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MAINTENANCE

MAINTENANCE PROCEDURE

4-19

MAINTENANCE PROCEDURE

INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)

Carry out the following maintenance only after the first 100 hours of operation on new machines.

Clean strainer of PTO lubricating oil filter

For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE.

INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)

Carry out the following maintenance only after the first 500 hours of operation on new machines.

Change oil in swing machinery case

Change oil in PTO case

Change oil in final drive case

For details of the method of replacing or maintaining, see EVERY 1000 HOURS and EVERY 2000 HOURS SER-
VICE.

INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000
HOURS)

Carry out the following maintenance only after the first 4000 hours of operation on new machines.

Check welded structure

For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE.

Содержание PC2000-8 BACKHOE

Страница 1: ...death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all pe...

Страница 2: ......

Страница 3: ...FOREWORD 11...

Страница 4: ...relevant personnel can read it at any time Storage location for the Operation and Maintenance Manual magazine box on the left side of the operator s seat If this manual is lost or damaged contact your...

Страница 5: ...or death Follow the instructions in the safety message The following signal words are used to alert you to information that must be followed to avoid damage to the machine This signal word indicates...

Страница 6: ...n for the earth moving machine transmitted from the opera tor s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096 The actual accelerati...

Страница 7: ...weight and size of the operator q Wear seat belt q Inspect and maintain the seat suspension and adjustment mechanisms 5 Steer brake accelerate shift gears for wheeled machines and move the attachment...

Страница 8: ...rk See the section RECOMMENDED APPLICATIONS 3 228 for further details DIRECTIONS OF MACHINE 1 In this manual the terms front rear left and right refer to the travel direction as seen from the operator...

Страница 9: ...1 m from the outside surface of the machine at a height of 1 5 m is shown in the diagram below The hatched area A shows the area where the view is blocked by part of the machine when mirrors or other...

Страница 10: ...diagram below The hatched areas B show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard Please be fully aware that there are places that cannot b...

Страница 11: ...or ordering replacement parts please inform your Komatsu distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 This is at the bottom right of the room under th...

Страница 12: ...top left of fuel filter 1 on the engine cylinder block as seen from the front of the machine Machine of poor fuel arrangement specification This is on top of the common rail cover on the engine cylin...

Страница 13: ...AND DISTRIBUTOR 1 Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU LTD 2 3 6 Akasaka Minato ku 101 Tokyo Japan Authorised representative Address...

Страница 14: ...SERIAL NUMBER PLATE according directive 2006 42 EC 1 A B C D E F G H A Machine designation type E Engine power B Serial Number F Product Identification Number C Year of construction G Manufacturer D O...

Страница 15: ...clares that this machine PC2000 8 Fulfills all the relevant provisions of following EC Directives The manufacturer Authorized representative KOMATSU LTD 2 3 6 Akasaka Minato ku Tokyo 107 8414 Japan KO...

Страница 16: ...ration according Directive 2006 42 EC Annex I point 1 7 4 2 c 1 13 SAFETY SAFETY 2 2 SAFETY LABELS 2 4 LOCATION OF SAFETY LABELS 2 5 SAFETY LABELS 2 6 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINT...

Страница 17: ...OM 3 84 SWITCHES OUTSIDE OF MACHINE 3 87 LAMP INSIDE OPERATOR S CAB 3 97 LAMP OUTSIDE OF MACHINE 3 100 CONTROL LEVERS AND PEDALS 3 102 DOOR LOCK 3 104 EMERGENCY EXIT FROM OPERATOR S CAB 3 104 EMERGENC...

Страница 18: ...ent 3 179 Seat Belt 3 184 Operations Before Starting Engine 3 185 STARTING ENGINE 3 189 AFTER STARTING ENGINE 3 192 Breaking in the New Machine 3 192 Engine Warm Up 3 193 Hydraulic Equipment Warm Up 3...

Страница 19: ...ING MACHINE AFTER LONG TERM STORAGE 3 239 TROUBLES AND ACTIONS 3 240 RUNNING OUT OF FUEL 3 240 PHENOMENA THAT ARE NOT FAILURES 3 240 TOWING THE MACHINE 3 241 SEVERE JOB CONDITION 3 241 DISCHARGED BATT...

Страница 20: ...ROM FUEL CIRCUIT 4 45 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 49 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4 60 INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR...

Страница 21: ...4 107 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 108 REPLACE ACCUMULATOR IN OIL COOLER CIRCUIT 4 109 EVERY 5000 HOURS MAINTENANCE 4 110 CHANGE OIL IN HYDRAULIC TANK CLEAN STRAIN...

Страница 22: ...RATIONS 7 2 OVERALL MACHINE VIEW 7 2 EXPLANATION OF COMPONENTS 7 3 SWITCHES 7 3 OPERATIONS 7 5 OPERATION OF WORK EQUIPMENT 7 5 PRECAUTIONS DURING OPERATION 7 7 EXCAVATOR WORK 7 11 PRECAUTIONS WHEN DIS...

Страница 23: ...ING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine When operating or servicing the machine always follow these precau...

Страница 24: ...S SEAT 2 152 PRECAUTIONS WHEN LEAVING MACHINE 2 162 EMERGENCY EXIT FROM OPERATOR S CAB 2 162 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 162 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 162 PROTECTION AG...

Страница 25: ...MENTS 2 362 PRECAUTIONS WHEN WORKING AT HIGH PLACES 2 362 PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2 372 PROPER TOOLS 2 372 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 382 PRECAUTIONS...

Страница 26: ...the correct place and always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off q There are also other labels in addition to the warning...

Страница 27: ...SAFETY SAFETY LABELS 2 5 LOCATION OF SAFETY LABELS 2 9JH14979B...

Страница 28: ...no one is on or near machine or in the swing area q Rotate cab for full view of travel path if it can be done safely q Use spotter if view is obstructed q Follow above even if the machine is equipped...

Страница 29: ...peration confirm the machine motion and indicated operating pattern when operating machines Pay attention to the circumference and operate slowly when confirming the machine motion 6 Caution for high...

Страница 30: ...t could cause injury q Read manual and adjusting track for safe and proper han dling 9 Caution for handling cable 09808 A0881 q Sign indicates an electric hazard from handling the cable q Read manual...

Страница 31: ...ot attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire 15 Caution about high pressure for common rail 6218 81 2980 High Pr...

Страница 32: ...tteries no sparks b Always wear safety glasses when working with batter ies c Keep children away from batteries d Caution battery acid e Read the operator s manual before working with batteries f Caut...

Страница 33: ...al thoroughly If there are any places in this manual that you do not understand ask the person in charge of safety to give an explanation PREPARATIONS FOR SAFE OPERATION 2 PRECAUTIONS REGARDING SAFETY...

Страница 34: ...pedal with mud or oil affixed to your shoes your foot may slip and this may cause a serious accident q Do not leave tools or a machine parts lying around inside the operator s compartment If tools or...

Страница 35: ...oil q Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace q When washing parts with oil use a non flammable oil Do not use diesel oil or gasoline Th...

Страница 36: ...ng operation and rub against other parts There is danger that this may lead to damage to the hoses and cause high pressure oil to spurt out leading to fire serious personal injury or death q Explosion...

Страница 37: ...RSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel NO JUMPING ON OR OFF MACHINE q Never jump on or off the machine Never get on or off a moving machine...

Страница 38: ...nd DO NOT GET CAUGHT IN WORK EQUIPMENT 2 The clearance in the area around the work equipment changes according to the movement of the link If you get caught you may suffer serious personal injury or d...

Страница 39: ...here is no one except the operator in the surrounding area They may be hit by falling objects or flying objects q When carrying out demolition or breaker operations install a front guard and always ke...

Страница 40: ...equipment side is broken there is a hazard that the operator may be directly hit or caught in the work equipment If the glass is broken stop operations immediately and replace the glass q The ceiling...

Страница 41: ...ing fences around the worksite q When traveling or operating in water or on soft ground check the water depth speed of the current bedrock and shape of the ground beforehand and avoid any place that w...

Страница 42: ...horn to warn people in the area When traveling or carrying out operations in places with poor visibility it is impossible to check for obstacles in the area around the machine and to check the conditi...

Страница 43: ...ust masks q Do not allow other persons to approach during the opera tion q Always observe the rules and regulations for the work site and environmental standards This machine does not use asbestos but...

Страница 44: ...re all at the Neutral position q Before starting the engine check that lock lever 1 is in LOCK position L q Adjust the mirrors so that the rear of the machine can be seen clearly from the operator s s...

Страница 45: ...machine will move when the power is connected q For machines equipped with a battery isolator switch wait for at least 3 minutes after turning the starting switch OFF then turn the battery isolator sw...

Страница 46: ...ard q Check the operating condition of the machine work equip ment arm boom travel and swing system q Check for any problem in the sound of the machine vibra tion heat smell or gauges check also that...

Страница 47: ...e ground and the machine may be turned over q If the view to the right side is poor raise the boom to ensure better visibility q For machines equipped with an auto deceleration system always turn the...

Страница 48: ...ator s cab facing uphill when travel down slopes set the operator s cab facing downhill Always check the firmness of the ground under the front of the machine when traveling q When traveling up a stee...

Страница 49: ...the downhill side when the bucket is loaded This operation is dangerous and may cause the machine to tip over q If the machine has to be used on a slope pile the soil to make a platform A that will ke...

Страница 50: ...broken materials or of the machine tipping over due to reaction from the impact q The not pass the bucket over the heads of other workers or over the operator s seat of dump trucks or other hauling e...

Страница 51: ...er and objects placed beside the road are buried in the snow and cannot be seen There is a hazard of the machine tipping over or hitting covered objects so always carry out opera tions carefully PARKI...

Страница 52: ...from moving out of position or coming off q Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove dirt from machine tracks On a rainy day in particular be extremely...

Страница 53: ...ling wire rope q Never tow a machine on a slope q During the towing operation never stand between the tow ing machine and the machine being towed LIFTING OBJECTS WITH BUCKET 2 PRECAUTIONS FOR LIFTING...

Страница 54: ...work equipment or swing to pull the load in any direction There is danger that the hook may break and the load come off causing the work equipment to move suddenly and cause personal injury q Do not...

Страница 55: ...r touch the levers q If necessary put up signs around the machine also Warning tag part number 09963 A1640 When not using this warning tag keep it in the toolbox If there is no toolbox keep it in the...

Страница 56: ...FOR INSPECTION AND MAINTENANCE q Stop the machine on firm level ground q Select a place where there is no hazard of landslides falling rocks or flooding STABILITY When dismantling or assembling the ma...

Страница 57: ...ipment control lever back and forth left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit and then move lock lever 1 to the LOCK position...

Страница 58: ...may contact the rotating parts and break or be sent flying q Release the residual pressure from the hydraulic system and place Lock lever 1 to its LOCK position For releasing of the residual oil pres...

Страница 59: ...work equipment or the machine will suddenly drop This is extremely dangerous Never work under the work equipment or the machine q If it is necessary to raise the work equipment or the machine and the...

Страница 60: ...lectrolyte level and add distilled water or commercially available battery filler solution to the UPPER LEVEL mark q Do not smoke or bring any flame close to the battery q Hydrogen gas is generated wh...

Страница 61: ...r switch Then begin the cable removal at the ground negative cable side When installing the battery cables be sure to begin with the positive cable side and finish at the ground cable side Tighten the...

Страница 62: ...rnal pressure in the circuit has been released If this is not done it may lead to serious personal injury or death Always do as follows q For details of the method of releasing the pressure see METHOD...

Страница 63: ...posed reinforcement wire layer q Covering swollen in places q Twisted or crushed movable portion q Foreign material embedded in covering PRECAUTIONS FOR HIGH VOLTAGE When the engine is running and imm...

