Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 6: Safety Labels
Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for ques- tions regarding information in this manual.
Page 7: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201.
Page 8: Vibration Levels
VIBRATION LEVELS FOREWORD VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 9 FOREWORD VIBRATION LEVELS • Do not repeatedly handle and lift loads. WENAM00061...
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Ditching work • Loading work • Levelling work For details of work procedure, see MACHINE OPERATIONS AND CONTROLS “RECOMMENDED APPLICA- TIONS (3-182)”.
Page 11: Directions Of Machine
FOREWORD INTRODUCTION DIRECTIONS OF MACHINE RKA36001 (A) Front (D) Right (B) Rear (E) Operator's seat (C) Left 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 forward direction. VISIBILITY FROM OPERATOR'S SEAT The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below.
Page 12 INTRODUCTION FOREWORD 12 m circumference visibility The figure below shows a visibility from the machine for a circumference of 12 m. Shaded areas (A), (B), (C), (E) and (F) in the figure show areas, the views of which are blocked when the machine is equipped with the mirrors and other visibility assistant devices.
Page 13: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is on the left side of the mounting location of the swing bracket.
Page 14: Service Meter Location
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: Komatsu Italia Manufacturing S.p.A. Address: Via Atheste, 4 35042 Este (PD) Italy Distributor name Address...
Page 15: Serial Plate
FOREWORD SERIAL PLATE SERIAL PLATE SERIAL NUMBER MACHINE DESIGNATION / TYPE OPERATING MASS YEAR OF CONSTRUCTION PRODUCT IDENTIFICATION NUMBER ENGINE POWER MANUFACTURER 1-13 WENAM00061...
Page 16: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Italia Manufacturing S.p.A Via Atheste, 4 35042 Este (PD) Italy Declares that this machine: PW98MR-10 Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive...
Page 17: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 BEFORE READING THIS MANUAL ......................1-2 SAFETY INFORMATION .......................... 1-3 SAFETY LABELS ............................. 1-4 NOISE............................... 1-5 VIBRATION LEVELS ..........................1-6 VIBRATION - OPERATING CONDITION ................... 1-6 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-6 INTRODUCTION ............................
Page 18 OTHER TROUBLE......................... 3-232 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 19 FOREWORD TABLE OF CONTENTS PRECAUTIONS FOR WELDING ....................... 4-2 DO NOT DROP THINGS INSIDE MACHINE ..................4-2 DUSTY JOBSITES..........................4-2 AVOID MIXING OIL..........................4-3 LOCK INSPECTION COVERS ......................4-3 BLEED AIR FROM HYDRAULIC CIRCUIT ..................4-3 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............. 4-3 CHECKS AFTER INSPECTION AND MAINTENANCE..............
Page 20 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-5 LUBRICATION CHART ........................7-5 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-18 WENAM00061...
Page 21: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly. WENAM00061...
Page 22: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 23: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS (1) Combined safety information label (a) Warning for operation, inspection and maintenance WENAM00061...
Page 24: Contents Of Safety Labels
SAFETY LABELS SAFETY (b) Danger when swinging the machine (8) Caution for handling battery (c) Caution when standing in operator cab (9) Caution for high temperature coolant and hydraulic (d) Warning when reversing (10) Emergency exit (e) Warning when leaving the operator's seat (11) Caution stop rotation during inspection and main- (f) Emergency steering tenance...
Page 25 SAFETY SAFETY LABELS (b) Danger when swinging the machine Check that there are no people in the operational range of the machine. (c) Caution when standing in operator cab • Take care when standing in the operator cab. • Before standing up from the operator's seat (such as when opening or closing the front window, or when removing or installing the bottom window, or when adjusting the opera- tor's seat), always lower the work equipment completely to...
Page 26 SAFETY LABELS SAFETY (d) Warning when reversing To prevent SEVERE INJURY or DEATH, do the following be- fore moving machine or its attachments: • Sound horn to alert people nearby. Be sure no one is on or near machine or in swing area. Rotate cab for full view of travel path if it can be done safe- Use spotter if view is obstructed.
Page 27 SAFETY SAFETY LABELS (f) Emergency steering Emergency steering is only to be used when stopping the ma- chine safely. (g) Warning against high-voltage cables • An electrocution hazard if the machine is brought too near to electric power lines. • Keep a safe distance from electric power lines.
Page 28 SAFETY LABELS SAFETY (i) Warning danger of falling objects • Do not operate where a danger of falling objects exists. Consult your dealer for fitting of FOPS (FALLING OBJECT PROTECTIVE STRUCTURE) protection. (2) Control levers operational function diagram (21D-00-41210) • In order to prevent an accident resulting in injury or death caused by error-operation, confirm the machine motion and indicated operating pattern, when operating machines.
Page 29 SAFETY SAFETY LABELS (a) Lifting capacity diagram (b) Caution for overloading machine • Do not exceed the specified lifting load. (c) Warning for lock lever • Read operation manual before operation. • With lock lever raised the control levers and pedals are dis- abled.
Page 30 SAFETY LABELS SAFETY (4) Warning when swinging or travelling in reverse (09833-A0881) WARNING • Before moving, check the surrounding areas, the rear- view mirror and the monitor to make sure no-one is near the machine. Failure to do so may result in seri- ous injury or death.
Page 31 SAFETY SAFETY LABELS (9) Caution for high temperature coolant and hydraulic oil (09653-A0481) • Never remove the cap when the engine is at operating (high) temperature. Steam or high temperature oil blowing up from the radiator or hydraulic tank will cause personal injury and/or burns.
Page 32 SAFETY LABELS SAFETY Read the manual before operating, inspection, maintenance, disassembly, assembly and transportation. (14) Caution for high-temperature (09817-A0753) (15) Caution do not start by short-circuiting (09842-A0481) Prohibition of short-circuit start (16) Caution against falling (09805-C0641) • Sign indicates a hazard of falling. •...
Page 33 SAFETY SAFETY LABELS (17) Caution when stowing front window (22P-00-11170) • Sign indicates a hazard from falling window. • After raising window, be sure to lock it in place with lock pins. (18) Caution for work equipment (09134-A0881) Keeping out of working range area •...
Page 34 SAFETY LABELS SAFETY (a) Never smoke or use any naked flame near the batteries. Do not generate sparks. (b) Always wear safety glasses when working with batteries. (c) Keep children away from batteries. KS000327 (d) Caution battery acid. (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases.
Page 35 SAFETY SAFETY LABELS (21) Lock front window (22P-00-11381) (22) Lifting decal (21D-00-41170) 2-15 WENAM00061...
Page 36: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 37: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 38 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
Page 39: Precautions When Getting On Or Off Machine
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE Explosion caused by lighting equipment • When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica- tions. • When taking the electrical power for the lighting equipment from the machine, see “POWER SUPPLY OUT- LET (3-116)”.
Page 40 In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...
Page 41 Do not get on or off the machine with tools in your hand. • If any step is damaged or deformed, do not stand on it. Repair or replace the damaged or deformed step immediately. Ask your Komatsu distributor for repair or replacement. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death.
Page 42 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY Set the gear selection switch to neutral (N). RKA48490 Engage the boom swing control pedal. Set the lock lever to LOCK position (L). Turn the starting switch to OFF position (A). Remove the starting switch key, lock the cab door and the front window and always take the key with you and keep it in the specified location.
Page 43: Do Not Get Caught In Work Equipment
No attempt should be made to repair these parts as this may have an adverse effect on component strength or durability. If such a repair is undertaken without authorisation from Komatsu there is a danger that a problem might occur that will lead to serious personal injury.
Page 44: Precautions Related To Attachments And Options
Any serious personal injury, or product failures, or physical loss or damage resulting from the use of unau- thorized attachments or parts will not be the responsibility of Komatsu. • When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential problems or safety and legal requirements. •...
Page 45: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 46 PRECAUTIONS FOR OPERATION SAFETY Voltage of Cables Safety distance. 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 47: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a "DANGER! Do NOT operate!"...
Page 48: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • Before starting the engine check that the safety locking lever (1) is on LOCK (L) and that the gear selector is in neutral (N). • Adjust the mirrors so that the rear of the machine can be seen easily from the operator's seat.
Page 49 SAFETY PRECAUTIONS FOR OPERATION • Fasten the seatbelt. When the brakes are applied sudden- ly, the operator may be thrown out of the operator's seat. It is dangerous and may cause personal injury. • Check the operating condition of the machine, work equip- ment, and travel, braking, steering and swing systems.
Page 50 PRECAUTIONS FOR OPERATION SAFETY • When driving the machine on a level ground, keep the work equipment 40 – 50 cm from the ground. If that height is not maintained between the work equipment and the ground, the work equipment may get stuck in the ground and the machine may tip over.
Page 51 SAFETY PRECAUTIONS FOR OPERATION • Keep the work equipment approximately 20 to 30 cm above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the ma- chine. • When driving the machine up slopes, set the operator's cab facing uphill, when driving downhill , set the operator's cab facing downhill.
Page 52 PRECAUTIONS FOR OPERATION SAFETY • Do not drive the machine on a slope covered with the steel plates. Even with slight slopes there is a hazard that the machine may slip. • Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes there is a hazard that the machine may slip.
