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EVERY 1500 HOURS MAINTENANCE

Maintenance for every 100, 250 and 500 hours should be performed at the same time.

METHOD FOR CHECKING CRANKCASE BREATHER

If the crankcase breather does not work normally, the engine does not conform to the exhaust gas regulations
under usage period. It is necessary to check the diaphragm for damage and the spring for breakage. Special
tools are needed for inspection and maintenance, so ask your Komatsu distributor to perform this work.

MAINTENANCE PROCEDURE

MAINTENANCE

4-88

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Содержание PC45MR-30403

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 50: ...er tools lying around in the work place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean the tidy to enable you to perform operations safely If t...

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

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

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

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

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

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

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

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

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

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

Страница 61: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 260: ...el tank 3 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove any mud affixed to the undercarriage LOCK Always lock the following places RE...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 411: ......

Страница 412: ...SPECIFICATIONS 5 1...

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

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

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

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

Страница 417: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 459: ......

Страница 460: ...REPLACEMENT PARTS 7 1...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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