Страница 64: ...quipment to go down under its own weight After stopping the engine set the lock lever to the LOCK position The accumulator and gas spring are charged with high pressure nitrogen gas If the accumulator...

Страница 65: ...lakes q Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters and batteries MERCURY CONTAINING COMPONENT S The monitor display backlight con...

Страница 66: ...nd even when they have not reached the specified replacement time q The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the machine END OF SERVICE LIFE 2 For...

Страница 67: ...OPERATION 13 WARNING Please read and make sure that you understand the safety volume before reading this section...

Страница 68: ...MACHINE VIEW ILLUSTRATIONS 3 OVERALL MACHINE VIEW 3 1 Bucket 9 Power container 2 Bucket cylinder 10 Hydraulic ladder 3 Arm 11 Sprocket 4 Arm cylinder 12 Track frame 5 Boom 13 Cab base 6 Boom cylinder...

Страница 69: ...arette lighter 24V power supply socket 12 Travel pedals 4 AM FM Radio 13 Travel levers 5 Air conditioner control panel 2 14 Lock lever 6 Air conditioner control panel 1 15 Horn switch 7 Engine emergen...

Страница 70: ...h 12 Fan reverse display lamp 4 Engine emergency stop switch 13 Rotating lamp switch if equipped 5 Room lamp switch 14 Greasing mode switch 6 Service center switch if equipped 15 Machine push up switc...

Страница 71: ...1 Truck counter 1 6 Auto deceleration selector switch 22 Truck counter 2 7 Function switches F1 F6 23 ECO gauge 8 Engine water temperature monitor 24 Fuel gauge 9 Engine water temperature gauge 25 Fue...

Страница 72: ...eck before starting screen Z Maintenance interval monitor screen 1 Engine oil pressure monitor 4 Engine oil temperature monitor 2 Charge level monitor 5 Air cleaner clogging monitor 3 Radiator coolant...

Страница 73: ...tant to completely understand methods of operating the equipment and the meanings of the displays MONITORING SYSTEM 3 X 1 2 Normal operation screen 1 2 pilot screen all lights up Y Check before starti...

Страница 74: ...ition opening screen S is displayed q After opening screen S has been displayed for 2 seconds the screen switches to Check before starting screen Y q After Check before starting screen Y has been disp...

Страница 75: ...nds then the screen goes out If There Is Abnormality When Starting Engine q If there is any abnormality when the engine is started Check before starting screen Y switches to Mainte nance interval warn...

Страница 76: ...ck before starting screen Y has been displayed for 2 seconds the screen switches to warning screen V or Error screen W If Any Abnormality Occurs During Operation q If any abnormality occurs during ope...

Страница 77: ...starting items that must be checked before starting the engine If there is any abnormality monitor for the location of abnormality will light up Radiator Coolant Level Monitor Monitor 1 warns the ope...

Страница 78: ...monitor screen goes out after 30 seconds and switches to the normal screen q For details of the method of confirming the maintenance interval see Maintenance Selector Switch 3 45 If it is desired to...

Страница 79: ...ONTROLS AND GAUGES 3 13 Hydraulic oil level monitor This monitor 5 warns the operator that the hydraulic oil level has gone down If there is lack of hydraulic oil the lamp lights up red so check the o...

Страница 80: ...ems which need to be repaired as soon as possible are displayed If there is any problem the appropriate monitor lamp will flash to indicate the location of the problem Displayed in center of screen in...

Страница 81: ...aining amount of fuel in the tank goes down to approx 200 liter the monitor portion lights up red so add fuel quickly Air Cleaner Clogging Monitor Monitor 3 warns the operator of a clogged air cleaner...

Страница 82: ...when condition is abnormal Monitor background D is red PTO Temperature Monitor When this monitor 6 is lighted up white in low temperatures carry out the warming up operation For details see Hydraulic...

Страница 83: ...mount of grease is low add grease quickly If monitor 9 does not go out even when greasing is carried out or when there is ample grease but the monitor is lighted up red contact your Komatsu distributo...

Страница 84: ...n then perform necessary actions These items should be observed while the engine is running If there is a problem the monitor for the abnormal location lights up red and buzzer sounds perform action i...

Страница 85: ...or 2 warns the operator that the hydraulic oil tem perature has risen If the hydraulic oil temperature becomes abnormally high abnormality display C is shown Stop operations and stop the engine or run...

Страница 86: ...has risen If the engine oil temperature becomes abnor mally high abnormal display C is given Stop operations and run the engine at low idling or stop the engine until the monitor changes to correct te...

Страница 87: ...itor 12 Engine oil pressure gauge 4 Auto deceleration monitor auto lowidle monitor 13 ECO gauge 5 Working mode monitor 14 Idle stop guidance 6 Engine coolant temperature gauge 15 Truck counter display...

Страница 88: ...cally actuated the preheating monitor lights up When the preheating is completed it goes out Automatic preheating is for a maximum of approx 30 seconds Swing Lock Monitor This monitor 2 informs the op...

Страница 89: ...rmittent actuation of wiper both upper and lower ones OFF Wiper stopped q For details of the positions of the wiper switch see CONTROLS AND GAUGES 3 3 Auto deceleration Monitor Auto Low idle Monitor M...

Страница 90: ...nitor 5 displays the mode for setting operations The monitor displays for the operation of the working mode switch are as follows P P mode heavy duty operation E E mode operation with emphasis on low...

Страница 91: ...ormality display Red range B position Engine speed changes to low idling engine coolant temperature monitor 1 shows abnormality dis play alarm buzzer sounds at same time The overheat prevention system...

Страница 92: ...raulic oil temperature The indicator should be in the green range during operations If the indicator starts to enter red range A during operations it shows that the hydraulic oil temperature is more t...

Страница 93: ...ine has been operated or the present time The service meter advances if the engine is running even if the machine is not moving The meter advances by 1 for every hour of operation of the engine regard...

Страница 94: ...carry out the warming up operation For details see Engine Warm Up 3 193 and Hydraulic Equipment Warm Up 3 195 Engine Oil Temperature Gauge This meter 11 shows the engine oil temperature The indica to...

Страница 95: ...uel consump tion target is being achieved If the gauge is in green range A it shows that the fuel consumption is within the target If the gauge is in orange range B it shows that the fuel consumption...

Страница 96: ...ck When truck counter switch b at the front as seen from the front of the machine on top of the left control lever is pressed the count advances Each time truck counter switch b is pressed the buzzer...

Страница 97: ...mode in use when it was started the previous time q When switch 1 is pressed the working mode selection screen list is displayed For each setting mode P or E is displayed on the pilot monitor at the t...

Страница 98: ...is automatically set as the working mode and the screen changes to Steps 3 and Steps 4 REMARK To return to the standard screen without changing the working mode press function switch F5 3 After selec...

Страница 99: ...leration function is ON if the work equipment and travel levers are returned to the N posi tion the engine speed will drop after 4 seconds from the operating speed to idling speed This makes it possib...

Страница 100: ...ds the engine speed drops from the work equipment speed to the idling speed In addition if the auto low idle function is ON after a further approx 30 seconds if the work equipment control levers and t...

Страница 101: ...center of the monitor display and after 2 sec onds the display returns to the standard screen Wiper Switch This switch 4 actuates the front window wiper Each time the switch is pressed the wiper swit...

Страница 102: ...iper A upper lower q Continuous operation of wiper top bottom B q Continuous operation of wiper top only C REMARK Each time wiper switch 4 is pressed the mode is displayed in the center of the monitor...

Страница 103: ...e the wiper will be actuated continuously When switch 5 is released the wiper will continue to operate for 2 cycles then stop q If the wiper is moving intermittenly and switch 5 is kept pressed contin...

Страница 104: ...tch when expanding function F2 Screen selector switch F3 Camera screen selector switch if equipped F4 Service meter clock display selector switch F5 Maintenance mode selector switch F6 User mode selec...

Страница 105: ...Press switch A immediately below the guidance icon dis play to operate the function The operation of the function switches if the initial screen is the standard screen is as follows Camera Screen Sele...

Страница 106: ...is pressed the whole screen shows the screen for the camera at the rear left of the machine q When function switch F2 is pressed the whole screen shows the screen for the camera at the rear center of...

Страница 107: ...left of the machine and the screen for the camera at the rear right of the machine can be displayed at the same time q When two screens are displayed at the same time the dis play changes more slowly...

Страница 108: ...creen returns to the standard screen To display the camera screen press function switch F3 again q Press the auto deceleration switch to turn the auto decel eration function ON OFF Even if the auto de...

Страница 109: ...ayed at the top left of the screen and flashes q When the error monitor or warning monitor is displayed press function switch F5 to return to the standard screen and check the content of the error or...

Страница 110: ...ES AND ACTIONS 3 240 Service Meter Clock Display Selector Switch 3 On the standard screen it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor disp...

Страница 111: ...nce interval settings h c Time remaining until maintenance h a b Change engine oil 500 Replace engine oil filter 500 Replace fuel pre filter 500 Replace fuel main filter 1000 Replace hydraulic oil dra...

Страница 112: ...reset the remaining time of a selected item highlighted in yellow REMARK When resetting the remaining time keep switch F6 pressed for at least 1 5 seconds If switch F6 is not kept pressed for at leas...

Страница 113: ...list screen On the reset screen if no switch is operated for more than 30 seconds the screen automatically switches to the maintenance list screen 2 The reconfirmation screen shown on the right is di...

Страница 114: ...down When on the last line it moves to the first line on the next page F4 Moves to previous item 1 line up When on the first line it moves to the last line on the previous page F5 Returns to standard...

Страница 115: ...djustment d Language selection e Economy mode adjustment f Auto Low idle setting g Truck counter reset h Fan reverse mode The operation for setting a h is as follows Adjusting Screen Use this screen a...

Страница 116: ...reen switches to the setting screen for the selected item a Standard screen adjustment b Camera screen adjustment only machines equipped with camera q On the mode selection screen shown on the right i...

Страница 117: ...adjust the brightness of the monitor screen night mode q When the working lamp switch is in day position b or OFF position c if the standard screen is adjusted it is possible to adjust the brightness...

Страница 118: ...ted item moves 1 segment to left F4 Indicator of selected item moves 1 segment to right F5 Returns to user menu F6 Accepts change and switches to next item setting ECO Display On this ECO display scre...

Страница 119: ...53 2 Select ECO display selection on the user menu then press function switch F6 The screen switches to the tar get setting command screen 3 Select ECO Display Target Select then press function switch...

Страница 120: ...on ment reduce the engine output to a point where there is no adverse effect on the operation Generally carry out energy saving operations in the green range Reducing the frequency of travel also help...

Страница 121: ...lock displayed on the pilot monitor of the standard display 1 On the standard screen press switch F6 2 Select Clock Adjustment on the user menu then press switch F6 The screen switches to the time adj...

Страница 122: ...s not necessary to change the hour setting press switch F6 F3 Time advances 1 hour F4 Time goes back 1 hour F5 Cancels change and returns to user menu F6 Accepts change and goes to setting for minutes...

Страница 123: ...ighted in yellow press switch F6 to highlight 12h 24h Mode a in yellow 2 Change the 12h 24h mode with the switches as follows The selected display mode b or c is highlighted in green F3 Moves 1 item t...

Страница 124: ...s change and returns to user menu F6 Accepts change and goes to setting for Time If the setting has been changed always press switch F6 REMARK Daylight saving time or summer time means moving the cloc...

Страница 125: ...the language to use for the display then press switch F6 The screen display changes to the selected lan guage q On the language selection screen it is possible to carry out the following operations wi...