Page 53 SAFETY PRECAUTIONS FOR OPERATION • 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 a danger that the load may spill or the bucket may hit the dump truck and cause serious personal injury or death.
Page 54 PRECAUTIONS FOR OPERATION SAFETY • Place the outriggers, the blade and the bucket on the ground; should space not make this possible, the working equipment must be placed in transport position. • Set the travel direction selection switch to neutral. RKA48490 •...
Page 55: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 56: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY • When swinging the upper structure on the loading platform, lower the work equipment, retract it, and per- form the operation slowly. • Always fold the mirrors and radio antenna. For the method of folding the mirrors and antenna, see “METHOD FOR ADJUSTING MIRRORS (3-139)” and “STOW ANTENNA (3-210)”.
Page 57: Lifting Operation By Using Lifting Device (Optional Equipment)
SAFETY PRECAUTIONS FOR OPERATION • Do not use the work equipment or swing to pull the load in any direction. There is danger that the hook may break and the load come off, causing the work equipment to move suddenly and cause personal injury. •...
Page 58 PRECAUTIONS FOR OPERATION SAFETY • The lifting link RLL (Rated Lifting Load) and part number (A) are stamped on the link as shown in figure. Always be sure to lift within the relevant lifting limits and not exceed- ing RLL. •...
Page 59: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the "DAN- GER! Do NOT operate!" warning tag. If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 60 PRECAUTIONS FOR MAINTENANCE SAFETY • Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. • Turn the starting switch to ON position. Operate the work equipment control lever back and forth, right and left 2 to 3 times fully to release the remaining internal pressure in the hydraulic circuit.
Page 61 SAFETY PRECAUTIONS FOR MAINTENANCE • Rotating parts such as the fan, fan belt are dangerous that they may easily catch a body part or an object someone wears. Be careful not to come close to the rotating part. • Never drop or insert tools or other objects into the fan, fan belt, or other rotating parts.
Page 62: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur. Al- ways observe the following. • Make sure the hoists or hydraulic jacks you use are in good condition and strong enough to handle the weight of the component.
Page 63 SAFETY PRECAUTIONS FOR MAINTENANCE HANDLE BATTERY Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. Danger of battery exploding When the battery is being charged, flammable hydrogen gas is generated and may explode.
Page 64 PRECAUTIONS FOR MAINTENANCE SAFETY • If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, pieces might be scattered, and it may cause serious personal injury or death. Always wear protective eyeglasses and gloves. •...
Page 65 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 66 It is dangerous and may cause personal injury. Always observe the following. • Always use the tyres specified by Komatsu and maintain the specified inflation pressure. • Before inflating tyres, always check the wheel rims and the tyre walls and tread for dents, cuts, broken plies, or other defects.
Page 67 SAFETY PRECAUTIONS FOR MAINTENANCE MAINTENANCE OF AIR CONDITIONER If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause frostbite. Never loosen any parts of the cooling circuit. PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials.
Page 68 WENAM00061...
Page 69: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section. WENAM00061...
Page 70: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket cylinder (2) Arm WENAM00061...
Page 71 (19) Outriggers (9) Blade cylinder (20) Outriggers cylinder (10) Front axle (21) Stop light - Direction light (11) Axle lock cylinder (22) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator (12) Dirt cover (23) Fusible link (13) Revolving lamp (24) Toolbox...
Page 72: Cab Equipment Names
GENERAL VIEW OPERATION CAB EQUIPMENT NAMES (1) Front window (6) Fire extinguisher (if equipped) (2) Ceiling window (7) Cup holder (3) Door handle (8) Radio box (4) Emergency escape hammer (9) Ashtray (5) Fuse WENAM00061...
Page 73: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES WENAM00061...
Page 74 GENERAL VIEW OPERATION (1) Machine monitor (30) “Autocruise” switch (2) Monitor control switch (31) Monitor (3) Air conditioner control switch (32) Steering wheel (4) Parking lights - instrument lighting - low beam (33) Steering wheel height adjuster switch (34) 2nd-line attachment proportional switch (5) R.H.
Page 75 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME RKA47630 AA: Display just with the indicators - BB: Display with camera and indicators (1) Service meter/ clock (19) Parking brake pilot lamp (2) Engine coolant temperature gauge (20) Work equipment lock pilot lamp (3) Engine coolant temperature caution lamp (21) Lock lever automatic lock release pilot lamp (4) Hydraulic oil temperature gauge...
Page 76 GENERAL VIEW OPERATION (35) F/N/R pilot lamp (38) Caution lamp (36) Indicator signalling tyre alignment (39) Action level display (37) Function switches (40) Camera image display REMARK The above figure does not show all of the caution lamp symbols. For detail, see “WARNING DISPLAY FOR AB- NORMALITIES AND FAULTS (3-15)”.
Page 77: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT RKA47640 (1) Warning display (4) Monitor switch area (2) Pilot display (5) Guidance icon display...
Page 78 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION RKA47650 • When the starting switch is turned to ON position, the opening screen GG is displayed. • After 2 seconds, the screen switches to the check before starting screen DD. •...
Page 79 End screen when any message has been received If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 80 F1, and the screen changes to Check Before Start- ing screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or cancelling the operator identifica- tion function. • Depending on the set value of “Operator ID Holding Time with Key OFF”...
Page 81 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 82 EXPLANATION OF COMPONENTS OPERATION • After displaying the checks before starting screen BB for 2 seconds, the screen changes to the warning screen FF or error screen EE. If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the error.
Page 83 OPERATION EXPLANATION OF COMPONENTS If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the error. Current abnor- mality screen is displayed. WARNING DISPLAY FOR ABNORMALITIES AND FAULTS NOTICE When any of action levels “L01”...
Page 84 EXPLANATION OF COMPONENTS OPERATION Whole camera image display screen The current cautions are indicated by flashing of caution lamp (5). When 2 or more cautions are generated, they are sequentially displayed starting from the leftmost side of the screen. REMARK For the action level display, see “ACTION LEVEL DISPLAY (3-17)”.
Page 85 Stop the work and run the engine at medium speed with no │ mittently load or stop it. │ If the condition is not improved, ask your Komatsu distributor for inspection and maintenance. │ │ Does not Lights up in...
Page 86 EXPLANATION OF COMPONENTS OPERATION Caution lamps and display colors Display color/Machine condition (action level) Symbol Type of caution lamp Yellow High temperature Engine coolant temperature caution lamp (L02) RKA51920 High temperature Hydraulic oil temperature caution lamp (L02) RKA51930 Abnormal Abnormal System state caution lamp (L03/L04) (L01)
Page 87 OPERATION EXPLANATION OF COMPONENTS Display color/Machine condition (action level) Symbol Type of caution lamp Yellow Abnormal Lock axle system caution lamp (L03) RKA51890 Gear engagement caution lamp Abnormal RKA51990 Engine overrun caution lamp (L02) RKA51940 Low pressure in the Hydraulic quick coupler system caution quick coupler system lamp (L03)
Page 88 EXPLANATION OF COMPONENTS OPERATION Operation on “Current Abnormality” screen On “Current Abnormality” screen, you can perform the following operations with switches F1, F2 and F5. F1: Displays next page. When on the last page, it displays the first page. F2: Displays the previous page. When on the first page, it dis- plays the last page.
Page 89 When action level “L03/L04” is displayed The caution lamp lights up in red and the alarm buzzer sounds continuously. Stop the machine immediately and ask your Komatsu distribu- tor for inspection and maintenance. When action level “L01” is displayed The warning lamp lights up in yellow.
Page 90 The engine durability may be lower but the machine can operate. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for inspection and maintenance as needed. ENGINE OIL PRESSURE CAUTION LAMP Engine oil pressure caution lamp warns about abnormality of engine lubricating oil pressure.
Page 91 The caution lamp lights up in yellow and indicates action level “L01”. The air conditioner system has abnormality. Ask your Komatsu distributor for inspection and maintenance as soon as possible. MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displays notices and alarms concerning maintenance time.
Page 92 When the oil pressure is low: The caution lamp lights up in red and the alarm buzzer sounds continuously and indicates action level “L04”. Stop the machine immediately and ask your Komatsu distribu- tor for inspection and maintenance. 3-24 WENAM00061...
Page 93 STEERING SYSTEM CAUTION LAMP This indicator signals faults in the steering system. When there is an abnormality: The caution lamp lights up in red and indicates action level “L03”. Stop the machine and ask your Komatsu distributor for inspec- tion. RKA48920 3-25 WENAM00061...
Page 94 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY AND METER DISPLAY RKA47900 Pilot display (1) Seat belt caution lamp (9) Indicator light signalling unlocking of the emergen- cy rotation (flashing) (2) Engine stop pilot lamp (10) Preheating pilot lamp (3) Parking brake pilot lamp (11) Auto-deceleration pilot lamp (4) Work equipment lock pilot lamp (12) Working mode display...
Page 95 OPERATION EXPLANATION OF COMPONENTS PREHEATING PILOT LAMP The preheating pilot lamp is displayed while the engine is pre- heated before started at temperature below 0 °C {32 °F} . When the temperature is low (in cold weather) and the auto- matic preheating function operates, the preheating pilot lamp lights up.
