container to catch the drain water under drain hose 3 4 Loosen drain valve 4 and drain the water 5 When fuel starts to drain from drain hose 3 tighten drain valve 4 immediately Tightening torque 0 2 to 0 45 Nm 0 02 to 0 046 kgm ...

Page 182: ...d of burns Wait for the temperature to go down then turn the cap slowly to release the pressure and remove it carefully 1 Open the rear engine hood and check that the cooling water level is between the FULL and LOW marks on the sub tank 1 If the water level is low add water through the water filler of sub tank 1 to the FULL level 2 After adding coolant tighten the cap securely 3 If the sub tank 1 ...

Page 183: ...nd no damage to the covering Check also that there is no loosened terminals If any tighten them Moreover pay particular attention to the electric wiring when checking the battery engine starting motor and alter nator Be sure to check that there is no inflammable material accumulated around the battery If any is found remove immediately Check Fuel Level Add Fuel WARNING When adding fuel never spill...

Page 184: ...tab of fuel filler cap F and tighten fuel filler cap F securely REMARK If breather hole 3 on the cap is clogged the pressure in the tank will drop and fuel will not flow Clean the hole from time to time Check Working Lamp Switch Check that the working lamps and lamps inside the instruments light up properly Check also that there is no dirt or damage If any lamp does not light up the bulb is probab...

Page 185: ... operator s seat so control levers and switches can be operated freely and easily with the operator s back against the backrest A Fore and aft adjustment Pull lever 1 up set the seat to the desired position then release the lever Fore and aft adjustment 160 mm 16 stages B Adjusting reclining REMARK The seat can be reclined more when the seat is pushed to the front The amount of reclining decreases...

Page 186: ...er setting the forward tilt or rear tilt to the desired height operate the opposite part to set the seat horizontal then secure in position Height adjustment 60 mm D Adjusting armrest height The height of armrest 5 can be adjusted up or down by changing the position of adjustment bolt 6 at the rear of the armrest Armrest height adjustment 33 mm E Overall fore and aft adjustment of seat Move lever ...

Page 187: ...s weight 60 150 kg H Heated seat Turn the heated seat switch ON to warm the seat cushion and the seat back Adjusting Angle of Rear View Camera If the image on the monitor is not aligned correctly remove cover 1 and adjust the mounting angle A of the rear view camera Amount of adjustment of angle A Within a range of 35 80 1 When removing cover 1 insert a flat headed screwdriver into the hole of cov...

Page 188: ...lt 4 is aligned with fourth from bottom scale B REMARK Part of the machine is shown on the monitor screen 5 After adjusting tighten bolt 4 Tightening torque 3 5 Nm 0 3 0 5 kgm Rear View Mirrors 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 injure someone seriously ...

Page 189: ... 8 1 0 kgm q When adjusting the side view mirror angle make an adjust ment so that the side of the machine comes into view on the mirror as shown in the figure at right Mirror B Adjust the mirror mount so that it is possible to see people at the rear right of the machine q Install the side view mirror in the location indicated in the fig ure at right M 40 mm q If the side view mirror does not move...

Page 190: ...ay from the machine can be seen W 1 m q If side view mirror C D does not move smoothly when adjusting its angle loosen mirror securing screw 6 Tightening torque of screw 6 0 98 1 47 Nm 0 10 0 15 kgm q When installing mirrors C and D make sure to leave clearance V to prevent contact between the mirror and mir ror stay V Min 10 mm ...

Page 191: ...ear the seat belt during operations q Fit the seat belt so that it is not twisted Fastening and Removing This seat belt has a wind in device so it is not necessary to adjust the length Fastening Seat Belt Hold grip 2 and pull the belt out from wind in device 1 check that the belt is not twisted then insert tongue 3 into buckle 4 securely When doing this pull the belt lightly to check that it is pr...

Page 192: ... is at the LOCK position L 2 Check that each control lever and control pedal is at the Neutral position If the control levers and control pedal are not being touched they will be at the Neutral position 3 Insert the key in starting switch 2 turn the key to the ON position B then carry out the following checks q If a password has been set the input display screen will be displayed on the monitor sc...

Page 193: ...conds the screen will change to the working mode travel speed display monitor Next it will switch to the standard screen q Engine coolant temperature gauge 9 q Engine coolant temperature monitor 10 q Fuel gauge 11 q Fuel level monitor 12 q Hydraulic oil temperature gauge 13 q Hydraulic oil temperature monitor 14 3 If the hydraulic oil temperature gauge goes out and cau tion lamp 15 stays lighted u...

Page 194: ...ed MAX position the engine will accelerate suddenly and cause damage to the engine parts q Do not keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes then start again from the beginning q After the engine starts wait for the engine oil pressure monitor to go out Do not touch the control levers or con...

Page 195: ... the right 4 If the preheating monitor does not light up or it lights up and then goes out to inform that the engine preheating has been completed turn the key in starting switch 3 to the START position C and start the engine REMARK If the ambient temperature is low the engine may not start even when the key in the starting switch 3 is kept at the START position for 20 seconds If this happens wait...

Page 196: ... After the preheating monitor goes off turn the key in starting switch 3 to START position C The engine will start If the engine cannot be started with the above procedure wait for at least two minutes then start again from Step 1 Turbo protect function The turbo protect function is a function to protect the turbocharger by keeping the engine speed at less than 1000 rpm immediately after the engin...

Page 197: ...ydraulic equipment thoroughly There are two types of warm up operation warm up the engine and warm up the hydraulic equipment In addition depending on the environment the method of carrying out the warm up operation may differ so carry out the warm up operation according to the items given in the appropriate section When only the engine is warmed up the hydraulic equipment is not warmed up so alwa...

Page 198: ...gine until the mon itor displays the correct temperature A Display when temperature is correct Monitor back ground C is blue B Display when temperature is low Monitor background C is white 3 Turn fuel control dial 2 to a point midway between low idling MIN and full speed MAX run the engine under no load at a mid range speed until engine coolant temperature monitor 1 displays the correct temperatur...

Page 199: ...tion q Carry out the warming up operation for the hydraulic equipment until the hydraulic oil temperature monitor displays the correct temperature When the hydraulic oil temperature is low the low temperature display shown in the diagram on the right is given A Display when temperature is correct Monitor back ground C is blue B Display when temperature is low Monitor back ground C is white q The w...

Page 200: ... the engine until engine coolant temperature monitor 1 displays the correct temperature For details of the procedure see Engine Warm Up 3 131 2 Turn swing lock switch 2 ON and check that the swing lock monitor lights up 3 To complete the warm up operation of the hydraulic equip ment more quickly set the working mode to P mode heavy duty mode For details of the procedure for setting the working mod...

Page 201: ... work equipment control lever 6 slowly in the direction to push out the arm A Operate the lever to the end of its travel and hold it in position for 30 seconds 10 Repeat the operation in Steps 6 to 9 for 5 minutes 11 Check that hydraulic oil temperature monitor 7 is display ing the correct temperature If the hydraulic oil temperature monitor is not displaying the correct temperature it is displayi...

Page 202: ...nitor 12 OFF q Engine preheating lamp 13 OFF q Engine water temperature gauge 14 Indicator in green range q Engine coolant temperature monitor 1 Displays cor rect temperature q Hydraulic oil temperature gauge 15 Displays green range q Hydraulic oil temperature monitor 7 Displays correct temperature q Fuel gauge 16 Displays green range q Fuel level monitor 17 Display is correct level 14 Check for a...

Page 203: ... background C is white For both normal temperatures and cold temperatures carry out the following operation 16 Check that fuel control dial 4 is at a point midway between low idling MIN and full speed MAX If it is not at the midway position set it to the midway posi tion and run the engine at a mid range speed before oper ating 17 Before starting operations repeat the following operations slowly 3...

Page 204: ...re monitor is not displaying the correct temperature it is displaying low temperature repeat Steps 6 to 10 until the display is the correct temper ature A Display when temperature is correct Monitor back ground C is blue B Display when temperature is low Monitor background C is white If the hydraulic oil temperature monitor displays the correct temperature the hydraulic equipment warm up opera tio...

Page 205: ...ect Monitor back ground C is blue q B Display when temperature is low Monitor back ground C is white 2 Push working mode selector switch 20 of the machine monitor to select the working mode to be used For details of the procedure for selecting the working mode see Working Mode Selector Switch 3 25 q Working mode monitor display 1 P mode For heavy duty operations 2 E mode For operations with emphas...

Page 206: ...CHINE OPERATIONS AND CONTROLS OPERATION 3 140 3 L mode For operations requiring fine control 4 B mode For breaker operations 5 ATT mode For operations with crusher or other double acting action attachment ...

Page 207: ...d Do not stop the engine abruptly except in an emergency If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Run the engine at low idle for about 5 minutes to cool down gradually 2 Turn the key in starting switch 1 to the OFF position A and stop the engine 3 Remove the key from starting switch 1 ...

Page 208: ...nd the horn q Do not allow anyone to enter the area around the machine q Clear any obstacles from the travel path q There is a blind spot at the rear of the machine so be particularly careful when traveling in reverse q If the travel levers or travel pedals is operated when the auto deceleration is being actuated the engine speed will suddenly rise so be careful when operating q When traveling che...

Page 209: ...art the machine either by pushing lever 5 forward slowly or by stepping on the front part of pedal 6 slowly q When sprocket is situated at the front of the machine Start the machine either by pulling lever 5 back slowly or by stepping on the rear part of pedal 6 slowly 3 Check that the travel alarm sounds properly If the travel alarm does not sound please contact your Komatsu distributor for repai...

Page 210: ...y pull the levers 5 backward or slowly depress the rear part of the pedals 6 to move the machine backward q When sprocket A is at the front of the machine Slowly push the levers 5 forward or slowly depress the front part of the pedals 6 to move the machine backward 3 Check that the travel alarm sounds properly If the travel alarm does not sound please contact your Komatsu distributor for repair RE...

Page 211: ...ON MACHINE OPERATIONS AND CONTROLS 3 145 Stopping Machine 3 Avoid stopping suddenly Give yourself ample room when stopping 1 Put the left and right travel levers 1 in the neutral position then stop the machine ...

Page 212: ... movement of the machine Use the travel levers to change direction Avoid sudden changes of direction as much as possible Espe cially when performing counter rotation spin turn stop the machine before turning Operate two travel levers 1 as follows Steering the Machine when Stopped When turning to the left Push the right travel lever forward to turn to the left when trav eling forward and pull it ba...

Page 213: ...eft A Forward left turn B Reverse left turn REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left pull the left travel lever back and push the right travel lever forward REMARK When using counter rotation to turn right pull the right travel lever back and push the left travel lever forward ...

Page 214: ...e auto deceleration function the engine speed will suddenly rise operate the levers carefully 1 Before starting the swing operation turn swing lock switch 1 OFF and check that swing lock monitor 2 has gone out a ON position b OFF position 2 Operate left work equipment control lever 3 to swing the upper structure A Left swing B Right swing 3 When not using the swing turn swing lock switch 1 ON Chec...

Page 215: ...control levers to operate the work equipment Note that when the levers are released they return to the HOLD position and the work equipment is held in that position q Arm control Move the left work equipment control lever to the front or rear to operate the arm q Swing control Move the left work equipment control lever to the left or right to swing the upper structure q Boom control Move the right...

Page 216: ...uce the engine speed to a mid range speed REMARK The control circuit on this machine is equipped with an accumulator Even if the engine is stopped if the starting switch key is turned to the ON position within 15 seconds after stopping the engine and the lock lever is set to the FREE position it is possible to use the lever operation to lower the work equipment to the ground This procedure can als...

Page 217: ...ffi cient mode to match the type of work NOTICE If breaker operations are carried out in a mode other than the breaker mode there is danger of breakage of the hydraulic equipment Do not carry out breaker operations in any mode except the breaker mode 1 If working mode selector switch 1 is pressed the working mode selection screen is displayed on the monitor Working mode Applicable operations P mod...

Page 218: ... switch 1 is kept pressed the selected mode is accepted and the screen returns to the standard screen q If the breaker mode is selected Really Set Breaker Mode is displayed on the screen To set to the breaker mode press switch F6 If switch F5 is pressed the screen returns to the working mode selection screen One Touch Power Max Switch The one touch power max Switch can be used during operations to...