Страница 126: ...s economy mode the engine output can be adjusted to improve the fuel consumption in E mode 1 On the standard screen press switch F6 2 Select Economy Mode Adjustment on the user menu then press switch...

Страница 127: ...is shipped it is set to E0 q On the Economy Mode Adjustment menu screen it is possible to carry out the following operations with switches F3 F6 F3 Moves to item below F4 Moves to item above F5 Cance...

Страница 128: ...the standard screen 2 Select Auto Low idle setting on the user menu then press function switch F6 The screen changes to the ON OFF screen for Auto Low idle setting 3 Select ON on the Auto Low idle set...

Страница 129: ...screen the auto low idle monitor lights up q When the auto low idle function is ON after the work equipment control levers and travel levers are placed at Neutral the engine speed automatically goes d...

Страница 130: ...1 to turn the auto decel eration function ON 2 When the auto deceleration function is turned ON the mode is displayed in the center of the monitor display and after 2 seconds the screen returns to the...

Страница 131: ...nter Reset It is possible to correct or clear the truck counter 1 Press function switch F6 on the standard screen 2 Select Truck Counter Reset on the user menu then press function switch F6 The screen...

Страница 132: ...F6 The screen switches to the selected item screen 01 TR1 CORRECT CLEAR Truck Counter Display 1 it is possible to correct or clear 02 TR2 CORRECT CLEAR truck counter Display 2 it is possible to correc...

Страница 133: ...em screen operate function switches F3 or F4 to correct the counter value then press function switch F6 to confirm q After confirming press function switch F5 to return to the previous screen q If no...

Страница 134: ...n switch F1 on the selected item screen then press function switch F6 to confirm The truck counter on the selected item screen is reset q After confirming press function switch F5 to return to the pre...

Страница 135: ...on switch F6 The screen will switch to the ALL CLEAR screen When the ALL CLEAR screen is displayed press function switch F6 to confirm q After confirming press function switch F5 to return to the prev...

Страница 136: ...ooler q Reverse rotation of the fan can be used for cleaning The fan blows the air to the outside to remove insects or dirt stuck to the net q After checking that no flammable or combustible material...

Страница 137: ...n press function switch F6 The screen switches to Reverse FAN on the Fan Reverse Mode screen 4 To reverse the direction of the fan press function switch F6 The screen switches to Now Changing on the a...

Страница 138: ...ine speed q When rotating the cooling fun in reverse while the engine is not running switch the display to this screen with the engine starting switch in ON position and then turn the switch to the ST...

Страница 139: ...tion switch F6 The screen switches to Now Changing on the action screen q If function switch F5 is pressed the screen returns to the previous screen 9 When the screen changes to Now Changing in the op...

Страница 140: ...n reverse press function switch F5 to switch to the initial screen then run the engine at low idling or stop the engine to carry out warming up or cooling operation On the initial screen if the coolan...

Страница 141: ...lamp switch if equipped 3 Engine emergency stop switch 12 Greasing mode selector switch 4 Service center switch if equipped 13 Machine push up switch 5 Room lamp switch 14 Boom shock less limit switch...

Страница 142: ...ctric current flows through the charging and lamp circuits Keep starting switch key in the ON position while the engine is running C START position This is the engine start position Keep the key at th...

Страница 143: ...he OFF position and the emergency stop is cancelled When this happens indicator lamp L goes out REMARK It is possible to judge the status ON OFF of the engine emer gency stop switch by checking the co...

Страница 144: ...position do not forget to turn it off Use this switch 5 to light up the room lamp a ON position Lights up b OFF position Goes out This lamp lights up even if the starting switch is at the OFF positio...

Страница 145: ...nation of monitor screen is at normal level Step Light Switch This switch 8 lights up the step to ensure safety at night when getting on or off the machine q If the switch is set to ON position a the...

Страница 146: ...ll it out and light your cigarette If the cigarette lighter is removed the socket can be used as the power source for the yellow flashing lamp The capacity of the cigarette lighter is 85W 24V x 3 5A 1...

Страница 147: ...boom thrust force to push up the chassis when moving down from a bench there is dan ger that the machine may suddenly go down and turn over so set to the high pressure setting With this switch 13 it...

Страница 148: ...is at the ON position q If the swing control lever is operated immediately after setting the swing lock switch to the ON posi tion swing drag may occur To avoid danger wait for approx 5 seconds after...

Страница 149: ...switch 2 q When switch 16 is pressed the buzzer emits a peep at the same time so it is possible to check that the switch 16 has been pressed q In addition when switch 16 is kept pressed for approx 3...

Страница 150: ...switch is in the OFF position do not forget to turn it off Use this switch 18 to light up the room lamp inside the cab base ON position Lights up OFF position Goes out 18 Room lamp switch cab base ro...

Страница 151: ...ed slightly slower than normal q When starting up the engine with E0E or E07 showing on the display and the engine does not run move this switch to position c Then the engine may be started After the...

Страница 152: ...soon as possible This switch 22 makes it possible to carry out operations for a short time when there is an abnormality in the emergency stop switch system but no monitor lights up and the engine cann...

Страница 153: ...mp switch pump room 32 Step light switch 26 Engine emergency stop switch front of power container 33 Step light switch 27 Engine emergency stop switch rear of power container 34 Nighttime maintenance...

Страница 154: ...engine room NOTICE It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position do not forget to turn it off Use this switch 24 to light up the room lamp insid...

Страница 155: ...will make an emergency stop When this happens indi cator lamp L lights up green to indicate that the engine emer gency stop switch has been actuated b OFF normal operation position When the engine em...

Страница 156: ...will make an emergency stop When this happens indi cator lamp L lights up green to indicate that the engine emer gency stop switch has been actuated b OFF normal operation position When the engine eme...

Страница 157: ...rgencies q When carrying out an emergency stop of the engine If engine emergency stop indicator lamp L is off pull down rope R Indicator lamp L will light up green and the engine will make an emergenc...

Страница 158: ...stop indicator lamp L is off pull down rope R Indicator lamp L will light up green and the engine will make an emergency stop q Cancelling engine emergency stop When indicator lamp L is lighted up pul...

Страница 159: ...d it immediately returns to the OFF condition but the step light continues to remain lighted up for approx 90 seconds q Use this switch at night when moving between the ground and the operator s cab w...

Страница 160: ...hted up until switch 34 is turned manually to OFF position b q Use this switch at night for maintenance work when it is desired to keep the steps or the passage lighted up q It is possible to light up...

Страница 161: ...iately after the fan stops rotating in reverse power is supplied to the fan reverse rotation solenoid for a short time in order to protect the hydraulic motor Before turning the battery isolator switc...

Страница 162: ...ecomes possible to start the engine Before starting the engine check that this switch is at the ON position b OFF position When the switch is turned counterclockwise from the ON posi tion the flow of...

Страница 163: ...mp Lighted up Green Engine emergency stop switch is at ON emergency stop position Light off Engine emergency stop switch S is at OFF normal operation position 1 Engine emergency stop Indicator lamp 5...

Страница 164: ...he OFF normal operation position before starting the engine again If lamp 2 is off when the starting switch is turned to the ON posi tion the engine can be started Fan Reverse Rotation Display Lamp Th...

Страница 165: ...he lamp goes off For more details see Engine Emergency Stop Cancel Switch 3 86 Ladder Warning Lamp This lamp 7 lights up red when any of the following devices have been lowered q Hydraulic ladder q Se...

Страница 166: ...ACHINE 3 9JH14996A 1 Proximity switch warning lamp 4 Engine emergency stop Indicator lamp 2 Proximity switch warning lamp 5 Engine emergency stop Indicator lamp if equipped 3 Engine emergency stop Ind...

Страница 167: ...these lamps light up red it is necessary to check the cause and carry out repairs so please ask your Komatsu distributor to carry out inspection Engine Emergency Stop Indicator Lamp These lamps 3 to 6...

Страница 168: ...lock the work equipment swing travel and attachment if equipped control levers Push the lever 1 down to apply the lock This lock lever 1 is a hydraulic lock even if it is in the lock position L the wo...

Страница 169: ...avel levers check if the track frame is facing the front or the rear If the sprocket is at the rear the track frame is facing the front With this lever 2 the travel direction of the machine is changed...

Страница 170: ...Neutral The boom and bucket are held in position and do not move DOOR LOCK 3 Use the door lock to fix the door in position after opening it 1 Push the door into catch 1 to lock it in position 2 When r...

Страница 171: ...them Take care not to slip on the broken and scattered pieces Hammer A is provided to help the operator get out of the cab in emergency when the cab door or window will not open q Hammer A is install...

Страница 172: ...rail and steps to ensure that you sup port yourself In particular the rope ladder will tend to swing and there is danger of falling off so be particularly careful to support yourself securely when cli...

Страница 173: ...pper 2 2 Remove snap hook 3 from the hook of escape door 1 then lower rope ladder 4 to the ground 3 Using handrails 5 and 6 support yourself and step on to fixed ladder 7 4 Climb down fixed ladder 7 W...

Страница 174: ...pe ladder 4 to the ground When doing this use handrail 8 and the rungs of fixed ladder 7 PRECAUTION WHEN STORING ROPE LADDER 3 When storing rope ladder 4 put a step of rope ladder 4 on installation br...

Страница 175: ...ree other places where additional fire extinguishers can be installed If you wish to have additional fire extinguishers please consult your Komatsu distributor The three places where additional fire e...

Страница 176: ...he Cap 1 Turn the cap until tight then insert the key into the key slot 2 Turn the starting switch key counterclockwise clockwise for the B type and remove the key Opening and Closing Cover with Lock...

Страница 177: ...sure that you extinguish the cigarette before clos ing the lid CUP HOLDER 3 There are 2 cup holders at the rear left of the operator s seat MAGAZINE BOX 3 This is on the left side of the operator s s...

Страница 178: ...DETAILED CONTROLS AND GAUGES OPERATION 3 112 HOOK 3 This is at the rear of the operator s compartment UTILITY BOX 3 This is under the assistant s seat...

Страница 179: ...temperature and air flow displays on display monitor 6 and air conditioner switch 7 go out and operation stops REMARK Even if switch 1 is turned OFF the lamp at the top of FRESH RECIRC selector switc...

Страница 180: ...ch to raise the set temperature press the switch to lower the set temperature q The temperature is generally set at 25 C q The temperature can be set in stages of 0 5 C q The sensors for the temperatu...

Страница 181: ...vents displayed q During automatic operation the vents are automatically selected A Rear vents top x 2 bottom x 2 B Face vents left x 1 right x 1 C Foot vents front x 1 rear x 1 D Defroster vents left...

Страница 182: ...ES OPERATION 3 116 q Rear vents A A1 Rear vents top 2 places A2 Rear vents bottom 2 places q Face vents B B1 Face vent left 1 place B2 Face vent right 1 place q Foot vents C C1 Foot vent front 1 place...

Страница 183: ...to the set temperature q When auto switch 8 is pressed the lamp above the auto switch lights up q Press switch 5 then use temperature control switch 3 to set the temperature and run the air conditione...

Страница 184: ...h 1 is pressed the display of tempera ture setting a and air flow b goes out and operation stops Air Conditioner Switch Use this switch 7 to start or stop the air conditioner cooling dehumidifying hea...

Страница 185: ...ir volume b are also shown on the monitor display 2 Use temperature set switch 3 to set to the desired tem perature The air flow combination of vents and selection of fresh or recirculated air is auto...

Страница 186: ...he lamps above auto switch 8 and air conditioner switch 7 go off stopping the operation of the air conditioner Manual Operation 1 Press fan switch 2 and adjust the air flow When doing this check that...

Страница 187: ...select the desired vents When this is done the display for vent c of the display monitor changes according to the selection 5 Press RECIRCL A or FRESH B on air source selector switch 5 Stopping Manual...

