Page 3: Foreword
FOREWORD WEAM014802...
Page 4 Komatsu distributor have gathered a considerable amount of experience over years of work in close contact with the users. If more information is needed, do not hesitate to contact your Komatsu distributor: he always knows how to get the best performance from the machine, he can recommend the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to safety standards rules....
Page 5 FOREWORD FOREWORD Storage location for the Operation and Maintenance Manual: WEAM014802...
Page 6: Safety Information
Komatsu machines are manufactured and sold according to the rules or standards of the countries where they have to work. If the machines have to work in other countries, it is necessary to check that every safety devices and technical specifications are in compliance with the regulations in force;...
Page 7 DANGER It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be held liable for any damage to persons, property or the machine, if this has been tampered with by modifying the standard settings of the hydraulic system.
Page 8 Some illustrations may be different from the details of the machine in your possession: this is due to the continuous improvements made to the machines. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 9: Noise Levels
Do not use fuel, petrol or solvents. q If the plates are damaged, ask for new ones to Komatsu or to your Komatsu distributor. q In case of replacement of a component provided with a noise plate, make sure that such a plate is applied also to the new part.
Page 10: Vibrations To Which The Operator Is Subjected
FOREWORD SAFETY INFORMATION VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED When the earth moving machine is used for its intended purpose, the vibration levels transmitted from the operator's seat are less than or equal to the vibration tested on the related class of machinery in accordance with ISO7096.
Page 11: Guide When Working In Areas Where Air Pollution
FOREWORD SAFETY INFORMATION 7. Minimize vibrations for long work cycle or long distance travelling. Q Reduce speed to prevent bounce. Q Transport machines long distances between worksites. 8. The following guidelines can be effective to minimize risks of low back pain. Q Operate the machine only when you are in good health.
Page 12: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Digging work q Leveling work q Ditching work q Loading work See paragraph "OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR (3-164)" for further details.
Page 13: Improper Or Unauthorized Uses
NOTICE q The instructions regarding the authorized optional equipment are given in the relevant operation and maintenance manuals; if the equipment is supplied by Komatsu, these publications are enclosed to this manual. q The instructions regarding the assembly of the authorized equipment, the controls requiring special arrangements on the machine and the hydraulic couplings necessary for the operation of such equipment are grouped in the final section of this manual.
Page 14: Running-In
FOREWORD INTRODUCTION RUNNING-IN All machines have been meticulously adjusted and tested before delivery. However, a new machine must be used with caution during the first 100 hours, for a correct running in of the different components. If the machine is subjected to excessive work load at the beginning of operation, its potential productivity and its functionality will be shortly and untimely reduced.
Page 15: Directions Of Machine
FOREWORD INTRODUCTION DIRECTIONS OF MACHINE (A) Forwards (E) Operator seat (B) Backwards (F) Sprocket   (C) Left Right In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket (F) is at the rear of the machine.
Page 16: Product Identification
PRODUCT IDENTIFICATION PRODUCT IDENTIFICATION The Komatsu excavator and its main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must be communicated to the distributor when requiring assistance and ordering spare parts.
Page 17: Machine Serial Number Plate (According Directive 2006/42/Ec)
FOREWORD PRODUCT IDENTIFICATION MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC) (A) Serial number (E) Machine designation type (B) Operating mass (F) Year of manufacture (C) Product identification number (G) Engine power (D) Manufacturer 1-15 WEAM014802...
Page 18: Engine Serial Number And Exhaust Gas Emission Plate
FOREWORD PRODUCT IDENTIFICATION ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE The serial number and the exhaust gas emission plate are located on the fuel filter support. CAB SERIAL NUMBER The serial number is stamped on the plate positioned on the external right hand side of the cab.
Page 19 FOREWORD PRODUCT IDENTIFICATION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Komatsu Italia Manufacturing S.p.A. Manufacturers name: Via Atheste, 4 Address: 35042 Este (PD) Italy Authorised Representative: Address: Distributor name: Address:...
Page 20: Table Of Contents
CONTENTS CONTENTS FOREWORD................................. 1-2 SAFETY INFORMATION............................1-4 NOISE LEVELS ............................1-7 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ..............1-8 GUIDE WHEN WORKING IN AREAS WHERE AIR POLLUTION.............. 1-9 INTRODUCTION..............................1-10 DEMOLITION WORK ..........................1-10 IMPROPER OR UNAUTHORIZED USES ....................1-11 MAIN CHARACTERISTICS ........................
Page 21 CONTENTS CAUTIONS RELATED TO ROPS......................2-24 ATTACHMENT INSTALLATION....................... 2-25 ATTACHMENT COMBINATIONS......................2-25 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ............2-25 CAB WINDOW GLASSES ........................2-25 UNAUTHORIZED MODIFICATIONS......................2-25 SAFETY AT JOBSITE ..........................2-26 WORKING ON LOOSE GROUND......................2-26 DISTANCE TO HIGH VOLTAGE CABLES....................2-27 ENSURE GOOD VISIBILITY ........................
Page 22 CONTENTS USE THE AIR CONDITIONER WITH CAUTION ..................3-99 INSPECTING AND SERVICING A MACHINE WITH AIR CONDITIONER ..........3-99 FUSES ................................3-100 MAIN FUSE ............................3-101 SUPPLEMENTARY POWER SUPPLY ......................3-102 CONTROLLER ..............................3-104 STORAGE COMPARTMENTS......................... 3-105 TECHNICAL DOCUMENTATION COMPARTMENT................3-105 CUP HOLDER ............................
Page 23 GUIDE TO MAINTENANCE ..........................4-2 MAINTENANCE NOTES ..........................4-5 OIL, FUEL, COOLANT AND GREASE ....................... 4-5 KOWA (KOMATSU OIL WEAR ANALYSIS)....................4-8 STORING OIL AND FUEL .......................... 4-9 FILTERS ..............................4-9 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM............4-9 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM ............
Page 24 CONTENTS MAINTENANCE PLAN............................4-21 MAINTENANCE PLAN ..........................4-21 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER ....... 4-23 MAINTENANCE PROCEDURES ........................4-24 WHEN REQUIRED ........................... 4-24 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE............ 4-44 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION ............4-44 MAINTENANCE EVERY 100 HOURS OF OPERATION .................
Page 25 SAFETY WARNING Read and make sure that the precautions outlined in this manual and the safety labels on the machine have been fully understood. Always closely observed these safety measures when starting or performing assistance on the machine. WEAM014802...
Page 26: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
Page 27: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS WEAM014802...
Page 28: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS Consult the manual. q Carefully read the contents of the manual before using the machine or performing maintenance operations. Safety distance. q Do not get too near the machine and do not stand within its operating range. Before leaving the operator’s seat q Before leaving the machine, lower the work equipment to the ground, shift the safety lever to position “lock”,...
Page 29 SAFETY SAFETY LABELS Caution when stowing front window q Make sure that the front windshield is always locked. Risk of burns q Do not open the radiator and the hydraulic oil tank when the engine is still hot. Risk of explosion on the hydraulic accumulator and gas spring q Working on the accumulator without due caution may cause explosion, leading to serious personal injury....
Page 30 SAFETY SAFETY LABELS Battery and electric cables q Risk of electric charges in case of work on the battery or the electric cables. (10) Battery q Precautions for working on the battery. (11) Do not open the hood. q Do not open or remove the hood when the engine is running.
Page 31 SAFETY SAFETY LABELS (13) Starter q Start the engine only when correctly seated in the driving position. Do not attempt to run the starter motor by tampering with the starter motor terminals. (14) Danger in the work area q Do not approach or stand within the equipment operating range when the boom and the bucket are raised.
Page 32 (19) Falling objects q Avoid working in places where there is the risk of falling objects. Contact your Komatsu distributor for the installation of safety guards. (20) Precautions with the KOMTRAX system q he signal indicates danger of explosion caused by a radio transmitter active in an explosive area.
Page 33 SAFETY SAFETY LABELS Caution when handling batteries q Never smoke or use any naked flame near the batteries, no sparks. q When handling batteries, always wear safety goggles. q Keep children away from batteries. KS000327 q Caution - battery acid. WEAM014802...
Page 34 SAFETY SAFETY LABELS q Read the operator’s manual before working with batteries. q Caution - explosive gases. Caution when standing in operator cab Hydraulic oil topping up (Only for machines in which synthetic biodegradable oil type HEES is used) 2-10 WEAM014802...
Page 35 SAFETY SAFETY LABELS Engine air suction filter Engine coolant AF-NAC q Fill Komatsu genuine engine coolant AF-NAC to prevent radiator damage by corrosion. Hydraulic oil topping up Refuelling Engine oil filter 2-11 WEAM014802...
Page 36 SAFETY SAFETY LABELS Fuel filter Coolant Coolant pressure 21D-98-11150 Hydraulic oil level Hydraulic oil filter 2-12 WEAM014802...
Page 37 SAFETY SAFETY LABELS Anchorage point Lifting point Emergency exit Electrical outlet q Only use this socket when engine is running. 2-13 WEAM014802...
Page 38 SAFETY SAFETY LABELS LIFTING CAPACITIES PLATES For detail, see "LIFTING CAPACITIES WITH BOOM" (5-6). q Boom q Boom with additional counterweight 2-14 WEAM014802...
Page 39 SAFETY SAFETY LABELS For detail, see "LIFTING CAPACITIES WITH TWO-PIECE BOOM" (5-9). q 2-piece boom q 2-piece boom with additional counterweight 2-15 WEAM014802...
Page 40 SAFETY SAFETY LABELS For detail, see "LIFTING CAPACITIES TABLES" (3-168). q Overload alarm 2-16 WEAM014802...
Page 41: Safety Rules
SAFETY SAFETY LABELS GENERAL PRECAUTIONS SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q 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 impaired, putting yourself and everyone else on your job site in danger.
Page 42: Fire Extinguisher And First Aid Kit
SAFETY SAFETY LABELS FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. q Make sure there are fire extinguishers and read the labels to make sure you know how to use them in emergency situations.
Page 43: Keep Operator's Compartment Clean
SAFETY SAFETY LABELS KEEP OPERATOR'S COMPARTMENT CLEAN q Always remove dirt and oil from the soles of shoes when entering the operator's compartment. If the pedal is operated with mud or oil under the soles of the shoes, the foot may slip, causing a serious accident.
Page 44: Handrails And Steps
SAFETY SAFETY LABELS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. q When ascending on or descending from the machine, use the handrail and the steps indicated by the arrows in the diagram on the right.
Page 45: Do Not Get Caught In Articulated Portion
SAFETY SAFETY LABELS DO NOT GET CAUGHT IN ARTICULATED PORTION The clearance around the work equipment will change according to the movement of the link. If you get caught, this may lead to serious personal injury. Do not allow anyone to approach any rotating or telescoping part. BURN PREVENTION q To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to...
Page 46: Fire Prevention And Explosion Prevention
SAFETY SAFETY LABELS FIRE PREVENTION AND EXPLOSION PREVENTION FIRE CAUSED BY FUEL OR OIL Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.
Page 47: Action If Fire Occurs
SAFETY SAFETY LABELS q If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury. EXPLOSION CAUSED BY LIGHTING EQUIPMENT q When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti- explosion specifications.
Page 48: Falling Objects, Flying Objects And Intruding Objects Prevention
If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.
Page 49: Attachment Installation
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 50: Safety At Jobsite
SAFETY SAFETY LABELS SAFETY AT JOBSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating. q Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Page 51: Distance To High Voltage Cables
SAFETY SAFETY LABELS DISTANCE TO HIGH VOLTAGE CABLES Digging operations near overhead electric lines are extremely d a n g e r o u s a n d t h e y m a y a l s o c a u s e d e a t h d u e t o electrocution;...
Page 52: Ensure Good Visibility
SAFETY SAFETY LABELS ENSURE GOOD VISIBILITY q Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely. Always do as follows. q When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up additional lighting in the work area if necessary.
Page 53: Signalman's Signal And Signs
SAFETY SAFETY LABELS SIGNALMAN'S SIGNAL AND SIGNS q Set up signs to inform of road shoulders and soft ground. q When it is necessary to position loads, make excavations or move the machine with reduced field of vision, the operator must be helped by another person standing on the ground and making signals to indicate the manoeuvres to be carried out, according to the specific signals defined by the relevant regulations.
Page 54 SAFETY SAFETY LABELS q MOVE THE LOAD AWAY IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical position directed towards the load to be moved away, move the hand in the direction of the movement to be carried out. q BRING LOAD NEARER...
Page 55 SAFETY SAFETY LABELS q LOWER THE BOOM With an arm extended in horizontal position and closed fingers, point the thumb downwards. q FOLD THE ARM With both hands clasped, point the thumbs inwards. RKA32990 q EXTEND THE ARM With both hands clasped, point the thumbs outwards. q FOLD THE BUCKET...
Page 56 SAFETY SAFETY LABELS q TRAVEL WHILE STEERING Lift the forearm corresponding to the inner steering side with clenched fist. Rotate the other fist vertically indicating the wheel’s turning direction. q TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels.
Page 57 SAFETY SAFETY LABELS q CARRY OUT THE MOVEMENTS SLOWLY One hand still in front of the hand that indicates the movement to be carried out. (The figure represents the “lift slowly” control). q STOP With one arm extended laterally, open the hand facing downwards and move the arm forwards and backwards.
Page 58: Emergency Exit From Operator's Cab
Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-34 WEAM014802...
Page 59: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. q Remove all dirt from the surfaces of windows, headlights and working lights and check the that the lights are functioning correctly.
Page 60 SAFETY SAFETY MACHINE OPERATION q Check that the lever of the safety device (1) is in the LOCK position (L). SAFETY RULES FOR STARTING ENGINE q Start and operate the machine only while seated. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 61: Functioning
SAFETY SAFETY MACHINE OPERATION FUNCTIONING CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. q Always fasten your seat belt. q Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel system, swing system, and steering system.
Page 62 SAFETY SAFETY MACHINE OPERATION SAFETY STANDARDS WHEN RUNNING q It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply. q When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. q Move at low speed and do not turn the steering wheel abruptly when moving over rough terrain.
Page 63 SAFETY SAFETY MACHINE OPERATION MOVING IN GRADIENTS q Operations on slopes and on river or lake banks with damp ground may result in the tipping over or slipping of the machine. q On hills, banks or slopes, keep the bucket very close to the ground (20-30 cm from the ground) and in case of emergency quickly lower it to the ground to help the machine stop.
Page 64 SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SLOPES q When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.
Page 65 SAFETY SAFETY MACHINE OPERATION q Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other hauling equipment. There is danger that the load may spill or the bucket may hit the dump truck and cause serious personal injury or death.
Page 66 SAFETY SAFETY MACHINE OPERATION q When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine. q Always lock the cab door, in order to prevent unauthorized persons from starting the machine. Always remove the key. q If the machine needs to be parked on a ravine, do so as follows.
Page 67: Transporting The Machine
SAFETY SAFETY MACHINE OPERATION TRANSPORTING THE MACHINE LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows: q Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.
Page 68: Battery
SAFETY SAFETY MACHINE OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 69 SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 70: Towing
SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "REMOVING THE MACHINE (3-191)". q Always wear leather gloves when handling wire rope.
Page 71: Lifting Objects With Lifting Device (Optional Equipment)
It is forbidden to weld hooks or ears to the bottom of the bucket. q If the machine is not equipped with an appropriate hook, contact the Komatsu distributor. q Fitting a lifting hook must be monitored and certified by the competent Authorised Body.
Page 72 SAFETY SAFETY MACHINE OPERATION q The lifting link RLL (Rated Lifting Load) and part number (A) are stamped on the link as shown below. q All components in the load line (eg.chains, shackles etc.) must be rated correctly for the load to be lifted. q When swinging or operating the work equipment, check carefully that the surrounding area is clear from objects, structures or any persons working around the machine.
Page 73 SAFETY SAFETY MACHINE OPERATION q The operator or person attaching the sling should inspect the bucket link lifting device and all components in the load line (e.g. chains, shackles etc.) visually for damage or deformation before use to ensure that they are not damaged or worn....
