Komatsu PC45MR-30403 Page 323 Operation And Maintenance Manual Download | Manualshive

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METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER... 4-89
METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA-

TOR (FOR CONTROL CIRCUIT) ........................................................................................................ 4-93

METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR ................................................... 4-97

EVERY 3000 HOURS MAINTENANCE ......................................................................................................... 4-98

METHOD FOR CHECKING AND CLEANING FUEL INJECTION SYSTEM............................................ 4-98

EVERY 4000 HOURS MAINTENANCE ......................................................................................................... 4-99

REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-99
METHOD FOR REPLACING ACCUMULATOR (FOR CONTROL CIRCUIT) ........................................ 4-100

EVERY 6000 HOURS MAINTENANCE ....................................................................................................... 4-101

METHOD FOR CLEANING KDPF ........................................................................................................ 4-101

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER

For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket dig-
ging operations, so set the maintenance intervals as follows.

Replace hydraulic filter element

On a new machine, replace the element after the first 100 to
150 hours, then perform further replacement of the element ac-
cording to the table.

Change of oil in hydraulic tank

Change the oil according to the table.

X:

Breaker operating ratio ( %)

Y: Replacement interval (H)
(A):Element of hydraulic tank
(B):Hydraulic oil

REMARK

Breaker operating ratio 100 % means that only the breaker is
used.
Breaker operating ratio 0 % means that the breaker is not used.

MAINTENANCE SCHEDULE

MAINTENANCE

4-14

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Summary of Contents for PC45MR-30403

Page 1: ...guage manual is necessary contact your local distributor for availability NOTICE Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual...

Page 2: ...ifornia to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to t...

Page 3: ...r the oper ator s seat If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replace...

Page 4: ...safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation wh...

Page 5: ...ATIONS DIRECTIONS OF MACHINE A Front B Rear C Left D Right E Operator s seat F Sprocket In this manual the terms front rear left and right refer to the travel direction as seen from the operator s sea...

Page 6: ...ollowing items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is located on the front left of revolving frame The design of the nameplate varies according to the district LO...

Page 7: ...displayed on the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Distributor name Address Phone Fax Service personnel P...

Page 8: ...TTACHMENTS AND OPTIONS 2 21 PRECAUTIONS RELATED TO CAB GLASS 2 21 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 22 PRECAUTIONS FOR OPERATION 2 23 PRECAUTIONS FOR JOBSITE 2 23 START ENGINE 2 26 PRE...

Page 9: ...THOD FOR LIFTING MACHINE 3 226 COLD WEATHER OPERATION 3 229 COLD WEATHER OPERATION INFORMATION 3 229 PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 3 231 AFTER COLD WEATHER SEASON 3 231 PRECA...

Page 10: ...SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 SPECIFICATIONS PC45MR 5 5 2 SPECIFICATIONS PC55MR 5 5 4 ATTACHMENTS AND OPTIONS 6 1 PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS 6 2 PRECAUTIONS WHEN SELECTING 6...

Page 11: ...EMENT OF DEFINED LIFE PARTS 7 2 DEFINED LIFE PARTS LIST 7 2 CONSUMABLE PARTS 7 3 CONSUMABLE PARTS LIST 7 3 RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 LUBRICATION CHART 7 5 METHOD FOR USING FUEL COOLAN...

Page 12: ...se read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions s...

Page 13: ...ly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new...

Page 14: ...n for handling accumulator 11 Caution when opening floor 12 Caution for adjusting track tension 13 Caution when changing control pattern 14 Prohibition of entering into swing range 15 Stop rotation du...

Page 15: ...during inspection and maintenance 8 Caution for handling ROPS 9 Caution for operation inspection and maintenance 10 Caution for high pressure fuel 11 Caution for handling cable 12 Caution for handling...

Page 16: ...ution for blast site machine with KOMTRAX 21 Caution for using seat belt 22 Caution when leaving operator s seat 23 Caution before operating 24 Caution for control pattern 25 Caution for electric cabl...

Page 17: ...CONTENTS OF SAFETY LABELS Caution for operation inspection and mainte nance 09651 03001 Caution before operating 22L 98 22160 Caution for using seat belt 09848 03000 SAFETY LABELS SAFETY 2 6...

Page 18: ...Caution when leaving operator s seat 09654 03001 Caution for electric cables 09801 03002 SAFETY SAFETY LABELS 2 7...

Page 19: ...Caution for control pattern 22N 98 51251 Caution for high temperature coolant 20M 98 83250 Caution for high temperature hydraulic oil 22L 98 22240 SAFETY LABELS SAFETY 2 8...

Page 20: ...r or muffler during or right after oper ation Never touch when hot Caution for handling cable 09808 03001 Caution for adjusting track tension 09657 03003 Stop rotation during inspection and mainte nan...

Page 21: ...hit by the work equipment of the machine Keep away from machine during operation Caution when opening or closing front win dow Machine with cab specification 09839 03001 Caution when stowing front win...

Page 22: ...as hydrogen Explosion Fire Blast or Projectile hazard Do not handle or charge until all safely precautions instructions have been read and understood Wear protective gloves protective clothing eye pro...

Page 23: ...etonation may be caused by an active radio transmitter in blast zone To prevent SEVERE INJURY or DEATH keep machine a safe distance away from a blast zone and a detonator or disconnect the wireless mo...

Page 24: ...inspection or maintenance on the machine If you are not feeling well or if you are under the influence of alcohol or medication your ability to safely operate or repair your machine may be severely im...

Page 25: ...dangerous Wipe off any mud or oil from the machine Always keep the machine clean If water gets into the electrical system electric devices will cause malfunctions and the machine will cause error If...

Page 26: ...t the fire extinguisher can always be used Provide a first aid kit in the storage point Perform periodic checks and add to the contents if necessary IF ANY PROBLEM IS FOUND If you find any problem in...

Page 27: ...s securely Be careful not to spill fuel on overheated surfaces or on parts of the electrical system After adding fuel or oil wipe up any spilled fuel or oil Put the greasy rags and other combustible m...

Page 28: ...soot in the exhaust gas Exhaust gas temperature may increase during the purifi cation process regeneration Do not bring any combustible material close to the outlet of the exhaust pipe When there are...

Page 29: ...ecurely If the handrails are damaged or deformed they need to be repaired immediately Ask your Komatsu distributor for that work Do not grip the control levers or lock lever when getting on or off the...

Page 30: ...p the operating portion on top of the lock lever 1 to set the lock lever 1 to LOCK position L and stop the engine If the seat is positioned forward your body or clothes will easily touch the levers Sh...

Page 31: ...form operations without it If the protective structure is welded or holes are drilled in it or it is modified in any other way its strength may drop Any modification is prohibited If the protective st...

Page 32: ...Komatsu distributor PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS Any personal injuries product failures physical loss or damage or influence on the environment resulting from the use of unauthorized...

Page 33: ...od ventilation If the engine or ma chine must be operated inside a building or underground where the ventilation is poor take steps to ensure that the en gine exhaust gas is removed and that ample fre...

Page 34: ...achine during operation In particular if you need to operate on a road protect pe destrian and cars by designating a person for jobsite traffic duty or by installing fences around the jobsite When tra...

Page 35: ...voltage cables prohibit anyone other than related persons to come close to the machine during operation If the machine should come too close or touch the electric cable to prevent electric shock the o...

Page 36: ...st in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsite where demolition work is performed or industrial waste is han dled Always observe the...

Page 37: ...Remove all dirt from the surface of the lens of the headlamps and working lamps and check that they light up correctly Check the coolant level fuel level and oil level in engine oil pan check for clog...

Page 38: ...ectrolyte before starting START ENGINE WITH JUMPER CABLES If any mistake is made in the method of connecting the jumper cables it may cause the battery to explode so always observe the following Alway...

Page 39: ...elt When the brakes are applied sudden ly the operator may be thrown out of the operator s seat It is dangerous and may cause personal injury Check that the movement of the machine matches the dis pla...

Page 40: ...other than the operator to get on the machine If there are any people in the area around the machine there is danger that they may be hit or caught by the machine and this may lead to serious persona...

Page 41: ...When driving the machine on the rough ground drive it at low speed and do not operate the steering suddenly There is a danger that the machine may tip over The work equip ment may hit the ground and t...

Page 42: ...ownhill Always be sure of the safety of the ground under the front of the machine when driving When driving the machine up a steep slope extend the work equipment to the front to improve the balance k...

Page 43: ...ock lever to LOCK position and then start the engine PRECAUTIONS WHEN OPERATING ON SLOPES When working on slopes there is a hazard that the machine may lose its balance and turn over when per forming...

Page 44: ...may collapse Never perform digging under an overhang Do not excavate too deeply under the front of the machine The ground under the machine may collapse and cause the machine to fall For a quick esca...

Page 45: ...ngs or other structures check the strength and the structure be fore starting operations There is a hazard of the building collapsing and causing serious injury or death Generally speaking the machine...

Page 46: ...personal injury or death Observe the following Park the machine on a firm level ground Select a place where there is no hazard of landslides fall ing rocks or flooding Lower the work equipment to the...

Page 47: ...e Take suitable steps to prevent the ramps from moving out of position or coming off 1 Chocks 2 Ramp 3 Ramp width 4 Angle of ramp Max 15 5 Block Be sure the ramp surface and the platform of trailer ar...

Page 48: ...nfirm that the wire rope or drawbar used for towing has ample strength for the weight of the ma chine being towed Never use the wire rope which has breaks in strands A reduced diameter B or kinks C Th...

Page 49: ...als to be used and place a signalman in position Prohibit anyone to enter the place where there is danger of contact with a lifted load or the danger from a falling load It is dangerous if a lifted lo...

Page 50: ...er 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 the tidy to enable you to perform operations safely If t...

Page 51: ...ce Turn the starting switch to ON position Operate the work equipment control lever back and forth right and left a few times fully to release the remaining internal pressure in the hydraulic circuit...

Page 52: ...ng When it is necessary to per form the maintenance with the engine running always observe the following One worker must always sit on the operator s seat and be ready to stop the engine at any time A...

Page 53: ...ous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment If any of the con trol levers is touched by accident or there is da...

Page 54: ...an the battery A wet wipe will prevent fire or explosion from static electricity Do not smoke or bring any open flame close to the battery Hydrogen gas is generated when the battery is being charged s...

Page 55: ...ttery firmly in the specified position Be careful that the fittings should not come to contact with the terminal at this time Install the cover above the battery so that it envelops the battery and it...

Page 56: ...ECAUTIONS FOR HIGH TEMPERATURE COOLANT To prevent burns from boiling water or steam spurting out when checking or draining the coolant wait for the coolant to cool down to a temperature where the radi...

Page 57: ...piping before the internal pressure is released serious personal injury or death can result When performing in spection or maintenance of the fuel piping system stop the engine and wait for at least...

Page 58: ...may fly out and cause serious injury or death or property damage When loosening grease drain plug 1 to loosen the track tension never loosen it more than 1 turn Loosen the grease drain plug slowly Nev...

Page 59: ...particles When using compressed air to clean the filter element or radiator wear protective eyeglasses anti dust mask gloves and other protective equipment MAINTENANCE OF AIR CONDITIONER If air condit...