Страница 188: ...doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display c on the display monitor to mode display M3 as shown in the di...

Страница 189: ...flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display c on the display monitor to the following mode q To...

Страница 190: ...agram on the right 3 Press FRESH RECIRC selector switch 5 to set to intake of outside air 4 Press temperature setting switch 3 and set temperature on the display 7 monitor to maximum heating In wet or...

Страница 191: ...entilation and cooling Temperature Control When the cooler is on set the temperature so that it feels slightly cool when entering the cab 5 or 6 C lower than the outside temperature This temperature d...

Страница 192: ...an one failure is detected press the or portion of temperature setting switch 3 to dis play the failures in turn q After completing the troubleshooting press OFF switch 1 again to return to the normal...

Страница 193: ...t the same time for more than 5 seconds while the fan is running the temperature display will switch between F and C Note that the unit is not displayed RADIO 3 Control Panel 3 s Liquid crystal displa...

Страница 194: ...ay For details of the method of adjusting the time see Setting Correct Time 3 131 AS PS button This button 5 actuates the auto store and preset scan functions q Auto store If this button is kept press...

Страница 195: ...s for tuning auto tuning and manual tuning 3 With the display 7 showing the desired frequency keep the desired Preset button No pressed for at least 1 5 sec onds The reception sound will disappear but...

Страница 196: ...o tuning will be cancelled and the setting will return to the fre quency in use before the button was pressed Method of Operating Mode q BAS Bass adjustment When button 2 is pressed BAS is displayed o...

Страница 197: ...by one hour M button Adjusts the minute each time the button is pressed the time advances by one minute q If the H or M button is kept pressed the time will advance continuously until the button is re...

Страница 198: ...to hear outside sounds during opera tion q If water gets into the speaker case or radio it may lead to an unexpected failure so be careful not to get water on the equipment q Do not wipe the scales o...

Страница 199: ...e equipment Pull out the connector plug for taking out electric power from the rear side of the panel Maximum usable electric power is 85 W 24 V x 3 5 A 12V Power Source 3 This power source can be use...

Страница 200: ...o first turn the starting switch to the OFF position wait over one minute then switch off the battery isolator switch The fuses protect the electrical equipment and wiring from burning out If the fuse...

Страница 201: ...enoid valve Starting motor cut relay 4 10A Cigarette lighter 5 20A Horn Flash light 6 10A Bottom dump solenoid valve 7 10A Rotating lamp 8 20A Spare lamp 9 10A Radio 10 30A Wipper Window washer 11 20A...

Страница 202: ...ng out When restoring the electrical circuit that has been shut off push in the reset button that sprang out when the circuit was cut off If the electric circuit is working properly the reset button w...

Страница 203: ...s circuit breaker is a large size breaker installed to circuits where a large capacity current is flowing In the same way as normal fuses and circuit breakers installed to the power board inside the c...

Страница 204: ...troller 2 VHMS controller Bottom dump solenoid valve Rotating lamp Rear and side lamp Radio Wiper Window washer 2 60A Swing holding brake solenoid valve Machine push up Boom anti vibration solenoid va...

Страница 205: ...r switch The fuses protect the electrical equipment and wiring from burning out If the fuse becomes corroded or white powder can be seen or the fuse is loose in the fuse holder replace the fuse Replac...

Страница 206: ...ve the negative terminal of the battery For machines equipped with the optional battery isolator switch turn the starting switch OFF then wait for at least 3 minutes before turning the battery isolato...

Страница 207: ...oolbox placed in the cab base room in the machine s front direction HANDLING GREASE PUMP AND GREASE GUN 3 The grease pump is stored under the center maintenance floor right side of machine The grease...

Страница 208: ...r s seat inside the cab room to the MANUAL position 2 Remove grease gun 1 from holder 2 then move to the greasing posture 3 Pull lever 3 of grease gun 1 with your finger When lever 3 is pulled the gre...

Страница 209: ...ere is only a small amount of grease left in the grease can the pump will not pump out grease so move the grease to the center or fill the can with new grease Supplying Grease When replacing grease ca...

Страница 210: ...oosening hexagonal screw 11 of the grease level sensor lift up limit switch 12 remove cap 13 then remove spring 14 4 Remove 2 wing nuts 15 5 Lift up grease can cover 16 vertically to remove it 6 Remov...

Страница 211: ...ll it to the new grease can that will replace the old grease can NOTICE Be careful not to drop clamp 19 when lifting the grease can up and tighten it securely REMARK If grease can is equipped with ref...

Страница 212: ...he shafts 11 Insert wire 23 of the grease level sensor through hole C in grease can cover 16 12 Be careful not to drop wire 23 into the grease can when inserting it Insert grease can cover 16 until it...

Страница 213: ...e remove the connection hose from the grease pressure feed pump A From grease pressure feed pump B To grease can q Komatsu does not handle grease pressure feed pumps but if the charging port is necess...

Страница 214: ...osing of the accumulator the gas must be released Contact your Komatsu distributor for proper disposal This machine is equipped with an accumulator in the control circuit The accumulator is a device t...

Страница 215: ...the engine starting switch to the ON position 4 Move the lock lever 1 to the free position F and oper ate the work equipment control lever and the attachment operation pedal optional back and forth a...

Страница 216: ...r operate the work equip ment If this happens the ladder warning lamp inside the opera tor s cab lights up red For details see Ladder Warning Lamp 3 99 This lock is cancelled when the ladder is stowed...

Страница 217: ...ep ladder lowering switch 3 on switch box 1 pressed until the ladder automatically stops REMARK The hydraulic ladder can be lowered also when the engine is not running but its move is not as fast as w...

Страница 218: ...on chain to the hook on the machine If the angle when the ladder comes down under its own weight is within 5 when the engine is started the ladder will automatically return to the stowing position so...

Страница 219: ...orking properly so adjust as follows to make actuating display lamp L light up cor rectly q If actuation display lamp L does not light up There is probably a problem with proximity switch 1 so change...

Страница 220: ...iately and ask for repairs to be carried out The machine can move so this is extremely dangerous For this reason when carrying out this operation always set the hydraulic ladder to the stowing positio...

Страница 221: ...connector b to connector D and connect con nector d to connector B 6 Connect the negative terminal of the battery start the engine then check that it is possible to operate the travel swing and work...

Страница 222: ...e KOMTRAX Plus equipment or the machine itself REMARK There is absolutely no need to inspect or operate the KOMTRAX Plus but if any abnormality is found please con tact your Komatsu distributor KOMTRA...

Страница 223: ...he machine equipped with this device is used such restriction or law has a priority than this warning KOMTRAX Plus specifications are as follows Rated horsepower 5 10 W Operating frequency 148 150 MHz...

Страница 224: ...ent cylinders linkage hoses Check for cracks excessive wear play in wotk equipment cylinders linkage and hoses If any problem is found repair it 2 Remove dirt and debris from around the engine battery...

Страница 225: ...If any problem is found repair it Tighten any loose bolts 9 Check for problem in gauges monitor Check for problem in the gauges and monitor in the operator s cab If any problem is found replace the pa...

Страница 226: ...the engine is stopped the coolant is at high temperature In addition pressure has accumulated inside the radiator If the cap is opened under these conditions it will cause burns Wait for the temperatu...

Страница 227: ...ant 4 After adding coolant tighten cap 5 securely then lower the cap lever to secure cap 3 in place 5 If the reserve tank 2 becomes empty there is probably water leakage After checking repair any abno...

Страница 228: ...o open cover 6 2 After removing cover 8 loosen radiator cap 9 slowly to release the pressure then push cap 9 in and loosen it further to remove it 3 Check that the coolant is in the hatched portion in...

Страница 229: ...machines equipped with a service center option see Method of Draining Adding Engine Oil 6 20 1 Open the door of the power container at the front of the machine 2 Remove dipstick G and wipe the oil of...

Страница 230: ...he oil level after the engine has been operated wait for at least 15 minutes after stopping the engine before checking If the machine is at an angle make it horizontal before checking Check Fuel Level...

Страница 231: ...ork equipment is not in the condition shown in the diagram on the right start the engine run the engine at low speed retract the arm and bucket cylinders lower the boom put the bucket teeth in contact...

Страница 232: ...the correct oil level is in blue range a1 on the gauge label shown in the diagram on the right q When the hydraulic oil is at high temperature 50 80 C the correct oil level is in red range b1 on the...

Страница 233: ...elow the correct line add oil through filler port F at the top of the hydraulic tank NOTICE Do not add oil above the correct level This may damage the hydraulic circuit and cause the oil to spurt out...

Страница 234: ...P2 q When using drain plugs P3 at bottom of hydraulic sub tank Loosen 2 drain plugs P3 at the bottom of the hydraulic sub tank and drain the oil The outlet port for draining the oil is drain tube B Wh...

Страница 235: ...or the oil temperature to go down before performing this operation NOTICE When checking the oil level park the machine on the level ground and start checking more than 15 min utes after the engine has...

Страница 236: ...ing monitor on the monitor panel does not light up 2 If it lights up immediately clean or replace the element For details of method of cleaning the element see CHECK CLEAN AND REPLACE AIR CLEANER ELE...

Страница 237: ...lso for loose terminals and tighten if necessary Be particularly careful to check the battery starting motor and alternator wiring Always check that no flammable materials are accumulated around the b...

Страница 238: ...d water from splashing and making the surrounding area dirty 2 Open drain valve 1 at the rear of the revolving frame and drain the sediment and water accumulated at the bottom of the water separator t...

Страница 239: ...d and may cause seri ous burns Wait for the temperature to go down before starting the operation q Fuel is highly flammable and dangerous Never bring flames near fuel The water separator is installed...

Страница 240: ...looking through transparent cap 1 If there is any water or sediment collected at the bottom set a container to catch the drain water under drain hose 3 3 Pull up fuel shut off lever A installed at the...

Страница 241: ...6 Push down fuel shut off lever A to open the fuel supply circuit 7 After completing the water drain operation bleed the air Use the same procedure as when replacing the fuel filter cartridge q For de...

Страница 242: ...Do not bring any fire or flame close The water separator serves to separate moisture mixed in the fuel NOTICE If float 1 goes above level line 2 there is danger that the separated water may be sucked...

Страница 243: ...water will drain from plug 4 4 When fuel starts to come out tighten plug 4 immediately Tightening torque 1 5 2 5 Nm 0 15 0 25 kgm 5 If the inside of filter case 6 is dirty with the sediment wash it F...

Страница 244: ...r defective operation of the buzzer 1 Before starting the engine turn the starting switch to the ON position and check that all monitors and gauges light up for approx 3 seconds and that the alarm buz...

Страница 245: ...lever 3 operated continuously for more than 1 minute A Fore and aft adjustment Pull lever 1 up set the seat to the desired position then release the lever Fore and aft adjustment 170 mm 10 mm x 17 sta...

Страница 246: ...nt range REMARK When the seat is pushed down the air is discharged The air makes a sound when it is discharged but this does not indicate any failure When lever 3 is pushed down the seat height may su...

Страница 247: ...rest portion as desired Push Tension becomes stronger Push Tension becomes weaker J Adjustment of armrest angle Armrest 8 can spring up to an angle of approx 90 In addi tion it is possible to rotate d...

Страница 248: ...nd screws 3 holding the mir ror then adjust to a position which gives the best view from the operator s seat In particular adjust so that people to the left and right side at the rear of the machine c...

Страница 249: ...t the angle of C2 mirror the way a view in the rear of the counterweight left portion can be seen D1 Adjust the angle of D1 mirror the way a view of the fuel tank right lower portion can be seen D2 Ad...

