Komatsu WA380-8 Page 58 Operation & Maintenance Manual Download | Manualshive

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• Do not smoke or bring any open flame close to the battery.
• Hydrogen gas is generated when the battery is being

charged, so remove the battery from the machine, take it
to a well-ventilated place, remove the battery caps, then
perform the charging.

• After charging, tighten the battery caps securely.

Danger from dilute sulphuric acid

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire. Always ob-
serve the following.

• When handling the battery, always wear protective eye-

glasses and rubber gloves.

• If battery electrolyte gets into your eyes, immediately wash

your eyes with large amounts of fresh water. After that, get
medical attention immediately.

• If battery electrolyte gets on your clothes or skin, wash it

off immediately with large amounts of water.

Danger of sparks

Sparks may be generated and they can cause a fire. Always observe the following.

• Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools

lying around near the battery.

• When removing the battery cables, turn the starting switch to OFF position and, after checking that the sys-

tem operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing, con-
nect the positive (+) cable first, then connect the ground.

• Tighten the battery cable terminals securely.
• Secure the battery firmly in the specified position.

PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause
serious personal injury or death. Always observe the following.

• When hitting pins or bucket teeth, broken pieces may be scattered, and it may cause personal injury to the

people in the surrounding area. Always check that there is no one in the surrounding area.

• If hard metal parts such as pins, bucket teeth, cutting

edges, or bearings are hit with a hammer, pieces might be
scattered, and it may cause serious personal injury or
death. Always wear protective eyeglasses and gloves.

• If the pin is hit with strong force, it may come out, and in-

jure people in the surrounding area. Do not allow anyone
to enter the surrounding area.

,&

,&

PRECAUTIONS FOR MAINTENANCE

SAFETY

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Summary of Contents for WA380-8

Page 1: ...is machine may be hazardous and cause injuries The operator and maintenance personnel must read this manual before commencing operation or maintenance Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals DANGER 2016 KOMATSU All Rights Reserved Printed in Europe 10 2016 ORIGINAL INSTRUCTIONS ...

Page 2: ... ...

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

Page 4: ... name and the serial No see the machine serial No plate In order to arrange the proper Operation and Maintenance Manual you will need to provide the machine model name and the serial No This manual uses the International System of Units SI for units of measurement For reference units that have been used in the past are given in The explanations values and illustrations in this manual have been pre...

Page 5: ...ubse quently installed electrical and electronic components comply with the EMV Directive 2004 108 EC in its current edition and bear the CE mark The following requirements also have to be met for subsequent installation of mobile communication systems e g radio telephone Only equipment approved by national legislation e g BZT approval for Germany may be used The unit must be fixed in position Por...

Page 6: ...GER This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury k k WARNING This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury k k CAUTION This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may a...

Page 7: ... the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used it is your responsibility to take th...

Page 8: ... the machine front rear left right are determined according to the view from the operator s seat in the direction of travel front of the machine VISIBILITY FROM OPERATOR S SEAT This machine complies with the visibility standard ISO5006 This machine maintains a proximity visibility of a height of 1 5 m at a point 1 m away from the outside surface of the machine and a visibility for a radius of 12 m...

Page 9: ...el Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the reagent for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transpa...

Page 10: ... IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE This is located at the center of the front frame on the right side of the machine The design of the nameplate differs according to the district LOCATION OF ENGINE NUMBER PLATE This is located at the right top of the engine rear part on the right side of the machine PRODUCT INFORMATION FOREWORD 1 8 ...

Page 11: ...D PRODUCT INFORMATION 1 9 Komatsu Ltd Tokyo Japan SERIAL NO PART NO MODEL PRODUCED BY KOMATSU GERMANY GmbH HANNOVER FEDERAL REPUBLIC OF GERMANY FOR g0047137 g0047138 Komatsu Ltd Tokyo Japan SERIAL NO PART NO MODEL PRODUCED BY KOMATSU GERMANY GmbH HANNOVER FEDERAL REPUBLIC OF GERMANY FOR FLUORINATED GREENHOUSE GASES Product contains fluorinated greenhouse gases HFC 134a GWP 1430 CO2 eq kg t 09971 1...

Page 12: ...nter bottom of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturer name Address Komatsu Germany GmbH Hanomag Strasse 9 30449 Hannover Germany Distributor name Address Phone Fax Service personnel PRODUCT INFORMATION FOREWORD 1 10 ...

Page 13: ...er FOREWORD DECLARATION OF CONFORMITY 1 11 C E 2 4 6 0 0 2 e v i t c e r i D y r e n i h c a M Electro Magnetic Compatibility Directive 2004 108 EC until 19 April 2016 2014 30 EU after 20 April 2016 C E 8 8 5 0 0 2 d e d n e m a C E 4 1 0 0 0 2 e v i t c e r i D e s i o N r o o d t u O Radio Equipment and Telecommunications Terminal Equipment Directive 1999 5 EC until 12 June 2016 6 1 0 2 e n u J ...

Page 14: ...icular the European Machi nery Directive lies with the customer who commissions retrofitting of the machine In the event of tools e g loading shovels being retrofitted by a third party supplier the technical specifications of the manufacturer must be taken into account For this purpose or for further information please be sure to consult Komatsu or your local Komatsu dealer RETROFITTING BY THIRD P...

Page 15: ...atsu Diesel Particulate Filter KVGT Komatsu Variable Geometry Turbo KCCV Komatsu Closed Crankcase Ventilation SCR Selective Catalytic Reduction DEF Diesel Exhaust Fluid ECSS Electrically Controlled Suspension System FOREWORD EXPLANATION OF ACRONYMS 1 13 ...

Page 16: ...S COMMON TO OPERATION AND MAINTENANCE 2 15 PRECAUTIONS BEFORE STARTING OPERATION 2 15 PREPARATIONS FOR SAFE OPERATION 2 15 PRECAUTIONS TO PREVENT FIRE 2 17 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 18 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 20 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 21 UNAUTHORIZED MODIFICATION 2 21 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 21 PRECAUTIONS WHEN RUNNI...

Page 17: ...PERATING AIR CONDITIONER 3 230 TRANSPORTATION 3 234 TRANSPORTATION PROCEDURE 3 234 LOADING AND UNLOADING WITH TRAILER 3 234 METHOD FOR LIFTING MACHINE 3 238 COLD WEATHER OPERATION 3 240 COLD WEATHER OPERATION INFORMATION 3 240 PRECAUTIONS AFTER DAILY WORK COMPLETION 3 241 PRECAUTIONS IN COLD WEATHER 3 241 AFTER COLD WEATHER SEASON 3 241 PRECAUTIONS FOR LONG TERM STORAGE 3 242 PREPARATION FOR LONG ...

Page 18: ...0 HOURS MAINTENANCE 4 52 EVERY 2000 HOURS MAINTENANCE 4 56 EVERY 4000 HOURS MAINTENANCE 4 69 EVERY 4500 HOURS MAINTENANCE 4 74 EVERY 8000 HOURS MAINTENANCE 4 74 EVERY 9000 HOURS MAINTENANCE 4 74 SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 SPECIFICATIONS WA380 8 5 2 NOISE EMISSION LEVELS 5 4 VIBRATION LEVEL 5 5 ATTACHMENTS AND OPTIONS 6 1 BUCKET AND TIRE SELECTION 6 2 HANDLE MULTIFUNCTION MONO LEVER 6 3 ...

Page 19: ... LUBRICANT 7 4 LUBRICATION CHART 7 4 METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 7 INDEX 8 1 FOREWORD TABLE OF CONTENTS 1 17 ...

Page 20: ......

Page 21: ...ase read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions strictly 2 1 ...

Page 22: ...RATOR S CAB 2 20 PRECAUTIONS FOR CLEANING CAB GLASS 2 20 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 20 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 21 UNAUTHORIZED MODIFICATION 2 21 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 21 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 21 PRECAUTIONS FOR OPERATION 2 22 PRECAUTIONS FOR JOBSITE 2 22 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2 22 PRECAUTI...

Page 23: ... OR WORK EQUIPMENT 2 36 USE PROPER TOOLS 2 37 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 37 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 37 PRECAUTIONS FOR WELDING 2 37 HANDLE BATTERY 2 37 PRECAUTIONS WHEN USING HAMMER 2 38 PRECAUTIONS FOR HIGH TEMPERATURE COOLANT 2 39 PRECAUTIONS FOR HIGH TEMPERATURE OIL 2 39 PRECAUTIONS FOR HIGH TEMPERATURE PARTS 2 39 PRECAUTIONS FOR HIGH PRESSURE OIL 2 39 PREC...

Page 24: ...rly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the safety labels see this manual or the actual label and place an order to your Komatsu distributor There are also other labels in addition to the warning s...

Page 25: ...LOCATION OF SAFETY LABELS SAFETY SAFETY LABELS 2 5 ...

Page 26: ...n 12 Prohibition of getting on or off fender 13 Caution while engine is running 14 Caution while engine is running 15 Caution for nearing machine 16 Prohibition of entering beneath work equipment 17 Caution for modification of ROPS FOPS 18 Prohibition of start by short circuiting 19 Caution for high temperature turbocharger 20 Caution for hot exhaust pipe 21 Caution for high pressure common rail 2...

Page 27: ...to lock position and take engine key with you before leaving ma chine Caution when traveling in reverse 09802 D0880 Sign indicates a hazard of rear working and advancing be hind Read manual before operation k k WARNING To prevent SEVERE INJURY or DEATH do the following before moving machine or its attachments Honk horn to alert people nearby Be sure no one is on or near the machine Use spotter if ...

Page 28: ...ohibition of trespassing 09162 C0641 Sign indicates a crush hazard between the articulating parts of the vehicle Keep away from the vehicle when it is moving Caution for frame lock bar 09161 C0641 Sign indicates a crush hazard between the articulating parts of the vehicle Lock vehicle with lock bar to avoid movement during main tenance and transportation SAFETY LABELS SAFETY 2 8 ...

Page 29: ...arefully read the manual and be sure to follow the instructions given therein Caution for high temperature coolant 09653 A0641 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool before removing cap Caution for high temperature oil and hydraulic oil 09653 A0641 Sign indicates a burn hazard from spu...

Page 30: ...ignal indicates an explosion Never drill cut with gas hit or disassemble Also keep open flame away Prohibition of getting on or off fender 09805 C0481 Sign indicates a hazard of falling Do not stand on this place here Caution while engine is running 09667 A0880 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance SAFETY LABELS SAFETY 2 10 ...

Page 31: ...on and maintenance Caution for nearing machine 09806 C0883 There is danger of being run over by machine Do not go close to machine Prohibition of entering beneath work equipment 09807 C0883 Sign indicates a crush hazard from falling off of working de vice Keep away when the working device is raised SAFETY SAFETY LABELS 2 11 ...

Page 32: ...eat Do not attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire Caution for high temperature turbocharger 09817 A0753 Sign indicates a burn hazard from touching heated parts such as engine motor or muffler during or right after oper ation Never touch when hot Caution for hot exhaust pipe 09817 A0753 Sign indicates a burn ...

Page 33: ...st zone Keep machine at a safe distance from a blast zone and detonator Caution when traveling in reverse Machine with rearview camera 09833 C0881 When backing up rear of machine is displayed on monitor Before moving look back and at mirror and monitor to con firm that no one is rear of machine Failure to do so can result in serious injury or death SAFETY SAFETY LABELS 2 13 ...

Page 34: ...Caution for handling DEF 09632 61480 DEF only To avoid engine damage or fire fill with DEF on ly Never use diesel fuel ᵎᵗᵔᵑᵐᵋᵔᵏᵒᵖᵎ SAFETY LABELS SAFETY 2 14 ...

Page 35: ... SAFE OPERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the safety related devices and use them properly Never remove any safety related devices Always keep them in good operating condition INSPECT MACHINE Check the machine before starting oper...

Page 36: ... machine to move unexpectedly resulting in serious personal injury or death Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such as flammable or explosive items into the ...

Page 37: ...d surfaces or on parts of the electrical system After adding fuel or oil wipe up any spilled fuel or oil Put greasy rags and other combustible materials into a safe container to maintain safety at the workplace When washing parts with oil use a non flammable oil Do not use diesel fuel or gasoline There is danger that they may catch fire Do not weld or use a cutting torch to cut any pipes or tubes ...

Page 38: ...ipment When checking fuel oil battery electrolyte or coolant always use lighting with anti explosion specifica tions When taking the electrical power for the lighting equipment from the machine see POWER SUPPLY OUT LET 3 119 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine alwa...

Page 39: ...ine be used for the lifting of personnel PRECAUTIONS WHEN STANDING UP FROM OPERATOR S SEAT When standing up from the operator s seat to adjust the opera tor s seat be sure to lower the work equipment completely to the ground lock the work equipment by pressing work equip ment lock switch 1 pilot lamp lights up and stop the engine by setting parking brake switch 2 to ON operation position A If the ...

Page 40: ...mergency escape door PRECAUTIONS FOR CLEANING CAB GLASS Clean the cab glass to ensure visibility during operation Make sure to clean the glass with a mop from the ground For the cleaning procedure see METHOD FOR WALK AROUND CHECK 3 159 DO NOT GET CAUGHT IN WORK EQUIPMENT If the clearance at the articulating portion changes and you get caught in it you will suffer serious personal injury or death D...

Page 41: ... not fasten your seatbelt properly it cannot display its effect Always fasten your seat belt while operating the machine UNAUTHORIZED MODIFICATION Komatsu will not be responsible for any personal injuries product failures physical loss or damage or influ ence on the environment resulting from modifications made without authorization from Komatsu Any modification made without authorization from Kom...

Page 42: ...ath on the jobsite so that there is no obstruction to travel operations PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse under the weight or vibration of the machine there is a hazard that the machine may fall or tip over Remember that the soil is we...

Page 43: ...ions in places with poor visibility always observe the following Allocate a signalman for jobsite duty if there are areas where the visibility is poor Only one signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up additional lighting equipment in the work area if necessary Stop operations if the visibility is poor becau...

Page 44: ... operate warning tag dis played it means that someone is performing inspection and maintenance of the machine If the warning tag is ignored and the machine is operated the person performing inspection or maintenance may be caught in the rotating parts or moving parts It is dangerous and may cause serious personal injury or death Do not start the engine or touch the levers CHECKS AND ADJUSTMENT BEF...

Page 45: ... may suddenly move off and this may lead to serious personal injury or death Always observe the following Start the engine only while sitting down in the operator s seat When starting the engine sound the horn as a warning Prohibit anyone other than the operator to get on the machine Do not attempt to start the engine by short circuiting the engine starting circuit This may cause fire serious pers...

Page 46: ...g the clips in contact with each other or with the machine For the starting procedure with the jumper cables see OPERATION START ENGINE WITH JUMPER CA BLES 3 250 PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly the machine will be unable to display its full perform ance It is dangerous and may cause serious personal injury or death When per...

Page 47: ... death If the engine stops de press the brake pedal immediately to stop the machine When driving the machine or performing operations always keep a safe distance from people structures or other machines to avoid coming into contact with them When traveling on a level ground keep the work equip ment A approximately 27 cm above the ground If that height is not maintained between the work equipment a...

Page 48: ...ght A of approximately 20 to 30 cm above the ground In case of emergency lower the work equipment to the ground immediately to help stopping the machine Always drive the machine straight up or down a slope Driving the machine at an angle or across the slope is ex tremely dangerous Do not turn on slopes or drive across slopes Always go down to a flat place to change the position of the machine then...

Page 49: ...eful not to approach too close to the edge of cliffs When making embankments or landfills or when dropping soil over a cliff dump one pile then use the next pile of soil to push the first pile The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of a slope When this happens there is danger that the travel speed will suddenly increase so be sure...

Page 50: ...r frozen surfaces are slippery so be extremely careful when traveling or operating the ma chine and do not perform abrupt lever operation Machine may slip even on a slight slope Be particularly careful when working on slopes Frozen road becomes soft when the temperature rises and the machine may tip over or be not able to es cape Be particularly careful when working on frozen road When traveling o...

Page 51: ...lled the machine weight transportation height and overall length differ Check beforehand that all bridges and other structures on the transportation route are strong enough to withstand the combined weight of the transporter and the machine being transported This machine needs to be divided into components for transportation depending on the regulation When transporting the machine consult your Ko...

Page 52: ...a cab always lock the door after loading the machine To prevent the door from opening during transportation For detail see TRANSPORTATION 3 234 When it is necessary to remove handrails and steps take care not to lose removed handrails and steps Install the removed handrails and steps securely TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and ...

Page 53: ...ce clean the tidy to enable you to perform operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop the machine on a firm level ground Select a place where there is no hazard of landslides falling rocks or flooding ONLY AUTHORIZED PERSONNEL As long as mainte...

Page 54: ...ent to the ground and stop the en gine before performing any inspection and maintenance Stop the engine work equipment is lowered to the ground and turn the starting switch to ON position Press work equipment lock switch 2 to release the work equip ment lock the pilot lamp goes off then operate work equipment control lever 1 to RAISE and LOWER position fully 2 to 3 times to release the remaining p...

Page 55: ...are dangerous that they may easily catch a body part or an object someone wears Be careful not to come close to the rotating part Never drop or insert tools or other objects into the fan fan belt or other rotating parts They may contact the rotating parts and break and be scattered It is dangerous If the automatic active regeneration of KDPF starts during maintenance work surroundings of KDPF beco...

Page 56: ...ces use a step ladder or other stand to ensure that the work can be performed safely There is a danger falling from high place that can lead to serious personal injury or death PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Machine or work equipment may fall and it is dangerous that serious personal injury or death may occur Al ways observe the following Do not perform inspection and mai...

Page 57: ...use etc PRECAUTIONS FOR WELDING Welding operations must always be performed by a qualified welder and in a place equipped with proper equip ment There is a hazard of gas fire or electric shock when performing welding so never allow any unqualified person to perform welding HANDLE BATTERY Before inspecting or handling the battery turn the key in the starting switch to OFF position and check that th...

