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Komatsu PW98MR-10, Operation & Maintenance Manual

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Komatsu PW98MR-10 Operation & Maintenance Manual Download Page 302

Problem

Main causes

Remedy

The engine does not start even if the
key in the starting switch is turned to
START position and the starting mo-
tor rotates.

Defective engine controller power
supply circuit

Replace. (*)

Defective relay

Replace. (*)

Defective connector on engine side

Check and repair loose or discon-
nected connector or wire breakage.
(*)

PHENOMENA AND ACTIONS FOR CHASSIS

• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.

Problem

Main causes

Remedy

Speed of travel, swing, boom, arm,
bucket is slow

Lack of hydraulic oil

Set oil to specified level. See
CHECKS BEFORE STARTING.

Pump generates abnormal noise.
(sucking in air)

Clogged element in hydraulic tank
strainer, lack of oil

Clean. See EVERY 2000 HOURS
MAINTENANCE.

Excessive rise in hydraulic oil temper-
ature

Loose fan belt

Check fan belt tension and replace.

Dirty oil cooler

Clean. See EVERY 500 HOURS
MAINTENANCE.

Lack of hydraulic oil

Set oil to specified level. See
CHECKS BEFORE STARTING.

Boom rises slowly or does not rise.

Lack of hydraulic oil

Set oil to specified level. See
CHECKS BEFORE STARTING.

PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS

• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.

Problem

Main causes

Remedy

Engine oil pressure caution lamp
lights up.

Lowered oil level in engine oil pan
(sucking in air)

Set 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 AMBIENT
TEMPERATURE and KOMATSU
GENUINE LUBRICANTS.

Clogged oil filter cartridge

Replace cartridge. See EVERY 500
HOURS MAINTENANCE.

Oil leakage due to improper connec-
tion or breakage of oil pipe or pipe
joint

Check, repair. (*)

Defective engine oil pressure sensor

Replace sensor. (*)

Defective monitor

Replace monitor. (*)

TROUBLES AND ACTIONS

OPERATION

3-234

WENAM00061

Summary of Contents for PW98MR-10

Page 1: ......

Page 2: ......

Page 3: ...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 recomme...

Page 4: ...at If this manual is lost or damaged contact Komatsu or your Ko matsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For details re...

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

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

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

Page 8: ...rain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedul...

Page 9: ...Do not repeatedly handle and lift loads FOREWORD VIBRATION LEVELS 1 7 WENAM00061...

Page 10: ...EN ISO 6165 and including equipment and attachment working tool e g pro cessor or breaker specifically designed to demolish cut loosen separate pick up transport and distribute component parts of buil...

Page 11: ...s seat when the operator s seat is facing the forward direction VISIBILITY FROM OPERATOR S SEAT The visibility of this machine required by visibility standards ISO 5006 are shown in the drawing below...

Page 12: ...ews of which are blocked when the machine is equipped with the mirrors and other visibility assistant devices Be fully aware that there is an area where the operator cannot see when operating the mach...

Page 13: ...LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE This is on the left side of the mounting location of the swing bracket The design of the nameplate differs according to the dist...

Page 14: ...UMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address Komatsu Italia Manufacturing S p A Via Atheste 4 35042 Este PD Italy Distributor...

Page 15: ...SERIAL PLATE A SERIAL NUMBER E MACHINE DESIGNATION TYPE B OPERATING MASS F YEAR OF CONSTRUCTION C PRODUCT IDENTIFICATION NUMBER G ENGINE POWER D MANUFACTURER FOREWORD SERIAL PLATE 1 13 WENAM00061...

Page 16: ...rectives 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 by 2005 88 EC R...

Page 17: ...2 17 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 19 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 23 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 23 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRU...

Page 18: ...3 203 HANDLE RADIO 3 210 3 210 STOW ANTENNA 3 210 TRANSPORTATION 3 211 PRECAUTIONS FOR TRANSPORTING MACHINE 3 211 SELECT TRANSPORTATION METHOD 3 211 LOADING AND UNLOADING WITH TRAILER 3 212 METHOD FO...

Page 19: ...ING 4 35 EVERY 100 HOURS MAINTENANCE 4 35 EVERY 250 HOURS MAINTENANCE 4 38 EVERY 500 HOURS MAINTENANCE 4 45 EVERY 1000 HOURS MAINTENANCE 4 59 EVERY 2000 HOURS MAINTENANCE 4 67 EVERY 4000 HOURS MAINTEN...

Page 20: ...FUEL COOLANT AND LUBRICANT 7 5 LUBRICATION CHART 7 5 METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OIL...

Page 21: ...d 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 strictl...

Page 22: ...en cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones...

Page 23: ...LOCATION OF SAFETY LABELS 1 Combined safety information label a Warning for operation inspection and maintenance SAFETY SAFETY LABELS 2 3 WENAM00061...

Page 24: ...ce 12 Danger do not enter within swing range 13 Warning for operation inspection and mainte nance 14 Caution for high temperature 15 Caution do not start by short circuiting 16 Caution against falling...

Page 25: ...or closing the front window or when removing or installing the bottom window or when adjusting the opera tor s seat always lower the work equipment completely to the ground set lock lever 1 securely...

Page 26: ...the front or ceiling window never stand up from the operator s seat before throwing the safety lock lever to the lock position Inadvertently touching any of the working equipment control levers might...

Page 27: ...g Warning against high voltage cables An electrocution hazard if the machine is brought too near to electric power lines Keep a safe distance from electric power lines h Warning no passengers No pass...

Page 28: ...by error operation confirm the machine motion and indicated operating pattern when operating machines Pay attention to the circumference and operate slowly when confirming the machine motion Carefull...

Page 29: ...ised the control levers and pedals are dis abled With lock lever lowered and the street mode switch is ON the machine can travel With lock lever lowered the control levers and pedals are operating d W...

Page 30: ...ing ROPS 09620 J2001 09620 A3001 If any modification is applied to the ROPS it may affect the strength and may not comply with the standard ROPS may provide less protection if it has been structural l...

Page 31: ...ap when cooling water or hydraulic oil is at high tempera ture 10 Emergency exit 09844 00050 11 Caution stop rotation during inspection and maintenance 09667 A088B Sign indicates a hazard of rotating...

Page 32: ...portation 14 Caution for high temperature 09817 A0753 15 Caution do not start by short circuiting 09842 A0481 Prohibition of short circuit start 16 Caution against falling 09805 C0641 Sign indicates a...

Page 33: ...in place with lock pins 18 Caution for work equipment 09134 A0881 Keeping out of working range area Sign indicates a hazard of being hit by the working device of the machine Keep away from the machine...

Page 34: ...generate sparks b Always wear safety glasses when working with batteries c Keep children away from batteries d Caution battery acid e Read the operator s manual before working with batteries f Cautio...

Page 35: ...21 Lock front window 22P 00 11381 22 Lifting decal 21D 00 41170 SAFETY SAFETY LABELS 2 15 WENAM00061...

Page 36: ...PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the...

Page 37: ...se fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such a...

Page 38: ...ventilated areas for storing oil and fuel Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any...

Page 39: ...ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine always observe the following Use the handrails and steps marked by arrows in the figure on the when getting o...

Page 40: ...any oil grease or mud on them Wipe it off immediately not to slip if any In addition tighten any loose bolt of the handrails and steps If the handrails and steps are damaged or deformed they need to b...

Page 41: ...S SEAT Before standing up from the operator s seat such as when opening or closing the front window or ceiling window when re moving or installing the bottom window or adjusting the posi tion of the...

Page 42: ...se the window as an emergency escape For details see EMERGENCY ESCAPE HAMMER 3 114 in this manual When escaping remove all the pieces of glass from the window frame first and be careful not to cut you...

Page 43: ...guards according to the operating conditions on the job site Always contact your Komatsu distributor for advice In such a case do not operate the machine without an addi tional guard Be sure to consul...

Page 44: ...attachments always read the instruction manual for the attachment and the general information related to attachments in this manual PRECAUTIONS RELATED TO CAB GLASS If the cab glass is broken during...

Page 45: ...l PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse...

Page 46: ...r Only one signalman should give signals When working in dark places turn on the working lamp and head lamps installed to the machine and set up additional lighting in the work area if necessary Stop...

Page 47: ...no problem with the operation of the machine If these checks are not performed properly problems may occur with the operation of the machine and there is a danger which may lead to serious personal in...

Page 48: ...ing the engine starting circuit This may cause fire serious personal injury or death IN COLD WEATHER If the warm up operation is not performed thoroughly and the work equipment is operated the reactio...

Page 49: ...or s cab Prohibit anyone other than the operator to get on the ma chine If there are any people in the area around the machine there is danger that they may be hit or caught by the machine and this ma...

Page 50: ...work equipment may hit the ground and the machine may lose its balance or it may damage the machine or structures in the area When using the machine to prevent serious personal in jury or death caused...

Page 51: ...ng the machine up a steep slope extend the work equipment to the front to improve the balance keep the work equipment approximately 20 to 30 cm above the ground and drive it at low speed When driving...

Page 52: ...t from the uphill side to the downhill side when the bucket is loaded This opera tion is dangerous and may cause the machine to turn over If the machine has to be used on a slope pile the soil to make...

Page 53: ...S Snow covered or frozen surfaces are slippery so be extremely careful when driving or operating the ma chine and do not perform abrupt lever operation Machine may slip even on a slight slope Be parti...

Page 54: ...travel direction selection switch to neutral Engage the boom swing control pedal Set the lock lever 1 to LOCK position L Turn the starting switch to OFF position A Remove the starting switch key lock...

Page 55: ...cliff Never use the work equipment to load or unload the machine There is danger that the machine may fall or tip over Always use ramps of adequate strength Be sure that the ramps are wide long and t...

Page 56: ...ght of the ma chine being towed Never use the wire rope which has cut strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Always wear leather...

Page 57: ...ohibit anyone to enter into place where there is danger of contact with a raised load or the danger from a falling load All components in the load line eg chains shackles etc must be rated correctly f...

Page 58: ...y be damaged due to abnormal loading making it unsafe to lift Where possible the lifting operation should be carried out with the bucket curled in order to increase visibility and prevent any obstruct...