Страница 250: ...seat belt so that it is not twisted REMARK The date of seat belt manufacture attached to the seat belt is the start of the 5 year period It is not the start of the 3 year period of actual usage Faste...

Страница 251: ...pedal are touched when the engine is started the machine may move unexpectedly and this may lead to serious personal injury 1 Check that battery isolator switch 1 and starting motor isolator switch 2...

Страница 252: ...buzzer does not sound there is probably a failure in the monitor so ask your Komatsu distributor to carry out repairs 2 After approx 2 seconds the screen switches to the work ing mode display monitor...

Страница 253: ...h 3 45 in the explanation for each component 5 Check that engine emergency stop lamp 26 is out If it is lighted up the monitor goes out and even if the starting switch is turned to the START position...

Страница 254: ...tch front of power container Engine emergency stop switch rear of power container Engine emergency stop switch left side of the machine if equipped Engine emergency stop switch right side of the machi...

Страница 255: ...d MAX position the engine will accelerate suddenly and cause damage to the engine parts q Do not keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the en...

Страница 256: ...ating has been completed turn the key in starting switch 3 to the START position C and start the engine REMARK If the ambient temperature is low the engine may not start even when the key in the start...

Страница 257: ...After the preheating monitor goes off turn the key in starting switch 3 to START position C The engine will start If the engine cannot be started with the above procedure wait for at least two minute...

Страница 258: ...n the environment the method of carrying out the warm up operation may differ so carry out the warm up operation according to the items given in the appropriate section When only the engine is warmed...

Страница 259: ...ine warm up operation starts automatically When the engine automatic warm up operation starts the engine speed is maintained at a speed higher than the normal low idling speed If the engine water temp...

Страница 260: ...ecking that the engine coolant temperature monitor displays the correct temperature carry out the warm up operation for the hydraulic equipment NOTICE Canceling automatic warm up operation If it becom...

Страница 261: ...itor back ground C is blue B Display when temperature is low Monitor back ground C is white q The warming up operation for the hydraulic equipment is necessary not only for the circuit between the pum...

Страница 262: ...g mode to P mode heavy duty mode For details of the procedure for setting the working mode see Working Mode Selector Switch 3 31 4 Move lock lever 3 slowly to the FREE position F then raise the bucket...

Страница 263: ...mperature monitor 7 is display ing the correct temperature If the hydraulic oil temperature monitor is not displaying the correct temperature it is displaying low temperature repeat Steps 6 to 10 unti...

Страница 264: ...17 Display is correct level 2 2 monitor screen q PTO temperature gauge 18 Displays green range q PTO oil temperature monitor 19 Displays correct temper ature q Engine oil temperature gauge 20 Displays...

Страница 265: ...ow Monitor background C is white For both normal temperatures and cold temperatures carry out the following operation 16 Check that fuel control dial 4 is at a point midway between low idling MIN and...

Страница 266: ...lic oil temperature monitor displays the correct temperature the hydraulic equipment warm up opera tion is completed After confirming that the hydraulic oil temperature monitor displays the correct te...

Страница 267: ...TION MACHINE OPERATIONS AND CONTROLS 3 201 q Working mode monitor display 1 P mode For heavy duty operations 2 E mode For operations with emphasis on fuel economy 3 Heavy lift mode For assisting opera...

Страница 268: ...ncy If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Run the engine at low idle for about 5 minutes to cool...

Страница 269: ...he starting switch is turned to the START position the engine will not start q Even when the key in the starting switch is turned to the ON position the machine monitor does not give a display q Indic...

Страница 270: ...the engine emergency stop switch at the OFF normal operation position Press engine emergency stop switch S installed at the front or rear of the power container and set it to engine stop position a q...

Страница 271: ...llows 1 Turn the head of engine emergency stop switch S to the right The switch will spring out slightly and will be reset to OFF normal operation position b When doing this check set indicator lamp L...

Страница 272: ...the engine emergency stop switch is pulled while the engine is running the engine stops and the machine monitor goes out q Even when the key in the starting switch is turned to the START position the...

Страница 273: ...ncelled 2 Turn the starting switch key to the ON position 3 Check that engine emergency stop warning lamp C on the console panel to the left of the operator s seat inside the cab is off 4 Start the en...

Страница 274: ...Ground Pull down fuel shut off lever 1 installed at the front right of the machine The engine will stop after approx 3 5 minutes q When starting the engine again after it has stopped move fuel shut o...

Страница 275: ...r This makes it possible to prevent the fuel inside the fuel tank from flowing out even if the fuel piping hoses are burned Fuel shut off valve 3 is connected to fuel shut off lever 1 and fuel shut of...

Страница 276: ...safe and sound the horn q Do not allow anyone to enter the area around the machine q Clear any obstacles from the travel path q There is a blind spot at the rear of the machine so be particularly car...

Страница 277: ...art the machine either by pushing lever 5 forward slowly or by stepping on the front part of pedal 6 slowly q When sprocket is situated at the front of the machine Start the machine either by pulling...

Страница 278: ...press the rear part of the pedals 6 to move the machine backward q When sprocket A is at the front of the machine Slowly push the levers 5 forward or slowly depress the front part of the pedals 6 to m...

Страница 279: ...OPERATION MACHINE OPERATIONS AND CONTROLS 3 213 1 Put the left and right travel levers 1 in the neutral position then stop the machine...

Страница 280: ...movement of the machine Use the travel levers to change direction Avoid sudden changes of direction as much as possible Espe cially when performing counter rotation spin turn stop the machine before t...

Страница 281: ...Forward left turn B Reverse left turn REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left...

Страница 282: ...auto deceleration function the engine speed will suddenly rise operate the levers carefully 1 Before starting the swing operation turn swing lock switch 1 OFF and check that swing lock monitor 2 has...

Страница 283: ...ontrol levers to operate the work equipment Note that when the levers are released they return to the HOLD position and the work equipment is held in that position q Arm control Move the left work equ...

Страница 284: ...g to the function of the auto deceleration device even if the fuel control dial is in the FULL position REMARK This machine is equipped with an accumulator in the operation circuit For this reason the...

Страница 285: ...the starting switch is turned to the ON position the work ing mode is automatically set to P mode Use the working mode selector switch to set to the most effi cient working mode for the type of job W...

Страница 286: ...orce to compact soil or break objects This is not only dangerous but will also drastically reduce the life of the machine Operations Using Travel Force Do not dig the bucket into the ground and use th...

Страница 287: ...the rock behind the principle of the lever will bring excessive force to bear on the machine or work equip ment and there is danger that this may lead to breakage or damage of the machine In such situ...

Страница 288: ...nt and frame and this will reduce the service life of the machine Digging Hard Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it af...

Страница 289: ...ine travels over rough parts of the ground sur face the thrusting load on the machine will increase and reduce the service life of the machine To protect the machine when traveling on rough ground or...

Страница 290: ...ravel speed keep the work equipment close to the ground and try to travel so that the center of the track passes over the obstacle Permissible Water Depth NOTICE When driving the machine out of water...

Страница 291: ...the bucket approx 100 to 150 cm from the ground Do not travel downhill in reverse q Never turn on slopes or travel across slopes Always go down to a flat place to perform these opera tions It may be l...

Страница 292: ...ine again q An accumulator is provided in the operation control circuit For this reason the work equipment can go down of its own weight for some time after the engine has stopped if the work equipmen...

Страница 293: ...tom of the bucket in contact with the ground Never push with the teeth The angle between the boom and arm should be 90 to 110 The same applies when using the inverted bucket When only one side is stuc...

Страница 294: ...orce of each cylinder When excavating use this angle effectively to optimize your working efficiency The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle toward...

Страница 295: ...foot under the bucket while standing at the side for the work q When removing or inserting pins be extremely careful not to get your fingers caught q Never insert your fingers into the pin holes when...

Страница 296: ...t and right NOTICE After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at both ends of the bushings be careful not to damage them 3 Align the arm with hole A...

Страница 297: ...s an additional safety measure thrust the bucket into the ground q If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accide...

Страница 298: ...ality is found in any of them take proper action after stopping the engine and in reference to TROUBLES AND ACTIONS 3 240 MACHINE INSPECTION AFTER DAILY WORK 3 1 Walk around the machine and check the...

Страница 299: ...ose the window 2 Door of cab base room 3 Fuel tank filler port 4 Hydraulic tank filler port 5 Power container front door 5 places 6 Power container rear door 3 places 7 Battery case cover 2 places 8 A...

Страница 300: ...sembled for transportation When transporting the machine please consult your Komatsu distributor METHOD OF LIFTING UNITS FOR TRANSPORTATION 3 WARNING q Never raise the machine with any worker on it q...

Страница 301: ...with large amounts of fresh water and see a doctor at once q When changing the coolant or when handling the coolant containing coolant that has been drained during repair of the radiator please conta...

Страница 302: ...so drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 Insulate it against cold temperature to ensure the machine can be...

Страница 303: ...ground and allow the machine to be moved the next morn ing q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing q Fill the fuel tank to capacity This mi...

Страница 304: ...or switch to the OFF position Put a cover on the battery during storage q Lock each control lever and pedal with the lock lever and pedal lock q To prevent rust fill with coolant to give a density of...

Страница 305: ...rease at all lubrication points q When the machine is stored for a long period moisture in the air will mix with the oil Check the oil before and after starting the engine If there is water in the oil...

Страница 306: ...ification machines if equipped see Bleeding air from fuel circuit with the electric priming pump 4 47 PHENOMENA THAT ARE NOT FAILURES 3 Note that the following phenomena are not failures q When the ar...

Страница 307: ...or this machine is 1 079 kN 110 027 kg Always carry out towing operations within the maximum towing capacity q If the machine sinks in mud and cannot get out under its own power or if the drawbar pull...

Страница 308: ...lling install the positive terminal first If a tool touches the positive terminal and the chassis there is danger that it will cause a spark so be extremely careful q If the terminals are loose there...

Страница 309: ...egative termi nal of the battery Be sure to attach the clips securely q Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than...

Страница 310: ...it is not a good conductor q When removing the booster cable exercise good care so that the booster cable clips may not contact each other or they contact the chassis NOTICE q The starting system for...

Страница 311: ...he problem machine Starting the Engine WARNING Always check that the lock lever is set to the LOCK position regardless of whether the machine is work ing normally or has failed Check also that all the...

Страница 312: ...the ON position The hydraulic tank strainer is not installed normally The starter isolator switch is in the OFF position The battery isolator switch is in the OFF position Check repair Replace Charge...

Страница 313: ...track shoe Does not swing Swing lock switch still applied Turn swing lock switch OFF Swing travel work equipment can not be operated Hydraulic ladder is not stowed Abnormal proximity switch for hydrau...

Страница 314: ...ECK BEFORE STARTING Clean or repair see EVERY 500 HOURS SERVICE Change cooling water clean inside of cooling system see WHEN REQUIRED Replace engine water level sensor Replace engine water temper atur...

Страница 315: ...ce See WHEN REQUIRED Check repair See adjustment of clearance above Check replace Check replace repair Engine hunts Air entering suction side of fuel line Clogged fuel strainer Drain water of fuel pre...

Страница 316: ...have inspection carried out immediately E14 Abnormality in throttle abnormality in fuel control dial Move machine to a safe posture and carry out inspection immediately E15 Abnormality in electronic...

Страница 317: ...the monitor the telephone number for the point of contact is displayed at the bottom of the error screen REMARK If no point of contact telephone number has been registered no telephone number is disp...

Страница 318: ...TROUBLES AND ACTIONS OPERATION 3 252...

Страница 319: ...MAINTENANCE 14 WARNING Please read and make sure that you understand the safety volume before reading this section...

