Komatsu PC490-11 Installation And Instruction Manual Download Page 215

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• In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com-

munication.

If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any
resulting impacts or damages.

OPERATION

EXPLANATION OF COMPONENTS

3-143

Summary of Contents for PC490-11

Page 1: ...se serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodical...

Page 2: ......

Page 3: ...uine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these re...

Page 4: ...Keep it in the magazine box on the left side of the operator s seat If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine model name and the ser...

Page 5: ...safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation wh...

Page 6: ...the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manu...

Page 7: ...the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 Sound power level emitted by the machin...

Page 8: ...tems Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager...

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

Page 10: ...o demolish cut loosen separate pick up transport and distribute component parts of buildings or civil engineering structures This machine is not prepared for use in Demolition Using this machine in de...

Page 11: ...ear of the machine VISIBILITY FROM OPERATOR S SEAT This machine complies with the visibility standard ISO 5006 This machine maintains a proximity visibility of a height of 1 5m at a point 1m away from...

Page 12: ...Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel...

Page 13: ...ing items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is located on the right bottom of the operator s cab The design of the nameplate differs according to the district L...

Page 14: ...S AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU UK Ltd Durham Road Birtley Chester le Street County Durham DH3 2QX United King...

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

Page 16: ...ollowing EC Directives Machine Directive 2006 42 EC Electro Magnetic Compatibility Directive 2004 108 EC until 19 April 2016 2014 30 EU after 20 April 2016 Outdoor Noise Directive 2000 14 EC amended b...

Page 17: ...R SAFE OPERATION 2 18 PRECAUTIONS TO PREVENT FIRE 2 19 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 21 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 23 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 23 PROTEC...

Page 18: ...FOR PARKING MACHINE 3 210 METHOD FOR CHECKING AFTER FINISHING WORK 3 212 LOCK 3 212 HANDLE AIR CONDITIONER 3 218 EXPLANATION OF AIR CONDITIONER EQUIPMENT 3 219 METHOD FOR OPERATING AIR CONDITIONER 3...

Page 19: ...BOLTS AND NUTS 4 10 MAINTENANCE SCHEDULE 4 12 MAINTENANCE SCHEDULE TABLE 4 12 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 13 MAINTENANCE PROCEDURE 4 15 WHEN REQUIRED 4 15 CHECK AUTOMATIC GREASE SYST...

Page 20: ...ETHOD FOR OPERATING ATTACHMENT 6 24 LONG TERM STORAGE 6 28 MAINTENANCE OF ADDITIONAL FILTER FOR BREAKER 6 29 SPECIFICATIONS 6 32 ARM PIN INFORMATION 6 33 ATTACHMENTS AND OPTIONS 6 34 INSTALL ATTACHMEN...

Page 21: ...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 22: ...ELECTROMAGNETIC INTERFERENCE 2 23 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 23 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 23 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 24 ACTIONS IN THE...

Page 23: ...NS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2 44 USE PROPER TOOLS 2 44 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 44 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 44 PRECAUTIONS FOR WELDING 2 44 H...

Page 24: ...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 25: ...LOCATION OF SAFETY LABELS a b c d e f g h KS000848 T T SAFETY SAFETY LABELS 2 5...

Page 26: ...Caution for handling cable 7 Caution stop rotation during inspection and mainte nance 8 Emergency escape 9 Caution against falling 10 Danger do not enter within swing range 11 Caution against work eq...

Page 27: ...in manual and in labels on machine Detailed explanations of the content of each label are as fol lows Warning for operation inspection and maintenance Warning a Read the manual before operating inspe...

Page 28: ...erate where a danger of falling objects exists Consult your dealer for fitting of FOPS FALLING OBJECT PROTECTIVE STRUCTURE protection Warning going too close to electric cables e An electrocution haza...

Page 29: ...perator cab g Take care when standing in the operator cab Before standing up from the operator s seat such as when opening or closing the front window or when removing or installing the bottom window...

Page 30: ...ching any of the working equipment control levers might cause the machine to start mov ing all of a sudden probably resulting in a serious in jury Caution when stowing front window 2 Caution when stow...

Page 31: ...s a hazard of flying plug from track adjuster that could cause injury Read manual regarding adjusting track for safe and proper handling Caution for handling cable 6 Caution when handling cable 09808...

Page 32: ...falling 09805 C0481 Sign indicates a hazard of falling Do not stand on the place here Danger do not enter within swing range 10 Prohibited to enter swing radius 09133 A3281 There is a danger of gettin...

Page 33: ...m the machine during operation Caution do not start by short circuiting 12 Prohibition of short circuit start 09842 A0481 Warning for quick coupler system 13 Warning for use of hydraulic quick coupler...

Page 34: ...ide of the machine Before moving look around and at mirror and monitor to confirm that no one is around the machine Failure to do so can result in serious injury or death Caution for handling battery...

Page 35: ...ter replacing fresh air filter remember to remove key from cover as the key may get damaged when cab door is opened Caution for blast jobsite 17 Caution of an explosive hazard caused by active radio t...

Page 36: ...ed to the ROPS it may affect the strength and may not comply with the standard ROPS may provide less protection if it has been structural ly damaged or involved in roll over Always wear seat belt when...

Page 37: ...d DEF only Never use diesel fuel Warning for operation inspection and maintenance 25 Warning for operation inspection and maintenance 09651 A0841 Read the manual before operating inspection maintenanc...

Page 38: ...TION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of...

Page 39: ...ay cause fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects...

Page 40: ...do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any flammable materials to a safe place before starting Fire caused by accumulation of combustib...

Page 41: ...the following Use the handrails and steps marked by arrows in the fig ure on the right when getting on and off the machine Do not climb on the step if it is damaged Damaged steps must be repaired imm...

Page 42: ...e control levers are touched by mistake there is danger that the machine may suddenly move and cause serious per sonal injury or death PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not...

Page 43: ...ate ROPS will not be able to fulfill its function Do not increase ma chine weight beyond the certified value by modifying the ma chine or by installing attachments to the machine Also if the function...

Page 44: ...to the operator from falling objects flying objects and intruding objects as detailed in the previous section Operator cabin FOPS falling object protective structure Front window guard In the event an...

Page 45: ...s is broken during operations stop operations and repair the cab glass immediately If the cab glass on the work equipment side is broken there is a hazard that the operator may be directly hit or caug...

Page 46: ...PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse...

Page 47: ...ose or touch the electric cable to prevent electric shock the operator should not leave the operator s compartment until it has been confirmed that the electricity has been shut off Also prohibit any...

Page 48: ...Map with mirror and rear view camera visibility aids fitted PRECAUTIONS FOR OPERATION SAFETY 2 28...

Page 49: ...y if there are areas where the visibility is poor Only one signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up addition...

Page 50: ...Always observe the regulations for jobsite and environmental standards This machine does not contain asbestos but any part which is not the genuine part it has risk of containing asbestos Always use...

Page 51: ...ATOR S SEAT 3 156 Check that there are no persons or obstacles above below or in the area around the machine PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to ser...

Page 52: ...m When disconnecting the jumper cables take care not to bring the clips in contact with each other or with the machine For the starting procedure with the jumper cables see OPERATION START ENGINE WITH...

Page 53: ...ople or obstacles in the surrounding area Before moving sound the horn to warn people in the surrounding area Check that the travel alarm and other alarms work properly If there is an area in the rear...

Page 54: ...machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine When passing over bridges or structures check first that the structure is s...

Page 55: ...ine stops move the control levers immediately to NEUTRAL position set the lock lever to LOCK position and then start the engine PRECAUTIONS WHEN OPERATING ON SLOPES When working on slopes there is a h...

Page 56: ...t may hit the dump truck and cause serious personal injury or death Generally speaking the machine is more liable to tip over when the work equipment is at the side than when it is at the front or rea...

Page 57: ...The machine may tip over or become buried in the snow Be careful not to go off the road or to get trapped in a drift of snow When performing snow removal the road and objects placed beside the road ar...

Page 58: ...ground only Avoid road edge or place near the cliff Never use the work equipment to load or unload the machine There is danger that the machine may fall or tip over Always use ramps of adequate streng...

Page 59: ...break during the towing operation Always wear leather gloves when handling the wire rope Never tow a machine on a slope During the towing operation never stand between the tow ing machine and the mac...

Page 60: ...o not leave the operator s seat while the load is being lift ed During the lifting operation reduce the engine speed and carry out the operation in L mode Never travel the machine while lifting the lo...

Page 61: ...l over and injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and avoid use of organic solvents for cleaning An organic solvent like benzene to...

Page 62: ...switch to ON position Operate the work equipment control lever back and forth right and left a few times fully to release the remaining internal pressure in the hydraulic circuit Then move lock lever...

Page 63: ...efore starting removal or installation operations for attachments Place attachments that have been removed from the ma chine in a stable condition so that they do not fall And take steps to prevent un...

Page 64: ...the work equipment and machine are not supported they may come down and it may cause serious per sonal injury or death Never use concrete blocks for supports Concrete blocks may break under even ligh...

Page 65: ...lphuric acid Any mistake in handling may cause serious personal injury explosion or fire Always ob serve the following When handling the battery always wear protective eye glasses and rubber gloves If...

Page 66: ...cap or plug slowly to release the internal pressure and remove the cap or plug PRECAUTIONS FOR HIGH TEMPERATURE PARTS To prevent burns from touching high temperature parts when checking or performing...

Page 67: ...loose or oil or fuel is found to be leaking from the mount stop operations and tighten to the specified torque If any damaged or deformed hoses or piping are found consult your Komatsu distributor Rep...

Page 68: ...ful spring that acts to reduce the impact on the idler If it is disassembled by mistake the spring may shoot out and cause serious personal injury or death If it is necessary to disassemble it ask you...

Page 69: ...OR DISPOSING OF WASTE MATERIALS 2 49 and MAINTENANCE OF AIR CONDITIONER 2 49 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution pay full attention to the way to dispose of waste materia...

Page 70: ...and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspection or the feeling when operating so always replace them at the specifie...

Page 71: ...ly open containers in a well ventilated area For the method of storing see STORE DEF 4 8 When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tai...

Page 72: ......

Page 73: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1...

Page 74: ...GENERAL VIEW MACHINE EQUIPMENT NAME 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Boom cylinder 7 Sprocket 8 Track frame 9 Track 10 Idler 11 Engine hood GENERAL VIEW OPERATION 3 2...

Page 75: ...12 Komatsu Closed Crankcase Ventilation hereafter KCCV ventilator 13 SCR 14 KDPF 15 Toolbox 16 Battery 17 Battery disconnect switch 18 System operating lamp 19 Fusible link 20 Grease pump holder OPER...