Page 219: ...wing force to compact soil or break objects This is not only dangerous but will also drastically reduce the life of the machine Operations Using Travel Force Do not dig the bucket into the ground and use the travel force to carry out excavation This will damage the machine or work equipment Prohibited to Extend Hydraulic Cylinder to End of Stroke If the work equipment is used with the cylinder rod...

Page 220: ... contacts the rock behind the principle of the lever will bring excessive force to bear on the machine or work equip ment and there is danger that this may lead to breakage or damage of the machine In such situations use only the force of the arm and bucket to carry out the digging operation If any excessive force is brought to bear the safety valve in the hydraulic system auto matically controls ...

Page 221: ...ent and frame and this will reduce the service life of the machine Digging Hard Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it after breaking up by some other means This will not only save the machine from damage but will make for better econ omy Operations When Machine is Not Stable Do not carry out operations when the machin...

Page 222: ... pedals suddenly or take any other action to move the machine quickly 2 Do not operate the levers or pedals suddenly from FOR WARD A to REVERSE B or from REVERSE B to FOR WARD A 3 Do not operate the levers or pedals suddenly do not release them suddenly to stop the machine when traveling at high speed High Speed Travel Operations on Rough Ground Do not travel at high speed on rough ground or rocks...

Page 223: ... will cause a big shock to the chassis and in particular to the tracks and this will cause damage to the machine For this reason always remove any obstacles or travel around them or take other steps to avoid traveling over such obstacles as far as possible If there is no way to avoid traveling over an obstacle reduce the travel speed keep the work equipment close to the ground and try to travel so...

Page 224: ...l 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 deeper than the center of carrier roller 1 Supply grease to the parts which have been under water for a long time until the used grease is projected out of the bearings around the bucket pin in particular ...

Page 225: ... across slopes Always go down to a flat place to perform these opera tions It may be longer but it will ensure safety q Always operate or travel in such a way that it is possi ble to stop safely at any time if the machine slips or becomes unstable q When traveling uphill if the shoes slip or it is impossi ble to travel uphill using only the force of the tracks do not use the pulling force of the a...

Page 226: ...opped on Slope If the engine stops when traveling uphill move the travel levers to the neutral position lower the bucket to the ground stop the machine then start the engine again Cab Doors on Slope q If the engine stops when the machine is on a slope never use the left work equipment control lever to carry out swing operations The upper structure will swing under its own weight q Do not open or c...

Page 227: ...bottom of the bucket in contact with the ground The angle between the boom and arm should be 90 to 110 The same applies when using the bucket installed in the reverse direction When only one side is stuck in mud use the bucket to raise the track then lay boards or logs and drive the machine out Tracks on Both Sides Stuck 3 When the tracks on both sides are stuck in mud and they slip making it impo...

Page 228: ...is from a 45 angle away from the machine to a 30 angle towards the machine There may be some differences depending on the excavation depth but try to stay within the above range rather than operat ing the cylinder to the end of its stroke Shovel Work 3 NOTICE The rock bucket PC 400 if equipped PC 450 standard interferes with the arm so it cannot be reversed to carry out excavation to the front A s...

Page 229: ...places where the swing angle is narrow work efficiency can be enhanced by locating the dump truck in a place easily visi ble to the operator Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side ...

Page 230: ...fingers caught q Never insert your fingers into the pin holes when aligning the holes Stop the machine on a firm and flat surface and do the work When performing joint work appoint a lead and follow that person s instructions and signals Replacement 3 1 Place the bucket in contact with a flat surface REMARK When removing the pins place the bucket so that it is in light contact with the ground If t...

Page 231: ...d dirt may enter the pin portion and cause abnormal wear of the pin Inversion 3 NOTICE The rock bucket PC 400 if equipped PC 450 standard interferes with the arm so it cannot be reversed to carry out excavation to the front 1 Place the bucket in contact with a flat surface REMARK When removing the pins place the bucket so that it is in light contact with the ground If the bucket is lowered strongl...

Page 232: ... seal if it has been damaged If a damaged seal is used without being replaced sand and dirt may enter the pin portion and cause abnormal wear of the pin PARKING MACHINE 3 WARNING q Avoid stopping suddenly Give yourself ample room when stopping q When stopping the machine select flat hard ground and avoid dangerous places If it is unavoidably necessary to park the machine on a slope insert blocks u...

Page 233: ... and right travel levers 1 in the neutral position The machine stops 2 Turn fuel control dial 2 to low idling position MIN and lower the engine speed 3 Lower the bucket horizontally until the bottom touches the ground 4 Set lock lever 3 in the LOCK position L ...

Page 234: ...ING THE ENGINE 3 141 MACHINE INSPECTION AFTER DAILY WORK 3 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 any mud affixed to the undercarr...

Page 235: ...lect the method of transportation to match the weight and dimensions given in SPECIFICATIONS PAGE 5 2 Note that the weight and dimensions given in SPECIFICATIONS may differ according to the type of shoe or arm or other attachments q Please consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard installed for the operator s cab ...

Page 236: ...erate any lever except the travel lever The center of gravity of the machine will change suddenly at the joint between the ramps and the trailer and there is danger of the machine losing its balance Travel slowly over this point If it is necessary to swing the work equipment on the trailer platform the footing is unstable so be extremely careful that the machine does not tip over If the work equip...

Page 237: ...prevent them from bending 3 Turn the travel speed selector switch to low speed travel Lo lamp lights up q Press travel speed selector switch 5 to switch the travel speed The travel speed Lo Mi Hi is displayed on the travel speed monitor 6 4 Turn auto deceleration switch 7 OFF and operate the fuel control dial to set the engine speed to low idling q Each time auto deceleration switch 7 is pressed i...

Page 238: ...tion of travel with the ramps and travel slowly Lower the work equipment as far as possible without caus ing interference When on the ramps operate only the travel lever Do not operate any other lever 8 When loading or unloading a machine with the work equip ment installed at the point where the tracks are on both the ramps and the ground surface turn the swing lock switch OFF then swing the upper...

Page 239: ... of wooden blocks Securing Machine 3 NOTICE q Stow the antenna and reassemble the mirrors so that they are within the width of the machine q To prevent damage to the bucket cylinder during transportation fit a wooden block at one end of the bucket cylinder to prevent it from touching the floor Load the machine onto a trailer as follows 1 Extend the bucket and arm cylinders fully then lower the boo...

Page 240: ...ntenna 1 in position q When unloading the machine from the trailer and operating it follow the opposite procedure from stowing to set radio antenna 1 vertical then secure it in position with bolt 2 Rear View Mirrors The mirrors are at the positions shown in the diagram on the right If they are damaged or are to be removed for shipment or are to be installed again use the following procedure q Afte...

Page 241: ...Loosen locknut 2 then remove mirror 1 from bracket 3 6 Remove bolt 4 then remove bracket 3 from the machine Installation Mirror A 1 Install support 3 and clamp 5 to the handrail then tighten with bolt 4 2 Install mirror 1 to bracket 3 then tighten locknut 2 Mirror B 3 Install support 3 and clamp 5 to the handrail then tighten with bolt 4 4 Install mirror 1 to support 3 then tighten lock bolt 2 ...

Page 242: ...y then put blocks 1 under the tires to prevent the trailer from moving q Set left and right ramps 2 parallel to each other and equally spaced to the left and right of center 3 of the trailer Make angle of installation 4 a maximum of 15 If the ramps bend a large amount under the weight of the machine put blocks under the ramps to prevent them from bending 3 Remove the chains and wire ropes fastenin...

Page 243: ...uipment pull in the arm under the boom then move the machine slowly 9 When the machine is horizontal on top of the rear wheels of the trailer stop the machine NOTICE q When unloading the machine always keep the arm and boom at an angle of 90 110 If the machine is unloaded with the arm pulled in it will cause damage to the machine q When moving onto the ramps do not thrust the bucket into the groun...

Page 244: ...at the machine may lose its balance NOTICE This method of lifting applies to the standard specification machine The method of lifting differs according to the attachments and options installed For details of the procedure for machines that are not the standard specification please consult your Komatsu distributor For weight see SPECIFICATIONS 5 2 When lifting the machine carry out the operation on...

Page 245: ...rack rollers from the rear However for machines equipped with a full roller guard for the track roller pass the wire rope under the track 6 Set the lifting angle A of the wire rope to 30 to 40 then lift the machine slowly 7 After the machine comes off the ground check the hook condition and the lifting posture and then lift slowly ...

Page 246: ...chine please ask your Komatsu distributor to divide the machine up into kits Posture for Each Unit Upper Structure Undercarriage Upper Structure Undercarriage without cab Item Unit PC450 PC450LC A mm 3 285 3 285 B mm 5 850 6 015 Overall width mm 3 340 3 440 Weight kg 24 510 25 510 Item Unit PC450 PC450LC A mm 3 205 3 205 B mm 5 850 6 015 Overall width mm 3 340 3 440 Weight kg 23 940 24 940 ...

Page 247: ...50 PC450LC A mm 1 670 B mm 1 840 Overall width mm 1 000 Weight kg 570 Item Unit PC450 PC450LC A mm 7 280 B mm 1 730 Overall width mm 985 Weight kg 4 600 Item Unit PC450 PC450LC A mm 4 890 B mm 1 950 Overall width mm 1 620 Weight kg 3 400 Item Unit PC450 PC450LC A mm 1 145 B mm 2 996 C mm 970 Weight kg 9 220 ...

Page 248: ...ame mounting bolts 1 front and rear 9 each on one side 2 Swing the upper structure to the side where the track frame gauge is to be reduced set it at 90 to track frame 2 then use the work equipment to jack up the track frame 3 Set blocks 3 20 to 30 cm wooden blocks towards the outside of track frame 2 then use the boom cylinder to lower the machine slowly The track frame 2 will slide and stop when...

Page 249: ... up the track frame REMARK Height H of the track frame being raised should be less than 50 mm Take care not to raise the track frame so much that the stopper bolt is distorted 3 Using the arm pull the machine to the front The track frame will slide 4 Extend the track frame until it comes into contact with the stopper then lower the machine slowly to the ground Install bolts 1 front rear each 9 bol...

Page 250: ...that has been drained when repairing the radiator please contact your Komatsu distributor or request a specialist company to carry out the operation Antifreeze is toxic Do not let it flow into drainage ditches or spray it onto the ground surface q Antifreeze is flammable Do not bring any flame close Do not smoke when handling antifreeze NOTICE q Use Komatsu Supercoolant AF NAC wherever available o...

Page 251: ...ity of the battery will also drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 Insulate it against cold temperature to ensure the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the charging rate from the following conversion table q As the battery capacity drastically ...

Page 252: ...e ground and allow the machine to be moved the next morn ing q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing q Fill the fuel tank to capacity This minimizes moisture condensation in the tank when the temperature drops q After operation in water or mud remove water from undercarriage as described below to extend undercarriage service life 1 Swing ...

Page 253: ...he stop valve to the LOCK position on machines ready for attachments Install the blind plugs to the elbows For details of the LOCK and FREE positions of the stop valve see ATTACHMENT REMOVAL AND INSTAL LATION 6 17 q To prevent corrosion be sure to fill the cooling system with Supercoolant AF NAC or permanent type anti freeze density between 30 and 68 DURING STORAGE 3 WARNING If it is necessary to ...

Page 254: ...g it q Wipe off the grease from the hydraulic cylinder rods q Add oil and grease at all lubrication points q When the machine is stored for a long period moisture in the air will mix with the oil Check the oil before and after starting the engine If there is water in the oil change all the oil STARTING MACHINE AFTER LONG TERM STORAGE 3 When starting the engine after long term storage carry out the...

Page 255: ... it off com pletely Be careful when opening the air bleed plug at the fuel filter head The system is still under pressure and fuel may spurt out 1 Loosen air bleed plug A at the fuel main filter head 1 2 Loosen wing nut 4 holding lever 3 of priming pump 2 3 Push in lever 3 repeatedly Check that bubbles come out with the fuel from air bleed plug A 4 Tighten air bleed plug A Tightening torque 4 9 to...