Страница 320: ...lubrication of the machine use the Komatsu genuine lubricants Moreover use oil of the specified viscosity according to the ambient temperature Windshield Washer Fluid Use ethyl alcohol window washer f...

Страница 321: ...frequently q When checking and replacing the oil or filters move the machine to a place where there is no dust and take care to prevent dust from entering the system Avoid Mixing Lubricants If a diff...

Страница 322: ...nance items been performed correctly q Have any tools or parts been dropped inside the machine It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage...

Страница 323: ...ticles dirt etc from getting in The majority of problems with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil q...

Страница 324: ...sity fuel with low lubricating ability is used the durabil ity may drop markedly COOLANT AND WATER FOR DILUTION 4 q Komatsu genuine Supercoolant AF NAC has the important function of preventing corrosi...

Страница 325: ...hyper white grease as it hardens CARRYING OUT KOWA Komatsu Oil Wear Analysis 4 KOWA is a maintenance service that makes it possible to prevent machine failures and downtime With KOWA the oil is period...

Страница 326: ...being sucked in If drums have to be stored outside cover them with a waterproof sheet or take other measures to protect them q To prevent any change in quality during long term storage be sure to use...

Страница 327: ...ystem is checking fan belt tension checking damage or wear to the fan belt and checking battery fluid level q Never install any electric components other than those specified by Komatsu q External ele...

Страница 328: ...r 21T 04 31170 q For details of the loading specification machine see WEAR PARTS 7 21 Item Part No Part Name Q ty Replacement fre quency Engine oil filter 600 211 1340 Cartridge 4 Every 500 hours serv...

Страница 329: ...below 0 C be sure to use the recommended multi grade oil even if the ambient temperature may become higher during the course of the day q If the machine is operated at a temperature below 20 C a separ...

Страница 330: ...C TO30 Hydraulic system Power train oil 20 C 50 C TO10 Hydraulic oil 20 C 50 C HO46 HM Grease fitting Note 3 Hyper grease Note 4 20 C 50 C GT2 T G2 TE Lithium EP grease 20 C 50 C G2 LI Cooling system...

Страница 331: ...lubricating ability of the grease in order to prevent squeaking of pins and bushings the use of G2 T or G2 TE is recommended Note 5 Coolant 1 Komatsu genuine Supercoolant AF NAC has the important func...

Страница 332: ...17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 11 8 14 7 27 34 59 74 98 123 153 190 1 2 1 5 2 8 3 5 6 0 7 5 10 0 12 5 15 5 19 5 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 0 52 3 70...

Страница 333: ...r condition after a certain period of usage This is impor tant to ensure that these parts maintain their full performance at all times Furthermore should anything abnormal be found on any of these par...

Страница 334: ...hose engine to heater 12 16 Swing line hose 4 17 Boom cylinder line hose backhoe 4 18 Arm cylinder line hose backhoe 7 19 Bucket cylinder line hose backhoe 7 20 Pump suction coupling 2 21 Fuel hose f...

Страница 335: ...NG AIR FROM FULE CIRCUIT 4 454 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 494 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4 604 INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASIN...

Страница 336: ...MERGENCY LADDER 4 1024 GREASING HYDRAULIC LADDER 4 1034 EVERY 2000 HOURS MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE 4 1044 CHECK GREASE LEVEL IN SWING PINION ADD GREASE 4 1054 CHECK ALTERNATOR STARTIN...

Страница 337: ...ER THE FIRST 500 HOURS 4 Carry out the following maintenance only after the first 500 hours of operation on new machines q Change oil in swing machinery case q Change oil in PTO case q Change oil in f...

Страница 338: ...q Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel light up If the element is cleaned frequently before the air cleaner clogging monitor light up the ai...

Страница 339: ...after it has been cleaned replace external ele ment 5 internal element 6 and O ring 8 REMARK Use dust indicator 4 as a guideline for the cleaning interval for the air cleaner element If tip D of the y...

Страница 340: ...at an angle insert your hand and push it in straight 4 After removing the outer element 5 cover the inner ele ment 6 with a clean cloth or tape to prevent dirt or dust from entering 5 Wipe off or brus...

Страница 341: ...or oil stuck to the seal portion of the new element or cleaned element Wipe off any dirt or oil 10 Push the outer element in straight with your hand when installing it to the air cleaner body If the o...

Страница 342: ...2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks in turn on opposite sides top bottom left right in the same way as when tig...

Страница 343: ...installed there is danger that the outer element will be damaged q The seal portion on imitation parts lacks precision and allows the entry of dust which leads to dam age of the engine Do not use such...

Страница 344: ...as follows 1 Align cover 3 with the element 2 Hook the tip of hook 2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position apply the hooks in turn o...

Страница 345: ...anticorrosion anti freeze and cooling properties and can be used continuously for two years or 4000 hours As a basic rule we do not recommend the use of any coolant other than Supercoolant AF NAC If y...

Страница 346: ...hines equipped with a service center option see Method of Draining Adding Coolant 6 26 Coolant is already diluted with distilled water so it is not flammable For details of the distilled water see COO...

Страница 347: ...14 Start the engine and run for approx 10 minutes at low idling 15 Stop the engine and open drain valves 6 and 7 to drain the water 16 After draining the water use a detergent to wash the tank For de...

Страница 348: ...h the link mating surface CHECK AND ADJUST TRACK TENSION 4 WARNING q For details of the method of starting the engine and operating the work equipment see BEFORE STARTING ENGINE 3 158 STARTING ENGINE...

Страница 349: ...easure the maximum deflection between bottom surface of the wooden bar and top surface of the track shoe Deflection a should be 10 30 mm Adjustment If the track tension is not at the standard value ad...

Страница 350: ...r rectly 4 Check that protrusion A of hydraulic cushion cylinder plunger 3 is within the specified value on both the left and right 5 If protrusion A is not within the specified value carry out Step 3...

Страница 351: ...on of the hydraulic cushion cylinder again after pump ing in grease If it is not within the correct range loosen the plug 1 one turn to release the grease and adjust If that protrusion of hydraulic cu...

Страница 352: ...track link does not become loose ask your Komatsu distributor to carry out repairs 1 Loosen plug 1 a little at a time to release the grease 2 Loosen plug 1 a maximum of 1 turn 3 If the grease does no...

Страница 353: ...sure to ask your Komatsu distributor for the replacement NOTICE q When replacing the bucket teeth be sure to replace all of them at once Should all the bucket teeth be not replaced at a time the bucke...

Страница 354: ...e adapter insert new pin 1 then tighten 90 clockwise with the socket wrench to lock the pin and complete the installa tion REMARK Turn the tooth upside down and rotate the installation positions Such...

Страница 355: ...the tooth pins cannot be removed in this procedure for safety s sake be sure to ask your Komatsu distributor for the replacement Prepare for a socket wrench for 16 mm width across flats 1 Set the buc...

Страница 356: ...e and mounting hole 7 7 Install new wear cap 6 by fitting it in adapter mounting hole 7 8 Clean the tooth mounting face fit tooth 2 in the adapter insert pin 1 and then lock the pin by turning a socke...

Страница 357: ...loop are sent flying around q Never hit the tooth against a boulder for the purpose of removing the slinging loop There is the danger that the broken slinging loop will be sent flying around in piece...

Страница 358: ...p 4 adapter 5 side shroud 6 NOTICE When cutting the slinging loop at each part of the bucket cut at the following cutting positions A A or B B according to the shape of the loop In addition when doing...

Страница 359: ...Fluid and Water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the following proportions before adding There are two types depending on the freez...

Страница 360: ...s appear there is lack of refrigerant gas so have your service shop add refrigerant immediately If the air condi tioner is run when there is lack of refrigerant gas it will cause damage to the compres...

Страница 361: ...Remove cover 1 2 Install a bolt 10 mm in bolt hole A of element 2 then hold the bolt and pull out element 2 3 Clean element 2 q When cleaning the element clean the dirt and dust stuck to side surface...

Страница 362: ...ICE If there is a change to high water temperature when operating the engine over several days when there is no change in the ambient temperature a possible reason is peeling of the sealing material a...

Страница 363: ...f the supply pump or the air bleed plug at the top of the fuel filter head is opened the residual pressure may spray out fuel Loosen the plug and breather slowly before open ing NOTICE The common rail...

Страница 364: ...es come out with the fuel tighten air breather 6 One place each on left and right sides of engine Tightening torque 4 9 6 9 Nm 0 5 0 7 kgm 4 Pump priming pump lever 4 again several times until it beco...

Страница 365: ...e first time after replacing the supply pump or modifying the piping or any other parts WARNING q After the engine is stopped all parts are at high temperature so there is danger of suffering burns Wa...

Страница 366: ...s in the instance that the engine stops due to fuel exhaustion or in the instance that the fuel hose tube or priming pump has been maintained or replaced In that case tilt the electric priming pump sw...

Страница 367: ...those for pilot selector valve circuit and main valve PPC circuit 6 Work equipment circuit Run the engine at less than 1000 rpm and operate the cylinders slowly Do not use sudden stopping and starting...

Страница 368: ...n hose from the pump case and fill the pump case with hydraulic oil through drain port 2 Oil will come out from the drain hose when it is removed so fix the mouthpiece of the hose at a position higher...

Страница 369: ...IRCUIT After the removal and installation of the swing motor and the disconnection and connection of the swing holding brake circuit piping bleed air from the brake circuit in the following manner CAU...

Страница 370: ...ts up BLEEDING AIR FROM IDLER CUSHION CIRCUIT Bleed the air from the idler cushion circuit before pumping grease into the hydraulic charge grease cylinder 1 Loosen plug 1 of the grease cylinder 1 turn...

Страница 371: ...flow out of air bleeding plug 3 and out of the plug 6 hole 7 Tighten air bleeding plugs 7 and 3 Left and right 2 places 8 Install plug 6 9 Finally tighten grease cylinder plug 1 Left and right 2 plac...

Страница 372: ...or valve and the disconnection and connection of the pilot selector valve circuit bleed air from the pilot selector valve circuit in the following manner REMARK If air is not bled at all or bled but i...

Страница 373: ...il free of air bub bles begins to flow out of bleeder A and then tighten bleeder A Tightening torque 8 8 9 8 Nm 0 9 1 0 kgm 3 Turn the swing lock switch to the ON position 4 Operate boom RAISE and SWI...

Страница 374: ...eration or an abnor mal noise from the PPC lever so be sure to follow the air bleeding instructions 1 Start up the engine and loosen bleeder A The bleeder is provided at the joint of the main valve sp...

Страница 375: ...INTENANCE PROCEDURE 4 57 Rear Side of Main Valve R Machine s rear side 1 Arm DUMP 4 locations 2 Boom LOWER 2 locations 3 Bucket DUMP 4 locations 4 Left travel forward 2 locations 5 Right travel forwar...

Страница 376: ...RE MAINTENANCE 4 58 Front side of main valve F Machine s front side 1 Arm DIGGING 3 locations 2 Boom RAISE 3 locations 3 Bucket DIGGING 4 locations 4 Right travel backward 2 locations 5 Left travel ba...

Страница 377: ...ork equip ment will not move for more than 10 seconds Do not oper ate the lever fully to make the work equipment move 2 Keep the engine running at low idling and operate each cylinder from a point 100...

Страница 378: ...mes 3 Screw in the hydraulic tank cap 4 Start up the engine and stop it after approx 10 seconds q Do not raise the engine rotation above 1000 rpm q Hold the work equipment control lever to the N posi...

Страница 379: ...lic tank and release the internal pressure inside the tank 2 Slowly loosen drain valve 1 installed inside the axle and let the remaining pressure inside the circuit to be released After more than 1 mi...