Page 58: ...les Do not leave tools lying around near the battery When removing the battery cables turn the starting switch to OFF position and after checking that the sys tem operating lamp goes out set the battery disconnect switch key to OFF position and pull it out When removing the battery cables remove the ground cable negative cable first When installing con nect the positive cable first then connect th...

Page 59: ...ses check that the internal pressure in the circuit has been released If this is not done serious personal injury or death may occur Always observe the following Do not perform inspection or replacement work with the circuit under pressure Release the pressure For details see STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2 34 If there is any leakage from the piping or hoses the surrou...

Page 60: ...hile the starting switch key is at ON position the work equipment goes down with its own weight After stopping the engine turn the work equipment lock switch to LOCK position and the parking brake switch to ON operation position The accumulator and gas spring are charged with high pressure nitrogen gas If the accumulator is handled mistakenly it may cause an explosion It is dangerous and may cause...

Page 61: ...yl alcohol base washer liquid Methyl alcohol base washer liquid may irritate your eyes so do not use it PERIODIC REPLACEMENT OF DEFINED LIFE PARTS For using the machine safely for a long period always perform periodic replacement of the defined life parts that have a particularly close relation to safety such as hoses and the seat belt Replacement of the defined life parts See PERIODIC REPLACEMENT...

Page 62: ...up there is a danger that the rim parts may fly off so set up a protective fence around the tire and do not stand directly in front of the rim Stand beside the tread when pumping up the tire Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under heavy load Never perform welding or light a fire near the tire Always release the inflation pressure from ...

Page 63: ...F avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is non flammable however in the case of a fire it may generate an ammonia gas Follow the instructions and prec...

Page 64: ......

Page 65: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 66: ...2 Bell crank 3 Bucket cylinder 4 R H side under mirror 5 Rearview mirror 6 Front working lamp 7 ROPS cab 8 Rear wheel 9 Stepladder 10 L H side under mirror 11 Turn signal lamp 12 Headlamp 13 Lift cylinder 14 Front wheel GENERAL VIEW OPERATION 3 2 ...

Page 67: ... Turn signal lever 9 Dimmer switch 10 Parking brake switch 11 Monitor switch 12 Cigarette lighter 13 Brightness adjustment switch of rear view monitor 14 Rear view monitor 15 Bucket control lever 16 Kickdown switch 17 Boom control lever 18 Work equipment lock switch 19 R H switch panel 20 Directional selector switch if equipped 21 Hold switch 22 Accelerator pedal 23 R H brake pedal 24 Starting swi...

Page 68: ...switch 5 Directional selector enable switch on R H switch panel if equipped 6 Remote positioner switch 7 Auto digging switch 8 Secondary steering switch Front switch panel 9 Front working lamp switch 10 Rear working lamp switch 11 Beacon lamp switch if equipped 12 Monitor brightness selector switch 13 Auto greasing switch 14 ECSS switch 15 Quick coupler switch if equipped GENERAL VIEW OPERATION 3 ...

Page 69: ...Turn signal pilot lamp L H 11 Headlamp high beam pilot lamp 12 Turn signal pilot lamp R H 13 Brake oil pressure caution lamp 14 Clearance lamp pilot lamp 15 Engine tachometer 16 Speedometer 17 Hydraulic oil temperature caution lamp 18 Hydraulic oil temperature gauge 19 Fuel level caution lamp 20 Fuel gauge 21 DEF level gauge 22 R H meter Select the fuel consumption gauge service meter odometer or ...

Page 70: ...hift indicator position display 36 Work equipment lock pilot lamp 36 Remote positioner display 37 Automatic shift pilot lamp 38 Torque converter lockup mode display 39 Shift hold pilot lamp 40 Preheating pilot lamp 40 Transmission cut off pilot lamp 41 Fan reverse display 42 Power mode display 43 Secondary steering pilot lamp 44 Aftertreatment devices regeneration display 45 Guidance display 46 Ma...

Page 71: ... EQUIPMENT NAME Inside of cab 1 24 V power supply 2 Rearview monitor 3 Ashtray 4 Open knob for alternate exit of cab 5 Fire extinguisher if equipped 6 Cool box 7 Cup holder 8 Open lock for cab L H door 9 Cab door handle 10 Fuse 11 Open handle for cab L H door 12 12 V power supply 13 AUX OPERATION GENERAL VIEW 3 7 ...

Page 72: ...Outside of cab 1 Slow blow fuse 2 Dust indicator 3 Articulation lock pin 4 Toolbox if equipped GENERAL VIEW OPERATION 3 8 ...

Page 73: ... DEF injector 7 SCR assembly 8 Komatsu Closed Crankcase Ventilation hereafter KCCV ventilator 9 Battery disconnect switch 10 System operating lamp 11 DEF pump 12 DEF filter 13 DEF tank OPERATION GENERAL VIEW 3 9 ...

Page 74: ...MENT FF Failure display screen A Warning display B Pilot display C Meter display D Monitor switch area REMARK For the user menu used for setting various items of the machine on the machine monitor see USER MENU 3 49 One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on the screen When there are fewer t...

Page 75: ...BB 3 The pointer of engine tachometer D moves one cycle 4 Speedometer E displays 88 for 2 seconds 5 The alarm buzzer sounds for 2 seconds then stops under the normal condition NOTICE If the lamps alarm buzzer etc do not work the machine monitor may be failed or the electric wiring may have breakage In this case ask your Komatsu distributor for repair REMARK When the engine is started the battery v...

Page 76: ...unction and operating method of engine shutdown sec ondary switch 1 see ENGINE SHUTDOWN SECONDARY SWITCH 3 109 BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION When starting switch is turned to OFF position the screen goes out In the following case the end screen is displayed for 5 seconds and then screen goes out End screen with message If there is any message from you...

Page 77: ... position On the ID number input screen LL with SKIP or MM without SKIP input the already registered ID number and press ENTER switch 1 The screen changes to the Check Before Starting screen BB If you input an incorrect ID number press RETURN switch 2 and clear an input character at a time On the ID number input screen LL with SKIP press menu switch 3 and the screen changes to the Check Be fore St...

Page 78: ...hine has trou ble starting screen AA is displayed for 2 seconds and then it is changed to the failure display screen FF When ENTER switch displayed in guidance icon 1 is pressed the Current Abnormality screen is displayed For the Current Abnormality screen and the remedies see CURRENT ABNORMALITY LIST DISPLAY 3 17 When the machine monitor is started if the time to the next maintenance of any item ...

Page 79: ...en is not displayed WARNING DISPLAY NOTICE Appearance of any of action levels L01 to L04 on the machine monitor indicates presence of an ab normality the machine Perform the inspection and maintenance according to ACTION LEVEL DISPLAY 3 16 These cautions do not guarantee the condition of the machine Do not simply rely on the monitor when carrying out checks before starting daily inspection Al ways...

Page 80: ...el caution lamp 12 DEF level caution lamp ACTION LEVEL DISPLAY Action level display indicates the degree of urgency of the ab normality currently generated on the machine by L01 to L04 The larger the number in the table is the more serious effects the abnormality may have on the machine if it is left with no ac tion When the machine monitor displays an action level take ap propriate actions accord...

Page 81: ...ated display avoid a long time usage of the secondary steering If the condition is not improved check the failure code and ask your Komatsu distributor for inspec tion and maintenance L01 OFF Does not sound Lights up in yellow Some functions may be restricted from use but the machine can operate When you finish the opera tion always have the inspection and maintenance performed Ask your Komatsu di...

Page 82: ...vel C Failure code Code to indicate the content of the failure Notify it when calling your Komatsu distributor D Failure name E Message Take appropriate remedies according to the displayed message F Contact telephone number The telephone number of the contact such as your Komatsu distributor is displayed If no point of contact telephone number is registered no telephone number is displayed Ask you...

Page 83: ...PERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about over heating of the engine coolant If the engine coolant temperature is abnormally high the lamp lights up in red and action level L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Place the machine in a safe place set the directional lever and directional selecto...

Page 84: ...the engine at a medium speed under no load until the lamp goes out FUEL LEVEL CAUTION LAMP The fuel level caution lamp warns about low remaining fuel lev el The lamp lights up in red if the fuel level is 28 ℓ or below Add fuel as soon as possible BRAKE OIL PRESSURE CAUTION LAMP The brake oil pressure caution lamp warns that the brake oil pressure is below the specified value When action level L03 ...

Page 85: ...orm the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed BRAKE OIL TEMPERATURE CAUTION LAMP The brake oil temperature caution lamp warns about overheat ing of the brake oil If the machine is operated continuously under severe condition or the brake is used frequently on a long downhill slope the brake oil temperature increases If the caution lamp...

Page 86: ...ault conditions that result in activation of the Inducement strat egy for engine derates to prompt to maintain or repair the emis sion control system When Lightning in red With Action level L04 DEF tank level is too low Inducement status is Severe Inducement Engine power is under heavy deration With Action level L03 DEF tank level is low Inducement status is Low level Inducement Engine power is un...

Page 87: ... operator that there is wrong operation of the directional selector switch or di rectional lever If the caution lamp lights up in red return the directional selec tor switch and directional lever to NEUTRAL position N WARNING DISPLAY The caution lamps displayed on the warning display section are as follows Take appropriate measures according to the speci fied remedies REMARK When 1 type of alarm i...

Page 88: ...tion and maintenance When action level is not displayed and lamp lights up in red When the engine is started the caution lamp lights up in red until the steering oil pressure rises above the specified value At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Wait until the caution lamp goes out and then start the machine SECONDARY STEERING SYSTEM CAUTION ...

Page 89: ...el L03 is displayed The caution lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow When you finish the operation always perform t...

Page 90: ...01 is displayed The lamp lights up in yellow if much soot is accumulated in KDPF After the operation is finished move the machine to a safe place and perform manual stationary regenera tion REMARK For details of the manual stationary regeneration see HANDLE Komatsu Diesel Particulate Filter KDPF 3 133 DEF SYSTEM CAUTION LAMP DEF system caution lamp alerts when abnormality in the sys tem are detect...

Page 91: ...system When action level L04 is displayed The lamp lights up in red At the same time the centralized warning lamp lights up and the alarm buzzer sounds con tinuously Stop the machine immediately and ask your Komatsu dis tributor for inspection and maintenance When action level L03 is displayed The lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds...

Page 92: ...ngine speed and travel speed RADIATOR COOLANT LEVEL CAUTION LAMP Radiator coolant level caution lamp warns about drop of radia tor coolant level If the lamp lights up in yellow and action level L01 is dis played inspect the coolant level in the reservoir tank and add coolant See METHOD FOR CHECKING COOLANT LEVEL ADDING COOLANT 3 163 If it occurs again in a short time the coolant may be leaking fro...

Page 93: ...NTROL SYSTEM CAUTION LAMP The fan control system caution lamp warns about abnormality in the fan control system When action level L03 is displayed The lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds intermit tently Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for in spection and maintenan...

Page 94: ...ed while the lamp is lit the screen changes directly to the Maintenance menu screen For operations on the Maintenance menu screen see MAINTENANCE SCREEN SETTING 3 75 By default the maintenance time caution lamp yellow is set to light up when the remaining time reaches 30 hours However you can change this setting To change the setting ask your Komatsu distributor CENTRALIZED WARNING LAMP The centra...

Page 95: ...d OFF When directional lever or directional selector switch if equipped is not in NEUTRAL position N while the parking brake is applied When the gear is shifted down or the travel direc tion is changed while the travel speed is high When the directional lever is not in NEUTRAL po sition N while the directional selector switch if equipped is effective The directional switch caution lamp flashes PIL...

Page 96: ...2 stage low idling pilot lamp 13 Clearance lamp pilot lamp 14 Work equipment lock pilot lamp 14 Remote positioner display 15 Shift lever position display 16 Automatic shift pilot lamp 17 Torque converter lockup mode display 18 Shift hold pilot lamp 19 Preheating pilot lamp 19 Transmission cut off pilot lamp 20 Fan reverse display 21 Power mode display 22 Secondary steering pilot lamp 23 Aftertreat...

Page 97: ...LAMP The turn signal pilot lamp flashes synchronously with the turn signal lamp when it is turned on HEADLAMP HIGH BEAM PILOT LAMP The headlamp high beam pilot lamp lights up when the head lamps are set to high beam CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lights up when the clearance lamps are turned on OPERATION EXPLANATION OF COMPONENTS 3 33 ...

Page 98: ...tion pilot lamp lights up in green when the directional selector enable switch on R H switch panel is effec tive It lights up in yellow when the directional selector switch is op erated wrongly This pops up when the directional selector enable switch on R H switch panel is turned on ECSS PILOT LAMP The ECSS pilot lamp lights up when ECSS is effective When ECSS switch is turned ON the display pops ...

Page 99: ...e mote positioner is effective When the remote positioner function is changed from OFF to ON the display pops up A When only RAISE operation is effective B When only LOWER operation is effective C When RAISE and LOWER operations are effective POWER MODE DISPLAY The power mode display indicates the set state of the power mode By selecting the mode with the power mode selector switch and with the mo...

Page 100: ...TION DISPLAY When the radiator fan is set in manual or auto reverse rotation mode if the fan starts to rotate in reverse fan reverse rotation pilot lamp A lights up This lamp flashes while the rotation direction is being changed If the condition for changing the fan rotation direction is not sat isfied changing condition satisfaction waiting pilot lamp B lights up For details of the method of sett...

Page 101: ... TRANSMISSION CUT OFF FUNCTION 3 198 AIR CONDITIONER DISPLAY The air conditioner display shows the operating state of the air conditioner For detail see HANDLE AIR CONDITIONER 3 224 MESSAGE DISPLAY The message display lights up when there is a message from Komatsu A There is unread message B There is any read message to which no reply is made To read the message see MESSAGE DISPLAY 3 91 CLOCK The ...

Page 102: ...F soot accumulation caution lamp lights up If KDPF soot accumulation caution lamp lights up cancel the re generation disable setting and perform manual stationary regeneration For the procedures of cancellation of regeneration disable setting and setting of manual stationary regeneration see HANDLE Komatsu Diesel Particulate Filter KDPF 3 133 SECONDARY STEERING SYSTEM PILOT LAMP The secondary stee...

Page 103: ...The work equipment lock pilot lamp lights up when the work equipment is locked This pops up on the screen when the work equipment is switched from the unlock mode to the lock mode For detail see WORK EQUIPMENT LOCK SWITCH 3 107 PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake is applied ECO GUIDANCE ECO guidance is displayed during the operation that lowers th...

Page 104: ...r over the maximum for exam ple to move bucket control lever to TILT while the bucket is fully tilted or reduce it further over the minimum Stop unnecessary relief The hydraulic relief deterrence message goes out automatically after 10 seconds BRAKE DRAGGING PREVENTION GUIDANCE If the accelerator pedal is depressed for more than 3 seconds while applying the brake during traveling the brake draggin...

Page 105: ...FF the notification of lockup recommendation is displayed on the monitor Reduce the fuel consumption by selecting the direct drive The notification of lockup recommendation goes out auto matically after 10 seconds This notification goes out when the lockup switch is turned ON This notification is not displayed for 2 hours after the previ ous display even if the condition for display is satisfied L...

Page 106: ...el Low Error guidance goes out in more than 15 seconds or when ENTER switch is pressed For the remaining amount of DEF see DEF LEVEL GAUGE 3 46 REMARK While monitor displays DEF level low error or maintenance warnings DEF level low guidance is not displayed METER DISPLAY 1 Torque converter oil temperature gauge 2 Engine coolant temperature gauge 3 ECO gauge 4 Hydraulic oil temperature gauge 5 Engi...

Page 107: ...ction level L02 is dis played At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently The engine output is then limited automatically Place the machine in a safe place set the directional lever and directional selector switch if equipped to NEUTRAL position N and run the engine at a medium speed with no load until the engine coolant temperature caution lamp g...

Page 108: ...ws the amount of fuel in the fuel tank If the indicator is in the red range the fuel level caution lamp lights up in red The fuel level is below 28 ℓ Check the fuel lev el and add fuel ECO GAUGE ECO gauge indicates the instantaneous fuel consumption fuel consumption rate at each moment The instantaneous fuel consumption varies depending on the operation ways accelerator operation travel speed gear...

Page 109: ...ances even if the machine is not being operated The service meter advances by 0 1 for 6 engine running mi nutes and by 1 for 1 engine running hour regardless of the en gine speed Odometer display Indicates the total distance that machine has traveled in kilo meters Clock display Indicates the current time A 12 hour display B 24 hour display REMARK If the battery is disconnected for a long period f...

Page 110: ...ights up in red the engine output and engine speed are limited For detail see HANDLE UREA SCR SYSTEM WARNING 3 142 When remaining level of DEF cannot be detected DEF level caution lamp 1 lights up in white REMARK Immediately after turning the starting switch to ON position and during the engine is running DEF level cau tion lamp 1 lights up in white However this does not indicate abnormality In co...

Page 111: ...ment Devices Regeneration menu screen When maintenance caution lamp lights up Displays the Main tenance menu screen When fan reverse pilot lamp lights up Displays the Machine Setting and Information menu screen When message pilot lamp lights up Displays the Message display menu screen When the menu switch is pressed on the user menu screen the menu screen changes ENTER SWITCH Pressing ENTER switch...

Page 112: ...switch moves the cursor up by one item When on the first line it moves to the last line On the value input screen the value is increased by one DOWN SWITCH Pressing the DOWN switch moves the cursor down by one item When on the last line it moves to the first line On the value input screen the value is decreased by one EXPLANATION OF COMPONENTS OPERATION 3 48 ...

Page 113: ...witches can be used as a numeric keypad to enter a numeric value such as a password Press a desired switch to enter a numeric value 0 to 9 which is indicated at the lower right of each switch For details of other switch functions see the explanation for each screen in USER MENU 3 49 The confirmation sound is heard when the switch is pressed but a reaction is taken the switch function is operated w...