Page 96 EXPLANATION OF COMPONENTS OPERATION The indicator functions as shown below. Indicator light on: the top turret and the lower carriage are aligned. Light off: the top turret and the lower carriage are not aligned. WORKING MODE DISPLAY The working mode display shows the setting of the working mode.
Page 97 EXPLANATION OF COMPONENTS MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY (3-87)”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply is made.
Page 98 EXPLANATION OF COMPONENTS OPERATION LOCK LEVER AUTOMATIC LOCK CANCEL PILOT LAMP The lock lever automatic lock release pilot lamp shows the state of the lock lever automatic lock cancel switch. The pilot lamp display when the lock lever automatic lock can- cel switch is operated is as follows.
Page 99 OPERATION EXPLANATION OF COMPONENTS E Mode Recommendation Guidance If light-load work is continued for more than 10 minutes in P or ATT/P mode, E mode recommendation message is displayed. When working on light load, set the working mode to E to re- duce unnecessary fuel consumption.
Page 100 EXPLANATION OF COMPONENTS OPERATION HYDRAULIC OIL TEMPERATURE GAUGE WARNING • To display the hydraulic oil temperature indicator the rear camera needs to be deactivated. To deac- tivate it, engage the travelling on street mode or put the controls locking lever to L (LOCK). For more details, see “STREET MODE SWITCH (3-51)”...
Page 101 OPERATION EXPLANATION OF COMPONENTS REMARK When the indicator reaches red range (B), the remaining fuel is 23 ℓ or less. When the indicator is in red range (B), fuel level lamp (D) lights up in red. The correct fuel level may not be displayed for a short time when the starting switch is turned to ON position, but this is not an abnormality.
Page 102 EXPLANATION OF COMPONENTS OPERATION ECO GAUGE ECO gauge shows the instantaneous fuel consumption. The instantaneous fuel consumption means the fuel consump- tion rate at each current moment, which varies with the work load and engine speed. When the gauge is in green range A, the instantaneous fuel consumption is at a good to medium level.
Page 103 OPERATION EXPLANATION OF COMPONENTS STEERING AND ROAD CIRCULATION DISPLAY RKA51970 AA: Displaying with camera and indicators - BB: Displaying just with the indicators - CC: Displaying only with the camera (1) Steering mode display (2) Road circulation display • In the CC display with just the camera, the steering - change mode error indicators are not visible. If, when selecting the type of steering, an indicator with a yellow background appears, switch the display to camera and indicators or just indicators to check the errors.
Page 104 EXPLANATION OF COMPONENTS OPERATION Symbol Color Type of indication Description Error Driving speed incorrect RKA54360 Error Align front wheels RKA54370 Error Align rear wheels RKA54380 Blue Information State of wheel alignment RKA54390 Green / Yellow Information / Error Information / Indications about steering mode RKA54400 For the meaning of each caution lamp and the remedy to take for it, see the section of each caution lamp.
Page 105 OPERATION EXPLANATION OF COMPONENTS Symbol Description 4 Wheel steering crab It cannot be used with a high speed (“HI”) RKA52020 Indicators with a yellow background (indicating steering active and moving not possible) Symbol Description Temporary 4 wheel steering cornering This activates automatically when it is necessary to regain the alignment of the rear wheels (for example when 2WS steering is set and the rear wheels go out of alignment) and when the steering mode change errors have been resolved.
Page 106 EXPLANATION OF COMPONENTS OPERATION To cancel this, the speed must be reduced. When the speed is correct, the light goes off. If the 4WS-C (crab) steering is selected, the machine must be stopped. RKA52100 ALIGN REAR WHEELS PILOT LAMP The rear wheels alignment indicator alarm comes on with a red light and signals that the rear wheels are not aligned.
Page 107 OPERATION EXPLANATION OF COMPONENTS INDICATOR SIGNALLING WRONG STEERING SELECTION FOR TRAVELLING ON ROADS The indicator lights up with a red light when the type of steering selected is different from 2WS when travelling on roads. Change the type of steering or deselect the travelling on street mode.
Page 108 EXPLANATION OF COMPONENTS OPERATION Symbol Color Type of indication Description Yellow Indication Axle locking activated RKA54470 Blue Indication Axle locking in AUTO mode not active RKA54480 Yellow Indication Axle locking in AUTO mode active AUTO RKA54490 Blue Information Street mode active Error The travelling speed is too high with street mode not...
Page 109 OPERATION EXPLANATION OF COMPONENTS The indicator takes the following appearance, depending of the selection of the direction of travel. F: forward (white) N: neutral (green) R: reverse (yellow) LOCK AXLE MODE PILOT LAMP The axle locking indicator displays the status and mode of the axle locking selected. By pressing the axle locking switch, the various activation modes are selected.
Page 110 EXPLANATION OF COMPONENTS OPERATION Indicator on with blue light: the street mode is activated and the controls of the levers are locked. Indicator on with red light: the travel speed is too high with street mode not active. Lower the speed or activate the trav- elling on street mode.
Page 111 OPERATION EXPLANATION OF COMPONENTS INDICATOR FOR SIGNALLING THE REAR WHEELS ARE NOT ALIGNED This warning indicator indicates the travelling on street mode is configured incorrectly because the rear wheels have lost their alignment. The alarm indicator (A) lights up red together with the indicator (B). The alarm buzzer sounds intermittently.
Page 112 EXPLANATION OF COMPONENTS OPERATION FUNCTION SWITCHES AND GUIDANCE ICONS • There are 6 function switches (1) (F1 to F6) at the bottom of the monitor display. The function of each switch differs according to the content of each screen. • The function of each function switch (1) on each screen can be confirmed by guidance icons (2) displayed above that switch.
Page 113 OPERATION EXPLANATION OF COMPONENTS (E) Switch F5: ECO guidance erase switch (While ECO guidance is displayed) (F) Switch F6: user menu display switch For the details of each function, see the detailed explanation of each item. RKA48110 Guidance icons and their functions differ with the contents of the displayed screen. However representative guidance icons frequently used and their functions are as follows: (G) Switch F1 or F3: Moves to the left item (When on the left end, it moves to the right end)
Page 114 For machines ready for installation of attachment, the attachment mode is added to the display. If you want to have automatic setting of P, E, L, B, ATT/P or ATT/E mode (optional default setting) when starting engine, ask your Komatsu distributor to change the setting. Procedure for operation When the working mode selector switch is pressed, the working mode selector screen is displayed on the monitor.
Page 115 OPERATION EXPLANATION OF COMPONENTS After selecting the desired mode, press function switch F6 and the mode is displayed in the center of the monitor dis- play. (Example: When the power mode is selected: “P”) After 2 seconds, the working mode display at the top right of the screen is highlighted in yellow.
Page 116 EXPLANATION OF COMPONENTS OPERATION When the auto-deceleration switch is pressed and the au- to-deceleration function is turned ON, the mode is dis- played in the center of the monitor display, and after 2 sec- onds, the screen returns to the standard screen. RKA48171 On the standard screen, auto-deceleration indication lamp lights up.
Page 117 OPERATION EXPLANATION OF COMPONENTS REMARK When the engine is started, the selected speed remains the same as the one set before the machine stopped. During loading and unloading operations from a trailer, never use the speed increase switch and always use the speed “CR”. Before switching the speed from “LO”...
Page 118 EXPLANATION OF COMPONENTS OPERATION TRAVEL SPEED REDUCTION SWITCH The travel speed reduction selector switch is used to change the speed in turn from “HI” to “LO” to “CR”. Every time it is pressed the selected speed decreases until the lowest speed is reached “CR”. “CR”...
Page 119 OPERATION EXPLANATION OF COMPONENTS REMARK Each time the travel speed reduction switch is pressed, the mode will be displayed enlarged on the monitor display and, af- ter two seconds, it will return to the standard screen. RKA48172 RKA48162 STREET MODE SWITCH The street mode switch activates/deactivates the travelling on roads function.
Page 120 EXPLANATION OF COMPONENTS OPERATION REMARK For travelling on flat public roads it is recommended that the speed be set to “HI”. The maximum speed can be adjusted also with the hand throttle. (For details, see “FUEL CONTROL DIAL (3-93)” BUZZER CANCEL SWITCH Buzzer cancel switch is used to stop the alarm buzzer for the warning item where there is an abnormality.
Page 121 OPERATION EXPLANATION OF COMPONENTS BLADE/OUTRIGGERS SELECTOR SWICTH On machines equipped with blade/outriggers, press button F2 to access the outriggers selection screen. REMARK The blade and the outriggers are controlled from the right joy- stick. For more details, see “BLADE/OUTRIGGERS CONTROL SWITCH (3-96)”...
Page 122 EXPLANATION OF COMPONENTS OPERATION Machine with front and rear blade Press button F1 to use the front blade. Press button F3 to use the rear blade. Press button F5 to simultaneously use front and rear blade. Press button F6 to return to the initial screen. To deselect, press the key corresponding to the attachment (keys F1, F3, ).
Page 123 OPERATION EXPLANATION OF COMPONENTS CAMERA IMAGE SELECTOR SWITCH Pressing the switch F3 on the standard screen it is possible to switch the monitor from camera images and indicators to just the image from the camera. On machines not equipped with a camera, the guidance icon related to switch F3 is not displayed.