Страница 380: ...et in If there is any dirt of dust around the fuel system clean it off thoroughly with fuel before starting the operation q To prevent dirt or dust from getting into the fuel circuit remove all dirt a...

Страница 381: ...so dirty that the position of float 6 cannot be checked replace case 4 9 Install screen 5 to the water separator holder 10 Replace O ring 7 with a new part 11 Tighten plug 1 insert case 4 so that flo...

Страница 382: ...fuel level add fuel q Check oil level in hydraulic tank add oil q Check oil level in PTO case add oil q Check air cleaner for clogging q Check working lamp switch q Check electric wiring q Check funct...

Страница 383: ...lug slowly to release the pressure q Prepare a handle 1 Set so that plug 1 on the outside of the machine is at the bottom position 2 Using a handle remove plug G and check the oil level The oil level...

Страница 384: ...te to go above the UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts q When adding distilled water in cold weather add it b...

Страница 385: ...s 1 Remove cap 2 at the top of the battery look through the water filler port 3 and check the electrolyte surface If the electrolyte does not reach the sleeve 4 add purified water e g commercially ava...

Страница 386: ...hem q Tightening torque 4658 245 Nm 475 25 kgm CHECK ALTERNATOR DRIVE BELT TENSION ADJUST 4 WARNING When carrying out inspection and adjustment set to the engine stop position as follows Press engine...

Страница 387: ...ve the alternator q If nut 9 is tightened the belt tension is increased if nut 9 is loosened the belt tension is reduced 2 After adjusting the belt tighten bolts and nuts 5 8 in the reverse order from...

Страница 388: ...engine stop position as follows Press engine stop switch 1 installed at the front of the power container on the left side of the machine or engine stop switch 2 installed at the rear of the power cont...

Страница 389: ...and move the compressor q If nut 10 is tightened the belt tension is increased if nut 10 is loosened the belt tension is reduced 2 After adjusting the belt tighten bolts and nuts 6 9 in the reverse or...

Страница 390: ...se serious burns Wait for the oil temperature to go down before performing this operation NOTICE After the machine has been operated for 6 months even if it has not been operated for 500 hours change...

Страница 391: ...ain valves P1 and P2 q Press drain valves P1 and P2 then turn them to open or close them and carry out the drain operation 4 If the filter cartridge is removed immediately after the engine is stopped...

Страница 392: ...here is danger of personal injury Always wear protective glasses dust mask and other protective equipment NOTICE When using compressed air to prevent damage to the fins keep a distance from the fins I...

Страница 393: ...the radiator side right side of machine and oil cooler side left side of machine then open door 1 Each door is installed with 6 bolts 2 A Oil cooler B Radiator 2 Remove dustproof nets 3 installed in f...

Страница 394: ...peration If steam cleaning high pres sure machine wash is carried out at close range there is danger that the internal fins of the heat exchange equipment may be deformed and this will cause early clo...

Страница 395: ...hind the assistant s seat then open box cover 1 Recirculated air filter 3 is inserted at the rear of box cover 1 2 Pull out recirculated air filter 3 to the front 3 Clean the recirculated air filter 3...

Страница 396: ...t is extremely dirty wash the filter in a neu tral detergent After washing dry it thoroughly before using it again If it is impossible to remove the clogging from the filter with compressed air or by...

Страница 397: ...ing 2 cartridges 1 Hydraulic pump drain filter cartridges 3 places 2 Swing travel motor drain filter cartridges 2 places REPLACE SWING TRAVEL MOTOR DRAIN FILTER CARTRIDGE 4 2 places 1 Using the filter...

Страница 398: ...iron particles or foreign material stuck to the bottom of the fil ter case or the outside of the cartridge If such materials are stuck to the cartridge of filter case there is probably an abnormality...

Страница 399: ...in the fuel filter head It is still under pressure so fuel may spurt out NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacin...

Страница 400: ...lever A installed to the front of the main pump inside the pump room and close the fuel supply cir cuit from the fuel tank S Shut off O Open 2 Set a container under the fuel pre filter cartridge to ca...

Страница 401: ...c priming pump 4 47 NOTICE q When adding fuel do not remove cap B Always add fuel from the 8 small holes A on the dirty side q After adding fuel remove cap B and install the fuel fil ter q Always fill...

Страница 402: ...ee REPLACE FUEL MAIN FILTER CARTRIDGE 4 85 12 Push down fuel shut off lever A installed to the front of the main pump inside the pump room so that it can supply fuel S Shut off O Open 13 Start the eng...

Страница 403: ...ose q Be careful when opening the air bleed plug in the fuel filter head It is still under pressure so fuel may spurt out NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has...

Страница 404: ...supply cir cuit from the fuel tank S Shut off O Open 2 Set the container to catch the fuel under the filter cartridge 3 Using a filter wrench turn filter cartridge 2 counterclock wise to remove it 4...

Страница 405: ...el q Remove cap B and install the fuel filter 5 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it 3 4 of a turn If the filter cartridge i...

Страница 406: ...quipped see Bleeding air from fuel circuit with the electric priming pump 4 47 8 Add fuel to the fuel tank until full to FULL mark on the fuel gauge 9 After replacing filter cartridge 2 loosen air ble...

Страница 407: ...face of the fuel tank then remove cover 3 2 Replace breather element 4 with a new part 3 Install cover 3 and nut 2 NOTICE q For machines equipped with the optional service cen ter see REPLACE FUEL TAN...

Страница 408: ...Adding Swing Machinery Case Oil Front 6 22 Method of Draining Adding Swing Machinery Case Oil Rear 6 23 q Oil refill capacity 60 liter 30 liter x 2 15 9 US gal 7 9 US gal x 2 1 Set a container under...

Страница 409: ...tick G If the oil does not reach the L mark add oil through oil filler port F 6 If the oil level is above the H mark loosen drain valve P to drain excess oil from the power train and check the oil lev...

Страница 410: ...inutes after stop ping the engine check the oil level REMARK For details of the method of draining and adding PTO case oil to machines equipped with a service center option see Method of Draining Addi...

Страница 411: ...MAINTENANCE MAINTENANCE PROCEDURE 4 93 2 Add a specified amount of power train oil from oil filler port F...

Страница 412: ...blown up and cause serious injury Always use safety glasses dust mask or other protective equipment 1 Open the door of the power container at the front of the machine then take out filter case 1 2 Ta...

Страница 413: ...stributor 4 Clean the removed parts in flushing oil 5 Install the new element in the place where old element 4 was installed 6 Set valve 3 strainer 5 and spring 2 on top of the ele ment 7 Set cover 1...

Страница 414: ...l filler port When releasing cap F oil may spurt out so turn it slowly to release the internal pressure then remove it 1 Remove nut 2 of breather assembly 1 at the top of the hydraulic tank then remov...

Страница 415: ...MAINTENANCE MAINTENANCE PROCEDURE 4 97...

Страница 416: ...ecified q Position of clamps q Detail of clamp portion A and portion B Tightening torques Clamp 1 24 0 25 0 Nm 2 45 2 55 kgm Clamp 2 10 0 11 0 Nm 1 02 1 12 kgm Clamp 3 24 0 25 0 Nm 2 45 2 55 kgm Clamp...

Страница 417: ...CTURE 4 Color check It is easy to use a color check to check visibly for cracks in welded structures After the first 4000 hour inspection check the revolving frame center frame boom and arm every 1000...

Страница 418: ...MAINTENANCE PROCEDURE MAINTENANCE 4 100 q Revolving frame A Important check points q Center frame A Important check points...

Страница 419: ...MAINTENANCE MAINTENANCE PROCEDURE 4 101 q Boom A Important check points q Arm A Important check points...

Страница 420: ...4 Check that there is no wear damage or other abnormality If any problem is found replace with genu ine parts NOTICE With a rope ladder 1 even if there is no visual wear or damage the rope will deter...

Страница 421: ...owered position as shown in the diagram on the right then pump in grease with a grease gun through grease fittings 1 to 4 REMARK Destination for grease pumped in through each grease fitting 1 Ladder c...

Страница 422: ...maining inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure q Oil refill capacity 85 liter each left and right q Prepare a handle 1 Set so that plug 1 on the out...

Страница 423: ...d the grease is extremely milky white remove bolt 3 under the track frame remove cover 4 then remove the inside cover Drain the grease and replace it completely with new grease Total grease capacity 8...

Страница 424: ...uld be carried out at the same time GREASE ENGINE MOUNT 4 if equipped Add grease with a grease gun through grease fitting 2 on engine mount 1 CHECK WATER PUMP 4 Check that there is no leakage of water...

Страница 425: ...any rubber parts If any problem is found the part must be replaced In this case please ask your Komatsu distributor to carry out the replacement NOTICE If the engine continues to be used when there ar...

Страница 426: ...installed to prevent fire if any fuel leaks and sprays into contact with high temperature parts of the engine Check visually and touch by hand to check that there are no missing caps no loose mountin...

Страница 427: ...time has not reached 4000 hours if the machine has been used for 2 years replace the accumulator 1 Remove the cap from oil filler port F at the top of the hydraulic tank to release the internal press...

Страница 428: ...ts gradually REMARK For details of the method of draining and adding hydraulic oil to machines equipped with a service center option see Method of Draining Adding Hydraulic Oil 6 25 q Oil refill capac...

Страница 429: ...il be careful not to get oil over yourself q After draining the oil tighten drain plugs P1 and P2 6 Remove cover 1 at the top of the hydraulic tank pull the top of rod 3 up from the top and take out s...

Страница 430: ...t Check that the hydraulic oil is at the correct level as follows q When the hydraulic oil is at normal temperature 15 30 C the correct oil level is in blue range a1 or a2 on the gauge label shown in...

Страница 431: ...ng posture is 2 in the diagram on the right the correct oil level on the gauge label is range a2 at normal tem perature and b2 at high temperature 10 After changing the hydraulic oil and cleaning the...

Страница 432: ...at the same time REPLACE INJECTOR NOZZLE ASSEMBLY 4 Please ask your Komatsu distributor to replace the injector assembly REPLACE HIGH PRESSURE PIPING CLAMP 4 Contact your Komatsu distributor to have t...

Страница 433: ...SPECIFICATIONS 15...

Страница 434: ...f engine Komatsu SAA12V140E 3 diezel engine Engine power kW rpm 713 1 800 ISO 9249 728 1 800 ISO 14396 A Overall length mm 17 030 B Overall height mm 7 135 C Overall width 1 mm 7 490 D Track width mm...

Страница 435: ...specification machine see SPECIFICATION 7 19 Working ranges Unit PC2000 8 A Max digging reach mm 15 780 B Max digging depth mm 9 235 C Max digging height mm 13 410 D Max vertical wall depth mm 2 710...

Страница 436: ...SPECIFICATIONS SPECIFICATIONS 5 4...

Страница 437: ...ATTACHMENTS AND OPTIONS 16 WARNING Please read and make sure that you understand the safety volume before reading this section...

Страница 438: ...ls for the machine and the attachment or option q If you lose the instruction manual or it is damaged always obtain an new copy from the attachment manufac turer or your Komatsu distributor PRECAUTION...

Страница 439: ...nstalled the working range becomes larger q If heavy work equipment is installed pay careful attention to the following precautions q The swing overrun the distance the work equipment moves before com...

Страница 440: ...f unauthorized attachments or options will not be the responsibility of Komatsu COMBINATIONS OF WORK EQUIPMENT 6 WARNING Depending on the type or combination of work equipment there is danger that the...

Страница 441: ...ts and attachments to suit the application The recommendations are given as a guide only based on typical conditions Select the combination of boom arm and bucket from the combinations shown in the ta...

Страница 442: ...t an oil filler pump unit and nozzle Wiggins made ZZ9A1 or an equiv alent are required X Position for stowing fuel quick charge lever 4 Lock plate Y Position for adding fuel to fuel quick charge lever...