Page 59: ...d injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and avoid use of organic solvents for cleaning An organic solvent like benzene toluene or...

Page 60: ...ing off the starting switch wait for ap proximately 1 minute and press the horn switch If the horn does not sound power is not conducted Engage the safety lock of the boom swing control Put blocks und...

Page 61: ...m the ma chine in a stable condition so that they do not fall And take steps to prevent unauthorized persons from entering the storage area PRECAUTIONS FOR WORKING AT HIGH PLACES When working at high...

Page 62: ...rk equipment and machine are not supported they may come down and it may cause serious per sonal injury or death Never use concrete blocks for supports Concrete blocks may break under even light loads...

Page 63: ...ic 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 batt...

Page 64: ...RECAUTIONS FOR HIGH TEMPERATURE PARTS To prevent burns from touching high temperature parts when checking or performing maintenance after stop ping engine check the parts have been cooled down to touc...

Page 65: ...he specified torque If any damaged or deformed hoses or piping are found consult your Komatsu distributor Replace the hose if any of the following problems are found Damaged hose or deformed hydraulic...

Page 66: ...PRING This machine is equipped with an accumulator Even after the engine stops if the work equipment control lever is operated after stop of the engine in the direction to lower the work equipment the...

Page 67: ...strial waste products METHOD FOR SELECTING WINDOW WASHER FLUID Use an ethyl alcohol base washer liquid Methyl alcohol base washer liquid may irritate your eyes so do not use it PERIODIC REPLACEMENT OF...

Page 68: ...WENAM00061...

Page 69: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 WENAM00061...

Page 70: ...GENERAL VIEW MACHINE EQUIPMENT NAME 1 Bucket cylinder 2 Arm GENERAL VIEW OPERATION 3 2 WENAM00061...

Page 71: ...er 12 Dirt cover 13 Revolving lamp 14 High beams 15 Low beam Direction light 16 Rear view camera if equipped 17 Engine hood 18 Rear axle 19 Outriggers 20 Outriggers cylinder 21 Stop light Direction li...

Page 72: ...B EQUIPMENT NAMES 1 Front window 2 Ceiling window 3 Door handle 4 Emergency escape hammer 5 Fuse 6 Fire extinguisher if equipped 7 Cup holder 8 Radio box 9 Ashtray GENERAL VIEW OPERATION 3 4 WENAM0006...

Page 73: ...CONTROLS AND GAUGES NAMES OPERATION GENERAL VIEW 3 5 WENAM00061...

Page 74: ...Windscreen wash switch Main windscreen wiper switch Horn 30 Autocruise switch 31 Monitor 32 Steering wheel 33 Steering wheel height adjuster 34 2nd line attachment proportional switch 35 Horn push bu...

Page 75: ...switch 15 Working mode selector switch 16 ECO guidance 17 Seat belt pilot lamp 18 Engine stop pilot lamp 19 Parking brake pilot lamp 20 Work equipment lock pilot lamp 21 Lock lever automatic lock rele...

Page 76: ...37 Function switches 38 Caution lamp 39 Action level display 40 Camera image display REMARK The above figure does not show all of the caution lamp symbols For detail see WARNING DISPLAY FOR AB NORMAL...

Page 77: ...RK For the user menu used for setting various items of the machine on the machine monitor see USER MENU DISPLAY SWITCH 3 60 One of the features of liquid crystal display panels is that there may be bl...

Page 78: ...If when the engine is started the work mode is B the opening screen GG is displayed for 2 seconds and then passes to the screen II confirming the hammer mode If you want to start working with this mod...

Page 79: ...ngine shutdown sec ondary switch 1 see ENGINE SHUTDOWN SECONDARY SWITCH 3 101 BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION RKA47660 When the starting switch is turned t...

Page 80: ...reen changes to Check Before Starting screen BB If you input an incorrect ID number press switch F5 and clear an in put character at a time On Operator ID Input screen LL without SKIP press switch F1...

Page 81: ...e of security enhance ment Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person BASIC OPERATION OF MACHINE MON...

Page 82: ...etail of the error Current abnor mality screen is displayed BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE RKA47810 If any abnormality occurs during operation the stand...

Page 83: ...ine urgently stop or pause the current operation If no action is taken the machine can be seriously affected Take necessary actions immediately RKA47820 1 Caution lamp 2 Caution lamp 3 Caution lamp 4...

Page 84: ...re displayed RKA47830 1 Action level display 2 Caution lamp 3 Caution lamp Standard screen only meter display When 1 type of caution is generated it is displayed on caution lamp 2 When 2 types of caut...

Page 85: ...rk move the machine to a safe place and then ask your Komatsu distributor for inspection and maintenance L02 Sounds inter mittently Lights up in red Stop the work and run the engine at medium speed wi...

Page 86: ...draulic system caution lamp Abnormal L03 L04 Abnormal L01 Engine system caution lamp Abnormal L03 L04 Abnormal L01 Auto idle stop sudden stop caution lamp Abnormal L03 Abnormal L01 Oil pressure cautio...

Page 87: ...tem L03 RKA51880 Steering system caution lamp Abnormal L03 For the meaning of each caution lamp and the remedy to take for it see the section of each caution lamp CURRENT ABNORMALITY DISPLAY SWITCH If...

Page 88: ...y engine coolant temperature When abnormal The caution lamp lights up in red and indicates action level L02 The engine coolant temperature has risen abnormally high While this lamp is lit the overheat...

Page 89: ...tor for inspection and maintenance When action level L01 is displayed The warning lamp lights up in yellow Some functions may be restricted from use but the machine can operate However the machine can...

Page 90: ...e then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow The engine durability may be lower but the machine can operat...

Page 91: ...n level L01 The air conditioner system has abnormality Ask your Komatsu distributor for inspection and maintenance as soon as possible MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displ...

Page 92: ...that the machine is close to tipping due to the load an audible warning is also given When the indicator comes on together with a buzzer immedi ately lower the load Refer to the lifting capacity tabl...

Page 93: ...re are faults in the hydraulic quick coupling system When there is an abnormality The caution lamp lights up in red and the alarm buzzer sounds intermittently and indicates action level L03 Stop the m...

Page 94: ...display 13 Travel speed pilot lamp 14 Blade outriggers pilot lamp Meter display 15 Service meter clock 16 ECO gauge 17 Engine coolant temperature gauge 18 Hydraulic oil temperature gauge 19 ECO guida...

Page 95: ...s the state of the swing parking brake cancel switch The pilot lamp display when the swing parking brake cancel switch is operated is as follows Pilot lamp flashes Swing parking brake cancel switch ON...

Page 96: ...hines ready for installation of attachments ATT P ATT P mode for operations of 2 way attachments like crusher etc ATT E ATT E mode for operations of 2 way attachments like crusher in emphasis of fuel...

Page 97: ...s stopped It goes out when the engine is started BLADE OUTRIGGERS PILOT LAMP The blade outriggers indicator indicates which attachment is selected Grey background attachment not selected Blue backgrou...

Page 98: ...guidance are as follows Idling Stop Guidance If no operation is performed for more than 5 minutes and the engine is idling the idling stop message is displayed on the monitor When waiting for work or...

Page 99: ...evention system is actuated as follows Red range A position Engine coolant temperature caution lamp E shows abnormality display Red range B position Engine speed changes to low idle engine coolant tem...

Page 100: ...range A the hydraulic oil temperature is as follows Red range A position 102 C or more Red range B position 105 C or more When the indicator is in red range A to B hydraulic oil temperature caution la...

Page 101: ...nning the service 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...

Page 102: ...l environment Perform energy saving operations in the green range Travel less frequently It also helps to save energy Consider the best way of operation for saving energy FUEL CONSUMPTION GAUGE Fuel c...

Page 103: ...ars switch the display to camera and indicators or just indicators to check the errors STEERING MODE DISPLAY The top part of the display displays the indicator lights that signal the type of steering...

Page 104: ...dicators signalling the steering mode show the type of steering that has been selected When the machine has met the required conditions for the type of steering selected the background colour changes...

Page 105: ...to 4WS R since the steering change mode errors have not been resolved RKA52050 It is not possible to go from 2WS to 4WS C since the steering change mode errors have not been resolved RKA52060 It is no...

Page 106: ...the wheels are aligned the light disappears ALIGN FRONT WHEELS PILOT LAMP The front wheels alignment indicator alarm comes on with a red light and signals that the front wheels are not aligned To can...

Page 107: ...ghts the state of the wheel alignment Green with wheels enlarged wheels aligned Yellow wheels not aligned DISPLAY SIGNALLING TRAVELLING ON ROADS The lower part of the display shows the indicators that...

Page 108: ...ive RKA54510 Red Error Erroneous street mode configuration because the turret is not aligned RKA54520 Red Error Erroneous street mode configuration because the 2WS mode is not selected RKA54530 Red Er...

Page 109: ...tor on with yellow light B C axle locking is in AUTO mode When the service brake is used the indicator C becomes yel low and axle locking is activated When the service brake is not used the indicator...

Page 110: ...nds continuously Deactivate the travelling on street mode and align the turret When the indicator switches off and the blue indicator comes on at the top of the monitor comes on activate the travellin...

Page 111: ...alarm buzzer sounds intermittently Take the machine to a safe place deactivate the travelling on street mode align the rear wheels and activate the travelling on street mode again MONITOR SWITCHES RK...

Page 112: ...even if it is pressed Even if guidance icon 2 is pressed it does not function Press function switch 1 directly under guidance icon 2 to operate the function When the monitor display shows the standard...

Page 113: ...to the left end I Switch F3 Moves to the item below forward When on the last line it moves to the first line J Switch F4 Moves to the item above backward When on the first line it moves to the last li...

Page 114: ...the working mode selector screen is displayed on the monitor For each set mode P E L B ATT P and ATT E are displayed at the top right of the monitor dis play For machines ready for installation of at...

Page 115: ...eceleration OFF Each time the switch is pressed the auto deceleration is switched between ON and OFF REMARK When the travelling on street mode is set the auto deceleration function is automatically ac...