Page 74: Safety Maintenance Information
SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG q Always attach the “DO NOT OPERATE“ warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 75 SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE q Stop the machine on a solid and flat surface q Turn the ignition switch to OFF, wait approximately one minute, then turn battery main switch to OFF and remove q Select a place where there is no hazard of landslides, falling rocks, or flooding.
Page 76 SAFETY SAFETY MAINTENANCE INFORMATION MAINTENANCE WITH ENGINE RUNNING To prevent personal injury, do not carry out maintenance with the engine running.If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. q One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 77 Do not hit or roll the accumulator, or subject it to any impact. q When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.
Page 78 Do not touch any internal components of the controller or fuel injector. If access to these components is necessary, contact your Komatsu distributor. 2-54 WEAM014802...
Page 79 Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. 2-55...
Page 80 If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 81 SAFETY SAFETY MAINTENANCE INFORMATION q Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. q Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.
Page 82 CHEMICAL HAZARD q During maintenance or dismalting operations, where there is a risk of contact with hazardous chemival substances, relevant safety precautions should be taken. If any doubt exists, contact your Komatsu distributor.  See also disposal of "WASTE MATERIALS" (2-56)
Page 83 40°C, then start moving the equipment to fill all the circuits with oil. Stop the engine and check the oil level (see "Check the oil level in the hydraulic tank and top up (3-116)"). FINAL DISPOSAL OF THE MACHINE q At the end of the working life of the machine, ask Komatsu distributor for the final disposal. 2-59 WEAM014802...
Page 84 SAFETY SAFETY MAINTENANCE INFORMATION 2-60 WEAM014802...
Page 85 FUNCTIONING WARNING Before reading this section, make sure you have read and understood the section on safety. WEAM014802...
Page 86: Machine Illustrations
FUNCTIONING MACHINE ILLUSTRATIONS MACHINE ILLUSTRATIONS GENERAL VIEW OF THE MACHINE WITH MONOBOOM Bucket (10) Sprocket Bucket cylinder (11) Undercarriage (12) Track Arm cylinder (13) Idler roller Boom (14) Blade cylinder Boom cylinder (15) Blade Supplementary light (if installed) (16) Boom swing cylinder Work light (17) Revolving support WEAM014802...
Page 87: General View Of The Machine With Two-Piece Boom
FUNCTIONING MACHINE ILLUSTRATIONS GENERAL VIEW OF THE MACHINE WITH TWO-PIECE BOOM Bucket (11) Cab Bucket cylinder (12) Sprocket (13) Undercarriage Arm cylinder (14) Track Two-piece boom cylinder (15) Idler roller Two-piece boom (16) Blade cylinder Boom (17) Blade Boom cylinder (18) Boom swing cylinder Supplementary light (if installed) (19) Revolving support...
Page 88: Controls And Gauges
FUNCTIONING MACHINE ILLUSTRATIONS CONTROLS AND GAUGES Supplementary cabin light switch (if installed) (19) Slew brake disable switch Control locking lever (safety lever) (20) Proportional switch for primary hydraulic tool circuit Left work equipment control lever (21) Hydraulic breaker control button Travel pedals (22) Proportional switch for secondary hydraulic tool circuit Travel levers...
Page 89 FUNCTIONING MACHINE ILLUSTRATIONS MACHINE MONITOR Standard screen (15) Translation speed selector button Screen with all indicator lights lit (16) Windscreen wiper button 'Maintenance required' screen (17) Air conditioner button (18) Engine oil pressure warning light Windscreen wiper button (19) Message indicator Buzzer mute button (20) Air conditioner indicator light Auto-deceleration switch...
Page 90: Instruments And Controls
FUNCTIONING INSTRUMENTS AND CONTROLS INSTRUMENTS AND CONTROLS The following paragraphs describe the devices that are necessary for correct operation of the machine. To perform the required operations correctly and safely, it is important to understand the equipment operating methods and the meaning of the information displayed. In order to understand the messages displayed on the monitor, select the language in the menu.
Page 91 FUNCTIONING INSTRUMENTS AND CONTROLS Specific to a model or some models Message Area 2 Translation Meaning OVERRUN PROTECT OVERRUN PROTECT Overrun protection WARMINGUP WARMINGUP Pre-heating HST OIL OVERHEAT HST OIL OVERHEAT Hydrostatic Transmission (HST) oil overheat HST OIL FILTER HST OIL FILTER Hydrostatic Transmission (HST) oil filter APPLY PKG BRAKE APPLY PKG BRAKE...
Page 92: Monitoring System
FUNCTIONING INSTRUMENTS AND CONTROLS MONITORING SYSTEM Standard screen Basic control indicator lights Screen with all indicator lights lit Counter, indicator light bar 'Maintenance required' screen Button panel Emergency lights Warning lights REMARK One of the characteristics of LCD panels is that there may be permanent black areas (pixels not lighting up) or white areas (pixels remaining lit).
Page 93 FUNCTIONING INSTRUMENTS AND CONTROLS BASIC FUNCTIONS OF THE MACHINE MONITOR Engine start in normal conditions q When the ignition key is turned to ON, the welcome screen GG is displayed. q After 2 seconds, the preliminary checks screen DD is displayed. q After another 2 seconds, screen HH is displayed, relative to the operating/translation mode.
Page 94 FUNCTIONING INSTRUMENTS AND CONTROLS Turning engine off in normal conditions q When the ignition switch is turned to ON, the end screen JJ is displayed for 5 seconds, after which the monitor switches off. Faults detected during engine start q If faults are detected during engine start, the preliminary checks screen DD is immediately followed by the 'maintenance required' screen CC and the error screen EE.
Page 95 FUNCTIONING INSTRUMENTS AND CONTROLS Faults detected during operation q In the event of faults detected during operation, the standard screen AA is followed by the error screen EE. REMARK The emergency, indicator and monitoring lights illuminate in the following colours. Standard screen Screen with all indicator lights lit 'Maintenance required' screen...
Page 96 FUNCTIONING INSTRUMENTS AND CONTROLS EMERGENCY WARNING LIGHTS CAUTION In the event of a red light, switch off the engine immediately or reduce engine speed to idle, check the parts in question and carry out any necessary corrective action. Check the status of these indicator lights frequently while the engine is running. In the event of problems indicated by a red light and the relative warning buzzer, perform the necessary corrective action immediately.
Page 97 FUNCTIONING INSTRUMENTS AND CONTROLS (2) Hydraulic fluid temperature warning light This warning light (2) informs the operator that the hydraulic fluid temperature has increased. If the hydraulic fluid temperature increases excessively, the warning light signals the fault condition (C). Stop working and switch off the engine or run at idle speed until the warning light returns to normal (B).
Page 98 FUNCTIONING INSTRUMENTS AND CONTROLS WARNING LIGHTS CAUTION If the warning lights illuminate in red, stop working as soon as possible and perform the necessary inspection and maintenance work. Ignoring warning signals may lead to malfunction. Check the status of these indicator lights frequently while the engine is running. In the event of malfunction, the screen displays the component requiring immediate maintenance....
Page 99 FUNCTIONING INSTRUMENTS AND CONTROLS (2) Hydraulic fluid temperature warning light I f th e w ar n i ng li g ht ( 2) i nd i c at es a n e x ce s s i v el y l ow temperature (A), carry out the warm-up procedure.
Page 100 FUNCTIONING INSTRUMENTS AND CONTROLS (5) Overload alarm light This warning light indicates that,during a lifting operation, the machine could overturn due to excessive load. Besides the warning light switching on, the alarm is sounded so it is necessary to lower the load. NOTE: This light is only active in work mode L.
Page 101 This warning light illuminates when the ignition switch is turned to ON. After 30 seconds, the indicator light extinguishes and the display returns to the normal screen. REMARK If you wish to modify the service interval settings, contact your Komatsu distributor. 3-17 WEAM014802...
Page 102 FUNCTIONING INSTRUMENTS AND CONTROLS INSTRUMENTS AND INDICATORS Indicator light bar (10) Engine coolant temperature indicator Engine preheating warning light (11) Hydraulic fluid temperature gauge Slew lock indicator light (12) Fuel gauge Windscreen indicator light (13) Hour counter, clock Automatic engine speed limiter system indicator light (14) ECO gauge Operating mode indicator light Travel speed warning light...
Page 103 FUNCTIONING INSTRUMENTS AND CONTROLS (2) Slew lock indicator light This indicator light (2) is not used. (3) Windscreen wiper indicator light This indicator light (3) indicates the status of the windscreen wiper. When the windscreen wiper button is pressed, the indicator light may assume the following states.
Page 104 Indicator light off: Air conditioner OFF (8) Message indicator light This indicator light (8) notifies the operator that a message has been received from Komatsu. For instructions on reading messages, see paragraph "USING THE FUNCTION KEYS (3-34)" ("b. Message indicator (machines with KOMTRAX)").
Page 105 FUNCTIONING INSTRUMENTS AND CONTROLS Indicators and counter (10) Engine coolant temperature indicator This gauge (10) indicates the engine coolant temperature. During normal operation, the needle should remain within the green area. If the needle exceeds the red zone (A), the overheat protection system is activated.
Page 106 FUNCTIONING INSTRUMENTS AND CONTROLS (11) Hydraulic fluid temperature gauge This gauge (11) indicates the hydraulic oil temperature. During normal operation, the needle should remain within the green area. If the gauge needle enters the red zone (A), the hydraulic oil temperature has reached or exceeded 102°C.
Page 107 FUNCTIONING INSTRUMENTS AND CONTROLS (13) Hour counter, clock The hour counter (13) displays the total operating hours of the machine or the current time. With the engine running, the hour counter advances even if the machine is not moving. The hour counter advances by 1 hour for every hour the machine is in operation, independently of engine speed.
Page 108 FUNCTIONING INSTRUMENTS AND CONTROLS (14) ECO gauge This gauge (14) indicates work load. When the gauge needle is in the green zone A, work load is between light and medium. When the needle is in the orange zone B, work load is high. REMARK The needle in the orange zone doe not indicate a problem for the machine.
Page 109 FUNCTIONING INSTRUMENTS AND CONTROLS BUTTON PANEL Operating mode selector button Buzzer mute button Auto-deceleration switch Function keys Translation speed selector button Air conditioner button Windscreen wiper button Windscreen washer button 3-25 WEAM014802...
Page 110 To change which of the modes available (P, E, L, B or ATT) is selected automatically on engine start (setting optional default mode), ask Komatsu distributor to change the setting. ATT/P and ATT/E modes may be selected by changing the attachment mode....
Page 111 FUNCTIONING INSTRUMENTS AND CONTROLS Selection procedure 1. Press the working mode selector (1) to access the relative screen. 2. To change working mode, press the F3 or F4 function keys or the working mode selector (1). REMARK If no input is received for more than five seconds, the selected working mode is automatically set and the monitor returns to the screen shown in steps 3 and 4.
Page 112 FUNCTIONING INSTRUMENTS AND CONTROLS 5. After another two seconds, the monitor returns to the standard screen. The orange indicator turns blue again. (2) Auto-deceleration switch With the control levers in neutral position, this button (2) automatically reduces engine speed and activates the fuel saving function.
Page 113 FUNCTIONING INSTRUMENTS AND CONTROLS 2. The automatic engine speed limiter indicator lights up on the standard screen. (When the automatic engine speed limiter is deactivated, the indicator is not lit.) 3-29 WEAM014802...
Page 114 FUNCTIONING INSTRUMENTS AND CONTROLS (3) Translation speed selector WARNING q When loading and unloading the machine onto and off a trailer, always manoeuvre at low speed (Lo). Never operate the translation speed selector while the machine is moving. q Attempting to change the speed setting when in motion may cause the machine to veer to one side. Always stop the machine before changing the translation speed.
Page 115 FUNCTIONING INSTRUMENTS AND CONTROLS (4) Windscreen wiper button This button (4) operates the front windscreen wiper. Pressing the button causes the corresponding indicator to assume one of the three possible states: ON  INT  stop (OFF). q INT indicator lit: Windscreen wiper operates intermittently q ON indicator lit: Windscreen wiper operates continuously q OFF indicator lit: Windscreen wiper stopped REMARK...
Page 116 FUNCTIONING INSTRUMENTS AND CONTROLS (5) Windscreen washer button Pressing this button (5) sprays windscreen washer fluid onto the windscreen. Spraying stops when the button is released. q If the button (5) is pressed while the windscreen wiper is off, the windscreen wiper is also activated in continuous mode.
Page 117 FUNCTIONING INSTRUMENTS AND CONTROLS (7) Function keys There are six function keys (7), from F1 to F6. The function of each key changes depending on the content of the current screen. With the standard screen, the functions of these keys are as follows.
Page 118 FUNCTIONING INSTRUMENTS AND CONTROLS USING THE FUNCTION KEYS q There are six function keys (A), from F1 to F6, at the bottom on the monitor. The function of each key changes depending on the current screen. q To verify the function of the keys (A) in each screen, refer to the symbols (B) displayed immediately above.
Page 119 FUNCTIONING INSTRUMENTS AND CONTROLS If the clock is displayed, press F4 to switch to the hour counter. If the hour counter is displayed, press F4 to switch to the clock. Maintenance mode selector Pressing F5 closes the standard screen and calls up the maintenance mode screen.
Page 120 30 hours, the value is highlighted yellow in the relative column. If the remaining time to the next interval is 0 hours, the value is highlighted red. If you wish to modify the service interval settings, contact your Komatsu distributor. 3-36 WEAM014802...
Page 121 FUNCTIONING INSTRUMENTS AND CONTROLS Operations available in reset service interval screen From the maintenance screen, press and hold F6 for at least 1.5 seconds to call up the reset service interval screen. Reset the remaining time from this screen. 1. When the reset screen appears as show in the figure to the right, press F6.
Page 122 FUNCTIONING INSTRUMENTS AND CONTROLS User mode selector Press F6 to display the machine settings screen. The following operations are possible from the user menu, using keys F3 to F6. q F3: Select next entry (1 row down). When on the last row, this selects the first row of the next page.
Page 123 FUNCTIONING INSTRUMENTS AND CONTROLS q F5: Return to standard screen. q F6: Display settings screen for selected parameter. If no buttons are pressed for 30 seconds when in the user menu, the monitor automatically returns to the previous screen. The following parameters are user-configurable. q a: Breaker/accessory settings (machines predisposed for accessories) q b: Message indicator (machines with KOMTRAX)
Page 124 FUNCTIONING INSTRUMENTS AND CONTROLS a. Breaker/attachment settings q On machines predisposed for accessories, the oil flow rate in B and ATT modes may be set in accordance with the attachment used. On machines not predisposed for accessories, these menus are not displayed. Modifying "breaker"...
Page 125 FUNCTIONING INSTRUMENTS AND CONTROLS 3. From the working mode selection screen shown on the right, select B (breaker) and press F6. In the working mode selection screen shown on the right, the following operations are possible using keys F3 to F6. q F3: Select next entry (1 row down).
Page 126 FUNCTIONING INSTRUMENTS AND CONTROLS In the breaker selection menu, the following operations are possible using keys F3 to F6. q F3: Select next entry (1 row down). q F4: Select previous entry (1 row up). q F5: Return to previous screen. q F6: Display settings screen for selected parameter.
Page 127 FUNCTIONING INSTRUMENTS AND CONTROLS 2. From the "breaker" selection screen, select one of the two values set for oil flow rate and press F6. q The default oil flow rate values are both set at 130 litres/min, as shown to the right. To select the oil flow rate, follow the procedure described in "USING THE FUNCTION KEYS (3-34)".
Page 128 FUNCTIONING INSTRUMENTS AND CONTROLS 2. From the breaker oil flow rate setting screen, select one of the two set values and press F6. q The default oil flow rate values are both set at 130 litres/min, as shown to the right. The oil flow rate currently set for B mode is highlighted by a B in front of the corresponding parameter, as shown to the right.
Page 129 FUNCTIONING INSTRUMENTS AND CONTROLS 3. From the "breaker" oil flow rate setting screen, modify the oil flow rate. q Use F3 or F4 to modify the oil flow rate then press F6 to confirm the modification and return to the previous screen.
Page 130 FUNCTIONING INSTRUMENTS AND CONTROLS 2. Select the breaker/attachment settings parameter in the user menu and press F6. 3. From the working mode selection screen shown to the right, select ATT - 2-way Attachment, and press F6. q In the working mode selection screen shown on the right, the following operations are possible using keys F3 to F6.
Page 131 FUNCTIONING INSTRUMENTS AND CONTROLS 4. The monitor displays the ATT - 2-way Attachment selection menu. q ATT - 2-way Attachment selection menu Selecting this parameter (a), the oil flow rate for ATT mode may be selected from the two set values. q ATT - 2-way Attachment oil flow rate setting menu Selecting this parameter (b), the oil flow rate set for ATT mode may be modified.
Page 132 FUNCTIONING INSTRUMENTS AND CONTROLS 2. From the ATT - 2-way Attachment selection menu, select one of the two values set for oil flow rate and press F6. q The default oil flow rate values are both set at 130 litres/min, as shown to the right. To select the oil flow rate, follow the procedure described in "USING THE FUNCTION KEYS (3-34)".
Page 133 FUNCTIONING INSTRUMENTS AND CONTROLS Modifying attachment flow rate settings 1. Select parameter (b) in the ATT - 2-way Attachment oil flow rate setting menu and press F6. 2. In the oil flow rate setting screen accessible from the ATT - 2-way Attachment selection menu, select one of the two values set for oil flow rate and press F6.