Page 76: ...2 Ceiling window 3 Door lock release lever 4 Drink box 5 Fuse 6 Auxiliary electric power if equipped 7 Fire extinguisher if equipped 8 Emergency escape hammer 9 Magazine box 10 Cup holder 11 AUX 12 A...

Page 77: ...CONTROLS AND GAUGES NAMES KS000852 1 Radio 2 Lock lever 3 L H work equipment control lever 4 One touch power maximizing switch 5 Travel pedal 6 Travel lever OPERATION GENERAL VIEW 3 5...

Page 78: ...tic lock cancel switch 26 1st attachment proportional control switch 27 2nd attachment proportional control switch if equipped 28 Breaker switch 29 Spare switch 30 Spare switch 31 Quick coupler switch...

Page 79: ...wing lock pilot lamp 29 Engine preheating pilot lamp or One touch power maximizing pilot lamp 30 Auto deceleration pilot lamp 31 Working mode display 32 Travel speed display 33 Radiator coolant level...

Page 80: ...itch 21 Engine oil pressure caution lamp 22 Charge level caution lamp 23 Radiator coolant level caution lamp 24 Seat belt caution lamp 25 Engine stop pilot lamp 26 Lock lever pilot lamp 27 Aftertreatm...

Page 81: ...nu used for setting various items of the machine on the machine monitor see USER MENU DISPLAY SWITCH 3 57 One of the features of liquid crystal display panels is that there may be black spots spots th...

Page 82: ...hine monitor see USER MENU DISPLAY SWITCH 3 57 One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on th...

Page 83: ...de travel mode display screen HH is displayed for 2 seconds the screen switches to standard screen AA If the working mode when the engine is started is B mode the opening screen GG is displayed for 2...

Page 84: ...switch 1 is turned OFF nor mal the machine monitor switches to the standard screen and you can start the engine with usual starting switch key op eration For the function and operating method of engin...

Page 85: ...operator identification function with SKIP is set the opening screen GG switches to ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting ID number for ope...

Page 86: ...If inputting incorrect ID number for 3 times continuously you cannot input ID number for 5 minutes Wait for more than 5 minutes try inputting ID number again As long as ID number input screen is displ...

Page 87: ...tarting screen BB for 2 seconds the screen changes to the mainte nance time warning screen CC After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the stand ard...

Page 88: ...ed is displayed on top of switch F5 Press switch F5 to check the detail of the error Current Abnor mality screen is displayed BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MAC...

Page 89: ...ormality Current Abnormality screen is displayed WARNING DISPLAY NOTICE Appearance of any of action levels L01 to L04 on the machine monitor indicates presence of an abnor mality the machine Take appr...

Page 90: ...ps 2 and 3 When 3 types of caution are generated they are displayed on caution lamps 2 3 and 4 When 3 types or more of caution are generated they are displayed on caution lamps 2 3 and 4 alternately a...

Page 91: ...n is generated it is displayed on caution lamp 2 When 2 types of caution are generated they are displayed on caution lamps 2 and 3 When 3 types or more of caution are generated they are displayed on c...

Page 92: ...machine to a safe place then ask your Komatsu distributor for inspection and maintenance L02 Sounds inter mittently Lights up in red Stop the operation and run the engine at medium speed with no load...

Page 93: ...tion lamp Abnormal L04 L03 Abnormal L01 Hydraulic system caution lamp Abnormal L04 L03 Abnormal L01 KDPF system caution lamp Abnormal L04 L03 Abnormal L01 KDPF soot accumulation caution lamp Abnormal...

Page 94: ...level caution lamp Abnormal L03 Air cleaner clogging caution lamp Clogged L01 Air conditioner system cau tion lamp Abnormal L01 Overload caution monitor Overload Maintenance time caution lamp Due time...

Page 95: ...medies according to the message displayed on the monitor Operation on the Current Abnormality screen On the Current Abnormality screen you can perform the follow ing operations with switches F1 F2 and...

Page 96: ...see METHOD FOR ENGINE WARM UP OPERATION 3 177 When temperature is correct The caution lamp lights up in blue HYDRAULIC OIL TEMPERATURE CAUTION LAMP The hydraulic oil temperature caution lamp warns abo...

Page 97: ...low 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 mai...

Page 98: ...5 KDPF SOOT ACCUMULATION CAUTION LAMP The KDPF soot accumulation caution lamp warns that soot is accumulated in KDPF or the filtering function of KDPF has low ered abnormally To cancel the alarm perfo...

Page 99: ...hen DEF is added after engine starting switch turn to OFF When DEF tank level sensor is defective REMARK For more information about the Inducement strategy and Inducement status concerning engine powe...

Page 100: ...The engine system caution lamp warns about abnormality in the engine system When action level L04 is displayed The caution lamp lights up in red and the alarm buzzer sounds continuously Stop the machi...

Page 101: ...nt level dropped The caution lamp lights up in yellow and indicates action level L01 The radiator coolant is insufficient Check the coolant level in the sub tank of the radiator and add coolant For de...

Page 102: ...your Komatsu distributor for inspection and maintenance as soon as possible MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displays notices and alarms concerning maintenance time This mo...

Page 103: ...on the maintenance tab screen see MAIN TENANCE SCREEN SETTING 3 78 OVERLOAD CAUTION LAMP The overload caution lamp warns that the machine is close to tipping due to the load an audible warning is als...

Page 104: ...ch power maximizing pilot lamp 10 Preheating pilot lamp 11 Auto deceleration pilot lamp 12 Working mode display 13 Travel speed display 14 ECO guidance Meter display 15 Engine coolant temperature gaug...

Page 105: ...oil temperature gauge 17 Fuel gauge 18 DEF level gauge 19 Fuel consumption gauge 20 Service meter clock 21 ECO gauge PILOT DISPLAY The pilot display at the top of the screen consists of the pilot lam...

Page 106: ...n nothing lights up Wiper stops For the position of the windshield wiper switch see MACHINE MONITOR EQUIPMENT NAME 3 6 AUTO DECELERATION PILOT LAMP The auto deceleration pilot lamp shows the setting o...

Page 107: ...tuated The following pilot lamp is displayed when the knob switch on the L H control lever is operated The actual pilot lamp display is shown at the position of preheating monitor 1 Pilot lamp lights...

Page 108: ...s during aftertreatment devi ces regeneration Stay away from the exhaust pipe outlet to prevent yourself from getting burnt Al so keep combustible materials away from the exhaust pipe outlet to preven...

Page 109: ...y regeneration see HANDLE Komatsu Diesel Particulate Filter KDPF 3 115 LOCK LEVER PILOT LAMP The lock lever pilot lamp lights up when the lock lever is in LOCK position It goes out when the lock lever...

Page 110: ...travel mode Hi and the fuel control dial at the High idle MAX position the travel partial mode recommendation message is displayed When traveling for a long time the fuel consumption can be reduced b...

Page 111: ...rature gauge shows the engine coolant temperature If the indicator is in green range during operations it is normal When the indicator goes beyond A of red range during opera tions the overheat preven...

Page 112: ...ge B position 105 C or more When the indicator is in red range A to B hydraulic oil temperature caution lamp E indicates abnormality When the engine is started if the indicator is at position C the hy...

Page 113: ...ervice meter advances even when the machine is not moving The service meter advances 0 1 every 6 operation minutes regardless of the engine speed Service meter display Clock display 12 hour display Cl...

Page 114: ...the machine A Shows the average fuel consumption of a day from 0 00 a m of the day to 0 00 a m of the next day B Shows the split fuel consumption under measurement C Shows the split fuel consumption w...

Page 115: ...ge to display the correct position Note that the following cases are not abnormal When DEF is added while the starting switch is kept at ON position When the starting switch is turned to ON position i...

Page 116: ...rate the function When the monitor display shows the standard screen the types of guidance icons and functions of function switches are as follows For the details of each function see the detailed exp...

Page 117: ...ance icons and their functions not explained above see the pages where the control methods of re spective screens are explained WORKING MODE SELECTOR SWITCH Use working mode selector switch to set the...

Page 118: ...gine ask your Komatsu distributor to change the setting How to use working mode selector switch 1 When working mode selector switch 2 is pressed the Working Mode selector screen is displayed on the mo...

Page 119: ...on the function to reduce fuel consumption when the control levers are at NEUTRAL position Auto deceleration pilot lamp lights up Auto deceleration ON Auto deceleration pilot lamp goes off Auto decel...

Page 120: ...ine is traveling the machine may deviate to one side even when traveling in a straight line Stop the machine before switching the travel speed Travel speed selector switch is used to select the travel...

Page 121: ...er switch actuates the front window windshield wiper Each time the switch is pressed it changes INT ON stop monitor goes out Windshield wiper pilot lamp INT lights up Windshield wiper op erates interm...

Page 122: ...fluid is sprayed out At the same time the wiper is actuated continuously When releasing switch the wiper continues to operate for 2 cycles then stops If the wiper is moving intermittently and the swi...

Page 123: ...operation of the function switches in the standard screen CAMERA IMAGE SELECTOR SWITCH On the standard screen you can select a display only for the camera image or a display only for the meter by pre...

Page 124: ...ull screen display MM is displayed on the entire screen When switch F3 is pressed on camera image full screen display MM message screen NN is displayed and no camera image is displayed On message scre...

Page 125: ...mage to No 4 camera image are not dis played No 1 camera image only is displayed in full screen If the machine is not equipped with No 3 camera display is changed each time switch F1 is pressed but No...

Page 126: ...if no operation is performed for 5 seconds after the screen switches to the air conditioner operation screen the screen automatically returns to the camera im age display For details of the air condit...

Page 127: ...y does not switch to another screen or re turn to the standard screen Press the buzzer cancel switch to stop the alarm buzzer for the abnormality of warning item Even if the buzzer cancel switch is pr...

Page 128: ...is flashing if no lever is operated for 10 seconds or more the screen automatically returns to the standard screen When the screen returns to the standard screen the cau tion lamp at the top left of t...

Page 129: ...Devices Regeneration d SCR Information e Maintenance f Monitor Setting g Mail Check These menus a to g are for setting and confirming the fol lowing items For operations in each menu see the detailed...

Page 130: ...Information Check of DEF level Urea SCR system information e Maintenance Check and reset of various Maintenance Times f Monitor Setting Screen Adjustment Screen Adjustment camera Clock Adjustment Lan...

Page 131: ...to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Returns to the standard screen F6 Displays the setting screen for selected item If no switch...