Page 60: ...ese components naturally changes over time and repeated use causes deterioration wear and fatigue As a result there is a hazard that these components may fail and cause serious personal injury or deat...

Page 61: ......

Page 62: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1...

Page 63: ...VIEW MACHINE EQUIPMENT NAME 1 Arm cylinder 2 Boom 3 Boom cylinder 4 Dirt cover 5 Track 6 Sprocket 7 Track frame 8 Idler 9 Blade cylinder 10 Blade 11 Bucket 12 Bucket cylinder 13 Arm GENERAL VIEW OPERA...

Page 64: ...14 Engine rear cover 15 Cooling cover 16 Battery 17 KDPF OPERATION GENERAL VIEW 3 3...

Page 65: ...om swing control pedal 7 Machine monitor 8 Horn switch 9 R H work equipment control lever 10 Travel speed selector switch 11 Blade control lever 12 Fuel control dial 13 Lamp switch 14 Starting switch...

Page 66: ...control lever 11 Travel speed selector switch 12 Blade control lever 13 Temperature control switch 14 Air flow selector switch 15 Air conditioner switch 16 Fuel control dial 17 Lamp switch 18 Starting...

Page 67: ...level caution lamp 11 Auto deceleration pilot lamp 12 Guidance icon 13 Engine coolant temperature caution lamp 14 Aftertreatment devices regeneration pilot lamp 15 Aftertreatment devices regeneration...

Page 68: ...UIPMENT NAME OTHER EQUIPMENT NAME CANOPY SPEC 1 Auxiliary electric power 2 Cup holder 3 Toolbox 4 Fuse 5 Operation and Maintenance Manual pocket 6 Grease pump holder 7 Fusible link OPERATION GENERAL V...

Page 69: ...oor lock release lever 5 Toolbox 6 Fuse 7 Operation and Maintenance Manual pocket 8 Power supply outlet 9 Emergency escape hammer 10 Small slide window 11 AUX if equipped 12 Cup holder 13 Ashtray if e...

Page 70: ...safely it is important to completely understand methods of operat ing the equipment and the meanings of the displays EXPLANATION OF MACHINE MONITOR EQUIPMENT AA Standard screen BB Warning or Error scr...

Page 71: ...and the machine monitor may restart but it is not a trouble BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While the engine shutdown secondary sw...

Page 72: ...r 5 seconds and then the screen goes out End screen when any message has been received If there is any message from your Komatsu distributor it is dis played on the end screen In this case turn the st...

Page 73: ...nance time warning when starting the engine opening screen CC changes to mainte nance time warning screen EE After displaying opening screen CC for 2 seconds the screen changes to maintenance time war...

Page 74: ...o warning screen BB After opening screen CC is displayed for 2 seconds the screen changes to warning screen BB After warning screen BB 1 and 3 are displayed for 2 seconds the screen automatically chan...

Page 75: ...For checking the details of error press function switch F3 and then existing error list screen is displayed EXPLANATION OF COMPONENTS OPERATION 3 14...

Page 76: ...ccurs during operation standard screen AA changes to warning screen BB After warning screen BB 1 and 3 are displayed for 2 seconds the screen automatically changes to warn ing screen BB 2 and 4 If the...

Page 77: ...For checking the details of error press function switch F3 and then existing error list screen is displayed EXPLANATION OF COMPONENTS OPERATION 3 16...

Page 78: ...the ma chine urgently stop or pause the current operation If no action is taken the machine can be seriously affected Take necessary actions immediately 1 Action level display 2 Seat belt caution lamp...

Page 79: ...ve the machine to a safe place and then ask your Komatsu distributor for the inspection and maintenance L02 Sounds inter mittently Lights up in red Stop the operation and run the engine at medium spee...

Page 80: ...l L04 L03 Abnormal L01 KDPF system caution lamp Abnormal L04 L03 Abnormal L01 KDPF soot accumulation caution lamp Abnormal L03 Accumulated L01 Engine system caution lamp Abnormal L04 L03 Abnormal L01...

Page 81: ...ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature When abnormal The caution lamp lights up in red and action level...

Page 82: ...yellow Some functions may be restricted for use but the machine can operate When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for inspection and...

Page 83: ...ance as needed KDPF SOOT ACCUMULATION CAUTION LAMP The KDPF soot accumulation caution lamp warns that soot is accumulated in KDPF or the filtering function of KDPF has low ered abnormally To cancel th...

Page 84: ...tions may be restricted for use but the machine can operate When you finish the operation always have the inspection and maintenance performed Ask your Komatsu distributor for the inspection and maint...

Page 85: ...yellow The maintenance time is approaching Prepare necessary parts for the maintenance REMARK You can check necessary maintenance items on Mainte nance menu screen by pressing function switch F4 on th...

Page 86: ...Preheating pilot lamp 4 Lock lever pilot lamp 5 Lock lever automatic lock cancel pilot lamp 6 Message display 7 Working mode display 8 Travel speed display 9 Auto deceleration pilot lamp Gauge display...

Page 87: ...t after preheating is completed Automatic preheating is for a maximum of approximately 15 seconds AUTO DECELERATION PILOT LAMP The auto deceleration pilot lamp shows the setting of the auto decelerati...

Page 88: ...f attachments ATT P ATT P mode For operations of 2 way attachments like crusher For machines ready for installation of attachment ATT E ATT E mode For operations emphasizing fuel consumption out of th...

Page 89: ...isplayed Lo Low speed travel Hi High speed travel REMARK Each time the travel mode is switched by the travel speed selector switch it lights up in yellow at the center of the monitor display and 2 sec...

Page 90: ...there is a message from Komatsu To read the message see CHECK MESSAGE Lights up in green There is an unread message Lights up in blue There is any read message to which no reply is made OFF There is n...

Page 91: ...r treatment devices regeneration The aftertreatment devices regeneration pilot lamp lights up during regeneration of the exhaust gas aftertreatment devices It goes out when the regeneration is complet...

Page 92: ...CK position It goes out when the lock lever is set in FREE position LOCK LEVER AUTOMATIC LOCK CANCEL PILOT LAMP The lock lever automatic lock cancel pilot lamp lights up when the lock lever automatic...

Page 93: ...blue White range Low temperature Graduation of gauge lights up in white When the graduation of gauge goes beyond white range C color changes to green Engine coolant temperature caution lamp D lights u...

Page 94: ...ts up in blue B Red range The remaining fuel level is low The remaining fuel level is 14 or less 3 7 U S Gal or less Fuel level caution lamp C lights up in red OFF Abnormal If communication error occu...

Page 95: ...peed Service meter display Clock display 12 hour display Clock display 24 hour display On the standard screen if you press function switch F2 you can switch between the clock display and the service m...

Page 96: ...t day Split under measurement display Displays the split fuel consumption under measurement Split measurement is stopped display Measurement of split fuel consumption is stopped REMARK Display on the...

Page 97: ...s fuel consumption is at a bad level REMARK Even if the graduation of gauge enters the yellow range there is no abnormality on the machine However for the conservation of global environment reduce the...

Page 98: ...function Press function switch 1 corresponding to guidance icon 2 to operate the function When monitor display is standard screen The types of guidance icons and functions of function switches are as...

Page 99: ...t line Function switch F3 Cancels any change and returns the screen to the previous screen Function switch F4 Enters the selection and contents to change and advances the screen to the next screen Fun...

Page 100: ...l consumption is reduced If either of the work equipment control lever or travel lever is operated with the engine at idle speed engine speed will return to the previous operating speed and you can pe...

Page 101: ...d the working mode selec tion screen is displayed For each set mode P E B ATT P and ATT E are displayed on working mode dis play at the top right of the monitor display For machines ready for installa...

Page 102: ...blue BUZZER CANCEL FUNCTION Perform the setting of working mode selection after starting the engine When buzzer cancel icon is displayed if you press function switch F8 alarm buzzer for abnormality of...

Page 103: ...Record b Machine Setting c Aftertreatment Devices Regeneration d Maintenance e Monitor Setting f Mail check These menus a to f are for setting and confirming the following items For operations in each...

Page 104: ...Check of mail contents and reply to mail On the user menu screen you can perform the following opera tions with function switches F1 to F4 F6 and F7 Function switch F1 Moves to the next item 1 line be...

Page 105: ...When on the left end menu it moves to the right end menu Function switch F7 Moves to the right menu When on the right end menu it moves to the left end menu REMARK If no switch is operated for 30 seco...

Page 106: ...tion Records screen following items are displayed Working Hours Engine On Average Fuel Consumption Actual Working Hours Ave Fuel Consumption Actual Working Fuel Consumption Idling Hours Economy Mode R...

Page 107: ...witch F1 Switches graphical displays of the average fuel consumption Function switch F3 Returns the screen to Working Record menu screen Function switch F8 Clears the graph data REMARK The displayed v...

Page 108: ...s switch F8 the reconfirmation screen is displayed 2 If you press function switch F4 graphs data of the last 12 hours and the last 1 week are both deleted and the screen returns to Ave Fuel Consumpn R...

Page 109: ...on Configurations menu screen On Configurations screen you can perform the following op erations with function switches F1 to F4 Function switch F1 Moves to the next item 1 line below When on the las...

Page 110: ...y Split Time Displays the average fuel consumption during the split measurement period Select Split Time to start the automatic measurement of fuel consumption OFF Does not display the fuel consumptio...

Page 111: ...yed at the top right of Operation Records screen If you want to stop the measurement press function switch F8 on Operation Records screen and move to Split Time Information screen and then press funct...

Page 112: ...splay the ECO gauge on the standard screen On ECO Gauge Display screen you can perform the follow ing operations with function switches F1 to F4 Function switch F1 Moves to the next item 1 line below...

Page 113: ...t Value screen you can perform the following operations with function switches F1 to F4 F6 and F7 Function switch F1 Decreases the target fuel consumption value by 1 Function switch F2 Increases the t...

Page 114: ...not displayed 1 Select Breaker Setting on Machine Setting menu screen and then press function switch F4 2 Breaker Setting screen is displayed Select the setting corresponding to the operation on Brea...

Page 115: ...s F1 to F4 F6 F7 and F8 Function switch F1 Moves to the previous alphabet numeral or symbol Function switch F2 Moves to the next alphabet numeral or symbol Function switch F3 Returns the screen to Bre...

Page 116: ...n per form the following operations with function switches F3 F4 F6 and F7 Function switch F3 Returns the screen to Breaker Setting screen without changing the flow rate Function switch F4 Enters the...

Page 117: ...m the fol lowing operations with function switches F1 to F4 F6 and F7 Function switch F1 Moves to the next item 1 line below When on the last line it moves to the first line Function switch F2 Moves t...

Page 118: ...the screen to Attachment Setting screen Function switch F6 Moves to the left letter When on the first letter it moves to the last letter Function switch F7 Moves to the right letter When on the last l...

Page 119: ...on switch F3 Returns to Attachment Setting screen without changing the flow rate Function switch F4 Enters the flow rate setting and returns the screen to At tachment Setting screen Function switch F6...