Page 114: ...ecords Check of ECO Guidance Records Check and reset of Average Fuel Consumption Record Configurations B Machine Setting and Information Setting for E light Mode E Mode Selection Setting for Manual Fan Reverse Mode Setting for Automatic Fan Reverse Mode 2 Stage Low Idle Setting Bucket Level Position Selection Auto Kick Down Setting Display and resetting of Trip Meter Auto Idle Stop Timer Setting L...

Page 115: ...erator ID G Message Display Check of message contents and reply to message On the user menu screen it is possible to perform the following operations with the switches 1 UP switch Moves to the item above When on the first item it moves to the last item 2 DOWN switch Moves to the item below When on the last item moves to the first item 3 ENTER switch Enters any selection or changes and proceeds to ...

Page 116: ... the above priority is given ENERGY SAVING GUIDANCE Each item of Energy Saving Guidance menu A is used for displaying and setting the notification relevant to energy saving Operation Records Eco Guidance Records Average Fuel Consumption Record Configurations OPERATING RECORD The Operation Records screen displays the following informa tion on a daily basis or during the split measurement period Wor...

Page 117: ...plit Time and split time measurement is stopped C Display while measurement is stopped D Dates and times when the measurement is started and stopped To start the split time measurement see the guidance icon and press ENTER switch 1 When the measurement is started the previous split time measurement results Average Fuel Consumption Display Operation Records and ECO Guidance Records are reset When t...

Page 118: ... GUIDANCE 3 39 In the Operational Advice section the advice to the ECO guidance that appeared most frequently is displayed The ECO guidance count increases when display condi tions are satisfied even if the ECO guidance is not dis played When Average Fuel Consumption Display is set to 1 Day 1 Day is displayed on the place shown with arrow in the right figure When Average Fuel Consumption Display i...

Page 119: ...tion Records and ECO Guidance Records are reset When the confirmation screen is displayed press ENTER switch 1 again to start the split measurement or press RE TURN switch 2 to cancel the start FUEL CONSUMPTION RECORD The Average Fuel Consumption Record screen alternately displays the following graphs Average fuel consumption for the Last 12 hours Average fuel consumption for the Last 7 days Selec...

Page 120: ...ance icon and press ENTER switch 1 When the confirmation screen is displayed press ENTER switch 1 again to clear or press RETURN switch 3 to cancel clearing REMARK If clearing is performed while the graph of the Last 12 hours is displayed only the graph of the Last 12 hours is cleared If clearing is performed while the graph of the Last 7 days is displayed both graphs of the Last 12 hours and Last...

Page 121: ...guidance Switching ON OFF of ECO Guidance Display at Key OFF Select Configurations from Energy Saving Guidance menu screen then press ENTER switch 1 SET DISPLAY OF FUEL CONSUMPTION GAUGE The display of the fuel consumption gauge can be set to the value on daily basis or during split measurement period 1 Select Average Fuel Consumption Display from Configu rations menu then press ENTER switch 1 OPE...

Page 122: ...s finished Select Split Time to start the split measurement automatically REMARK For the display of the average fuel consumption display see L H AND R H METER 3 44 Setting of 1 Day or Split Time is also applied to the display of the Operation Records and ECO Guidance Records When stopping the split measurement see OPERATING RECORD 3 52 or ECO GUIDANCE RECORD 3 54 SWITCH DISPLAY NON DISPLAY OF ECO ...

Page 123: ...GAUGE 3 44 If the ECO Gauge Display is set to OFF the items of ECO Gauge Display Fuel Target Value is not displayed SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE ECO Gauge Target Value A the upper limit value of the green range can be changed 1 Select ECO Gauge Display Fuel Target Value from Con figurations menu then press ENTER switch 1 OPERATION EXPLANATION OF COMPONENTS 3 59 ...

Page 124: ...consumption indi cated when the ECO gauge is at the maximum is also in creased in proportion If the target fuel value is decreased the fuel consumption indi cated when the ECO gauge is at the maximum is also de creased in proportion For the ECO gauge see ECO GAUGE 3 44 SWITCH DISPLAY NON DISPLAY OF ECO GUIDANCE Display non display of ECO guidance displayed on the stand ard screen can be switched 1...

Page 125: ...FF displays of ECO Guidance Display at Key OFF and ECO Guidance Records are not displayed ECO Guidance Records however is not reset SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF Display non display of the Operational Advice indicated on the end screen when the key is turned to OFF position can be switched 1 Select ECO Guidance Display at Key OFF from Configu rations menu then press ENTER ...

Page 126: ...ion menu B setting and information of the machine are checked or changed SELECTION OF E light MODE OR E MODE Function of E light mode E mode E mode Economy mode The engine output is set lower than in P mode Power mode and this mode im proves the fuel efficiency E light mode The engine output during digging is set lower than in E mode and this mode improves the fuel efficiency further The engine ou...

Page 127: ... k k CAUTION When rotating the fan in the reverse direction beware extremely that dirt will not fly out and cloth etc will not be wound in the fan Dust may blow up During reverse rotation check that there is no people in the surrounding area In the manual fan reverse mode the fan may be rotated in reverse to blow off mud or dirt sticking to the radiator 1 Set the engine speed to low idle OPERATION...

Page 128: ...he torque converter oil temperature is less than 120 C It is 10 seconds or more after the engine was started 3 Press ENTER switch 1 to rotate the fan in the reverse di rection or press RETURN switch 2 to cancel If the fan reverse operation is performed without satisfying the condition for reversing the fan the screen shown in the figure is displayed and the fan rotation direction cannot be switche...

Page 129: ...s after the fan rotation direction is re versed Stop the engine The coolant temperature hydraulic oil temperature or tor que converter oil temperature overheats the caution lamp of the oil temperature gauge or coolant temperature gauge on the machine monitor lights up in red then action level L02 is displayed while the fan is rotating in reverse RADIATOR FAN AUTOMATIC REVERSE MODE k k CAUTION When...

Page 130: ...tion for 4 minutes once for every 30 minutes Initially Mode A is selected When you want other than above settings for the duration and cycle of the fan reverse rotation consult your Komatsu distributor REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met Other than OFF is set in Automatic Fan Reverse Mode The set chan...

Page 131: ... normal direction Turn the automatic fan reverse mode OFF The set duration time for the automatic fan reverse mode has elapsed Stop the engine The coolant temperature hydraulic oil temperature or torque converter oil temperature overheat the caution lamp of the oil temperature gauge or coolant tempera ture gauge on the machine monitor lights up in red then L02 is displayed while the fan is rotatin...

Page 132: ...n creases OFF The 2 stage low idling does not operate SELECT BUCKET LEVEL POSITION The bucket cylinder length when the bucket is in the level position depends on the type of the bucket It is nec essary to set the level position according to the installed bucket NOTICE If the level position is not set appropriately the bucket positioner may not function normally EXPLANATION OF COMPONENTS OPERATION ...

Page 133: ...t When using a newly delivered machine or installing another bucket to a currently used machine you must adjust the level position of the bucket 1 Select a type of bucket whose level position is to be ad justed from the Bucket Level Position Selection screen then press the menu switch 2 Select the Bucket Level Position Adjustment then press ENTER switch The adjustment mode starts OPERATION EXPLANA...

Page 134: ...ucket type A to C without repeating the level position adjustment procedure Bucket Level Position Initialization You can return the adjusted bucket level position to the default value 1 Select a type of bucket you want to initialize from the Bucket Level Position Selection screen then press the menu switch 2 Select the Bucket Level Position Initialization then press ENTER switch The initialization...

Page 135: ...menu then press ENTER switch 1 2 Select ON OFF then press ENTER switch 1 REMARK For the detail of the gear speed see GEAR SPEED SWITCH 3 107 TRIP METER The overall travel distance after the previous resetting can be checked by using the Trip Meter You can reset the travel distance according to the following pro cedure 1 Select Trip Meter on Machine Setting and Information menu then press ENTER swi...

Page 136: ...The engine is running normally The machine is stopped The accelerator pedal is not depressed The transmission is in NEUTRAL N The engine is not in warm up operation The engine coolant and hydraulic oil are not overheating Aftertreatment devices are not in regeneration The parts of DEF system are not in thawing control mode 1 Select Auto Idle Stop Timer Setting on Machine Setting and Information me...

Page 137: ...rd screen 4 If the idle state is further continued and the countdown reaches 0 second the engine stops At the same time the parking brake is applied and the work equipment lock works Turn unnecessary switches to OFF position to prevent the battery to run out REMARK When the auto idle stop starts while the parking brake is off re lease the parking brake by turning it on once and turning it off agai...

Page 138: ... Setting ON OFF state when starting switch is turned to OFF position previous time is selected when starting switch is turned to ON position The default is ON Start AFTERTREATMENT DEVICES REGENERATION Each item of Aftertreatment Devices Regeneration menu C is for settings and operations of the aftertreatment devices re generation For details of the aftertreatment devices regeneration see HANDLE Ko...

Page 139: ...acement intervals and their remaining times to the next replacement are displayed Maintenance item Interval h Default Air Cleaner Cleaning or Change Coolant Change Fuel Prefilter Change 500 Engine Oil Change 500 Engine Oil Filter Change 500 T M Oil Filter Change 1000 Fuel Main Filter Change 1000 T M Oil Change 1000 Axle Oil Change 2000 Hydraulic Oil Change 2000 Hydraulic Oil Filter Change 2000 Hyd...

Page 140: ... the maintenance interval and the maintenance notice time consult your Komatsu distrib utor When the maintenance time caution lamp 2 is lit on the stand ard screen press the menu switch and the screen automati cally displays the Maintenance menu screen E METHOD FOR RESETING REMAINING TIME FOR MAINTENANCE After performing maintenance reset the remaining time for maintenance according to the followi...

Page 141: ...reconfir mation screen is displayed To cancel press RETURN switch 2 3 On the reconfirmation screen shown in the figure when ENTER switch 1 is pressed again the remaining time is reset and the screen returns to the Maintenance menu screen To cancel press RETURN switch 2 REMARK If the remaining time and the replacement interval are the same the remaining time cannot be reset MONITOR SETTINGS Each it...

Page 142: ...ect ON or OFF then press ENTER switch 1 ON Displays the reference line OFF Hides the reference line REMARK For the rearview monitor and the reference line see HANDLE REAR VIEW MONITOR 3 132 and METHOD FOR AD JUSTING REAR VIEW CAMERA ANGLE 3 178 This setting is held even if the starting switch is turned to OFF position The default is ON REVERSE INTERLOCK ENABLED MODE In this mode display method of ...

Page 143: ...he rear view monitor only when trav eling in reverse OFF Always displays images on the rear view monitor REMARK This setting is held even if the starting switch is turned to OFF position The default is ON METER DISPLAY SELECTION This is used for the selection of the items to be displayed on L H meter display A or R H meter display B OPERATION EXPLANATION OF COMPONENTS 3 79 ...

Page 144: ...election of the items to be displayed on the L H meter display 1 Select LH Meter Display Selection on the Meter Display Selection menu then press ENTER switch 1 2 Select the items to be displayed then press ENTER switch 1 The following 3 items can be selected SMR Service Meter ODO Odometer CLK Clock EXPLANATION OF COMPONENTS OPERATION 3 80 ...

Page 145: ...h 1 2 Select the items to be displayed then press ENTER switch 1 The following 4 items can be selected FUEL Average Fuel Consumption SMR Service Meter ODO Odometer CLK Clock REMARK For details of each item see L H AND R H METER 3 44 The default of R H meter is FUEL Average Fuel Consump tion SCREEN ADJUSTMENT This function is used for the adjustment of brightness of the machine monitor 1 Select Scr...

Page 146: ... the brightness in the night mode can be adjusted The brightness of night illumination for the switch panel and op eration switches are adjusted synchronously with the bright ness of the machine monitor CLOCK ADJUSTMENT On the clock adjustment menu you can change the setting of the clock displayed on the standard screen The following items can be changed GPS Synchronization Calendar Time 12hour or...

Page 147: ...be set manually REMARK This setting is held even if the starting switch is turned to OFF position The default is OFF When the machine is in the environment where the radio waves from GPS cannot be received the automatic setting function might be disable Turning the GPS Synchronization ON disables selecting the Calendar and Time CALENDAR SETTING Adjust the date of the machine monitor OPERATION EXPL...

Page 148: ...alendar one year 2 DOWN switch Puts calendar back one year 3 RETURN switch Cancels the change and returns the screen to Clock Adjustment menu 4 ENTER switch Proceeds to setting for month 3 When month display B is highlighted in yellow operate the switches as follows to change month display When it is not necessary to change the month setting press ENTER switch 4 1 UP switch Advances calendar one m...

Page 149: ...he machine monitor clock 1 Select Time from the Clock Adjustment menu and press ENTER switch 4 REMARK If ON is selected for the setting of GPS Synchroniza tion you cannot select the Time 2 The Time screen is displayed When time display D is highlighted in yellow operate the switches as follows to change time display When it is not necessary to change the time setting press ENTER switch 4 1 UP swit...

Page 150: ... the screen to the Clock Adjustment screen 12 HOUR AND 24 HOUR DISPLAY MODE Choose either a 12 hour display am pm or a 24 hour display 1 Select 12hour or 24hour Mode from the Clock Adjust ment menu then press ENTER switch 1 2 Select 12hour or 24hour then press ENTER switch 1 12hour Select 12H display AM PM 24hour Select 24 hour display REMARK This setting is held even if the starting switch is tur...

Page 151: ...n rises early in summer in our daily life This setting is held even if the starting switch is turned to OFF position The default is OFF LANGUAGE SETTINGS The language displayed on the machine monitor can be selected The languages that can be selected are as follows English Japanese French Spanish Portuguese Italian German Swedish Dutch Danish Norwegian Fin nish Icelandic Czech Hungarian Polish Slo...

Page 152: ...fication on the Operator ID menu The Operator ID menu is not displayed when the operator identification function is disabled REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identi fication function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted the identified ID is displa...

Page 153: ... for 1 second 2 The Operator ID Change screen is displayed Input the already registered ID on the Operator ID Change screen and press ENTER switch 1 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen On the Monitor Setting menu screen the inputted ID is displayed in the column of Operator ID OPERATION EXPLANATION OF COMPONEN...

Page 154: ...he screen returns to the Monitor Setting menu screen In this case the identified ID is not changed On the Operator ID screen if no switch is operated for more than 30 seconds the screen automatically changes to the Monitor Setting menu screen In this case the identified ID is not changed WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is av...

Page 155: ...e identified ID is not changed On the Operator ID screen if no switch is operated for more than 30 seconds the screen automatically changes to the Monitor Setting menu screen In this case the identified ID is not changed MESSAGE DISPLAY On machines equipped with KOMTRAX you can see the mes sages from your Komatsu distributor on this User Message menu G When there is any message message display 1 o...

Page 156: ... is dis played B Serial No of message C Validity D Text E Reply field In case of a message requesting for reply the Numeric Input is displayed Make any reply to the message REPLY TO MESSAGE 1 When replying to a message input the selected item num ber shown in the text of the message by using the switch panel Each switch of the switch panel corresponds to the number shown on the lower right of the ...

Page 157: ...itch key is set to OFF position The service meter and odometer can be displayed even if the machine monitor is not turned ON 1 Press UP switch 2 while holding down DOWN switch 1 when the starting switch is in OFF position Service meter A and odometer B are displayed while both switches are held down NOTICE If the monitor screen is displayed during other operations while the starting switch is at O...

Page 158: ...SWITCHES g0038111 1 ECSS switch 2 Front working lamp switch EXPLANATION OF COMPONENTS OPERATION 3 94 ...

Page 159: ...n be removed from the starting switch the electrical current to the electrical system is cut and the engine stops In addition the parking brake is applied automatically B ON position Electric current flows through the charging and lamp circuits Keep the switch at this position while the engine is running When the ambient temperature is low during engine startup the engine preheating pilot lamp lig...

Page 160: ...ument panel lamp light up Position c Headlamps light up together with the lamps lit in position b REMARK The lamp switch can be operated regardless of the turn signal lever position DIMMER SWITCH The dimmer switch is used to switch the headlights between high and low beams Position L Low beam Position H High beam TURN SIGNAL LEVER The turn signal lever is used to operate the turn signal lamp Posit...

Page 161: ...P mode by pressing the kickdown switch Use this switch to increase the rim pull further during scooping or for scrape up work In E mode 2nd E mode 1st E mode 1st P mode In P mode 2nd P mode 1st P mode In the auto shift mode if the travel speed is 10 5 km h or slower the kickdown switch operates and the gear speed can be shifted down to 1st from any gear speed of the forward or reverse travel This ...

Page 162: ...tor and rear view monitor while lamp switch is turned ON When operating the machine with the headlamp lighting up dur ing the day if this switch is set to Day mode monitor screen does not loose the brightness A Day position The monitor screen is set to the day mode B Night position The monitor screen is set to the night mode REMARK When the lamp switch is turned to OFF position operating this swit...

Page 163: ...may result Stop the machine and then apply the parking brake If the parking brake was used as a secondary brake when the machine was traveling at high speed ask your Komatsu distributor for inspection of the parking brake system The parking brake switch is used to apply the parking brake Position A ON actuated The parking brake is applied and the parking brake pilot lamp lights up on the monitor P...

Page 164: ...witch E of the front wiper switch is rotated the front windshield wiper operates If push button F is pressed washer fluid is sprinkled on the front window glass while the push button is held down The switch position can be checked by the position of round mark G Position A OFF Wiper is stopped Position B INT Wiper moves intermittently Position C Wiper moves at low speed Position D Wiper moves at h...

Page 165: ... lamps must be turned off when the machine is traveling on a public road Use the rear working lamp switch to light up the rear working lamps Position A The working lamps light up Position B The working lamps go out When position A is pressed the pilot lamp lights up and the working lamps turn ON ECSS SWITCH k k WARNING If the ECSS switch is turned ON during travel or with the work equipment raised...