Page 132: ...F3 Displays the next page When on the last page it displays the first page F4 Displays the previous page When on the first page it dis plays the last page F5 Returns the screen to the Energy Saving Gu...

Page 133: ...l consumption during the last 12 hours or the graph of daily fuel consumption during the last 1 week Operation on the Average Fuel Consumption Record screen Press switch F1 F2 or F5 on the Average Fue...

Page 134: ...n during the last 1 week Switching be tween them is available Deleting the average fuel consumption records 1 When switch F1 CLEAR is pressed the reconfirmation screen shown in the figure is displayed...

Page 135: ...FF Operations on the Configurations screen Press switches F3 to F6 to perform the following operations on the Configurations screen F3 Moves to the next item 1 line below When on the last line it move...

Page 136: ...oves to the last line on the previous page F5 Cancels the setting and returns to Configurations screen F6 Changes the setting and returns to Configurations screen 2 The Average Fuel Consumption Displa...

Page 137: ...r ECO Guidance Records 2 screen then press the measure ment stop switch F1 STOP SWITCH DISPLAY NON DISPLAY OF ECO GAUGE It is possible to change the setting of Display Non display of ECO gauge 7 1 Sel...

Page 138: ...uel consumption value the upper limit value of the green range of the ECO gauge 1 Select the target fuel consumption value displayed in the ECO Gauge Target Value 9 from the Configurations screen then...

Page 139: ...t line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting change and re...

Page 140: ...e previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting change and returns to Configurations screen F6 Changes the setting and returns...

Page 141: ...eaker Setting menu you can change the name of breaker displayed on the monitor and the breaker oil flow rate setting For machines that have no attachment the Breaker Setting menu is not displayed 1 Se...

Page 142: ...symbol F5 Returns the screen to the Breaker Setting screen without changing the name F6 Enters the change and returns the screen to the Breaker Setting screen Changing Breaker Oil Flow Rate Setting 1...

Page 143: ...the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels the selection and returns the screen to the Machine Setting menu screen F6 Alloca...

Page 144: ...evel F4 Increases the oil flow rate by 1 level F5 Returns to the Attachment Setting screen without changing the oil flow rate F6 Enters the oil flow rate setting and returns to the At tachment Setting...

Page 145: ...speed decreases as well To increase the fan speed oper ate the fuel control dial to increase the engine speed When reversing the fan rotation while the engine is stopped wait until this screen appear...

Page 146: ...witch F5 on the screen shown in the figure 8 Press switch F6 when the confirmation screen shown in the figure is displayed If switch F5 is pressed the screen returns to the previous screen 9 If the sc...

Page 147: ...n is reversed while KDPF system caution lamp or KDPF soot accumulation caution lamp is lit the engine speed and fan speed may not increase even when the fuel control dial is set to High idle MAX posit...

Page 148: ...han that specified in the service menu 3 When the idling time reaches 30 seconds before the set time the monitor returns to the standard screen and changes to the countdown screen If you set the lock...

Page 149: ...ch item of Aftertreatment Devices Regeneration menu c is to make settings for the aftertreatment devices regeneration For details of the aftertreatment devices regeneration see HANDLE Komatsu Diesel P...

Page 150: ...k Cleaning 4500 Fuel Doser Cleaning 4500 Hydraulic Oil Change 5000 a Maintenance items b Default maintenance interval settings h c Time remaining until maintenance h 1 When using engine oil for cold d...

Page 151: ...intenance time reset screen On the maintenance menu screen if switch F6 is kept pressed for at least 1 5 seconds the screen changes to the maintenance time reset screen Reset the remaining time to the...

Page 152: ...light switch is at day mode ON and the screen is adjusted it is possible to adjust the brightness of the monitor screen day mode As long as mark is displayed in the upper right cor ner of the screen b...

Page 153: ...en then press switch F6 The screen switches to the selection menu for the clock adjustment The following 5 items can be changed a GPS Synchronization b Calendar c Time d 12h 24h Mode e Daylight Saving...

Page 154: ...switch F6 F3 Calendar goes back 1 year F4 Calendar advances 1 year F5 Cancels change and returns the screen to Clock Ad justment screen F6 Proceeds to setting for month 3 When month display B is highl...

Page 155: ...the screen to Clock Ad justment screen F6 Proceeds to setting for the minute 3 When minute display E is highlighted in yellow operate the switches as follows to change minute display E If it is not ne...

Page 156: ...s to the next item 1 line below Moves to the top line when on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when on the top line F5 Cancels change and returns to...

Page 157: ...ck and change the Operator ID which is under identification on the Operator ID menu The Operator ID menu is not displayed when the operator identification function is disabled REMARK Contact your Koma...

Page 158: ...the screen returns to the Monitor Setting menu screen On the Monitor Setting menu screen as the same way when the starting switch is ON and SKIP is se lected is displayed in the column of Operator ID...

Page 159: ...screen and press F6 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen When you press switch F6 after inputting the ID which i...

Page 160: ...ssage to your Komatsu distributor Reply to the message according to the replying method mentioned below If the starting switch is turned to OFF position when there is any unread message the message wi...

Page 161: ...ng the monitor switch Each switch corresponds to the value shown on the right side below the switch If you input an incorrect number press switch F5 and you can clear an input character at a time If s...

Page 162: ...switch if equipped 9 Ceiling window wiper switch if equipped 10 Cigarette lighter 11 Room lamp switch 12 Seat heater switch 13 Engine shutdown secondary switch 14 Pump secondary drive switch 15 Swing...

Page 163: ...uel control dial is used to control the engine speed and out put a Low idle MIN The position where the dial is turned fully to the left b High idle MAX The position where the dial is turned fully to t...

Page 164: ...ps light up and monitor illumination is set to day mode c OFF position Lamps go out The monitor illumination is set to day mode HORN SWITCH Horn switch is located on R H work equipment control lever W...

Page 165: ...ossible If this switch is moved to Emergency position by mistake while the machine is operating normally L03 appears in the display If L03 is displayed during operation press switch F5 to check whethe...

Page 166: ...NOTICE The lock lever automatic lock cancel switch is used to disable the lock lever automatic lock function and enable the operations of the work equipment and machine temporarily when the lock lever...

Page 167: ...quipped Revolving lamp switch is used to light up the yellow revolving lamp on top of the cab a ON Lights up b OFF OFF ROOF WIPER SWITCH if equipped The roof wiper switch is used to actuate the roof w...

Page 168: ...op engine position by mistake while the machine is operating normally Engine Shutdown Secondary SW In Operation is displayed on the machine monitor If Engine Shutdown Secondary SW In Operation is disp...

Page 169: ...lanation of these switches operation 1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH The 1st attachment proportional control switch is a roller proportional control switch used to operate the 1st at tachme...

Page 170: ...ed the machine is less moved up during digging work and the operator can dig smoothly Use this position for the general normal operation for ordinary soil soft rocks blasted rocks etc b High pressure...

Page 171: ...quipped REMARK The lock lever is of hydraulic lock type Accordingly when it is in LOCK position L the control levers or control pedals move but the machine does not move Automatic lock function of loc...

Page 172: ...perform operations with your foot on the pedal the machine may suddenly start if you de press the pedal by mistake and this may lead to serious personal injury or death Be extremely careful when using...

Page 173: ...control a Boom RAISE b Boom LOWER Bucket control c Bucket DUMP d Bucket CURL N NEUTRAL The boom and bucket are held in position and do not move OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING ROOF WIND...

Page 174: ...opening or closing the front window stop the machine on a level ground lower the work equipment to the ground stop the engine then perform the operation When opening the front window hold the handle s...

Page 175: ...aces on the right and left top sides of the front window and pull levers B 2 places to re lease the locks at the top of the front window The top of the front window will come out OPERATION EXPLANATION...

Page 176: ...he front win dow are not for pulling up the front window Do not pull up the front window with the handles A 5 Check that lever B is securely at LOCK position If the arrow on lock case F matches the po...

Page 177: ...rip right and left handles A and pull down lever B to release the lock 3 Grip the handle C at the bottom of the front window with your left hand and the handle D at the top with your right hand push t...

Page 178: ...k Removal of front window lower side 1 Open the front window upper side then hold grip 1 pull it up and remove the lower side window REMARK If sand or dust is collected at the bottom of the front win...

Page 179: ...use the hammer A to break the glass and escape through the window METHOD FOR USING DOOR LOCK k k WARNING Before the releasing the door lock always place the machine on a level ground Never release th...

Page 180: ...caps and covers For the locations and opening or closing method of the cap with lock and cover see LOCK 3 212 Insert the key as far as it will go to the shoulder A and turn it If the key is turned wh...

Page 181: ...TRAY This is on top of the console box on the left side of the opera tor s seat Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid NOTICE While removing the...

Page 182: ...hen it is used at 1 place 144 W 12 V x 12 A When it is used at 2 places 144 W in total REMARK Use 12 V power source while engine is running FUSE NOTICE Before replacing a fuse be sure to turn the star...

Page 183: ...on seat with heater 13 5 A Air conditioner ECU power source 14 5 A Key ACC signal 15 20 A Working lamp 16 10 A Radio backup room lamp system operating lamp 17 20 A Monitor Pump controller 18 30 A Engi...

Page 184: ...d 2 may be broken Open the battery box cover on the right side of the machine to check the fusible links and re place them 1 Fusible link for 24 V power supply 2 Fusible link for 24 V continuous power...

Page 185: ...always remove the switch key If someone turns the key to ON position carelessly this is extremely dangerous NOTICE Keep battery disconnect switch in ON position except the following cases When the ma...

Page 186: ...e controller mount ed on the machine is turned ON Lamp 1 lights up in green when the controller is turned ON and goes out in 1 to 6 minutes after the starting switch is turned to OFF position Before o...

Page 187: ...DPF system regardless of the quantity of the accumulat ed soot During the aftertreatment devices regeneration the aftertreatment devices regeneration pilot lamp 1 stays lit on the monitor REMARK Even...

Page 188: ...mately 5 minutes Then stop the engine REMARK If the lock lever is in LOCK position the manual stationary regeneration may start automatically to protect the KDPF If KDPF soot accumulation caution lam...

Page 189: ...er which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals For details see METHOD FOR CLEANING KDPF 4 78 The engi...

Page 190: ...een A is displayed first The action level goes out 2 seconds after and the screen changes to standard screen B If the lock lever is set to LOCK position or all the work equipment control levers are se...

Page 191: ...and per form the manual stationary regeneration PROCEDURE FOR MANUAL STATIONARY REGENERATION k k CAUTION Exhaust gas temperature may increase higher than the previous models during the aftertreatment...