Page 120: ...ange the auto idle stop timer setting after starting the engine 1 Select Auto Idle Stop Timer Set on Machine Setting menu screen and then press function switch F4 2 Select the setting time on Auto Idl...

Page 121: ...hen the elapsed time of idling reaches 30 seconds be fore the preset time the machine monitor returns to the standard screen and changes to the countdown screen and the guidance icon on the bottom rig...

Page 122: ...dle stop function only the engine is stop ped The machine monitor inverter etc as well as the electri cal components including the lamps wipers and radio keep their states before the engine is stopped...

Page 123: ...REATMENT DEVICES REGENERATION Each item of Aftertreatment Devices Regeneration menu screen is for settings and operations of the aftertreatment devi ces regeneration EXPLANATION OF COMPONENTS OPERATIO...

Page 124: ...ch to Maintenance Due Time Reset screen If no switch is operated for 30 seconds on Maintenance menu screen the screen automatically returns to the standard screen When the maintenance time caution lam...

Page 125: ...tch is operated for more than 30 seconds the screen automatically changes to Maintenance screen 4 Press function switch F4 on the reconfirmation screen The remaining time is reset and the screen retur...

Page 126: ...brightness of the screen and the screen returns to Monitor Setting menu screen Function switch F4 Allocates the change of brightness of the screen and the screen returns to Monitor Setting menu screen...

Page 127: ...ollowing operations with function switches F1 to F4 Function switch F1 Moves to the next item 1 line below When on the last line it moves to the first line Function switch F2 Moves to the previous ite...

Page 128: ...ecessary On GPS Synchronization screen you can perform the following operations with function switches F1 to F4 Function switch F1 Moves to the next item 1 line below When on the last line it moves to...

Page 129: ...he following op eration You can change the numeral displayed in yellow Function switch F1 Puts back the numeral by 1 Function switch F2 Advances the numeral by 1 Function switch F3 Cancels the date ch...

Page 130: ...yed Change the time according to the following operation You can change the numeral displayed in yellow Function switch F1 Puts back the numeral by 1 Function switch F2 Advances the numeral by 1 Funct...

Page 131: ...hour mode with am or pm Change the display mode of clock with the following opera tion Function switch F1 Moves to the next item 1 line below When on the last line it moves to the first line Function...

Page 132: ...the display mode of clock with the following opera tion Function switch F1 Moves to the next item 1 line below When on the last line it moves to the first line Function switch F2 Moves to the previous...

Page 133: ...anguage screen is displayed Select the language to be displayed and then press func tion switch F4 The language to be displayed on the machine monitor is changed On Language screen you can perform the...

Page 134: ...u distributor on the mail check menu screen by pressing function switch F4 Message is distinguished as follows according to the lighting states of the message display Lights up in green There is unrea...

Page 135: ...tioned as follows If the starting switch is turned to OFF position when there is any unread message the message will be displayed on the end screen and when the monitor is started next time the messag...

Page 136: ...sage If a message requests reply make a reply to the message Function switch F1 The message scrolls down Function switch F2 The message scrolls up Function switch F3 Return to the standard screen Func...

Page 137: ...the input value by 1 Function switch F3 Cancels the input value and returns the screen to the mail confirmation menu screen Function switch F4 Validates the input value and the screen changes to the...

Page 138: ...switch 2 Travel speed selector switch 3 Fuel control dial 4 Lamp switch 5 Starting switch 6 Pump secondary drive switch 7 Lock lever automatic lock cancel switch 8 Engine shutdown secondary switch OPE...

Page 139: ...control switch 5 Air flow selector switch 6 Air conditioner switch 7 Fuel control dial 8 Lamp switch 9 Starting switch 10 Pump secondary drive switch 11 Lock lever automatic lock cancel switch 12 Eng...

Page 140: ...hts up C START position This is the position to start the engine Keep the key at START position C during cranking Release your hand off the key immediately after the engine has been started The key in...

Page 141: ...ation is set to night mode b Day position Lamps light up and monitor illumination is set to day mode c OFF position Lamps go out The monitor illumination is set to day mode HORN SWITCH If you press th...

Page 142: ...e engine Travel speed selector switch is used to switch the travel mode Lo display Low speed travel Hi display High speed travel The travel speed is automatically set to low speed travel Lo when the s...

Page 143: ...the injection of the window washer fluid and the wiper operation are performed simultaneously If the wiper switch is released it returns to the wiper and wash er position b the injection of the windo...

Page 144: ...of the hydraul ic system errors DXA8KB and DXA8KA If There is the hydraulic system error repair the error as soon as possible Check that the pump secondary drive switch is in NORMAL position b If not...

Page 145: ...he work equipment control lever or travel lever is in NEUTRAL position this function is actuated by mistake and the machine or the work equipment may not move The machine or the work equipment can be...

Page 146: ...he cover of engine shutdown secondary switch is closed and the switch is in NORMAL position If not set it to NORMAL position 1 Raise cover 1 and open it 2 Turn the engine shutdown secondary switch to...

Page 147: ...ver 2 L H work equipment control lever 3 Travel lever with pedal 4 Swing lock cover 5 Boom swing control pedal 6 R H work equipment control lever 7 Blade control lever 8 Floor lock release lever EXPLA...

Page 148: ...lock lever automatic lock function assists the operator in judgment to reduce damage caused by accident It is not a device to stop the work equipment or machine in all situations Even if the lock lev...

Page 149: ...tate If you press the function switch F3 on Lock Lever Auto Locked screen the screen returns to the pop up display screen of it To cancel the lock lever automatic lock function return the lock lever t...

Page 150: ...facing the front When entering to the operator s seat there is a danger that your toe may get caught on the travel pedal When you do not perform the pedal operation always fold the pedals When you pe...

Page 151: ...d the control pedal is touched by mistake this may cause a serious injury or death The swing lock cover is used to lock the boom swing control pedal When the boom swing control pedal is covered with t...

Page 152: ...floor in strong winds Open and close the cab or floor while pulling the floor lock re lease lever Pull the floor lock release lever to FREE position F and lock is released Release the floor lock rele...

Page 153: ...te with one matching to the operation of the machine as well The control pattern card is located at the position shown in the figure Machine with canopy specification The control pattern card is locat...

Page 154: ...r is used to operate the boom and bucket Boom operation e Boom RAISE f Boom LOWER Bucket operation g Bucket DUMP h Bucket CURL N NEUTRAL The boom and bucket are held in position and do not move OPERAT...

Page 155: ...e firmly with both hands and lift it up Do not release your hands until the window is fixed When closing the front window the window may move quicker under its own weight Hold the han dles securely wi...

Page 156: ...does not move any more to the rear side of cab push the right and left handles 1 upward and fix the front window securely 7 Check that the handle locks 2 are securely fixed When pushing the handles 1...

Page 157: ...locks 2 forward with your thumb pull down the right and left handles 1 to open the front window 5 Hold the right and left handles 1 and lower the front win dow slowly forward slantwise 6 When the bot...

Page 158: ...window glass with the hammer be extremely careful not to get injured with scattered pieces of broken glass To prevent injury remove the broken pieces of glass remaining in the frame before escaping th...

Page 159: ...the door handle and knob whenever opening or closing the cab door Be careful not to get your hands caught between the front pillar or center pillar When there is anyone inside the cab always call out...

Page 160: ...the machine 1 Push the cab door against the catch part 1 to lock it in position Fix the cab door against the catch part 1 securely When getting on or off the machine hold the inside hand rail 2 To cl...

Page 161: ...on the rear left of the operator s seat ASHTRAY Machine with cab if equipped An ashtray is located on the right side of the operator s seat It is magnet type so you can install it to appropriate place...

Page 162: ...er the floor Do not start the engine while floor is open If any damage or problem is found at the floor opening lock part stop the work close the floor and then ask your Komatsu distributor for repair...

Page 163: ...ion L Be sure to operate the lock lever by the operating por tion on the top 2 Put the wooden blocks on the front and rear sides of the tracks so that the machine does not move 9 J A 0 5 4 6 6 EXPLANA...

Page 164: ...2 Remove the cover fixing bolts 3 M8 4 pieces and re move the cover 4 3 Remove the floor tilt fixing bolts 5 M14 2 pieces 4 Pull the engine rear cover 6 backward to open it Open the engine rear cover...

Page 165: ...elease lever is not in RE LEASE position Pull back the handle with your right hand and repeat the preceding procedure again Since the gas spring assists the opening of floor the force to push up the f...

Page 166: ...n 15 until its upper part hook to prevent from coming off catches the pin 17 of inserting part se curely NOTICE Check that the lock pin securely catches the pin and the pin does not come off The secon...

Page 167: ...ear cover 4 backward to open it Open the engine rear cover 4 fully and it is secured by rod 5 4 Remove the floor tilt fixing bolts 6 M14 4 pieces REMARK If the floor tilt fixing bolts 6 are hard to be...

Page 168: ...ush up the floor decreases in the following cases Take care When outside air temperature is low When the force of gas spring decreases due to the long term operation 9 Once the floor rises push it up...

Page 169: ...remove the lock pin 15 hold the handle 11 and while pulling it up remove the lock pin 15 2 While pulling the floor lock release lever 10 to FREE po sition F with your left hand hold the handle 11 with...

Page 170: ...ine part of the same size 7 Close the engine rear cover 6 8 Tighten the floor tilt fixing bolts 5 M14 2 pieces Tightening torque 156 8 to 196 0 Nm 16 0 to 20 0 kgm 116 to 145 lbft REMARK If any of the...

Page 171: ...and hold the handle 9 with your right hand and push it down slowly to the direction of arrow approximately 45 to release the first lock 3 Hold the handle 9 with your right hand and lower the floor slo...

Page 172: ...riginal position and install the air clean er mounting bracket with bolts A 7 Close the engine rear cover 4 8 Tighten the floor tilt fixing bolts 3 M14 2 pieces Tightening torque 156 8 to 196 0 Nm 16...

Page 173: ...nal electric equipment always close the cap If the cap is left open rainwater etc enters and may cause short circuit Capacity of this power supply is 120 W 12 V x 10 A Use the power outlet as a power...

Page 174: ...ose in the fuse holder replace the fuse Replace the fuse with the one of the same capacity Fuse capacities and circuit names Machine with canopy specification No Capacity Name of circuit 1 5 A Working...

Page 175: ...e 8 20 A Air conditioner and heater 9 10 A External power supply 10 5 A ACC signal 11 30 A Working lamp Travel lamp and additional work ing lamp 12 10 A Radio and system operating lamp if equipped 13...

Page 176: ...g switch is turned to START position the fusible link 1 2 or 4 may be broken Fusible link 3 is suspected of disconnection if it is hard to start the engine even after the engine preheating has been pe...

Page 177: ...is located inside the cover under the operator s seat GREASE PUMP HOLDER It is located inside the dirt cover on the front right of the machine Keep the grease pump hooked on this holder while it is n...

Page 178: ...the accumulat ed soot During the regeneration of KDPF aftertreatment devices regen eration pilot lamp 1 stays lit on the machine monitor REMARK Even if aftertreatment devices regeneration pilot lamp 1...