Page 256: ... When going down a steep slope at low speed a noise will be emitted from the travel motor brake valve TOWING THE MACHINE 3 WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope Always check that the wire rope used for towing has ample strength for the weight of the machine being towed Never u...

Page 257: ...nly in emergencies LIGHTWEIGHT TOWING HOLE 3 WARNING q The shackle must always be used q Hold the wire rope level and direct it straight to the track frame q Move the machine slowly and be careful not to apply any sudden load to the wire rope There is a hole in the track frame to fit the shackle when towing light objects Permissible towing load Max 154 000N 16 000 kgf SEVERE JOB CONDITION 3 q When...

Page 258: ...ber gloves q When removing the battery first disconnect the cable from the ground normally the negative terminal When installing install the positive terminal first If a tool touches the positive terminal and the chassis there is danger that it will cause a spark so be extremely careful q If the terminals are loose there is danger that the defective contact may generate sparks that will cause an e...

Page 259: ...negative terminal of the battery Be sure to attach the clips securely q Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or dry up and this may cause the battery to catch fire and explode q If the battery electrolyte is frozen do no...

Page 260: ...nnection to the upper structure frame a spark will be caused connect the cable to a spot as far away from the battery as possi ble Avoid the work equipment however because it is not a good conductor q When removing the booster cable exercise good care so that the booster cable clips may not contact each other or they contact the chassis NOTICE q The starting system for this machine uses 24V For th...

Page 261: ...hether the machine is work ing normally or has failed Check also that all the control levers are in the neutral position 1 Make sure the clips are firmly connected to the battery terminals 2 Start engine of the normal machine and run it at high idle speed 3 Turn the starting switch of the problem machine to the START position and start the engine If the engine doesn t start at first try again afte...

Page 262: ...hen starting switch is turned to ON Defective wiring Defective starting motor Insufficient battery charge Check repair Replace Charge Pinion of starting motor keeps going and out Insufficient battery charge Defective safety relay Charge Replace Starting motor turns engine slug gishly Insufficient battery charge Defective starting motor Charge Replace Starting motor disengages before engine starts ...

Page 263: ...ise sucking in air Clogged element in hydraulic tank strainer lack of oil Clean see EVERY 2000 HOURS SERVICE Excessive rise in hydraulic oil tem perature Loose fan belt Dirty oil cooler Lack of hydraulic oil Check fan belt tension replace Clean see EVERY 500 HOURS SERVICE Add oil to specified level see CHECK BEFORE STARTING Track comes off Track too loose Adjust track tension see WHEN REQUIRED Abn...

Page 264: ...NG Check fan belt tension adjust replace Change coolant flush inside of cooling system see WHEN REQUIRED Clean or repair see EVERY 500 HOURS SERVICE Replace thermostat Tighten cap or replace packing Replace sensor Replace monitor Radiator coolant level monitor lights up Engine does not start when starting motor is turned Lack of fuel Air in fuel system Defective fuel injection pump or defective no...

Page 265: ...sition normal operations become possible but have inspection carried out immediately E03 Swing brake system error Move the swing brake cancel switch up to release the brake When applying the swing brake operate the swing lock switch manually Depending on the cause of the problem it may not be possible to release it In any case have inspec tion carried out immediately E10 Engine controller power so...

Page 266: ...n the monitor the telephone number for the point of contact is displayed at the bottom of the error screen REMARK If no point of contact telephone number has been registered no telephone number is displayed It is necessary to register the telephone number please ask your Komatsu distributor to carry out the registration ...

Page 267: ...MAINTENANCE 14 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 268: ...lways report to the person in charge and carry out suitable action Fuel Strainer If your machine is equipped with a fuel strainer do not remove it while fueling Welding Instructions q Cut off power Wait for approx one minute after turning off the engine starting switch key and then disconnect the negative terminal of the battery q Do not apply more than 200 V continuously q Connect grounding cable...

Page 269: ...ls see BLEEDING AIR FROM HYDRAULIC SYS TEM 4 45 Hydraulic Hose Installation q When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace with new parts When doing this be careful not to forget to assemble the O rings and gaskets q When installing the hoses do not twist them or bend them sharply If they are installed so their service life will be...

Page 270: ... water metal particles dirt etc from getting in The majority of problems with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil q Never mix oils of different grades or brands q Always add the specified amount of oil Having too much oil or too little oil are both causes of problems q If the oil in the work equipme...

Page 271: ...portant function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of antifreeze coolant is essential Komatsu machines are supplied with Komatsu Supercoolant AF NAC Komatsu Supercoolant AF NAC has excellent anticorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu Supercoolant AF NAC ...

Page 272: ...t machine failures and downtime With KOWA the oil is periodically sampled and analyzed This enables early detection of wear of the machine drive parts and other problems We strongly recommend you to use this service The oil analysis is carried out at actual cost so the cost is low and the results of the analysis are reported together with recommendations which will reduce repair costs and machine ...

Page 273: ...take other measures to protect them q To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first FILTERS 4 q Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace all filters periodically For details see the Ope...

Page 274: ...OUTLINE OF SERVICE MAINTENANCE 4 8 EXPLANATION OF LUBRICATION CHART DECAL 4 Interval of service Change filter Lubrication by greasing G Amount of oil required at change liters Check oil level change EO ...

Page 275: ... 4 66 4 75 11 Boom cylinder foot pin Grease 4 55 12 Boom foot pin Grease 4 55 13 Bucket cylinder foot pin Grease 4 54 14 Boom cylinder rod pin Grease 4 54 15 Arm cylinder foot pin Grease 4 54 16 Boom arm coupling pin Grease 4 54 17 Arm cylinder rod end Grease 4 54 18 Swing pinion Lubricate 4 58 19 Engine oil filter fuel water separator Change filter 4 59 20 Fuel main filter Change filter 4 67 21 D...

Page 276: ... system is checking fan belt tension checking damage or wear to the fan belt and checking battery fluid level q Never install any electric components other than those specified by Komatsu q External electro magnetic interference may cause malfunction of the control system controller before install ing a radio receiver or other wireless equipment contact your Komatsu distributor q When working at t...

Page 277: ...out additional fuel filter Every 1000 hours With additional fuel filter Additional fuel filter 600 319 3440 Cartridge 1 Every 500 hours Hydraulic tank breather 20Y 60 21410 Element 1 Every 500 hours Additional breather for hydraulic tank 421 60 35170 Element 1 Every 1000 hours Corrosion resistor 600 411 1571 Cartridge 1 Every 1000 hours Hydraulic oil filter 208 60 71122 07000 15210 Element O ring ...

Page 278: ...below 0 C be sure to use the recommended multi grade oil even if the ambient temperature may become higher during the course of the day q If the machine is operated at a temperature below 20 C a separate device is needed so consult your Komatsu distributor q When the fuel sulfur content is less than 0 2 change the engine oil according to the period inspection table given in this Operation and Main...

Page 279: ...e the recommended oils Reservoir Fluid type AMBIENT TEMPERATURE Recommended komatsu Fluids Min Max Engine oil pan Engine oil 30 C 30 C Komatsu EOS0W30 Note 1 25 C 40 C Komatsu EOS5W40 Note 1 20 C 40 C Komatsu EO10W30DH 15 C 50 C Komatsu EO15W40DH 0 C 40 C Komatsu EO30DH Swing machinery case Final drive case Damper case Power train oil Note 2 30 C 50 C TO30 Hydraulic system Power train oil 20 C 50 ...

Page 280: ...ercoolant AF NAC has excellent anticorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu Supercoolant AF NAC is strongly recommended wherever available 2 For details of the ratio when diluting super coolant with water see CLEAN INSIDE OF COOLING SYSTEM 4 27 Supercoolant AF NAC may be supplied in premix In this case always top off with premix sol...

Page 281: ...d diameter of bolt a mm Width across flats b mm Tightening torque Target value Service limit 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 52 3 70 3 90 235 285 320 400 455 565 610 765 785 980 23 5 29 5 33 0 41 0 46 5 58 0 6...

Page 282: ...ther such parts at the same time Have your Komatsu distributor replace the critical parts SAFETY CRITICAL PARTS LIST 4 No Safety critical parts for periodic replacement Q ty Replacement interval 1 Fuel tank block 1 Every 2 years or 4000 hours whichever comes sooner 2 block fuel pre filter 1 3 Fuel pre filter supply pump 1 4 Supply pump engine controller base 1 5 Engine controller base fuel main fi...

Page 283: ...EARANCE 4 394 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 4 404 CHECK AND MAINTENANCE AIR CONDITIONER 4 414 WASHING WASHABLE FLOOR 4 424 CHECK GAS SPRING 4 454 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 454 CHECKS BEFORE STARTING EVERY 50 HOURS MAINTENANCE LUBRICATING 4 484 EVERY 250 HOURS MAINTENANCE LUBRICATE SWING CIRCLE 4 494 CHECK OIL LEVEL IN SWING MACHINERY CASE ADD OIL 4 654 CHECK OIL LEVEL IN FIN...

Page 284: ...CE CHANGE OIL IN FINAL DRIVE CASE 4 754 CLEAN HYDRAULIC TANK STRAINER 4 764 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 764 CHECK ALTERNATOR 4 794 CHECK ENGINE VALVE CLEARANCE ADJUST 4 794 CHECK VIBRATION DAMPER 4 794 EVERY 4000 HOURS MAINTENANCE CHECK WATER PUMP 4 804 CHECK STARTING MOTOR 4 804 REPLACE ACCUMULATOR FOR CONTROL CIRCUIT 4 804 CHECK FOR LOOSENESS OF ...

Page 285: ...e ele ment according to the table on the right q Change oil in hydraulic tank Change the oil according to the table on the right q Replacing additional filter element for breaker if equipped Use a guideline of 250 hours for use of the breaker operat ing ratio for the breaker 50 or more and replace the element according to the table on the right X Breaker operating ratio Y Replacement interval H A ...

Page 286: ... 4 Carry out the following maintenance only after the first 1000 hours of operation on new machines q Check engine valve clearance adjust Special tools are needed for inspection and maintenance so contact your Komatsu distributor For details of the method of replacing or maintaining see the section on EVERY 2000 HOURS SERVICE ...

Page 287: ...clogging monitor light up the air cleaner will not be 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 ele ment q If inspection cleaning or maintenance is carried out with the engine running dirt will enter the engine and cause damage to the engine Always stop the ...

Page 288: ... in straight 4 After removing the outer element 5 cover the inner ele ment 6 with a clean cloth or tape to prevent dirt or dust from entering 5 Wipe off or brush off the dirt stuck to cover 3 and the inside of the air cleaner body 7 6 Remove any dirt or dust that is accumulated to evacuator valve 4 installed to cover 3 NOTICE When cleaning the element do not hit or beat it against anything 7 Direc...

Page 289: ... or oil stuck to the seal portion of the new element or cleaned element Wipe off any dirt or oil 11 Push the outer element in straight with your hand when installing it to the air cleaner body If the outer element is held and rocked lightly up and down and to the left and right while pushing it in the outer element can be inserted easily NOTICE Be sure to install the air cleaner element facing in ...

Page 290: ...ll cover 3 as follows 1 Align cover 3 with the element 2 Hook the tip of hook 2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks in turn on opposite sides top bottom left right in the same way as when tightening bolts 4 Always install cover 3 so that the evacuator 4 is facing the ground A 5 When cover 3 is installed check tha...

Page 291: ... to evacuator valve 4 installed to cover 3 NOTICE q The inner element must not be cleaned and used again When replacing the outer element replace the inner element at the same time q If the inner element is not installed properly and the outer element and cover are installed there is danger that the outer element will be damaged q The seal portion on imitation parts lacks precision and allows the ...

Page 292: ...en or the outer element is not pushed in straight and cover 3 is assembled by force to hook 2 there is danger that the hook and air cleaner body may be damaged so be careful when assembling 9 Install cover 3 as follows 1 Align cover 3 with the element 2 Hook the tip of hook 2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks i...