Page 192: ...tep 6 the screen shown in the figure may be displayed This indicates that the opera tions in steps 1 to 4 were not performed correctly or there is trouble other than KDPF soot accumulation abnormality...

Page 193: ...ation dis appears and the screen returns to the standard screen At this time to display the explanation of the manual stationary regeneration again press switch F6 on the standard screen to display th...

Page 194: ...n repeat the procedure from step 6 If the machine needs to be moved during the manual stationary regeneration stop the regeneration tempo rarily and move the machine referring to the after treatment d...

Page 195: ...ard screen Press switch F6 on the standard screen 2 Operate switches F1 and F2 to select Aftertreatment De vices Regeneration menu C to display Aftertreatment Devices Regeneration screen 3 Select the...

Page 196: ...amp 3 may light up but this does not indicate abnormality Also during the regeneration to protect the system the regener ation disable cannot be operated When the regeneration is performed to protect...

Page 197: ...After treatment Devices Regeneration screen is displayed If the screen is not displayed operate switches F1 and F2 to display Aftertreatment Devices Regeneration screen 2 Select Cancel of the regenera...

Page 198: ...NH3 and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water The Komatsu Urea SCR System continuously monitors its operation conditions and stores information...

Page 199: ...res in the engine system If DEF out of the standard is filled or used by mistake contact your Komatsu dis tributor About the operation of Urea SCR system The Urea SCR System automatically starts opera...

Page 200: ...in 4 levels from Warning Continuous Warning Low level Inducement and Severe Inducement The DEF level caution lamp 1 on the machine monitor will light up audible alert will start then Action level will...

Page 201: ...2 gradations of the DEF level gauge light up in the red range DEF level caution lamp 1 lights up in red No Action level is displayed Press F6 to display the SCR Information screen Inducement status 4...

Page 202: ...storation function to move the machine to a safe place and add DEF Inducement strategy when abnormalities are detected in the Urea SCR System devices Except abnormalities in the KDPF and the EGR syste...

Page 203: ...n yellow on the machine monitor 2 for two seconds and goes out Press F6 to display the SCR Information screen when the Standard screen is on SCR Information screen message 4 1 Please inspect and maint...

Page 204: ...ue to the engine power deration capability of the ma chine will be limited Move the machine to the safe place and contact your Ko matsu Distributor The duration of Low level Inducement is 10 hours The...

Page 205: ...1 DEF system caution lamp 2 and Action Level displayed on the machine monitor 3 au dible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine powe...

Page 206: ...system caution lamp 2 lights up in yellow The action level L03 lights up in red at action level dis play 3 Press F6 to display the SCR Information screen when the Standard screen is on SCR Informatio...

Page 207: ...er derate This engine power restoration works only when the Inducement status is Severe Induce ment and relieves back temporarily to the power deration of Low level Inducement The operator can re stor...

Page 208: ...tion screen displays remaining time to the next Inducement status in the column 6 and information on the Urea SCR System condition 4 and the current status of In ducement 5 Warning The audible alert s...

Page 209: ...m system caution lamp 1 lights up in red DEF system caution lamp 2 lights up in red The action level L03 lights up in red at action level dis play 3 Press F6 on the standard screen to display the SCR...

Page 210: ...cluded in Urea SCR systems In case the Urea SCR system advances to Severe Inducement engine power is derated heavily This may cause difficulties of moving the machine to a safe place for adding DEF or...

Page 211: ...displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Low level Inducement for the maximum of 30 minutes The remaining time minutes sec...

Page 212: ...of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the previous Inducement and whether the n...

Page 213: ...aminate DEF pump and DEF injector which will cause the failure of the machine Never reuse the DEF filter KOMTRAX KOMTRAX equipment may not be mounted on machines for some countries or regions OUTLINE...

Page 214: ...starting switch to OFF position and turn the battery dis connect switch key to OFF position Then remove the key When the battery disconnect switch is turned to OFF position it is possible to prevent...

Page 215: ...tor judges that it is necessary to suspend KOMTRAX com munication If you do not observe the above rules neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or d...

Page 216: ...turbocharger or other high tempera ture engine parts If any dirt or combustible materials are found remove them For removal of dirt from the radiator see METHOD FOR CHECKING AND CLEANING RADIATOR FINS...

Page 217: ...vices and also KDPF connections for leakage of exhaust gas and deposition of soot If any problem is found ask your Komatsu distributor for repair 16 Check around SCR for exhaust gas leakage Check the...

Page 218: ...he machine Unscrew the strainer valve cap H to open position J Place the fuel hose 2 into the fuel barrel placed next to the machine Remove the fuel cap F 3 Refuel Pump with Auto Shut off Refuel Syste...

Page 219: ...switch 4 After finishing refuelling make sure the master switch 4 is returned to the OFF position A float gauge G will rise out of the filler neck of the tank when it is nearing full capacity Position...

Page 220: ...t so that it moves smoothly For details see Adjustment of drain valve METHOD FOR ADJUSTING DRAIN VALVE 1 Turn valve 6 at the bottom of the fuel tank to CLOSE po sition S 2 Place a container under the...

Page 221: ...switch key to ON position within 15 sec onds after stopping the engine and move each control lev er for work equipment and travel to the full stroke in all directions The internal pressure is released...

Page 222: ...cap and the tank and insert it 2 Rotate the oil filler cap clockwise and lock it with the key The mark on the oil filler cap matches with the key mark on the tank METHOD FOR CHECKING COOLANT LEVEL ADD...

Page 223: ...he radiator and then add it to the sub tank METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may...

Page 224: ...hort circuiting on the electrical wiring promptly ask your Komatsu distributor to locate the cause of it and to perform the repair Keep the top surface of the battery clean and check the vent hole in...

Page 225: ...uantity is 76 or less Since the fuel level is low add fuel 2 After checking turn the starting switch back to OFF posi tion 3 Open fuel filler cap F on the fuel tank and add fuel through the filler por...

Page 226: ...performing operations on a slope or traveling on a rough ground When the remaining DEF level is low it may become the warning level if DEF pump sucks air or if DEF level suddenly drops If DEF is store...

Page 227: ...ns 5 By sight gauge 4 add DEF through the filler port until float 5 reaches line F 6 Refill capacity of DEF tank 39 Line 7 in the sight gauge indicates approximately 10 be low line F and line 8 indica...

Page 228: ...at day mode b 3 After inspection turn the lamp switch to OFF position c and the working lamp goes out 4 After checking turn the starting switch back to OFF posi tion If the lamps do not light up a br...

Page 229: ...ck to the original position Pull up the reclining adjustment lever and set the seat back to a position which is comfortable for operation then release the lever REMARK Sit with your back against the b...

Page 230: ...eight of the armrest can be adjusted up or down by using the knob at the rear of the armrest Armrest height adjustment 43 mm 1 Loosen knob 1 at the rear of the armrest 2 Pull plunger 2 3 Adjust the he...

Page 231: ...PENSION SEAT HARDNESS Air suspension seat if equipped Operate the suspension switch to adjust the hardness of the suspension If you press the suspension switch the suspension be comes hard If you pull...

Page 232: ...operate it so that the shaft of the headrest becomes straight If it is forcibly twisted the installation part may be broken METHOD FOR ADJUSTING MIRRORS k k WARNING Be sure to adjust the mirrors befor...

Page 233: ...person at the rear left end of the machine 3 If you cannot adjust loosen mounting bolts 1 of the mir ror and stay and adjust the angles If the mirror is adjusted by loosening the mounting bolts be sur...

Page 234: ...que of mounting bolt 6 6 0 to 7 0 Nm 0 61 to 0 71 kgm Mounting position 7 74 mm NOTICE Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L bec...

Page 235: ...ound The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Adjust the mirror so that you can see a person at the rear right of the mach...

Page 236: ...el ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped When returning the mirror to its regular position perform the following...

Page 237: ...during the work make sure that the following conditions are met before starting the work The machine is placed on a firm level ground The work equipment is lowered to the ground in secure posture The...

Page 238: ...s adjust the camera before starting work If it is not adjusted properly you cannot secure the visibility and a serious personal injury or death may result When adjusting the angle of the camera prepar...

Page 239: ...on the monitor is not aligned correctly adjust mounting angle A of the rearview camera in the following pro cedure Angle A can be adjusted within the range from 32 to 53 1 Insert a flat head screwdriv...

Page 240: ...rding to the record Take care of shim 6 since it comes off together with cover 1 4 Loosen camera mounting bolts 5 3 places and adjust camera mounting angle A so that corner D of mounting bracket C is...

Page 241: ...ar period It is not the start of the 3 year period of actual usage This seat belt has a retractable device so it is not necessary to adjust the length METHOD FOR FASTENING SEAT BELT 1 Hold grip 2 and...

Page 242: ...LOCK position L 3 Check that all control levers and control pedals are at NEUTRAL position If the control levers and control pedals are not being touched they will be at NEUTRAL position 4 Insert the...

Page 243: ...mately 2 seconds and the following caution lamps and meters light up for ap proximately 2 seconds Radiator coolant level caution lamp 4 Charge level caution lamp 5 Engine oil pressure caution lamp 6 E...

Page 244: ...nd check methods for caution lamp see WARNING DISPLAY 3 17 7 If the maintenance due time has passed for certain items maintenance due time caution lamp 18 is lit in red for 30 seconds Press user menu...

Page 245: ...keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes then start again from the beginning After the en...

Page 246: ...engine may not start even when the key in starting switch 3 is kept at START position for 20 seconds If this happens wait for at least 2 minutes then start again from the beginning To preheat the engi...

Page 247: ...unterclockwise from OFF position A The preheating pilot lamp lights up and preheating of the engine starts Preheating continues while the key in starting switch 3 is held counterclockwise The preheati...

Page 248: ...d Particularly in a cold weather be sure the warm up operation is completed Keep away from the exhaust pipe while the engine is running and immediately after stopping the engine Keep combustible mater...

Page 249: ...shorten the machine life Be sure to break in the machine for the initial 100 hours as indicated on the service meter Make sure that you fully understand the descriptions in this manual then run in th...

Page 250: ...speed Run the engine with no load until engine coolant temperature caution lamp 1 displays proper temperature Display A when temperature is proper Caution lamp background C is blue Display B when temp...

Page 251: ...MARK Turbo protect function takes priority over the engine automatic warm up When the turbo protect function activates run the engine at low idle even the engine coolant temperature is 30 C or less Th...