Page 179: ...atter which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals Ask your Komatsu distributor for clean ing the insi...

Page 180: ...n changes to Aftertreatment Devices Regeneration screen C after 3 seconds only the first time If the manual sta tionary regeneration is not performed the screen returns to standard screen B after 30 s...

Page 181: ...il the manual stationary regeneration is performed If the KDPF soot accumulation caution lamp 2 lights up in red immediately stop the machine in a safe place and per form the manual stationary regener...

Page 182: ...ionary regeneration can be performed while KDPF soot accumulation caution lamp 2 is lit and the warm up operation has completed 1 Move the machine to a safe place and stop it while the en gine is runn...

Page 183: ...essed the screen shown in the figure may be displayed This indicates that the procedure from step 1 to 4 is not performed correctly or there is trouble other than KDPF soot accumulation abnormality Ch...

Page 184: ...gauge indicates correct tem perature If it indicates low temperature lights up in white per form the warm up operation and repeat the procedure from step 1 If the manual stationary regeneration still...

Page 185: ...generation is stopped automatically Return the lock lever to LOCK position L and return the fuel control dial to Low idle MIN position then repeat the procedure from step 6 If the machine needs to be...

Page 186: ...move the ma chine to a safe place and perform manual stationary regen eration If the operation is continued without performing the man ual stationary regeneration it may cause the failure of KDPF or t...

Page 187: ...eration disable is canceled by turning starting switch to OFF position When the automatic regeneration needs to be kept disa bled perform the procedure from step 1 to 5 each time you start the engine...

Page 188: ...screen returns to Aftertreatment Devices Re generation screen 4 The screen returns to Aftertreatment Devices Regenera tion screen and regeneration is disabled REMARK When the regeneration is disabled...

Page 189: ...tion switches F6 and F7 to display Aftertreatment Devices Regener ation screen 2 On Aftertreatment Devices Regeneration screen select Cancel of Regeneration Disable and then press function switch F4 C...

Page 190: ...the regeneration disable set the lock lever to LOCK position and set the fuel control dial to Low idle MIN position then cancel the regeneration disable The regeneration disable setting is also cancel...

Page 191: ...nside network of the machine It can be useful for you to perform the machine management by yourself Your Komatsu distributor uses the above ma chine information for supply of service to the customers...

Page 192: ...ound the engine battery and radiator Check for dirt accumulated around the engine and radiator Also check for combustible material dry leaves twigs etc around the battery engine muffler or other high...

Page 193: ...damaged repair it Clean the surface of the mirror and adjust the angle so that the rear lower area can be seen from the operator s seat 11 Check the seat belt and mounting hardware Check the seat bel...

Page 194: ...sure to operate the lock lever by the operating por tion on the top 3 Operate the work equipment control lever slowly to right and left to swing the upper structure so that the drain valve comes betw...

Page 195: ...h the fuel 6 Open the drain valve 5 to discharge the sediment and water which is accumulated in the bottom together with the fuel Be careful not to get fuel on yourself 7 When only clean fuel flows ou...

Page 196: ...t of dust indicator 3 If the red piston is protruding clean or replace the element immediately For the cleaning method of the element see METHOD FOR CHECKING CLEANING AND REPLACING AIR CLEANER 3 After...

Page 197: ...rod 2 2 Pull the cooling cover 3 backward to open it 3 Turn the rod 4 to LOCK position L and fix the cooling cover 3 with the rod 4 Check for water and sediment If the red ring 5 of water separator s...

Page 198: ...the work equipment to the ground 5 Set the lock lever to LOCK position Be sure to operate the lock lever by the operating portion on the top 6 Stop the engine 2 Place a container under the fuel prefil...

Page 199: ...o operate the lock lever by the operating por tion on the top 3 Operate the blade control lever to lower the blade to the ground 4 Operate the work equipment control levers and re tract arm cylinder a...

Page 200: ...uge G It is appropriate if the oil level is between H and L If the oil level is below level L the hydraulic oil is insuffi cient If the hydraulic oil is insufficient add oil according to the following...

Page 201: ...and stop the engine Wait for the hydraulic oil to cool down sufficiently then drain the exces sive oil through the drain plug P REMARK The oil level varies with the oil temperature Use the following a...

Page 202: ...draulic tank is pressurized NOTICE If the hydraulic tank is not pressurized air is sucked in the pump and it affects the components badly 10 Return the plate 8 on the oil filler port F of the hydrauli...

Page 203: ...dia tor If the radiator cap is removed in this condition it may cause burn injury Always wait for the temperature to go down turn the radiator cap slowly to release the pressure and then remove it wit...

Page 204: ...mpty leakage of coolant should be suspected After checking repair any abnormality immediately If no abnormality is found check the level of the coolant in the radiator If it is low add coolant to the...

Page 205: ...oth 3 Fully insert dipstick G into the dipstick pipe then remove it 4 Check if the oil is sticking up to between marks H and L on dipstick G It is appropriate if the oil level is between marks H and L...

Page 206: ...vent hole NOTICE Perform inspection for the piping of battery starting motor and alternator with extreme care Perform inspection to confirm that the fuses have no defect and their capacity is proper...

Page 207: ...tch 1 and turn it to ON posi tion The machine monitor lights up 2 Check the fuel level with fuel gauge 2 After checking turn the starting switch 1 back to OFF po sition If the fuel level is low add fu...

Page 208: ...o time and check there is no clogging 4 Close dirt cover 3 METHOD FOR CHECKING HORN 1 Turn the starting switch to ON position 2 Check that the horn sounds immediately when the horn switch is pressed I...

Page 209: ...r tilt fixing bolts 3 M14 2 pieces in front of canopy pole are tightened securely If any of the floor tilt fixing bolts 3 is loosened tighten it Tightening torque 156 8 to 196 0 Nm 16 0 to 20 0 kgm 11...

Page 210: ...check the floor tilt fixing bolt 6 If any of the floor tilt fixing bolt 6 is loosened tighten it Tightening torque 156 8 to 196 0 Nm 16 0 to 20 0 kgm 116 to 145 lbft REMARK If any of the floor tilt f...

Page 211: ...loor tilt fixing bolts 3 If any of the floor tilt fixing bolts 3 is loosened tighten it Tightening torque 156 8 to 196 0 Nm 16 0 to 20 0 kgm 116 to 145 lbft REMARK If any of the floor tilt fixing bolt...

Page 212: ...D AFT DIRECTION Operate lever 1 upward set the seat to the desired position and then release the lever Fore aft adjustment 180 mm 7 1 in REMARK Adjust the position of operator s seat according to the...

Page 213: ...ng conditions must be met before starting the work to prevent the machine from moving dur ing the work The machine is placed on a level ground The work equipment is lowered to the ground in secure pos...

Page 214: ...ing the work The machine is placed on a level ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Adjust the mirror so that t...

Page 215: ...in the mirror as shown in the figure 2 Check that you can see a person at the rear right of the machine PROCEDURE FOR ADJUSTING MACHINE RIGHT REAR MIRROR k k CAUTION The following conditions must be...

Page 216: ...tart of the 5 year period It is not the start of the 3 year period of actual usage This seat belt has a retractable device so it is not necessary to adjust the length METHOD FOR FASTENING SEAT BELT 1...

Page 217: ...ne does not start 2 Check that each lever is in NEUTRAL position 3 Insert the key into the starting switch 2 and turn it to ON position B 4 Check the machine monitor Check the machine monitor accordin...

Page 218: ...er 30 sec onds For the method of checking the maintenance time see EXPLANATION OF COMPONENTS MAINTE NANCE SCREEN SETTING 5 Press the lamp switch 3 and check if the working lamps light up If the workin...

Page 219: ...is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation When operating the machine always keep the covers closed unless you perform inspection NOTICE Do...

Page 220: ...in starting switch 3 to START position C The engine starts REMARK When the ambient temperature is low the engine may not start even if the key in starting switch 3 is kept at START position for 20 sec...

Page 221: ...tely Check the oil level oil leakage etc and take proper meas ures REMARK White smoke may be discharged for a short time immedi ately after the engine is started or during the aftertreatment devices r...

Page 222: ...ONDITION AND UNUSUAL NOISE OF ENGINE When starting the engine check that the engine causes no abnormal noise and that it starts up easily and smoothly Check that there is no abnormal noise when the en...

Page 223: ...t you fully understand the descriptions in this manual then run in the machine while paying atten tion to the following points Run the engine at idle for 15 seconds immediately after starting it up Do...

Page 224: ...control dial 1 to midpoint c between Low idle MIN position a and High idle MAX position b Run the engine at medium speed with no load for approxi mately 5 minutes REMARK If the ambient temperature is...

Page 225: ...Set lock lever 2 to LOCK position L Be sure to operate the lock lever 2 by the operating por tion on the top 7 Operate the following levers and pedals and check that the machine does not move Work eq...

Page 226: ...ions for all the work equip ment boom arm and bucket swing travel and at tachment if equipped Check the direction of the track frame before operating the travel lever 1 Set the working mode to P mode...

Page 227: ...or 30 seconds 5 After the warm up operation check that the machine moni tor 1 is in the following conditions 6 Engine coolant temperature gauge The graduation of gauge is within normal range 7 Fuel ga...

Page 228: ...al to circulate the warm hydraulic oil to all control circuits Repeat the following operation slowly 3 to 5 times before starting the actual work Boom operation RAISE h LOWER j Arm operation IN f OUT...

Page 229: ...ne equipped with attachment control pedal For the machine equipped with proportional lever For attachment operations change the working mode to the attachment mode to perform Warm up operation for hyd...

Page 230: ...ow idle for approximately 5 minutes and then stop the engine REMARK If the starting switch is turned to ON position or START position soon after the engine is stopped the engine coolant temperature ga...

Page 231: ...front and rear travel are reversed right and left steering are reversed Check that the area around the machine is safe sound the horn before starting the machine Keep people away from the machine Clea...

Page 232: ...eight a of 40 to 50 cm 15 7 to 19 7 in 2 Operate the blade control lever 4 to raise the blade 3 Check the sprocket position A 4 After checking the sprocket position A perform the oper ation in conform...

Page 233: ...he travel mode setting at travel speed display on machine monitor 8 REMARK When the engine is started the speed mode is automati cally set to low speed travel Lo While traveling in high speed travel H...

Page 234: ...a of 40 to 50 cm 15 7 to 19 7 in 2 Operate the blade control lever 4 to raise the blade 3 Check the sprocket position A 4 After checking the sprocket position A perform the oper ation in conformity wi...

Page 235: ...he travel mode setting at travel speed display on machine monitor 8 REMARK When the engine is started the speed mode is automati cally set to low speed travel Lo While traveling in high speed travel H...

Page 236: ...METHOD FOR STOPPING MACHINE Avoid a sudden stop Stop the machine gradually Set right and left travel levers 1 in NEUTRAL position N The machine stops OPERATION MACHINE OPERATIONS AND CONTROLS 3 175...

Page 237: ...Lo and travel speed becomes slow When the load decreases the travel mode turns to Hi again Use 2 travel levers 1 or travel pedals 2 to change direction to travel Avoid sudden changes of direction to...