Страница 443: ...t caught by the fuel quick charge lever or lever operating handle and this may cause injury q When operating the stopper be careful not to get a finger pinched NOTICE q After completing the fuel filli...

Страница 444: ...ur left hand to hold lever operating handle 1 then use both hands to lower lever operating handle 1 3 Check that the stopper 4 is at the LOCK position com pletely open as shown in the diagram on the r...

Страница 445: ...ing handle 1 slightly towards the front of the machine then push up until lock bar 3 enters the oblong hole in lock plate 2 q Do not touch lock plate 2 when doing this 8 Push lock plate 2 slightly to...

Страница 446: ...ferent from the breather on the machine is not equipped with the fuel quick charge Use the following procedure to replace the fuel tank breather element every 1000 hours 1 Open breather cover 1 on top...

Страница 447: ...B position 3 Lower the fuel quick charge to the fuel filling position For details see PROCEDURE FOR OPERATING FUEL CHARGE 6 7 4 Cover the front of proximity switch 1 installed to the fuel quick charge...

Страница 448: ...is change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place After moving the machine contact your Komatsu distributor immediately and ask fo...

Страница 449: ...lts 1 and 2 of the clamp holding the connec tor cable 4 Interchange connector a and connector c Connect connector a to connector C and cover connec tor c and connector A with cap X 5 Interchange conne...

Страница 450: ...onnect the negative terminal of the battery start the engine then check that it is possible to operate the travel swing and work equipment If they cannot be operated there is probably some other cause...

Страница 451: ...Coolant coupler 2 Service panel 13 Engine oil coupler 3 Service arm cylinder 14 Fuel coupler 4 Proximity switch 15 Grease coupler 5 Detector plate 16 Grease full indicator 6 Service arm lowering switc...

Страница 452: ...operate the work equip ment If this happens the ladder warning lamp inside the opera tor s cab lights up red For details see Ladder Warning Lamp 3 99 This lock is cancelled when the service arm is st...

Страница 453: ...swing circle until the service arm automatically stops REMARK When the lock lever is in the FREE position the service arm cannot be operated It is possible to lower the service arm even when the engi...

Страница 454: ...ys set the service to the switch to the LOCK position If it is at the FREE position it becomes possible to operate the service arm from the ground so there is danger that this may lead to a serious ac...

Страница 455: ...le force feed pumps but if a force feed pump coupler is needed please consult your Komatsu distributor NOTICE q Before connecting the service center coupler and force feed pump coupler wipe off all di...

Страница 456: ...temperature immediately after the engine is stopped and may cause serious burns Wait for the oil temperature to go down before performing this operation q Refill capacity for oil pan 122 liter 1 Open...

Страница 457: ...ine oil 6 After completing the draining and adding of engine oil remove the force feed pump coupler 7 Install the cap to the coupler 8 Set drain valve P of the oil pan to shut position S 9 Run the eng...

Страница 458: ...e cap of swing machinery oil front coupler 1 and connect the force feed pump coupler securely 4 Start to drain and add swing machinery oil 5 After completing the draining and adding of swing machin er...

Страница 459: ...e cap of swing machinery oil rear coupler 1 and connect the force feed pump coupler securely 4 Start to drain and add swing machinery oil 5 After completing the draining and adding of swing machin ery...

Страница 460: ...t for the oil temperature to go down before performing this operation NOTICE Park the machine on flat ground and stop the engine After waiting for more than 30 minutes after stop ping the engine check...

Страница 461: ...re starting the operation q When removing the cap from the oil filler oil may spurt out so turn it slowly to release the internal pressure then remove it q When removing holder cover of the strainer t...

Страница 462: ...down then open the cap slowly to release the pressure q When cleaning the cooling system with the engine running set the lock lever to the LOCK position to prevent the machine from moving q For detail...

Страница 463: ...be touched by hand then raise cap lever 4 of cap 3 at the top of the reservoir tank and release the pressure inside the reservoir tank 4 Remove water filler cap 5 5 Set drain valve P under the machin...

Страница 464: ...nder the machine to shut position S 12 Push down cap lever 4 of cap 3 at the top of the sub tank then install water filler cap 5 13 Check that the coolant in the reserve tank is in the range between t...

Страница 465: ...l the cap to the coupler Method of Adding Grease 6 1 Remove the cap of grease coupler 1 and connect the force feed pump coupler securely 2 Open force feed pump basic pressure valve 2 or start the grea...

Страница 466: ...urs Set the service center to the lowered position as shown in the diagram on the right then pump in grease with a grease gun through grease fittings 1 to 3 REMARK Destination for grease pumped in thr...

Страница 467: ...rent from the breather on the machine is not equipped with the service center Use the following procedure to replace the fuel tank breather element every 1000 hours 1 Open breather cover 1 on top of t...

Страница 468: ...the ON B position 3 Lower the service arm For details see When Lowering Service Arm Setting to Position for Use 6 17 4 Cover the front of proximity switch 1 installed to the ser vice arm with steel p...

Страница 469: ...center This change in the combination of the connectors is a temporary measure to enable the machine to be moved to a safe place After moving the machine contact your Komatsu distributor immediately...

Страница 470: ...ts 1 and 2 of the clamp holding the connec tor cable 4 Interchange connector a and connector c Connect connector a to connector C and cover connec tor c and connector A with cap X 5 Interchange connec...

Страница 471: ...nect the negative terminal of the battery start the engine then check that it is possible to operate the travel swing and work equipment If they cannot be operated there is probably some other cause s...

Страница 472: ...IONS 6 CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE 6 1 Check that the starting switch key is at OFF position A 2 Set the battery isolator switch to OFF position b q For details of the battery isolato...

Страница 473: ...power source cable through external power source insertion port 2 5 Remove the cap of jump start receptacle 3 then connect the external power source cable to jump start receptacle 3 6 Close cover 1 of...

Страница 474: ...t is possible to send machine data without stopping the machine by using the satellite communications functions of ORBCOMM communications company Please ask your Komatsu distributor to make the initia...

Страница 475: ...G SHOVEL 17 WARNING When using a loading shovel specification the method for operation is different in some way from the standard machine This section gives the explanation for the parts that are diff...

Страница 476: ...ATIONS LOADING SHOVEL 7 2 MACHINE VIEW ILLUSTRATIONS 7 OVERALL MACHINE VIEW 7 1 Bucket 7 Sprocket 2 Bottom dump cylinder 8 Track frame 3 Bucket cylinder 9 Track shoe 4 Arm 10 Idler 5 Arm cylinder 11 B...

Страница 477: ...OPERATOR S CAB 3 75 1 Starting switch 11 Rotating lamp switch if equipped 2 Fuel control dial 12 Greasing mode selector switch 3 Engine emergency stop switch 13 Machine push up switch 4 Service center...

Страница 478: ...ox 5 seconds to give a signal to the dump truck and others in the surrounding area Bottom Dump Switch Press switches 18 and 19 on the work equipment control lever to open and close the front bucket If...

Страница 479: ...r and the movement of the work equipment is as shown in the diagram on the right When the lever is released it returns to the HOLD position and the work equipment is held in position q If the work equ...

Страница 480: ...OPERATIONS LOADING SHOVEL 7 6 Boom operation A Boom RIASE B Boom LOWER Bucket operation A Bucket DUMP B Bucket CURL Bottom dump operation A OPEN B CLOSE...

Страница 481: ...uch operations have to be per formed pile soil to make a platform A on the slope so the machine is kept horizontal during operation q Do not travel up or down steep slopes There is danger that the mac...

Страница 482: ...se the Dropping Force of the Bucket for Operations Do not use the dropping force of the bucket as a pickaxe breaker or pile driver This will bring excessive force to bear on the rear of the machine an...

Страница 483: ...force to bear on the work equipment so do not use the rear bucket in this way Be Careful not to Spill the Load When the bucket is fully loaded do not raise the boom fully If the boom is raised fully...

Страница 484: ...achine from damage but will make for better econ omy Phenomena that do not Indicate Failure Note that the following phenomena are not failures q When starting or stopping the swing noise will be emitt...

Страница 485: ...ly A simple method of seeing the angle of the bucket teeth to the ground surface is to use the teeth and the part of the rear bucket shown in the diagram on the right Check that the part of the rear b...

Страница 486: ...e before removing the cap 1 Stop the machine on firm horizontal ground lower the work equipment to the ground as shown in the diagram on the right then stop the engine q Set the lock lever to FREE pos...

Страница 487: ...d counterweight When transporting the machine please consult your Komatsu distributor MACHINE CONFIGURATION FOR TRANSPORT 7 WARNING q Never raise the machine with any worker on it q When carrying out...

Страница 488: ...ock lever securely to the LOCK position Greasing of the work equipment is normally carried out automatically but if any abnormal noise is heard from the pins carry out greasing manually through the gr...

Страница 489: ...linder bottom pin LH 3 Bottom dump cylinder head pin RH F Grease fitting 4 Bottom dump cylinder head pin LH 7 Arm top pin RH1 14 Bucket cylinder bottom pin LH 8 Arm top pin LH1 15 Boom top pin RH 9 Ar...

Страница 490: ...installed on the chassis 19 Boom foot pin RH 23 Arm cylinder head pin RH 20 Boom foot pin LH 24 Arm cylinder head pin LH 21 Arm cylinder bottom pin RH F Grease fitting 22 Arm cylinder bottom pin LH 25...

Страница 491: ...LOADING SHOVEL MAINTENANCE 7 17 q Greasing point chart...

Страница 492: ...in RH1 8 Arm top pin LH1 9 Arm top pin RH2 10 Arm top pin LH2 11 Arm cylinder head pin RH 12 Arm cylinder head pin LH 13 Bucket cylinder bottom pin RH 14 Bucket cylinder bottom pin LH 15 Boom top pin...

Страница 493: ...Engine power kW rpm 713 1 800 ISO 9249 728 1 800 ISO 14396 A Overall length mm 13 075 B Overall height mm 8 180 C Overall width 1 mm 7 490 D Track width mm 810 E Height of cab mm 7 030 F Tail swing r...

Страница 494: ...ING SHOVEL Working ranges Unit PC2000 8 A Max digging reach mm 13 170 B Max reach at ground level mm 11 940 C Max digging height mm 14 450 D Max digging depth mm 3 190 E Min reach at ground level mm 7...

Страница 495: ...orms one unit with the cap Part number 21T 04 31170 Item Part No Part Name Q ty Replacement frequency Engine oil filter 600 211 1340 Cartridge 4 Every 500 hours service Fuel pre filter 1 600 319 3440...

Страница 496: ...e check before starting if there is any danger of interference and operate with caution COMBINATION OF WORK EQUIPMENT 7 Select the combination of boom arm and bucket from the combinations shown in the...

Страница 497: ...INDEX 18...

Страница 498: ...INDEX 8 2...

Страница 499: ...18 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 16 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 14 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 18 PREPARATIONS FOR SAFE OPERATION 2 11 PROTECTI...

Страница 500: ...PRECAUTIONS FOR MAINTENANCE 2 33 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2 33 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 38 PRECAUTIONS FOR OPERATION 2 19 LIFTING OBJECTS WITH BUCKET...

Страница 501: ...ration levels 1 4 VISIBILITY FROM OPERATORSSEAT 1 7 W WEAR PARTS 4 10 7 21 WEAR PARTS LIST 4 10 7 21 WORK EQUIPMENT CONTROLS AND OPERATIONS 3 217 WORKING MODE 3 219 Y YOUR MACHINE SERIAL NUMBERS AND D...

Страница 502: ...INDEX 8 6...

Страница 503: ...COLOPHON 19...

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