Page 293: ... AF NAC Komatsu Supercoolant AF NAC has excellent anticorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu Supercoolant AF NAC is strongly recommended wherever available When using Komatsu Supercoolant AF NAC there is no need to use a corrosion resistor When no corrosion resistor is used use the special cover 600 411 9000 Please consult your Ko...

Page 294: ...er ditches or drain it onto the ground surface Use antifreeze and appropriate water for diluting for details see COOLANT AND WATER FOR DILUTION 4 5 We recommend use of an antifreeze density gauge to control the mixing proportions Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant Prepare a hose to supply antifreeze coolant and water 1 Stop the m...

Page 295: ...ter start and run the engine at low idling speed After the water temperature rises above 90 C run the engine for about 10 minutes 9 Stop the engine and open drain valves 6 7 to drain the water 10 After draining the water clean the radiator with detergent For the cleaning method follow the instruction of deter gent 11 Close drain valves 6 7 12 Install the covers 4 and 5 13 Replace the corrosion res...

Page 296: ...ighten radiator cap 3 18 Install cover 2 19 Close the engine hood CHECK AND TIGHTEN TRACK SHOE BOLTS 4 If the machine is used with track shoe bolts 1 loose they will break so tighten any loose bolts immediately Tightening 1 First tighten to a tightening torque of 392 39 2 Nm 40 4 kgm then check that the nut and shoe are in tight contact with the link mating surface 2 After checking tighten a furth...

Page 297: ... surface of the track shoe Deflection a should be 10 30 mm If the track tension is not at the standard value adjust it in the following manner Adjustment WARNING There is danger of plug 1 flying out under the high inter nal pressure of the grease Never loosen plug 1 more than 1 turn Never loosen any part other than plug 1 Never put your face in the mounting direction of plug 1 If the track tension...

Page 298: ...e given below If track tension is not relieved by this procedure contact your Komatsu distributor for repairs 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the grease does not come out smoothly move the machine forwards and backwards a short distance 4 Tighten plug 1 5 To check if the tension is correct run the engine at low idle move th...

Page 299: ...ly during the replacement work so always wear protective equip ment like safety glasses and gloves 1 To make it possible to knock out pin of tooth 1 put block 5 under the bottom of the bucket and set so that the bot tom surface of the bucket is horizontal 2 Check that the work equipment is in a stable condition then set the lock lever to the LOCK position L 3 Use a hammer and drift to knock out lo...

Page 300: ...hed by hand 5 Clean the surface of adapter 4 and remove the soil with a knife 6 Use your hand or a hammer to push rubber pin lock 3 into the hole of the adapter 4 When doing this be careful that the rubber pin lock 3 does not fly out from the adapter surface 7 Clean the inside of teeth 1 then install it to adapter 4 If there is mud affixed to it or if there are protrusions the teeth 1 will not ent...

Page 301: ...le in the tooth 1 and knock it in so that the top surface of lock pin 2 is the same height as the surface of tooth 1 10 After replacing a bucket tooth always check the following 1 After the lock pin 2 has been knocked in completely check that it is secured by the teeth 1 and surface 2 Lightly hit lock pin 2 in the reverse direction from which it was hit in 3 Lightly hit the tip of the teeth 1 from...

Page 302: ...t there is no one in the surrounding area q There is a hazard that fragments will fly during the replacement work so always wear protective equip ment like safety glasses and gloves 1 To make it possible to knock out pin 1 of tooth 2 put block 5 under the bottom of the bucket and set so that the bottom surface of the bucket is horizontal 2 Check that the work equipment is in a stable condition the...

Page 303: ...MAINTENANCE MAINTENANCE PROCEDURE 4 37 4 Clean the mounting face Fit a new tooth 2 in the adapter push in pin 1 partially by hand then lock it with a hammer to install the tooth to the bucket ...

Page 304: ...e replacement opera tion so always wear safety glasses gloves or other protective equipment Side Cutters Loosen mounting bolts 2 then remove side cutter 1 Replace the side cutter bolts and nuts with new parts Tightening torque for bolts 3040 to 3630 Nm 310 to 370 kgm Shroud 1 Place a bar on the head of pin 1 hit the bar with a ham mer to knock out the pin then remove tooth 2 REMARK If it cannot be...

Page 305: ... bucket to one side so that all the play can be measured at one place the right side in the diagram Use a clearance gauge for easy and accurate measure ment 3 Loosen 4 plate mounting bolts 2 and loosen plate 3 The shim is a split type so the operation can be carried out without removing the bolts 4 Remove shim 4 corresponding to the amount of play a measured above Example In the case of play of 3 ...

Page 306: ...n There are two types depending on the freezing temperature 10 C general use and 30 C cold area use select according to the area and season Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the follow ing proportions before adding Mixture ratio of washer fluid at 30 C cold area Area season Proportions F...

Page 307: ...rent No refrigerant REMARK When there are bubbles the refrigerant gas level is low so contact your Komatsu distributors to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor Inspection During Off Season Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all pa...

Page 308: ...nectors inside the operator s cab q Never spray water above the pedestal of the operator s seat 2 q If any water splashes on the surrounding equipment be sure to wipe it off With the washable floor it is possible to flush out the dirt on the cab floor directly with water Washing Washable Floor Mat 1 Stop the machine on horizontal ground lower the bucket to the ground and then stop the engine 2 Whe...

Page 309: ...6 Pull the knob of floor mat holder clip 5 and remove clip 5 7 Remove the floor mat 8 Remove the cap from water drain hole 3 9 Flush out the dirt on the floor directly with water through water drain hole 3 10 After completing the washing operation install the cap in water drain hole 3 11 Fit the floor mat then secure it with floor mat holder plate 4 12 Secure the floor mat in position with the flo...

Page 310: ...ll side 2 Put blocks under the track and dig the work equipment into the ground Method Using Block WARNING Select a firm flat place Put strong blocks under the undercarriage to stabilize the machine and be extremely careful when carry ing out the operation 1 Raise the chassis with the boom and arm When doing this operate the levers slowly 2 Insert block 5 under the raised track to make the machine...

Page 311: ...TARTING ENGINE 3 128 Run the engine at low idle for 10 minutes after starting then start operations 3 Bleeding air from cylinders 1 Run the engine at low idle and extend and retract each cylinder 4 to 5 times taking care that a cylinder is not moved to the end of its stroke Stop the cylinder approx 100 mm short of its stroke end 2 Next operate each cylinder 3 to 4 times to the end of its stroke 3 ...

Page 312: ...oad for 2 minutes Repeat this procedure on both the left and right sides 6 Bleeding air from attachment when installed If a breaker or other attachment has been installed run the engine at low idle and operate the attachment pedal repeatedly approx 10 times until the air has been bled from the attachment circuit NOTICE q If the method of bleeding the air from the attachment itself is specified by ...

Page 313: ...ATION section q Drain water and sediment from fuel tank q Check oil level in hydraulic tank add oil q Check oil level in engine oil pan add oil q Check for water and sediment in water separator drain water q Check coolant level add coolant q Check electric wiring q Check fuel level add fuel q Check working lamp switch q Check function of horn ...

Page 314: ...ine was subjected to jobs in the water be sure to grease the wet pins 1 Set the machine to the greasing posture shown on the right lower the work equipment to the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Arm Link coupling pin 1 place 2 Arm Bucket connection pin 1 place...

Page 315: ...for every 50 hours service should be carried out at the same time LUBRICATE SWING CIRCLE 4 1 Lower the work equipment to the ground 2 Using a grease pump pump in grease through the grease fittings shown by arrows 2 places 3 After greasing wipe off any old grease that was pushed out ...

Page 316: ...q Battery electrolyte is dangerous If it gets in your eyes or on your skin wash it off with a large amount of water and consult a doctor NOTICE q When adding distilled water to the battery do not allow the battery electrolyte to go above the UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts q When adding distilled water i...

Page 317: ...olyte Level from Side of Battery If it is impossible to check the electrolyte level from the side of the battery or there is no display of the UPPER LEVEL line on the side of the battery check as follows 1 Remove cap 2 at the top of the battery look through the water filler port 3 and check the electrolyte surface If the electrolyte does not reach the sleeve 4 add distilled water so that the level...

Page 318: ...hten bolts and nuts 1 2 and 3 to secure alternator 5 Tightening torque Lock nut 1 and 4 137 2 53 9 Nm 14 5 5 kgm Bolt 2 33 3 4 9 Nm 3 4 0 5 kgm Bolt 3 127 4 19 6 Nm 13 2 kgm NOTICE q Check each pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove q In case any of the following occurs ask the Komatsu ...

Page 319: ...prox 14 16 mm at a force of approx 6 kg 4 When the position of the compressor is determined tighten nut 3 and bolt 2 to lock it in position NOTICE q Check each pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove q In case any of the following occurs ask the Komatsu distributor in your territory to r...

Page 320: ...ed to jobs in the water be sure to grease the wet pins q When carrying out heavy duty operations such as hydraulic breaker operations carry out the greas ing every 100 hours 1 Set the machine to the greasing posture shown on the right lower the work equipment to the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe of...

Page 321: ...ing any fire or flame close NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing the filter cartridge always use a genuine Komatsu part q The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle If any part other than a genuine Komatsu filter c...

Page 322: ...g a filter wrench turn filter cartridge 2 counterclock wise to remove it 7 Remove seal 5 from transparent cap 4 then clean the cap If transparent cap 4 is damaged replace it with a new part 8 Coat new seal 5 with clean fuel or oil then install it to transparent cap 4 9 Install transparent cap 3 to new filter cartridge 2 q Tightening torque for transparent cap 10 0 Nm 10 Check that the drain valve ...

Page 323: ...oo far the packing will be damaged and this will lead to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing so always tighten the correct amount q When tightening with a filter wrench be extremely careful not to dent or damage the filter 13 Turn the valve 1 at the bottom of the fuel tank to the OPEN position O 14 After replacing the filter cartridge start the...

Page 324: ...olving frame and remove cover 2 3 Insert scale 3 through inspection and maintenance hole A into the grease and check that height S of the grease is at least 54 mm If the grease level is low add grease 4 Check if the grease is milky white If it is milky white it is necessary to change the grease Please contact your Komatsu distributor The total amount of grease is 33 liters 29 7 kg 5 Install cover ...

Page 325: ... lever of drain valve P slowly drain the oil then raise the lever to close the valve 3 Open the front engine hood 4 Using a filter wrench turn filter cartridge 2 counterclock wise to remove it 5 Clean the filter holder fill the new filter cartridge with clean oil coat the thread and packing surface of the new filter cartridge with clean oil or coat it thinly with grease then install it to the filt...

Page 326: ... filler port F so that the oil level is between the H and L marks on dipstick G 8 Run the engine at idle for a short time then stop the engine and check that the oil level is between the H and L marks on the dipstick For details see Check Oil Level in Engine Oil Pan Add Oil 3 114 9 Install cover 1 ...

Page 327: ...2 Loosen screw 2 and pull up net 3 3 Clean net 3 it is to be installed again as instructed in the step 8 4 Remove 5 bolts 4 then move bracket 5 to the side and make a gap between radiator fins 6 and oil cooler fins 7 5 Inspect the front and rear of radiator fins 6 oil cooler fins 7 after cooler fins 8 and condenser fins 9 for dirt dust dry leaves etc Blow them away with compressed air if any Steam...

Page 328: ...nit Cleaning Recirculated Air Filter 1 Remove wing bolts 1 from the inspection window at the bottom rear left on the inside of the operator s cab then take out the recirculated air filter 2 Clean the filter with compressed air If there is oil on the fil ter or if the filter is extremely dirty wash it in a neutral agent After rinsing it in water dry it thoroughly before using it again Replace the f...

Page 329: ...horoughly before using it again Replace the filter with a new part every year If the clog ging of the filter cannot be removed by blowing with air or washing in water replace the filter immediately 3 After cleaning return filter 3 to its original position and close the cover Use the starting switch key to lock the cover Do not forget to remove the starting switch key REMARK The FRESH filter must b...

Page 330: ...perature immediately after the engine is stopped and may cause burns Wait for the temperature to go down before starting the work q When removing the oil filler cap turn it slowly to release the internal pressure then remove it 1 Remove the cap of oil filler F at the top of the hydraulic tank 2 Replace element 1 inside the cap ...