Page 166: ...gle is 25 deg or larger from the level If the travel speed exceeds 5 km h while the gear speed is 2nd to 4th ECSS operates automatically If the travel speed decreases below 4 km h ECSS stops operation au tomatically When the bucket is empty and the work equipment is posi tioned at a low height you may feel the poor damper ECSS effect This is not an abnormality FRONT WORKING LAMP SWITCH k k WARNING...

Page 167: ...WARNING When starting the machine off an uphill turn the transmission cut off switch to OFF position depress the accelerator pedal while depressing brake pedal and then release the brake pedal gradually to allow the machine to start off This prevents the machine from rolling back Press position A of the transmission cut off switch to set it ON or OFF If you release your hand from the switch it aut...

Page 168: ... on flat ground where the maximum power is not needed Switch the mode between E light mode and E mode on the monitor For the method of switching see SELEC TION OF E light MODE OR E MODE 3 62 P mode The engine output is high Use the power mode for the production conscious operation REMARK To perform operations with effective fuel consumption usually set to E light mode E mode With these modes the e...

Page 169: ...he transmission shift mode selector switch lights up when position of A or C is selected Lamp does not light up when position B is selected TORQUE CONVERTER LOCKUP SWITCH The torque converter lockup switch is used to turn the torque converter lockup function ON and OFF Each time position A of the switch is pressed the function switches between ON and OFF If you release your hand from the switch it...

Page 170: ...installed Keep the auto digging switch off when driving the machine on public road The auto digging switch is used to turn on and off the auto dig ging Each time position A of the switch is pressed the function switches between ON and OFF If you release your hand from the switch it automatically re turns to its original position For the method of the auto digging see METHOD FOR AU TO DIGGING 3 205...

Page 171: ...fore operating the work equipment lock switch make sure that work equipment control lever A is in HOLD position When operating the work equipment lock switch be sure not to touch work equipment control lever A The work equipment lock switch is a device used to lock the work equipment The work equipment is locked the pilot lamp lights up or un locked the pilot lamp goes out each time you press posi...

Page 172: ...ear speed switch is set to the 1st position the gear speed is fixed to the 1st speed The gear speed is not shif ted automatically The gear speed is shifted automatically between the set gear speed of the switch and 2nd depending on the travel speed The gear speed is shifted down from the 2nd to the 1st by pressing the kickdown switch of the boom control lever When the auto shift and auto kickdown ...

Page 173: ...lity on this switch If the engine shutdown secondary switch is set to STOP ENGINE position 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 the machine monitor check that the switch cover is closed and the switch is in NORMAL position If not return it to NOR...

Page 174: ...witch to NORMAL position QUICK COUPLER SWITCH if equipped Use the quick coupler switch to install or remove the attach ment Position a Release Push the switch in to the position a then pull lock A in the direction of the arrow b and release the connection While the quick coupler switch is pushed the quick coupler lock release pilot lamp 1 lights up and the alarm buzzer sounds intermittently And it...

Page 175: ...Start the engine after turning the directional lever to NEUTRAL position N Position F FORWARD Position N NEUTRAL Position R REVERSE REMARK Do not maintain the directional lever at the intermediate position between positions F and N or between po sitions N and R Although the transmission operates as displayed on the monitor screen the alarm buzzer sounds STEERING TILT LOCK LEVER k k WARNING Stop th...

Page 176: ...t up degrading its function and may result in serious personal injury or death Do not put your foot on the brake pedal unnecessarily NOTICE Frequent braking increases the axle oil temperature As a result the alarm buzzer may sound and the warning lamp may light up for protection of the brake discs Observe the following ways of operation to prevent the increase of the axle oil temperature Try to av...

Page 177: ...ator pedal is used to adjust the speed and output of the engine It freely controls the engine from low idle to high idle BUCKET CONTROL LEVER NOTICE Even if the engine is stopped if the starting switch is at ON position and lock of the work equipment is cancelled pilot lamp is not lit the work equipment can be operated The bucket control lever is used to operate the bucket Position a TILT When the...

Page 178: ...urned to FLOAT position the lever stops in that position When the remote boom positioner is enabled the boom stops at the preset position and the lever returns to HOLD position at the same time When the remote positioner is not set the lever remains in FLOAT position and does not return OTHER COMPONENTS METHOD FOR OPENING AND CLOSING CAB DOOR k k CAUTION Always check that the cab door is locked in...

Page 179: ... the door opens to the full open posi tion OPEN LOCK FOR CAB L H DOOR Use this to fix the door in position after opening it or when getting on and off the operator s cab 1 Push the door against catch 1 to lock it in position 2 When keeping the door open fix it securely to the catch 3 When getting on or off the machine hold the inside hand rail 4 When closing the door push down knob 2 to release th...

Page 180: ...ous Never operate the machine with the door open Always operate the machine while the door is fully closed or locked half open Alternate exit door closed fully or locked half open When door knob 1 is pressed down completely the door is locked with fully closed state When cooling or heating the cab keep the door locked and fully closed with this function If the door knob 1 is pulled up the door is ...

Page 181: ...ide door wide and go out To return the door knob to the locked state grip door knob 1 and pull it toward the rear of the machine Match the guide rail of the door knob with the guide pin on the guide cab side and push in the door knob toward the front Check that the guide pin is inserted into the guide rail securely and push in and fix door knob 1 to the lock position OPERATION EXPLANATION OF COMPO...

Page 182: ...ing op eration They can be kept warm during the heating operation Do not put things which smell or break easily or leak water etc in this box Do not use this box as a holder for small objects CUP HOLDER The cup holder is located at the rear left of the operator s seat ASHTRAY This is on the right side of the operator s seat Always extinguish your cigarette before putting it in the ashtray and be s...

Page 183: ...the equipment When cigarette lighter 1 is removed its socket can be used as a 24 V power supply The capacity is 85 W 24 V x 3 5 A REMARK Use 24 V power source while engine is running 12 V power supply Power supply take out 2 can be used as a 12 V power supply The capacity is 144 W 12 V x 12 A Power supply take out 3 can be used as a 12 V power supply The capacity of 12 V power supply is 144 W 12 V...

Page 184: ... devices used does not exceed the capacity of the fuse FUSE NOTICE When replacing the fuse be sure to turn the starting switch to OFF position and after confirming that the system operating lamp is not lit set the battery disconnect switch key to OFF position The fuses protect the electrical component and wiring from burning out If the fuse becomes corroded or looks white powdery or the fuse is lo...

Page 185: ...sion seat 14 30 A Rear heated wire glass 15 5 A Engine control key switch accessory Fuse box B No Fuse capacity Name of circuit 1 15 A Horn 2 20 A Transmission control 3 5 A Parking brake 4 5 A Secondary steering 5 15 A Work equipment positioner 6 10 A Backup lamp and brake lamp 7 30 A Wiper and washer 8 20 A Air conditioner blower 9 5 A Main compressor 10 10 A Monitor main circuit 11 30 A Main la...

Page 186: ...in power supply 1 3 50 A Main power supply 2 4 120 A Charge circuit 5 120 A Heater relay ribbon heater FRAME LOCK BAR k k WARNING When performing maintenance or transporting the machine always set the frame lock bar to LOCK position Always disengage the frame lock bar when traveling If it is not disengaged the steering wheel be comes inoperative and this may lead to serious personal injury or deat...

Page 187: ...d down handle 6 of towing pin 1 4 When removing it perform the procedure in the reverse or der TOOL BOX if equipped The toolbox is inside the step on the left of the machine METHOD FOR OPENING AND CLOSING REAR FULL LENGTH FENDER AND EN GINE SIDE COVER Right and left METHOD FOR OPENING REAR FULL LENGTH FENDER AND ENGINE SIDE COVER OPERATION EXPLANATION OF COMPONENTS 3 123 ...

Page 188: ...lide rear full length fender 1 out ward 4 Raise lock lever 5 and turn it then lower the lock lever at LOCK position L Rear full length fender 1 is locked 5 Pull door opening lever 6 to unlock 6 Push up engine side cover 7 to open 7 Pull cover 8 toward you and open it EXPLANATION OF COMPONENTS OPERATION 3 124 ...

Page 189: ...ngth fender 4 and slide it in ward and return the rear full length fender to its original position GREASE PUMP HOLDER if equipped The grease pump is installed to the holder in the toolbox on the inside of the left step of the machine After using the pump wipe off the grease from its outside and install it in position Insert the grease pump into the holder and fix it with the rubber band FIRE EXTIN...

Page 190: ...tion carelessly this is extremely dangerous NOTICE Keep battery disconnect switch in ON position except the following cases When the machine is stored for a long time more than a month When repairing the electrical system When performing electric welding When handling the battery When replacing the fuse etc Do not turn the battery disconnect switch to OFF position while the system operating lamp i...

Page 191: ...tion every electric system of the machine becomes inoperable The memory of the clock on the monitor is lost Set them again when using Immediately after the starting switch is turned to OFF posi tion data is saved on each controller Before turning the battery disconnect switch to OFF posi tion make sure that system operating lamp 4 below the battery disconnect switch is off Immediately after the re...

Page 192: ...s lit BACKUP ALARM This alarm sounds as soon as the machine moves in reverse to warn people behind the machine When moving the machine in reverse perform the following procedure Set the directional lever to REVERSE position R Set the directional selector switch if equipped to RE VERSE position Set the directional selector switch of the multifunction mono lever if equipped to REVERSE position HANDL...

Page 193: ...the figure For details see AUTO GREASING PILOT LAMP 3 34 AU TO GREASING SWITCH 3 99 and CHECKING AUTO GREASING AND OPERATION METHOD FOR FILLING GREASE 4 39 Turn the starting switch to ON position B The power supply to the grease pump is turned on The auto greasing pilot lamp is lit for 2 seconds Display and control unit The display and control unit are protected by a transparent plastic cover agai...

Page 194: ... operating one of the two push buttons It is used for displaying current values and preset parameters In addition the display is used for operator prompting during setting of operating parameters Display Denotation Explanation Control function t TIMER PA PAUSE The control unit operates as a time controlled contact maker TIMER and is in the PAUSE state Part of lubrication cycle Input and display va...

Page 195: ...in the FAULT mode The sequence of opera tions is stopped Fault Cycle Switch No signal from cycle switch during pump running time The control unit is in the FAULT mode The sequence of opera tions is stopped Operation Hour Meter The subsequently displayed values are the operating hours of the con trol unit Fault Hour Meter The values displayed in the following are the fault hours which are the time ...

Page 196: ...itch during pump running time The control unit is in the FAULT mode The sequence of opera tions is stopped If the fault message will appear again after the reset consult your Komatsu distributor HANDLE REAR VIEW MONITOR k k WARNING Never operate any of the switches while traveling If you do so there is a danger that you may make an error in the machine operation or neglect to watch the travel path...

Page 197: ...e exhaust pipe outlet and around the aftertreatment devices to prevent being burnt Also keep combustible materials away from the exhaust pipe outlet and around the aftertreatment devices to prevent a fire When there are thatched houses dry leaves or pieces of paper near the job site set the system to the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after...

Page 198: ... manual stationary regeneration For details of the procedure see PROCEDURE FOR MAN UAL STATIONARY REGENERATION 3 137 Two types of monitor display require the manual stationary re generation depending on the level of urgency When the directional lever is turned to NEUTRAL position N and the parking brake switch is turned to the PARKING posi tion the manual stationary regeneration may start automati...

Page 199: ...neration is completed the soot accumulation level may not be 0 This is caused by the accumulated noncombustible material in the exhaust gas and is not a failure Since noncombustible matter which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals For details see METHOD FOR CLEANING KDPF 4 74 The engine speed or en...

Page 200: ...conds every 2 hours If KDPF soot accumulation caution lamp 2 lights up in yellow stop the machine in a safe place and perform the manual stationary regeneration When the degree of emergency is high KDPF soot accumulation caution lamp 2 lights up in red and the action level L03 lights up in red 4 If the machine is stopped completely the screen changes to the Aftertreatment Devices Regeneration scre...

Page 201: ... with engine running 2 Check that there is no person or combustible matter around the machine particularly in the direction of the ex haust gas flow 3 Release your foot from the accelerator pedal and set the directional lever to NEUTRAL position N 4 Set the parking brake switch to ON position A and apply the parking brake 5 Press the menu switch to display Aftertreatment Devices Regeneration scree...

Page 202: ...d in 3 parts on the monitor panel When ENTER switch is pressed the regeneration can be started immediately regardless of which part is dis played When RETURN switch is pressed the display returns to the standard screen If no monitor switch is operated for 30 seconds the explanation display of the manual stationary regenera tion is not displayed and the screen returns to the standard screen At this...

Page 203: ... regeneration disable and cancel of regeneration disable procedures described in the following When restarting the manual stationary regeneration secure the safety of the machine and around it then cancel the regeneration disable 8 After the manual stationary regeneration is completed the screen automatically returns to the standard screen PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE ...

Page 204: ... the engine During the regeneration to protect the system even if the regeneration disable is set aftertreatment devices regen eration pilot lamp 2 may light up but this does not indi cate abnormality Also during the regeneration to protect the system the regeneration disable cannot be operated When the regeneration is performed to protect the system the exhaust temperature is lower than that of w...

Page 205: ...eration screen is not displayed display it by pressing the menu switch several times 2 Select Cancel of Regeneration Disable and press EN TER switch and the regeneration disable is canceled If soot accumulation level 1 lights up 3 or more the re generation may be started automatically REMARK When canceling the regeneration disable release the ac celerator pedal set the directional lever in NEUTRAL...

Page 206: ...to take prompt actions to maintain and correct inappropriate behaviors of Urea SCR systems by utiliz ing visible and audible alerts and engine power derate in addition Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions The Komatsu Urea S...

Page 207: ...e noticed as a delay in the start of functioning of the pump and the injector The heating system is also activated automatically during operation to prevent DEF from freezing whenever the ambient temperature drops below a certain threshold where DEF in the system may freeze In the event that the ambient temperature drops further than a temperature where the heating system is capable of maintaining...

Page 208: ...afe place and add DEF Warning 2 gradations of the DEF level gauge light up in the red range The DEF level caution lamp 1 lights up in red No audible alert No Action level is displayed Press the menu switch to display the SCR Information screen Inducement status 4 1 DEF low level warning appears Add DEF to the DEF tank immediately Continuous Warning The audible alert sounds in Intermittent alarm 2 ...

Page 209: ...rm No gradation of the DEF level gauge lights up The DEF level caution lamp 1 lights up in red The Action level L04 is displayed in red 5 Press the menu switch to display the SCR Information screen When all gradations of the DEF level gauge go off DEF re filling amount is approximately 26 5 ℓ to fill up the DEF tank Inducement status 4 4 Engine power is under heavy de ration Engine power can be re...

Page 210: ...that advances to speed limitation to low idle Engine power deration starts with Action Level L03 Low level Inducement and advances to further deration when L04 Severe Inducement is displayed If L03 is displayed move the machine to a safe place and contact your Komatsu distributor The content of the warning can be checked on the SCR Information screen of the user menu Perform the following procedur...

Page 211: ...r Ko matsu Distributor The duration of Continuous Warning is 5 hours The re maining time Hours and Minutes to Low level Induce ment is displayed in the column 5 of the SCR Informa tion screen In Low level Inducement engine performance will be de rated Low level Inducement The audible alert sounds in Intermittent alarm The DEF system caution lamp 1 lights up in red Action level L03 lights up in red...

Page 212: ...hine monitor For the engine power restoration procedure refer to the section of Temporary Restoration from Induce ment in this manual Inducement strategy when abnormality is found in the KDPF System by the Urea SCR system If any abnormality is detected in the KDPF System through the Urea SCR system the Inducement strategy is activated The inducement strategy progresses in 4 levels Warning Continuo...

Page 213: ...ction level dis play 3 Press the menu switch to display the SCR Information screen SCR Information screen message 5 1 Please inspect and maintain SCR system Engine power is derated Move the machine to the safe place and contact your Ko matsu Distributor If operation continues for 5 hour after Warning started without taking any actions instructed by the Action Level table Inducement advances to Con...

Page 214: ...Low level Inducement is 10 hour The remaining time Minutes to Severe Inducement is displayed in the column 6 of SCR Information screen In Severe Inducement engine power will be derated fur ther Move the machine to the safe place and contact your Ko matsu Distributor Severe Inducement The audible alert sounds in Non stopping alarm The KDPF system caution lamp 1 lights up in red DEF system caution l...

Page 215: ...e Inducement strategy includes visual alert by the Engine system caution lamp 1 DEF system caution lamp 2 and Action Level displayed on the machine monitor 3 au dible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine power deration starts with Action Level L03 Warning Continuous Warning and Low level Inducement and advances to further deratio...

Page 216: ...ystem caution lamp 2 lights up in yellow The action level L03 lights up in red at action level dis play 3 Press the menu switch to display the SCR Information screen SCR Information screen message 5 2 Without treat ment engine power will be derated Move the machine to the safe place and contact your Ko matsu Distributor The duration time of Continuous Warning is 5 hour The remaining time Minutes t...

Page 217: ...el Inducement The operator can re store engine power through the machine monitor For the engine power restoration procedure refer to the section of Temporary Restoration from Inducement in this manual If Inducement advances to Severe In ducement and it becomes necessary to restore engine power use the engine power restoration function to move the machine to a safe place and contact your Komatsu di...

Page 218: ... the SCR Information screen alternate every 15 seconds as shown in the graphics A and B 3 Press the enter switch 2 while the pop up menu screen B is displayed The Engine power Recovery window pops up If the enter switch 2 is not pressed for 30 seconds Standard Screen will be displayed and start again by pressing the menu switch 1 The remaining number of operations of Temporary Resto ration from in...