Page 134 FUNCTIONING INSTRUMENTS AND CONTROLS 3. The oil flow rate setting may be modified from the 2-way attachment oil low rate setting menu. q Use F3 or F4 to modify the oil flow rate then press F6 to confirm the modification and return to the previous screen.
Page 135 Message indicator (machines with KOMTRAX)3 On machines with KOMTRAX, messages sent by your Komatsu distributor may be read by accessing the message display menu. The corresponding indicator at the top left illuminates if there are any messages to be read.
Page 136 FUNCTIONING INSTRUMENTS AND CONTROLS 3. The monitor displays “No message“. Press F5 to return to the standard screen. c. Screen settings The screen brightness, contrast and backlighting levels can be adjusted from the screen settings menu. 1. From the standard screen, press F6. 2.
Page 137 FUNCTIONING INSTRUMENTS AND CONTROLS 3. Select the parameter you wish to modify (a or b) and press F6. The monitor displays the setting screen for the selected parameter. q (a): Adjusting the standard monitor q (b): Adjusting the video camera monitor (machines with video camera only) In the selection screen shown on the right, the following operations are possible using keys F3 to F6.
Page 138 FUNCTIONING INSTRUMENTS AND CONTROLS In the screen for parameters 1) and 2), the following operations are possible using function keys F2 and F6. q F2: Resets all settings to default values q F3: The cursor for the parameter selected moves by one segment to the left.
Page 139 FUNCTIONING INSTRUMENTS AND CONTROLS d. Clock adjustment From this menu, the clock displayed in the standard screen may be adjusted. 1. From the standard screen, press F6. 3-55 WEAM014802...
Page 140 FUNCTIONING INSTRUMENTS AND CONTROLS 2. Select “Clock Adjustment“ in the user menu and press F6. The monitor displays the time setting screen. q The following three parameters may be modified. (a) Clock adjustment (b) 12/24 hour mode (c) Daylight saving 3-56 WEAM014802...
Page 141 FUNCTIONING INSTRUMENTS AND CONTROLS 3. From the clock adjustment screen, the following operations are possible using the function keys from F3 to F6. Time Adjust time setting. 1) If “Time“ (a) is not highlighted in yellow, press F6 to highlight the parameter. The hour value (b) turns orange....
Page 142 FUNCTIONING INSTRUMENTS AND CONTROLS 12h/24h Mode Select the 12 hour (am/pm) or 24 hour field. q (b): 24 hour field q (c): 12 hour field (am/pm) 1) If “12h/24h Mode“ (a) is not highlighted in yellow, press F6 to highlight the parameter. 2) Modify the mode as follows.
Page 143 FUNCTIONING INSTRUMENTS AND CONTROLS e. Language selection The language used on the monitor may be selected from the language selection menu. The following languages are selectable. Japanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian and Thai REMARK With reference to the languages which cannot be selected, set the English language in the monitor and follow the table of the messages in the paragraph "MONITOR MESSAGE (3-6)".
Page 144 FUNCTIONING INSTRUMENTS AND CONTROLS 3. Select the desired language and press F6. The language selected in the menu is now displayed. In the language selection screen shown on the right, the following operations are possible using keys F3 to F6. q F3: Select following option.
Page 145 FUNCTIONING INSTRUMENTS AND CONTROLS 2. Select “Economy Mode Adjustment“ in the user menu and press F6. The Economy mode adjustment screen is displayed. 3. Select the desired E mode from the three options displayed. The following levels may be set. q E0: Default q E1: Economy - Setting 1 q E2: Economy - Setting 2...
Page 146: Switches And Push Buttons
FUNCTIONING INSTRUMENTS AND CONTROLS SWITCHES AND PUSH BUTTONS Ignition switch (12) Proportional switch for secondary hydraulic tool circuit Hand accelerator (if installed) Cigarette lighter (13) Quick connector control button (if installed) Proportional switch for primary hydraulic tool circuit (14) Hydraulic quick coupler switch (if fitted) Hydraulic breaker control button (15) Supplementary cabin light switch (if installed) Horn button...
Page 147 FUNCTIONING INSTRUMENTS AND CONTROLS (1) Ignition switch This is a four-position rotary switch and is used to switch the engine on and off. Position OFF (A) When the switch is in this position, the ignition key can be inserted and removed. When the key is turned to this position, the power supply to the electric circuit is interrupted and the engine stops.
Page 148 FUNCTIONING INSTRUMENTS AND CONTROLS (3) Cigarette lighter The cigarette lighter (3) is used to light cigarettes. Push it inwards, it will return to its original position after a few seconds. Extract it to light your cigarette. If the cigarette lighter is removed, the socket can be used as power supply.
Page 149 FUNCTIONING INSTRUMENTS AND CONTROLS (7) Overhead light NOTICE Make sure to switch off the overhead light after use. If it is not switched off, the battery will run down. The overhead light (7) is used to check the instruments and the inside of the cab when visibility is scarce.
Page 150 FUNCTIONING INSTRUMENTS AND CONTROLS (9) Slew brake disable switch NOTICE This switch temporarily enables manoeuvres in the event of a malfunction in the revolving frame slew brake system. It must not be used permanently. The failure that caused the anomaly must be repaired immediately. This switch (9) is used to temporarily enable manoeuvres in the event of a malfunction in the revolving frame slew brake system (when display shows code "E03").
Page 151 FUNCTIONING INSTRUMENTS AND CONTROLS (12) Accessory proportional switch (2nd line) (if present) Use this switch (12) to operate the attachment. For further details about the use of the switch, see "MACHINE C O N F I G U R AT I O N F O R T H E I N S TA L L AT I O N O F ATTACHMENTS (6-8)".
Page 152 FUNCTIONING INSTRUMENTS AND CONTROLS (16) Battery main switch The battery main switch is located inside the battery compartment and can be accessed after opening the left rear door. Turn the key anticlockwise, to (O) OFF, to interrupt the current supplied by the battery to the electrical system; for safety reasons, extract the key after turning the switch to OFF.
Page 153: Control Levers And Pedals
FUNCTIONING INSTRUMENTS AND CONTROLS CONTROL LEVERS AND PEDALS Safety device control lever Blade control lever Translation levers (with pedals and automatic engine Pedal lock speed limiter system) Boom swing control pedal Left hand work tool control lever (with automatic Two-piece boom control pedal (if installed) engine speed limiter system) Right hand work tool control lever (with automatic engine speed limiter system)
Page 154 FUNCTIONING INSTRUMENTS AND CONTROLS (1) Safety device control lever WARNING q Before leaving the cab, lower the equipment to the ground and shift the safety lever to position “lock”. If the safety lever is not in the LOCK position (L) and the control levers are touched by mistake, this may lead to serious injury.
Page 155 FUNCTIONING INSTRUMENTS AND CONTROLS (2) Travel levers WARNING q Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt. q Before moving the machine, make sure that the sprocket (A) is positioned at the rear of the machine and that the safety locks are engaged;...
Page 156 FUNCTIONING INSTRUMENTS AND CONTROLS (3) Left hand work tool control lever (with automatic engine speed limiter system) (4) Right hand work tool control lever (with automatic engine speed limiter system) WARNING q Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt.
Page 157 FUNCTIONING INSTRUMENTS AND CONTROLS (5) Blade control lever WARNING Before moving the machine, make sure that the blade is completely raised. The lever (5) is used to control the blade. (a) Lower (b) Lift (6) Boom swing control pedal lock WARNING Always shift the safety lever to LOCK position (L) when the boom swing is not required, during travel and when parking the machine.
Page 158 FUNCTIONING INSTRUMENTS AND CONTROLS (7) Boom swing control pedal WARNING q When the boom is swung to the left with retracted work equipment, if the bucket is wider than a standard bucket it may come into contact with the cab. q Always check the distance between the bucket and the cab and work manoeuvring the equipment with care.
Page 159: Cab
FUNCTIONING OPENING ROOF WARNING When opening or closing the cab roof, always set the safety device lever to the LOCK position (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents. Opening 1.
Page 160: Windshield
FUNCTIONING WINDSHIELD WARNING q When opening or closing the upper windshield, the lower windshield or the cab door, always lock the controls with the safety device lever (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents. q Before opening or closing the windshield, stop the machine on a level surface, lower the work equipment completely to the ground and stop the engine.
Page 161 FUNCTIONING 4. Seize the handles (A) at the right and left top of the windscreen and pull the locking levers (B) to release the windscreen. 5. Seize the lower handle (C) with your left hand from the inside of the cab and with your right hand seize the upper handle (D).
Page 162 FUNCTIONING 6. Pull it upwards and push it against the retainer (E) until engaging the glass. 7. Make sure that the safety lever is in the LOCK position (L). REMARK q The retainer has been correctly fitted if the arrow on the retainer (F) corresponds to the arrow on the locking lever (B).
Page 163 FUNCTIONING 3. Seize the right and left handles (A) and pull down the locking lever (B) to release the stop. 4. Seize the handle (C) at the bottom of the front glass with your left hand and the handle (D) on the upper part of the same with your right hand, push forward, then lower slowly.
Page 164 FUNCTIONING Removing the lower windshield 1. Open the upper windscreen as described previously, grip the handle (1), then pull the lower windscreen upward and remove. 2. After removing the lower windscreen, stow away in the rear of the cab and secure in place with the fastener (2). Proceed as follows.
Page 165: Sliding Door
FUNCTIONING 4) Turn the lock (2) 90° clockwise into the LOCK (L) position and fasten the windscreen upper part. NOTICE After completing the above operation, check that the windscreen is securely fastened and cannot move. The windscreen may fall if not secured correctly. 4) To refit the lower windscreen, repeat the above procedure in reverse order.
Page 166: Emergency Exit Hammer
FUNCTIONING EMERGENCY EXIT HAMMER WARNING q When it is necessary to break the window with the hammer, pay attention not to get injured by glass chips. q Before leaving the operator cab, remove any glass fragments from the window edges and take care not to injure yourself.
Page 167: Hoods And Doors Fitted With A Lock
FUNCTIONING HOODS AND DOORS FITTED WITH A LOCK HOODS AND DOORS FITTED WITH A LOCK Use the ignition key to open and close the locks. For details on fitting locked casings, see "HOODS AND DOORS FITTED WITH A LOCK (3-83)". Insert the key completely into the lock and turn it.
Page 168: Engine Cover
FUNCTIONING HOODS AND DOORS FITTED WITH A LOCK ENGINE COVER WARNING When carrying out an inspection or maintenance operation inside the engine hood, always open it completely and make sure that it is kept open by the apposite rod. NOTICE q If it is not necessary to open the cover, always keep it locked.
Page 169: Side Cover
FUNCTIONING HOODS AND DOORS FITTED WITH A LOCK SIDE COVER WARNING q Never climb on the side cover as this may lead to slipping and falling. q When carrying out an inspection or maintenance operation inside the side cover, always open it completely and make sure that it is kept open by the apposite lever.
Page 170: Pump Compartment And Battery Compartment Doors
FUNCTIONING HOODS AND DOORS FITTED WITH A LOCK PUMP COMPARTMENT AND BATTERY COMPARTMENT DOORS WARNING When inspecting or working inside the battery inspection hatch, always open the hatch completely and ensure that it is securely supported by the safety rod. NOTICE Keep the covers locked.
Page 171: Air Conditioner
The coolant contained in the air conditioning system is considered special waste and must be collected and disposed of according to the antipollution regulations in force. q For specific maintenance to carry out on the conditioning system, contact a Komatsu distributor. Non- compliance with these instructions may cause serious damage and even death.
Page 172: Air Conditioner Control Panel
FUNCTIONING AIR CONDITIONER AIR CONDITIONER CONTROL PANEL OFF Button FRESH AIR/RECIRCULATE selector Fan buttons Screen on monitor Temperature control buttons Air conditioner button Vent selector Sunlight sensor Auto button (1) OFF Button This button (1) turns off the fan and air conditioner. REMARK Pressing this button (1) does not display the air conditioner settings screen on the monitor.
Page 173 FUNCTIONING AIR CONDITIONER (2) Fan buttons These buttons (2) set the air flow. There are six fan speed levels. q Press button E to increase fan speed; press button R to reduce fan speed. q In Auto mode, fan speed is adjusted automatically. Fan speed level display on monitor A: LCD Display B: Fan speed...
Page 174 FUNCTIONING AIR CONDITIONER (4) Vent selector This button (4) is used to select vents. q When button (4) is pressed, the image shown on the monitor (7) changes and the is directed through the vents displayed. q In Auto mode, vents are selected automatically. (A): Rear vents (2 points) (B1): Head level vent (1 point) (B2): Foot level vent (1 point)
Page 175 FUNCTIONING AIR CONDITIONER (5) Auto button If button (5) is pressed, fan speed, vent selection and air source (FRESH/RECIRCULATE) are automatically adjusted in accordance with the set temperature. q Press button (5), adjust the temperature with buttons (3) and set the air conditioner to automatic mode. q When switching from automatic to manual mode, the vent and air source (FRESH/RECIRCULATE) selection buttons may be used.
Page 176: Operating Modes
FUNCTIONING AIR CONDITIONER (8) Air conditioner button Button (8) turns the air conditioner (with cooling, dehumidifying and heating functions) on and off. q Press the air conditioner button (8) while the fan is running (indicator (b) shown on the monitor). The air conditioner turns on and starts functioning.
Page 177 FUNCTIONING AIR CONDITIONER 2. Press the temperature setting button (3) to set the desired temperature. Fan speed, vent selection and air source (fresh or recirculate) are automatically adjusted in ac cordanc e with the temperature set, and the ai r conditioner is activated automatically to achieve the set temperature.
Page 178 FUNCTIONING AIR CONDITIONER Manual operation 1. Press the fan speed buttons (2) and adjust the fan speed. Check that the monitor (7) displays the temperature (a) and fan speed settings (b). 2. Press the air conditioner button (8) to turn the air conditioner on.
Page 179 FUNCTIONING AIR CONDITIONER 4. Press the vent selection button (4) and select the desired air vents. The image displayed on the monitor changes to show the new vent selection (c). 5. Press the RECIRCULATE/FRESH selector (6) and select between recirculated internal air or fresh air drawn from outside.
Page 180 FUNCTIONING AIR CONDITIONER Operation with cool air at head level and warm air at foot level To have cool air at head level and warm air at foot level, proceed as follows. 1. Use the fan speed buttons (2) to adjust the fan speed. Check that the monitor (7) displays the temperature (a) and fan speed settings (b).
Page 181 FUNCTIONING AIR CONDITIONER 4. Adjust the fan speed buttons (2), temperature control buttons (3) and the air source selector (6) as desired. Demister function 1. Press the fan speed buttons (2) and adjust the fan speed. Check that the monitor (7) displays the temperature (a) and fan speed settings (b).
Page 182 FUNCTIONING AIR CONDITIONER 3. Press the air source selector (6) and set to "fresh air" mode. 4. Press the temperature control button (3) until the 'maximum heating' setting is displayed on the monitor (7). 5. Adjust the vents (A), (B1) and (B2) so that the air is directed towards the windscreen....
Page 183: Use The Air Conditioner With Caution
Any malfunction detected in the air conditioner system or sensors will be indicated on the monitor by the message “A/C Controller Error“. If the message “A/C Controller Error“ is displayed, ask your Komatsu distributor to inspect and repair the system. 3-99...
Page 184: Fuses
FUNCTIONING FUSES FUSES NOTICE q Before replacing fuses, be sure to first turn the starting switch to the OFF position, wait for over one minute, then switch the battery disconnect switch to OFF and take out the battery disconnect switch key.
Page 185: Main Fuse
FUNCTIONING FUSES Position Capacity Associated circuit (14) Reserve (15) Air conditioner (16) Backup radio, internal light (17) Monitor, controller, starter switch (18) Engine controller (19) Engine controller (20) PPC oil pressure inhibitor solenoid MAIN FUSE NOTICE q Before replacing fuses, be sure to first turn the starting switch to the OFF position, wait for over one minute, then switch the battery disconnect switch to OFF and take out the battery disconnect switch key.
Page 186: Supplementary Power Supply
SUPPLEMENTARY POWER SUPPLY NOTICE When installing electrical equipment not supplied by Komatsu, ensure that the operating voltage is 24 V and maximum power rating does not exceed 240 W (10 A or equivalent). If you intend to install electrical equipment with higher power ratings, contact your Komatsu distributor.
Page 187 After use, replace the cap. Use this outlet only when the engine is working. For 24V devices, do not exceed 240W (equivalent to 10A). If you intend to install devices with higher power ratings, contact your Komatsu Distributor. 3-103 WEAM014802...
Page 188: Controller
NOTICE q Avoid letting water, mud or liquids fall on the controller, since this may cause damage. q If failures are detected on the controller, contact the Komatsu distributor. The chassis controller and the KOMTRAX controller are installed in the rear panel at the back of the operator cab.
Page 189: Storage Compartments
FUNCTIONING STORAGE COMPARTMENTS STORAGE COMPARTMENTS TECHNICAL DOCUMENTATION COMPARTMENT NOTICE The use and maintenance manual is an integral part of the machine and must accompany it even in case of resale. On the back of the operator seat there is a compartment for the Use and maintenance manual and other documents.
Page 190: Pump Support For Greasing
FUNCTIONING STORAGE COMPARTMENTS PUMP SUPPORT FOR GREASING WARNING Soon after the engine has stopped, the temperature of the components is very high and may cause burns. Wait for the temperature to become lower before carrying out the greasing procedure. Open the door of the tool compartment. The standard tools are stowed inside this compartment.
Page 191: Komtrax System