Page 252: ...ipment is necessary not only for the circuit between the pump and cylinders and between the pump and motor but also for the control circuits Do not perform the opera tion just for one cylinder or moto...

Page 253: ...for 30 seconds 2 Move R H work equipment control lever 5 slowly in the direction bucket DUMP position C Operate the lever to the end of its stroke and hold it in the position for 30 seconds 3 Next mov...

Page 254: ...ature then check that all the instruments caution lamps and pilot lamps on the machine monitor are in the following conditions Radiator coolant level caution lamp 8 OFF Charge level caution lamp 9 OFF...

Page 255: ...ck that the hydraulic oil temperature caution lamp displays proper temperature If it is not displaying the proper temperature repeat step 2 until hydraulic oil temperature caution lamp 7 displays the...

Page 256: ...hange the working mode to the attachment mode Attachment operation One way A Other way B 15 Check that hydraulic oil temperature caution lamp 7 displays proper temperature If the hydraulic oil tempera...

Page 257: ...e perform the op eration after completion of the warm up operation METHOD FOR OPERATION AFTER COMPLETION OF WARM UP OPERATION 1 Check that hydraulic oil temperature caution lamp 7 dis plays proper tem...

Page 258: ...ing operations B mode For breaker operations ATT P mode For operations of 2 way attachments like crusher ATT E mode For operations of 2 way attachments like crusher fuel economy conscious operations M...

Page 259: ...es regeneration the components may be damaged When stopping the engine stop the aftertreatment devices regeneration first according to PROCEDURE FOR AFTER TREATMENT DEVICES REGENERATION DISABLE SET TI...

Page 260: ...he machine s main power is maintained for 7 seconds If the starting switch key is turned to OFF A position while the engine is still hot guidance 2 may be dis played on the machine monitor To cool dow...

Page 261: ...close to the machine during operation Clear any obstacles from the travel path There is a blind spot at the rear of the machine so be particularly careful when traveling in reverse If the travel lever...

Page 262: ...the rear parts of pedals 6 slowly 4 When travelling check that the alarm sounds normally If the travel alarm does not sound ask your Komatsu distributor for repair REMARK In low temperatures if the m...

Page 263: ...alarm sounds normally If the travel alarm does not sound contact your Komatsu distributor for repair REMARK In low temperatures if the machine travel speed is not normal thoroughly perform the warm up...

Page 264: ...anges of direction to travel as much as possible Especially when performing counter rotation turn spin turn stop the machine before turning Operate 2 travel levers 1 as follows PIVOT TURN When turning...

Page 265: ...ft 1 Pull the left travel lever toward you 2 Push the right travel lever forward The machine make a counter rotation turn to the left Counter rotation turn to right 1 Pull the right travel lever towar...

Page 266: ...heck that swing lock pilot lamp 2 is lit METHOD FOR OPERATING WORK EQUIPMENT k k WARNING If the levers are operated when the engine speed is decreased by the auto deceleration function the en gine spe...

Page 267: ...conds after stopping the engine and the lock lever is set to FREE position it is possible to use the lever operation to lower the work equipment to the ground This procedure can also be used for relea...

Page 268: ...tions are performed in a mode other than the breaker mode there is danger of breakage of the hydraulic equipment Do not perform breaker operations in any mode except the breaker mode Set the working m...

Page 269: ...ing operation Make effective use of this function whenever necessary in combination with the working mode Press the L H knob switch once and keep it pressed The operating power increases as long as th...

Page 270: ...extended PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging nor use the dropping force of the bucket as a mattock breaker or pile driver Th...

Page 271: ...large vibration occurs in the machine and can crack the work equipment or frame If the bucket blade slides and collides with a rock an excessive impact load occurs in the work equipment and frame and...

Page 272: ...damage the undercover and frame In the worst case the hydraulic components are dam aged and a serious accident can result During operation keep checking the track top for crushed stones soil and sand...

Page 273: ...o cool down If the machine travels continuously for a long time with the tracks loosened it may break the undercarriage parts When driving the machine for a long time check the track ten sion every 1...

Page 274: ...OIL AND DIRT NOTICE When driving the machine out of water if the angle of the machine exceeds 15 the rear of the upper structure will go under water and water will be thrown up by the cooling fan This...

Page 275: ...Always operate or travel in such a way that it is possi ble to stop safely at any time if the machine slips or becomes unstable When travelling uphill if the shoes slip or it is impos sible to travel...

Page 276: ...en start the engine again Pay attention to DEF level Before working on a slope or travelling on a rough ground check DEF tank and add sufficient amount of DEF as necessary If the remaining DEF level b...

Page 277: ...d set the travel lever to FORWARD position to drive the machine out RECOMMENDED APPLICATIONS In addition to the following it is possible to further increase the range of applications by using various...

Page 278: ...ncy can be enhanced by locating the dump truck in a place easily visi ble to the operator Loading is easier and capacity greater if you begin from the rear of the dump truck body than if loading is do...

Page 279: ...s Stop the machine on a firm and flat surface and do the work When performing joint work appoint a leader and follow that person s instructions and signals METHOD FOR CHANGING BUCKET Replace the bucke...

Page 280: ...ETHOD FOR INVERTING BUCKET NOTICE The rock bucket cannot be used for shovel work in the inverted position since it interferes with the arm Invert the bucket according to the following procedure 1 Lowe...

Page 281: ...them until the next use 5 Install the stopper bolts and nuts for each pin then grease the pins REMARK Lubricate with grease thoroughly until the grease comes out from the end faces When replacing the...

Page 282: ...dard machines METHOD FOR PARKING MACHINE k k WARNING Avoid a sudden stop Stop the machine gradually Place the machine on a firm and level place Do not park the machine on a slope If it is unavoidably...

Page 283: ...on The machine stops 2 Turn fuel control dial 2 to Low idle MIN position and lower the engine speed 3 Lower the bucket horizontally until the bottom touches the ground 4 Set lock lever 3 in LOCK posit...

Page 284: ...machine and check the work equipment machine exterior and undercarriage also check for any leakage of oil or coolant If any problems are found repair them 2 Fill the fuel tank 3 Check the engine comp...

Page 285: ...key to CLOSE position B then remove the key METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK 1 Insert the key into the key slot 2 Turn the key counterclockwise and ope...

Page 286: ...er treatment devices are still hot Accordingly wait until they have cooled down before opening or closing the engine hood METHOD FOR OPENING ENGINE HOOD 1 Insert the key into the key slot 2 Turn the k...

Page 287: ...tay is set in the lock position securely When closing it hold the handle securely since the DEF tank filler cap cover may move down be cause of its own weight If it is not locked it may close suddenly...

Page 288: ...wer the cover 3 Turn the key clockwise to lock and remove it Position A OPEN Position B CLOSE LOCK METHOD FOR OPENING AND CLOSING CAB DOOR When opening the door locked door 1 Insert the key into the k...

Page 289: ...B CLOSE LOCK When locking the door 1 Close the door and insert the key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key OPERATION MACHINE OPERATIONS AND CONTRO...

Page 290: ...ow the air conditioner may not work In this case circulate recirculation air to warm the inside of the cab After that turn the air conditioner switch ON the air conditioner will work If any abnormalit...

Page 291: ...used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH You can adjust the air f...

Page 292: ...5 C Monitor display and function Monitor display C Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to set temperature 32 0 Max heating REMARK If the mode is set to auto mo...

Page 293: ...mode AUTO SWITCH Use the auto switch for automatic selection of the air flow vents and air source FRESH RECIRC according to the set temperature Press this switch then use temperature control switch 1...

Page 294: ...etting to take in fresh air or to demist the window glass DISPLAY MONITOR This monitor display indicates the status of temperature setting a air flow rate b and vents c When OFF switch 1 is pressed th...

Page 295: ...the cab caused by changes in the strength of the sun s rays beforehand and automatically adjusts the temperature METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically...

Page 296: ...the set temperature and the air conditioner is operated auto matically to provide the set temperature REMARK When vent monitor c displays d or e and engine coolant temperature is low the air flow is...

Page 297: ...djust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Turn air conditioner switch 2 ON 3 Use temperature control switch 3 to set to the desi...

Page 298: ...monitor changes according to the selection 5 Press FRESH RECIRC air selector switch 5 and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH METHOD FOR ST...

Page 299: ...r blow ing to the feet set as follows 1 Press fan switch 1 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector sw...

Page 300: ...3 Turn on the air conditioner switch 3 4 Adjust fan switch 1 temperature control switch 4 and FRESH RECIRC selector switch 5 to the desired posi tions HANDLE AIR CONDITIONER OPERATION 3 228...

Page 301: ...and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch 2 and set vent display on the monitor to f or g as sho...

Page 302: ...0 of maximum heating 5 Adjust vents A B1 and B2 so that the air blows onto the window glass Vents C and D are fixed and cannot be adjusted 6 When operating in the rainy season or when it is desired t...

Page 303: ...button 5 Preset button 6 Display selector button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is shown on display As long as...

Page 304: ...will be canceled For the sound adjusting method see METHOD FOR CONTROLLING RADIO 3 233 DISPLAY A Band name AUX frequency clock and other character numeric information are displayed B Frequencies are d...

Page 305: ...ust the fre quency Press the button and the frequency increases press the button and the frequency decreases Hold down the button and the frequency increases continuously hold down the button and the...

Page 306: ...ile a frequency is displayed press button 1 of preset button 2 and the preset number P 1 appears on the display The preset number is shown for 0 5 seconds and then the frequency is displayed METHOD FO...

Page 307: ...REGISTER RANGE BASS 1 Press sound control button 1 to light up BAS on the dis play You can adjust the low register range bass of the sound 2 Press tuning time adjustment button 2 to adjust the low reg...

Page 308: ...antenna 1 and stow the antenna 1 to the bottom part 2 After stowing the antenna 1 tighten the bolt 2 to fix it SPACE FOR RADIO CASSETTE The radio cassette is not factory fitted If fitment is required...

Page 309: ...that the weight and dimension given in SPECIFICATIONS weight and dimension may differ accord ing to the type of track shoe or arm or other attachments Consult your Komatsu distributor for details of t...

Page 310: ...work equipment for loading and unloading operations Always use ramps The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer and it is dangerous that the m...

Page 311: ...ps to prevent them from bending 4 Push travel speed selector switch 5 to set the travel speed to low Lo lights up The travel speed Lo Mi Hi is displayed on travel speed display 6 5 Turn auto decelerat...

Page 312: ...possible without caus ing interference On the ramps operate only the travel lever Do not operate any other lever 10 When loading a machine with the work equipment instal led at the point where the tra...