Page 219: ...yed in the column 4 on the SCR Information screen If it is decided NOT to activate Temporary Restoration from Inducement after having progressed to the Engine Power Recovery window follow the steps explained in this section To deactivate Temporary Restoration from Inducement function 1 Press the return switch 5 while the Engine Power Re covery window is displayed This procedure is split from proce...

Page 220: ...Low level Inducement The alerts resume the previous Inducement If this occurs utilize Temporary Restoration from Inducement and move to the machine to a safe place and contact your Komatsu distributor The maximum duration of power restoration is 30 minutes and 3 operations are allowed To activate Temporary Restoration from Inducement refer to the Temporary Restoration from Inducement section in th...

Page 221: ...you want to do this ask your Komatsu distributor for disconnecting power supply cable of KOMTRAX Also if there are any requirements or regulations of the territory or country where the machine equipped with this device is used such requirements or regulations have a priority than this warn ing When checking for compliance with regulations refer to the following KOMTRAX equipment satel lite communi...

Page 222: ...hand For the registration and usage records of KOMTRAX consult your Komatsu distributor If the machine has been lent out by the customer the borrower or another third party may have been using the KOMTRAX Confirm with the lessor about using condition of KOMTRAX Komatsu may suspend KOMTRAX communication in the following cases When Komatsu judges that KOMTRAX is used by an unregistered customer When...

Page 223: ...xhaust gas Check the engine for leakage of oil and exhaust gas and check the cooling system for coolant leakage If any problem is found repair it 4 Check the fuel line for leakage Check for leakage of fuel or damage to the hoses and tubes If any problem is found repair it 5 Remove dirt and check DEF line for leakage Check for dirt accumulated around the DEF tank and clean blue DEF tank filler cap ...

Page 224: ... wipe with a clean soft and dry cloth 15 Check the rearview mirrors Check the rear view mirror for trouble If it is damaged repair it Clean the surface of the mirror and adjust the angle so that the area at the rear can be seen from the operator s seat 16 Check the side under view mirrors Check for damage to the side under view mirrors If they are damaged repair them Clean the surface of the mirro...

Page 225: ...ty do not use the following tires Wear Tires with a tread grooves of less than 15 of that of a new tire Tires with extreme uneven wear or with stepped type wear Damage Tires with damage that has reached cords 1 or with cracks in the rubber Tire with cut or broken cords 1 When tires are peeled separated Tires with damaged bead 2 Leaking or improperly repaired tubeless tires Deteriorated deformed or...

Page 226: ... 4 tighten plug 2 immediately to stop draining Tightening torque 0 2 to 0 45 Nm 0 02 to 0 046 kgm REMARK On this machine a sensor is installed to detect if wa ter accumulates in transparent cup 3 When the water separator caution lamp 5 lights up in red on the machine monitor it indicates that water ac cumulates in transparent cup 3 In this case as well use the procedure above to drain the water Wh...

Page 227: ...placing the filter When the plug 2 has been removed during the cleaning work apply grease to O ring 6 and tighten with your finger until it stops METHOD FOR CHECKING COOLANT LEVEL ADDING COOLANT k k WARNING Do not open the radiator cap unless necessary When checking the coolant level check the reser voir tank when the engine is cold Immediately after the engine is stopped the coolant is at high te...

Page 228: ...el of the coolant in the radiator If it is low add coolant of the same density in radiator according to the coolant density table in METH OD FOR CLEANING INSIDE OF COOLING SYSTEM 4 20 then add coolant to the reservoir tank If coolant is added more than usual check for coolant leakage Check that there is no abnormality such as oil in the cool ant METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN ADDI...

Page 229: ...r if the coolant level is normal it is not a problem If the coolant level is low add coolant METHOD FOR CHECKING DUST INDICATOR 1 Check that the red line in the transparent portion of dust in dicator 1 does not indicate 7 5 kPa 0 076 kg cm2 If the red line indicates 7 5 kPa 0 076 kg cm2 clean or re place the air cleaner element immediately For the cleaning method of the element see METHOD FOR CHEC...

Page 230: ...ly stopped If fuel is excessively added fuel may inflate and flow out when ambient temperature increased and it is dangerous Also it may cause fire If any fuel has spilled wipe it up completely Fuel is highly flammable and dangerous Never bring any open flame near fuel NOTICE When restarting the engine that has stopped due to run out of fuel all air must be sufficiently bled from the circuit For t...

Page 231: ...as NOTICE Do not add DEF more than line F of sight gauge 5 DEF may leak through the breather When the ambient temperature is low and DEF may freeze do not add it more than line 9 of sight gauge 5 Be careful of the DEF line to be added when performing operations on a slope or traveling on a rough ground When the remaining DEF level is low it may become the warning level if DEF pump sucks air or if ...

Page 232: ...el gauge 1 on the machine monitor When adding DEF perform actions written in DEF LEVEL CAUTION LAMP 3 22 3 After checking turn the starting switch back to OFF posi tion A 4 Set the frame lock bar 2 to LOCK position L MACHINE OPERATIONS AND CONTROLS OPERATION 3 168 ...

Page 233: ...e filler port until float 6 reaches line F 7 Line 8 in the sight gauge indicates approximately 5 ℓ be low line F and line 10 indicates approximately 10 ℓ Line 9 is the max adding line when DEF may freeze in cold weather 8 After adding align claw 11 of the cap with groove 12 of the filler port and close the cap securely by turning it clock wise by 90 9 Set the frame lock bar 2 to FREE position F OP...

Page 234: ...OUT Operate the window washer and check that the washer fluid spouts out normally If the fluid does not spout out normally clean the washer nozzle hole with a fine wire such as a safety pin If the condition does not become normal ask your Komatsu distributor to perform inspection and repair METHOD FOR CHECKING WIPER FUNCTION Operate the wiper in the Intermittent Low and High mode and check that it...

Page 235: ... the air flows out of the vents properly onto the front glass If there is any abnormality ask your KOMATSU distributor for testing and repair Operate the rear heated wire glass switch and check that the rear glass surface is heated properly If there is any abnormality ask your KOMATSU distributor for testing and repair METHOD FOR CHECKING LOCKS Check that all places can be locked properly For the ...

Page 236: ...ward Sit with your back against the backrest when adjusting If your back is not on the backrest it may suddenly return to the original position Adjustment amount Forward tilt 21 any degree is acceptable if it is greater than 21 Backward tilt 33 2 After adjusting release the lever METHOD FOR TILTING SEAT Pull the lever up and move the front side of the seat cushion up and down to the desired positi...

Page 237: ... is low or when the machine has not been used for a while it takes time to raise the seat to desired height since no air is in the suspension You can adjust the seat to desired height more quickly by pressing the switch while reducing the load on the seat METHOD FOR ADJUSTING SEAT CUSHION IN FORE AFTER DIRECTION Operate the lever upward set the seat cushion to the desired position then release the...

Page 238: ...rmrest angle Amount of adjustment 35 Forward tilt 12 backward tilt 23 REMARK You can flip up the armrest METHOD FOR ADJUSTING LUMBER SUPPORT Turn the knob to the right or left and give proper tension to the waist part METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS By operating the knob the damping force of the suspension damper can be adjusted MACHINE OPERATIONS AND CONTROLS OPERATION 3 174 ...

Page 239: ...e knob to 2nd stage position d or 1st stage position c The damper becomes softer METHOD FOR WARMING UP SEAT if equipped When the switch is operated in the A direction the heater in side the seat cushion is activated When it is operated in the B direction the heater is turned off Turn off the switch when the temperature of cushion becomes correct k k CAUTION Using the heater for a long time may cau...

Page 240: ...not se cure the visibility and may be injured or may lead to a serious personal injury or death The tightening torque for the mirror mounting bolts is set at an optimum value If it is loosened by unexpected contacts ask your Komatsu distributor for adjustment Mirrors A B Adjust the mirror to a position which gives the best view from the operator s seat of the blind spot at the right and left sides...

Page 241: ...sition where you can easily see the hatched area in the figure The reference values of the visibility range are as follows Visibility range left 2500 mm Visibility range right 2500 mm Mirror A Hatched area a must be in view Mirror B Hatched area b must be in view Mirror C Hatched area c must be in view Mirror D Hatched area d must be in view OPERATION MACHINE OPERATIONS AND CONTROLS 3 177 ...

Page 242: ...rm If you try to work standing on the counterweight there is a danger of serious injury or death due to falling off from the machine Install only the Komatsu genuine camera Adjusting rear view camera angle Adjust the angle of the rear view camera so that people within 1 m away from the machine s rear part W is displayed in the monitor at the operator s seat If the image on the monitor is not align...

Page 243: ... Loosen mounting bolts 1 3 places and adjust angle A REMARK A part of the machine is shown on the monitor screen 2 After adjusting tighten bolts 1 3 places OPERATION MACHINE OPERATIONS AND CONTROLS 3 179 ...

Page 244: ...ening the seat belt check that there is no problem in the belt mounting bracket or belt If it is worn or damaged replace it Even if no problem can be seen in the belt replace the seat belt every 3 years from starting usage or 5 years after manufacture whichever comes sooner The date of manufacture of the belt is shown on the back of the belt Before operating fasten the seatbelt Be sure to use the ...

Page 245: ...r METHOD FOR ADJUSTING LEVER STAND k k WARNING When adjusting the lever stand make sure that the work equipment is locked the pilot lamp in the switch is lit If the work equipment control levers are touched by accident when adjusting the lever stand the work equipment may move suddenly and cause a serious personal injury or death METHOD FOR ADJUSTING ARMREST HEIGHT AND ANGLE The height and angle o...

Page 246: ... control levers are not locked and they are touched by accident when starting the engine the work equipment may move unexpectedly and this may lead to a serious injury or death Perform the check before starting the engine according to the following procedure 1 Check that battery disconnect switch S is in ON position I 2 Check that parking brake switch 1 is in ON position A 3 Check that directional...

Page 247: ...ds The pointer of engine tachometer swings once If the monitor does not light up there may be a failure or wire breakage Ask your Komatsu distributor for inspec tion Also after all of the monitors gauges and centralized warning lamp light up perform the self check to check that the secondary steering function operates normally For details see OPERATION SELF CHECK FUNCTION FOR SECONDARY STEERING 3 ...

Page 248: ...that preheating pilot lamp 2 stays lit depends on the ambient temperature as shown in the table Ambient temperature C Lighting time sec 1 to 15 0 to 30 Below 15 30 REMARK Usually the engine is preheated sufficiently by the automatic preheating If it is needed to extend the pre heating time turn the key in starting switch 1 to position D Do not preheat the engine more than 30 seconds however 2 When...

Page 249: ...ine Exhaust gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not accelerate the engine abruptly until it is warmed up This machine is equipped with the automatic warm up function to heat the coolant more quickly and the tur bo protect function to protect the turbocharger In cold weather startup the engine speed may not change for...

Page 250: ...engine again 3 After the engine starts and its speed increases release your hand from the key of starting switch 1 The key returns automatically to ON position B REMARK When the engine is started white smoke may come out of the exhaust pipe It is fine water particles which are pro duced from moisture or water vapor and which seem white thus it does not indicate a problem The smell of the exhaust g...

Page 251: ...X Engine speed rpm Y Coolant temperature C METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE k k WARNING If there has been any emergency stop abnormal actuation or other trouble turn the starting switch key to OFF position If you cannot stop the engine by turning the starting switch to OFF position use the engine shut down secondary switch to stop the engine If the work equipment is operated ...

Page 252: ...ly on a level ground with no obstacles around and check the brake performance If any problem is found in operation of the brake ask your Komatsu distributor for adjustment METHOD FOR CHECKING CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR Depress the brake pedal fully and check that the pedal is not too close to the floor Also check that the feeling when operating the brake pedal is normal If any problem...

Page 253: ...bucket control lever to TILT position A and return to HOLD position B repeatedly to warm up hy draulic oil Relieve the circuit at TILT position A for a maximum of 10 seconds Oil reaches the relief pressure through the above opera tions and hydraulic oil gets warmer in a shorter time 4 Turn the steering wheel slowly approximately 10 times to the right and left to warm up hydraulic oil in the steeri...

Page 254: ... engine coolant temperature or transmission oil temperature is high when the cooling fan is rotating in reverse it rotates at a fixed speed in proportion to the engine speed regardless of any oil or coolant temperature METHOD FOR STOPPING ENGINE k k WARNING Keep away from the exhaust pipe immediately after stopping the engine NOTICE If the engine is abruptly stopped before it has cooled down servi...

Page 255: ...e damage to the devi ces METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND SHIFTING GEAR AND STOPPING MACHINE METHOD FOR MOVING MACHINE k k WARNING Always disengage the frame lock bar during traveling If it is not disengaged the steering becomes inoperative and this may lead to serious personal injury or death Before moving the machine off check that the area around the machine is safe th...

Page 256: ... 5 and set parking brake switch 6 to OFF position C to release the parking brake Keep R H brake pedal 5 depressed REMARK When the parking brake remains applied even if parking brake switch 6 is at OFF position C turn the parking brake switch to ON position B then turn it to OFF posi tion C again 5 Set gear speed switch 7 to the desired position Position a 1st speed Position b 2nd speed Position c ...

Page 257: ...ition R REVERSE When selecting FORWARD NEUTRAL or REVERSE with this switch 8 set directional lever 7 to NEUTRAL posi tion and directional selector enable switch on R H switch panel 12 to ON position 7 Release R H brake pedal 5 then depress accelerator pedal 9 REMARK When moving the machine off at an uphill set transmission cut off switch 10 to OFF position move the directional lever in position wh...

Page 258: ...t gear abruptly Use the brake to reduce the travel speed before shifting gear Shift gear as follows Set gear speed switch 1 to the desired position to shift gear Position a 1st speed Position b 2nd speed Position c 3rd speed Position d 4th speed MACHINE OPERATIONS AND CONTROLS OPERATION 3 194 ...

Page 259: ...al the shift down is not enabled to protect overrun of the engine In such case the centralized warning lamp lights up and the alarm buzzer sounds If the alarm buzzer sounds release the accelerator pedal immediately depress the brake pedal to reduce the speed and then shift the gear METHOD FOR SWITCHING BETWEEN FORWARD AND REVERSE k k WARNING When switching the travel direction between FORWARD and ...

Page 260: ... X Travel speed km h Y Engine speed rpm In auto shift mode If you perform a directional change when the auto shift mode is selected the gear speed changes automatically for example from F3 to R2 from F4 to R2 from R3 to F2 or from R4 to F2 allowing you to move the machine off quicker than usual However if you try directional switching during a high speed travel such as region A or B in the table t...

Page 261: ...ng the opera tor s seat be sure to lock the work equipment by pressing the work equipment lock switch the pilot lamp lights up Keep depressing the brake pedal until the parking brake pilot lamp lights up on the machine monitor even when the parking brake switch has been turned ON NOTICE Never use the parking brake switch to brake the machine when the machine is traveling except in an emergency App...

Page 262: ...ction switches between ON and OFF When you release your hand the switch returns automatically to its original position When the brake pedal is depressed the brakes are actuated and the transmission is returned to NEUTRAL at the adjusted brake pedal depressing position REMARK For adjustment of the depressing position of the brake pedal see METHOD FOR ADJUSTING TRANS MISSION CUT OFF POSITION 3 199 A...

Page 263: ...FF POSITION k k CAUTION Apply the parking brake before starting adjustment of the transmission cut off position Adjust the brake pedal depressing position 1 Start the engine with starting switch 1 set parking brake switch 2 to ON operation position 2 Press a of transmission cut off switch 3 to set it to ON position Check that the transmission cut off pilot lamp is lit 3 Depress brake pedal 4 to ad...

Page 264: ...ondary steering system so do not stop the engine during travel It is particularly dangerous if the engine is stopped while the machine is traveling on slopes so never try such practice If the engine stops place the machine immediately in a safe place When the machine is traveling turn steering wheel 1 to the desired direction then the machine turns to the direc tion Front and rear frames of this m...

Page 265: ...heck for 3 seconds For detail see SELF CHECK FUNCTION FOR SECONDARY STEERING 3 201 When the secondary steering controller detects lack of oil pres sure in the steering system steering oil pressure caution lamp red 3 and centralized warning lamp 4 lights up and the alarm buzzer sounds intermittently When this happens if the machine is traveling at 2 km h or above the electric pump motor is automati...

Page 266: ...machine to ON position the lockup mode is turned on When changing the setting see LOCKUP FUNCTION SETTING WHEN KEY IS ON 3 73 k k WARNING While traveling a downhill A of 6 or steeper do not de press the accelerator pedal to the stroke end regardless of ON or OFF of the torque converter lockup function mode Otherwise accidents can be caused by an excessive speed NOTICE During the high speed travels...

Page 267: ... even when the torque converter lockup function mode is OFF When the travel speed reaches 40 0 km h or above the centralized warning lamp lights up and the alarm buz zer sounds If the alarm buzzer sounds depress the brake immediately to reduce the travel speed The alarm buzzer stops sounding when the travel speed is reduced to 39 5 km h or below METHOD FOR OPERATING WORK EQUIPMENT NOTICE Even if t...

Page 268: ...turned to FLOAT position the lever stops in that position When the remote boom positioner is enabled the boom stops at the preset position and the lever returns to HOLD position at the same time When the remote positioner is not set the lever remains in FLOAT position and does not return METHOD FOR OPERATING BUCKET The bucket control lever is used to operate the bucket Position a TILT When the buc...

Page 269: ...down to 1st by the kickdown switch the machine is set in the auto digging mode as well When the gear speed is fixed to 1st in the manual shift mode if the kickdown switch is pressed the machine is set in the auto digging mode 4 If the bucket is fully tilted the auto digging mode is finished The auto digging mode can be canceled by performing the following operations When the auto digging mode is c...

Page 270: ... REMARK If the travel speed is 3 km h or less during the auto digging mode the boom may rise automatically When the gear speed is fixed to 1st in the manual shift mode if the kickdown switch is pressed the machine is set in the auto digging mode 5 If the bucket is fully tilted the auto digging mode is finished The auto digging mode can be cancelled by performing the following operations When the a...