Page 116: ...lamp lights up When the auto deceleration is OFF the indication lamp goes out SWITCH FOR INCREASING TRAVEL SPEED The travel speed increase selector switch is used to change the speed in turn from CR t...

Page 117: ...hine must be at a standstill with the service brake pressed The passage from CR to LO can be carried out at any time If the service brake is not pressed correctly the warning indica tor shown in the f...

Page 118: ...the selected speed remains the same as the one set before the machine stopped During loading and unloading operations from a trailer always use the speed CR Before switching the travel speed from HI...

Page 119: ...engine is started the mode remains the same as the one set when the engine stopped To correctly activate the street mode the following conditions need to be met The steering mode should be 2WS a The...

Page 120: ...the warning item where there is an abnormality REMARK The system does not let you silence the buzzer for certain warnings or indications This is not a system error AIR CONDITIONER SWITCH The air condi...

Page 121: ...attachment is selected When the indicator has a green background the attachment is operating In the outriggers blade mode screen it is possible to carry out the operations through buttons from F1 to F...

Page 122: ...tial screen To deselect press the key corresponding to the attachment keys F1 F2 F3 Machine with front outriggers Press button F1 to use the front left outrigger Press button F2 to use the front right...

Page 123: ...anging the camera image display on the monitor On standard screen AA the camera image is always displayed on the left part of the monitor On standard screen AA when switch F3 is pressed camera image f...

Page 124: ...K raised position when switch F3 is pressed on camera image full screen display NN message screen PP is displayed and no camera image is displayed On message screen PP when switch F3 is pressed or whe...

Page 125: ...s possible to operate the following modes The air conditioner can be operated When the air conditioner switch is operated the screen switches to A C Setting screen When the screen switches to A C Sett...

Page 126: ...h is pressed the cam era image display screen does not switch to another screen or return to the standard screen display For the auto deceleration switch see AUTO DECELERA TION SWITCH 3 47 Press the b...

Page 127: ...ing if no lever is operated for 10 seconds or more the screen automatically returns to the standard screen When the screen returns to the standard screen the cau tion lamp at the top left of the scree...

Page 128: ...b Machine settings c Maintenance d Monitor Setting e Mail Check These menus a to e are for setting and confirming the fol lowing items For operations in each menu see the detailed explanation pages of...

Page 129: ...e Mail Check Check of mail contents and reply to mail On the user menu screen it is possible to perform the following operations with switches F1 to F6 F1 Moves to the left menu When on the left end...

Page 130: ...rgy Saving Guidance menu a is used for displaying and setting the notification relevant to energy saving Check of Operation Records Check of ECO Guidance Records Check and reset of Average Fuel Consum...

Page 131: ...id ance menu screen then press switch F6 On the ECO Guidance Records menu display the frequency of display of the ECO guidance on a daily basis or during the split measurement period Operations on ECO...

Page 132: ...ta F2 Switches graphical displays of the average fuel consump tion F5 Returns the screen to Energy Saving Guidance menu screen REMARK The displayed value of fuel consumption may differ from the actual...

Page 133: ...available Setting Average Fuel Consumption Display Switching ECO Gauge Display Non display Setting ECO Gauge Display Fuel Target Value Switching ECO Guidance Display Non display Switching ECO Guidance...

Page 134: ...ible to change the display of fuel consumption gauge 5 and the setting of Display Non display 1 Select Average Fuel Consumption Display 6 from Con figurations screen then press switch F6 RKA48230 EXPL...

Page 135: ...ng Guidance menu a screen to Operation Records 1 screen or ECO Guidance Records 2 screen then press the measurement stop switch F1 STOP On this screen it is possible to perform the following oper atio...

Page 136: ...urns the screen to Configurations screen SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE It is possible to change the target fuel consumption value the upper limit value of the green range of...

Page 137: ...r ations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first li...

Page 138: ...item 1 line below When on the last 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...

Page 139: ...F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels the se...

Page 140: ...e as you like You can use alphabet letters A to Z Arabic numerals 0 to 9 symbols and and the space 1 On Breaker Setting screen select a breaker to change its name then press switch F6 2 The Breaker Na...

Page 141: ...ect Attachment Setting 3 on Machine Setting b screen then press switch F6 2 On Attachment Setting screen shown in the figure select an attachment to adjust and press switch F6 On Attachment Setting sc...

Page 142: ...creen It is not possible to change the name for No Attachment setting Changing 2 Way Attachment Oil Flow Rate Setting 1 Select an attachment to change its oil flow on Attachment Setting screen then pr...

Page 143: ...gure and then press switch F6 On the Auto Idle Stop Timer Setting screen shown in the figure you can perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When...

Page 144: ...function is ON the number of the times that the engine was stopped when it was not at low idle the engine speed is 1400 rpm or higher is displayed as L01 at and after 1000 and as L03 at and after 2000...

Page 145: ...perated for 30 seconds on the Maintenance menu screen the screen automatically returns to the standard screen When the maintenance time caution lamp is lit on the standard screen press F6 on the stand...

Page 146: ...tor Screen Adjustment Screen Adjustment Camera Clock Adjustment Language Operator ID SCREEN ADJUSTMENT Use Screen Adjustment menu to adjust brightness of the monitor screen 1 Select Screen Adjustment...

Page 147: ...velling on street mode 1 Select Screen Adjustment Camera 2 on Monitor Set ting menu screen then press switch F6 Adjusting the brightness of the camera s screen 1 Select Screen adjustments camera 3 the...

Page 148: ...returns to Screen Adjustment Camera screen CLOCK ADJUSTMENT Clock Adjustment menu is used to change the setting of the clock displayed on the standard screen of the monitor 1 Select Clock Adjustment...

Page 149: ...ted CALENDAR SETTING Adjust the date of the monitor REMARK As long as GPS Synchronization menu is turned on Calendar menu is not selectable 1 Select Calendar b on Clock Adjustment screen then press sw...

Page 150: ...he switches as follows to change hour display D If it is not necessary to change the hour setting press switch F6 F3 The time goes back 1 hour F4 The time advances 1 hour F5 Cancels change and returns...

Page 151: ...t time 1 Select Daylight Saving Time e on Clock Adjustment screen then press switch F6 2 The Daylight Saving Time screen is displayed F3 Moves to the next item 1 line below Moves to the top line when...

Page 152: ...item above F5 Cancels change and returns to the Monitor Setting screen F6 Accepts change and returns the screen to the Monitor Setting screen OPERATOR ID You can check and change the Operator ID whic...

Page 153: ...be changed A message is displayed below and the screen returns to Monitor Setting menu screen On Monitor Setting menu screen the inputted ID is displayed in the column of Operator ID When you press sw...

Page 154: ...not changed WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is available without SKIP the identified ID number is not displayed in Operator ID...

Page 155: ...is distinguished as follows according to the lighting states of message display 1 Lights up in green A There is unread message Lights up in blue B There is any read message to which no reply is made O...

Page 156: ...rmation menu e The selected item number is written in place 5 of the message text Input the number by using the monitor panel switch Each switch corresponds to the value shown on the right side below...

Page 157: ...SWITCHES OPERATION EXPLANATION OF COMPONENTS 3 89 WENAM00061...

Page 158: ...er operation switch 30 2nd line attachment proportional switch 31 Horn push button 32 Rototilt extra if equipped 33 Quick coupler switch if equipped 34 Not used 35 Axle lock quick lock 36 Not used 37...

Page 159: ...to reach the maximum travel speed set by the hand throttle and press the direction switch a The light c comes on and the drive pedal locks in place To deactivate the system just press the brake pedal...

Page 160: ...f the control panel and the dipped beam headlamps a The lights are off and the control panel lighting is off daytime mode b The position lights come on and the control panel lighting is on night mode...

Page 161: ...rns to OFF position A Start the engine immediately by turning the key to START position C REMARK If the lock lever is not at LOCK position L the engine does not start Check that the lock lever is at L...

Page 162: ...r resolving activation errors 4WS C SWITCH The switch is used to engage or block the activation of the crab steering 4WS C a Activating the 4WS crab mode 4WS C b Blocking the activation of the steerin...

Page 163: ...agement of the parking brake is displayed on the moni tor Each time that it is engaged the machine monitor displays the icon a enlarged for 2 seconds After 2 seconds the monitor returns to a normal di...

Page 164: ...CH The breaker operation switch is on the right PPC valve lever and it is used to operate the breaker For handling of the breaker control switch see BREAKER OP ERATION SWITCH 6 10 BLADE OUTRIGGERS CON...

Page 165: ...sound the horn ROTOTILT EXTRA SWITCH if equipped The Rototilt operation switch is on the left PPC valve lever and it is used to operate the Rototilt extra AXLE LOCK QUICK LOCK NOTICE The switch is loc...

Page 166: ...n any problem occurs on the pump control system Do not use it except for emergency Repair the problem as soon as possible If this switch is moved to emergency position by mistake while the machine is...

Page 167: ...set back b Normal When normal switch is set forth PARKING BRAKE RELAY DEACTIVATION SWITCH The switch allows you to release the parking brake if there is a fault with the relay a Disconnecting the park...

Page 168: ...bnormal and emergency condition Repair the problem as soon as possible For details of the lock lever automatic lock function see LOCK LEVER 3 103 The switch for annulling the automatic locking levers...

Page 169: ...sition by mistake while the ma chine is operating normally Engine Shutdown Secondary SW in Operation is displayed on the machine monitor If Engine Shutdown Secondary SW in Operation is displayed on th...

Page 170: ...screen is displayed return the engine shutdown secondary switch to normal position b QUICK COUPLER SWITCHES In order for the hydraulic attachment to work the switch on the left instrument panel and t...

Page 171: ...the control levers or control switches are touched by mistake it may lead to serious personal injury or death Always check that the lock lever is in LOCK position When pulling the lock lever up or wh...

Page 172: ...equipment or machine in all situations Even if the lock lever automatic lock function works the work equipment or machine may not stop immediately or may stop after moving by a certain distance Also t...

Page 173: ...Non compliance with these rules may lead to serious accidents Select the forward F or backward R direction with the selec tor switch on the right joystick Operate the pedal gradually in order to avoi...