Page 124 EXPLANATION OF COMPONENTS OPERATION Operations with the camera screen when the controls locking lever is raised The following is the method of changing the camera image display on the monitor. • On standard screen AA, the camera image is always displayed on the left part of the monitor. •...
Page 125 OPERATION EXPLANATION OF COMPONENTS Operations with the camera screen when the travelling on street mode is active The following is the method of changing the camera image display on the monitor. • When the forward drive is engaged (F) or the machine is in neutral (N) the screen QQ is displayed. •...
Page 126 EXPLANATION OF COMPONENTS OPERATION • Press the speed increase switch. For information about the speed increase switch, see “SWITCH FOR INCREASING TRAVEL SPEED (3-48)”. When the travel speed is increased, the indicator of the monitor at the top is highlighted in yellow for 2 seconds; af- ter this it turns blue.
Page 127 OPERATION EXPLANATION OF COMPONENTS Actions against warning during camera image display If a trouble occurs on the machine while the camera image dis- play screen is being displayed, the caution lamp flashes at the top left of the screen. RKA48210 •...
Page 128 EXPLANATION OF COMPONENTS OPERATION USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. RKA48163 USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
Page 129 OPERATION EXPLANATION OF COMPONENTS (c) Maintenance • Check and reset of various maintenance times. (d)“Monitor Setting” • “Screen Adjustment” • “Screen Adjustment (Camera)” • “Clock Adjustment” • “Language” • “Operator ID (if activated)” (e) Mail Check • Check of mail contents and reply to mail. On the user menu screen, it is possible to perform the following operations with switches F1 to F6.
Page 130 EXPLANATION OF COMPONENTS OPERATION F3: Moves to the next item (1 line below). When on the last line, it moves to the first line. F4: Moves to the previous item (1 line above). When on the first line, it moves to the last line. F5: Returns the screen to the standard screen.
Page 131 OPERATION EXPLANATION OF COMPONENTS Operation on “Operation Records” screen On “Operation Records” screen, you can perform the following operations by pressing switch F3 to F5. F3: Displays the next page. When on the last page, it displays the first page. F4: Displays the previous page.
Page 132 EXPLANATION OF COMPONENTS OPERATION CHECK FUEL CONSUMPTION RECORD Select “Average Fuel Consumption Record” (3) from “Energy Saving Guidance” menu screen, then press switch F6. On “Average Fuel Consumption Record” menu, display the graph of hourly average fuel consumption during “Last 12 hours”...
Page 133 OPERATION EXPLANATION OF COMPONENTS Deleting “Average Fuel Consumption Record” When switch F1 (“CLEAR”) is pressed, the reconfirmation screen shown in the figure is displayed. When the switch F6 is pressed, graphs of data of “Last 12 hours” and “Last 7 days” are both deleted, and the screen returns to the “Average Fuel Consumption Record”...
Page 134 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE It is possible to change the display of fuel consumption gauge (5) and the setting of Display/Non-display. RKA48230 Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. 3-66 WENAM00061...
Page 135 OPERATION EXPLANATION OF COMPONENTS “Average Fuel Consumption Display” screen appears. • “1 Day” Displays the average fuel consumption from 0:00 a.m. of the day to 0:00 a.m. of the next day. • “Split Time” Displays the average fuel consumption during “Split Time”...
Page 136 EXPLANATION OF COMPONENTS OPERATION Select “ECO Gauge display” (8) from “Configurations” screen, then press switch F6. “ECO Gauge Display” setting screen appears. • “ON”: Displays the ECO gauge (7) on the standard screen. • “OFF”: Does not display ECO gauge (7) on the stand- ard screen.
Page 137 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE It is possible to change the setting of Display/Non-display of ECO guidance (10). RKA48250 Select “ECO Guidance display” (11) from “Configurations” screen, then press switch F6. “ECO Guidance Display” setting screen appears. •...
Page 138 EXPLANATION OF COMPONENTS OPERATION Select “ECO Guidance Display at Key OFF” (13) from “Configurations” screen, then press switch F6. The setting screen for “ECO Guidance Display at Key OFF” appears. • “ON”: Displays ECO Guidance (12) on the end screen. •...
Page 139 OPERATION EXPLANATION OF COMPONENTS ADJUST ECONOMY MODE Select “Economy Mode Adjustment” (1) on “Machine Setting” menu screen, then press switch F6. On the “Economy Mode Adjustment menu”, you can adjust the engine output in E mode. In the Economy Mode, the higher the selected number starting from E0 becomes, the lower the engine output becomes.
Page 140 EXPLANATION OF COMPONENTS OPERATION On “Breaker Setting” screen shown in the figure, select breaker, and press switch F6. On the “Breaker Setting” screen shown in the figure, you can perform the following operations with switches F1 to F1: Changes the name of the selected breaker setting. F2: Changes the oil flow rate of the selected breaker set- ting.
Page 141 OPERATION EXPLANATION OF COMPONENTS The “Breaker Oil Flow Rate Setting” screen is displayed. On the “Breaker Oil Flow Rate Setting” screen, you can perform the following operations with switches F3 to F6. F3: Decreases the flow rate by 1 level. F4: Increases the flow by 1 level.
Page 142 EXPLANATION OF COMPONENTS OPERATION Select an attachment to change its name on “Attachment Setting” screen, then press switch F6. The “Attachment Name Setting” screen is displayed. On the “Attachment Name Setting” screen, you can per- form the following operations with switches F1 to F6. F1: “CLEAR”...
Page 143 OPERATION EXPLANATION OF COMPONENTS AUTO IDLE STOP TIMER SETTING The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with the lock lever in LOCK position for a set time. The auto idle stop function operates only when the following conditions are satisfied. •...
Page 144 EXPLANATION OF COMPONENTS OPERATION When countdown reaches 0, the engine stops and the screen changes to the Auto Idle Stop in Operation screen. To prevent battery discharging, turn off unnecessary switches. REMARK While the auto idle stop is activated, only the engine is stopped and the machine monitor, inverter, etc., as well as the electrical components including the air conditioner, ra- dio, lamps, and wipers keep their states before the engine...
Page 145 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on “Maintenance Due Time Reset” screen On the “Maintenance” menu screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the “Maintenance Due Time Reset”...
Page 146 EXPLANATION OF COMPONENTS OPERATION The reconfirmation screen is displayed. If switch F6 is pressed again, the remaining time is reset and the screen returns to the “Maintenance” menu screen. REMARK • When canceling the reset, press switch F5. The screen returns to the “Maintenance” menu screen. •...
Page 147 OPERATION EXPLANATION OF COMPONENTS REMARK • If the light switch is at night mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode). • If the light switch is at day mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (day mode).
Page 148 EXPLANATION OF COMPONENTS OPERATION Setting the camera display in travelling on street mode Select “Camera view mode” (4), then press key F6. RKA54661 Select the camera display mode when reverse gear is engaged: “Normal”: the camera is not displayed. “Reverse synchronisation”: the camera is automatically displayed with a full screen.
Page 149 OPERATION EXPLANATION OF COMPONENTS GPS SYNCHRONIZATION SETTING On machines equipped with KOMTRAX, turning on “GPS Syn- chronization” menu enables automatic setting of the monitor's date and time in accordance with the clock of GPS. F3: Moves to the next item (1 line below). Moves to the top line when on the bottom line.
Page 150 EXPLANATION OF COMPONENTS OPERATION When date display (C) is highlighted in yellow, operate the switches as follows to change day display (C). If it is not necessary to change the day, press switch F6. F3: Calendar goes back 1 day. F4: Calendar advances 1 day.
Page 151 OPERATION EXPLANATION OF COMPONENTS Select “12h/24h Mode” (d) on “Clock Adjustment” screen, then press switch F6. “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below). Moves to the top line when it is on the bottom line. F4: Moves to the previous item (1 line above).
Page 152 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 153 OPERATION EXPLANATION OF COMPONENTS When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID” on “Monitor Setting” menu screen. Select operator ID (5) on “Monitor Setting” menu screen, then press switch F6 for 1 second. “Operator ID Change”...
Page 154 EXPLANATION OF COMPONENTS OPERATION • When you press switch F6 after inputting the ID which is not registered to “Operator ID Change” screen, a message is displayed below and the screen returns to “Monitor Setting” menu screen. In this case, the identified ID is not changed. •...
Page 155 In this case, the identified ID is not changed. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this menu (e). When there is any message, the message display of the standard screen lights up.
Page 156 EXPLANATION OF COMPONENTS OPERATION CHECK MESSAGE On the standard screen, press switch F6. When there is any message, message display (1) lights While message display (1) is lit, press switch F6, and mail confirmation menu (e) directly opens. Select mail confirmation menu (e), and you can read the arrived message.
Page 157: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES 3-89 WENAM00061...
Page 158 EXPLANATION OF COMPONENTS OPERATION (1) Free (24) 1st-line attachment proportional switch (2) Free (25) Radio mute switch (3) Free (26) Free (4) Free (27) Blade/outriggers control switch (5) Rear working lamps switch (28) Camera activation switch (6) Front working lamps switch (29) Breaker operation switch (7) Revolving lamp switch (30) 2nd-line attachment proportional switch...