Page 238: ...ad the preceding procedure by replacing the word left with right then operate the right travel lever OPERATION FOR COUNTER ROTATION TURN Counter rotation turn to left 1 Pull the left travel lever towa...

Page 239: ...L H work equipment control lever 1 to the right and left The upper structure swings a Swing RIGHT The upper structure swings to the right b Swing LEFT The upper structure swings to the left When you d...

Page 240: ...to operate the work equipment When the levers are released they return to NEUTRAL position and the work equipment is held in that position Arm operation Move the L H work equipment control lever back...

Page 241: ...k equipment control lever to the right and left Bucket moves in or out Boom swing operation Depress either right or left of the Boom swing control ped al Boom swings either right or left MACHINE OPERA...

Page 242: ...he engine is stopped if the starting switch key is turned to ON position and the lock lever is set to FREE position following work equipment operations are possible Lower the work equipment to the gro...

Page 243: ...tions of 2 way attachment such as crusher etc production conscious operation ATT E mode Operations of 2 way attachment such as crusher etc fuel consumption conscious operation METHOD FOR OPERATING WOR...

Page 244: ...Do not use the travel force to perform excavation by digging the bucket into the ground This damages the machine or work equipment PROHIBITION OF OPERATIONS USING HYDRAULIC CYLINDERS TO STROKE END If...

Page 245: ...back to a rock and use it as a lever to dig This can apply an excessive force to the chassis and work equipment and the machine may break As shown in the figure dig by using only the force of the arm...

Page 246: ...can shorten the service life of the machine PROHIBITION OF DIGGING OPERATION ON HARD ROCKY GROUND Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavat...

Page 247: ...G OPERATIONS Although lifting operation with this machine is prohibited it is permitted only when the special lifting hook is installed PROHIBITION OF SUDDEN LEVER OR PEDAL SHIFT DURING HIGH SPEED TRA...

Page 248: ...high speed for 1 5 hours or more the temperature of lubricating oil inside the track roll ers and final drive will rise up and oil seal may be damaged to cause oil leakage Stop driving for 30 minutes...

Page 249: ...try to drive the machine so that the center of the track passes over the obstacle PRECAUTIONS FOR HIGH SPEED TRAVEL On uneven roadbeds such as rock beds or uneven roads with large rocks drive the mach...

Page 250: ...ine with cover unlocked it may open and hit surrounding object to lead accident PERMISSIBLE DEPTH OF WATER SOIL AND DIRT NOTICE When traveling the machine out of water if the angle of the machine exce...

Page 251: ...erating the machine in order to stop it safely when the machine slips or be comes unstable When the machine is traveling uphill if the shoes slip or it is impossible to travel uphill using only the fo...

Page 252: ...ture shown in the figure with bucket height b at 20 to 30 cm 7 9 to 11 8 in and drive the machine Braking on downhill slope Set the travel lever in NEUTRAL position and the brake will be applied If en...

Page 253: ...tuck pull out the machine according to the following procedure 1 Move the bucket to the side of the stuck track and press the ground with it The track is raised 2 Place logs wooden blocks etc under th...

Page 254: ...angle effectively The range for excavating with the arm is from a 45 angle c away from the machine to a 30 angle d towards the ma chine There may be some differences depending on the excavation depth...

Page 255: ...a place easily visi ble to the operator Loading is easier and capacity becomes greater if you place the machine at the rear of the dump truck than if loading is done from the side LEVELING WORK Use th...

Page 256: ...seals are fitted at both ends of the bushings be careful not to damage them If the dust seal is damaged replace it with a new one when replacing the bucket If a damaged seal is used without being repl...

Page 257: ...B then remove the bucket 1 4 Align the arm 2 with hole 4 of the replacement bucket 5 Align the link 3 with hole 5 of the replacement bucket 6 Apply grease to pins A and B and insert them into holes 4...

Page 258: ...ion always before leaving the operator s seat Lower the blade to the ground on the downhill side 1 Set the R H and L H travel levers 1 in NEUTRAL posi tion N The machine stops 2 Turn the fuel control...

Page 259: ...e coolant temperature gauge The graduation of gauge is within normal range 9 Fuel gauge The graduation of gauge is within normal range 10 Caution lamp display OFF If any problem is found perform maint...

Page 260: ...el 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 undercarriage LOCK Always lock the following places RE...

Page 261: ...e rear cover COVER WITH LOCK Use the starting switch key to open and close the covers with locks Insert the starting switch key as far as it will go to shoulder A and turn it If the starting switch ke...

Page 262: ...the engine rear cover closed during operation unless you perform inspection NOTICE Always keep the engine rear cover locked unless you need to open it When it is locked the engine rear cover opening...

Page 263: ...ve of rod 4 The engine rear cover 3 will be free 2 Close the engine rear cover 3 and push it to fix securely 3 Insert the starting switch key into the key slot 1 4 Turn the starting switch key to LOCK...

Page 264: ...engine rear cover fully until it is fixed with the rod Fix the cooling cover securely with the rod at LOCK position METHOD FOR OPENING COOLING COVER 1 Pull up the cooling cover opening lever 1 The co...

Page 265: ...FREE position F The cooling cover 2 becomes free 2 While pulling up the cooling cover opening lever 1 close the cooling cover 2 3 Push down the cooling cover opening lever 1 and secure the cooling co...

Page 266: ...is locked by checking the direction of the key slot of the dirt cover opening knob METHOD FOR OPENING DIRT COVER 1 Insert the starting switch key into the key slot of dirt cover opening knob 1 2 Turn...

Page 267: ...cover 3 becomes free 2 Close dirt cover 3 gently and push it to fix securely 3 Insert the starting switch key into key slot 1 4 Turn the starting switch key to LOCK position B and then remove the sta...

Page 268: ...ing the door lock do not put your arm out of cab or put your hand on the frame of cab door The cab door may suddenly close and cause injury Use the door lock to fix the cab door in an opened position...

Page 269: ...old the handle inside cab door and push the cab door to the door lock 3 and fix it securely 5 Check that the cab door is securely fixed to the door lock 3 MACHINE OPERATIONS AND CONTROLS OPERATION 3 2...

Page 270: ...inside the cab door and pull the cab door and hold the cab door handle 2 to close the cab door 3 Insert the starting switch key into the key slot 1 4 Turn the starting switch key to LOCK position B a...

Page 271: ...cooling If you smoke when the air conditioner is on the smoke may hurt your eyes In such case open the window and turn the lever to FRESH for a while for ventilation and cooling to discharge the smok...

Page 272: ...sition Air flow rate is low 0 OFF position Air flow stops AIR VENT Blow direction can be adjusted by turning the louver of each vent FRESH RECIRC AIR CHANGEOVER LEVER Use FRESH RECIRC air selector lev...

Page 273: ...p inside the air conditioner switch lights up METHOD FOR OPERATING AIR CONDITIONER METHOD FOR STARTING AIR CONDITIONER 1 Turn the air flow selector switch and adjust the air flow 2 Press the air condi...

Page 274: ...RECIRC air selector lever to select ei ther FRESH a or RECIRC b METHOD FOR STOPPING AIR CONDITIONER 1 Press the air conditioner switch and turn it off The lamp inside the switch goes out 2 Turn the a...

Page 275: ...es of the material used rubber shoes and road liners offer various advantages Howev er their weak point is a lack of strength Accordingly you can extend the service life of the rubber shoes and road l...

Page 276: ...road where oil etc is accumulated When storing the machine for a long period 3 months or more store it indoors to avoid direct sunlight and rain Do not drive the machine into a high temperature place...

Page 277: ...s are very slippery on wet steel plates snow covered or frozen road surfa ces Beware of slip when traveling on a face of slope or operating on a slope If the rubber shoes and road liners are used in a...

Page 278: ...e shown in the figure Mechanism that rubber shoe comes off The rubber shoe comes off in the following cases When riding over a level difference by driving the machine in reverse 1 Clearance a is made...

Page 279: ...r track rollers deviate from the core metal because of misalignment of the rubber shoes A Frame side B Rubber shoe side When the machine travels in reverse with idler under the condition shown in the...

Page 280: ...sporting the machine choose the transportation method in reference to the weight and dimensions shown in SPECIFICATIONS Note that the weight and dimension shown in SPECIFICATIONS may differ in accorda...

Page 281: ...er and correct the direction On the ramps operate only the travel lever Do not op erate any other lever It is dangerous to use the work equipment for loading and unloading operations Always use ramps...

Page 282: ...ease oil or ice on the machine tracks or ramp surface PROCEDURES FOR LOADING MACHINE 1 Park a trailer on a flat and firm place Maintain a safe distance from the road shoulder 2 Apply the trailer brake...

Page 283: ...structure in parallel 8 Before moving the machine onto the ramps check that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trai...

Page 284: ...m cylinder to their stroke end and then lower the boom gently Put a block under the tip of the bucket link to prevent the bucket cylinder from touching the floor 3 Set the lock lever securely to LOCK...

Page 285: ...3 of the trail er Make the installation angle A at 15 or less If the ramps bend largely under the weight of the machine put blocks under the ramps to prevent them from bending 5 Remove the chains or w...

Page 286: ...he blade control lever backward to raise the blade 2 Operate the work equipment control levers and raise the work equipment 11 Push the travel levers forward and drive the machine slow ly toward the r...

Page 287: ...balance k k CAUTION Do not lift the machine by using lifting hooks 4 pla ces on top of the cab If you do so cab will be broken so never use these hooks Do not lift the machine by using the holes whic...

Page 288: ...comes parallel to the undercarriage After controlling the boom swing control pedal set the swing lock cover to LOCK position 6 Operate the work equipment control levers and extend the bucket cylinder...

Page 289: ...ucture swung Be careful not to pinch the hoses 5 Set the lifting angle a between the front and rear wire ropes at 30 to 40 and then sling the machine slowly up ward 6 After the machine comes off the g...

Page 290: ...your skin wash it off with large amount of fresh water and see a doctor immediately When handling the cooling water containing coolant that has been drained during changing the coolant or repairing th...

Page 291: ...op Maintain the battery charging rate as close as possible to 100 Insulate it against cold temperature to ensure that the machine can be start ed easily in the next morning REMARK Measure the gravity...

Page 292: ...tank This minimizes moisture condensation in the tank when the temperature drops After operation in water or mud remove water from undercarriage according to the procedure to extend un dercarriage ser...

Page 293: ...Disconnect the negative terminal of the battery and cover it or remove it from the machine and store it separately When the machine is equipped with the battery disconnect switch turn the starting sw...

Page 294: ...n consult your Komatsu distributor before using it Perform the following items when using the machine after long term storage Wipe off the grease from the piston rods of the hydraulic cylinder Add oil...

Page 295: ...f fuel all air must be sufficiently bled from the fuel circuit PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT 1 Pull engine rear cover 1 toward you to open it Open engine rear cover 1 fully and it is s...

Page 296: ...from air bleeding bolt 9 tighten air bleeding bolt 9 8 Turn the key in starting switch to ON position B 9 10 to 15 seconds later return it to OFF position A The air is bled automatically with automat...

Page 297: ...rming bucket CURL operation from a high posi tion for digging under no load the bucket speed drops mo mentarily at the horizontal position The bucket or arm wobbles by itself during heavy duty dig gin...