KOMTRAX SYSTEM q KOMTRAX is a system that uses wireless communication technology to monitor machines. q The KOMTRAX system can be used only after contacting the Komatsu Distributor and having entered into a contract with him. q As it is a wireless system, the KOMTRAX equipment uses radio waves; therefore, a due permit is required as well as compliance with the regulations in force in the country or territory where the machine is used....
Page 192 FUNCTIONING KOMTRAX SYSTEM q Be careful not to let water deposit on the communication terminals or their cables. q Do not disconnect or tamper with the KOMTRAX communication terminal; consult the Komatsu Distributor in case of failures. REMARK As KOMTRAX is a wireless system, it cannot be used inside tunnels, undergrounds, buildings or in mountainous areas where radio waves cannot be received....
Page 193: Use Of The Machine And Related Controls
Any oil or fuel leaks may cause fire in the machine. Always carry out accurate controls and repair the possible failures; if they repeat, contact the Komatsu distributor. q Carry out this check with the machine parked on level ground. If the machine is inclined, position it horizontally before carrying out the check.
Page 194 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 9. Check the driver's post access handles and the steps to get on the machine. Make sure that there are no damaged or loose bolts, repair any damaged parts and tighten any loose bolts. 10.
Page 195 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Checks performed before starting the engine DANGER q During refuelling and oil topping-up, do not smoke, and for the level checks do not use open flames or lighting means that have not been type-approved, as they may cause fire. q If during topping-up fuel, oil or lubricant is spilled, immediately clean the areas stained.
Page 196 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Checking the engine oil level and topping up WARNING Soon after the machine has been stopped the engine is very hot and may cause burns; let the engine cool down to 40-45°C before carrying out any check. CAUTION When carrying out an inspection or maintenance operation inside the engine hood, always open it completely and make sure that it is kept open by the apposite rod.
Page 197 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Check fuel level and top up WARNING q When refuelling, avoid spilling fuel, since this may cause a fire hazard. If fuel is spilled, wipe it up immediately. q Fuel is highly flammable; do not use naked flames and do not smoke when refuelling. Hold the fuel gun constantly in contact with the filler.
Page 198 Check that the filter placed at the end of the pipe is clean. q In case of malfunction of the refilling automatic stop system, consult the Komatsu local Distributor and do not use the system until the problem is solved.
Page 199 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 3. Insert the fuel pipe free end (3) into the fuel container. 4. To start the refilling, turn the pump switch (4) to ON and press the starter switch (5). Refilling will continue automatically until the fuel reaches the maximum level of the tank.
Page 200 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Check the oil level in the hydraulic tank and top up WARNING q Carry out this check when the oil is cold, with the machine positioned on level ground, bucket and arm cylinders retracted and bucket teeth resting on the ground.
Page 201 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 3. If the oil level is below the mark L, open the side hood (1), open the cap (3) lock (2) and top up through the filler. REMARK The oil level varies according to its temperature. Then keep to the following instructions: q Before operation: near level (L)...
Page 202 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Check the filter clogging indicator 1. Open the engine hood and make sure that the red piston is not visible in the indicator (1). 2. If the red piston is visible, clean or replace the filtering element immediately.
Page 203 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Adjusting the drain valve If the drain valve (4) is difficult to open and close, grease the O- ring of the valve to facilitate movement. 1. Place the valve (5) next to fuel pre-filter cartridge (1) at closed position (S).
Page 204 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Draining the fuel tank WARNING q When draining the fuel tank, avoid spilling fuel, since this may cause fires. q If some fuel is accidentally spilled, clean the dirty area immediately, in order to prevent it from getting slippery and to avoid fires.
Page 205 OFF. q If cable harness have short-circuit traces, contact the Komatsu distributor to find the failure cause and repair it.
Page 206 1. Turn the ignition switch to position ON. 2. Press the button positioned on the right lever and make sure that the horn works correctly. If the horn does not sound, contact your Komatsu distributor, who will carry out the necessary repairs. 3-122...
Page 207 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Adjustment WARNING q Adjust the position of the seat before starting work or when taking the place of another operator. q Adjust the seat so that the control levers and the switches can be easily used by the operator seated with his back against the backrest.
Page 208 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Rear view mirrors WARNING q Always check the cleaning and correct orientation of the rear-view mirrors before starting to work; they must allow to control the rear area control without moving the log in relation to the normal working position....
Page 209 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS q Adjust the side mirror angle in a way that will enable you to see the machine side, as shown in the picture on the right. Mirror (B) Fix the mirror (4) support (3) in the position given in the picture. (F): approx 100 mm Adjust the front right mirror in a way that will enable the driver sitting in his/her seat to view the right hand side of the machine...
Page 210 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Mirrors (C) and (D) Adjust the mirror (C) in a way that will enable the driver sitting in his/her seat to view the rear of the machine. Adjust the mirror (D) in a way that will enable the driver sitting in his/her seat to view any people standing at a 1 m distance from the machine.
Page 211 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Seat belt WARNING q Before fastening the seat belt, make sure that the fastening brackets or the belt itself do not show any anomaly. If there are damaged or worn parts, change the belt. q The safety belt can be replaced also if there are not failures or wear signs according to the following program.
Page 212 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Operations to be carried out before starting the engine WARNING q When starting the engine, make sure that the safety lever is in the LOCK position (L). q If the control levers are not locked and are inadvertently touched when the engine is started, the work equipment may move suddenly and cause serious accidents.
Page 213 If any of these indicators fail to illuminate or the buzzer does not sound, the monitor is probably faulty; contact Komatsu distributor for repairs. 2) After approximately 2 seconds, the monitor displays the working mode and translation speed parameters. The standard screen is then shown.
Page 214 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Starting the engine Start-up with hot engine or mild weather WARNING q Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. Once the engine is started, the operator is absolutely responsible for the damages deriving from false manoeuvres or failure to observe safety regulations..
Page 215 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 3. Turn the ignition key (3) to position START to start the engine. 4. As soon as the engine starts, release the key, which will automatically return to position ON. 5. Let the engine idle for the first 15 seconds soon after starting the engine and do not operate any control lever or the hand accelerator.
Page 216 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Starting with cold engine or in cold climates WARNING q Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. Once the engine is started, the operator is absolutely responsible for the damages deriving from false manoeuvres or failure to observe safety regulations..
Page 217 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 2. Shift the hand accelerator (2) to the idling position. 3. Keep the key in the ignition switch (3) in preheating position (HEAT) and make sure that the preheating warning light (4) comes on. After approximately 30 seconds, the preheating warning light (4) starts blinking and goes on for 10 seconds, indicating that the preheating phase has been completed.
Page 218 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Turbo protection function The turbo protection function protects the turbocompressor; it keeps engine speed below 1150 rpm right after the engine starts. q When the turbo protection function is activated, engine speed remains below 1150 rpm regardless of the fuel grip position.
Page 219: After Starting The Engine
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS AFTER STARTING THE ENGINE WARNING q Emergency stop If a failure has occurred or an anomaly has been observed, turn the ignition key to position OFF. q Do not perform any operation or press abruptly any levers or pedals when the hydraulic fluid temperature is low.
Page 220 Verify that there are no unusual noises when the engine is started, when the engine is idling or when the rpm is increased slightly. q Check that the engine starts easily and smoothly; if abnormal noise is heard, contact Komatsu distributor for inspection.
Page 221 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Warming the engine NOTICE q Do not accelerate the engine abruptly until warming operations have finished. q Do not accelerate abruptly before completing the warming-up operations. Do not let the engine run at low idling or high idling speed for more than 20 minutes without interruption.
Page 222 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS (A) Correct temperature: blue bottom of warning light (C) (B) Low temperature: white bottom of warning light (C) If the coolant temperature warning light displays the correct temperature, the engine warming operation is finished. After checking the status of the temperature warning light of the engine coolant, check the hydraulic system warming operation.
Page 223 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Warming the hydraulic system WARNING q When warming up the hydraulic system, check that no persons or obstacles are in the surrounding area, blow the horn and begin to work. q Warming up the hydraulic fluid is necessary also for the circuit between the pump and the cylinders, between the pump and the engine and also for the control circuits.
Page 224 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 3. Move the safety lever (2) to FREE position (F) and lift the bucket from the ground. 4. Turn the fuel grip (3) halfway between the MIN and MAX positions. NOTICE During the retraction movement, check that the working tools do not interfere with the body of the machine or the ground.
Page 225 13. Check that the colour of exhaust gases, noises and vibrations return to normal. In case of any problem, contact your Komatsu distributor. In harsh weather conditions (ambient temperature below 0 °C), even if the hydraulic fluid temperature warning light indicates the correct temperature, repeat the operation in point 14 to warm the whole hydraulic system.
Page 226 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS If the temperature is normal or low, perform the operation indicated below. 15. Check that the fuel grip (3) is halfway between the MIN and the MAX positions. If it is not, bring it to central position and cause the engine to run at average speed.
Page 227 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS q Blade Lifting (a)  Lowering (b) q Select the corresponding working mode for each accessory. q Accessories activation 17. Check that the hydraulic fluid temperature warning light (6) shows the correct temperature. If the hydraulic fluid temperature warning light displays a temperature that is too low, repeat points 5 to 9 until the correct temperature is displayed.
Page 228 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS More operations once warming operations have finished 1. Check that the hydraulic fluid temperature warning light (6) shows the correct temperature. (A) Correct temperature: blue bottom of warning light (C) (B) Low temperature: white bottom of warning light (C) 2.
Page 229 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 3) L mode Lifting and positioning operations with maximum control. 4) B mode Operations with the breaker 5) ATT Mode Operations with the crusher or other double action accessories. 3-145 WEAM014802...
Page 230: Stopping The Engine
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS STOPPING THE ENGINE NOTICE q The engine stop under stress shortens the useful life. q Do not stop the engine under stress, unless in emergency cases. Do not stop the engine suddenly, except in case of emergency.
Page 231: How To Move The Machine
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS HOW TO MOVE THE MACHINE WARNING q Before moving the machine, make sure that you perfectly know the control functions and all the relevant safety regulations. q The operator must be seated in the driving position with fastened seat belt. q Before operating the travel levers, check the direction of the undercarriage.
Page 232 (3) slowly backward or press the bottom of the pedal (4) slowly to move the machine off. 4. Make sure that the travel alarm functions correctly. If the alarm does not sound, contact the Komatsu distributor, who will carry out all the necessary repair operations. REMARK In harsh weather conditions, if the travel speed of the machine is not normal, carry out warming operations....
Page 233 (3) slowly forward or press the top of the pedal (4) slowly to start moving in reverse. 4. Make sure that the travel alarm functions correctly. If the alarm does not sound, contact the Komatsu distributor, who will carry out all the necessary repair operations. REMARK In harsh weather conditions, if the travel speed of the machine is not normal, carry out warming operations....
Page 234: Steering The Machine
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS STEERING THE MACHINE Steering (changing direction) WARNING q Before operating the travel control levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levers is inverted. q Avoid abrupt changes of direction as much as possible.
Page 235 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Changing direction when the machine is moving When steering to the left: If the left travel lever is shifted back to the neutral position, the machine will steer to the left. (A) Forward left (B) Back left REMARK To steer to the right, operate the right travel lever in the same...
Page 236: Turret Rotation
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS TURRET ROTATION WARNING q The rear part of the machine extends over the length of the tracks. Before rotation operations check either directly or through the mirrors, that the surrounding area is safe. q When the autodeceleration function is active and the engine speed is low, if the control lever is operated, engine speed will increase abruptly;...
Page 237: Work Equipment Controls And Functions
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS WORK EQUIPMENT CONTROLS AND FUNCTIONS WARNING If the lever is operated when engine speed has been reduced by the autodeceleration function, engine speed will go up abruptly; therefore, the levers should be operated with care. Working tools are controlled by the levers positioned to the operator's right and left.
Page 238 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS q Bucket control Move the right lever left or right to operate the bucket. q Boom swing control Use the rotation control pedal to rotate the first boom. q Blade control Move the lever on the right of the operator's seat forward or backward to operate the blade.
Page 239: Work Mode
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS WORK MODE Use the working mode selector (1) to choose the most appropriate mode for the operating conditions or the kind of work to be done. Observe the following procedure to select the proper working mode. When the starter key is in ON, the working mode is the one set before the last shutdown.
Page 240: Unauthorized Operations
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS UNAUTHORIZED OPERATIONS WARNING q Do not attempt to operate the work equipment control levers during travel. q If it is necessary to operate the work equipment control levers while the machine is moving, carry out this operation with the maximum care.
Page 241 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Especially when the crusher or other large accessories are used, if the movements reach the end of the stroke, the pins around the bucket and the bucket cylinder pin may be subject to excess loads and may break.
Page 242 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Abrupt operation of levers and pedals when driving at high speed 1. If you wish to move the machine fast, do not operate the levers or pedals abruptly or perform any other operation. 2.
Page 243: Precautions For Use
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS PRECAUTIONS FOR USE Travel function Travelling on big stones, logs or other obstacles subjects the frame and in particular the tracks to considerable strain, which damages the machine. For this reason, it is always advisable to remove any obstacles or to avoid them, if possible.
Page 244 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Avoid bumping the blade Be careful not to hit the blade against rocks or boulders, since this may damage the blade or the cylinders. Blade position during digging operations When carrying out deep digging operations with the blade at the front, be careful to prevent the boom cylinder from hitting the blade.
Page 245: Precautions To Be Taken When Travelling On Slopes
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES WARNING q When travelling downhill on steep slopes, slow down using the travel levers and the hand accelerator. Do not travel downhill on slopes whose inclination exceeds 15°. q Swinging or using the work equipment on slopes may cause the machine to lose stability and overturn, therefore it is advisable to avoid these operations.
Page 246 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 2. When travelling uphill on a slope, position the work equipment as shown in the diagram on the right. Braking when travelling downhill To brake when travelling downhill, shift the travel levers to the neutral position. This will automatically engage the brakes.