Page 271: ...st not be set to NEUTRAL position N while trav eling or traveling downhill Set the direction of directional lever or directional selector switch if equipped in the traveling direction of the machine It is dangerous that the engine brake is disabled and the steering wheel becomes heavier The transmission and other parts of the power train may be damaged and it may cause serious personal injury or d...

Page 272: ...r mality Check the oil level and coolant level as well When stopping the machine in extremely cold areas do as follows Do not stop the engine abruptly to prevent the radiator coolant temperature from rising sharply Cool the radiator coolant down gradually before stopping the engine Always travel with the bucket empty Never travel with calcium chloride or dry ballast in the tires PAY ATTENTION TO D...

Page 273: ...riving the machine for ward stop the bucket once at height A a position ap proximately 30 cm from the ground then lower it further slowly If the bucket hits the ground the front tires come off the ground the tires will slip 2 Shift down in front of the piled soil As soon as completing the shift down depress the accelerator pedal to scoop the soil Minimize the accelerator pedal depressing distance ...

Page 274: ...t tilting back the bucket and load the bucket fully If the bucket edge is moved up and down while digging with the bucket by using rim pull the front tires will come off the ground and this will cause the tire slippage 6 If too much material is loaded in the bucket perform quick DUMP and TILT operation of the bucket to shake off the excessive load so that the load does not spill during haul ing DI...

Page 275: ...voidable to drive the machine forward for the leveling work do not set the bucket dumping angle to more than 20 The work equipment may be damaged Keep ECSS switch turned OFF during leveling work 1 Scoop earth and sand into the bucket and then while driv ing the machine in reverse tilt the bucket forward to dump earth and sand bit by bit to spread them 2 When leveling the ground tilt the bucket for...

Page 276: ...od condition When performing load and carry operation see PRECAUTIONS FOR LOAD AND CARRY OPERATION 3 223 LOADING WORK Select an efficient loading method which minimizes the number of turns and travel distance according to the job site k k WARNING Level the job site constantly Avoid sudden steering or braking while the boom is being raised with the bucket loaded This is dangerous Never thrust the w...

Page 277: ...ve the machine forward to load the soils onto the dump truck The smaller the turning angle of the wheel loader is the more efficient the operation becomes Before raising the boom to the maximum height after filling the bucket with load shake the bucket near the ground to stabilize the load then raise the bucket This will prevent the load from spilling to the rear PRECAUTIONS FOR FORKING WORK When ...

Page 278: ...beeps and the bucket stop position is set to that position And the monitor displays the position setup level When resetting the bucket stop position hold down posi tion b of switch 1 for more than 1 second The buzzer beeps indicating that the bucket stop position so far set has been reset The position is then returned to the level position A B or C that has been specified from Bucket Level Positio...

Page 279: ...on checkup procedure Lower the boom once move the boom control lever to RAISE detent position and then release your hand from the lever The boom rises and then stops at the moment when the boom control lever returns from the detent position to HOLD position REMARK When setting RAISE detent if the boom is very close to the position specified by the positioner approximately within 2 the boom control...

Page 280: ...ame time the boom stops METHOD FOR OPERATING LOWER REMOTE BOOM POSITIONER 1 Set the boom to a desired LOWER stop position between the horizontal level and approximately 30 cm above the ground 2 Set the boom control lever to HOLD position and press po sition a of switch 1 A beep sounds and the position is set Operation checkup procedure Raise the boom above the horizontal level once move the boom c...

Page 281: ...p position is reset If the boom control lever is set to FLOAT position while the stop position is reset the boom is set to the float mode and moved freely by the external force applied REMARK When the boom is above the horizontal level the boom RAISE stop position setting and its reset opera tion can be made And when the boom is below the horizontal level the boom LOWER stop position set ting and ...

Page 282: ... in the switch lights up Even if the parking brake switch is turned ON there is danger until the parking brake pilot lamp on the moni tor lights up Keep depressing the brake pedal NOTICE Never use the parking brake switch to brake the machine when the machine is traveling except in an emergency Ap ply the parking brake after the machine is stopped 1 Release accelerator pedal 1 then depress brake p...

Page 283: ...e has overheated do not stop the engine suddenly Run it at a medium speed to cool it gradually before stopping CHECKS AFTER STOPPING ENGINE 1 Perform walk around check for oil or coolant leakage and for abnormality in work equipment exterior parts and undercarriage If oil or coolant leakage or any abnormality is detected repair it 2 Check DEF tank pump injector hose and joint for leakage If any ab...

Page 284: ...conditioner fresh air filter 6 DEF inspection cover 7 Battery disconnect switch cover The starting switch key is commonly used for locks 1 to 7 METHOD FOR OPENING AND CLOSING CAP WITH LOCK The fuel tank filler cap is equipped with lock Use the starting switch key to open and close the cap MACHINE OPERATIONS AND CONTROLS OPERATION 3 220 ...

Page 285: ... key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key METHOD FOR OPENING AND CLOSING HYDRAULIC OIL FILLER PORT CAP PROCEDURES FOR OPENING HYDRAULIC OIL FILLER PORT CAP 1 Remove bolts 1 2 pieces then open cover 2 2 Turn cap 3 counterclockwise and open it PROCEDURES FOR CLOSING HYDRAULIC OIL FILLER PORT CAP 1 Turn cap 3 clockwise and close it securely without ...

Page 286: ...und on a tubeless tire Do not install the tire protector mesh chain to rear wheels Do not to use tires such as urethane tires that weigh remarkably more than the standard tires since the ma chine can be damaged due to an unexpected load If a tire not specified by Komatsu is used rim dis placement may occur between the tire and rim Opera tor comfort may be degraded as well 1 Side wall 2 Shoulder 3 ...

Page 287: ...force Low end of range in the following table If the deflection of the tire is excessive raise the inflation pressure within the limits given in the following table to give a appropriate deflection see deflection ratio Tire size Pattern H Free height mm Air pressure kPa kg cm2 Ground sandy ground Normal road When shipped from the plant Stock pile Stock pile Digging 23 5 R25 L3 Rock Standard specif...

Page 288: ...d maintenance When the air conditioner is not used every day to prevent loss of the film of oil at various parts run the air conditioner with the engine at low speed from time to time and perform cooling or dry heating for several minutes To prevent leakage of the refrigerant from the air conditioner cooling circuit operate the air conditioner for several minutes 2 or 3 times a month during the of...

Page 289: ...mbol OFF SWITCH The OFF switch is used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH Use the fan switch to adjust the air flow from the fan in the manual operation When switch A is pressed while the air conditioner power supply is OFF the electric power for the air conditione...

Page 290: ...witch to raise the set temperature press the switch to lower the set temperature The set temperature is indicated on the display monitor The temperature is generally set at 25 C The temperature can be set in stages of 0 5 C Monitor display and function Monitor display Set temperature 18 C Max cooling 18 5 to 31 5 C Adjusts temperature inside cab to set temperature 32 C Max heating REMARK If the mo...

Page 291: ...om the vents displayed When this switch is pressed in the defroster mode the vents right before being switched to DEF is selected During automatic operation the vents are automatically selected A FACE 2 places B FOOT 2 places C DEF 2 places D DEF 2 places Liquid crystal dis play Vent mode Vent Remarks A B C D Face vent Face and foot vents Foot vent Foot and defroster vents Defroster vent Cannot be...

Page 292: ...to the environment If the environment changed suddenly by leaving cab door open for a long time etc the control of air conditioner may change temporarily but this is not a failure Even if the control changes it returns automatically to control the air according to the environment after certain period of time elapses FRESH RECIRC AIR SELECTOR SWITCH Use FRESH RECIRC air selector switch to switch th...

Page 293: ...ir conditioner switch to start and stop the cooling heating or drying function When the air conditioner switch is pressed while the main power switch is turned ON the air conditioner is turned ON and the air conditioner operation symbol is indicated on the display monitor If the switch is pressed again it is turned OFF and the op eration symbol on the display monitor goes out OPERATION HANDLE AIR ...

Page 294: ...r from the vents to match the strength of the sun s rays Only in automat ic operation mode In addition it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun s rays beforehand and automatically adjusts the temperature METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of opera...

Page 295: ...s set do not operate the temperature control switch unnecessarily It may take longer time to reach the set temperature To heat or cool air quickly set the temperature display to 18 0 C max cooling or 32 0 C max heating If any switch is operated during automatic operation the function of that switch is applied first and AUTO on the air conditioner monitor goes out and the man ual operation is selec...

Page 296: ...ax heating 4 Press vent selector switch and select the desired vents At this time the display for the vent of the display monitor changes according to the selection 5 Press the FRESH RECIRC air selector switch and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH REMARK To heat or cool the air quickly set the temperature dis play to 18 0 C max cooling ...

Page 297: ... to Hi METHOD FOR OPERATING DEMIST Dew condensation adhered to the inside of the window glass can be removed by demist operation 1 Press the defroster switch to set the vents in DEF mode 2 Press air conditioner switch and perform the cooling or dry heating operation To remove the dew condensation quickly press the fan switch to set the air flow to Hi REMARK Do not decrease the set temperature too ...

Page 298: ... is necessary to change the travel direction return to the ground or to the bed of the trailer then change the travel direction The center of gravity of the machine shifts suddenly at the joint of the ramps and the trailer so there is a danger of the machine losing its balance Accordingly pass this point slowly When loading or unloading always use ramps or a platform Proceed as follows PROCEDURES ...

Page 299: ...bar to LOCK position L 6 Lock the front frame and rear frame 7 Set chocks at the front and rear of the tires to prevent the machine from moving during transportation 8 Tie one end of each chain or wire rope of appropriate strength to the tie down holes as shown in the figure and secure the machine Secure the machine so that it will not move during transportation In particular fix the machine secur...

Page 300: ...Securing position Fixing angle A 66 B 30 C 26 D 30 Expected trailer width E 2990 mm TRANSPORTATION OPERATION 3 236 ...

Page 301: ...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 If the ramps bend a large amount under the weight of the machine put blocks 5 under the ramps to prevent them from bending 4 Remove the chains and wire ropes fastening the machine 5 Set the frame lock bar to FREE position F 6 Start the engine Warm the engine up fully in c...

Page 302: ...in the switch lights up Set the frame lock bar to the LOCK position Never enter the area under or around a lifted machine There is a danger of the machine losing its balance Use the procedure below to set the machine in the proper posture and use the sling when lifting the machine NOTICE This method of lifting applies to the standard specification machine The method of lifting differs depending on...

Page 303: ...from articulating 5 Use the lifting tools such as the wire rope and sling suita ble for the weight of the machine as shown in the figure of the lifting position Extend the wire rope and fix the ma chine NOTICE Use protectors etc so that the wire ropes will not be broken at sharp edges or narrow places Use spreaders and bars having sufficient width so that they will not touch the machine Open the r...

Page 304: ...ge interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR CLEANING INSIDE OF COOLING SYSTEM 4 20 DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break the devices in the tank The parts inside the tank may be affected Add DEF to the specified amount for cold weather below the level of when DEF may freeze For the specified amount of DEF see METHOD FOR ...

Page 305: ...oards prevent the tracks from freezing to the ground and allow the machine to move the next morn ing Open the drain valve and drain any water collected in the fuel system to prevent it from freezing Fill up the fuel tank This minimizes moisture condensation in the tank when the temperature drops In cold weather condition add DEF to the defined level strictly If adding more than the defined level i...

Page 306: ...will coat moving parts At the same time charge the battery as well When operating the work equipment wipe off all the grease from the hydraulic cylinder rods If the machine is equipped with an air conditioner operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner compressor Always run the engine at low idle when doing this In addition check the re...

Page 307: ...gine and then start it again If SCR system still has abnormality after the engine is restarted contact your Komatsu distributor If DEF is kept in DEF tank for more than 1 year ask your Komatsu distributor for replacement Dispose of the drained DEF according to the local regulations and rules Aged DEF may have smell of ammonia Replace the DEF in a well ventilated place and take care not to inhale i...

Page 308: ...ng operation never stand between the towing machine and the machine being towed Operate the machine slowly and be careful not to ap ply any sudden load to the wire rope If there is a failure in the brake system the brakes will not work so be extremely careful NOTICE Tow the machine only for a short distance such as to a place for inspection and maintenance Do not tow the machine for a long distanc...

Page 309: ...et on the machine being towed and operate the steering in the direction that the ma chine is towed TOW THE MACHINE WHOSE ENGINE CANNOT BE STARTED When towing the machine with the engine stopped observe the following procedures 1 The transmission oil does not lubricate the system so remove the front and rear drive shafts If necessary chock the tires to prevent the machine from moving 2 The steering...

Page 310: ...mergency release valve try ing to stop the machine the parking brake does not work immediately If the pressure in brake accumulator is high do as follows When the brake oil pressure caution lamp is not lit while the key is turned to ON position 1 Turn the starting switch to OFF position A 2 Loosen lock nut 1 of the release valve by turning it coun terclockwise 3 Open the release valve by turning g...

Page 311: ...edure in steps 1 to 6 REMARK If the pressure in brake accumulator is low the parking brake caution lamp may not go out or the alarm buzzer may sound continuous beep In this case release the brake For details see METHOD FOR RELEASING PARKING BRAKE WITH BOLT 3 247 METHOD FOR RELEASING PARKING BRAKE WITH BOLT 1 Remove plugs 1 and 2 in front of the transmission case 2 Remove 2 bolts among mounting bol...

Page 312: ...ery or do nothing that will cause sparks Battery electrolyte is dilute sulfuric acid and it will at tack your clothes and skin If it gets on your clothes or on your skin immediately wash it off with a large amount of clean water If it gets in your eyes wash the eyes immediately with clean water then consult a doctor for medical treat ment When handling batteries always wear protective eye glasses ...

Page 313: ...struction manual accompanying the charger and observe the following Set the voltage of the charger to match the voltage of the battery to be charged If the correct voltage is not selected the charger may overheat and cause an ex plosion Connect the positive charger clip of the charger to the positive terminal of the battery then connect the negative charger clip of the charger to the nega tive ter...

Page 314: ...starting system for this machine uses 24 V Accordingly the normal machine must be equipped with a 24 V power supply The sizes of the jumper cables and clips should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected Check...

Page 315: ...ne If the engine does not start try it again after 2 minutes or more PROCEDURE FOR DISCONNECTING JUMPER CABLES After the engine has started disconnect the jumper cables in the reverse of the order in which they were con nected 1 Remove the clip of jumper cable B from engine block E on the failed machine 2 Remove the clip of jumper cable B from the negative terminal of battery D on the normal machi...

Page 316: ...arge battery Defective starting motor Replace Starting motor turns engine sluggish ly Insufficient battery charge Charge battery Defective starting motor Replace Starting motor disengages before engine starts Defective wiring Defective ring gear and pinion Check repair Insufficient battery charge Charge battery Preheating pilot lamp does not light up Defective wiring Check repair Defective heater ...

Page 317: ...S MAINTENANCE Air is in brake system Bleed air Brake drags or remains applied Vent hole of brake valve is clogged Clean Brake squeals Disc has worn Replace disc Large amount of water is in axle oil Change the axle oil Axle oil is deteriorated due to over use of brake Change the axle oil Steering Steering wheel is heavy Hydraulic oil in the hydraulic tank is insufficient Add oil to specified level ...

Page 318: ...KS BEFORE STARTING Improper oil is used Viscosity is im proper Replace oil See USE OF FUEL METHOD FOR USING FUEL COOL ANT AND LUBRICANTS ACCORD ING TO AMBIENT TEMPERATURE 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 Defecti...

Page 319: ...e or bluish Water entry in the aftertreatment de vices Check repair Breakage of the aftertreatment devi ces Replace the aftertreatment devices Excessive oil in oil pan Set oil to specified level See CHECKS BEFORE STARTING Improper fuel Replace with specified fuel Exhaust gas turns black from time to time Breakage of the aftertreatment devi ces Replace the aftertreatment devices Clogged air cleaner...

Page 320: ...ER CAR TRIDGE 4 50 If CA2249 or CA559 is not cleared even after the re placement ask your Komatsu distributor for an inspection immediately even though the machine can perform normal operation When failure code CA4166 SCR Temperature Sensor ECU High Temperature Error is displayed raise the cool ing fan speed by raising engine speed to emit heat inside the engine room Telephone number for the point...

Page 321: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 322: ...e the strainer while adding DEF WELDING INSTRUCTIONS When conducting weld repair turn the starting switch to OFF position 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 Connect grounding cable within 1 m of the area to be welded If grounding cable is connec...

Page 323: ...OR REPLACING HYDRAULIC OIL FILTER ELEMENT 4 57 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with new parts When doing this be careful not to forget to assemble O rings and gaskets When installing the hoses do not twist them or bend them sharply If they are installed so their service ...

Page 324: ...ature For detail see RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 CLOSE ENGINE SIDE COVER SECURELY When closing the engine side cover after inspection and maintenance lock it securely with the catcher If the engine side cover is not locked with the catcher the engine side cover may open PRECAUTIONS FOR MAINTENANCE MAINTENANCE 4 4 ...

Page 325: ...e careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too much oil or too little oil are both cau...

Page 326: ...e Coolant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu recommends the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious problems such as corrosion of the engine and aluminum parts of the cooling system When using antifreeze always observe the ...

Page 327: ... used to prevent seizure and noises at the joints This construction equipment is used under heavy duty conditions Komatsu recommends using the recom mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual Grease fittings not included in the MAINTENANCE section are the grease fittings for overhaul so they do not need gre...

Page 328: ... sheet or take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first STORE DEF Completely seal up its container for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container Make sure that transfer equip ment and...

Page 329: ... is damaged This will cause an electrical leakage and may lead to malfunction of the machine Do not wash the inside of the operator s cab with water When washing the machine be careful not to let water get into the electrical components When removing the connectors of electrical components after washing the machine or in the rain wipe off the water drop stuck around connectors before removing the ...