Page 331: ...to the filler pipe 3 Pull out dipstick G and check that the oil level is between the H and L marks on the dipstick 4 If the oil does not reach the L mark on dipstick G add engine oil through dipstick insertion hole When refilling remove bleeding plug 1 5 If the oil level is above the H mark on dipstick G loosen drain valve P and drain the excess oil q When draining the oil first pull hose 2 out fr...

Page 332: ...ug P perpendicular to the ground surface 2 Remove plug F using the handle When the oil level reaches a point 10 mm below the bottom of the plug hole the correct amount of oil has been added 3 If the oil level is too low install plug F operate the travel levers and drive forward or in reverse to rotate the sprocket one turn Then repeat Step 2 to check again 4 If the oil level is low add oil through...

Page 333: ...lug in the fuel filter head It is still under pressure so fuel may spurt out NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing the filter cartridge always use a genuine Komatsu part q The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle ...

Page 334: ... cap B and install the filter cartridge 6 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it 3 4 of a turn If the filter cartridge is tightened too far the packing will be damaged and this will lead to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing so always tighten the correct amount 7 Turn th...

Page 335: ...ing nut 6 securely to lock lever 5 in position Target tightening torque 11 8 Nm 1 2 kgm 15 After replacing the filter cartridge start the engine and run it at low idling for 10 minutes Check for leakage of fuel from the filter seal surface If any fuel is leaking check the tightening of the filter car tridge If there is still fuel leakage repeat Steps 1 4 to remove the filter cartridge and if any d...

Page 336: ...ver 1 When doing this the cover may fly out under the force of spring 2 hold the cover down when removing the bolts 4 After removing spring 2 valve 3 and strainer 4 take out element 5 q Inspect the bottom of the filter case for dirt and remove it if any Take good care then not to let fall the dirt into the hydraulic tank REMARK If the mounting bolts of cover 1 loosened in Step 3 are left for appro...

Page 337: ...n q Refill capacity 20 liters 1 Remove cover A of the inspection hole Only demolition specification machine 2 Set a container under drain valve P under the machine body to catch the oil 3 Loosen drain valve P under the body drain the oil then tighten the drain valve again q When draining the oil first pull hose 2 out from inspection hole B then turn the drain valve to the OPEN position 4 Remove di...

Page 338: ...gine check the oil level 1 Open the door on the left side of the machine 2 Remove plug P and check that the oil is up to near the bottom of the plug hole If the oil level is low remove cap F and add oil through the oil filler port to the bottom of the hole of plug P NOTICE If excess oil is supplied drain it to the specified amount to avoid overheating 3 Install plug P and cap F 4 Close the door CH...

Page 339: ...en removing the oil filler cap turn it slowly to release the internal pressure then remove it 1 Remove nut 2 of breather assembly 1 at the top of the hydraulic tank then remove cover 3 2 Replace filter element 4 with a new element 3 Install cover 3 and nut 2 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR for breaker 4 If equipped A special tool is needed for inspecting and charging with nitroge...

Page 340: ... front engine hood 2 Screw in 2 valves 1 at the top of the corrosion resistor 3 Using a filter wrench turn cartridge 2 to the left to remove it 4 Install a new filter cartridge after coating oil on its sealing face In the installation turn the cartridge by two thirds of one turn after the packing surface comes to contact with the sealing face of the cartridge stand A genuine Komatsu filter cartrid...

Page 341: ... the plug slowly to release the pressure q Refill capacity each 10 5 liters q Prepare a handle 1 Set the TOP mark at the top with the TOP mark and plug P perpendicular to the ground surface 2 Set a container under plug P to catch the oil 3 Remove plugs P and F with the handle and drain the oil REMARK Check the O rings in the plugs for damage If necessary replace with new ones 4 Tighten plug P 5 Ad...

Page 342: ...holds spring 2 then tighten with the bolt CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CON TROL CIRCUIT 4 WARNING The accumulator is charged with high pressure nitrogen gas so mistaken operation may cause an explo sion which will lead to serious injury or damage When handling the accumulator always do as follows The pressure in the hydraulic circuit cannot be completely removed When...

Page 343: ...gram on the right CHECKING FUNCTION OF ACCUMULATOR 4 CAUTION When carrying out the inspection check first that there is no person or obstacle in the surrounding area Check the nitrogen gas charge pressure as follows 1 Stop the machine on firm level ground 2 Hold the work equipment in the maximum reach posture arm fully out bucket fully dumped at a height A 1 5 m from the ground Carry out Steps 3 5...

Page 344: ... contact your Komatsu distributor for inspection 7 This completes the inspection After completion of the inspection set the lock lever to the LOCK position and turn the starting switch to the OFF position METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT 4 1 Place the work equipment on the ground Close the crusher attachment jaws etc 2 Operate the work equipment lock lever to the LOCK position 3 I...

Page 345: ...ition 8 Insert the lock pin in position a so that the attachment control pedal cannot be operated If equipped CHECK ALTERNATOR 4 Contact your Komatsu distributor to have the alternator checked If the engine is started frequently have this inspection carried out every 1000 hours CHECK ENGINE VALVE CLEARANCE ADJUST 4 Special tools are needed for inspection and maintenance so contact your Komatsu dis...

Page 346: ...r damage When handling the accumulator always do as follows The pressure in the hydraulic circuit cannot be completely removed When removing the hydraulic equip ment do not stand in the direction that the oil spurts out when carrying out the operation In addition loosen the bolts slowly when carrying out the operation Do not disassemble the accumulator Do not bring it near flame or dispose of it i...

Page 347: ...amps 1 to 15 If there is any looseness or hardened rubber contact your Komatsu distributor for replace ment CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 Check for any missing fuel spray prevention caps 1 to 11 or fuel spray prevention cover 12 and check also for any hardened rubber portions If there are any missing caps or cover or the rubber is hardened please con tact your K...

Page 348: ...nance q Refill capacity 248 liters q Prepare a handle for the socket wrench 1 Swing the upper structure so that hydraulic tank drain plug P and drain plug A at the bottom of the pump suction tube are in the middle between the left and right tracks 2 Retract the arm and bucket cylinders then lower the boom and put the teeth in contact with the ground 3 Set the lock lever to the LOCK position and st...

Page 349: ...ined 7 Add the replacement amount of oil through oil filler F Check that the oil level is between the H and L lines on the sight gauge G For details of oil level check see Check Oil Level in Hydraulic Tank Add Oil 3 113 8 Install the undercover 1 and 2 9 Bleed the air from the hydraulic circuit For details of the method of bleeding the air from the hydraulic circuit see BLEEDING AIR FROM HYDRAU LI...

Page 350: ...000 2000 and 4000 hours service should be carried out at the same time REPLACE HIGH PRESSURE PIPING CLAMP 4 Contact your Komatsu distributor to have the engine high pressure clamps replaced REPLACE FUEL SPRAY PREVENTION CAP 4 Contact your Komatsu distributor to have the fuel spray prevention cap replaced ...

Page 351: ...SPECIFICATIONS 15 ...

Page 352: ...t capacity m3 1 9 Name of engine KOMATSU SAA6D125E 5 diesel engine Rated horsepower of engine kW HP rpm 257 345 1 900 A Overall length mm 11 940 11 940 11 940 B Overall height mm 3 635 3 635 3 635 C Overall width mm 3 490 3 590 3 490 D Track shoe width mm 600 700 600 E Height of cab mm 3 250 3 250 3 250 F Radius of upper structure mm 3 645 3 645 3 645 G Overall length of track mm 5 055 5 355 5 376...

Page 353: ...00 A Max digging reach mm 12 025 12 025 10 713 B Max digging depth mm 7 820 7 820 6 401 C Max digging height mm 10 915 10 915 10 360 D Max vertical wall digging depth mm 6 870 6 870 4 876 E Max dumping height mm 7 565 7 565 7 067 F Min dump height mm G Max digging reached at ground level mm 11 820 11 820 10 481 ...

Page 354: ...Boom length 4 Hydraulic pressure 37 3 MPa WORKING CONDITIONS q WITH BUCKET 1914 kg q IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE q WITH FULLY EXTENDED BUCKET CYLINDER q ON A COMPACT HORIZONTAL LEVEL GROUND q WITH 600 mm WIDTH SHOE Loads do not exceed 87 of hydraulic capacity or 75 of tip ping capacity l...

Page 355: ...SPECIFICATIONS SPECIFICATIONS 5 5 6 7m Boom PC450 8 ...

Page 356: ...SPECIFICATIONS SPECIFICATIONS 5 6 6 7m Boom PC450LC 8 ...

Page 357: ...SPECIFICATIONS SPECIFICATIONS 5 7 6 7m Boom PC450LCHD 8 ...

Page 358: ...37 3 MPa WORKING CONDITIONS q WITH BUCKET 1914 kg 2 4m 2 9m 3 4m Arm 1115 kg 4 0m Arm 1189 kg 4 8m Arm q IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE q WITH FULLY EXTENDED BUCKET CYLINDER q ON A COMPACT HORIZONTAL LEVEL GROUND q WITH 600 mm WIDTH SHOE Loads do not exceed 87 of hydraulic capacity or 75 of...

Page 359: ...SPECIFICATIONS SPECIFICATIONS 5 9 7 0m Boom PC450 8 ...

Page 360: ...SPECIFICATIONS SPECIFICATIONS 5 10 7 0m Boom PC450LC 8 ...

Page 361: ...ATTACHMENTS ANDD OPTIONS 16 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 362: ...uals for the machine and the attachment or option q If you lose the instruction manual or it is damaged always obtain an new copy from the attachment manufac turer or your Komatsu distributor PRECAUTIONS WHEN REMOVING OR INSTALLING 6 When removing or installing the attachment or option obey the following precautions and take care to ensure safety during the operation q Carry out the removal and in...

Page 363: ...installed the working range becomes larger q If heavy work equipment is installed pay careful attention to the following precautions q The swing overrun the distance the work equipment moves before completely stopping after the swing brake is applied will be greater There is danger of hitting objects if the swing overrun is miscalculated so allow extra space to the swing position when swinging q T...

Page 364: ...oose in the case of loss of hydraulic pressure If in doubt consult the manufacturer of the quick coupler 3 Read the instruction manual of the quick coupler carefully and follow the recommendations If in doubt about the installation or operation consult your Komatsu dealer 4 The pressure regulation valve 2 allows the pressure at the quick coupler to be limited according to the quick coupler manufac...

Page 365: ...nt bucket To pick up a new bucket or attachment 1 Position the quick coupler over the new bucket or attachment 2 Operate switch 1 NOTE The switch has a safety lock mechanism to prevent accidental operation Slide the lock towards you then rock the switch The lamp on the switch will come on and a warning buzzer will sound 3 With switch 1 in position B press and hold button 2 on the left hand lever t...

Page 366: ...structions in ATTACHMENT REMOVAL AND INSTALLATION WARNING Check daily that the hoses and fittings in the quick coupler piping system are in good condition Pay par ticular attention to the hoses and fittings at the arm end as these can be damaged easily In case of dam age or leakage of oil stop work Loss of oil could lead to the bucket or attachment falling and killing an exposed person The damage ...

Page 367: ...speed and use the L mode for fine control operations q Depending on the posture of the work equipment there is the danger that the wire or load may slip off the hook Always be careful to maintain the correct hook angle to prevent this from happening q Never travel the machine while lifting a load q If the bucket with hook is turned and used for operations it will hit the arm during dumping operati...

Page 368: ... FREE Hydraulic oil flows L LOCK Hydraulic oil stops When removing or installing attachments set this valve to the LOCK position Z Z a 1 Stop valve 6 Accumulator 2 Selector valve 7 1st Attachment proportional control switch 3 Attachment control pedal 8 2nd Attachment proportional control switch 4 Lock pin 9 Breaker switch 5 Breaker circuit additional oil filter ...

Page 369: ... Control Pedal WARNING Do not carry out operations with your foot on the pedal If the pedal is depressed by mistake the attach ment may suddenly move and cause a serious accident Lock the pedal with the lock pin when you are not operating the attachment This pedal 3 is used to control the attachment When the front center neutral and rear of the pedal are depressed the movement of the attachment is...