Page 247: Getting The Machine Out Of Mud
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS GETTING THE MACHINE OUT OF MUD Always proceed carefully to avoid getting stuck in mud. However, if the machine gets stuck in mud, proceed as indicated below. When one side only gets stuck NOTICE When the 1st or 2nd boom is used to lift the machine, always place the lower part of the bucket in contact with...
Page 248: Operations That Can Be Performed With The Hydraulic Excavator
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR In addition to those listed below, numerous other applications are possible through the use of optional equipment. Digging with reversed bucket When the machine is in the position shown in the diagram on the right, the maximum digging and thrusting force of each cylinder is achieved when the bucket cylinder and its articulated joint, the arm cylinder and the arm are at 90°...
Page 249 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS Loading operations In locations where the angle of rotation is reduced, the operational efficiency can be increased by placing the truck in such a way that it is visible to the Operator. Loading operations are easier and the loading capacity greater if the excavator loads from the rear of the truck rather from than the side.
Page 250: Lifting Objects With Lifting Device
The owner and operators must be familiar with all legal guidelines and regulations that govern the use of the equipment both as an earth moving machine and as a load handling machine. Contact the Komatsu distributor for further information. q Before proceeding with load handling, ensure that there are no persons in the machine's operational range and signal the beginning of the working operation by sounding the acoustic alarm.
Page 251 It is forbidden to weld hooks or ears to the bottom of the bucket. q If the machine is not equipped with the appropriate hook, contact the Komatsu distributor. q Fitting a lifting hook must be monitored and certified by the competent Authorised Body q It is forbidden to exceed the lifting load limits specified in the machine diagrams....
Page 252 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS LIFTING CAPACITIES TABLES DANGER The excavator used in handling operations must conform with current local regulations and be equipped with safety valves and an overload alarm in compliance with EN 474-5. WARNING The load does not exceed 87% of the hydraulic lifting capacity or 75% of the tipping limit.
Page 253: Bucket Replacement And Inversion
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS BUCKET REPLACEMENT AND INVERSION WARNING q When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet. q The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during work.
Page 254: Parking The Machine
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS PARKING THE MACHINE WARNING q Avoid stopping machine abruptly. Always calculate a sufficient safety distance when stopping. q Park the machine on firm and level ground. Avoid parking the machine on slopes. If it is absolutely necessary to park the machine on a slope, put blocks under the tracks and thrust the work equipment into the ground to prevent the machine from moving.
Page 255: Checks To Be Carried Out Before Stopping The Engine
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 5. Shift the safety lever (2) to the LOCK position (L). CHECKS TO BE CARRIED OUT BEFORE STOPPING THE ENGINE Check the engine coolant temperature (1), the engine oil pressure (2) and the fuel level (3) on the machine monitor. 3-171 WEAM014802...
Page 256: Checks To Be Carried Out After Work
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS CHECKS TO BE CARRIED OUT AFTER WORK 1. Carry out a visual check of the work equipment and the undercarriage from the outside, verifying also if there are oil or water leakages. If any anomaly is observed, provide for the necessary repairs. 2.
Page 257: Road Liners
FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS ROAD LINERS Information on the road liners The road liners have exceptional characteristics that cannot be found in steel tracks. However, if they are used as if they were steel tracks, it is impossible to exploit all the advantages they offer. Do not subject the road liners to excessive stress and always take in consideration the conditions of the worksite and the nature of the operations to be performed.
Page 258 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS q Do not use the machine lifting one track only by means of the work equipment. This damages the road liner and may also cause them to come off. q When the rubber parts of the road liners are worn out or damaged to the extent that the head of the bolts is scratched, change the road liner immediately.
Page 259 FUNCTIONING USE OF THE MACHINE AND RELATED CONTROLS 2. When travelling uphill in reverse, avoid steering at the beginning of the slope. If this is absolutely necessary, carry out the manoeuvre gradually. 3. Avoid traveling along the edge of slopes or on rough ground with one track raised (machine inclination exceeding 10°) and with the other track on flat ground.
Page 260: Transportation
FUNCTIONING TRANSPORTATION TRANSPORTATION When transporting the machine, observe all the laws and regulations in force, paying special attention to safety. TRANSPORT PROCEDURE As a general rule, the machine must be transported on a trailer. Choose the trailer according to the weight and dimensions of the machine indicated in paragraph "SPECIFICATIONS (5-2)"....
Page 261: Loading And Unloading The Machine
FUNCTIONING TRANSPORTATION LOADING AND UNLOADING THE MACHINE WARNING q During loading and unloading operations, make sure that the low travel speed is selected (“Lo” warning light on) and always travel at low speed. q During loading and unloading operations, let the engine idle, reduce speed and operate the machine slowly.
Page 262 FUNCTIONING TRANSPORTATION During the loading and unloading operations, always use ramps or a platform and proceed as indicated below. Loading the machine REMARK Load and unload the machine on/from the truck/trailer only on firm and level ground. Keep a safety distance from the edge of the road. 1.
Page 263 FUNCTIONING TRANSPORTATION 6. Stop the machine where requested, then slowly rotate the turret of 180°. Securing the machine on the means of transport After positioning the machine on the trailer, it is necessary to secure it by proceeding as indicated below. NOTICE q Keep the aerial and the other components.
Page 264 FUNCTIONING TRANSPORTATION Release REMARK Load and unload the machine on/from the truck/trailer only on firm and level ground. Keep a safety distance from the edge of the road. 1. Engage the trailer brakes and insert the wedges (1) under the wheels to prevent it from moving. 2.
Page 265 FUNCTIONING TRANSPORTATION 8. Lift the working tools, retract the arm under the boom and move the machine slowly. 9. Once the machine is in horizontal position on the rear wheels of the trailer, stop the machine. NOTICE q When the machine is unloaded, the boom and the arm must be at an angle between 90°...
Page 266: Lifting The Machine
The lifting procedure is valid only for standard machines. The lifting method changes depending on the accessories and optional equipment installed on the machine. In case of machines with different specifications, contact your Komatsu distributor for more detailed information.
Page 267 FUNCTIONING TRANSPORTATION 6. Pass the metal cables between the first and the second carrier roller starting from the front, and between the first and the second carrier roller starting from the back. 7. Place the wooden blocks between the cables of metal and the machine to avoid them both getting damaged.
Page 268: Using The Machine In The Cold Season
"CLEANING OF THE COOLING SYSTEM AND CHANGING THE COOLANT (4-80)". 2. Do not mix different brands of antifreeze. 3. If there are doubts about the coolant standard, refer to the Komatsu distributor to have more accurate information. Battery WARNING q The battery produces flammable gas, therefore keep flames and sparks away from it.
Page 269 FUNCTIONING USING THE MACHINE IN THE COLD SEASON When the ambient temperature drops, the capacity of the battery decreases accordingly. If the battery charge is low, the electrolyte may freeze. Keep the battery charge level as high as possible and insulate the battery against excessively low temperatures, in such a way as to be able to start the machine easily when starting work in the morning.
Page 270: Precautions To Be Taken Every Day At The End Of Work
FUNCTIONING USING THE MACHINE IN THE COLD SEASON PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK DANGER Spinning the tracks is dangerous; when performing this operation pay the utmost attention that no one comes close to the machine. q To prevent the mud and water present on the undercarriage from freezing, thus making it impossible to move the machine the following morning, always take the following precautions.
Page 271: Long Periods Of Inactivity
FUNCTIONING LONG PERIODS OF INACTIVITY LONG PERIODS OF INACTIVITY BEFORE A PERIOD OF INACTIVITY NOTICE q To protect the cylinder rods when the machine is not used, position the work equipment as shown in the figure.  (This serves to prevent the cylinder rods from rusting). q Before removing the battery, stop the engine, wait at least one minute, and afterwards turn the battery main switch to OFF and extract the specific key.
Page 272: Recommendations For Machines Equipped With Komtrax System During Long Periods Of Inactivity
White: the battery must be replaced. AFTER A PERIOD OF INACTIVITY NOTICE If the machine is stored without the monthly antirust treatment, contact the Komatsu distributor for maintenance. Before using the machine after a long period of inactivity, carry out the operations listed below.
Page 273: Engine Start-Up After Prolonged Inactivity
FUNCTIONING LONG PERIODS OF INACTIVITY ENGINE START-UP AFTER PROLONGED INACTIVITY When the engine is started after prolonged inactivity, accurately perform the warming operations. For more details, see "Warming the engine (3-137)". ALLOWED AMBIENT TEMPERATURE RANGE DURING THE OPERATION AND STORAGE OF THE MACHINE FOR A LONG TIME The recommended ambient temperature range for operation and long term storage is -20°C to +45°C.
Page 274: Troubleshooting
FUNCTIONING TROUBLESHOOTING TROUBLESHOOTING IF FUEL RUNS OUT COMPLETELY Before starting the engine after running out of fuel, refuel and bleed the fuel system. Air vent procedure 1. Loosen the grip of the supply pump (1), take it out and pump until the movement becomes difficult. REMARK It is not necessary to remove the cap on the upper part of the pre-filter and the fuel main filter.
Page 275: Removing The Machine
FUNCTIONING TROUBLESHOOTING REMOVING THE MACHINE WARNING q When removing the machine, use a metal cable suitable for the weight of the machine to be removed. For more details, see "SAFETY RULES FOR TOWING (2-46)". q Do not apply sudden loads to the cable. When the machine is stuck in mud and cannot get out with its own power, or in case of failure, before removing it pass wire cables around the central part of the undercarriage, as shown...
Page 276: If The Battery Is Down
FUNCTIONING TROUBLESHOOTING IF THE BATTERY IS DOWN WARNING q It is dangerous to charge the battery when it is installed in the machine. Always remove it before recharge. q Before any operation related to the battery, stop the engine, wait at least one minute, and afterwards turn the battery main switch to OFF and extract the specific key.
Page 277 FUNCTIONING TROUBLESHOOTING Removing and installing the battery WARNING q Before removing the battery, stop the engine, wait at least one minute, and afterwards turn the battery main switch to OFF and extract the specific key. If a tool is touching the positive terminal and the machine structure at the same time, there is risk of sparking.
Page 278 FUNCTIONING TROUBLESHOOTING Charging the battery When charging the battery, always follow the instructions given in paragraph "IF THE BATTERY IS DOWN (3-192)" and in the user's manual of the battery charger, and proceed as indicated below. q During recharge the battery produces hydrogen, which is flammable and may explode, therefore for this operation it is necessary to remove the battery from the machine, position it in a well ventilated place and remove the caps...
Page 279 FUNCTIONING TROUBLESHOOTING Starting with booster cables When starting the engine with booster cables, proceed as indicated below. Connecting and disconnecting the booster cables WARNING q When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (–).
Page 280 FUNCTIONING TROUBLESHOOTING Connecting the booster cables Before connecting the batteries via additional cables, make sure that the starter key of both the machines and the battery main switch of the machine to be started are turned to OFF. Connect the additional cables as instructed below and observing the order number in the diagram.
Page 281: Other Troubles
Electrical circuit q ( ): Always contact the Komatsu distributor when you must carry out these operations. q If the anomaly or its cause is not included in the table below, contact your Komatsu distributor for the necessary repair. TROUBLE...
Page 282 TROUBLESHOOTING Frame q ( ): Always contact the Komatsu distributor when you must carry out these operations. q If the anomaly or its cause is not included in the table below, contact your Komatsu distributor for the necessary repair. TROUBLE...
Page 283 TROUBLESHOOTING Engine q ( ): Always contact the Komatsu distributor when you must carry out these operations. q If the anomaly or its cause is not included in the table below, contact your Komatsu distributor for the necessary repair. TROUBLE...
Page 284 FUNCTIONING TROUBLESHOOTING TROUBLE CAUSE SOLUTION q Fuel with low cetane rating. q Change with fuel in compliance with standards. q Overheating. q See pag. 3-12. Abnormal noises (during combustion q Inside of exhaust silencer q Change exhaust silencer. or in mechanical parts). damaged.
Page 285 FUNCTIONING TROUBLESHOOTING Electronic control system If an error code is shown on the display of the machine, implement the countermeasures indicated in the following self- diagnosis table. Machine monitoring system Error code Error type Counteraction When the operation switch of the emergency pump is in the emergency position (high), the Pump control system error regular operations can be performed but the...
Page 286 If the monitor displays an error screen, a telephone number is shown on the same window. REMARK If there is no number registered, no number will be displayed. The telephone number must be registered; therefore, request your Komatsu distributor to do it. 3-202 WEAM014802...
Page 287 MAINTENANCE 1T:<n+> WARNING Before reading this section, make sure you have read and understood the section on safety. WEAM014802...
Page 288: Guide To Maintenance
Check the hour meter every day to verify if it is necessary to carry out any maintenance operation. Komatsu genuine spare parts Use original Komatsu parts specified in the Spare Parts catalogue. To ensure safe assembly and operation of the machine, we recommend the use of original Komatsu spare parts.
Page 289 Control of oils and worn filters When changing oils or filters, check if metal particles are present. If there are large quantities of metal particles, contact your Komatsu distributor. Fuel filter If the machine is provided with a fuel filter in the filler neck, do not remove it while refuelling.
Page 290 MAINTENANCE GUIDE TO MAINTENANCE Bleeding the hydraulic system After repairing or replacing the hydraulic equipment or after removing the hydraulic piping, it is necessary to bleed the air from the circuit. (See "BLEEDING THE HYDRAULIC SYSTEM (4-41)"). Hydraulic hose assembly q Keep naked flames away from these fluids and avoid smoking.
Page 291: Maintenance Notes
Maintain the prescribed levels when topping up the oil. Too much or too little oil can cause malfunctions. q If the oil in the working equipment is not clear, there is probably water or air in the circuit. Contact Komatsu distributor.
Page 292 2 years or 2000 hours. As a general rule, we do not recommend the use of refrigerants different than Supercoolant Komatsu (AF- NAC). If another coolant is used, you may experience problems such as corrosion of the engine and the aluminium components of the cooling system.
Page 293 MAINTENANCE GUIDE TO MAINTENANCE Grease q Grease is used to prevent seizing and noise related to the joints. q These construction equipment are used in heavy working conditions. Always use the recommended grease and adhere to the replacement intervals as well as the ambient temperatures recommended in this manual. q The greased parts not covered by the maintenance section must be lubricated during servicing, therefore they need to be lubricated.
Page 294: Kowa (Komatsu Oil Wear Analysis)
Many years of experience and the availability of countless data and information allow Komatsu to accurately determine the conditions of the machine. This also allows us to locate troubles and suggest the most suitable and fast repair solutions.
Page 295: Storing Oil And Fuel
External electromagnetic interference may cause a malfunction of the controller of the control system; before installing a radio receiver or any other wireless tools, contact Komatsu distributor. q Do not connect any optional device to the fuses, ignition switch, battery, relays, etc.; for the installation of any optional equipment, contact your Komatsu distributor.
Page 296: Notes On The Maintenance Of The Hydraulic System
MAINTENANCE GUIDE TO MAINTENANCE NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM q Be extremely careful when performing maintenance operations on the hydraulic system, since soon after work the oil is very hot. The circuit is pressurized not only during work, but also at the end of work. q The maintenance operations required for the hydraulic system are the following: Q Daily check of the oil level in the tank.
Page 297: Parts Subject To Wear
Thanks to the continued commitment of Komatsu intent on improving the quality of the product, the spare parts code may change, therefore the serial number of the machine should be given to the Komatsu distributor in order to receive the latest version of the component.
Page 298: Fuel, Coolant And Lubricants
MAINTENANCE FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS Ambient temperature (°C) Fluid recommended Topping up Fluid type by Komatsu Min. Max. – 20 KomatsuEO10W30DH Engine oil pan Engine oil – 15 Komatsu EO15W40DH Komatsu EO30DH Final reduction gears Transmission oil...
Page 299: Recommended Brands, Quality Recommended For Products Different Than Original Komatsu Oil