Page 174: ...the braking efficiency Do not press the brake pedal suddenly when moving down a steep slope since the wheels may slip Before travelling on roads make sure that the lever beside the pedal is locked in...

Page 175: ...y until reach ing the connection position C C Working brake position Apply the working brake to block the machine when working with digging equipment To release the working brake press the upper part...

Page 176: ...oom swing control pedal a Swing RIGHT b Swing LEFT N NEUTRAL Boom is held at current position WORK EQUIPMENT CONTROL LEVERS The left work equipment control lever is used to operate the arm and upper s...

Page 177: ...osition If the lock lever is at FREE position and the control lever control pedal or control switch is touched by mistake it is dangerous and may cause serious personal injury or death When opening or...

Page 178: ...er to LOCK position L 3 Check that the windshield wiper is in the right position 4 Hold two handles A on the right and left top sides of the front window and pull two levers B to release the locks at...

Page 179: ...dow Do not pull up the front window with the handles A 6 Check that lever B is securely at LOCK position If the arrow on lock case F matches the position of the arrow on lever B the lock is engaged Ch...

Page 180: ...h to the front then lower slowly REMARK The handles A on the right and left sides of the front win dow top are not for pulling up and down the window Do not pull up the front window with the handles A...

Page 181: ...de window REMARK If sand or dust is collected at the bottom of the front win dow lower side it will be difficult to remove the window In addition when stowing the sand and dust stuck to the glass will...

Page 182: ...oid opening or closing the door on the ramps or trailer platform because the operating effort may sud denly change Be careful not to get your hands caught between the front pillar or center pillar If...

Page 183: ...ch key to open and close the locks on the covers For the locations of the lockable covers see LOCK 3 191 Insert the key as far as it will go to the shoulder A If the key is turned before it is inserte...

Page 184: ...there is a danger that the ashtray may break POWER SUPPLY OUTLET NOTICE When installing an electrical component which is not a product of Komatsu limit its capacity to maxi mum 240 W in the 24 V spec...

Page 185: ...2 to 3 Parts No Ko matsu 08056 00212 08056 00230 08055 00040 08055 00041 08055 00060 08055 00061 12V 24V power sources When cigarette lighter A is removed the lighter socket can be used as a power sou...

Page 186: ...t names F01A Fuses No Fuse A Name of circuit 1 5 Redundant resistor working lamp switch 2 30 Solenoid valves 3 5 PPC hydraulic lock solenoid 4 10 Window washer Cigarette lighter 5 10 Horn 6 5 Free 7 1...

Page 187: ...he rear left of the operator s seat After using spare fuses replenish them immediately One spare fuse is installed for each 5 A 10 A 20 A 25 A and 30 A FUSIBLE LINK NOTICE When replacing the fusible l...

Page 188: ...F02 22U 06 11270 2 45 A Continuous power supply F03 20T 06 81230 3 120 A Alternator F05 421 06 22830 Preheating F06 CONTROLLER NOTICE Do not let water mud or beverage spill on the controller This will...

Page 189: ...connect switch is turned to OFF position 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 positio...

Page 190: ...r mount ed on the machine is turned ON System operating lamp 1 lights up in green when the control ler is turned ON and goes out in a few minutes after the starting switch is turned to OFF position Be...

Page 191: ...ble radio communication The GPS Global Positioning System receiver and communication system are equipped in the vehicle man agement system The machine information such as the machine maintenance maint...

Page 192: ...is machine equipped with KOMTRAX or using it in a foreign country The KOMTRAX may already have been registered and used if the machine is purchased as second hand For the registration and usage record...

Page 193: ...om the areas around the engine battery and radiator Check for dirt accumulated around the engine and radiator Also check for flammable material dry leaves twigs etc around the battery engine muffler o...

Page 194: ...ge to the rear view mirror If it is damaged repair it Clean the surface of the mirrors and adjust the angle so that the operator can see the rear lower area from the operator s seat 11 Check the seat...

Page 195: ...1 For details see METHOD FOR OPENING ENGINE HOOD 3 192 2 Lock securely with hood support lever 2 3 Check if the red piston is protruded at the arrow portion of dust indicator 3 4 If the red piston is...

Page 196: ...ompletely then fol low the procedure to drain the water REMARK If transparent cup 4 is dirty or it is difficult to see the inside clean transparent cup 4 when replacing fuel pre filter cartridge 3 Whe...

Page 197: ...hing the drained fuel 9 Set valve 7 to OPEN position O METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very h...

Page 198: ...r port F 4 Remove the cap of oil filler port F gradually to re lease the internal pressure 5 Remove the cap of oil filler port F 6 Add oil through oil filler port F until the oil level comes between l...

Page 199: ...care 1 Open dirt cover 1 on the right side of the machine 2 Lock securely with hood support lever 2 3 Check reservoir tank 3 If the coolant level is within the range between FULL and LOW the coolant...

Page 200: ...H decrease it to a proper level according to the following procedure 1 Place a container under drain plug P at the bottom of the engine oil pan to catch the oil 2 Drain excessive engine oil through dr...

Page 201: ...d wipe it up completely If fuel has spilled over soil or sand remove that soil or sand Fuel is highly flammable and dangerous Never bring any open flame near fuel 1 Turn the starting switch to ON posi...

Page 202: ...ponents Do not dry up the refilling pump Monitor the fuel level during refilling in order to avoid pump dry up Check that the filter placed at the end of the pipe is clean In case of malfunction of th...

Page 203: ...utton 6 to start filling and press it again to in terrupt it When the floating switch reaches its maximum level the pump stops automatically If the button 6 is not pressed to interrupt the filling or...

Page 204: ...After checking turn the starting switch back to OFF position If the lamps do not light up a broken bulb or disconnected wire are the possible causes Ask your Komatsu distributor for repairs Method for...

Page 205: ...ore starting each operation or when the operators change shift Adjust the operator s seat so that control levers and switches can be operated freely and easily with the operator s back against the bac...

Page 206: ...t height It is possible to move the seat up or down by combining adjustments forward tilt and rear tilt After setting the forward tilt or rear tilt to the desired height operate the opposite part to s...

Page 207: ...ance with the weight of operator and select optimum suspension level NOTICE To obtain the optimum adjustment turn the knob so that the indicator of the weight display kg in the transparent portion of...

Page 208: ...o the maximum 2 Rotate the support 1 of the mirrors so that it is perpendic ular in relation to the cabin 3 Adjust the mirror A so that the side of the machine is re flected in the mirror as shown in...

Page 209: ...anding at a distance of 1 m from the machine 1 Adjust the mirror so that the rear side of the machine is re flected in the mirror as shown in the figure If mirror does not move smoothly when adjusting...

Page 210: ...height of the steering wheel 2 Unscrew the steering wheel s lock nut anti clockwise 2 After adjusting tighten the steering wheel s lock nut clockwise 2 METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE k k...

Page 211: ...the monitor is not aligned correctly adjust mounting angle A of the rear view camera in the following procedure Angle A can be adjusted within the range from 30 to 60 deg 1 Insert a flat head screwdri...

Page 212: ...angle A of the camera to about 45 with re spect to the horizontal plane 5 After adjusting tighten bolts 5 Tightening 11 8 to 14 7 Nm 1 2 to 1 5 kgm REMARK A part of the machine is shown on the monito...

Page 213: ...It is the start of the 5 year period It is not the start of the 3 year period of actual usage This seat belt has a winding device so it is not necessary to adjust the length Fasten seat belt 1 Hold gr...

Page 214: ...right D switches of the joysticks to prevent the neutral detection system from recognising the position derived from shifting as that of neutral 1 Check that battery disconnect switch S is in ON posit...

Page 215: ...nput screen is displayed on the monitor input the ID number and press input confirmation switch F6 3 For detail see WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP 3 84 REMARK Contact you...

Page 216: ...h has exceeded the maintenance interval and perform maintenance immediately For details see MAINTENANCE SCREEN SETTING 3 76 METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL WEATHER k k...

Page 217: ...o start the engine again 1 Check that lock lever 1 is at LOCK position L If lock lever 1 is in FREE position F the engine does not start 2 Check that the driving direction selection switch is in neu t...

Page 218: ...o out even after 4 to 5 seconds have passed stop the engine immediately Check the oil level check for leakage of oil and take the necessary action METHOD FOR STARTING ENGINE IN COLD WEATHER k k WARNIN...

Page 219: ...engine again When the ambient temperature is low start the engine according to the following procedure 1 Check that lock lever 1 is at LOCK position L If lock lever 1 is in FREE position F the engine...

Page 220: ...e control levers or control pedal while the engine oil pressure caution lamp is lit If the engine oil pressure caution lamp does not go out even after 4 to 5 seconds have passed stop the engine immedi...

Page 221: ...he warm up operations for the hydraulic equipment and engine separately Warm up of the hydraulic equipment thoroughly ensures that the hydraulic oil is warmed up and that warm hydraulic oil circulatin...

Page 222: ...s will have an adverse effect on the environment and also on the internal structure of the engine If it is neces sary to run the engine at idle for 20 minutes or more apply a load from time to time or...

Page 223: ...d C is white If the engine coolant temperature caution lamp displays the proper temperature the engine warm up operation is completed Then perform the warm up operation for the hydraulic components ME...

Page 224: ...y for the circuit between the pump and cylinders and between the pump and motor but also for the control circuits Avoid carrying out the op eration for just one cylinder or engine or in just one di re...

Page 225: ...ork equipment control lever 4 slowly in the direction to pull in bucket D Operate the lever to the end of its travel and hold it in position for 30 sec onds 2 Move right work equipment control lever 4...

Page 226: ...e is low Caution lamp background C is white If engine coolant temperature caution lamp 1 displays low temperature perform warm up operation until the proper temperature is displayed For detail see MET...

Page 227: ...value Display A when temperature is proper Caution lamp background C is blue Display B when temperature is low Caution lamp background C is white If hydraulic oil temperature caution lamp 6 is displa...

Page 228: ...perate the boom move the right joystick backwards or forwards Bucket control To operate the bucket move the right joystick right or left 2 piece boom control Press the control pedal to operate the 2 p...