Page 159 OPERATION EXPLANATION OF COMPONENTS “AUTOCRUISE” SWITCH NOTICE The “Autocruise” switch should only be used when travelling long stretches of roads. Never operate the switch before moving the machine. Do not use it on roads obstructed with snow or icy roads or inside building sites.
Page 160 EXPLANATION OF COMPONENTS OPERATION HIGH BEAM SWITCH The light switch is used to switch on the dipped-beam and main-beam headlamps. Dipped-beams (if on) Switching dipped-beam and main-beam headlamps High beams When the lever is shifted to this position the high RKA48410 beams come on and the light switch returns to position (a).
Page 161 OPERATION EXPLANATION OF COMPONENTS (C): START position This is the position to start the engine. Keep the key at this position during cranking The key will return to ON position (B). (D): HEAT (preheating) position When starting in cold weather, turn the key to this position. When the key is turned to HEAT (preheating) position (D), the HEAT pilot lamp lights up.
Page 162 EXPLANATION OF COMPONENTS OPERATION REMARK This machine controls the main pump for the best matching by controlling the engine electronically. The dial has a dead zone but it is not abnormal. Range (c) Dead zone (engine speed is constant) P mode: 22% E mode: 30% Position (d) High idle...
Page 163 OPERATION EXPLANATION OF COMPONENTS The switch is used to set the axle locking in two modes. Press (a) to select the axle locking mode. Release the switch and press (b) to use the automatic axle locking mode. Each time the axle locking mode is selected, the state is dis- played on the monitor.
Page 164 EXPLANATION OF COMPONENTS OPERATION ATTACHMENT 1 PROPORTIONAL SWITCH The 1st-line attachment proportional switch is on the right PPC valve lever and it is used to operate the attachment. For handling of the 1st-line attachment proportional switch, see “ATTACHMENT 1 PROPORTIONAL SWITCH (6-10)”. RKA48500 ATTACHMENT 2 PROPORTIONAL SWITCH The 2nd-line attachment proportional switch is on the left PPC...
Page 165 OPERATION EXPLANATION OF COMPONENTS HORN PUSH BUTTON The horn push button is used to sound the horn. RKA48390 CAMERA ACTIVATION SWITCH This switch is located on the right joystick and is used to pass rapidly from the camera screen plus indicators to the one dis- playing just the camera and vice-versa.
Page 166 EXPLANATION OF COMPONENTS OPERATION When activated the green indicator (a) is displayed on the ma- chine monitor. Every time the switch is pressed the axle locking is enabled/ disabled. RKA48515 ROOM LAMP SWITCH NOTICE If the room lamp is left to be turned on, the batteries may be exhausted.
Page 167 OPERATION EXPLANATION OF COMPONENTS SWITCH ENABLING TRANSLATION CIRCUIT IN AN EMERGENCY NOTICE • The switch enabling the translation circuit allows you to move short distances in an emergency when faults show up in the gear selector. The travel direction is set with the travel direction switch in an emergency.
Page 168 • After moving the machine or work equipment temporarily by operating this switch, stop the engine, return the switch to normal position (b), and then ask your Komatsu distribu- tor for repair. RKA48520 3-100...
Page 169 OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch. • If the engine shutdown secondary switch is moved to engine stop position by mistake while the ma- chine is operating normally, “Engine Shutdown Secondary SW in Operation”...
Page 170 EXPLANATION OF COMPONENTS OPERATION • When the starting switch is turned to ON position while the engine shutdown secondary switch is in the engine stop position (a), “Engine Shutdown Secon- dary SW in Operation” is displayed on the machine monitor. If this screen is displayed, return the engine shutdown secondary switch to normal position (b).
Page 171: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS RKA48530 (1) Lock lever (7) Steering column lock (2) L.H. work equipment control lever (8) Steering wheel (3) R.H. work equipment control lever (9) Steering wheel column position adjuster (4) Swing lock cover (10) Brake pedal (5) Boom swing control pedal (11) 2-piece boom control pedal...
Page 172 When the hydraulic oil temperature is low (When the hydraulic oil temperature caution lamp in- dicates low temperature) • When the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends • When system has failure •...
Page 173 OPERATION EXPLANATION OF COMPONENTS To cancel the lock, return the lock lever to LOCK position (L), check that each control lever and the attachment switch are in neutral, and then release the lock lever again. TRAVEL PEDAL WARNING • Before operating the drive pedal, make sure that the top turret is facing the oscillating front axle; if the tower is turned 180°, the controls are inverted.
Page 174 EXPLANATION OF COMPONENTS OPERATION STEERING WHEEL WARNING Before operating the drive pedal, make sure that the top turret is facing the oscillating front axle; if the tower is turned 180°, the controls are inverted. The machine can be steered by turning the steering wheel in the desired direction.
Page 175 OPERATION EXPLANATION OF COMPONENTS This mechanical device is positioned on the left side of the ped- al and has following positions. For travel on roads (lever pressed forward) This position allows the brake pedal to move freely and must always be selected for travelling on roads.
Page 176 EXPLANATION OF COMPONENTS OPERATION The swing lock cover is used to lock the boom swing control pedal. The pedal is locked by covering it with the plate. (L): LOCK (F): FREE BOOM SWING CONTROL PEDAL WARNING When a bucket wider than the standard bucket is installed, if the upper structure is swung to the left with the work equipment pulled in, the bucket interferes with the cab and can cause a serious personal injury or death.
Page 177: Other Equipment
OPERATION EXPLANATION OF COMPONENTS OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING CEILING WINDOW WARNING When leaving the operator's seat, set the lock lever securely to LOCK position. If the lock lever is at FREE position and the control lever, control pedal, or control switch is touched by mistake, it is dangerous and may cause serious personal injury or death.
Page 178 EXPLANATION OF COMPONENTS OPERATION Opening Stop the machine on a level ground, lower the work equipment to the ground, then stop the engine. Set the lock lever to LOCK position (L). Check that the windshield wiper is in the right position. Hold two handles (A) on the right and left top sides of the front window, and pull two levers (B) to release the locks at the top of the front window.
Page 179 OPERATION EXPLANATION OF COMPONENTS Hold lower handle (C) with your left hand from inside the operator's cab, and with your right hand, grip top handle (D). Pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window. REMARK You may not use the two grips (A) on the left and right top sides of the front window to pull up the front window.
Page 180 EXPLANATION OF COMPONENTS OPERATION Set the lock lever to LOCK position (L). Grip right and left handles (A), and pull down lever (B) to release the lock. Grip handle (C) at the bottom of the front window with your left hand and handle (D) at the top with your right hand, push to the front, then lower slowly.
Page 181 OPERATION EXPLANATION OF COMPONENTS Check that lever (B) is securely at LOCK position. • If the arrow on lock case (F) matches the position of the arrow on lever (B), the lock is engaged. Check vis- ually. • If the arrow on lock case (F) does not match the posi- tion of the arrow on lever (B), the lock is not engaged.
Page 182 EXPLANATION OF COMPONENTS OPERATION Set lock (2) to FREE position (F) and press the upper side of the glass. Turn lock (2) 90 deg. counterclockwise to LOCK posi- tion (L) to fix the upper side of the glass. NOTICE When stowing the glass, lock it securely and check that there is no play.
Page 183 OPERATION EXPLANATION OF COMPONENTS If it should become impossible to open the cab door for any reason, and it is necessary to make an emergency escape from the operator's compartment, use hammer to escape. To escape from the operator's cab, use hammer to break the glass and escape through the window.
Page 184 POWER SUPPLY OUTLET NOTICE When installing an electrical component which is not a product of Komatsu, limit its capacity to maxi- mum 240 W in the 24 V specification (equivalent to 10 A). When installing an electrical component of capacity larger than above value, consult your Komatsu distributor.
Page 185 OPERATION EXPLANATION OF COMPONENTS Left connector No.: M10 Right connector No.: M09 For the connection type connector, see the following table. Left connector No.: M10 X type housing (2 poles) Terminal Grommet AVS 0.5 to AVS 0.5 to Body Rear holder AVS 2 to 3 AVS 2 to 3 1.25...
Page 186 EXPLANATION OF COMPONENTS OPERATION FUSE NOTICE Before replacing a fuse, be sure to turn the starting switch to OFF position, then turn the battery discon- nect switch to OFF position. • The fuse holder is installed inside the cover at the rear left of the operator's seat.
Page 187 OPERATION EXPLANATION OF COMPONENTS F01B Fuses Fuse (A) Name of circuit Front right light on cabin Light on arm (optional) Antithief c. Quick coupler Refuel pump RKA52300 Front left light on cabin Rear light on cabin Rototilt Parking brake (10) Direction light (11) Road light (main fuse)
Page 188 Do not let water, mud, or beverage spill on the controller. This will cause failures. • If any problem occurs in the controller, do not repair it by yourself. Contact your Komatsu distribu- tor for repair. The pump controller and KOMTRAX controller are installed in- side the rear cover at the rear of the operator's cab.
Page 189 OPERATION EXPLANATION OF COMPONENTS TOOLBOX AND GREASE PUMP STORAGE COVER Open the door of the tool compartment located on the left cabin access ladder. This contains the standard tools supplied and the greasing pump. FIRE EXTINGUISHER (if equipped) A fire extinguisher is prepared at the rear part inside the opera- tor's cab.