In the areas where freezing is not a problem, it is essential to use of an antifreeze coolant. All Komatsu equipment are supplied with Komatsu Supercoolant coolant (AF-NAC). The Supercoolant Komatsu (AF-NAC) has high anticorrosion, antifreeze and coolant properties, so it can be used regularly for 2 years or 2000 hours....
Page 300: Approved Synthetic Biodegradable Lubricants Type Hees
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended: Supplier Synthetic biodegradable oil HEES KOMATSU BO 46 G4 (KES 07.872) AGIP —...
Page 301: Tightening Torques
If it is necessary to replace a screw or a nut, always use Komatsu original spare parts having the same size of the part to be replaced. q Nm (Newton metre): 1 Nm = 0.102 kgm...
Page 302: Standard Tightening Torques For Flexible Hoses (Orfs)
If not specified otherwise, tighten the nuts of the hoses applying the torque specified in the table. If it is necessary to replace a hose, always use Komatsu original spare parts having the same size of the part to be replaced.
Page 303: Lubrication
MAINTENANCE LUBRICATION LUBRICATION LUBRICATION DIAGRAM NOTICE q For details on how to lubricate specific parts, see "LUBRICATION (4-45)" - "LUBRICATION (4-54)". q The type of lubricant to be used is indicated in the lubricant table (see "FUEL, COOLANT AND LUBRICANTS (4-12)"). BOOM Grease Filter...
Page 304: 2-Piece Boom
MAINTENANCE LUBRICATION 2-PIECE BOOM Grease Filter 4-18 WEAM014802...
Page 305: Periodical Change Of Safety-Related Components
MAINTENANCE PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS To ensure safety at any moment while driving and using the machine, the operator must carry out all the routine maintenance operations prescribed. Furthermore, the operator must periodically change the components indicated in the table in the following page, which are especially related to safety and fire-prevention rules.
Page 306: Safety-Related Parts
MAINTENANCE PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS SAFETY-RELATED PARTS Safety-related components that periodically need changing Q.ty Change interval Fuel pipe (fuel tank - injection pump) Fuel return pipe (return - fuel coolant intake hole) Fuel coolant return pipe (fuel coolant outlet hole - fuel tank) Pump outlet pipe (pump - delivery pipe check valve) Pump outlet pipe (pump - PP pipe check valve) Pump outlet pipe (pump - LS pipe check valve)
Page 307: Maintenance Plan
MAINTENANCE MAINTENANCE PLAN MAINTENANCE PLAN If the machine is equipped with hydraulic breaker, the maintenance schedule for some components will be different. For further details, see "MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER (4-23)". MAINTENANCE PLAN WHEN REQUIRED CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE ..................
Page 308: Maintenance Plan
MAINTENANCE MAINTENANCE PLAN ENGINE EXHAUST PIPE TIGHTENING CLAMPS CHECK ......................4-73 MAINTENANCE EVERY 2000 HOURS OF OPERATION CHANGING THE OIL IN THE SWING REDUCTION GEAR ......................4-74 CHANGING THE OIL IN THE FINAL REDUCTION GEARS......................4-76 CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER...................4-77 CLEANING OF THE COOLING SYSTEM AND CHANGING THE COOLANT ................4-80 CHECKING THE ALTERNATOR AND THE STARTER ........................4-83 CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ....................4-83...
Page 309: Maintenance Intervals In Case Of Use Of The Hydraulic Breaker
MAINTENANCE MAINTENANCE PLAN MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER The hydraulic oil used in the machines provided with hydraulic breaker deteriorates more quickly than the oil used in normal digging machines, therefore it is advisable to respect the following maintenance plan. CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100–150 hours of operation and for the successive changes keep to the...
Page 310: Maintenance Procedures
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE PROCEDURES WHEN REQUIRED CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE WARNING q Remove the air filter only after stopping the engine and do not start the engine if the air filter is open. q When compressed air is used to clean the filter, dust may get into the eyes. Wear safety goggles and a dust mask during the cleaning operations.
Page 311 MAINTENANCE MAINTENANCE PROCEDURES 3. Remove the external cartridge (4). REMARK Never remove the safety cartridge (5) as the dust damages the engine. 4. Clean inside the air filter body and the cover (3). NOTICE When cleaning the cover (3), do not remove the exhaust valve (6).
Page 312 MAINTENANCE MAINTENANCE PROCEDURES 8. Put the clean filter in position, install the cover (3) and lock the couplings (2). CAUTION Check the O-ring (7) condition before installing the cover (3); replace it if damaged. 9. Press the button on the filter clogging indicator (1) so that the red piston returns to its original position.
Page 313 MAINTENANCE MAINTENANCE PROCEDURES 3. Remove the external cartridge (4). REMARK Never remove the safety cartridge (5) as the dust damages the engine. 4. Clean inside the air filter body and the cover (3). NOTICE When cleaning the cover (3), do not remove the exhaust valve (6).
Page 314: Shoe Fixing Screws Check And Tightening
MAINTENANCE MAINTENANCE PROCEDURES SHOE FIXING SCREWS CHECK AND TIGHTENING WARNING q To compensate for the inevitable settling movements, it is indispensable to check the tightening torque of the screws (1) after the first 30 hours of operation.  Carry out another check after the first 100 hours of running-in and, if the screws have become loose again, repeat the check after 200 hours of operation.
Page 315: Checking And Adjusting The Track Tension
Do not loose any component apart from the valve (4). If the trac k tension doe s not decre ase a fter this operation, contact your Komatsu distributor. CAUTION If the resistance met when injecting the grease is excessive, move the machine forward and backward covering a short distance.
Page 316 It is extremely dangerous to let the grease out following any procedure different from those illustrated below. q If the track tension cannot be reduced with this operation, contact your Komatsu distributor, who will provide for the necessary repairs.
Page 317: Checks The Road Liners
If “a” is less then 5 mm, change the track. CHANGING THE ROAD LINERS q If it is necessary to change all the road liners, contact your Komatsu distributor, who will carry out the necessary operations. q When, on the other hand, only some road liners must be changed, use the special tool that can be required to Komatsu distributor.
Page 318: Bucket Teeth Replacement
If it is impossible to remove the teeth using this procedure, for safety reasons, it is advisable to have the tooth removed by a Komatsu distributor. Replace the bucket teeth before the adapter starts to wear. 1. Place the lower surface of the bucket on a block (5) and make sure the working tools are in a stable position.
Page 319 MAINTENANCE MAINTENANCE PROCEDURES 4. After ejecting the pin (1), remove the tooth (2) and the ring (3). 5. Clean the mounting surfaces and insert the ring (3) in the slot of the tooth holder (4). 6. Insert a new tooth (2) in the adapter, partially finger tighten the pin (1), then fit it with a hammer and lock the tooth on the bucket.
Page 320: Checking The Windshield Fluid Level And Topping Up
MAINTENANCE MAINTENANCE PROCEDURES CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING UP The reservoir (1) is positioned in the side cover and contains detergent for the front windshield; make sure that the reservoir is always full. If necessary, add non-flammable detergent an ethyl alcohol based of the type used for cars....
Page 321: Air Conditioner Maintenance And Checking
(C) - Without colour, transparent: no coolant. REMARK When bubbles are detected, the refrigerant gas level is low; therefore, contact the Komatsu distributor for topping up. If the conditioner is used even when the coolant level is low, the compressor may result damaged.
Page 322 MAINTENANCE MAINTENANCE PROCEDURES Check and maintenance operations Elements to check and Kind of check and kind of maintenance Maintenance interval maintenance operations Twice a year (spring, Coolant gas Quantity autumn) Condenser Clogged fins Every 500 hours Compressor Operating conditions Every 4000 hours V-belt Damages, tension Every 250 hours...
Page 323: Checking, Cleaning And Lubricating The Guide Of The Cab Sliding Door
1. Spray the lubricant on the guide (1) and on the roller (2) uniformly. 2. After lubrication, slide the door and make sure that it can be easily opened and closed. If it is still difficult to move the door, contact your Komatsu distributor for the necessary repairs. 4-37 WEAM014802...
Page 324: Washing The Floor
MAINTENANCE MAINTENANCE PROCEDURES WASHING THE FLOOR The floor can be washed with water. WARNING q When the machine is inclined, use blocks to stabilize it and carry out the necessary operations very carefully. q If the control levers are inadvertently touched, the work equipment or the machine may move suddenly and cause serious accidents.
Page 325 MAINTENANCE MAINTENANCE PROCEDURES Washing 1. Incline the machine.  For more details, see "How to incline the machine (4-38)". 2. Swing the revolving frame slowly, so that the water draining hole (1) on the cab floor is positioned on the lower side.
Page 326: Gas Spring Check
Do not drill or weld the gas spring, do not use oxy-hydrogen flames. q Do not hit, crush or knock the gas spring. q The gas must be released when disposing of the gas spring. Refer to Komatsu distributor to have this operation carried out.
Page 327: Bleeding The Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURES BLEEDING THE HYDRAULIC SYSTEM For further details, see "Starting the engine (3-130)". If it is necessary to refer to the engine starting operations, to the machine steering or stopping procedure, see section "FUNCTIONING". Bleeding the pump NOTICE If the pump is operated without filling it with hydraulic oil, it may be damaged.
Page 328 MAINTENANCE MAINTENANCE PROCEDURES Bleeding the swing motor REMARK Carry out this operation only after completely draining the oil in the swing motor housing. NOTICE If the swing motor is not bled, the motor bearings may be damaged. 1. Remove the cover (1) placed between the hydraulic oil tank and the cab.
Page 329 MAINTENANCE MAINTENANCE PROCEDURES 2. Let the engine idle and turn the work equipment 90° to move them to the side of the track. 3. Force the first boom until the track is lifted from the ground, spin the track for two minutes. Repeat this procedure on both the left and right side of the machine.
Page 330: Checks To Be Carried Out Before Starting The Engine
WARNING Dirt, oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires. Check frequently and repair any leakage immediately; if they occur repeatedly, contact your Komatsu distributor. For details on the following items, see "Checks performed before starting the engine (3-111)".
Page 331: Maintenance Every 100 Hours Of Operation
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE EVERY 100 HOURS OF OPERATION LUBRICATION NOTICE q Clean the grease nipples before applying the greasing pump. q After lubrication, remove all the contaminated grease that may have spread out of the nipples. q If the machine is used in difficult conditions, carry out this operation more frequently than usual. q As a general rule, it is important to consider that each cylinder is provided with two grease nipples positioned on the couplings and that each pin serving as fulcrum point for a movement is provided with at least one grease nipple.
Page 332: Top-Up And Level Check For The Rotation Reduction Unit Oil
MAINTENANCE MAINTENANCE PROCEDURES TOP-UP AND LEVEL CHECK FOR THE ROTATION REDUCTION UNIT OIL WARNING q Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40–45°C before draining the oil. q The operation must be carried out with the machine positioned on firm and level ground.
Page 333: Maintenance Every 250 Hours Of Operation
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE EVERY 250 HOURS OF OPERATION CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS AND TOPPING UP WARNING q Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40–45°C before draining the oil.
Page 334: Battery Electrolyte Level Check
MAINTENANCE MAINTENANCE PROCEDURES BATTERY ELECTROLYTE LEVEL CHECK WARNING q Carry out this check with the machine parked on level ground. q Check the level only when the engine is stopped and, if necessary, add distilled water only before starting the operations. q Always wear protective goggles and waterproof gloves.
Page 335 Komatsu distributor or the battery manufacturer. 6. After topping up, screw in the plug (2).
Page 336 If the distilled water added goes over the MAXIMUM reference mark, take out excess electrolyte with a small pump and neutralise it with sodium bicarbonate, then rinse out with abundant running water or consult the Komatsu distributor or the battery manufacturer. Whenever possible, use an indicator to check electrolyte level If an indicator can be used to check electrolyte level, proceed as indicated below.
Page 337: Checking And Adjusting The Fan Belt Tension
MAINTENANCE MAINTENANCE PROCEDURES CHECKING AND ADJUSTING THE FAN BELT TENSION WARNING Soon after the machine has been stopped the engine is very hot and may cause burns; let the engine cool down to 40-45 °C before carrying out any check. Checking the cartridge 1.
Page 338: Checking And Adjusting The Air Conditioner Compressor Belt Tension
If the belt is stretched and there is no allowance for adjustment, or if it is cut or cracked, please contact Komatsu distributor for replacement. CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION WARNING q Soon after the machine has been stopped the engine is very hot and may cause burns; let the engine cool down to 40-45 °C before carrying out any check.
Page 339 NOTICE Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu service engineer unless specific instructions are given in this manual. Adjustment 1. Loosen the screws (1) and (2).
Page 340: Maintenance After The First 500 Hours Of Operation
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil HEES is used) The following maintenance operation must be carried out after the first 500 hours of operation, together with the maintenance operations to be carried out every 500 hours.
Page 341 MAINTENANCE MAINTENANCE PROCEDURES Boom swing coupling pin (2 points) Boom swing cylinder base pin (1 point) Boom swing cylinder head pin (1 point) Boom swing lifting cylinder base pin (1 point) Boom swing lifting cylinder head pin (1 point) 4-55 WEAM014802...
Page 342 MAINTENANCE MAINTENANCE PROCEDURES Arm cylinder base pin (1 point) Arm cylinder head pin (1 point) Bucket cylinder base pin (1 point) (10) Bucket cylinder head pin (1 point) (11) Arm pin (1 point) 4-56 WEAM014802...
Page 343 MAINTENANCE MAINTENANCE PROCEDURES (12) Arm-bucket connection pin (1 point) (13) Fulcrum link pin (5 points) (14) Blade coupling pin (2 points) (15) Blade cylinder base pin (1 point) (16) Blade cylinder head pin (1 point) 4-57 WEAM014802...
Page 344 MAINTENANCE MAINTENANCE PROCEDURES POSITIONING BOOM LUBRICATION (if installed) Arm-bucket coupling pin (1 point) Fulcrum link pin (1 point) Bucket cylinder base pin (1 point) Boom-arm coupling pin (1 point) Arm cylinder head pin (1 point) Arm cylinder base pin (2 points) Boom cylinder head pin and two-piece boom articultaion (3 points) Two-piece boom cylinder head pin (1 point) Two-piece boom cylinder base pin (1 point)
Page 345: Changing The Engine Oil And The Engine Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURES CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE WARNING q Change the oil with the machine parked on a level surface and the work equipment resting on the ground. q Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40–45°C before draining the oil.
Page 346: Replacement Of Fuel Pre-Filter Cartridge
NOTICE q Komatsu original filter cartridges have a special filter with a high filtering capacity. When a filter cartridge is replaced, always use Komatsu original components. q The common rail injection system of this machine consists of very accurate components with respect to the conventional pump-injection systems....
Page 347 MAINTENANCE MAINTENANCE PROCEDURES 8. During installation, apply some oil on the sealing surface and bring it in contact with filter cartridge sealing surface (4). 9. Tighten the transparent sump (3) by 1/4 - 1/2 of a turn. REMARK q Do not tighten the transparent cap in an excessive way to avoid damaging the O-ring, as this might cause fuel leakage.
Page 348 MAINTENANCE MAINTENANCE PROCEDURES 12. Check that the discharge valve (2) is tightly closed. 13. Place the valve (1) next to fuel pre-filter cartridge at open position (O). 14. After replacing the filter cartridge (4), bleed the air as described below. 15.
Page 349: Checking The Grease Level In The Ball-Bearing Ring Pinion And Topping Up
(3). 3. Check the grease. 4. If the grease is milky white, change it. To carry out this operation, contact your Komatsu distributor. 5. Install the grease filler cover (3). 6. Install the cover (1). RKA35920...
Page 350: Cleaning And Inspection Of The Radiator Fins, Oil Cooler, Final Cooler, Fuel And Air Conditioner Condenser Cooler
MAINTENANCE MAINTENANCE PROCEDURES CLEANING AND INSPECTION OF THE RADIATOR FINS, OIL COOLER, FINAL COOLER, FUEL AND AIR CONDITIONER CONDENSER COOLER WARNING If compressed air, steam or water are directed on a person they can cause injuries. Always wear safety glasses and gloves. NOTICE q When using compressed air, always keep the nozzle at a safety distance, in order to avoid damaging the fins.
Page 351: Cleaning The Air Conditioner Filters
MAINTENANCE MAINTENANCE PROCEDURES CLEANING THE AIR CONDITIONER FILTERS WARNING q When compressed air is used to clean the filter, dust may get into the eyes. Wear safety goggles and a dust mask during the cleaning operations. q Before cleaning the fresh or recirculation air filter, always check that the sliding door is locked in closed or open position.
Page 352: Hydraulic Reservoir Bleed Device Replacement
MAINTENANCE MAINTENANCE PROCEDURES HYDRAULIC RESERVOIR BLEED DEVICE REPLACEMENT WARNING q Immediately after the engine stops, the components and the oil are at high temperature and may cause burns. Before starting operating, wait till the temperature goes down. q When the cap of the oil filler is removed, turn it slowly to release the internal pressure. 1.
Page 353: Draining The Hydraulic Oil Tank
MAINTENANCE MAINTENANCE PROCEDURES DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used) WARNING q Retract the arm and bucket cylinders completely, rest the bucket teeth on the ground and, after stopping the engine, eliminate the residual pressures from the equipment (by shifting the controls more than once) and from the tank (by slowly loosening the filler cap).