Page 313: ...ion put a block under the tip of the bucket link to prevent the bucket cylinder from touching the floor After loading the machine onto a trailer secure the machine as follows 1 Extend the bucket and a...

Page 314: ...TIE DOWN POINT Place blocks under both ends of the tracks to prevent the ma chine from moving during transportation and secure the ma chine with chains or wire ropes of appropriate strength In par tic...

Page 315: ...1 from sup port 3 2 Loosen bolt 4 and remove support 3 and clamp 5 from the handrail Mirror C Loosen mounting bolt 2 then remove mirror 1 from support 3 METHOD FOR INSTALLING MIRROR Mirrors A B 1 Ins...

Page 316: ...gh place that can lead to serious personal injury or death Check the scaffolding and ensure your safety before starting the work If installation or removal work of the handrail is improper there is a...

Page 317: ...torque 98 to 123 Nm 10 0 to 12 5 kgm METHOD FOR REMOVING AND INSTALLING REVOLVING WARNING LAMP METHOD FOR REMOVING REVOLVING WARNING LAMP 1 Remove connector A of the revolving warning lamp When removi...

Page 318: ...the connector firmly until a click sound can be heard PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm level ground Maintain a safe distance from the road shoulder 1 Apply t...

Page 319: ...sed it switches OFF to ON to OFF in turn When auto deceleration switch 7 is turned OFF the auto deceleration pilot lamp 8 goes out 9 Raise the work equipment and move slowly 10 When the machine is hor...

Page 320: ...prevent the machine from moving unexpectedly Never enter the area under or around a lifted machine Never try to lift the machine in any other posture nor using other lifting equipment than those given...

Page 321: ...ngle A of the wire rope to 30 to 40 then sling the machine slowly 9 After the machine comes off the ground check the hook condition and the lifting posture and then sling the ma chine upward slowly SP...

Page 322: ...e is raised too high the stopper bolt will be pried and bent 5 Pull track frame 2 with chain block 4 and spread the gauge 6 Lower the machine body softly on the ground 7 Install bolts 1 4 pieces on fr...

Page 323: ...st be 50 mm or lower If the track frame is raised too high the stopper bolt will be pried and bent 5 Pull track frame 2 with chain block 4 and spread the gauge 6 Pull the track frame until it reaches...

Page 324: ...e interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR CLEANING INSIDE OF COOLING SYSTEM 4 20 DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break th...

Page 325: ...following precautions Remove all the mud and water from the machine body In particular wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud dirt or drops of water on the...

Page 326: ...l for all equipment with the ones of the specified viscosity For details see RECOM MENDED FUEL COOLANT AND LUBRICANT 7 5 If the machine is parked for long time in the cold weather condition quality of...

Page 327: ...set the stop valve to the LOCK position Install the blind plugs to the elbows For explanation of LOCK and FREE states of the stop valve see METHOD FOR REMOVING AND IN STALLING ATTACHMENT 6 21 To preve...

Page 328: ...ciently according to the procedure in METHOD FOR ENGINE WARM UP OPERATION 3 177 If the machine has been stored for more than 2 months perform the following procedure Before starting the engine replace...

Page 329: ...ON position Lamp 2 flashes and the electric fuel feed pump operates Check that lamp 2 is not lit After the specified time approximately 7 minutes lamp 2 goes out automatically and the fuel feed pump s...

Page 330: ...valve PRECAUTIONS FOR TOWING MACHINE k k WARNING Always use the correct towing equipment and towing method Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled...

Page 331: ...tion of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to seri ous personal injury or death Select the appropriate tools and methods The shackle must alwa...

Page 332: ...ing batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the ground normally the negative terminal When installing first connect the...

Page 333: ...tive charger clip of the charger to the nega tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when perform...

Page 334: ...24 V battery The sizes of the jumper cables and clips should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the cable...

Page 335: ...Remove the clip of jumper cable B from the revolving frame E of the failed machine 2 Remove the clip of jumper cable B from the negative terminal of battery D on the normal machine 3 Remove the clip o...

Page 336: ...switch is at ON position Defective monitor Replace Defective oil pressure caution switch Replace When startability at low temperature is poor if you touch the outside of the electric heater by hand a...

Page 337: ...oil pan sucking in air Set oil to specified level See CHECKS BEFORE STARTING Improper oil is used Viscosity is im proper Replace oil See METHOD FOR US ING FUEL COOLANT AND LUBRI CANTS ACCORDING TO AM...

Page 338: ...NANCE Defective fuel injection pump or de fective nozzle Replace pump or nozzle Starting motor turns engine sluggish ly See ELECTRICAL SYSTEM Preheating caution lamp does not light up See ELECTRICAL S...

Page 339: ...on the Current Abnormality screen re place both fuel main filter and fuel prefilter immediately For details of replacement see METHOD FOR REPLACING FUEL PRE FILTER CARTRIDGE 4 51 and METHOD FOR REPLA...

Page 340: ......

Page 341: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1...

Page 342: ...not remove the strainer while adding DEF WELDING INSTRUCTIONS When performing welding turn the starting switch to OFF position check that the system operating lamp is not lit Turn the battery disconn...

Page 343: ...ECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with new parts When doing this be careful...

Page 344: ...closing the engine hood after inspection or maintenance make sure that the catch is securely locked If the engine hood catch is not locked there is a danger that the engine hood may open PRECAUTIONS...

Page 345: ...y always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry of such impurities Take...

Page 346: ...nd cooling properties and can be used continuously for 2 years or 4000 hours Komatsu recommends the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious problems such...

Page 347: ...ng the recom mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual Grease fittings not included in the periodic mainten...

Page 348: ...have to be stored outside cov er them with a waterproof sheet or take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of first in f...

Page 349: ...you If the key is left in the switch someone may turn ON the power by mistake It is dangerous that causes an electric shock For the operation of the battery disconnect switch see BATTERY DISCONNECT SW...

Page 350: ...the part that is removed Thread diame ter of bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 2 31 66 113 172 1 35 3 2 6 7...

Page 351: ...rget value Allowable range Nm kgm Nm kgm 02 19 44 4 5 35 to 54 3 5 to 5 5 03 22 74 7 5 54 to 93 5 5 to 9 5 04 27 103 10 5 84 to 132 8 5 to 13 5 05 32 157 16 0 128 to 186 13 0 to 19 0 06 36 216 22 0 17...

Page 352: ...NE FILTER AND REMOVING DIRT 4 41 CHECK AUTOMATIC GREASE SYSTEM 4 41 PERIODIC CHECKS 4 41 REFILLING GREASE 4 42 GREASING PROCEDURE 4 42 SYSTEM TEST 4 42 CHECKS BEFORE STARTING 4 43 EVERY 50 HOURS MAINT...

Page 353: ...TROL CIRCUIT 4 76 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIPING CLAMP HARD ENING OF RUBBER 4 77 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 77 EV...

Page 354: ...use of the breaker operating ratio of the breaker 50 or more and replace the element ac cording to the table X Breaker operating ratio Y Replacement interval H A Hydraulic tank element pilot filter el...

Page 355: ...nner element If any dirt enters the engine it can damage the engine Be sure to stop the engine before checking cleaning or servicing the air cleaner Do not check clean or service the air cleaner when...

Page 356: ...to vacuator valve 4 installed to cover 3 remove it 7 When the outer element has been cleaned 6 times or used for 1 year replace it When the element needs to be replaced Replace the inner and outer ele...

Page 357: ...ngine When inserting the element into the body if the rubber at the tip is swollen or the outer element is not pushed in straight and cover 3 is installed by force with hook 2 there is a danger that t...

Page 358: ...outer element in the following procedure 1 Open the door at the rear left side of the machine remove hooks 2 6 places and remove cover 3 2 Hold outer element 5 rock it lightly up and down and to the r...

Page 359: ...ock it lightly up and down and to the right and left while pushing it in the element can be inserted easily 8 Install cover 3 as follows 1 Check that O ring 8 is fitted to cover 3 2 Align cover 3 with...

Page 360: ...the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious problems such as corrosion of the engine and aluminum parts of the cooling system To maintain the anti corros...

Page 361: ...olts A 2 pieces then open cover 1 3 Check that the coolant temperature is low enough to make it possible to touch the radiator cap surface by bare hand turn radiator cap 2 slowly until it hits the sto...

Page 362: ...ATIONS AND CHECKS BEFORE STARTING ENGINE 3 170 and METHOD FOR START ING ENGINE 3 173 METHOD FOR STARTING EN GINE 3 173 10 Set the swing lock switch to ON position a and check that the swing lock pilot...

Page 363: ...side C Operate the lever to the end of its travel and hold it in position for 30 seconds 3 Move the L H work equipment control lever slowly in the direction to the arm IN side B Operate the lever to t...

Page 364: ...then fill with Non Amine Engine Coolant to the middle between FULL and LOW marks NOTICE If the sub tank is extremely dirty and it is difficult to clean replace it with a new one 17 After draining the...

Page 365: ...low idle for 5 minutes to remove the air from the coolant then run at high idle for a further 5 minutes Keep radiator cap 2 removed during the above opera tions 22 Stop the engine wait for approximat...

Page 366: ...ionally and keep it in the standard range For performing the inspection and adjustment of the track shoes park the machine on the level and solid ground METHOD FOR CHECKING TRACK TENSION 1 Run the eng...

Page 367: ...se does not come out smoothly move the machine forward and backward a short distance 3 Tighten plug 1 4 To check if the tension is correct run the engine at low idle move the machine slowly forward by...

Page 368: ...it the rubber pin lock may break Set it against the back of the pin 4 After removing lock pin 2 and rubber pin lock 3 check them 5 If lock pin 2 and rubber pin lock 3 are used in the condi tion below...

Page 369: ...t tooth 1 to adapter 4 and check that when tooth 1 is pressed strongly the rear face of the hole for the pin of teeth 1 is at the same level as the rear face of the hole for the pin of adapter 4 If th...

Page 370: ...EPLACING BUCKET TEETH HORIZONTAL PIN TYPE Replace the bucket teeth before the adapter starts to wear k k WARNING It is dangerous if the work equipment moves by mistake when the tooth is being replaced...

Page 371: ...when replacing the side cutter and shroud of the bucket Set the work equipment in a stable condition set the lock lever securely to LOCK position L and stop the engine As the pin is driven out with s...

Page 372: ...LEARANCE k k WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance Lower the work equipment to the ground set it in a stable condition stop the engine and...

Page 373: ...or dust get in when adding fluid Mixture ratio of pure washer fluid and water The correct mixing proportion varies with the ambient temperature Add washer fluid diluted with water at the following pr...