Page 298: ...e machine NOTICE The maximum towing capacity for this machine is 42000 N 4280 kg Do not tow any load greater than this If the machine sinks in mud and cannot get out under its own power or if the mach...

Page 299: ...off with a large amount of water If it gets in your eyes wash the eyes immediately with water then consult a doctor for medical treatment When handling batteries always wear protective eye glasses an...

Page 300: ...ait for approximately 2 minutes after turning the starting switch to OFF position and then disconnect the negative terminal If the negative terminal is removed without waiting for 2 minutes the data i...

Page 301: ...eck that it does not move If it moves tighten it again securely 1 Place the battery in the specified position If chloride is accumulated on the top surface of battery and around terminals clean them w...

Page 302: ...ach the clips securely Set the charging current to 1 10 or less of the value of the rated battery capacity When performing rapid charging set it to less than the rated battery capacity If the charger...

Page 303: ...osion Firmly connect the cables and clips Check that the lock levers and parking brake levers if equipped of both machine are in LOCK posi tion Control levers must be in NEUTRAL position To prevent da...

Page 304: ...not start try again after at least 2 minutes PROCEDURE FOR DISCONNECTING JUMPER CABLES After the engine has started disconnect the jumper cables in the reverse of the order in which they were con nect...

Page 305: ...alternator Replace Starting motor does not rotate even when starting switch is turned to START position Defective wiring Check repair Insufficient battery charge Charge battery Blown fuse Replace Batt...

Page 306: ...raulic tank strainer Clean See EVERY 2000 HOURS MAINTENANCE Excessive rise in hydraulic oil temper ature Lack of hydraulic oil Set oil to specified level See CHECKS BEFORE STARTING Loose fan belt Adju...

Page 307: ...em Change coolant flush inside of cool ing system See WHEN REQUIRED Clogged radiator fins or damaged fin Clean or repair See EVERY 500 HOURS MAINTENANCE Defective thermostat Replace thermostat Loose r...

Page 308: ...rance Adjust valve clearance Exhaust gas color is white or bluish Excessive oil in oil pan Set oil to specified level See CHECKS BEFORE STARTING Improper fuel Replace with specified fuel Exhaust gas t...

Page 309: ...enables operations temporarily For details of the pump secondary drive switch see PUMP SECONDARY DRIVE SWITCH Immediately ask your Komatsu distributor for an inspection and repair after the operation...

Page 310: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1...

Page 311: ...hile filling oil or fuel PRECAUTIONS FOR WELDING When conducting welding repair turn the starting switch to OFF position and wait for approximately 2 mi nute and then disconnect the negative terminal...

Page 312: ...cover at the right side of machine is opened for inspection and maintenance if you swing the boom to right do it with the dirt cover opened half way If the dirt cover is fully opened it may interfere...

Page 313: ...of coolant or oil Have all nuts and bolts been tightened Checks while the engine is running For the checks when the engine is running see SAFETY TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING and...

Page 314: ...o blood in the human body always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry...

Page 315: ...rformance The ASTM diesel fuel recommended by Komatsu may contain 5 or less of biofuel The EN diesel fuel may contain 7 or less of it Use the fuel which is filled into the storage tank or the fuel tan...

Page 316: ...on and Maintenance Manual If the grease fitting which is not described in the periodic maintenance section becomes stiff or it creaks after being used for long time add grease according to the descrip...

Page 317: ...tively Coupled Plasma analyzer is used for measuring the concentration of iron copper and other metal powder in the oil Measurement of quantity of iron particles A PQI Particle Quantifier Index measur...

Page 318: ...ttery disconnect switch key if equipped is turned to OFF position for the maintenance work always pull out the key and keep it with you If the key is left in the switch someone may turn on the power b...

Page 319: ...re has gone down some parts may still be under internal pressure so when loos ening plugs bolts or hose connections do not stand directly in front of the parts and loosen slowly to re lease the intern...

Page 320: ...13 17 19 22 13 3 31 67 111 172 1 35 3 2 6 8 11 3 17 5 9 8 22 8 48 8 81 4 127 11 8 to 14 7 27 to 34 59 to 74 98 to 123 153 to 190 1 2 to 1 5 2 8 to 3 5 6 to 7 5 10 to 12 5 15 5 to 19 5 8 7 to 10 8 20 3...

Page 321: ...45 18 0 to 25 0 130 to 181 36 46 245 25 0 181 197 to 294 20 0 to 30 0 145 to 217 42 55 294 30 0 217 246 to 343 25 0 to 35 0 181 to 253 Face seal Nominal No of threads a Width across flats b mm Tighten...

Page 322: ...BOOM SWING CYLINDER FOOT PIN 4 54 METHOD FOR WASHING WASHABLE FLOOR 4 56 METHOD FOR CHECKING GAS SPRING 4 57 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 4 58 METHOD FOR CHECKING SWING PINION GREASE...

Page 323: ...MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker the hydraulic oil deteriorates faster than for normal bucket dig ging operations so set the maintenance interva...

Page 324: ...HOURS Until first 100 hours operation perform the following maintenance every 10 hours Lubrication of swing equipment Lubrication of work equipment For details of the method of replacement or maintena...

Page 325: ...ter element if it is cleaned 5 times repeatedly or used throughout a year Replace the inner element as well at the same time METHOD FOR CHECKING AIR CLEANER 1 Pull engine rear cover 1 toward you to op...

Page 326: ...ing 4 Clean the dust sticking inside the air cleaner body 7 and on the cover 5 by using a clean cloth or brush 5 If any dust is attached to the vacuator valve 8 installed to the cover 5 remove it 6 Wh...

Page 327: ...y cause break age of the air cleaner element or serious damage to the engine When inserting the element into the body if the rubber at the tip is swollen or the outer element is not pushed in straight...

Page 328: ...learance is too large remove the cover 5 and then install it again 14 Press the button of dust indicator and return the red piston to the original position NOTICE Replace the outer element when the du...

Page 329: ...rt or dust from entering 5 Clean the dust sticking inside the air cleaner body 7 and on the cover 5 by using a clean cloth or brush 6 If any dust is attached to the vacuator valve 8 installed to the c...

Page 330: ...wrong direction it may cause break age of the air cleaner element or serious damage to the engine When inserting the element into the body if the rubber at the tip is swollen or the outer element is n...

Page 331: ...ce is too large remove the cover 5 and then install it again 15 Press the button of dust indicator and return the red piston to the original position NOTICE Replace both inner and outer elements when...

Page 332: ...ir cleaner element facing in the correct direction Install so that the bottom of the air cleaner element a face where no hole is drilled comes to cov er 5 end If it is installed in wrong direction it...

Page 333: ...cover 5 is installed check that the clear ance between air cleaner body 7 and cover 5 is not too large If the clearance is too large remove the cover 5 and then install it again 7 Press the button of...

Page 334: ...ement will be damaged The sealing portion of the improper part lacks precision and allows the entry of dust which leads to damage of the engine Do not use such improper part Be sure to install the air...

Page 335: ...d check that the clear ance between air cleaner body 7 and cover 5 is not too large If the clearance is too large remove the cover 5 and then install it again 9 Press the button of dust indicator and...

Page 336: ...reeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu recommends the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious proble...

Page 337: ...over 1 backward to open it Open the engine rear cover 1 fully and it is secured by rod 2 4 Pull the cooling cover 3 backward to open it 5 Turn the rod 4 to LOCK position L and fix the cooling cover 3...

Page 338: ...iator 12 Start the engine and run it at low idle Continue running the engine at low idle for 10 minutes 13 Stop the engine 14 Open the drain valve 6 to drain the tap water 15 After draining the tap wa...

Page 339: ...middle between FULL and LOW 21 Stop the engine 22 Approximately 3 minutes later add coolant to near the mouth of the water filler port 23 Tighten the radiator cap 5 securely 24 Turn the rod 4 to FREE...

Page 340: ...d consult a doctor Do not use a dry wipe to clean the battery A wet wipe will prevent fire or explosion from static elec tricity NOTICE Do not add the electrolyte to the battery exceeding UPPER LEVEL...

Page 341: ...immediately remove cap 3 and add purified water e g commercially available replenishment water for a battery to UPPER LEVEL line REMARK If the purified water is added to above UPPER LEVEL line of bat...

Page 342: ...to bottom of sleeve 5 so surface tension causes electrolyte surface to bulge and poles ap pear bent B Low level Electrolyte level is not up to bottom of sleeve 5 so poles appear straight and not bent...

Page 343: ...3 Operate the work equipment control lever slowly to the right and left to swing the upper structure so that the fuel prefilter comes between the tracks 4 Operate the work equipment control levers and...

Page 344: ...the handle 7 to CLOSE position S and loosen the drain plug 8 8 Drain the water until the red ring 9 contacts to the bottom of transparent cup 10 9 Tighten the drain plug 8 10 Turn the transparent cup...

Page 345: ...10 Replace the O ring with a new one if needed 16 Install the transparent cup 10 to top of fuel prefilter and tighten it clockwise Tightening torque 27 to 33 Nm 2 8 to 3 4 kgm 19 9 to 24 4 lbft 17 Tur...

Page 346: ...oe bolt 1 for looseness If any looseness of the bolt is found retighten it according to the following procedure 1 Tighten the bolt in the order shown in the figure Tightening torque 118 to 157 Nm 12 t...

Page 347: ...ately Check for looseness of the road liner shoe bolt 1 If any looseness of the bolt is found retighten it according to the following procedure 1 Tighten the bolt in the order shown in the figure Tigh...

Page 348: ...rface of the track If deflection a is in the standard range 10 to 30 mm 0 4 to 1 2 in the track tension is correct If the deflection is out of the standard range adjust it into the standard range METH...

Page 349: ...any other part of your body close to grease drain plug 5 1 Loosen grease drain plug 5 gradually to release the grease If the grease does not come out smoothly move the machine forward and backward a...

Page 350: ...a is reduced by wear the drawbar pull will drop For judgment of replacement repair and continuation of use of the road liner consult your Komatsu distributor METHOD FOR REPLACING ROAD LINER When all t...

Page 351: ...lace the track with a new one Cut of rubber shoe steel cords If more than a half of the steel cord layer is cut on either side replace the track with a new one Separation of rubber shoe core metal If...

Page 352: ...d the track becomes loose for 5 to 30 hours after the tension is set to the specified value while the machine travels repeatedly If you adjust the track tension at short intervals until the initial lo...

Page 353: ...ent system under high pressure If the adjustment is performed with the procedure oth er than following grease drain plug 5 may fly out and cause serious injury or death Do not loosen grease drain plug...

Page 354: ...form the work Items to be prepared Grease pump Steel pipe Set the machine to the following conditions before replacing the rubber shoes Set the machine in the posture shown in the figure 1 Start the e...

Page 355: ...Do not loosen any part other than grease drain plug 1 Do not put your face hands feet or any other part of your body close to grease drain plug 1 Before removing the rubber shoe track check that the i...