Page 354 MAINTENANCE MAINTENANCE PROCEDURES 2. Open the lock (2). 3. Loosen the oil filler cap (3) slowly. 4. Remove the drain plug (P) and let all the condensate flow out of the tank. Collect the condensate in a container with suitable capacity. 5.
Page 355: Maintenance Every 1000 Hours Of Operation
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE EVERY 1000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS. CHANGING THE HYDRAULIC OIL FILTER WARNING q Soon after the machine has been stopped, the hydraulic oil is very hot and may cause burns; let it cool down to 40–45°...
Page 356 MAINTENANCE MAINTENANCE PROCEDURES 1. Open the side cover (1). 2. Open the lock (2). 3. Loosen the cap (3) slowly to release any residual pressure from tank. 4. Remove the cover (4). REMARK During this operation, the cover is pushed upward by the spring (5);...
Page 357: Changing The Fuel Filter Cartridge
NOTICE q Komatsu original filter cartridges have a special filter with a high filtering capacity. When a filter cartridge is replaced, always use Komatsu original components. q The common rail injection system of this machine consists of very accurate components with respect to the conventional pump-injection systems....
Page 358 MAINTENANCE MAINTENANCE PROCEDURES q Replace the gasket (3). NOTICE q Do not refill the new cartridge with fuel oil. q Remove the cap (B) before installing the new cartridge. 7. Tighten the cartridge until the gasket makes contact with the sealing surface, then give a further 3/4 turn. NOTICE Do not use the wrench to lock the filter, in order to avoid damaging the filter itself and causing fuel leakages.
Page 359: Engine Exhaust Pipe Tightening Clamps Check
MAINTENANCE MAINTENANCE PROCEDURES ENGINE EXHAUST PIPE TIGHTENING CLAMPS CHECK Contact Komatsu distributor to check the tightening of the clamps of air filter - turbocompressor - final cooler - engine. 4-73 WEAM014802...
Page 360: Maintenance Every 2000 Hours Of Operation
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS and every 1000 HOURS. CHANGING THE OIL IN THE SWING REDUCTION GEAR WARNING q Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40–45°C before draining the oil.
Page 361 MAINTENANCE MAINTENANCE PROCEDURES 4. Place a container under the hose (3) and remove the oil drain plug (4). 5. Refit the plug (4), making sure the gasket is intact. 6. Remove the dipstick (G) and proceed with the filling. Use oil of the prescribed type (for details see "FUEL, COOLANT AND LUBRICANTS (4-12)").
Page 362: Changing The Oil In The Final Reduction Gears
MAINTENANCE MAINTENANCE PROCEDURES CHANGING THE OIL IN THE FINAL REDUCTION GEARS WARNING q Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40–45°C before draining the oil. q Loosen the cap slowly to release any residual pressure.
Page 363: Changing The Hydraulic Oil And Cleaning The Intake Filter
MAINTENANCE MAINTENANCE PROCEDURES CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER (Only for machines in which synthetic biodegradable oil HEES is used) WARNING q Retract the arm and bucket cylinders completely, rest the bucket teeth on the ground and, after stopping the engine, eliminate the residual pressures from the equipment (by shifting the controls more than once) and from the tank (by slowly loosening the filler cap).
Page 364 MAINTENANCE MAINTENANCE PROCEDURES 1. Open the side cover (1). 2. Open the lock (2). 3. Slowly loosen the filling cap (3) to release the remaining pressure of the tank. 4. Remove the drain plug (P) and let the oil flow out, gathering it into a container with suitable capacity.
Page 365 MAINTENANCE MAINTENANCE PROCEDURES 5. Loosen the screws and remove the cover (4). REMARK During this operation, be careful to the thrusting force of the spring (5). 6. Remove the rod (6), the spring (5) and the filter (7). 7. Remove any dirt from the filter (5), then wash it with clean diesel oil or wash oil.
Page 366: Cleaning Of The Cooling System And Changing The Coolant
2 years or 2000 hours. As a general rule, we do not recommend the use of refrigerants different than Supercoolant Komatsu (AF-NAC). If another coolant is used, you may experience problems such as corrosion of the engine and the aluminium components of the cooling system.
Page 367 MAINTENANCE MAINTENANCE PROCEDURES WARNING q Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns; let the engine cool down until it reaches approximately 40–45°C before changing the coolant. q Slowly loosen the radiator cap, in order to release any residual pressure.
Page 368 MAINTENANCE MAINTENANCE PROCEDURES 4. Check that the cooling water temperature has decreased enough to allow the radiator cap (4) to be unscrewed to the stop in order to relieve the pressure. 5. Press the radiator cap (4), unscrew until it stops and remove it.
Page 369: Checking The Alternator And The Starter
CHECKING THE ALTERNATOR AND THE STARTER The brush may be worn or the bearing may be without grease. Contact your Komatsu distributor for the necessary inspection or repair. If the engine is started frequently, carry out this check every 1000 hours.
Page 370 MAINTENANCE MAINTENANCE PROCEDURES Accumulator operation check CAUTION Before starting check operations, make sure that no person or other obstacles are in the surrounding area. Replace the accumulator every 2 years or 4000 hours, based on the situations checked before. Check nitrogen loading pressure as follows. 1.
Page 371 If the tool does not descend or stops at the middle of the course, the accumulator pressure is not enough. Refer to your Komatsu distributor for check operations. 7. When the check is completed, take the safety device lever back to the LOCK position (L) and turn the start-up key to OFF.
Page 372 MAINTENANCE MAINTENANCE PROCEDURES 4. To release the pressure in the hydraulic circuit, take the locking lever to FREE and fully operate in all directions each control lever of the tools and the accessories control button. 5. Take the locking lever to LOCK to lock the working tool control levers and accessories control button.
Page 373: Maintenance Every 4000 Hours Of Operation
Make sure that the slack in the pulley is not excessive, that the drain hole is not clogged, and check for oil or water leakages. If there is any anomaly, contact your Komatsu distributor, who will provide for the necessary repairs or changes.
Page 374: Checking The High Pressure Hose Clamps And The Rubber Hardening
(2 positions) between the fuel pump and the common rail. In case of any problems, ask your Komatsu Distributor to replace the damaged parts. CHECKING THE PRESENCE OF THE FUEL SPLASH PROTECTION PLUG AND OF ANY...
Page 375: Maintenance Every 5000 Hours Of Operation
MAINTENANCE MAINTENANCE PROCEDURES MAINTENANCE EVERY 5000 HOURS OF OPERATION Carry out simultaneously with the maintenance operations scheduled every 100; 250; 500 and 1000 hours. CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER WARNING q Retract the arm and bucket cylinders completely, rest the bucket teeth on the ground and, after stopping the engine, eliminate the residual pressures from the equipment (by shifting the controls more than once) and from the tank (by slowly loosening the filler cap).
Page 376 MAINTENANCE MAINTENANCE PROCEDURES 1. Open the side cover (1). 2. Open the lock (2). 3. Slowly loosen the filling cap (3) to release the remaining pressure of the tank. 4. Remove the drain plug (P) and let the oil flow out, gathering it into a container with suitable capacity.
Page 377 MAINTENANCE MAINTENANCE PROCEDURES 5. Loosen the screws and remove the cover (4). REMARK During this operation, be careful to the thrusting force of the spring (5). 6. Remove the rod (6), the spring (5) and the filter (7). 7. Remove any dirt from the filter (5), then wash it with clean diesel oil or wash oil.
Page 378: Final Disposal Of The Machine
MAINTENANCE FINAL DISPOSAL OF THE MACHINE FINAL DISPOSAL OF THE MACHINE For safe dismantling of the machine at end of service life, please contact Komatsu distributor. 4-92 WEAM014802...
Page 379: Specifications
SPECIFICATIONS WEAM014802...
Page 380 SPECIFICATIONS SPECIFICATIONS Unit of measureme Version with steel tracks Operating weight Standard boom 12000 Bucket capacity 0.38 Engine diesel Komatsu Engine — SAA4D95LE-5 Engine power (ISO 14396: 2002) kW / rpm 72.1 / 2200 Arm 1850 mm 6696 Total length...
Page 381: Operating Characteristics
SPECIFICATIONS OPERATING CHARACTERISTICS OPERATING CHARACTERISTICS Boom and steel tracks version Unit of measure Arm (2000 mm) Arm (2300 mm) ment Max. digging outreach 7515 7795 Max. digging depth 4450 4750 Max. digging height 6590 6740 Max. digging depth on vertical wall 2522 2800 Max.
Page 382 SPECIFICATIONS OPERATING CHARACTERISTICS Two-piece boom and steel tracks version Unit of measure Arm (1850 mm) Arm (2000 mm) ment Max. digging outreach 7950 8100 Max. digging depth 4520 4670 Max. digging height 8250 8390 Max. digging depth on vertical wall 3490 3635 Max.
Page 383: Lifting Capacities Tables
SPECIFICATIONS LIFTING CAPACITIES TABLES LIFTING CAPACITIES TABLES DANGER q Carry out lifting operations only with the machine positioned on firm and flat ground. q The excavator used in handling operations must conform with current local regulations and be equipped with safety valves and an overload alarm in compliance with EN 474-5. For detail see "LIFTING OBJECTS WITH LIFTING DEVICE (3-166)".
Page 384: Lifting Capacities With Boom
SPECIFICATIONS LIFTING CAPACITIES TABLES LIFTING CAPACITIES WITH BOOM REMARK The load does not exceed 87% of the hydraulic lifting capacity or 75% of the tipping limit. *Load limited by the hydraulic lifting capacity and not by the tipping limit. Arm L= 1850 mm Unit of measurement: (kg) Max.
Page 385 SPECIFICATIONS LIFTING CAPACITIES TABLES Arm L= 2000 mm Unit of measurement: (kg) Max. 6.0 m 4.5 m 3.0 m 1.5 m 4.5 m * 1590 1380 * 1560 1340 3.0 m 1360 1140 1580 1320 * 1910 * 1910 1.5 m 1270 1060 1510...
Page 386 SPECIFICATIONS LIFTING CAPACITIES TABLES Arm L= 2300 mm + additional counterweight Unit of measurement: (kg) Max. 6.0 m 4.5 m 3.0 m 1.5 m 4.5 m * 1360 * 1360 * 1390 * 1390 * 1630 * 1630 3.0 m * 1370 1160 * 1600...
Page 387: Lifting Capacities With Two-Piece Boom
SPECIFICATIONS LIFTING CAPACITIES TABLES LIFTING CAPACITIES WITH TWO-PIECE BOOM REMARK The load does not exceed 87% of the hydraulic lifting capacity or 75% of the tipping limit. *Load limited by the hydraulic lifting capacity and not by the tipping limit. Arm L= 1850 mm Unit of measurement: (kg) Max.
Page 388 SPECIFICATIONS LIFTING CAPACITIES TABLES Arm L= 2000 mm Unit of measurement: (kg) Max. 6.0 m 4.5 m 3.0 m 1.5 m 4.5 m 1220 1000 1530 1260 * 1860 * 1860 3.0 m 1040 1480 1200 1.5 m 1390 1130 1040 1350 1090...
Page 389 SPECIFICATIONS LIFTING CAPACITIES TABLES Arm L= 2300 mm + additional counterweight Unit of measurement: (kg) Max. 6.0 m 4.5 m 3.0 m 1.5 m 4.5 m 1240 1010 * 1650 1390 * 1630 * 1630 3.0 m 1080 1640 1330 1.5 m 1030 1550...
Page 390 SPECIFICATIONS LIFTING CAPACITIES TABLES 5-12 WEAM014802...
Page 391 OPTIONAL EQUIPMENT WARNING Before reading this section, make sure you have read and understood the section on safety. WEAM014802...
Page 392: General Precautions For Safety
When installing attachments or options to the machine, it is necessary to pay attention to safety. Please obey the following precautions strictly when selecting, installing, or using attachments or options. Please consult your local Komatsu distributor for accessories or optional equipment other than those described in this manual.
Page 393 WARNING When calculating the allowable mass of attachments, the mass of the bucket, see the explanation of lift- ing capacity chart PC118MR-8 ("LIFTING CAPACITIES TABLES (5-5)").  For an attachment not intended to bear a load, for example a breaker, it should not exceed the minimum lift capacity of the machine as shown on the related lift capacity charts (see "LIFTING CAPACITIES...
Page 394: Specifications
OPTIONAL EQUIPMENT SPECIFICATIONS SPECIFICATIONS Hydraulic specifications q Max. service valve flow (1st equipment) 130 litres/min q Standard service valve working pressure (1st equipment) 29.4 MPa (294 bar) q Optional safety service valve working pressure (1st equipment) 19.6 MPa (196 bar) q Standard service valve safety pressure (equipment 1) 32.4 MPa (324 bar) ARM-PIN INFORMATION - 0.500...
Page 395: Equipment Use Guide
Komatsu is not liable for injuries, accidents or damage resulting from the unauthorised use of accessories and optional equipment. COMBINATIONS OF WORK EQUIPMENT...
Page 396 The recommendations are given as a guide only, based on typical conditions. q To dig and load hard or rocky earth, it is advisable to use a long-life reinforced bucket, highly wear-resistant. Characteristics of the equipment (managed exclusively by Komatsu or its authorised distributor) Main dimension...
Page 397: Long Arm
OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE Equipments characteristics (to be managed by operator) Main dimension Working Working Lifting Weigth Picture pressure flow capacity capacity Height Width Description Category reference l/min Bucket 300 mm Tool – – – – 0.103 – Bucket 400 mm Tool –...
Page 398: Machine Configuration For The Installation Of Attachments
OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS POSITION OF THE DEVICES Selection valve Accessory proportional switch 1st line Hydraulic breaker activation button Accessory proportional switch 2nd line (if present) (1) Selection valve This valve switches the hydraulic fluid flow. q Position (a): when the is used hydraulic breaker...
Page 399 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE (2) Accessory proportional switch 1st line This switch is used to activate general accessories. It is possible to adjust the amount of oil flow by moving the switch. If the selected working mode is not accessories mode, this switch cannot be activated.
Page 400 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE HYDRAULIC CIRCUIT Connection of the hydraulic circuit When the accessory is connected, connect the hydraulic circuit as follows. 1. Connect the accessory tube supplied by the manufacturer. The dimensions machine side are those shown on the right.
Page 401 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE 3. Turn the starter key to ON and take the locking lever to FREE. 4. Within 15 seconds after the engine stops, fully move, in all directions, each control lever (working tools and travel) and the accessories control button to release internal pressure.
Page 402 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE 9. After having checked that the oil temperature is low, remove the cover form the inlet and outlet hole (2 points). NOTICE q Make sure that the tube end is not dirty or with mud. q If the O-ring is damaged, replace it with a new one.
Page 403 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE 5. Open the side cover (1). 6. Open the lock (2). 7. Slowly loosen the filling cap (3) to release the remaining pressure of the tank. 8. Remove the tubes accessory side. Install the caps on their two holes....
Page 404 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE ACCESSORIES ACTIVATION WARNING When the autodeceleration function is active and the engine speed is low, if the control lever is operated, engine speed will increase abruptly; therefore, you should be especially careful. q When the oil flow rate is changed for the "breaker" mode, consult point "USING THE FUNCTION KEYS (3- 34)"...
Page 405 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE 13. Press the selector for the working mode (1) or the function keys F3 or F4 in order to select the "breaker" mode (B). 14. Once the "breaker" mode (B) is highlighted in yellow, confirm the selections in one of the following ways. q Press and hold down the selector for the working mode (1).
Page 406 OPTIONAL EQUIPMENT EQUIPMENT USE GUIDE Precautions during use 1. Check that the working mode is mode ATT. 2. Check that the rod of the selection valve (2) is the "accessory" position (crusher, etc.). NOTICE For any further precautions to implement when using an accessory, consult the manual supplied by the accessory manufacturer.
Page 407: Hydraulic Quick Coupler
4. The pressure adjustment valve (2) allows to limit the quick coupling pressure based on the manufacturer's recommendations. Check the quick coupling specifications and check that the valve is correctly set. 5. Make sure that a duly qualified technician installs the quick coupling. In case of doubts, contact the Komatsu distributor.
Page 408: Functioning
If the buzzer of the monitor sounds, solve the problem before proceeding with the work. In particular, check that there are no leaks in the system. In case of doubts, contact the Komatsu distributor. To unlock the bucket or accessory 1.
Page 409 OPTIONAL EQUIPMENT HYDRAULIC QUICK COUPLER To connect another bucket or accessory 1. Place the quick coupling on the bucket or accessory. 2. Press the switch (1). NOTICE The switch has a safety mechanism which prevents accidental activation. Slide the stop near itself and then press the switch.
Page 410: Recommended Attachment Operations
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. q Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selection of optimum attachments.
Page 411 OPTIONAL EQUIPMENT RECOMMENDED ATTACHMENT OPERATIONS When applying impact, push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm (2 in) off the ground. Do not let the machine come further off the ground than this amount. When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking...
Page 412 OPTIONAL EQUIPMENT RECOMMENDED ATTACHMENT OPERATIONS WRONG USAGE To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. q Do not operate all cylinders to the end of their strokes. Always leave approximately 5 cm to spare. q Using the mount to gather in pieces of rock.
Page 413 OPTIONAL EQUIPMENT RECOMMENDED ATTACHMENT OPERATIONS q Twisting the chisel when it penetrates the rock. q Pecking operations. q Extending the bucket cylinder rod fully and thrusting to raise the machine off the ground. POSTURE OF HYDRAULIC BREAKER TO BE GREASED Be sure to grease the breaker, holding it in the right posture.
Page 414 OPTIONAL EQUIPMENT RECOMMENDED ATTACHMENT OPERATIONS NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use. Be sure to grease the breaker, holding it in the right posture.
Page 415: Installing And Removing The Additional Counterweight
OPTIONAL EQUIPMENT INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT WARNING q To lift the additional counterweight, use properly dimensioned cables and avoid using worn cables or cables with broken strands. q Do not lift the additional counterweight in any other way than described here below, since it may lose balance.
Page 416 OPTIONAL EQUIPMENT INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT 6-26 WEAM014802...