Page 229: ...ic oil temperature caution lamp 6 displays the proper temperature the hydraulic equipment warm up operation is completed After checking that hydraulic oil temperature caution lamp 6 displays the prope...

Page 230: ...economy conscious operations RKA48167 L mode For operations requiring fine control RKA48166 B mode For breaker operations RKA48165 ATT P mode For operations of 2 way attachment such as crusher RKA481...

Page 231: ...gine abruptly except the case in an emergency If the engine is overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it Stop the engine...

Page 232: ...tion pedal is activated the engine speed is increased abruptly and therefore as a result par ticular attention must be paid Check that the travel alarm works properly If the travelling on street mode...

Page 233: ...3 50 Slow speed to be used when it is necessary to move the machine with precision the speed is limited to 4 km h Low speed to be used when working on uneven terrain on steep slopes the speed is limi...

Page 234: ...accumulators runs out it is possible to brake five times If there is a problem with the service brake it is possible to stop the machine using the parking brake switch 4 1 Release the drive pedal 1 2...

Page 235: ...ting lamp and obscure or switch off the work lights Make sure that the turret is directed towards the front swing axle NOTICE The travelling direction must be selected with the en gine at low rpm and...

Page 236: ...ngage the boom swing control pedal 2 9 Check that the outriggers or the blade have been raised and that the work equipment are raised from the ground by at least 40 50 cm 10 Check that the work brake...

Page 237: ...adjusting the engine rpm with the hand throttle Autocruise activation k k WARNING The operator must be seated in the driving position with fastened seat belt Comply with all the road traffic regulati...

Page 238: ...ck the turret alignment and align it if necessary For detail see TURRET ALIGNMENT INDICATOR 3 42 10 Check the alignment of the rear wheels and align them if necessary For detail see INDICATOR FOR SIGN...

Page 239: ...STEERING WHEEL 3 142 METHOD FOR SWINGING MACHINE k k WARNING Before swinging machine make sure that there is no one within its operating range and that there are no obstacles in the surrounding area...

Page 240: ...e arm Swing control Move the L H work equipment control lever to the right and left The upper structure swings Boom control Move the R H work equipment control lever back and forth You can operate the...

Page 241: ...ngine is stopped if the starting switch key is turned to ON position within 15 seconds after stopping the engine and the lock lever is set to FREE position it is possible to use the lever operation to...

Page 242: ...any mode except the breaker mode 1 Press working mode selector switch 1 The screen changes to working mode selection screen 2 Press the working mode selector switch or function switch F3 or F4 to sele...

Page 243: ...reduces the life of the machine PROHIBITION OF OPERATIONS USING TRAVEL FORCE Do not use the travel force to perform excavation by digging the bucket into the ground This damages the machine or work eq...

Page 244: ...et back to a rock and use it as a lever to dig This can apply an excessive force to the chassis and buck et and the machine may break In this case dig by using only the force of the arm or bucket If a...

Page 245: ...ION ON HARD ROCKY GROUND Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it after breaking up by some other means This will not only save the mac...

Page 246: ...chine around them or take other steps to avoid traveling over such obstacles as far as possible If there is no way to avoid traveling over an obstacle reduce the travel speed keep the work equipment c...

Page 247: ...ADE Be careful not to hit the blade against rocks or boulders This will cause premature damage to the blade or cylinders PRECAUTIONS FOR BLADE POSITION DURING BACKHOE OPERATION When digging in front o...

Page 248: ...uld be taken to avoid risks for the operator and anyone in the vicinity Always respect the following precautions Swinging operations or operating the work equipment on slopes machine may lose its bala...

Page 249: ...if the wheels slip or it is impossible to travel uphill do not use the pulling force of the arm to help the machine travel uphill Always check the work area for snow landslips gravel loose ground and...

Page 250: ...ground Do not raise with the teeth in contact with the ground The angle between the boom and arm should be 90 to 110 deg The same applies when using the bucket installed in the reverse direction 1 Us...

Page 251: ...fferences depending on the excavation depth but try to stay within the above range rather than operat ing the cylinder to the end of its stroke SHOVEL WORK A shovel is suitable for excavating at a pos...

Page 252: ...efficiency can be enhanced by locating the dump truck in a place easily visi ble to the operator Loading is easier and capacity becomes greater if you stop the machine at the rear of the dump truck t...

Page 253: ...cillate and pose a risk to objects and persons as well as to the machine itself Position the machine on a solid and flat terrain Ensure that the work area is free from obstacles and that there are no...

Page 254: ...pins be extremely careful not to get your fingers caught Never insert your fingers into the pin holes when aligning the holes Stop the machine on a firm and flat surface and do the work When performin...

Page 255: ...l with a new one if it is damaged If a damaged seal is used without being replaced sand and dirt may enter the pin portion and cause abnormal wear of the pin Invert k k WARNING When reversing a bucket...

Page 256: ...o hole 1 and hole 2 respectively REMARK Fit O ring 3 to mounting portion 1 of arm 5 and bucket 4 Fit O ring 3 to arm 5 as shown in the figure since it is damaged easily when bucket 4 is installed Afte...

Page 257: ...CK position before leaving the operator s seat Lower the blade and or the outriggers to the ground on the downhill side Check that the turret is facing the oscillating front axle and align the turret...

Page 258: ...the starting switch to OFF position A Remove the starting switch key lock the cab door and the front window and always take the key with you and keep it in the specified location METHOD FOR CHECKING...

Page 259: ...these places METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pull ing the cov...

Page 260: ...hen driving the machine always keep the engine hood closed unless you are inspecting NOTICE Always keep the hood locked unless you need to open it You can see if the cover is locked by checking the di...

Page 261: ...er 3 from the hood fixing position 2 Securely fix hood support lever 3 to the lever lock 3 Lower and press the hood slowly to lock it securely 4 Insert the key into the key slot 5 Turn the key clockwi...

Page 262: ...s keep the cover locked unless you need to open it You can see if the cover is locked by checking the direction of the key slot of the cover knob METHOD FOR OPENING DIRT COVER 1 Insert the key into th...

Page 263: ...OR OPENING AND CLOSING BATTERY INSPECTION COVER k k CAUTION When inspecting or servicing the inside of the cover be sure to fix the cover open by using the cov er support lever When operating the mach...

Page 264: ...m hole 6 of the bottom cover 2 Insert cover support lever 4 into cover mounting hole 5 3 Close cover 3 slowly 4 Insert the key into key slot 1 5 Turn the key clockwise and remove it METHOD FOR OPENING...

Page 265: ...Position B LOCK Lock 1 Close the cover and insert the key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key RKA48870 OPERATION MACHINE OPERATIONS AND CONTROLS 3...

Page 266: ...is low the air condi tioner may not work In this case circulate recirculation air to warm the inside of the cab After that turn the air condi tioner switch ON the air conditioner will work If any abno...

Page 267: ...for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH You can adjust the air flow b...

Page 268: ...t temperature is indicated on the display monitor The temperature is generally set at 25 C 77 F The temperature can be set in stages of 0 5 C 0 9 F Monitor display and function Monitor display Set tem...

Page 269: ...atically selected A Rear vent 2 places B1 Face vent 1 place B2 Foot vent 1 place C Foot vent 1 place D Front window glass vent 2 places Air blows out from the vents marked with Monitor display Air ven...

Page 270: ...selector switch to switch the air source between recirculation of the air inside the cab and in take of fresh air from the outside During automatic operation the selection of inside air RE CIRC and ou...

Page 271: ...d SUNLIGHT SENSOR Sunlight sensor automatically adjusts the flow of air from the vents to match the strength of the sun s rays In addition it au tomatically detects changes in the temperature inside t...

Page 272: ...ally selected according to the set temperature and the air conditioner is operated auto matically to provide the set temperature REMARK When d or e is displayed in vent c if the engine coolant tempera...

Page 273: ...this time check that set temperature a and air flow rate b are displayed on A C Setting screen of the moni tor 2 Press air conditioner switch 8 to turn it ON 3 Press temperature control switch 3 to se...

Page 274: ...monitor changes according to the selection 5 Press FRESH RECIRC selector switch 6 and select recir culation of the air inside the cab RECIRC or intake of fresh air from outside FRESH METHOD FOR STOPPI...

Page 275: ...this time check that set temperature a and air flow rate b are displayed on A C Setting screen of the moni tor 2 Press vent selector switch 4 and set the vent display as shown in the figure 3 Press a...

Page 276: ...ck that set temperature a and air flow rate b are displayed on A C Setting screen of the moni tor 2 Press vent selector switch 4 and set the vent display to f or g shown in the figure 3 Press FRESH RE...

Page 277: ...hat the air blows onto the window glass Vents C and D are fixed and cannot be adjusted 6 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumid...

Page 278: ...at the re placement of the battery the clock may be initialized In such a case set it again For handling of the battery disconnect switch see BATTERY DISCONNECT SWITCH 3 121 RADIO MUTE SWITCH The swi...

Page 279: ...safety SELECT TRANSPORTATION METHOD When transporting the machine choose the transportation method in reference to the weight and dimensions shown in SPECIFICATIONS 5 2 Note that the weight and dimens...

Page 280: ...amps do not operate any lever except for the travel lever It is dangerous to use the work equipment for loading and unloading operations Always use ramps The center of gravity of the machine will chan...

Page 281: ...istance from the road shoulder Loading machine on the trailer 1 Apply the trailer brakes securely then put chocks 1 under the tires to prevent the trailer from moving 2 Set right and left ramps 2 para...

Page 282: ...the forward gear F and move slowly 10 When the machine is positioned stop it put it in neutral N and turn the turret 180 degrees 11 Lower the blade and or the outriggers 12 Extend the bucket and arm...

Page 283: ...ood at one end of the bucket cylinder 1 to prevent it touching the floor 2 Secure the machine in the correct position by putting wedges 2 before and behind each wheel 3 Secure the machine with tie dow...

Page 284: ...rom moving 2 Set right and left ramps 2 parallel to each other and equally spaced to the right and left of center 3 of the trail er Make angle of installation 4 a maximum of 15 deg If the ramps bend a...