Page 370: ... is operated in direction D it will cause damage or defective operation of the breaker To prevent this when using the breaker always set the lock pin to position b q Before changing the position of the lock pin stop the engine Attachment 2 Control if equipped Proportional control rolling switch Switch 8 operates the 2nd attachment circuit e g clamshell rotation The switch 8 is a roller proportiona...

Page 371: ...oles in it or weld it Do not hit it roll it or subject it to any impact When disposing of the accumulator the gas must be released Please contact your Komatsu distributor to have this work carried out This accumulator 6 is installed to reduce the peak pressure in the hydraulic circuit when a breaker is used Normally do not touch it NOTICE On machines equipped with a breaker it is necessary to inst...

Page 372: ... as an option and the mode is set to B mode 1 The system is set to the breaker operation circuit 1 way circuit 2 The hydraulic oil flowing to the breaker circuit flows to the additional filter for the breaker 3 The relief pressure valve is set to low pressure Set pressure when machine is shipped from factory 17 2 MPa 175 kgf cm2 4 It is possible to use the selector mode to adjust the maximum oil f...

Page 373: ...d of the stop valve piping Two spots on the left and right Be careful not to lose or damage any part that has been removed 2 Connect attachment piping 2 provided by the attachment maker to the part from which the plug was removed Step 1 For the mouthpiece size and accumulator add on the action to take differs according to the attachment manufac turer so please consult your Komatsu distributor ...

Page 374: ...th of the oil flow is as shown in the diagram below When the front of the pedal is depressed oil flows to the piping on the left side of the work equipment when the rear of the pedal is depressed oil flows to the piping on the right side of the work equipment When a breaker is installed only the front of the pedal can be used ...

Page 375: ...e safety glasses dust mask or other protec tive equipment NOTICE For details of the replacement interval for the element MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 19 q Prepare a container to catch the oil 1 Lower the work equipment to the ground and stop the engine 2 Turn the starting switch to the ON position B then set the lock lever to the FREE position F 3 After carrying out Step 2 operate ...

Page 376: ... case 2 8 Turn filter case 2 to the left remove it then take out ele ment 3 9 Clean the removed parts then install new element 3 q Element 3 must be installed facing in the correct direction Set direction Y with the holes in it facing up and insert the hole in element 3 on the protruding portion inside filter head 4 10 Install new O ring 5 to filter case 2 then screw filter case 2 into filter head...

Page 377: ...set the lock lever to the FREE position F 3 After carrying out Step 2 operate each work equipment control lever and attachment control pedal fully to the front rear left and right 2 or 3 times within 15 seconds to release the internal pressure in the hydraulic circuit 4 Set the lock lever to LOCK position L 5 Loosen slowly oil filler cap F on top of the hydraulic tank to eliminate the internal pre...

Page 378: ...ttachment side Install the plugs to the two outlets The plugs are used to prevent the attachment from incor rect operation caused by mixing in of foreign matter After the plugs are correctly installed store the attachment 8 Pull out the mounting pins 2 places remove the attach ment then install the bucket For details of the procedure for installing the bucket see BUCKET REPLACEMENT AND INVERSION 3...

Page 379: ... arm with pin A and then pin B 3 Lower the attachment to the ground and stop the engine 4 Turn the starting switch to the ON position B then set the lock lever to the FREE position F 5 After carrying out Step 4 operate each work equipment control lever and attachment control pedal fully to the front rear left and right 2 or 3 times within 15 seconds to release the internal pressure in the hydrauli...

Page 380: ...ly Take care that no dust mud etc adheres to the hose mouthpiece portions If O ring is damaged replace it with a new one 9 Connect the hose at the attachment side When doing this check the direction of flow of the oil and be careful not to make any mistake 10 Turn the rotor on the stop valve installed to the piping for the inlet port and outlet port on the side face of the arm to the FREE position...

Page 381: ... pin of the pedal to the LOCK position to prevent the pedal from being operated The method of operating the attachment is as follows Operation When Using Breaker 6 NOTICE When carrying out breaker operations use the breaker mode If the breaker mode is not used the breaker may be damaged Breaker can be operated using either the breaker switch or attachment control pedal 1 Breaker Switch With the wo...

Page 382: ...q Keep working mode selector switch 1 pressed q Press switch F6 q Leave as it is for 5 seconds 3 If the breaker mode is selected Really Set Breaker Mode is displayed on the screen To set to the breaker mode press switch F6 q If switch F5 is pressed the screen returns to the work ing mode selection screen without changing to the breaker mode q If a slide arm or other special attachment is installed...

Page 383: ...element For details see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 19 Operation When Using General Attachment 1 e g Crusher 6 General attachment 1 can be operated using either the rolling switch on the right lever or right attachment control pedal 1 Proportional Control Rolling Switch With the working mode set to ATT mode rolling the switch up produces movement of the attachment rolling down pro...

Page 384: ...e of the following to accept the selection Q Keep working mode selector switch 1 pressed Q Press switch F6 Q Leave as it is for 5 seconds q On the user menu attachment setting it is possible to make the attachment mode inactive q When using the attachment mode check that the attach ment mode is active before starting operations Precautions when using q Check that the stop valve is at the FREE posi...

Page 385: ...ons see Working Mode Selection 6 24 LONG TERM STORAGE 6 If the equipment is not to be used for a long time do as follows q Set the stop valve in the LOCK condition q Fit a plug at the tip of the stop valve piping q Set the lock pin at the LOCK position If there is no breaker or general attachment installed operating the pedal may cause overheating and other prob lems SPECIFICATIONS 6 Hydraulic spe...

Page 386: ...omatsu distributor may not only cause problems with safety but may also have an adverse effect on the operation of the machine and the life of the equipment q Any injuries accidents or damage resulting from the use of unauthorized attachments or options will not be the responsibility of Komatsu ATTACHMENT COMBINATIONS 6 WARNING Depending on the type or combination of work equipment there is danger...

Page 387: ...h the undercarriage Operate the boom carefully Categories of use For general digging Digging or loading sand gravel clay etc For light duty digging Digging or loading dry uncaked earth and sand mud etc For loading work Loading dry loose earth and sand q For digging or loading hard soil or soft rock it is recommended that the strengthened bucket with high durabil ity and high wear resistance be emp...

Page 388: ... soil On rough ground with large obstacles such as boulders or fallen trees travel at low speed B Normal soil soft ground These shoes cannot be used on rough ground where there are large obsta cles such as boulders or fallen trees Travel at Hi or Mi speed only on flat ground and if it is impossible to avoid going over obstacles shift down and travel at half speed in Lo C Extremely soft ground swam...

Page 389: ... hydraulic excavator the kind of attachments or the model of specific attachments that can be mounted will vary Hence consult your Komatsu distributor for the selection of optimum attachments HYDRAULIC BREAKER 6 Main Applications q Crushed rock q Demolition work q Road construction This attachment can be used for a wide range of applications including demolition of buildings breaking up road surfa...

Page 390: ...arry out breaking operations closer to the edge The direction of penetration of the chisel and the direction of the breaker body will gradually move out of line with each other always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly to prevent using the impact force when there is no resistance Prohibited Works To ensure that the mac...

Page 391: ...sing the mount together in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock ...

Page 392: ... the ground Greasing Supply grease in the correct position NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result soil and sand will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use There fore be sure to grease the breaker holding it in the right posture ...

Page 393: ...ilure or fire on the KOMTRAX equipment or the machine itself Your Komatsu distributor will carry out removal and installation of KOMTRAX q Do not allow cables or cords to become caught do not damage or pull cables or cords by force Short circuits or disconnected wires may cause failure or fire on the KOMTRAX equipment or the machine itself q For anyone wearing a pacemaker make sure that the commun...

Page 394: ... 6 34 SUPER LONG FRONT BOOM AND ARM 6 OPERATION INSTRUCTION 6 NOTE Specifications are subject to change without notice PC450LC 8 Track shoe mm Operating weight kg Ground pressure kg cm2 600mm 700mm 800mm PC450LC 8 Max Digging Reach to bucket teeth mm 20000 ...

Page 395: ...e recommended Please follow these recom mendations A Type of work R Recommended work C Work requiring caution N Work that is not permitted Work 1 Dredge rivers specific gravity max 1 8 R 2 Hauling loading dry sand sg max 1 8 R 3 Digging hauling piled soil sg max 1 8 R 4 Digging clay layers C 5 Digging bank C 6 Quarry work or digging bedrock N ...

Page 396: ...y that are found q Check daily for any oil leakage q 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 immediately Locations for checking are shown below USING SUPER LONG FRONT 6 WARNING NEVER slew the machine if no work equipment is fitted WARNING Take care when raising the work equipment...

Page 397: ...oper ations CAUTION Do not use the POWER MAX switch Do not use in P mode CAUTION Do not bring any shock loading on the work equipment CAUTION Do not apply any side load to the bucket CAUTION Attachments like breakers and fork grabs may not be used CAUTION Use with engine throttle at 70 80 for ease of use and safety CAUTION Do not operate the super long front control levers in the same way as a sta...

Page 398: ...rack and travel slowly q Do not use any bucket with a capacity greater than shown in this table Buckets which do not conform to this table must not be used Do not use any attachment which imposes vibration loading onto the equipment WHEN TRAVELLING 6 q Lower the boom pull in the arm keep the work equipment parallel to the track and travel slowly q Never mount obstacles when travelling on rough gro...

Page 399: ...am q When the safety lock lever is raised take care not to touch the work equipment control lever If the safety lock lever is not properly locked at the upper position the work equipment and swing will move creating a potentially dangerous situation q When the safety lock lever is lowered take care not to touch the work equipment control lever This lever locks the work equipment swing and attachme...

Page 400: ...nt q With the track frame facing to the rear the machine will move in the reverse direction by forward travelling and in the forward direction by reverse travelling q When the travel lever is used check to see if the track frame is facing forward or backward If the sprocket is located to the rear the track frame is facing forward This indicates operation of the pedal 1 FORWARD 2 REVERSE The lever ...

Page 401: ...e boom and bucket When the lever in Neutral N position the boom and the bucket will be retained in the position in which they stop NOTICE q For levers 2 3 and 4 the engine speed changes as follows because of the auto deceleration mechanism q When the travel lever and work equipment control levers are at neutral even if the fuel control dial is above the mid range position the engine speed will dro...

Page 402: ...for installing link 1 Lower the boom and extend the arm cylinder to set in the stow posture 2 When the arm cylinder is almost at the end of the stroke lower the boom slowly to bring the bucket or bucket link into light contact with the ground 3 Remove the A end of the supporting link from the boom held by a pin then install it to the arm with the pin When doing this raise the boom slightly and ret...

Page 403: ...RONT MACHINE 6 to top of counterweight PC450LC 8 20m super long front Undercarriage type LC A Overall shipping height mm B Overall shipping length mm C Transport length mm D Track length mm E Track length on ground mm F Tail swing radius mm G Machine tail height mm H Overall height of cab mm ...

Page 404: ...super long front A Maximum digging height mm B Maximum dumping height mm C Maximum digging depth mm D Maximum vertical wall digging depth mm E Maximum digging depth for 2400mm level mm F Minimum digging reach mm G Maximum reach at ground level mm H Minimum swing radius mm I Maximum height of minimum swing mm ...

Page 405: ... exceed the maximum loading conditions described in the METHOD OF WORK section of this manual Data provided for PC450 LC 20m Super Long Front with 800mm trackshoe including 450kg bucket A Reach from swing centre B Bucket hook height F Rating over the front S Rating over the side MAX Rating at maximum reach Limited by hydraulic capacity rather than rated stability Loads do not exceed 87 of hydrauli...

Page 406: ...should be carried out SERVICE ITEM Page EVERY 50 HOURS SERVICE LUBRICATING 1 Arm Link coupling pin 1 point 6 47 2 Arm Bucket coupling pin 1 point 6 47 3 Link coupling pin 2 points 6 47 4 Bucket cylinder rod end 1 point 6 47 5 Bucket Link coupling pin 1 point 6 47 CHECK EVERY 100 HOURS SERVICE LUBRICATING 1 Arm cylinder foot pin 1 point 6 48 2 Boom Arm coupling pin 1 point 6 48 3 Arm cylinder rod e...