Komatsu PC118MR-8 Operation And Maintenance Manual

Table of Contents

Foreword

Safety Information

Introduction

Product Identification

Safety Labels

Safety Machine Operation

Safety Maintenance Information

Machine Illustrations

Instruments and Controls

Cab

Hoods and Doors Fitted with a Lock

Air Conditioner

Fuses

Supplementary Power Supply

Controller

Storage Compartments

Komtrax System

Use of the Machine and Related Controls

Transportation

Using the Machine in the Cold Season

Long Periods of Inactivity

Troubleshooting

Guide to Maintenance

Parts Subject to Wear

Fuel, Coolant and Lubricants

Tightening Torques

Lubrication

Periodical Change of Safety-Related Components

Maintenance Plan 4

Maintenance Plan

Maintenance Procedures

When Required

Checks to be Carried out before Starting the Engine

Maintenance after the First 50 Hours of Operation

Maintenance Every 100 Hours of Operation

Maintenance Every 250 Hours of Operation

Maintenance after the First 500 Hours of Operation

Maintenance Every 500 Hours of Operation

Maintenance Every 1000 Hours of Operation

Maintenance Every 2000 Hours of Operation

Maintenance Every 4000 Hours of Operation

Maintenance Every 5000 Hours of Operation

Final Disposal of the Machine

Specifications

Operating Characteristics

Lifting Capacities Tables

General Precautions for Safety

Specifications

Equipment Use Guide

Hydraulic Quick Coupler

Recommended Attachment Operations

Installing and Removing the Additional Counterweight

Quick Links

Chapters

Related Manuals for Komatsu PC118MR-8

Summary of Contents for Komatsu PC118MR-8