Page 285: ...speed Each time auto deceleration switch is pressed it switches OFF to ON to OFF in turn When auto deceleration switch is turned OFF the auto de celeration pilot lamp goes out 8 Raise the work equipm...

Page 286: ...chine horizontal When performing lifting operations do as follows to prevent the machine from moving unexpected ly Operate the work equipment lock lever to LOCK position Set the swing lock cover in LO...

Page 287: ...eck the hook condition and the lifting posture and then sling the machine slowly Lifting the machine without outriggers and blade k k WARNING The pins used for lifting must be fit in their seat with s...

Page 288: ...Lifting the machine with blade Hook up the chains to the blade 3 as shown RKA52600 RKA52610 TRANSPORTATION OPERATION 3 220 WENAM00061...

Page 289: ...nt change interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR CLEANING INSIDE OF COOLING SYSTEM 4 18 BATTERY k k WARNING The battery generates flammable gas Do not bring any op...

Page 290: ...hine on a firm dry ground If this is not possible position it on wooden planks to avoid the wheel icing on the ground thus making starting up difficult next morning Open the drain valve and drain any...

Page 291: ...n Amine Engine Coolant AF NAC to give a density of at least 30 for the engine coolant MAINTENANCE DURING LONG TERM STORAGE k k WARNING If it is necessary to perform the rust prevention operation while...

Page 292: ...information and radio tuning information may be lost In this case set the information again In this case set the information again Check the tyres pressure When starting the engine warm it up suffici...

Page 293: ...it in and out until the movement becomes heavy REMARK It is not necessary to remove the plugs at the fuel prefilter head and at the fuel main filter head 3 Push in and tighten the knob of feed pump 1...

Page 294: ...rawbar used for towing has ample strength for the weight of the ma chine being towed Never use a wire rope which has breaks in strands A reduced diameter B or kinks C There is a danger that the rope m...

Page 295: ...the screws or the safety split pins and couple the chain to the pin Method of towing the machine with outriggers Fit a suitable pin 3 in the hole indicated and keep it in the housing with the screws o...

Page 296: ...then consult a doctor for medical treat ment When handling batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the ground normally...

Page 297: ...nting hardware 9 and mounting bolts 8 Allowable tightening torque of mounting bolt 9 8 to 19 6 Nm 1 to 2 kgm 7 2 to 14 5 lbft 3 Install cable 6 on the positive terminal side 4 Connect connecting cable...

Page 298: ...l of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery...

Page 299: ...h a 24 V battery The sizes of the jumper cables and clips should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the ca...

Page 300: ...er cables in the reverse of the order in which they were con nected 1 Remove the clip of jumper cable B from the revolving frame E of the failed machine 2 Remove the clip of jumper cable B from the ne...

Page 301: ...sufficient battery charge Charge battery Preheating pilot lamp does not light up Defective wiring Check repair Defective heater relay Replace Defective monitor Replace Oil pressure caution lamp does n...

Page 302: ...eplace Dirty oil cooler Clean See EVERY 500 HOURS MAINTENANCE Lack of hydraulic oil Set oil to specified level See CHECKS BEFORE STARTING Boom rises slowly or does not rise Lack of hydraulic oil Set o...

Page 303: ...HOURS MAINTENANCE Defective thermostat Replace thermostat Loosened radiator filler cap in high altitude operation Tighten cap or replace packing Defective monitor Replace monitor Starting motor rotate...

Page 304: ...g the pump secon dary drive switch to upper emergency position For de tails of the switch see PUMP SECONDARY DRIVE SWITCH 3 98 After that immediately ask your Komatsu distributor for in spection and r...

Page 305: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 WENAM00061...

Page 306: ...osition and after confirming that the system operating lamp is turned off set the battery disconnect switch key to OFF position and pull it out Do not apply a voltage higher than 200 V continuously Co...

Page 307: ...rtened and they may be damaged CHECKS AFTER INSPECTION AND MAINTENANCE If you forget to perform the inspection and maintenance unexpected problems may occur and this may lead to personal injury Always...

Page 308: ...handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry of such impurities Take particular care not to le...

Page 309: ...such as corrosion of the engine and aluminum parts of the cooling system When using antifreeze always observe the precautions given in Operation and Maintenance Manual Non Amine Engine Coolant AF NAC...

Page 310: ...t the oil is well mixed before sampling Perform sampling at regular fixed intervals Do not perform sampling on rainy or windy days when water or dust can get into the oil For further details of KOWA c...

Page 311: ...the operator s cab with water When washing the machine be careful not to let water get into the electrical components When removing the connectors of electrical components after washing the machine or...

Page 312: ...lbft 6 8 10 12 14 10 13 17 19 22 13 3 31 67 111 172 1 35 3 2 6 8 11 3 17 5 9 8 22 8 48 8 81 4 127 11 8 to 14 7 27 to 34 59 to 74 98 to 123 153 to 190 1 2 to 1 5 2 8 to 3 5 6 to 7 5 10 to 12 5 15 5 to...

Page 313: ...NF 19 44 4 5 32 5 35 to 54 3 5 to 5 5 25 3 to 39 8 11 16 16UN 22 74 7 5 54 2 54 to 93 5 5 to 9 5 39 8 to 68 7 13 16 16UN 27 103 10 5 75 9 84 to 132 8 5 to 13 5 61 5 to 97 6 1 14UNS 32 157 16 0 115 7 1...

Page 314: ...METHOD FOR CHECKING GAS SPRING 4 30 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 4 31 METHOD FOR CHECKING WHEEL NUT TIGHTENING 4 33 METHOD FOR CHECKING AND ADJUSTING TOE IN 4 33 METHOD FOR BLEEDING...

Page 315: ...ARANCE 4 75 METHOD FOR REPLACING KCCV FILTER ELEMENT 4 75 EVERY 4000 HOURS MAINTENANCE 4 78 REPLACE DEFINED LIFE PARTS 4 78 METHOD FOR CHECKING WATER PUMP 4 79 METHOD FOR REPLACING ACCUMULATORS FOR CO...

Page 316: ...REMARK Breaker operating ratio 100 means that only the breaker is used Breaker operating ratio 0 means that the breaker is not used MAINTENANCE SCHEDULE TABLE MAINTENANCE 4 12 WENAM00061...

Page 317: ...rear axle oil Change the front axle oil For details about the replacement method see the section MAINTENANCE EVERY 1000 HOURS INITIAL 500 HOURS MAINTENANCE ONLY AFTER THE FIRST 500 HOURS Only for mach...

Page 318: ...ner cannot display its normal per formance and the cleaning effect decreases 3 Check if the red piston is projected into the transparent part of dust indicator 3 If the red piston is projected clean t...

Page 319: ...tap it or hit it against something Do not use the element with damaged pleats or a damaged gasket or seal Wrap an unused element and keep it in a dry place 6 Replace element 0 2 MPa 2 1 kg cm2 or less...

Page 320: ...procedure 1 Set a new outer element 7 2 Align matchmarks 11 on the body and cover 6 3 Install cover 6 and fix it with clip 5 10 Press the button of dust indicator 3 and return the red piston Replace e...

Page 321: ...nstall the new in ner element k k CAUTION When installing the cover 6 check O ring 10 for scratches or damages and replace O ring with a new one if any 6 Install cover 6 according to the following pro...

Page 322: ...2 years or every 4000 hours whichever comes sooner The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the us...

Page 323: ...t into drainage ditches or drain it onto the ground surface Non Amine Engine Coolant AF NAC is already diluted with distilled water so it is not flammable For dilution water see HANDLE OIL FUEL COOLAN...

Page 324: ...Open drain valve 8 at the bottom of the radiator 10 Remove drain plug 9 of the cylinder block and drain the coolant 11 After draining the coolant close drain valve 8 12 Tighten drain plug 9 and add ci...

Page 325: ...nt control lever slowly in the direction arm OUT position A Operate the lever to the end of its stroke and hold it in the position for 30 seconds Repeating the operations from step 1 to 4 moves the po...

Page 326: ...the work equipment in a stable condition stop the engine and set the lock lever securely to LOCK position As the pin is driven out with strong force it is dangerous that the pin may fly out Check that...

Page 327: ...s diameter than that of the pin to be extracted 4 Clean the mounting surfaces and insert the ring 3 in the slot of the tooth holder 4 5 Insert the new tooth 2 in the tooth holder partially push the pi...

Page 328: ...djust it by tightening bolts 2 5 Tighten bolts 2 4 pieces If bolts 2 are too stiff to tighten pull out pin stopper bolt 5 for easier tightening METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL ADDING FLU...

Page 329: ...motor fan Operating condition does it make ab normal noise When required Control mechanism Operating condition does it function normally When required Piping mounts Mounting condition looseness at ti...

Page 330: ...at the 3 places in the figure If mud etc is stuffed the door does not move smoothly If the door does not slide smoothly due to stuffed mud etc clean and grease the sliding door rail 1 and roller 2 ME...

Page 331: ...perform the operation When opening the front window hold the handle securely with both hands pull up and do not let go until the lock catch is locked When closing the front window the window will mov...

Page 332: ...lbft METHOD FOR WASHING WASHABLE FLOOR On the washable cab floor it is possible to flush out the dirt directly with water k k WARNING Select a firm flat place for work When setting the machine at an a...

Page 333: ...essary reposition plug 2 and the mat Machines with blade NOTICE During the operation be careful not to get water on the monitor connector air conditioner and its filter inside the operator s cab 1 Sto...

Page 334: ...ng is charged with high pressure nitrogen gas so improper handling may cause an explo sion resulting in serious personal injury or death When handling always observe the following Do not disassemble D...

Page 335: ...pring METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT If necessary see the paragraphs for starting the engine and moving steering stopping the machine in OPERA TION section Bleeding air from pump Perfo...

Page 336: ...roke end 3 Operate each cylinder 3 to 4 times to each stroke end 4 Operate each cylinder 4 to 5 more times to each stroke end All air is bled Bleeding air from swing motor Perform it only when the oil...

Page 337: ...heel toe in is due to impacts or vibrations that depend on the type of surface on which the machine works Another reason that should lead the operator to perform this check is abnormal wear of the fro...