Page 407: ...reasing posture on next page then lower the work equipment to the ground and stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Arm Link coupling pin 1 point 2 Arm Bucket coupling pin 1 point 3 Link coupling pin 2 points 4 Bucket cylinder rod end 1 point 5 Bucket Link coupling pin 1 point 1...

Page 408: ... environment 1 Set the work equipment in the greasing posture below then lower the work equipment to the ground and stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Arm cylinder foot pin 1 point 2 Boom Arm coupling pin 1 point 3 Arm cylinder rod end 1 point 1 5 6 3 4 7 8 9 2 AM091510C 1 A...

Page 409: ...OM AND ARM 6 49 4 Bucket cylinder foot pin 1 point 5 Arm link coupling pin 1 point 6 Arm bucket coupling pin 1 point 7 Link coupling pin 2 points 8 Bucket cylinder rod end 1 point 9 Bucket Link coupling pin 1 point AM091470D 5 6 AM091480D 9 7 8 7 ...

Page 410: ...SUPER LONG FRONT BOOM AND ARM ATTACHMENTS ANDD OPTIONS 6 50 ...

Page 411: ...ure that you understand the safety volume of the standard machine operation and maintenance manual before reading this section This chapter describes only the High Reach Demolition machine Therefore please refer to operation and maintenance section of the standard machine ...

Page 412: ...HINE 7 1 2 3 4 5 7c 6 9 10 11 12 13 8 7b 7a 1 Attachment 8 Boom cylinder quantity two 2 Bucket cylinder 9 FOPS 3 Arm 10 Idler 4 Arm cylinder 11 Track frame 5 Intermediate Link 12 Sprocket 6 Intermediate Link Cylinder 13 Counterweight 7 Boom three sections 7a Boom 1 7b Boom 2 7c Boom 3 ...

Page 413: ...on machine for lifting operations CAUTION Do not use Power Max function with High reach Demolition Equipment fitted CAUTION The machine is not suitable for breaker use in any configuration Do not use breaker mode or breaker equipment CAUTION If any lever is operated in the deceleration range the engine speed will increase suddenly so be careful when operating the levers ...

Page 414: ...e that they are in the correct place and always keep them clean When cleaning them do not use organic solvents or gasoline there may cause the labels to peel off q There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way q If the labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers fo...

Page 415: ... 5 SAFETY LABELS 7 1 208 00 KA110 WARNING q Medium Reach Configuration boom 2 removed q When the second boom is removed the attachment can hit the operator cab or chassis q Operate work equipment slowly and carefully to avoid any injury and damage Medium Reach boom 2 removed ...

Page 416: ...hing the safety lock lever down be careful not to touch the work equipment control lever Lever 1 is a device which locks the work swing and travel equipment and attachment if equipped control levers Pull the lever up to apply the lock This lock lever is a hydraulic lock so even if it is in the lock posi tion the work equipment control lever and travel lever will move but the work equipment travel ...

Page 417: ...quipment fitted This lever 2 is used to switch the direction of travel of the machine shows the operation of the pedal a FORWARD The lever is pushed forward The pedal is angled forward b REVERSE The lever is pulled back The pedal is angled back N Neutral The machine stops This indicates operation of the pedal REMARK q Machines equipped with travel alarm If equipped If the lever is shifted to the a...

Page 418: ... in undercarriage adjustment mode Boom operation Bucket operation a RAISE b LOWER c DUMP d CURL N Neutral The boom and bucket are held in position and do not move Hydraulic variable gauge undercarriage mode c Undercarriage wider d Undercarriage narrower N Neutral Undercarriage is held in position and does not move REMARK q The engine speed for all control levers travel work equipment attachment is...

Page 419: ...nds upon the type of crusher fitted Standard motion Operate switch forwards attachment rotates clockwise Operate switch backwards attachment rotates anti clockwise A The direction of rotation depends on the crusher Breaker Use WARNING The machine is not suitable for breaker use in any configura tion Do not use breaker mode or breaker equipment See main machine operating manual for operation with b...

Page 420: ...q Do not put your foot on the pedal except when operating it If you rest your foot on the pedal during operations and you depress the pedal by mistake the crusher may move suddenly and cause serious damage or injury q Intermediate Link moves when the pedal 5 is depressed q When depressing pedal intermediate link moves Depressing front Link out Depressing rear Link in q Screw lock pin into hole in ...

Page 421: ... when in the deceleration range the engine speed will suddenly increase so be careful when operating the levers q When the proportional control switch 11 is operated forward the attachment is actuated in forward direction When the rear of the switch is operated the attachment is actuated in reverse direction b 11 OPEN CLOSE RH Lever CLOSE OPEN ...

Page 422: ...g a raise or lower movement of the cab q Always ensure that no one is near the cab when the cab is raising or lowering q Before tilting the cab up or down make sure that there are no loose objects stored in the cab which may fall This could cause obstruction to control or injury to the operator The raise lower operation of the cab is activated by push button 7 located in the panel in front of the ...

Page 423: ...e that operations can be carried out in safety The buzzer will only sound if switch 9 is in DLF mode q If the boom goes outside the hatched range the red range on the boom angle gauge the alarm buzzer will sound If this happens raise the boom to bring the boom angle indicator inside the green range The alarm buzzer will then stop q The buzzer is fitted with a stop switch 8 but never turn this swit...

Page 424: ...is used to turn on the roof wiper and to operate the washer The switch has 3 positions a ON is with the rear end of the switch down The wiper is on b ON is with the rear end of the switch pressed and held down The wash wipe is on c OFF The wiper washer system is off 1 Nozzle 2 Ceiling window 3 Ceiling wiper c 10 c a b ON OFF 1 2 3 ...

Page 425: ...to the greasing points shown in the diagram q Check for cracks furrows in the base metal q Check for wear and damage to the base metal q Perform all checks required by the basic machine manual 1 Boom top pin 1 place 6 Arm 2 places 2 Intermediate link cylinder 2 places 7 Bucket cylinder 2 places 3 Boom cylinder 4 places 8 Arm cylinder 2 places 4 Boom foot 2 places 9 Intermediate link top pin 1 plac...

Page 426: ...k that the ground inside the operating range is flat and firm q Never operate the boom outside the specified working range There is danger that the machine may overturn As far as possible always carry out operations to the front of rear of the tracks do not carry out work to the left or right of the tracks Max working radius to front and rear 13 m For details of the working range WORKING RANGE AND...

Page 427: ... the specified working range If you do the machine may fall over WARNING To ensure long life of the work equipment and to carry out work safely avoid the following kinds of operation q Do not travel at high speed q Do not operate the control levers suddenly q Do not start or stop the swing suddenly Working area 13 m INCORRECT INCORRECT INCORRECT ...

Page 428: ...M 7 18 q Do not use hitting force for demolition work q Do not use the swing force for hitting operations q Do not use the dropping force of the machine for operations q Do not use the travel force of the machine for operations INCORRECT INCORRECT INCORRECT INCORRECT ...

Page 429: ... and crush at one blow q Do not pick up objects and raise or lower them q When gripping objects do not use cylinder to shake them WARNING If there is external force bearing on the attachment when hit ting against an object the cylinder may come out and break so be extremely careful when operating INCORRECT INCORRECT INCORRECT ...

Page 430: ...ome allowance at the stroke end when extending or retracting the cylinder If the machine is operated with the bucket cylinder at the extract ing end piston 1 strikes cylinder head 2 As a result cylinder head mounting bolt 3 may become loose and the cylinder piston may come out eventually Confirmation and inspection before and after work Check the bolts of the bucket cylinder head for looseness If ...

Page 431: ...figuration Do not install a hydraulic breaker for breaking work If you do the work equipment will be damaged WHEN WORKING IN MEDIUM REACH CONFIGURATION 7 When in medium reach configuration boom 2 removed WARNING q When the second boom is removed the attachment can hit the operator cab or chassis q Operate work equipment slowly and carefully to avoid any injury and damage ...

Page 432: ...levers until they are horizontal 5 Return to the cab start the engine and set the safety lock lever into the operation position 6 Operate the SLEW function It may be necessary to travel the machine forwards and backwards to allow the tracks to extend If travelling is necessary move the machine slowly and carefully adjusting the steering controls as necessary Slew left undercarriage width decreases...

Page 433: ...d work equipment lever is used to operate the boom and bucket The right hand pedal is used to operate the intermediate link The movements of the levers right hand pedal and work equipment is shown in the figure on the right If the levers and the right hand pedal are released they return to their neutral positions and the work equipment is held at the current posi tion q While the machine is stoppe...

Page 434: ... The left wrist control lever controls rotation q Attachment rotates when the button 2 is operated forward or backward Direction of rotation depends upon the type of crusher fitted Standard motion Operate switch forwards attachment rotates clockwise Operate switch backwards attachment rotates anti clockwise A The direction of rotation depends on the crusher b 1 2 3 1 Right pedal Intermediate link ...

Page 435: ... RAISING WORK EQUIPMENT 7 Operate the work equipment slowly In particular operate the work equipment as slowly as possible during lowering operations Operate as follows 1 Extend boom cylinder 2 Extend intermediate link cylinder RH Lever Open Close Boom cylinder Intermediate link cylinder ...

Page 436: ...OPERATION HIGH REACH DEMOLITION EQUIPMENT 27M 7 26 3 Extend arm cylinder Arm cylinder ...

Page 437: ... green range of the boom angle gauge At this time boom angle A is 81 and maximum working radius B is 13 m at the arm top point 2 When raising and lowering the crusher retract the arm and intermediate link so that the arm top point will not exceed above working radius B 13 m 3 Take care that the boom angle indicator does not exceed the green range Do not work in the red range For raising and loweri...

Page 438: ...he alarm buzzer sounds return the boom to a position where the buzzer stops If the alarm buzzer does not sound when the boom is below the specified angle inclination gauge in red range make sure that the boom angle alarm buzzer switch A is set so that the alarm is active If the button is set correctly adjust the angle sensor plate as follows Boom inclination gauge Green range Boom 1 Red range A c ...

Page 439: ... of the inclination gauge is on line P between the green range and red range 3 Loosen bolt B and move plate 2 to the left or right to fix dimension L so that the buzzer sounds at this position REMARK Set clearance so that there is no contact even when the boom is moved WARNING This adjustment should only be performed by Komatsu Certi fied Mechanics Failure to adjust properly may result in an unsaf...

Page 440: ...NT 27M 7 30 POSTURE WHEN LEAVING MACHINE 7 WARNING When leaving the operator s compartment put the machine in the following posture for reasons of safety 1 When leaving the machine for a long time 2 When leaving the machine for a short time ...

Page 441: ...n a different order REMARK A Komatsu demolition work equipment support system is available through your dealer This system should be used to hold the demolition work equipment when it is removed PROCEDURE FOR INSTALLATION AND REMOVAL OF DEMOLITION DIGGING EQUIPMENT 7 REMOVAL OF HIGH REACH WORK EQUIPMENT 7 1 There must be plenty of room available to manoeuvre the machine for removal of work equipme...

Page 442: ... Left and Right Support Items 1 and 2 to form the complete Stand Section shown in the diagram Lift the work equipment using boom raise cylin ders so that the supports are free from the ground Lower the equipment so that Support A settles onto the ground Stand B will still be free of the ground WARNING Securely fix the brace pins with the spring pins provided 8 Relieve the pressure in the hydraulic...

Page 443: ...e first boom release pins 13 Open the valves on the pin retract circuit left and right side of the demolition first boom to allow hydraulic pressure to be applied to the retractable pins C closed no power to pin D open retractable pin will operate 14 Make sure that personnel are clear from the boom release pins and start the engine WARNING Make sure that the changeover valve on the demolition firs...

Page 444: ...settled onto the ground simulta neously lower the first boom section and reverse the machine to disengage the upper pin from the demolition equipment Reverse the machine away from the demolition equipment 17 Ensure that all exposed bores pins hoses and tubes are thoroughly protected from corrosion and foreign matter WARNING When reversing the machine from the demolition work equip ment make sure t...