Page 190 Even if the starting switch is in OFF position, the controller may operate. The system operating lamp lights up at this time, but it is not a failure. • After the starting switch has been turned OFF, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. 3-122 WENAM00061...
Page 191 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 192 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 193: Machine Operations And Controls
Accumulation of flammable material or leakage of fuel or oil around the high temperature parts such as the engine muffler or battery may cause fire. Check carefully, and if any problem is found, repair it or contact your Komatsu distributor. If the machine is inclining, make it level before checking.
Page 194 12. Check the bucket with hook for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, ask your Komatsu distribu- tor for repair. 13. Check and clean the camera Check the camera for any abnormality.
Page 195 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK Swing the upper structure so that inspection cover (1) is between the wheels. Open cover (1) with the hand. Place a container under drain hose to receive fuel. RKA50390 Open drain valve (2) to discharge the sediment and water in the bottom together with the fuel.
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT Open engine hood (1). For details, see “METHOD FOR OPENING ENGINE HOOD (3-192)” Lock securely with hood support lever (2). RKA47580 Check for water and sediment. The water separator forms one unit with fuel prefilter (3).
Page 197 OPERATION MACHINE OPERATIONS AND CONTROLS Turn valve (8) to CLOSE position (S). Place a container under the fuel prefilter cartridge to re- ceive the fuel. RKA47561 Loosen drain valve (6) and drain water and sediments from transparent cup (4), and also drain all the fuel from fuel prefilter cartridge (3).
Page 198 MACHINE OPERATIONS AND CONTROLS OPERATION “State B” When setting the machine posture to state B, follow the procedure below. Start the engine, and run it at low speed. Lower the blade and/or the outriggers to the ground. Extend the arm and bucket cylinders. Swing the boom to the center.
Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS If oil is added in state B, pressurize the hydraulic tank by performing steps 8) to 10). NOTICE If the hydraulic tank is not pressurized, air is sucked in the pump and it affects the components badly.
Page 200 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to make the repair. • Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clog- ged with dirt or dust, wash the battery cap to clear the breather hole.
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Perform inspection for the piping of “battery”, “starting motor”, and “alternator” with particular care. • Perform inspection to confirm that the fuses have no defect and their capacity is proper. • Perform inspection to confirm that there is no disconnection or trace of short-circuiting in the electric wiring and no damage to the coating.
Page 202 Check that the filter placed at the end of the pipe is clean. • 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 203 OPERATION MACHINE OPERATIONS AND CONTROLS Release the lock (1) and open the cover (2). Open the right hand side door (3). Remove the filling hose (4). Remove the plug of the fitting (5) inside the side bonnet (3) and connect the filling tube (4) to the fitting. Check if the valve is open and put the free end of the refilling hose in the container for fuel.
Page 204 After checking, turn the starting switch back to OFF position. If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs.
Page 205 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the lock lever to LOCK position to pre- vent any accidental contact with the control levers. •...
Page 206 MACHINE OPERATIONS AND CONTROLS OPERATION Push lever (2) down to adjust the angle of the front of the seat. (4 stages) • To raise the angle at the front of the seat, keep the lever pushed down and apply your weight to the rear of the seat. •...
Page 207 OPERATION MACHINE OPERATIONS AND CONTROLS Fore-and-aft adjustment of seat unit (D) Raise lever (6) adjust the desired position, then release lever (6). The operator's seat, right and left control levers, and lock lever all slide (move) together. Fore-and-aft adjustment: 120 mm (12 stages) RKA52843 Hardness adjustment of suspension seat (E) As turning knob (7) clockwise or counterclockwise, suspension...
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRRORS (A) AND (A1) Adjust the mirror support in a way that will enable you to see the people in the rear left hand side with the mirror (A) and in the lateral front right hand side with the mirror (A1). If the mirror is removed, install it to the position shown in the figure.
Page 209 OPERATION MACHINE OPERATIONS AND CONTROLS PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (C) Adjust the rear view mirror (C) in such a way that the operator seated in its driving seat is able to view the machine rear side and persons standing at a distance of 1 m from the machine. RKA54090 RKA54100 Adjust the mirror so that the rear side of the machine is re-...
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING STEERING WHEEL WARNING • The steering wheel is power-assisted; if the engine stops, steering requires considerable effort and becomes imprecise, with serious consequences for the safety of the machine. If this condition occurs, stop the machine with the parking brake and immediately contact your Ko- matsu distributor.
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the angle of the rear view camera so that people within 1 m away from the machine's rear part (W) appears in the ma- chine monitor at the operator's seat. RKA48620 RKA50410 RKA48630 If the image on the monitor is not aligned correctly, adjust mounting angle (A) of the rear view camera in the following procedure.
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION Remove bolts (4) (2 places). Remove cover (1). Loosen the screws (5) (no. 3) of the camera and adjust the installation angle (A) of the camera to about 45° with re- spect to the horizontal plane. RKA54640 After adjusting, tighten bolts (5).
Page 213 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING • When starting the engine, check that the lock lever is securely at LOCK position. If the lock lever is not locked securely and the control levers or control pedal are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury or death.
Page 215 On the input display screen displayed on the monitor, input the password and push input confirmation switch F6 (3). REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the pass- word. •...
Page 216: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION The screen changes to the working mode and travel speed display screen after approximately 2 seconds, and then it changes to the standard screen. • Engine coolant temperature gauge (6) • Engine coolant temperature caution lamp (7) •...
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • Do not start the engine with the fuel control dial near High idle (MAX) position. If you do so, the engine parts may be damaged. • Do not keep the key in starting switch (2) at the START position continuously for more than 20 seconds.
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION When the engine starts, release the starting switch key (2). The key will return to ON position (B). REMARK When the engine is started, the battery voltage may sud- denly drop depending on the temperature and the battery condition.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • Do not start the engine with the fuel control dial near High idle (MAX) position. If you do so, the engine parts may be damaged. • Do not keep the key in starting switch (2) at the START position continuously for more than 20 seconds.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION Hold starting switch key (2) in HEAT (preheating) position (D). Preheating monitor (4) lights up, and after approximately 30 seconds it flashes for 10 seconds to notify completion of preheating. After preheating monitor (4) goes out, turn starting switch key (2) to START position (C).
Page 221: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 222 METHOD FOR RUNNING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS Turn fuel control dial (2) to the middle between Low idle (MIN) and High idle (MAX) to run the engine at a medium speed. RKA48652 Run the engine with no load until engine coolant temperature caution lamp (1) displays proper temperature. •...
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (2) to Low idle (MIN) position. The engine automatic warm-up is canceled, and the en- gine speed is lowered. REMARK Turbo protect function takes priority over the engine automatic warm-up. When the turbo protect function activates, run the engine at low idle even the engine coolant temperature is 30 °C or less.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS Set the working mode to P mode (heavy-duty operation mode). Warm up the hydraulic component quickly. For the details of the working mode setting procedure, see “WORKING MODE SELECTOR SWITCH (3-46)”. RKA48160 Move lock lever (2) slowly to FREE position (F). Raise the bucket from the ground.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION Slowly activate the pedal of the positioning arm forward (E) to extend it completely. Activate the pedal to the full extent and hold it in position for 30 seconds. Retract the arm completely and maintain it in position (F) for 30 seconds. Repeat the operation of step from 5 to 7 for 5 minutes.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS If any problem is found, contact your Komatsu distributor. 13. Hydraulic system warm-up operation in cold weather NOTICE In cold temperatures (ambient temperature below 0°C (32°F)), even when the hydraulic oil tempera- ture caution lamp displays the proper temperature, perform the "warm-up operation for hydraulic equipment in cold temperatures"...
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION Swing control To rotate the turret, shift the left joystick to the left or to the right. Boom control - Blade/outriggers control To operate the boom, move the right joystick backwards or forwards. Bucket control To operate the bucket, move the right joystick right or left.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS For the additional equipment, select the right working mode. RKA48500 16. Deactivate the camera and check that the indicator light (6) of the hydraulic oil temperature (6) indicates the correct value. • Display (A) when temperature is proper: Caution lamp background (C) is blue.
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION Press the working mode selector switch of the machine monitor to select the working mode to be used. RKA48190 Display of working mode P mode E mode Heavy-duty operations For fuel economy conscious operations RKA48160 RKA48167 L mode B mode...
Page 231: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stopping the engine. NOTICE If the engine is stopped abruptly, the service lives of com- ponent parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency.
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR MOVING MACHINE WARNING • Before moving the machine, make sure that you perfectly know the control functions and all the rel- evant safety regulations. • The operator must be seated in the driving position with fastened seat belt. •...
Page 233 “PARKING BRAKE SWITCH (3-95)” RKA48490 11. Gradually operate the travel pedal (4). Check that the trav- el alarm works properly. If the alarm does not sound, con- tact the Komatsu Dealer, who will carry out all the neces- sary repair operations. RKA49000 3-165...
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING MACHINE WARNING Avoid a sudden stop. Stop the machine gradually. RKA52360 Stopping in normal situations Release the drive pedal (1) and press the brake pedal (2) to stop the machine. Put the gear in neutral (N) with the switch on the right joy- stick (3).