Page 330: ...f bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 3 30 5 66 5 111 177 1 35 3 15 6 75 11 3 18 11 8 to 14 7 27 to 34 59 to 74 98 to 123 157 to 196 1 2 to 1 5 2 8 to 3 5 6 0 to 7 5 10 0 to 12 5 16 to 20 16 18 20 22 24 24 27 30 32 36 277 385 549 746 927 28 3 39 3 56 76 94 5 245 to 309 343 to 427 490 to 608 682 to 829 824 to ...

Page 331: ...77 to 245 18 0 to 25 0 10 33 41 216 22 0 177 to 245 18 0 to 25 0 Face seal Nominal No of hose Nominal size thereads per inch a Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 02 9 16 18UN 19 44 4 5 34 to 54 3 5 to 5 5 03 11 16 16UN 22 74 7 5 54 to 93 5 5 to 9 5 04 13 16 16UN 27 103 10 5 84 to 132 8 5 to 13 5 05 1 14UNS 32 157 16 0 128 to 186 13 0 to 19 0 06 1 3...

Page 332: ...MAINTENANCE 4 41 METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK 4 41 EVERY 100 HOURS MAINTENANCE 4 41 METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 4 42 METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER 4 42 EVERY 250 HOURS MAINTENANCE 4 43 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 4 43 METHOD FOR TESTING PARKING BRAKE 4 45 METHOD FOR CHECKING AND ADJUSTING AIR CONDITION...

Page 333: ...METHOD FOR CHECKING WATER PUMP 4 72 METHOD FOR CHECKING STARTING MOTOR 4 72 METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR 4 72 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIPING CLAMP HARD ENING OF RUBBER 4 73 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 73 EVERY 4500 HOURS MAINTENANCE 4 74 METHOD FOR CLEANING KDPF 4 74 METHOD FOR CLE...

Page 334: ...r where the foothold is poor be careful not to fall because of the re action when pulling out the outer element NOTICE Do not clean the element before the air cleaner clogging caution lamp on the machine monitor lights up or the yellow piston of the dust indicator laps over the peripheral red zone 7 5 kPa 0 076 kg cm2 If the element is cleaned frequently before the air cleaner clogging caution lam...

Page 335: ...t indica tor 1 display of the air cleaner entered the red 7 5 kPa posi tion After the cleaning press the dust indicator button to reset it If the yellow piston enters the red 7 5 kPa position soon after the cleaning the element must be replaced For the element replacement procedure see METHOD FOR REPLACING AIR CLEANER ELEMENT 4 18 Electric air cleaner clogging sensor Clean the air cleaner element ...

Page 336: ... pull out outer element 4 When pulling out the element use the air cleaner pull out jig hold the handrail tight in one hand and put your feet on the step to support your body NOTICE Never remove inner element 5 Dusts may enter causing the engine failure 4 Clean the inside of the air cleaner body cover 2 and va cuator valve 6 MAINTENANCE PROCEDURE MAINTENANCE 4 16 ...

Page 337: ...2 1 kg cm2 from the inside of the outer element along the pleats 6 Blow along the pleats from the outside then blow again from the inside 7 Peel off a seal after cleaning the element each time 8 After cleaning illuminate the inside of the element with an electric bulb to check If the element has a small hole or thin part replace it k k CAUTION When installing the cover 2 check O ring 7 for scratch...

Page 338: ...aps over the red zone 7 5 kPa 0 08 kg cm2 soon after the cleaning or if the air cleaner clogging caution lamp lights up replace both the inner and outer elements METHOD FOR REPLACING AIR CLEANER ELEMENT 1 Remove clips 1 4 pieces and remove cover 2 2 Install on board air cleaner pull out jig 3 to the narrow part of outer element 4 MAINTENANCE PROCEDURE MAINTENANCE 4 18 ...

Page 339: ...en quickly install the new in ner element NOTICE Be sure to install the air cleaner element facing in the cor rect direction Install so that the bottoms A and B of the air cleaner el ement face where no hole is drilled come to cover 2 end If it is installed in wrong direction it may cause break age of the air cleaner element or serious damage to the en gine 6 Install cover 2 according to the follo...

Page 340: ...ng system and changing coolant Non Amine Engine Coolant AF NAC Every 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 use of coolant is essential Komatsu machines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Coolant AF NAC has ex...

Page 341: ...illed water so it is not flammable For dilution water see COOLANT AND WATER FOR DILUTION 4 6 Check the density with a coolant tester Items to be prepared A container whose capacity is enough to receive the specified capacity of coolant A hose to add coolant 1 Place the machine on a level ground then stop the engine 2 Remove radiator top cover 3 Check that the coolant temperature is low enough to m...

Page 342: ...right and left to warm up hydraulic oil in the steering valve k k WARNING If you turn the steering wheel and stop turning it while the oil temperature is low a time lag might result until the machine stops after the turning operation In such case set the frame lock bar to LOCK position L for safety and perform the warm up operation in a large place At that time be sure not to relieve the oil press...

Page 343: ...nutes At this time keep both of the R H and L H radiator caps removed 18 Drain the coolant in reservoir tank 19 Clean the inside of reservoir tank 20 Add Non Amine Engine Coolant to the middle between FULL and LOW 21 Stop the engine 22 Approximately 3 minutes later add Non Amine Engine Coolant up to the mouth of the coolant filler port 23 Tighten the radiator cap METHOD FOR CHECKING OIL LEVEL IN T...

Page 344: ...ls are marked on the dipstick A ENG STOP Engine is stopped B ENG LOW IDLE Engine is running at low idle 6 If the oil level is higher than mark H do as follows 1 Remove inspection window 1 of the undercover 2 Drain the excessive oil through drain plug P 3 Check the oil level again 7 If the oil is at the correct level insert dipstick G in the dip stick pipe and tighten the oil filler cap Checking of...

Page 345: ... approxi mately 5 minutes and check the oil level METHOD FOR CHECKING OIL LEVEL IN AXLE CASE AND ADDING OIL k k WARNING When checking the oil level apply the parking brake and fix the front and rear frames using the frame lock bar Immediately after the engine is stopped parts and oil are still very hot Wait for the temperature to go down and then start the work If ooze of oil is recognized on the ...

Page 346: ...that the amount of the lubricating oil for the axle with Limited Slip Differential may be different Always use the specified lubricating oil 5 If the oil level exceeds the upper groove H drain the ex cessive oil through drain plug P and then check the oil level again 6 If the oil level is appropriate install plug 1 Tightening torque 127 to 177 Nm 13 to 18 kgm METHOD FOR CLEANING AXLE BREATHER k k ...

Page 347: ...nd dust mask If dirt or dust is stuck to the condenser clean them by using water If water pressure is excessive the fin may be deformed So cleaning by using pressurized water must be done from a sufficiently distant position 1 Open the engine side cover 2 Wash condenser 1 with water from the top METHOD FOR CLEANING RADIATOR FIN AND COOLER FIN k k WARNING When the engine is running do not open the ...

Page 348: ...gh idle operation time as follows depending on the clogging level Ordinary clogging 1 to 2 minutes Excessive clogging 2 to 3 minutes When the cleaning is completed set the engine speed to low idle and restore the rotation of the fan to normal METHOD FOR REVERSING AUTOMATIC OPERATION FAN For the automatic reverse rotation of the fan see RADIATOR FAN AUTOMATIC REVERSE MODE 3 65 REMARK When the fan r...

Page 349: ... equipment 4 Check the rubber hoses If any hose is cracked or hardened by age replace with a new one Also check and tighten all loose hose clamps 5 After cleaning close fan guard 3 and rear grille 1 METHOD FOR CLEANING FIN WITH ENGINE SIDE COVER OPEN 1 Open the engine side cover on the right and left sides of the machine 2 Insert the air nozzle through the clearance between radia tor 1 oil cooler ...

Page 350: ...n the right and left sides of the machine and open those covers 2 Insert the air nozzle and blow dust out forward of the machine Steam or water may be used instead of the compressed air 3 Install covers for cleaning 8 on the right and left side of the machine after blowing dust out METHOD FOR INVERTING AND REPLACING BOLT ON CUTTING EDGE k k WARNING It is dangerous if the work equipment moves by mi...

Page 351: ...he bucket from lowering Raise the bucket to make its bottom surface level 2 Remove the bolts and nuts 1 and 2 and remove bucket teeth 3 3 Clean the mounting surface of bucket teeth 3 4 Install a new teeth to the bucket Eliminate the clearance between the teeth and top face of the bucket by inserting shims Continue the adjustment with shims until the insertion of 0 5 mm 0 02 in thick of shim become...

Page 352: ...f arrow by hand or ham mer and remove tooth 2 6 Check the torque to unlock the pin by using torque wrench according to the following procedure 1 Rotate the shaft of pin 1 with torque wrench and set it to the lock state 90 2 Rotate the shaft from the lock state 90 to free state 0 3 Check that the maximum torque is 11 Nm 1 12 kgm and above If the torque value is low replace the pin with a new one T1...

Page 353: ...G WINDOW WASHER FLUID LEVEL ADDING FLUID Check the water level in window washer tank 1 and if it is in sufficient add the window washer fluid for automobiles Be careful not to let dirt or dust get in when adding fluid METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING LEVEL OF REFRIGERANT GAS k k WARNING If the refrigerant used in the air conditioner gets into your eyes or is ...

Page 354: ...n viewed through sight glass x Bubbles are seen Gaseous and liquid refrigerants are mixed y No bubble All refrigerant becomes liquid and transpar ent z Milky white Oil and refrigerant are separated and their mixture is milky white MAINTENANCE AND SCHEDULE OF AIR CONDITIONER Check point Check items Maintenance schedule Check before operation 6 months in spection Replacement interval Filter Clogging...

Page 355: ...ING FUNCTION OF ECSS ACCUMULATOR For handling of the accumulator see HANDLE ACCUMULATOR AND GAS SPRING 2 40 1 Turn on the ECSS switch The function of the hydraulic spring of the accumulator reduces the bounce of the machine by absorbing the vertical motion of the machine in travel 2 Compare the vertical motion of the machine when the ECSS switch is turned to ON position and OFF posi tion If there ...

Page 356: ...he specified pressure Select the tires according to the conditions of use and the weight of the attachments of the machine Use the tires shown in the following table The travel speed displayed varies with the tire size NOTICE For usability of tires consult your Komatsu distributor Do not install the tire protector mesh chain to rear wheels Do not to use tires such as urethane tires that weigh rema...

Page 357: ...aveling at high speed or operating under heavy load Check the tire inflation pressure before starting work while the tires are cold When inflating a tire use an air chuck which can be fixed to the air valve of the tire as shown in the figure Do not work in front of the rim but work on the tread side of the tire 1 Measure the inflation pressure with a tire inflation pressure gauge 2 Adjust the infl...

Page 358: ...ter cleaning install the element to the breather body At that time install the element in correct direction Direct the surface marked 5 towards up and install 7 Install cover 3 8 Tighten nut 2 Tightening torque 10 to 14 Nm 1 0 to 1 4 kgm 9 Close the engine side cover NOTICE If the element is dirty or damaged replace with new one METHOD FOR LUBRICATING REAR FULL LENGTH FENDER HINGE If rear full len...

Page 359: ...N METHOD FOR FILLING GREASE NOTICE Fill in only clean lubricant by using a suitable tool A or B Soiled lubricant leads to serious system trouble If the grease tank is emptied below MIN mark the air bleeding of whole system must be performed To bleed air from the auto greasing system consult your Komatsu distributor Maintenance work should be performed if needed or every 50 hours If any problem occ...

Page 360: ...hey are explained Checks before starting engine METHOD FOR WALK AROUND CHECK 3 159 Check for damage wear play in work equipment cylinders linkage and hoses Remove dirt and debris from around the engine battery and radiator Check around the engine for leakage of coolant oil and exhaust gas Check the fuel line for leakage Remove dirt and check DEF line for leakage Remove dirt from around the aftertr...

Page 361: ...heck Low Speed Run And Acceleration Of Engine Test Parking Brake Check Brake Check Clearance Between Brake Pedal And Floor Check Abnormal Points Detected Up To Previous Day Run In The New Machine For Ordinary Operation EVERY 50 HOURS MAINTENANCE METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK 1 Open the rear full length fender on the right side of the machine 2 Place a container to catch dra...

Page 362: ... spurt out Lower the bucket to the ground and stop the engine Wait for 5 minutes before checking oil level Oil level should be between H and L marks on sight gauge G 1 Check with sight gauge G 2 Loosen the bolt turn cover 1 and open it 3 If the level is below L mark add through filler port F METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER k k WARNING When using compressed air there is a dange...

Page 363: ...ECTROLYTE LEVEL Perform this procedure before operating the machine Inspect the battery electrolyte level according to the standard at least once a month k k WARNING Do not use the battery if the battery electrolyte level is below LOWER LEVEL line If you do so it will reduce the service life of the battery In addition it may cause an explosion The battery generates inflammable hydrogen gas and the...

Page 364: ...nt hole of the battery cap then close the cap securely Keep the battery top surface clean and wipe off dirt on it using a wet cloth REMARK If purified water is added to above the UPPER LEVEL U L line use a syringe to lower the level to the UPPER LEVEL U L line Neutralize the removed fluid with baking soda sodium bicarbonate then flush it away with a large amount of water If necessary consult your ...

Page 365: ...bottom of the sleeve use a syringe to remove electrolyte Neutralize the removed fluid with baking soda sodium bicarbonate then flush it away with a large amount of water If necessary consult your Komatsu distributor or a battery manufacturer METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the elect...

Page 366: ...CONDITIONER COMPRESSOR BELT IS RE PLACED Press the middle point between the compressor pulley and crankshaft pulley with your thumb approximately 98 N 10 kg The standard deflection is 8 to 11 5 mm When you use a belt tension gauge the tension is normal if it is in the range of 530 to 745 N 54 to 76 kg REMARK When the belt is replaced with a new one the above value is employed as the initial tensio...

Page 367: ...djustment or has slipping sound or squeak because of cuts or cracks of the belt When the new V belt is installed readjust it after operating for 1 hour METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS RETIGHTEN ING BOLTS Loosening of wheel hub bolt 1 accelerates the wear of the tires and causes accidents 1 Check the bolt for loosening and tighten it further if neces sary Always turn the bolts in t...

Page 368: ...r 1 minute and then stop it 4 Turn the starting switch to ON position and repeat depressing the brake pedal If the brake oil pressure caution lamp does not light up when the brake pedal is depressed 6 times the gas pressure in the accumulator is normal If the brake oil pressure caution lamp lights up when the brake pedal is depressed 5 times or less the gas pressure in the accumulator may be low A...

Page 369: ...n stall it REMARK Check that there is no old packing stuck to filter head 2 If there is any old packing stuck to the holder it will cause leakage of oil 9 When installing the cartridge tighten it until the sealing surface contacts filter head 2 then tighten it 3 4 turn 10 After replacing the filter cartridge refill with engine oil through oil filler port F until the oil level is between H and L ma...

Page 370: ...ner to catch the drained fuel Filter wrench When replacing the fuel main filter cartridge every 1000 hours replace the fuel prefilter cartridge first 1 Open the engine side cover on the right side of the ma chine 2 Place a container under the fuel prefilter cartridge to catch the fuel 3 Loosen drain valve 1 and drain water and sediments from transparent cup 2 and also drain all the fuel from fil t...

Page 371: ...ng connector 4 be extremely careful not to let water get on the connector If water gets on connector 4 dry it completely before connecting it 14 After completing the replacement of filter cartridge 3 bleed air from the circuit Bleed the air as follows 1 Fill up the fuel tank with fuel to the level where the float is at the highest position 2 Loosen the knob of feed pump 6 pull it out then pump it ...

Page 372: ...rts than those in the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a substitute When performing inspection and maintenance of the fuel system be careful not to let any foreign material get in more than ever before If dust sticks to the fuel system wash i...

Page 373: ...ne runs out of fuel use the same procedure to operate feed pump 3 and bleed the air 8 Push in and tighten the knob of feed pump 3 9 After replacing the filter cartridge start the engine and run it at low idle for 10 minutes 10 Check the filter seal surface for fuel leakage If there is any leakage of fuel check the tightening condition of the filter cartridge If there is still leakage of fuel follo...

Page 374: ...strainer 4 is damaged replace it with a new one 8 Install strainer 4 to the case Replace O ring of tube 3 with a new one and install tube 3 9 Add the refill capacity of oil through oil filler port F 10 After adding oil check that the oil level is proper For de tails see METHOD FOR CHECKING OIL LEVEL IN TRANSMISSION CASE ADDING OIL 4 23 11 Check the transmission case for oil leakage METHOD FOR REPL...

Page 375: ... a further 2 5 turns with the filter wrench 7 Check that the oil level is proper For details see METHOD FOR CHECKING OIL LEVEL IN TRANSMIS SION CASE ADDING OIL 4 23 8 Check the transmission oil filter for oil leakage METHOD FOR CLEANING TRANSMISSION BREATHER 1 Loosen bolts 1 4 pieces and remove cover 2 2 After removing dirt and dusts around breather remove breather 3 and immerse it in detergent li...

Page 376: ...for every 50 100 250 500 and 1000 hours service should be performed at the same time METHOD FOR CHANGING OIL IN HYDRAULIC TANK CLEANING HYDRAULIC TANK STRAINER k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spout out Turn it s...

Page 377: ...trainer 8 then wash it in flush ing oil If strainer 8 is damaged replace it with a new one 12 Refill with the specified quantity of hydraulic oil through oil filler port F then install the cap 13 Check the hydraulic oil level Check that the hydraulic oil is at the specified level For details see METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 4 42 METHOD FOR REPLACING HYDRAULIC OIL FILT...