Page 445: ...rted by the Komatsu Digging Equipment Stand available from your dealer WARNING Make sure that all personnel are a safe distance from the dig ging equipment while the machine is moving 1 With the high reach equipment removed from boom 1 and demolition boom 1 attached to the base machine manoeuvre the machine slowly towards the demolition digging boom 2 Before arriving at the digging equipment lower...

Page 446: ...d Right Support Items 1 and 2 6 Withdraw the pins connecting the Support Braces Item 3 to Left and Right Support Item 1 and 2 7 Withdraw the spring pins from the pins connecting the digging boom to the Left and Right Support 8 Withdraw the pins connecting the digging boom to the Left and Right Support REMARK It may be necessary to adjust the position of the boom raise cylin ders to allow easy with...

Page 447: ... Damage could occur if the pins are not correctly aligned WARNING q Never use ANY other control to cause the hydraulic pins to move This could cause injury damage or death q Make sure that the assistant and all other personnel are not positioned where risk of injury can occur 12 Attach the safety plates to the exposed ends of the adjustable pins 13 Close the valves on the left and right side of th...

Page 448: ...y 17 Reconnect the grease lines 18 If the digging arm is not fitted carry out the steps in CON NECTING DIGGING ARM TO DEMOLITION DIGGING BOOM 7 39 If the digging arm is fitted purge the hydraulic circuits of air by following the steps in PURGING AIR PRO CEDURES 7 41 DEMOLITION BOOM 1 DEMOLITION DIG BOOM DEMOLITION BOOM 2 HOSES POSITION HIGH REACH FUNCTION DEMOLITION DIG FUNCTION A LEFT LOWER Att R...

Page 449: ...r lifting equipment of the correct rating to prevent possibility of equipment falling Remember to switch the Equipment change over switch in the cab to High Reach when the High Reach Demolition equipment is installed The demolition digging equipment stand comprises only one stand section The stand includes the items shown below CONNECTING DIGGING ARM TO DEMOLITION DIGGING BOOM 7 REMARK Follow proc...

Page 450: ...to the right hand end of the pin 8 Lock pin in place with plate left side of work equipment CAUTION Before reconnecting each hose check that there are no foreign particles in the hydraulic lines and that all connections are clean 9 Remove plugs from the hydraulic lines and reconnect WARNING Take care to reconnect the hydraulic lines in the correct order Improper operation of the machine will occur...

Page 451: ...ations run the engine at normal speed PROCEDURE FOR PURGING AIR FROM BOOM LOCK VALVE PPC CIRCUIT 7 WARNING While monitoring oil temperature loosen the cap of the hydraulic oil tank to release residual pressure purge air in the tank 1 PRECAUTIONS FOR PURGING AIR FROM BOOM LOCK VALVE PPC CIRCUIT 1 To mount the demolition high reach boom and arm purge air from the boom lock valve PPC circuit before o...

Page 452: ... plug 1 set boom control lever to DOWN and wait until oil flows continuously until bubbles cease CAUTION WHEN SELECTING THE ABOVE METHOD WATCH OUT FOR SPURTING OIL AND PREPARE A PROTEC TIVE COVER AND OIL PAN TO PREVENT THE AREA FROM BEING POLLUTED BY OIL q Run the engine at half throttle speed q Set the boom control lever to DOWN at full stroke and keep it at this position for approximately 2 minu...

Page 453: ...MARK Before executing this work stop the engine and release residual pressure in the piping while monitoring oil temperature PURGING AIR FROM HYDRAULIC DRIFT PREVENTATIVE VALVE PPC CIRCUITS OF MID LINK AND ARM CYLINDER 7 REMARK Purge air in accordance with section Purging air from hydraulic drift preventative valve PPC circuit of boom cylinder 1 Connection of hydraulic drift preventative valve PPC...

Page 454: ...PURGING AIR PROCEDURES HIGH REACH DEMOLITION EQUIPMENT 27M 7 44 Figure 2 Drain Line Figure 3 Mid link PPC line Fig 4 Arm PPC line ...

Page 455: ...hine is reduced when the equipment is in this position Always move the machine EXTREMELY SLOWLY and do not slew the machine 3 Make sure the trailer is firmly secured and will not move when the machine approaches 4 Slowly mount the trailer making sure at all times that the tracks are properly aligned with the trailer If the machine becomes misaligned reverse the machine from the trailer and start a...

Page 456: ...standard excavator see main machine manual CAUTION Make sure that the additional counterweight is removed when the demolition digging equipment is fitted TRANSPORTATION high reach demolition equipment alone 7 PROCEDURE FOR LOADING ON TO TRAILER 7 CAUTION It is the responsibility of the transporting company to ensure that the load is secure and safe This procedure includes the following basic steps...

Page 457: ...lied warning tag onto the safety lock lever 5 Assemble the work equipment support to the work equipment brackets The demolition work equipment stand is in two sec tions Each section consists of three items 6 Insert pins supplied with the machine to locate the boom brackets onto the Stand brackets position A B Action 1 WARNING Securely fix the pins with the spring pins supplied position C Action 2 ...

Page 458: ...again NEVER try to steer or slew the machine when it is in contact with the trailer Do not exceed an angle of 15 degrees from the horizon tal as shown 11 As the machine slowly travels onto the trailer the weight of the work equipment will rock the machine onto the trailer Gently move the machine further onto the trailer so that it stabilises INSTALL THE EQUIPMENT ONTO THE TRAILER 12 Carefully lowe...

Page 459: ...ulic circuit When hydraulic lines are separated make sure that all open ends are plugged 15 Disconnect the banked hydraulic connectors on the top of the demolition first boom A connect B disconnect 16 Disconnect the individual hydraulic connections around the demolition first boom 17 Separate the grease hoses and protect the exposed ends in the same way as the main hydraulic lines Plug the open en...

Page 460: ...the first boom section to settle stand B onto the trailer Then simultaneously lower the first boom and reverse the machine away from the demolition equipment to disengage the upper pin 23 Ensure that all exposed bores pins hoses and tubes are thoroughly protected from corrosion and foreign matter WARNING When reversing the machine from the demolition work equip ment make sure that all operators ar...

Page 461: ...orking ranges Unit HIGH REACH A Maximum working height to pin at arm end mm 27100 B Maximum forward reach mm 13000 C Minimum swing radius of arm end pin max height mm 4100 D Tail Swing radius mm 3740 E Height at Max Reach mm 16650 F Minimum boom angle from ground degrees 81 Operating weight 600mm shoes kg 57585 Operating weight 700mm shoes kg 57035 ...

Page 462: ...nges Unit MEDIUM REACH A Maximum working height to pin at arm end mm 23140 B Maximum forward reach mm 14410 C Minimum swing radius of arm end pin max height mm 3550 D Tail Swing radius mm 3740 E Height at Max Reach mm 12180 F Minimum boom angle from ground degrees 70 Operating weight 600mm shoes kg 54865 Operating weight 700mm shoes kg 55315 ...

Page 463: ...Maximum Dumping Height bucket teeth mm 10900 11510 C Maximum Digging Depth bucket teeth mm 4775 5255 D Maximum Vertical Wall Digging Depth mm 4045 4520 E Maximum Digging Reach mm 12840 13410 F Maximum Digging Reach at Ground Level mm 12645 13255 G Minimum Swing Radius Bucket loaded mm 3450 3425 H Tail Swing Radius mm 3740 3740 Operating weight 600mm shoes kg 49285 48540 Operating weight 700mm shoe...

Page 464: ...Maximum Dumping Height bucket teeth mm 8215 8750 C Maximum Digging Depth bucket teeth mm 6555 7035 D Maximum Vertical Wall Digging Depth mm 5060 6255 E Maximum Digging Reach mm 11680 12290 F Maximum Digging Reach at Ground Level mm 11470 12090 G Minimum Swing Radius Bucket loaded mm 3900 3870 H Tail Swing Radius mm 3740 3740 Operating weight 600mm shoes kg 49285 48540 Operating weight 700mm shoes ...

Page 465: ...0mm x 640mm x 550mm 5280 kg EQUIPMENT EXCAVATION BOOM WITH ARM HIGH REACH 2900mm arm 3400mm arm A TOTAL HEIGHT Incl Hydraulic lines 3025 mm 3025 mm 3425 mm B HEIGHT 2980 mm 2980 mm 3250 mm C LENGTH 8780 mm 9330 mm 11412 mm D TIP RADIUS 1845 mm 1845 mm SUPPORT WEIGHT 320 kg 320 kg 720 kg 2nd BOOM WEIGHT 3125 kg 3125 kg 1720 kg 3rd BOOM WEIGHT 2500 kg MID LINK WEIGHT 1050 kg ARM WEIGHT 1715 kg 1659 ...

Page 466: ...LCD 8 with mid boom PC450 LCD 8 without mid boom A Overall width of Upper Structure 1 2995mm B Overall height of Cab with OPG 3485mm B1 Overall height of Cab without OPG 3265mm C Tail Length 3705mm D Clearance under counterweight 1320mm E Machine Tail Height 3107mm F Ground Clearance 685mm G Track Length on ground 4350mm HWG 4315mm H Track Length 5355mm I Swing Centre to front distance 15170mm 111...

Page 467: ...Tail Height 3107mm 3107mm 3107mm 3107mm F Ground Clearance 685mm 685mm 685mm 685mm G Track Length on ground 4350mm HWG 4315mm 4350mm HWG 4315mm 4350mm HWG 4315mm 4350mm HWG 4315mm H Track Length 5355mm 5355mm 5355mm 5355mm I Swing Centre to front distance 8850mm 8730mm 9390mm 9365mm J Track Gauge 2390 28902 HWG 2280 3130 2 2390 28902 HWG 2280 3130 2 2390 28902 HWG 2280 3130 2 2390 28902 HWG 2280 3...

Page 468: ...g capacity rating overside LEGEND 1 Position of lifting point 2 Arm length 3 Boom length 4 Hydraulic pressure 37 3 MPa WORKING CONDITIONS q WITH BUCKET 1914 kg q IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHOULD BE DEDUCTED FROM THE VALUES OF THIS TABLE q WITH FULLY EXTENDED BUCKET CYLINDER q ON A COMPACT HORIZONTAL LEVEL GROUND WITH 600 mm WIDTH SH...

Page 469: ...INDEX 18 ...

Page 470: ...INDEX 8 2 ...

Page 471: ... 7 56 GENERAL VIEW OF MACHINE 7 2 7 51 7 52 7 53 7 54 GREASE PUMP HOLDER 3 108 H HANDLING MACHINES EQUIPPED WITH KOMTRAX6 33 BASIC PRECAUTIONS 6 33 HANDLING OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 4 HIGH REACH DEMOLITION EQUIPMENT 27M 7 1 I INTRODUCTION 1 5 L LIFTING MACHINE 3 178 LOADING AND UNLOADING WITH TRAILER 3 170 LOCKING 3 168 LONG TERM STORAGE 3 187 AFTER STORAGE 3 188 BEFORE STORAGE...

Page 472: ...H BUCKET 2 34 OPERATION 2 24 STARTING ENGINE 2 22 TOWING 2 33 TRANSPORTATION 2 30 SAFETY MAINTENANCE INFORMATION 2 35 SERVICE METER LOCATION 1 12 SPECIFICATIONS 5 2 STARTING ENGINE 3 128 STEERING THE MACHINE 3 146 STOPPING THE ENGINE 3 141 SUN ROOF 3 78 SWINGING 3 148 SWITCHES 3 69 7 4 T TIGHTENING TORQUE LIST 4 15 TIGHTENING TORQUE SPECIFICATIONS 4 15 TOOL BOX 3 108 TRANSPORTATION 3 169 TRANSPORT...

Page 473: ...COLOPHON 18 ...

Page 474: ...COLOPHON 8 2 PC450 450LC PC450LCD 7E0 GALEO HYDRAULIC EXCAVATOR Form No UEAM007200 2007 KOMATSU All Rights Reserved Printed in Belgium 03 07 ...

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