Page 338: ...mm wrench 3 Tighten the bleed screw 1 4 Bleed the front and rear braking units one after the other following the same procedure METHOD FOR UNLOCKING PARKING BRAKE k k WARNING In case of failure in the...

Page 339: ...Hydraulic Tank Adding Oil Method For Checking Coolant Level Adding Coolant Method For Checking Oil Level In Engine Oil Pan Adding Oil Method For Checking Electric Wiring Method For Checking Fuel Leve...

Page 340: ...may cause burn injury Accordingly wait until they have cooled down before starting the work Prepare a container to receive oil 1 Loosen bolt 1 and move cover 2 2 Pull out dipstick 6 3 Wipe off the oi...

Page 341: ...he used grease that may have spread out of the joints METHOD FOR LUBRICATING PARKING BRAKE CYLINDER The lubrication points are located on the parking brake cylinder levers 1 Perform cleaning the greas...

Page 342: ...ther side up 1 Remove the protection 1 2 Perform cleaning the grease nipples 3 By using a grease pump apply grease to the grease fit tings marked by arrows 4 Remove the used grease that may have sprea...

Page 343: ...he rubber cover to prevent a fire while taking care not to roll it up If the rubber cover rolls up and blocks the fuel cooler the fuel cooler may overheat Put the rubber cover under the fuel cooler If...

Page 344: ...to its original position REMARK If the purified water is added to above UPPER LEVEL U L line remove the fluid by using a syringe to lower the level to UPPER LEVEL U L line Neutralize the removed flui...

Page 345: ...water tighten cap 2 securely 7 Return rubber cover 1 to its original position REMARK If distilled water is added beyond the lower point of the sleeve use a syringe to remove the electrolyte Neutral i...

Page 346: ...4 When the compressor is positioned fix it by tightening bolts 10 and 11 5 Check again if the belt tension is appropriate Adjust it again if it is not within the proper range 6 Check each pulley for b...

Page 347: ...pin 2 points 7 Blade arm fulcrum pin 2 points 8 Blade cylinder head pin 2 points 9 Tie rod blade coupling pin 2 points 10 Arm blade coupling pin 2 points 3 After greasing wipe off any old grease that...

Page 348: ...ole 2 Use a 12 mm wrench METHOD FOR CHECKING THE OIL LEVELS IN THE REAR AXLE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Accordin...

Page 349: ...he lubricant reaches the hole 1 2 If necessary restore the level through the hole 1 Use a 17 mm wrench EVERY 500 HOURS MAINTENANCE Maintenance for every 100 and 250 hours should be performed at the sa...

Page 350: ...ing to the following procedure 1 Set the boom to the swing neutral position and supply grease to the pin 2 Swing the boom to the left stroke end and supply grease to the pin 3 Swing the boom to the ri...

Page 351: ...wo piece boom articula tion 3 points 16 Two piece boom cylinder head pin 1 point 17 Two piece boom cylinder base pin 1 point 3 After greasing wipe off any old grease that is pushed out METHOD FOR CHAN...

Page 352: ...ge of oil 9 When installing the new filter cartridge apply clean engine oil or grease to its packing and thread portion When installing the cartridge tighten it until the packing surface contacts the...

Page 353: ...ering ability When replacing parts Komatsu recommends using Komatsu genuine parts The common rail fuel injection system used on this machine consists of more precise parts than those in the convention...

Page 354: ...ace then install it to the filter head NOTICE When filling the filter cartridge with fuel do not re move cap B Always fill with fuel from 8 small holes A on the dirty side After filling with fuel remo...

Page 355: ...y damage or pinched for eign material on the packing surface is found replace it with a new cartridge and repeat steps 9 to 16 to install it METHOD FOR CHECKING SWING PINION GREASE LEVEL ADD GREASE 1...

Page 356: ...Always wear personal protective items such as protective eyeglasses and dust mask NOTICE When using compressed air for cleaning blow it keeping some distance as perpendicular to the core as possible t...

Page 357: ...side 11 Spread and clean the condenser NOTICE At this time take care that forces are not applied to the tube part of the air conditioner hoses If any tube part is broken the refrigerant is released an...

Page 358: ...cover with cover support lever 3 4 Remove filter 2 5 Clean filter 2 with compressed air If there is oil on the filter or if the filter is extremely dirty wash it in a neutral detergent After rinsing...

Page 359: ...e the cap of oil filler port F gradually to release the internal pressure 5 Remove the cap of oil filler port F 6 Remove nut 6 of breather 5 and then remove cover 7 7 Replace filter element 8 with a n...

Page 360: ...wrench handle 1 Retract the arm and bucket cylinders completely extend the two piece boom cylinder completely and lower the boom until the bucket teeth rest on the ground Lower the blade to the ground...

Page 361: ...nd fix it with bolt 5 METHOD FOR CLEANING THE ELECTRIC COMMUTATOR OF THE ROTATING JOINT k k WARNING Only use the product approved by Komatsu Ask your Komatsu distributor for further information After...

Page 362: ...jury or death or damage When handling always observe the fol lowing The pressure in the hydraulic circuit cannot be completely removed When removing the hydraulic equipment do not stand in the directi...

Page 363: ...t for the temperature to go down and start the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pressure then remove it NOTICE If the machine is equip...

Page 364: ...o be set between the hydraulic tank and cover 5 If the O ring is damaged replace it 15 Place valve 7 and spring 6 onto the element 16 Set cover 5 in position and install it with the bolts while pressi...

Page 365: ...vel in the swing machinery case Check that the oil level is between H and L of dipstick G For the oil level check procedure see METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE ADDING OIL 4 36 7...

Page 366: ...oned on level ground and at operating temperature so that the oil becomes fluid and can be easily drained which facilitates the elimination of any suspended solid particles Differential 1 Loosen the c...

Page 367: ...arts and oil are still very hot and may cause burn injury Wait until they have cooled down before starting the work This operation must be carried out with the machine positioned on level ground and a...

Page 368: ...he horizontal axis 4 Add oil of the prescribed type until reaching the lower edge of the hole itself 5 Put back the filler cap 3 and carry out some travel move ments stop the machine and check the lev...

Page 369: ...f the hole of oil level check plug G 7 Install oil level check plug G and the plug of oil filler port F 8 Install undercover 1 METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE k k WARNING After the eng...

Page 370: ...ion system Never use a substitute When performing the inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt sticks to any part use fuel to wash it of...

Page 371: ...ain filter head When the engine runs out of fuel use the same proce dure to operate feed pump 6 and bleed the air 11 After bleeding air push in the knob of feed pump 4 and tighten it 12 After replacin...

Page 372: ...ds are generated which deposit on the fil ters and clog them The maximum concentration of ordinary oil must not exceed 1 of the total quantity of oil NOTICE NOTICE If the machine is equipped with a hy...

Page 373: ...of the machine 10 Place the oil container under drain plug P at the bottom of the machine 11 Remove drain plug P to drain the oil by using the socket wrench handle When removing drain plug P be caref...

Page 374: ...level is between H and L lines on sight gauge G For the method of checking the oil level see METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 3 129 21 Install the cap of oil filler port F 22...

Page 375: ...ing Do not hit or roll them or subject them to any impact When disposing the gas must be released Ask your Komatsu distributor for replacement of the belt NOTICE If the nitrogen gas charge pressure in...

Page 376: ...d the work equipment in the maximum reach posture arm fully out bucket fully dumped at height 1 5 m from the ground 3 Perform the following procedure within 15 seconds REMARK After the engine stops th...

Page 377: ...omatsu distrib utor for inspection This completes the inspection After completion of the inspection set the lock lever to LOCK position and turn the starting switch to OFF position Method for releasin...

Page 378: ...he work equipment control levers and the attachment control switch fully to the front rear left and right to release the pressure in the control circuit 4 Set lock lever to LOCK position to lock the w...

Page 379: ...TICE If the engine is operated without the filter element the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by su...

Page 380: ...1 2 Move loosened bolt 3 and nut 4 along the groove of el bow 2 to position A shown in the figure 3 By using the filter wrench loosen cover 7 of KCCV venti lator 1 At this time tube 5 and hose 6 rotat...

Page 381: ...2 pieces fitted to the top and bottom of the new element and insert the element into the body REMARK You can install the element with either side up 6 Replace O ring 10 of ventilator body 8 with new...

Page 382: ...l system Fuel hose Spill hose Ask your Komatsu distributor for replacement 2 Engine lubrication system Turbocharger lubrication hose Engine oil filter hose 3 Work equipment hydraulic system Main pump...

Page 383: ...he oil spurts out when performing the operation In addition loosen the bolts slowly when performing the operation Do not disassemble Do not bring them near flame or dispose of them in fire Do not perf...

Page 384: ...RUBBER The fuel spray prevention caps 10 places on the fuel injection piping and both ends of the high pressure piping act to prevent the fuel from coming into contact with high temperature parts of t...

Page 385: ...equipped with a hydraulic breaker the hydraulic oil deteriorates faster than in the normal bucket digging operation Accordingly perform maintenance referring to MAINTENANCE INTERVAL FOR HYDRAULIC BREA...

Page 386: ...of the machine 10 Place the oil container under drain plug P at the bottom of the machine 11 Remove drain plug P to drain the oil by using the socket wrench handle When removing drain plug P be caref...

Page 387: ...level is between H and L lines on sight gauge G For the method of checking the oil level see METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 3 129 21 Install the cap of oil filler port F 22...

Page 388: ...WENAM00061...

Page 389: ...SPECIFICATIONS 5 1 WENAM00061...

Page 390: ...tal length with rear blade 5940 6070 B Overall height mm 3860 3900 C Total width with blade mm 2350 2350 D Wheelbase mm 2200 2200 E Boom distance mm 2670 2800 F Rear outriggers distance mm 960 960 Rea...

Page 391: ...ax dumping height mm 6330 6525 C Max digging depth mm 4055 4305 D Max vertical wall digging depth mm 3415 3650 E Max digging reach mm 7585 7835 F Max digging reach at ground level mm 7290 7560 G Min s...