Page 356: ...ged with the sprocket and idler 6 Adjust the rubber shoe track tension by referring to METHOD FOR CHECKING AND ADJUSTING RUB BER SHOES TRACK TENSION 7 Check that the rubber shoe track is securely enga...

Page 357: ...re shown in the figure so that the pin of bucket tooth 1 can be driven out 1 Start the engine and run it at low idle 2 Set the lock lever to FREE position F Be sure to operate the lock lever by the op...

Page 358: ...aligned with bottom face C The steel ball is about to come off Rubber 6 of rubber pin lock 3 is broken The steel ball sinks Rubber 6 of rubber pin lock 3 is deteriorated and steel ball 7 sinks into i...

Page 359: ...that the top surface of lock pin 2 is the same height as the surface of bucket tooth 1 9 After replacing a bucket tooth always check the following After the lock pin 2 is driven in completely its tip...

Page 360: ...sher tank as a guideline If the window washer fluid is added over the guideline it may leak Mixing proportion of pure window washer fluid and water The proper mixing proportion varies with the ambient...

Page 361: ...HOD FOR CHECKING AND CLEAN ING RADIATOR FINS OIL COOLER FINS FUEL COOLER FINS AND AIR CONDI TIONER CONDENSER FINS Air conditioner compres sor Operating condition Every 4000 hours V belt Damage tension...

Page 362: ...le running the engine at high idle and operating the air conditioner at high speed Check the condition of the refrigerant gas Hydrofluorocarbons HFC 134a that circulates the refrigerant circuit throug...

Page 363: ...Pull engine rear cover 1 toward you to open it Open engine rear cover 1 fully and it is secured by rod 2 2 Pull cooling cover 3 toward you to open it 3 Turn rod 4 to LOCK position L and fix cooling co...

Page 364: ...hrough grease fittings 7 6 After greasing wipe off any old grease that is pushed out 7 Install cover 6 with bolts 5 8 Turn rod 4 to FREE position F and close cooling cover 3 9 Close engine rear cover...

Page 365: ...filters inside the operator cab get wet during the cleaning 1 Start the engine 2 Set the lock lever to FREE position F Be sure to operate the lock lever by the operating portion on the top 3 Place the...

Page 366: ...t or roll it or subject it to any impact When disposing of it the gas must be released Ask your Komatsu distributor to perform this work Gas springs are installed inside the left console 1 place at th...

Page 367: ...ir securely 1 Open the dirt cover 1 Open the dirt cover 1 fully and it will be secured by the cover support lever 2 2 Loosen the bolt 3 of the hydraulic tank move the plate 4 on the oil filler port F...

Page 368: ...leted Proceed to the next operation METHOD FOR BLEEDING AIR FROM CYLINDER NOTICE If the engine runs at high speed immediately after the startup or if a cylinder is pushed up to its stroke end the air...

Page 369: ...f its stroke and relieve it to remove the air completely 10 Operate the work equipment control levers and extend the boom cylinder bucket cylinder and arm cylinder to their stroke end Set the work equ...

Page 370: ...c tank If a breaker or other attachment is installed perform the air bleeding procedure until the air is completely bled from the attachment circuit 1 Turn the fuel control dial to Low idle MIN positi...

Page 371: ...ibutor to perform the work 1 Open the floor For details see METHOD FOR OPENING FLOOR UNIT 2 Remove the bolts 1 2 pieces on top of the revolving frame and remove the cover 2 3 Check that the grease is...

Page 372: ...om fuel tank Check dust indicator Check water separator drain water and sediment Check oil level in hydraulic tank add oil Check coolant level add coolant Check oil level in engine oil pan add oil Che...

Page 373: ...ion on a new machine Items to be prepared Grease pump 1 By using a grease pump pump in grease through the grease fittings shown by arrows 1 Swing pinion 1 place 2 Swing circle 1 place 2 Check visually...

Page 374: ...rating por tion on the top 3 Push the blade control lever forward to lower the blade to the ground 4 Operate the work equipment control levers to extend bucket cylinder and arm cylinder to their strok...

Page 375: ...oom cylinder rod end 1 place 14 Arm cylinder foot pin 1 place 15 Arm cylinder rod end 1 place 16 Boom and arm connection pin 1 place 17 Bucket cylinder foot pin 1 place REMARK For the greasing to boom...

Page 376: ...air conditioner compressor Press the belt with a finger at a point midway between idle pulley 3 and compressor 4 approximately 58 8 N ap proximately 6 0 kg If deflection a is in the standard range 5...

Page 377: ...When using the compressed air there is a danger that dirt may scatter and cause personal injury Wear the protective equipment such as the protective eyeglasses and dust mask NOTICE As a guideline the...

Page 378: ...are excessive metal powder or foreign material contact your Komatsu distributor 4 Install the drain plug P 5 Pull the engine rear cover 1 backward to open it Open the engine rear cover 1 fully and it...

Page 379: ...of engine oil through oil filler port F 10 Run the engine at low idle for a while and then stop it 11 Check the oil level in the engine oil pan Check that the oil level is between H and L marks on di...

Page 380: ...precise parts than those in the conventional injection pump and nozzles If any fuel prefilter element other than a Komatsu genuine part is used foreign material may get in and cause problems with the...

Page 381: ...1 backward to open it Open the engine rear cover 1 fully and it is secured by rod 2 3 Pull the cooling cover 3 backward to open it 4 Turn the rod 4 to LOCK position L and fix the cooling cover 3 with...

Page 382: ...hing oil 13 Install the element and O ring 12 to transparent cup 10 14 Insert the red ring 9 into transparent cup 10 and fill it with fuel 15 Check the condition of O ring 12 installed to transparent...

Page 383: ...replacing the parts Komatsu recommends using Komatsu genuine parts The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection p...

Page 384: ...pply thin film of fuel to the packing face Do not fill the new fuel filter cartridge with fuel 9 Remove the cap B at center and install the fuel filter car tridge to the mounting face of fuel filter c...

Page 385: ...p for fuel leakage If the fuel leaks check according to the following procedure 1 Check the fastening condition of the fuel filter cartridge 2 If the fuel leaks remove the fuel filter cartridge in ste...

Page 386: ...E When using compressed air for cleaning blow it from some distance as perpendicular to the core as possible to avoid damaging the fins Damage on the fins can cause water leakage and overheat ing In a...

Page 387: ...nt distance from the machine when performing the work If steam cleaning high pressure machine wash is per formed at close distance there is a danger that the in ternal fins of the heat exchange equipm...

Page 388: ...er 1 Loosen the knob 1 and remove the filter inspection cover 2 2 Remove the fresh air filter 3 3 Clean the fresh air filter 3 with compressed air If there is oil on the fresh air filter or if the fil...

Page 389: ...Loosen the bolt 3 of the hydraulic tank move the plate 4 on the oil filler port F and turn the cap of the oil filler port F slowly to remove it Release the internal pressure 3 Remove the nut 6 of bre...

Page 390: ...by the operating portion on the top 10 Stop the engine 11 Tighten the cap of oil filler port F on the hydraulic tank se curely By doing so the hydraulic tank is pressurized NOTICE If the hydraulic ta...

Page 391: ...Do not stand in front of the plug when you loosen the plug Items to be prepared Container to catch drained oil Hexagonal wrench 1 Bring plug P to the lowest position 2 Place a container under plug G t...

Page 392: ...If deflection is in the standard range 9 to 13 mm 0 354 to 0 512 in the fan belt tension is correct If the deflection is out of the standard range adjust it into the standard range according to the f...

Page 393: ...or cracks When replacing the belt with a new one ask your Komatsu distributor to perform the work When the new V belt is installed readjust it after operating for 1 hour 7 After the adjustment is com...

Page 394: ...lease the internal pres sure then remove it carefully NOTICE If the machine is equipped with a hydraulic breaker the hydraulic oil deteriorates faster than in the nor mal bucket digging operation Acco...

Page 395: ...all the cover 6 with the cover mounting bolts 5 10 Start the engine 11 Set the lock lever to FREE position F Be sure to operate the lock lever by the operating portion on the top 12 Operate the work e...

Page 396: ...ase each of right and left refill capacity 0 7 0 18 U S Gal Items to be prepared Container to catch drained oil Hexagonal wrench 1 Bring plug P to the lowest position 2 Place a container under plug P...

Page 397: ...the crankcase breather does not work normally the engine does not conform to the exhaust gas regulations under usage period It is necessary to check the diaphragm for damage and the spring for breaka...

Page 398: ...tank refill capacity 20 5 28 U S Gal Items to be prepared Container to catch the drained oil Socket wrench handle 1 Set the machine in the posture shown in the figure 1 Start the engine 2 Set the lock...

Page 399: ...essure 4 Place the oil container under the drain plug P at the bot tom of the machine to catch the drained oil 5 Remove the drain plug P to drain the oil by using the socket wrench handle When removin...

Page 400: ...rainer 12 Fix the strainer 12 with bolt 9 13 Install the hose 8 and fix it with hose clamp 7 14 Install the undercover 6 with bolts 5 to the bottom of the hydraulic tank 15 Add the refill capacity of...

Page 401: ...r by the operating portion on the top 21 Stop the engine 22 Tighten the cap of oil filler port F on the hydraulic tank se curely By doing so the hydraulic tank is pressurized NOTICE If the hydraulic t...

Page 402: ...he gas must be released Ask your Komatsu distributor to perform this work NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued it becomes impossible to rel...

Page 403: ...2 Operate the boom swing control pedal to swing the boom to the center position 3 Operate the work equipment control lever and raise the work equipment to height a of 1 5 m and hold there 5 Set the lo...

Page 404: ...d If the work equipment goes down under its own weight and the teeth contact the ground the accumulator is normal If the work equipment does not go down or stops at halfway ask your Komatsu distributo...

Page 405: ...e center position 3 Operate the work equipment control lever slowly to the boom LOWER direction and lower the boom and make tooth contact to the ground For the attachment such as crusher etc keep the...

Page 406: ...essure in the hy draulic circuit set the lock lever to LOCK position L Be sure to operate the lock lever by the operating portion on the top If the machine is equipped with the attachment control peda...

Page 407: ...CLEANING FUEL INJECTION SYSTEM If the fuel injection system does not operate normally engine performance cannot be obtained thoroughly It is necessary to check and clean the fuel injection system Spec...

Page 408: ...r comes sooner DEFINED LIFE PARTS LIST No Periodical replacement parts 1 Fuel system Fuel hose Spill hose Ask your Komatsu distributor for replacement 2 Engine lubrication system Engine oil filter hos...

Page 409: ...ssemble Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disposing of it the...

Page 410: ...Maintenance for every 100 250 500 1000 1500 2000 and 3000 hours should be performed at the same time METHOD FOR CLEANING KDPF Ask your Komatsu distributor for cleaning the inside of KDPF MAINTENANCE...

Page 411: ......

Page 412: ...SPECIFICATIONS 5 1...

Page 413: ...0 2400 27 7 37 7 2400 2400 A Overall length mm ft in 5330 17 6 B Overall height mm ft in 2550 8 4 2590 8 6 C Overall width mm ft in 1960 6 5 D Track width mm ft in 400 1 4 E Tail swing radius mm ft in...