Page 374: ...n required Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of the compressor Check level of refrigerant gas k k WARNING If...

Page 375: ...curely to LOCK position L before leaving the operator s seat Select a firm flat place for work When setting the machine at an angle use strong blocks to stabilize the base of the machine and be extrem...

Page 376: ...e machine is set at angle by using blocks 2 Swing the upper structure slowly so that water drain holes 3 in the cab floor are at a low position 3 Lower the work equipment to the ground and set the ma...

Page 377: ...jections 2 into the holes METHOD FOR SETTING MACHINE AT ANGLE You can set the machine at an angle by using a slope or blocks Consider the condition of the machine and select the safe method METHOD FOR...

Page 378: ...n doing this check that the machine is always stable METHOD FOR CHECKING GAS SPRING k k WARNING The gas spring is charged with high pressure nitrogen gas so improper handling may cause an explo sion r...

Page 379: ...h drain port Oil will come out when the drain hose is removed so se cure the hose fitting at a position higher than the level of the oil in the hydraulic tank 3 After completing the air bleed operatio...

Page 380: ...Run the engine at low idle loosen air bleeder 4 and tighten it when oil flows out 2 Run the engine at low idle and swing the upper structure 90 to bring the work equipment to the side of the track 3...

Page 381: ...e filter 1 3 Clean filter 1 Thoroughly clean the filter to remove dirt from its side face as well 4 Replace O ring 3 with a new one 5 Install cleaned filter 1 Tightening torque for plugs 2 270 30 Nm 2...

Page 382: ...er hose 3 Fix the filler hose onto the filler coupling 7 4 Fill the reservoir up to the maximum level indicated on the reservoir 8 5 Remove the filler hose and fit the dust cap 6 Fix the filler hose o...

Page 383: ...sec on 0 2 sec off 3 The continuous test cycle ends after the starter switch is moved to the OFF position A A test cycle can only be started when the system is not in the pump phase of a current greas...

Page 384: ...50 hours operation on a new machine After the machine is subjected to digging work in the water be sure to grease the wet pins Items to be prepared Grease pump 1 Park the machine on a level and firm...

Page 385: ...onsult a doctor Do not use a dry wipe to clean the battery A wet wipe will prevent fire or explosion from static electrici ty NOTICE Do not add the electrolyte to the battery exceeding UPPER LEVEL lin...

Page 386: ...the battery check as follows 1 Remove cap 2 at the top of the battery and check the electrolyte level through electrolyte filler port 3 2 If the electrolyte does not reach the sleeve 4 always add the...

Page 387: ...alue METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 1 Loosen bolt 3 and nut 4 2 Rotate nut 5 clockwise to move compressor 6 3 Press the centre between crankshaft pulley A and com pressor pulley...

Page 388: ...chine is used with loose bolts connecting the centre frame and track frame the bolts will break If any looseness of connecting bolt is found retighten it 1 Check for looseness of the bolts 1 connectin...

Page 389: ...such as hydraulic breaker operations perform the greas ing every 100 hours 1 Set the work equipment on the level and firm ground in the maintenance posture as shown in the figure then lower it to the...

Page 390: ...ay cause burn injury Accordingly wait until they have cooled down before starting the work Refill capacity of oil pan 38 Items to be prepared Container to receive drained oil Filter wrench 1 Remove co...

Page 391: ...nt level is normal it is not a problem There is no problem even if the emulsified matter cannot be removed completely after changing oil METHOD FOR REPLACING FUEL PRE FILTER CARTRIDGE k k WARNING Afte...

Page 392: ...e with fuel do not re move cap B Always fill with fuel from small holes A 8 places on the dirty side After filling with fuel remove cap B and install the fuel filter Always fill with clean fuel Be car...

Page 393: ...bolts 1 2 pieces on the top of the revolving frame and remove cover 2 3 Insert ruler 3 into the grease through inspection and ad justment hole A Check that the height of grease S in the area where th...

Page 394: ...dirt leaves etc stuck to the fins blow it off with compressed air NOTICE Steam or water may be used instead of the com pressed air However when performing powerful steam cleaning high pressure machine...

Page 395: ...here will be a rumbling sound from the air conditioner unit METHOD FOR CLEANING RECIRCULATION AIR FILTER 1 Remove wing bolts 1 from the inspection window at the bottom rear left inside the operator s...

Page 396: ...nnot be removed by blowing with air or washing in water replace the filter immediately If the filter is damaged or deformed replace it with new one 4 After cleaning return filter 5 REMARK The fresh ai...

Page 397: ...line H of dipstick G loosen drain valve P to drain the excessive oil When draining the oil take hose 2 out of inspection hole B and place an oil container under hose 2 then open the drain valve 7 Afte...

Page 398: ...TURES FOR CRACKS Before checking be sure to remove any excessive dirt e g from undercarriage and excessive grease e g around area of articulating joint pins from areas of the machine to be checked Che...

Page 399: ...r dirt or other materi al and remove any if found Take extreme care that the dirt does not fall into the hy draulic tank 6 Clean the removed parts by using cleaning oil 7 Install the new element in th...

Page 400: ...k G and air bleeding plug 1 4 Add oil through the pipe for dipstick G by the refill capaci ty 5 Check the oil level For the procedure see METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE ADDING O...

Page 401: ...eeding plug of the fuel filter head take care There may be remaining pres sure and fuel may spout out NOTICE Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filte...

Page 402: ...he filter head then tighten it 3 4 of a turn If the filter cartridge is fastened too much the packing will be damaged and this leads to leakage of fuel If the filter cartridge is too loose fuel will a...

Page 403: ...omatsu distributor to perform this work METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn...

Page 404: ...freezing of DEF or deposition of urea After the engine is stopped the devices are operated for a few minutes Replace the element after DEF system devices stop Improper assembly of DEF tank breather e...

Page 405: ...plug P perpendicular to the ground surface 2 Place the oil container to receive oil under plug P 3 Remove plugs P and F by using the handle and drain oil Check O rings attached to the plugs for damag...

Page 406: ...serious injury or death For handling always observe the following The pressure in the hydraulic circuit cannot be completely removed When removing the hydraulic equipment do not stand in the direction...

Page 407: ...obstacle in the surrounding area Check the nitrogen gas charge pressure as follows 1 Place the machine on a flat ground 2 Hold the work equipment in the maximum reach posture arm fully OUT bucket full...

Page 408: ...does not go down or stops in midway the charged pressure of the gas in the accumulator for the hy draulic circuit has probably dropped Ask your Komatsu distrib utor for inspection This completes the...

Page 409: ...tion A and then stop the engine 2 Turn the starting switch to ON position B 3 Set lock lever to FREE position F then operate the work equipment control levers and the attachment control pedal if equip...

Page 410: ...rty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil Therefore do not start the engine without the filter element The filter element cannot...

Page 411: ...er vapor in the blowby gas However if the coolant level is normal it is not a problem 3 Remove used O ring 6 sticking to case 4 and install a new O ring contained in the service kit Apply engine oil t...

Page 412: ...t of the body and tighten it with the hand firmly until it stops 7 By using the special wrench further tighten the ring 1 15 to 2 15 turns 1 to 2 ridges of the ring If the engine is operated with the...

Page 413: ...F filter may cause leakage of DEF Replace the DEF filter in the correct pro cedure After the engine is stopped DEF system devices automatically purge DEF in DEF injector and DEF pump and return it to...

Page 414: ...an take it out together with filter removal tool 3 If filter 6 cannot be removed from DEF pump grip filter removal tool 3 pull it down then it will be removed 7 Slide filter 6 down and remove spacer 5...

Page 415: ...er hose 3 Work equipment hydraulic system Main pump delivery hose Pump delivery hose Pump branch hose Main pump LS hose Hydraulic drive fan hose Intake fan Swing line hose Main suction hose External w...

Page 416: ...it Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disposing of it the gas...

Page 417: ...performed Ask your Komatsu distributor for replacement METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER Check fuel spray prevention caps 1 to 11 and fuel spray prevention...

Page 418: ...matsu distributor for replacement EVERY 5000 HOURS MAINTENANCE Maintenance for every 50 250 500 and 1000 hours service should be performed at the same time METHOD FOR CHANGING OIL IN HYDRAULIC TANK k...

Page 419: ...ame amount of oil can be drained from 2 pla ces by removing plug P from the tank bottom first and then plug A from the suction tube 7 Remove drain plug P from the tank bottom to drain the oil Check th...

Page 420: ...u distributor for replacement of the engine high pressure piping METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps EVERY 900...

Page 421: ...SPECIFICATIONS 5 1...

Page 422: ...360 F Tail swing radius mm 3645 G Overall length of track mm 5055 5385 H Distance between tumbler centres mm 4020 4350 I Height of handrail mm 3450 Min ground clearance mm 570 Travel speed Lo Mi Hi km...

Page 423: ...ging reach mm 12030 B Max digging depth mm 7755 C Max digging height mm 10980 D Max vertical wall digging depth mm 6805 E Max dumping height mm 7630 F Min dumping height mm 2970 G Max reach at ground...

Page 424: ...raulic pressure 37 3 MPa WORKING CONDITIONS WITH BUCKET 1914 kg IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM VALUES OF THIS TABLE...

Page 425: ...6 7m Boom PC490 11 SPECIFICATIONS SPECIFICATIONS 5 5...

Page 426: ...6 7m Boom PC490LC 11 SPECIFICATIONS SPECIFICATIONS 5 6...

Page 427: ...Pa WORKING CONDITIONS WITH BUCKET 1914 kg 2 4m 2 9m 3 4m Arm 1115 kg 4 0m Arm 1189 kg 4 8m Arm IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDU...

Page 428: ...7 1m Boom PC490 11 SPECIFICATIONS SPECIFICATIONS 5 8...

Page 429: ...7 1m Boom PC490LC 11 SPECIFICATIONS SPECIFICATIONS 5 9...

Page 430: ......

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

Page 432: ...leader and follow his her instructions Use a crane when handling heavy objects 25 kg or more The crane must be operated by a qualified operator Never go under a load raised by the crane Do not perform...

Page 433: ...t see the following EX PLANATION OF LIFT CAPACITY CHART 6 7M BOOM 5 4 EXPLANATION OF LIFT CAPACITY CHART 7 1M BOOM 5 7 should be taken into consideration For an attachment not intended to bear a load...

Page 434: ...valves 5 and 6 allow the attachment pressure and the release pressure for the quick coupler to be limited according to the coupler manufacturer s recommendation respectively Maximum cir cuit pressure...