Page 392: ...RKA55390 SPECIFICATIONS SPECIFICATIONS 5 4 WENAM00061...

Page 393: ...m h 9 4 Forward fast HI km h 32 5 Reverse slow CR km h 4 1 Reverse low speed LO km h 9 4 Reverse fast HI km h 32 5 Inflation pressure for individ ual tyres 18 19 5 16 PR bar 4 5 18 19 5 16 PR MITAS ba...

Page 394: ...A Reach from swing centre B Bucket hook height 1 Position of lifting point 2 Arm length 3 Boom length 4 Hydraulic pressure 26 5 MPa OF Lifting capacity rating overfront OS Lifting capacity rating ove...

Page 395: ...y load limited by hydraulic capacity rather than tipping With blade and outriggers arm L 1900 twin tyre Unit kg A Max 6 0 m 5 0 m 4 0 m B 4 5 m 1070 690 1240 830 1460 1220 1580 1580 3 0 m 910 580 1200...

Page 396: ...1270 1 5m 1240 730 1590 920 2260 1300 With rear blade arm L 1650 twin tyre Unit kg A Max 6 0 m 5 0 m 4 0 m B 4 5 m 1220 720 1300 770 1550 1150 1720 1720 3 0 m 1040 590 1270 750 1750 1060 2370 1550 1...

Page 397: ...1460 1180 1580 1580 3 0 m 890 540 1180 760 1630 1080 2230 1580 1 5 m 850 520 1110 700 1500 960 0 m 920 570 1080 670 1440 900 2040 1270 1 5m 1160 730 1460 920 2080 1300 With front blade arm L 1650 twin...

Page 398: ...not exceed 87 of hydraulic capacity or 75 of tipping capacity load limited by hydraulic capacity rather than tipping With blade and outriggers arm L 1900 twin tyre Unit kg A Max 6 0 m 5 0 m 4 0 m B 4...

Page 399: ...1360 1620 1620 3 0 m 1400 660 1550 900 1810 1260 2290 1840 1 5 m 1420 630 1720 840 2160 1140 0 m 1390 690 1750 810 2290 1080 3140 1520 1 5m 1280 880 1990 1100 2730 1550 With rear outriggers arm L 190...

Page 400: ...m 1280 880 1990 1100 2730 1550 With front blade arm L 1650 twin tyre Unit kg A Max 6 0 m 5 0 m 4 0 m B 4 5 m 1570 850 1540 910 1600 1340 1760 1760 3 0 m 1520 710 1620 890 1890 1250 2430 1810 1 5 m 150...

Page 401: ...m 5 0 m 4 0 m B 4 5 m 1570 1070 1540 1140 1600 1600 1760 1760 3 0 m 1520 910 1620 1110 1890 1540 2430 2230 1 5 m 1500 870 1760 1060 2220 1430 0 m 1470 950 1740 1050 2290 1380 3140 1950 1 5m 1330 1220...

Page 402: ...WENAM00061...

Page 403: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1 WENAM00061...

Page 404: ...llow his her instructions Use a crane when handling heavy objects 25 kg or more 55 1 lb or more The crane must be operated by a qualified operator Never go under a load raised by the crane Do not perf...

Page 405: ...k k WARNING When calculating the allowable mass of attachments the mass of the bucket see the following LIFTING CA PACITIES 5 6 For an attachment not intended to bear a load for example a breaker it s...

Page 406: ...ure If in doubt consult the manufacturer of the coupler Read the instruction manual of the quick coupler carefully and follow the recommendations If in doubt about the installation or operation consul...

Page 407: ...lock The switch has a safety lock mechanism to prevent accidental operation Slide the lock towards you then rock the switch The lamp on the switch will come on NOTICE Operation will only take place i...

Page 408: ...on Pay particular attention to the hoses and fittings at the arm end as these can be damaged easily In case of damage or leakage of oil stop work Loss of oil could lead to the bucket or attachment fal...

Page 409: ...ulic system The quick coupler will move to released position 4 Position the quick coupler in the mating portion of the bucket or attachment moving the bucket cylinder arm and boom as necessary Follow...

Page 410: ...g on the posture of the work equipment there is a danger that the wire or load may slip off the hook Al ways be careful to maintain the correct hook angle to pre vent the slipping off Never drive the...

Page 411: ...itch 4 2nd line attachment proportional switch 5 Additional filter for breaker 6 Accumulator for low pressure SELECTOR VALVE The selector valve switches the flow of the hydraulic oil Position a When u...

Page 412: ...IONAL FILTER FOR BREAKER The additional filter for breaker prevents deterioration of the hy draulic oil when using a breaker The oil flows only when the selector valve is set in the breaker position A...

Page 413: ...eed the air according to that procedure 1 Start the engine For details see METHOD FOR STARTING ENGINE 3 148 Run the engine at low idle for 10 minutes and then start the following work 2 To bleed all a...

Page 414: ...tion F 4 Operate each control lever work equipment travel and attachment control switch fully in each direction within 15 seconds after the engine is stopped to release the internal pressure in the hy...

Page 415: ...plugs to outlets 2 places The plugs are used to prevent the attachment from making incorrect operation caused by mixing in of foreign matter After the plugs are correctly installed store the attach m...

Page 416: ...3 186 2 Place the attachment on a horizontal place install pin A and then pin B in this order to the arm 3 Lower the attachment to the ground and stop the engine 4 Turn the starting switch to ON posi...

Page 417: ...on within 15 seconds after the engine is stopped to release the internal pressure in the hydraulic circuit 7 Set the lock lever to LOCK position L 8 Turn the starting switch to OFF position A RKA52830...

Page 418: ...ion of flow of the oil and be careful not to make any mistake After installing the attachment check the oil level in the hydraulic tank METHOD FOR OPERATING ATTACHMENT k k WARNING If the travel levers...

Page 419: ...hes F3 or F4 to select Breaker Mode B Breaker mode B is highlighted in yellow 3 With breaker mode B highlighted in yellow enter the selec tion by performing either of the following operations Hold dow...

Page 420: ...FOR OPERATING GENERAL ATTACHMENT SUCH AS CRUSHER ETC Operate attachment 1 proportional switch The attachment operates CHECK POINTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER ETC Is the working mod...

Page 421: ...draulic specifications Flow rate Attachment mode 125 min Breaker mode 80 min Cracking pressure of safety valve When breaker is used 17 2 MPa 175 kg cm2 When another attachment is used 19 6 MPa 200 kg...

Page 422: ...loss or damage resulting from the use of unauthor ized attachments or parts will not be the responsibility of Komatsu INSTALL ATTACHMENT k k WARNING Depending on the type or combination of work equipm...

Page 423: ...chments or the models consult your Komatsu distributor HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows Crushing rock Road construction This attachment ca...

Page 424: ...e chisel gradually deviates from the direction of the breaker body Adjust the direction with the bucket cylinder so that it keeps the proper direction Always keep the chisel pressed against the impact...

Page 425: ...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 AND OP...

Page 426: ...y cylinder at the stroke end Posture of hydraulic breaker to be greased NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt will enter...

Page 427: ...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 ATTACH...

Page 428: ...WENAM00061...

Page 429: ...REPLACEMENT PARTS 7 1 WENAM00061...

Page 430: ...portant to ensure that these parts maintain their full performance at all times Furthermore should anything abnormal be found on any of these parts replace it with a new one even if the periodic repla...

Page 431: ...connection hose Boom cylinder hose Arm connection hose Arm cylinder hose 1st and 2nd boom connection hose 2 piece boom hose Bucket cylinder hose Travel line hose Attachment additional line hose Blade...

Page 432: ...ment Part No Part Name Q ty Replacement in terval Engine oil filter 600 211 2111 Cartridge 1 Every 500 hours of operation Fuel prefilter 600 319 4110 Cartridge 1 Hydraulic tank breather 421 60 35170 E...

Page 433: ...haracteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system Since the high pressure fuel injection device r...

Page 434: ...level Change power train oil Check power train oil level Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter METHOD...

Page 435: ...UTTO FLUID 68 F 100 Hydraulic circuit Hydraulic oil 20 C 50 C HO46 HM KES Hydraulic system with synthetic bio degradable oil Synthetic biode gradable oil 20 C 40 C B046 G4 Grease fitting Hyper grease...

Page 436: ...n Amine Engine Coolant AF NAC 1 The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of coolant is ess...

Page 437: ...up operation Cancel 3 155 Avoid mixing oil 4 3 Axle lock quick lock 3 97 Axle lock switch 3 94 B Backhoe work 3 182 Basic operation of machine monitor 3 10 Basic operation of machine monitor when sta...

Page 438: ...rget fuel consumption value 3 68 ECO guidance 3 30 ECO guidance record Check 3 63 Economy mode Adjust 3 71 Electric wiring Check 3 132 Electrical system Phenomena and actions 3 232 Electromagnetic int...

Page 439: ...3 97 Hydraulic breaker 6 21 Hydraulic circuit 6 11 Hydraulic circuit Bleed air 4 31 Hydraulic circuit Connect 6 11 Hydraulic oil filter element Replace 4 59 Hydraulic oil temperature caution lamp 3 2...

Page 440: ...onitor Operate when operator identifica tion function is available without skip 3 86 Machine monitor equipment name 3 7 Machine operations and controls 3 125 Machine ready for installation of attachme...

Page 441: ...lding 2 42 4 2 Precautions for working at high places 2 41 Precautions for working on slopes 3 180 Precautions for working under machine or work equipment 2 42 Precautions related to attachments and o...

Page 442: ...5 Steering wheel 3 106 Steering wheel Adjusting 3 142 Steering wheel column position adjuster 3 105 Stop engine before performing inspection and main tenance 2 39 Stopper Check clearance in opening fr...

Page 443: ...and gas spring 2 46 When operating on slopes 2 32 When required 4 13 Window washer fluid Check level Add 4 24 Window washer fluid select 2 47 Window washer switch 3 91 Work equipment Lubricate 4 45 W...

Page 444: ...F10003 WHEELED EXCAVATOR Form No WENAM00061 2016 KOMATSU All Rights Reserved Printed in Japan 07 2016 WENAM00061...

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