Page 414: ...rtical wall digging depth mm ft in 3070 10 1 E Maximum dumping height mm ft in 4000 13 1 F Minimum swing radius of work equipment mm ft in 2380 7 10 Minimum swing radius of boom 1840 6 0 G Maximum rea...

Page 415: ...7 7 37 7 2400 2400 A Overall length mm ft in 5550 18 3 B Overall height mm ft in 2550 8 4 2590 8 6 C Overall width mm ft in 1960 6 5 D Track width mm ft in 400 1 4 E Tail swing radius mm ft in 1120 3...

Page 416: ...tical wall digging depth mm ft in 3030 9 11 E Maximum dumping height mm ft in 4200 13 9 F Minimum swing radius of work equipment mm ft in 2285 7 6 Minimum swing radius of boom 1760 5 9 G Maximum reach...

Page 417: ......

Page 418: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1...

Page 419: ...e machine and the attachment or option If you lose the instruction manual or it is damaged obtain a new copy from the attachment manufacturer or your Komatsu distributor PRECAUTIONS WHEN REMOVING AND...

Page 420: ...a safe distance from the surroundings If heavy work equipment is installed pay attention to the following precautions The swing overrun the distance the work equipment moves before completely stopping...

Page 421: ...ine is safe when performing the swing operation Depending on the posture of the work equipment there is a danger that the wire or load may slip off the hook Al ways be careful to maintain the correct...

Page 422: ...ON OF COMPONENTS ON MACHINES WITH ATTACHMENT EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT CON TROL PEDAL 1 Selector valve 2 Attachment lock cover 3 Attachment control pedal ATTACHMENTS AND OP...

Page 423: ...ENTS ON MACHINES WITH PROPORTIONAL LEV ER 1 Selector valve 2 1st line attachment proportional switch 3 Breaker operation switch 4 Horn switch HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACH...

Page 424: ...l flows to the piping on the left side of the arm operator s seat side ATTACHMENT LOCK COVER For the machine equipped with attachment control pedal k k WARNING When the attachment is not used set the...

Page 425: ...flows to the piping on the left side of the arm operator s seat side BREAKER OPERATION SWITCH For the machine equipped with proportional lever The breaker operation switch is used to operate the brea...

Page 426: ...e or damage the removed parts 3 Connect the attachment piping provided by the attachment manufacturer Joint screw size is as follows Left side of arm 1 2 G Right side of arm 3 4 G 4 Change over the hy...

Page 427: ...nt control pedal repeatedly with running the engine at low idle For the machine equipped with proportional lever operate the proportional switch or breaker operat ing switch repeatedly with running th...

Page 428: ...the position for breaker 1 way turn spool 1 counterclockwise until it stops and set it to position b for breaker 1 way When changing it to the position for general attach ment such as crusher 2 way t...

Page 429: ...If the working mode display does not indicate the breaker mode set it to breaker mode according to the follow ing procedure 1 Press function switch F5 on the standard screen Working Mode screen is dis...

Page 430: ...achment may sud denly move if you depress the pedal by mistake and this may lead to serious personal injury or death Do not rest your foot on the attachment control pedal except when you operate the p...

Page 431: ...proportional switch or breaker op eration switch by mistake this may lead to serious personal injury or death 1 Check that the working mode is set to the breaker mode B on the machine monitor 2 Turn t...

Page 432: ...n the standard screen Working Mode screen is displayed 2 Select attachment mode ATT P or ATT E with function switches F1 or F2 or F5 3 While attachment mode ATT P or ATT E is selected press function s...

Page 433: ...he attachment control pedal the attachment may sud denly move if you depress the pedal by mistake and this may lead to serious personal injury or death Do not rest your foot on the attachment control...

Page 434: ...en the working mode is selected if you press 1st line attachment proportional switch or breaker op eration switch by mistake this may lead to serious personal injury or death 1 Check that the working...

Page 435: ...ICATIONS Hydraulic specifications Max flow rate engine speed at 2400 rpm 70 min Safety valve setting pressure 17 2 MPa 175 kg cm2 OTHER TROUBLE For the machine equipped with proportional lever PHENOME...

Page 436: ...performing electric welding When handling the battery When replacing the fuse etc Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit If it is turned OFF w...

Page 437: ...Switch key 1 can be pulled out and inserted and the current from the battery is cut out I ON position The current from the battery flows into the circuit Before starting the machine be sure to set th...

Page 438: ...are lost when you try to start the engine next time L04 is displayed on the machine monitor and the engine may not start If the engine cannot be started ask your Komatsu distribu tor for inspection an...

Page 439: ...up inside of operator s compart ment Warm air flow can be adjusted in 2 levels with heater switch Use this switch after the engine coolant is warmed up Position 0 Stops the air flow Position 1 Operate...

Page 440: ...engine rear cover 1 fully and it is secured by rod 2 2 Turn the valve attached to the water manifold counter clockwise to open 3 Close the engine rear cover 1 4 Turn the heater switch to adjust the ai...

Page 441: ...ector button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is displayed on the display As long as AUX is selected AUX id displ...

Page 442: ...lock SOUND CONTROL BUTTON Press the sound control button and the sound adjustment is ready Each time sound control button is pressed BAL Balance TRE Treble and BAS Bass will be selected in this order...

Page 443: ...if you pull out the input plug when AUX is selected or if you push in or pull out the plugs of the equipment to connect You can hear the sound through the speaker of the machine when you connect a com...

Page 444: ...ek When a proper frequency is picked up the tuning automatically stops METHOD FOR ADJUSTING FREQUENCY AUTO PRESETTING 1 Press band AUX selector button 1 and select FM or AM 2 Hold down sound control b...

Page 445: ...on and the speaker output on the L side increases by 1 L1 to L7 METHOD FOR ADJUSTING HIGH REGISTER RANGE TREBLE 1 Press sound control button 1 to light up TRE on the dis play You can adjust the high r...

Page 446: ...portion You can adjust the minute 5 Press tuning time adjustment button 2 to adjust the minute If you press button MINUTE display increases by 1 If you press button MINUTE display decreases by 1 6 Pre...

Page 447: ...LOCK position and change the control pattern of the machine NOTICE The control pattern cards are replaceable If the control pattern is changed replace the control pattern card with the one for the new...

Page 448: ...on L Be sure to operate the lock lever by the operating portion on the top 2 Open the inspection window at the bottom left of the ma chine Open the inspection window at the bottom left side of the mac...

Page 449: ...the operator s seat 8 Start the engine and set the lock lever in FREE position F Be sure to operate the lock lever by the operating portion on the top 9 Operate the work equipment control levers slow...

Page 450: ...ing if there is any danger of interference and operate it with care Table of the combination of attachments which can be installed to the standard arm and long arm Can be used Can be used only for lig...

Page 451: ...models consult your Komatsu distributor HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows Demolition work Crushing rock Road construction This attachment...

Page 452: ...of penetration of the chisel and the direction of the breaker body will gradually move out of line with each oth er always adjust the bucket cylinder to keep them aligned Always keep the chisel presse...

Page 453: ...o not work by using the swing force Do not move the chisel while performing breaking operation Do not perform breaker operation in horizontal or upward direc tion Do not work under water RECOMMENDED A...

Page 454: ...stroke end When greasing the hydraulic breaker set it in the specified posture NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt wi...

Page 455: ...perpendicularly 2 Insert the grease pump perpendicularly to the greasing point Wrong posture Do not perform greasing when the hydraulic breaker is lowered to the ground Do not perform greasing when t...

Page 456: ...able to the breaker are as follows Cutting reinforcing bars and steel frames Demolition of concrete structures Prohibited operations To ensure that the machine has a long life and to ensure that opera...

Page 457: ...hich cannot bear the machine weight or breaking impacts Do not perform work near the undercarriage of the machine Do not work while the machine is inclined on debris etc Do not work by using the swing...

Page 458: ...e breaker bites into the material diagonally an excessive force is applied to it and the machine is damaged Do not extend the bucket cylinder or arm cylinder sharply Do not raise the boom sharply ATTA...

Page 459: ......

Page 460: ...REPLACEMENT PARTS 7 1...

Page 461: ...ation like deformation or cracking replace the clamps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose...

Page 462: ...parts in parentheses are to be replaced at the same time Item Part No Part Name Q ty Replacement in terval Engine oil filter YM129150 35153 Cartridge 1 Every 500 hours Fuel prefilter YM129A00 55730 E...

Page 463: ...ower separate devices are needed so consult your Komatsu distributor NOTICE The fuel used must be ultra low sulfur diesel fuel To ensure good fuel consumption characteristics and ex haust gas characte...

Page 464: ...rication interval Even if the same symbol is used in the lubrication chart the recommended genuine oil may differ according to the lubrication points and the ambient temperature The symbols used in th...

Page 465: ...e engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level Change engine oil filter Change hydraulic oil filter Ch...

Page 466: ...ydraulic oil system 55 14 5 20 5 28 Cooling system 8 8 2 32 Fuel tank 65 17 2 REMARK Specified capacity means the total amount of fluid including the fluid in the tank and the piping Refill capacity m...

Page 467: ...gine Coolant AF NAC is already diluted In this case fill up the tank with pre diluted fluid Never dilute the Non Amine Engine Coolant with ordinary water RECOMMENDED BRANDS AND QUALITIES OTHER THAN KO...

Page 468: ...ust 3 151 Alternator and starting motor Check 4 97 Always use clean washer fluid 4 2 Antenna Stow 6 29 Appoint leader when working with others 2 39 Ashtray 3 100 Attachment Bleed air 4 61 Attachment I...

Page 469: ...7 Dust indicator Check 3 135 Dusty jobsite 4 3 E ECO gauge 3 36 ECO gauge Set target fuel consumption value 3 52 Electric wiring Check 3 145 Electrical components Handle 4 9 Electrolyte level Check wh...

Page 470: ...h as crusher etc of machines with attachment control pedal Operate 6 16 General attachment such as crusher etc of machines with proportional lever Operate 6 17 General attachment such as crusher etc C...

Page 471: ...new machine 3 162 Machine Secure 3 223 Machine Start Travel forward and reverse Stop 3 170 Machine Steer Change the direction 3 176 Machine Stop 3 175 Machine Swing 3 178 Machine Travel forward 3 171...

Page 472: ...ng with trailer 3 220 Precautions for long term storage 3 232 Precautions for maintenance 2 39 4 2 Precautions for noise 2 47 Precautions for opening and closing cooling cover 4 3 Precautions for open...

Page 473: ...t Check looseness Tighten 4 38 Room lamp switch 3 82 Rubber shoes Check 4 42 Rubber shoes Check Adjust track tension 4 43 Rubber shoes Check track tension 4 43 Rubber shoes Decrease Adjust track tensi...

Page 474: ...211 Volume control button 6 24 W Warning display 3 17 Warranty of rubber and road liners shoes 3 214 Washable floor Wash 4 56 Water separator Check Drain water and sediment 3 136 Wear well fitting cl...

Page 475: ...PC45MR 5 PC55MR 5 HYDRAULIC EXCAVATOR Form No TEN00763 04 2018 KOMATSU All Rights Reserved Printed in Japan 02 2018...

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