Page 435: ...witch 1 in position B press and hold button 2 on the left hand lever to activate quick coupler REMARK When switch 1 and switch 2 are operated together a warning 3 on monitor appears to inform that the...

Page 436: ...al operation Slide the lock towards you then rock the switch The lamp on the switch will come on and a warning buzzer will sound 3 Depending on the design of the quick coupler it may be necessary to o...

Page 437: ...keep your machine in the best condition for long periods of time it is essential to follow the instructions in this Operation and Maintenance Manual Commercially available grease additives may be good...

Page 438: ...not be available with some specifica tions SYSTEM OPERATION The system performs all operations automatically When the starting switch is in the ON position the grease pump will at pre defined interva...

Page 439: ...essary Yellow lamp 5 flashing Minimum level in the reservoir has been reached Reset by filling the reservoir Red lamp 6 flashing System out of order Immediate action required Possible causes Insuffici...

Page 440: ...unit and its surroundings Attention avoid using high pressure wash directly on the pump 9 Replace or clean the pump filler filter behind the connector on the reservoir every 500 hours REFILLING GREAS...

Page 441: ...ing the machine or to vent the system a continuous lubrication cycle run can be performed 1 Move the starter switch to the ON position B 2 Depress the test button 9 on the pump for more than six secon...

Page 442: ...les if necessary Every time a test cycle is carried out grease is added to the grease points This will increase grease usage and can cause excessive greasing of the grease points AUTOMATIC GREASE SYST...

Page 443: ...n L mode The wire or sling may come off the hook depending on the working posture Pay sufficient attention to the hook angle so that the sling does not come off Never drive the machine while lifting a...

Page 444: ...ctor valve 3 Attachment control pedal 4 Lock pin 5 Additional filter for breaker 6 Accumulator 7 1st Attachment proportional control switch 8 2nd Attachment proportional control switch 9 Breaker switc...

Page 445: ...k k WARNING If you perform operations with your foot on the pedal the attachment may suddenly move if you de press the pedal by mistake and this may lead to serious personal injury or death Lock the p...

Page 446: ...ng the breaker use the working mode selector switch on the monitor switch portion to set the working mode to B mode and set the lock pin to position b when using the pedal When using the crusher use t...

Page 447: ...g If breaker operation is performed without having an accumulator installed the service life of the machine will be reduced Contact your Komatsu distributor for further information regarding the break...

Page 448: ...breaker mode switch to operate breaker and release to stop METHOD FOR CHANGE OVER AND CONNECT HYDRAULIC CIRCUIT FOR MACHINE READY FOR INSTALLATION OF ATTACHMENT NOTICE The return circuit when a breake...

Page 449: ...ped from the factory 20 6 MPa 210kg cm2 4 Maximum oil flow can be adjusted in user mode If ATT P or ATT E mode is turned on when the optional attachment is installed 1 Crusher circuit 2 way circuit is...

Page 450: ...switch according to the select ed working mode Depending on the attachment it is necessary to change the oil flow in the service circuit For setting of the flow see METHOD FOR OPERATING ATTACHMENT 6...

Page 451: ...METHOD FOR REMOVING AND INSTALLING ATTACHMENT k k WARNING Lower the attachment to the ground and stop the engine METHOD FOR REMOVING ATTACHMENT 1 Turn the starting switch to ON B position 2 Set the lo...

Page 452: ...ed store the attach ment 8 Pull out the mounting pins 2 places remove the attach ment then install the bucket For the installation procedure of the bucket see METHOD FOR REPLACING AND INVERTING BUCKET...

Page 453: ...equipment control lever and attach ment control pedal fully to the front rear right and left a few times within 15 seconds to release the internal pres sure in the hydraulic circuit 7 Set the lock le...

Page 454: ...d will suddenly increase Be careful If you perform operations with your foot on the pedal the attachment may suddenly move if you de press the pedal by mistake and this may lead to serious personal in...

Page 455: ...er the breaker mode 1 Press the working mode selector switch 1 The screen changes to the working mode selection screen 2 Press the working mode selector switch 1 or press switches F3 or F4 to select b...

Page 456: ...ulic oil when using the breaker is much faster than in the normal operations so check the maintenance time with MAINTENANCE SCHEDULE 4 12 When considering whether it is necessary to install an accumul...

Page 457: ...rting operations On Attachment Setting of the user menu it is possible to make the attachment mode inactive CHECK POINTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER ETC Is the stop valve in FREE pos...

Page 458: ...ting to allow 2 attachments The switch on left lever is a roller proportional control switch Rolling the switch up produces rotation in one di rection rolling down produces rotation in the opposite di...

Page 459: ...Always wear protective equipment such as protective eyeglasses and dust mask NOTICE For the element replacement interval see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 13 Items to be prepared Conta...

Page 460: ...n is completed replace the additional filter for breaker according to the following procedure METHOD FOR REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER 1 Loosen oil filler cap F slowly on the top of...

Page 461: ...truding part inside filter head 4 6 Fit new O ring 5 to filter case 2 and screw filter case 2 into filter head 4 7 After the top of filter case 2 touches the filter head tight en it further at least 1...

Page 462: ...se 1 Tightening torque 25 to 35 Nm 2 6 to 3 6 kgm SPECIFICATIONS Hydraulic specifications Max flow when merged 275 2 min Safety valve relief set pressure of service valve Port A 21 6 MPa 220 kg cm2 ot...

Page 463: ...ARM PIN INFORMATION A A B B KS000370 2 4 1 3 A A B B PC490 LC 11 1 370 mm 0 2 0 7 3 370 mm 1 0 0 0 2 100 mm 0 036 0 090 4 100 mm 0 036 0 090 ATTACHMENTS AND OPTIONS ARM PIN INFORMATION 6 33...

Page 464: ...ndercarriage Operate the boom carefully Categories of use Select a proper attachment for each use General digging Digging or loading sand gravel clay etc Light duty digging Digging and loading dry and...

Page 465: ...are in accordance with EN474 5 2006 A1 2009 E ROCK BUCKET SELECTION Rock bucket selection NOTICE Rock bucket is allowed with Heavy Duty specification only The values shown are based on 90 bucket fill...

Page 466: ...button return cancel 2 Navigation button up 3 Enter button 4 Navigation button left 5 Navigation button down 6 Navigation button right 7 Monitor display screen SYSTEM OPERATION The system is automatic...

Page 467: ...ons SYSTEM ERRORS The system automatically monitors for system abnormalities in the event of an error the monitor display screen 7 will display ERR and an audible intermittent buzzer will sound In the...

Page 468: ...shift down and travel at half speed in Lo C Extremely soft ground swampy ground Use the shoes only in places where the machine sinks and it is impossible to use A or B shoes These shoes cannot be use...

Page 469: ...e attachments or the models consult your Komatsu distributor HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows Crushing rock Road construction This attachm...

Page 470: ...of the chisel gradually deviates from the direction of the breaker body Adjust the direction with the bucket cylinder so that it keeps the proper direction Always keep the chisel pressed against the i...

Page 471: ...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 ATTACHMENTS A...

Page 472: ...th any cylinder at the stroke end Posture of hydraulic breaker to be greased NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt will...

Page 473: ...olding it in the right posture shown below Lower the chisel perpendicularly to the ground Insert the grease gun perpendicularly to the greasing point Wrong posture ATTACHMENTS AND OPTIONS RECOMMENDED...

Page 474: ......

Page 475: ...REPLACEMENT PARTS 7 1...

Page 476: ...perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses and replace defective hoses as required When replacing hoses always replace O rings...

Page 477: ...Cartridge 1 Every 500 hours Fuel prefilter 600 319 4800 Cartridge including O ring 1 Every 500 hours Hydraulic oil filter 208 60 71124 07000 15210 Element O ring 1 1 Every 1000 hours Breather of hydr...

Page 478: ...70 34191 Tooth Pin Lock 5 5 5 Horizontal pin type 208 70 14152 09244 03036 Tooth Pin 5 5 Side cutter type 208 70 34160 208 70 34170 Side cutter left Side cutter right 1 1 Shroud type 208 934 7132 113...

Page 479: ...ed must be ultra low sulfur diesel fuel 10ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled hig...

Page 480: ...draulic oil level Change power train oil Check power train oil level Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV fil...

Page 481: ...F tank 30 C 50 C DEF Note 6 Engine oil pan Swing machi nery case Final drive case each of right and left Damper case Hydraulic oil sys tem Cooling system Fuel Tank DEF tank Speci fied ca pacity 42 0 2...

Page 482: ...can be used continuously for 2 years or 4000 hours Non Amine Engine Coolant AF NAC is strongly recommended wherever available 2 For details of the density of Non Amine Engine Coolant AF NAC see METHOD...

Page 483: ...nditioner fresh recirc filter Clean 4 55 Air conditioner pilot lamp 3 35 Air conditioner recirculation air filter Clean 4 55 Air conditioner switch 3 51 3 222 Air conditioner system caution lamp 3 30...

Page 484: ...Control levers and pedals 3 98 Control pedals 6 15 Controls and gauges names 3 5 Coolant 3 252 Coolant Check level Add 3 150 Coolant and water for dilution 4 6 Cooling system Clean inside 4 20 Counter...

Page 485: ...ance 4 65 Every 250 hours maintenance 4 45 Every 4000 hours maintenance 4 75 Every 4500 hours maintenance 4 78 Every 50 hours maintenance 4 44 Every 500 hours maintenance 4 48 Every 5000 hours mainten...

Page 486: ...or s compartment 2 19 Inspecting machine 2 18 Introduction 1 8 Investigate and confirm jobsite conditions 2 26 J Jumper cable Connect 3 262 Jumper cable Disconnect 3 263 K KCCV filter element Replace...

Page 487: ...Method for checking before starting 3 145 Method for operation when using general attachment 1 e g crusher 6 27 Method for operation when using general attachment 2 e g clamshell rotation crusher rot...

Page 488: ...r machine or work equipment 2 44 Precautions related to attachments and options 2 24 Precautions related to cab glass 2 25 Precautions related to protective structure 2 23 Precautions to prevent fire...

Page 489: ...tter Replace 4 31 Sound balance Adjust 3 235 Sound control button 3 232 Space for radio cassette 3 236 Specifications 5 2 6 32 Spread and narrow track frame gauge 3 249 Stability 2 41 Standard tighten...

Page 490: ...lay 3 17 Washable floor Wash 4 35 Washable floor mat Clean 4 35 Water pump Check 4 75 Water separator Check Drain water and sediment 3 148 Wear well fitting clothes and protective equipment 2 18 Weldi...

Page 491: ......

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