Page 378: ...xtend and retract each of the steering bucket and boom cylinders 4 to 5 times tak ing care not to move them to the stroke end stop them approximately 100 mm before the stroke end NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end air taken inside the cylinder may cause damage to the piston packing 10 Extend and retract each of the steer...

Page 379: ...osen the bolts and remove the cover 3 Remove the cap of oil filler port F 4 Remove snap ring 2 of breather 1 remove breather cap 3 and replace filter element 4 with a new one 5 Install breather cap 3 and snap ring 2 6 Close the cap of oil filler port F METHOD FOR CHANGING OIL IN AXLE CASE k k WARNING When changing the oil apply the parking brake and secure the front and rear frames with the frame ...

Page 380: ... by using level plug 1 See METHOD FOR CHECKING OIL LEVEL IN AXLE CASE AND ADDING OIL 4 25 REMARK When the given work requires to use the brake more frequently than usual replace the axle oil earlier than the usual timing METHOD FOR REPLACING AIR CONDITIONER FRESH RECIRC AIR FILTERS Remove both the recirculation air filter and fresh air filter in the same way as in the cleaning procedure and replac...

Page 381: ...oove E and end face D of the guide In such case ask your Komatsu distributor to perform in spection and replacement of the part If the disc wear approaches the wear limit check the con dition frequently regardless of the maintenance interval 3 Install cap nut 1 Tightening torque 29 4 to 39 2 Nm 3 0 to 4 0 kgm REMARK On a new machine the position of the end face of rod 2 is adjusted so that it matc...

Page 382: ...ools are necessary for inspection and maintenance Ask your Komatsu distributor to perform this work METHOD FOR CHECKING VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber If any cracks or peeling are found contact your Komatsu distributor to have the parts replaced METHOD FOR REPLACING KCCV FILTER ELEMENT k k WARNING After the engine has been operated a...

Page 383: ...body 2 and remove element 5 There may be oil accumulated or sticking in the case and element Take care not to spill the oil when replacing the element REMARK When the ambient temperature is low water or emulsified matter may stick to the inside of KCCV because of con densation of water vapor in the blowby gas However if the coolant level is normal it is not a problem 3 Remove used O ring 6 stickin...

Page 384: ...2 are oval When inserting take extreme care so that those bases are matched with each other 5 Align the position of mark 13 on the case with that of mark 8 of the filter body label then install the case to the filter body The case can be installed only when its claws 14 are cor rectly inserted in grooves 10 of the filter body When in serting take extreme care so that protrusion 15 in the case is j...

Page 385: ... machine Never operate the machine without DEF filter attached nor use the filter other than Komat su genuine parts DEF filter cannot be flushed Flushing or regenerating of it will degrade the performance of filter and will cause the breakage of DEF tank Never reuse the DEF filter Improper assembly of DEF filter may cause leakage of DEF Replace the DEF filter in the correct pro cedure DEF freezes ...

Page 386: ... fig ure 2 Remove filter cap 3 at the bottom of DEF pump and re move equalizing element 4 3 Turn cap 6 of filter removal tool 5 and remove it 4 Check the installation of spacer 7 5 Insert filter removal tool 5 into the bottom of the DEF pump and thrust in with hand MAINTENANCE PROCEDURE MAINTENANCE 4 66 ...

Page 387: ...r removal tool 5 pull it down then it will be removed 8 Slide filter 8 down and remove spacer 7 from filter re moval tool 5 9 Pull filter 8 up while pushing in the tip of filter removal tool 5 and remove it 10 Return the removed spacer 7 to filter removal tool 5 and keep them 11 Insert a new filter and a new equalizing element into the bottom of DEF pump and lightly tighten them with hand 12 Tight...

Page 388: ... DEF tank breather element Flushing or regenerating of it will degrade the performance of element and will cause the breakage of DEF tank Never reuse the DEF element Always stop the engine and clean around DEF tank before replacing After the engine is stopped DEF system devices automatically purge DEF in DEF injector and DEF pump and return it to DEF tank to prevent malfunction of the devices caus...

Page 389: ...install 4 Install cover 5 and nut 4 5 Install cover 2 with bolt 1 EVERY 4000 HOURS MAINTENANCE Maintenance for every 50 100 250 500 1000 and 2000 hours service should be performed at the same time REPLACE DEFINED LIFE PARTS These parts change in material wear and deteriorate as they are aged Replace them every 2 years or every 4000 hours whichever comes sooner MAINTENANCE MAINTENANCE PROCEDURE 4 6...

Page 390: ...AFT Use the special grease for drive shaft and perform greasing every 4000 hours or every 2 years If the special grease is not used but common lithium base grease is used perform greasing every 1000 hours after then Part No of special grease for the drive shaft 56B 20 19910 1 Remove inspection windows 1 and 2 of the undercover 2 By using a grease pump pump in grease through the grease fittings sho...

Page 391: ...Viewed from the rear side of the machine MAINTENANCE MAINTENANCE PROCEDURE 4 71 ...

Page 392: ... any problem is found ask your Komatsu distributor to perform disassembly repair or replacement METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked If the engine is started frequently have this inspection performed every 1000 hours METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR Ask your Komatsu distributor to perform the work MAINTENANCE...

Page 393: ...distributor for replacement METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER The fuel spray prevention caps on the fuel injection piping and both ends of the high pressure piping act to pre vent the fuel from coming into contact with high temperature parts of the engine and causing a fire if the fuel should leak or spray out Check fuel spray prevention caps 14 places v...

Page 394: ...FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps METHOD FOR REPLACING STARTING MOTOR For the machines equipped with the auto idle stop function Ask your Komatsu distributor for replacement of the starting motor EVERY 9000 HOURS MAINTENANCE Maintenance for every 50 100 250 500 1000 and 4500 hours service should be performed at the same time ME...

Page 395: ...SPECIFICATIONS 5 1 ...

Page 396: ... lifted up mm 5585 D Overall width mm 2765 E Min ground clearance mm 455 F Bucket width mm 2990 G Dumpling clearance 1 Cutting edge BOC tip mm 2970 2895 H Dumpling reach 1 Cutting edge BOC tip mm 1080 1110 I Bucket dump angle max height deg 49 5 Min turning radius Cutting edge BOC tip mm 7265 Center of outside tire mm 6320 Permissible towing load kN kg 131 13360 Max speed At lock up Forward 1st km...

Page 397: ... 1 Value when bucket dump angle is 45 SPECIFICATIONS SPECIFICATIONS 5 3 ...

Page 398: ... the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5 dB in accordance with ISO 11201 Sound power level emitted by the machine measured ac cording to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European di rective 2000 14 EC This value includes an uncertainty of 2 5 dB ...

Page 399: ...ng and traveling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedule time to maintain terrain conditions 4 Use a seat that meets ISO 7096 and keep the seat maintained and adjusted Adjust the seat and suspension for the weight and size of the operator Wear seat belt Inspect and maintain the seat sus...

Page 400: ......

Page 401: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1 ...

Page 402: ...23 5 25 16PR L3 Rock Soft ground 23 5 25 16PR L3 Rock Loading of blasted rock Excavating bucket with segment edge 2 7 m3 General foothold 23 5R25 L3 Rock 23 5 25 16PR L3 Rock Soft ground 23 5R25 L3 Rock 23 5 25 16PR L3 Rock Ground with many large boulders 23 5R25 L3 Rock 23 5 25 16PR L3 Rock Soft ground with many large boulders 23 5R25 L3 Rock 23 5 25 16PR L3 Rock BOC Abbreviation for Bolt On Cutt...

Page 403: ...d switch 4 Multifunction mono lever directional selector switch 5 PCS Proportional Control Switch MULTIFUNCTION MONO LEVER The multi function mono lever is used to operate the boom and bucket NOTICE Do not use FLOAT position when lowering the bucket Use FLOAT for leveling work ATTACHMENTS AND OPTIONS HANDLE MULTIFUNCTION MONO LEVER 6 3 ...

Page 404: ... When the multi function mono lever is pulled further from the TILT position the lever stops in that position When the buck et reaches the position preset by the bucket positioner the lev er returns to the HOLD position Position f DUMP KICKDOWN SWITCH When traveling in forward 2nd if kickdown switch 2 is press ed the gear is shifted down to forward 1st Use this switch to increase the traction forc...

Page 405: ...event the engine from overrunning even if the kickdown switch is pressed HOLD SWITCH When HOLD switch on the top of the lever is pressed to fix the gear speed in the auto shift mode the transmission is fixed to the gear speed indicated on shift indicator A of the machine monitor and shift hold pilot lamp B lights up When this switch is pressed again the shift hold function is canceled and the pilo...

Page 406: ...ROL SWITCH PCS Proportional Control Switch is used to operate the third attachment The hydraulic oil discharged by the switch operation is in pro portion to the stroke of the switch The switch has 2 control modes continuous mode and propor tional mode You can set the maximum flow when the switch is operated and change the control mode on the monitor Position A RETRACT Position B NEUTRAL However wh...

Page 407: ...k switch ON Turn the starting switch key to OFF position Stop the engine Cancel the continuous mode on the monitor Proportional mode This mode does not have the detent control function which the continuous mode has REMARK The hydraulic oil discharged volume is in proportion to the stroke of the switch in both continuous mode and proportional mode LCD UNIT 1 Flow control mode pilot lamp Continuous ...

Page 408: ...lot lamp lights up when the detent con trol is performed in the continuous mode A to D are displayed in order at intervals of 0 5 seconds ATTACHMENT OIL FLOW LEVEL The attachment oil flow level indicates the set maximum flow level It indicates level 0 to 8 according to the set attachment oil flow in green A in the normal state and in orange B in the detent control mode HANDLE MULTIFUNCTION MONO LE...

Page 409: ...tting and the setting is completed If you press menu switch 1 at this time you can change the setting of the selected attachment You can save up to 5 settings 3 To change the setting name select Attachment Name and press ENTER switch 2 Change the alphabet at the cursor with UP or DOWN switches and move the cursor with menu switch 1 After completing the change press ENTER switch 2 ATTACHMENTS AND O...

Page 410: ...e or Continuous Mode 5 Select Attachment Flow and press ENTER switch 2 You can set the maximum flow at the switch full stroke and the flow during the detent control in the continuous mode Change the flow with UP or DOWN switches and then press ENTER switch 2 You can set the maximum flow in the range of 25 to 200 ℓ min at intervals of 25 ℓ min HANDLE MULTIFUNCTION MONO LEVER ATTACHMENTS AND OPTIONS...

Page 411: ...1 Tilt the attachment 2 Pull lock A of the quick coupler switch in the direction of the arrow b and push in to RELEASE position a Keep the switch pressed until the work of step 6 is completed When the quick coupler release is operated the quick cou pler lock release pilot lamp 1 lights up and the alarm buz zer sounds intermittently 3 Operate lever 2 from HOLD position B to TILT position e while qu...

Page 412: ... the quick coupler switch The switch returns to its original position the pilot lamp 1 for releasing quick cou pler goes out and the alarm buzzer stops sounding 8 Drive the machine slowly in reverse and separate the at tachment from the machine TO INSTALL ATTACHMENT 1 Set the coupler tilted forward posture on a level ground stop the machine at the position just before attachment hook and the coupl...

Page 413: ...ssed into a Retract coupler plunger while keeping it at TILT position e from the state that the coupler contacts to tilt end stopper 4 Check that the lock pins have been removed The lock pin indicators 3 may not be visible 5 Operate lever 2 from HOLD position B to DUMP posi tion f and set the coupler tilted forward 6 Raise the coupler slowly as the machine travels forward keep raising it until cou...

Page 414: ... your hand off the quick coupler switch The switch re turns to its original position the pilot lamp 1 for releasing quick coupler goes out and the alarm buzzer stops sound ing 10 Operate lever 2 from HOLD position B to TILT position e keep it and pull out the coupler plunger to lock the at tachment g0038107 g0038102 B B g0038109 g0038102 B B g0038100 HANDLE QUICK COUPLER ATTACHMENTS AND OPTIONS 6 ...

Page 415: ... that the lock pin indicators 3 on left and right side are visible moved out 12 Check that the quick coupler and the attachment are com pletely locked g0038108 ATTACHMENTS AND OPTIONS HANDLE QUICK COUPLER 6 15 ...

Page 416: ......

Page 417: ...REPLACEMENT PARTS 7 1 ...

Page 418: ...following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the defined life parts DEFINED LIFE PARTS LIST No Periodical replacement parts Replacement interval 1 Fuel system Fuel hose Spi...

Page 419: ...ngine oil filter 6736 51 5142 Cartridge 1 Every 500 hours Fuel prefilter 600 319 3610 Cartridge 1 Fuel main filter 600 319 3750 Cartridge 1 Every 1000 hours Transmission oil filter 714 07 28713 Cartridge 1 Transmission strainer 56D 15 19311 Strainer 1 07000 75085 O ring 1 Every 1000 hours DEF tank breather 421 60 35170 Element 1 Every 2000 hours KCCV filter 600 331 2900 Element 1 Hydraulic oil fil...

Page 420: ...ult your Komatsu distributor NOTICE The fuel used must be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high precision parts and lu...

Page 421: ...ing of the symbol Read the Operation and Maintenance Manual Greasing of the grease Change of the engine oil Check oil level in engine oil pan Change hydraulic oil Check oil level in hydraulic oil Change power train oil Change power train oil filter REPLACEMENT PARTS RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 ...

Page 422: ...40 LA KES Diesel Engine Oil Note 1 Engine oil for KDPF Oil Change interval 500 hours 20 C 40 C EO10W30 LA KES Diesel Engine Oil 15 C 50 C EO15W40 LA KES Diesel Engine Oil Transmission case Power train oil 30 C 50 C TO10 KES Note 2 Hydraulic system Power train oil 20 C 50 C TO10 KES Bio oil 15 C 40 C BO46 G4 Hydraulic oil 20 C 50 C HO46 HM KES Engine oil 20 C 50 C EO10W30 DH 15 C 50 C EO15W40 DH Ax...

Page 423: ...of the brake If the machine is equipped with the Limited Slip Differential use AXO80 regardless of the ambient temperature Do not use TO50 Note 5 For the machine with auto greasing see AUTO GREASING 3 128 Note 6 Hyper grease G2 TE has high performance When it is necessary to improve the lubricating performance of the grease in order to prevent squeaking of pins and bushings the use of G2 TE is rec...

Page 424: ......

Page 425: ... Air conditioner recirculation air filter and fresh air filter Replace 4 60 Air conditioner switch 3 229 Air conditioner switch or numeral key 3 49 Air conditioner system caution lamp 3 29 Alternate exit of cab Check 3 171 Alternator Check 4 62 Alternator belt Check Replace 4 56 Always use clean washer fluid 4 2 Appoint leader when working with others 2 33 Armrest angle Adjust 3 174 Armrest height...

Page 426: ...Check level Add 3 167 DEF Store 4 8 DEF filter 3 156 DEF filter Replace 4 65 DEF hose Replace 4 74 DEF level Check 3 208 DEF level caution lamp 3 22 DEF level gauge 3 46 DEF low level guidance 3 41 DEF system caution lamp 3 26 DEF system high temperature stop caution lamp 3 27 DEF tank Clean 4 74 DEF tank breather element Replace 4 68 Defined life parts list 4 70 7 2 Defroster Operate 3 233 Defros...

Page 427: ...on of machine monitor equipment 3 10 Explanation of multifunction mono lever 6 3 F Fan Operate in reverse manually 4 28 Fan control system caution lamp 3 29 Fan reverse rotation display 3 36 Fan switch 3 225 Filter 4 8 Fin Clean by rotating cooling fan in reverse 4 28 Fin Clean with compressed air 4 28 Fins Open engine side cover Clean 4 29 Fins Open rear grille Clean 4 28 Fire extinguisher 3 125 ...

Page 428: ...pedals 3 112 Leveling work 3 211 Lever stand Adjust 3 181 Lever stand Adjust in fore and aft direction 3 182 Lifting of personnel prohibited 2 19 Load and carry operation 3 212 Loading stock piles and blasted rocks 3 209 Loading work 3 212 Location of engine number plate 1 8 Location of product identification number PIN ma chine serial number plate 1 8 Location of safety labels 2 5 Lock 3 220 Lock...

Page 429: ...r functions of machine monitor 3 93 Other precautions 2 43 Other trouble 3 251 Outline of KOMTRAX 3 157 Outline of maintenance 4 5 P Parking brake Check 3 188 4 45 Parking brake Release 3 245 Parking brake Release with bolt 3 247 Parking brake Release with parking brake emergen cy release valve 3 246 Parking brake pilot lamp 3 39 Parking brake switch 3 99 PCS Set 6 9 PCS Proportional Control Switc...

Page 430: ...isplay Select 3 81 Radiator coolant level caution lamp 3 28 Radiator fan automatic reverse mode 3 65 Radiator fan manual reverse mode 3 63 Radiator fin and cooler fin Clean 4 27 Raise remote boom positioner Operate 3 215 Raise remote boom positioner Release 3 216 Rear full length fender and engine side cover Close 3 125 Rear full length fender and engine side cover Open 3 123 Rear full length fend...

Page 431: ...owing pin Use 3 122 Towing when engine can run 3 245 Towing when engine does not run 3 245 Transmission breather Clean 4 55 Transmission case Change oil Clean strainer 4 53 Transmission case Check oil level Add oil 4 23 Transmission cut off function 3 198 Transmission cut off function Apply brake 3 200 Transmission cut off pilot lamp 3 37 Transmission cut off position Adjust 3 199 Transmission cut...

Page 432: ...vel Add 4 33 Window washer fluid select 2 41 Window washer fluid spouting out Check 3 170 Wiper function Check 3 170 Work equipment Operate 3 203 Work equipment lock pilot lamp 3 39 Work equipment lock switch 3 107 Work equipment system caution lamp 3 21 Work place Clean Tidy 2 33 Y Your machine serial numbers and distributor 1 10 INDEX 8 8 ...

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