Page 235: Method For Traveling On Road
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TRAVELING ON ROAD WARNING • Before moving the machine, make sure that you perfectly know the control functions and all the rel- evant safety regulations. • The operator must be seated in the driving position with fastened seat belt. •...
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION Position the rotating support and the chassis aligning the collimation marks as shown in the figure. RKA52350 Position the arm aligning the decal to the collimation marks as shown in the figure. RKA54110 Lower the blade and/or the outriggers. If the machine has outriggers, secure them with the safety cords.
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS 14. Check the alignment of the rear wheels, and align them if necessary. For detail, see “INDICATOR FOR SIGNALLING THE REAR WHEELS ARE NOT ALIGNED (3-43)”. 15. Put the hand throttle (3) to the desired engine speed. For detail, see “FUEL CONTROL DIAL (3-93)”. 16.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION Check that there are no people or obstacles around the area. Start the engine and set the lock lever (1) to FREE position (F). If you have to travel on a road, align the marks and secure the outriggers and the bucket with safety cords.
Page 239: Method For Selecting Steering Mode
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR SELECTING STEERING MODE Three steering modes are available: • 2WS steering: to be used when moving fast and when travelling on roads • 4WS steering (cornering): to be used in the tight spaces of construction sites •...
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION Use the R.H. and L.H. work equipment control levers to operate the work equipment. When the levers are released, they return to NEUTRAL position and the work equipment is held in that position. • Arm control Move the L.H.
Page 241: Handle Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS • Boom swing control Depress either right or left of the boom swing control ped- You can swing the boom. • Blade or outriggers control Press the blade/outriggers control switch on the right joy- stick. When the blade/outriggers mode is active, the icon (a) is displayed on the machine monitor for 2 seconds and it is possible to control the blade/outriggers selected, whose indicator lights (b) become green.
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION Working mode Applicable operations Normal digging or loading operations P mode (production conscious operation) Normal digging or loading operations E mode (fuel consumption conscious operation) Aligning or lifting operations (fine control op- L mode eration) B mode Breaker operations Operations of double-acting attachment on...
Page 243: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING • Do not operate the work equipment control lever when the machine is traveling. • If any lever is operated when the auto-deceleration is being actuated, the engine speed will sudden- ly increase, so be careful when operating. PROHIBITION OF OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging, nor use the dropping force of the bucket as a mattock, breaker, or pile driver. This will drastically reduce the life of the machine. PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig.
Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces. As a result, large vibration occurs in the machine and can crack the work equipment or frame.
Page 246: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION GROUND WHOLE THE BOTTOM SIDE OF BLADE TO SUPPORT MACHINE When using the blade as an outrigger, never support the ma- chine with only one end of the blade. PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELING Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the under- carriage), and this will cause damage to the machine.
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR FOLDING BLADE When folding in the work equipment to the travel or transporta- tion posture, be careful not to let the bucket hit the blade. PRECAUTIONS FOR HITTING BLADE AGAINST OBJECTS DURING OPERATING BLADE Be careful not to hit the blade against rocks or boulders.
Page 248: Precautions For Working On Slope
MACHINE OPERATIONS AND CONTROLS OPERATION PERMISSIBLE DEPTH OF WATER, SOIL AND DIRT NOTICE When traveling the machine out of water, if the angle of the machine exceeds 15 °, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan, and it may leads breakage of fan.
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS Do not travel downhill in reverse. Never turn on slopes or travel across slopes. Always go down to a flat place to perform these operations. It may be a longer way, but it will ensure safety. Always operate or travel in such a way that it is possible to stop safely at any time if the machine slips or becomes unstable.
Page 250: Method For Escaping From Mud
MACHINE OPERATIONS AND CONTROLS OPERATION WHEN OPERATING ON SLOPE • Never perform swing operation on a slope by using the left work equipment control lever if the engine stops. The upper structure will swing under its own weight. • Do not open or close the slide door while traveling or operating the machine on a slope. The operating effort may suddenly change.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS When the condition of the machine is as shown in the figure (angle between "bucket cylinder and link" and "arm cylinder and arm" is 90 deg.), the maximum excavation force is ob- tained from the pushing force of each cylinder. When excavating, you can optimize your working efficiency by using this angle effectively.
Page 252 MACHINE OPERATIONS AND CONTROLS OPERATION SIDE DITCHING WORK The operator can perform ditching work in a narrow space by combining swing and boom swing operations. LOADING WORK In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator.
Page 253: Method For Lifting Objects With Lifting Device
In the absence of such a device, the machine can only be used as an earth moving machine. If the machine is not equipped with the appropriate hook, contact the Komatsu distributor. Fitting a lifting hook must be monitored and certified by the competent Authorised Body.
Page 254: Method For Replacing And Inverting Bucket
MACHINE OPERATIONS AND CONTROLS OPERATION The lifting capacities outlined in the tables relate to machines equipped with a standard bucket. METHOD FOR REPLACING AND INVERTING BUCKET WARNING • When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When performing this operation, always wear goggles, hard hat, gloves, and other personal protec- tive items.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS Align arm (5) with hole (1) of the replacement bucket. Align link (6) with hole (2) of the replacement bucket. Apply grease to pins (A) and (B) and insert them into holes (1) and (2) of the bucket. REMARK •...
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, be careful not to damage them. Remove the double nut of stopper bolt at arm pin (A) and link pin (B), then pull out the bolts.
Page 257: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Place the machine on a firm and level place. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, put blocks under the wheels. As an additional safety measure, thrust the bucket into the ground.
Page 258: Method For Checking After Finishing Work
MACHINE OPERATIONS AND CONTROLS OPERATION Engage the boom swing control pedal (3). Set the lock lever (4) to LOCK position (L). Check the engine coolant temperature and engine oil pres- sure with the machine monitor. • If the engine coolant temperature gauge is in the red range, cool down the coolant until the gauge enters the green range, and stop the engine.
Page 259: Lock
OPERATION MACHINE OPERATIONS AND CONTROLS LOCK Lock position Always lock the following places: (1) Operator's cab door (2) Toolbox and grease pump storage cover (3) Engine hood (4) Dirt cover (5) Battery inspection cover (6) Air conditioner fresh air filter storage cover REMARK RKA48830 Use the starting switch key to lock and unlock all these places.
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING ENGINE HOOD CAUTION • When opening or closing the engine hood, place the machine on a level ground, lower the work equipment to the ground, stop the engine, then perform the operation. •...
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS For checks before starting For maintenance METHOD FOR LOCKING ENGINE HOOD Hold the grip of hood (2) and remove hood support lever (3) from the hood fixing position. Securely fix hood support lever (3) to the lever lock. Lower and press the hood slowly to lock it securely.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING DIRT COVER CAUTION • Never stand on the cover. You may slip and fall. • When inspecting or servicing the inside of the cover, be sure to fix the cover open by using the cov- er support lever.
Page 263 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR LOCKING DIRT COVER Hold the grip of hood (2) and remove hood support lever (3) from the hood fixing position. Securely fix hood support lever (3) to the lever lock. Lower and press the hood slowly to lock it securely. Insert the key into the key slot.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION Remove cover support lever (4) from mounting hole (5) of cover (3). Insert cover support lever (4) into hole (6) of the bottom cover. METHOD FOR LOCKING BATTERY INSPECTION COVER Remove cover support lever (4) from hole (6) of the bottom cover.
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS Position (A): OPEN Position (B): LOCK RKA48870 Lock Close the cover and insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key. 3-197 WENAM00061...
Page 266: Handle Air Conditioner
RKA48880 tion lamp lights up on the monitor screen. If the air condi- tioner system caution lamp lights up, ask your Komatsu distributor for inspection and repair. VENTILATION • When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform ventilation and cooling.
Page 267: Explanation Of Air Conditioner Equipment
OPERATION HANDLE AIR CONDITIONER EXPLANATION OF AIR CONDITIONER EQUIPMENT RKA48890 (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Fan switch (7) Monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Sunlight sensor (5) Auto switch OFF SWITCH This switch is used for stopping the fan and air conditioner.
Page 268 HANDLE AIR CONDITIONER OPERATION Monitor display and air flow Monitor display Air flow rate Air flow "low" Air flow "medium 1" Air flow "medium 2" Air flow "medium 3" Air flow "medium 4" Air flow "high" TEMPERATURE SET SWITCH Use the temperature set switch to adjust the temperature inside the cab.
Page 269 OPERATION HANDLE AIR CONDITIONER VENT SELECTOR SWITCH Use vent selector switch to select the vents. • When vent selector switch is pressed, the arrow display on the monitor switches and air blows out from the vents dis- played. • During automatic operation, the vents are automatically selected.
Page 270 HANDLE AIR CONDITIONER OPERATION AUTO SWITCH Use the auto switch for automatic selection of the air flow, vents, and air source (FRESH/RECIRC) according to the set temperature. • Press this switch, then use temperature control switch (1) to set the temperature, and run the air conditioner under automatic control.
Page 271: Method For Operating Air Conditioner
OPERATION HANDLE AIR CONDITIONER AIR CONDITIONER SWITCH Use air conditioner switch for turning the air conditioner (cool- ing, dry heating) ON or OFF. • Press air conditioner switch when the fan is operating (when display (b) is shown on the display monitor). The air conditioner is switched ON and starts to work.
Page 272 HANDLE AIR CONDITIONER OPERATION Set temperature (a) and air flow rate (b) are displayed on “A/C Setting” screen. Use temperature control switch (3) to set to the desired temperature. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated auto- matically to provide the set temperature.
Page 273 OPERATION HANDLE AIR CONDITIONER METHOD FOR MANUAL OPERATION Press fan switch (2) and adjust the air flow. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting” screen of the moni- tor. Press air conditioner switch (8) to turn it ON.
Page 274 HANDLE AIR CONDITIONER OPERATION Press vent selector switch (4) and select the desired vents. At this time, the display of vent (c) on “A/C Setting” screen of the monitor changes according to the selection. Press FRESH/RECIRC selector switch (6) and select recir- culation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
Page 275 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. Press fan switch (2) and adjust the air flow rate. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting”...
Page 276 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING DEFROSTER Press fan switch (2) and adjust the air flow rate. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting” screen of the moni- tor.
Page 277 OPERATION HANDLE AIR CONDITIONER Press temperature control switch (3) and set temperature to 32.0 of maximum heating. Adjust vents (A), (B1), and (B2) so that the air blows onto the window glass. (Vents (C) and (D) are fixed and cannot be adjusted). RKA50500 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify...
Page 278: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 279: Transportation
OPERATION TRANSPORTATION TRANSPORTATION PRECAUTIONS FOR TRANSPORTING MACHINE When transporting the machine, observe all related laws and regulations, and be careful to assure safety. SELECT TRANSPORTATION METHOD When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS (5-2)”.
Page 280: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER WARNING Always observe the following when loading or unloading the machine from a trailer. • Select the firm, level ground when loading or unload- ing the machine. Maintain a safe distance from the road shoulder.
Page 281 OPERATION TRANSPORTATION WARNING Always observe the following regarding the ramps and trailer platform. • Use ramps with ample width, length, thickness, and strength and install them with a maximum slope of 15 deg. When using piled soil, compact the piled soil fully to prevent the slope face from collapsing. •...
Page 282 TRANSPORTATION OPERATION • Each time auto-deceleration switch is pressed, it switches OFF to ON to OFF in turn. • When auto-deceleration switch is turned OFF, the au- to-deceleration pilot lamp goes out. When loading, lift the blade and/or outriggers and position the machine with bucket raised and facing forwards.
Page 283 OPERATION TRANSPORTATION Securing the machine After positioning the machine on the trailer, fix it as shown be- low. RKA52400 Position a block of wood at one end of the bucket cylinder (1) to prevent it touching the floor. Secure the machine in the correct position by putting wedges (2) before and behind each wheel.
Page 284 TRANSPORTATION OPERATION Y= 20°–50° Protect the end of the exhaust pipe (5). RKA52420 RKA52380 PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm, level ground. Maintain a safe distance from the road shoulder. Apply the trailer brakes securely, then put chocks (1) under the tires to prevent the trailer from moving.
Page 285 OPERATION TRANSPORTATION Set the lock lever to FREE position (F). Set the slow speed (CR). For detail, see “SWITCH FOR INCREASING TRAVEL SPEED (3-48)”. RKA48158 Turn auto-deceleration switch OFF and operate the fuel control dial to set the engine to low speed. Each time auto-deceleration switch is pressed, it switches OFF to ON to OFF in turn.
Page 286: Method For Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
Page 287 OPERATION TRANSPORTATION Set the lock lever to LOCK position (L). Stop the engine. Check that there is nothing around the operator's seat, and then get off the machine. Close the cab door and front window securely. Connect the hoisting means and check that no cable or chain will interfere with the machine. NOTICE The lifting points are symmetrical.
Page 288 TRANSPORTATION OPERATION Lifting the machine with blade Hook up the chains to the blade (3) as shown. RKA52600 RKA52610 3-220 WENAM00061...
Page 289: Cold Weather Operation
When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 290: Precautions After Daily Work Completion
COLD WEATHER OPERATION OPERATION Electrolyte Temper- ature 20 °C 0 °C -10 °C -20 °C Charging Rate (%) 1.28 1.29 1.30 1.31 1.26 1.27 1.28 1.29 1.24 1.25 1.26 1.27 1.23 1.24 1.25 1.26 • As the battery capacity drastically drops in low temperatures, cover or remove the battery from the ma- chine, store the battery in a warm place, and install it again the next morning.
Page 291: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 292 PRECAUTIONS FOR LONG-TERM STORAGE OPERATION • Insert the battery disconnect switch key and turn it to ON position. For the operation method, see “BATTERY DISCONNECT SWITCH (3-121)”. • If the machine is stored for a long period with the battery disconnect switch OFF or the battery terminal dis- connected, the clock information and radio tuning information may be lost.
Page 293: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system before starting the engine. Always check the fuel level to prevent running out of fuel. If the engine has stopped due to run out of fuel, all air must be sufficiently bled from the fuel circuit.
Page 294: Precautions For Towing Machine
TROUBLES AND ACTIONS OPERATION • When performing bucket CURL operation from a high posi- tion for digging under no load, the bucket speed drops mo- mentarily at the horizontal position. • The bucket or arm wobbles by itself during heavy-duty dig- ging operations.
Page 295: Precautions For Severe Job Condition
OPERATION TROUBLES AND ACTIONS Disengage the gear by manually positioning the control rod (1) in neutral. Check that the parking brake is disengaged. For details, see “PARKING BRAKE SWITCH (3-95)” If there is a fault with the parking brake relay, use the emergency lever.
Page 296: Precautions For Discharged Battery
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 297 OPERATION TROUBLES AND ACTIONS METHOD FOR REMOVING BATTERY Open engine hood (1). Lock the engine hood securely with the hood support lever. Open battery inspection cover (2). Lock the battery inspection cover securely with the cover support lever. Remove wing nuts (3) (2 places). Remove rubber cover (4).
Page 298 TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, it is dangerous that the battery may explode. Al- ways follow the instructions in “PRECAUTIONS FOR DIS- CHARGED BATTERY (3-228)” and the instruction manual accompanying the charger, and do as follows.
Page 299 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 300: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 301 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Charge level caution lamp does not Defective alternator Replace. (*) go out even when engine is running. Defective wiring Check, repair. (*) Loose fan belt Check fan belt tension and replace. Unusual noise is generated from al- Defective alternator Replace.
Page 302 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 303 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Steam spurts out from top of radiator Lowered coolant level, leakage of Check, add coolant, repair. See (pressure valve). coolant CHECKS BEFORE STARTING. Loose fan belt Check fan belt tension, replace. (*) Dirt or scale accumulated in cooling Change coolant, flush inside of cool- system...
Page 304 “METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE (4-49)” and “METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE (4-65)”. If “CA2249” or “CA559” does not disappear even after the replacement, ask your Komatsu distributor for inspection immediately, even though the machine can perform normal operation.
Page 305: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section. WENAM00061...
Page 306: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 307: Avoid Mixing Oil
MAINTENANCE PRECAUTIONS FOR MAINTENANCE • When checking and replacing the oil or filters, move the machine to a place where there is no dust and take care to prevent dust from entering the system. AVOID MIXING OIL Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil.
Page 308: Outline Of Maintenance
Komatsu distributor. • When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend you to use the Komatsu oil clinic to check the characteristics of the oil in detail. FUEL •...
Page 309 The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible.
Page 310 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 311: Handle Electrical Components
Never install any electrical components other than those specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. •...
Page 312: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 313 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Tighten the hoses to the torque shown in the table. Width Tightening torque acros Nominal - No. of Target value Allowable range s flats threads "a" "b" Nm kgm lbft Nm kgm lbft (mm) 9/16-18UNF...
Page 314: Maintenance Schedule
250 hours. For details, see the oil part number and note in “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (7-6)”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 50 HOURS MAINTENANCE (ONLY AFTER THE FIRST 50 HOURS) ..........4-13 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) ..........
Page 315: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE TABLE METHOD FOR DRAINING THE HYDRAULIC OIL TANK ............... 4-55 METHOD FOR CLEANING THE ELECTRIC COMMUTATOR OF THE ROTATING JOINT ....4-57 METHOD FOR CHECKING THE BRAKE ACCUMULATOR PRECHARGE PRESSURE......4-58 EVERY 1000 HOURS MAINTENANCE ......................4-59 METHOD FOR CHECKING THE BRAKING PRESSURE ...............
Page 316 MAINTENANCE SCHEDULE TABLE MAINTENANCE REMARK Breaker operating ratio 100% means that only the breaker is used Breaker operating ratio 0% means that the breaker is not used 4-12 WENAM00061...
Page 317: Maintenance Procedure
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) Adjust the parking brake. For checking and adjusting contact the Komatsu dealer. INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Carry out the following maintenance operations after the first 250 hours of work.
Page 318 MAINTENANCE PROCEDURE MAINTENANCE Check Open engine hood (1). For detail, see “METHOD FOR OPENING ENGINE HOOD (3-192)”. Fix the cover with cover support lever (2). RKA47580 NOTICE Do not clean the element before the red piston is projected into the transparent part of dust indicator (3). If the element is cleaned frequently before the red piston protrudes, the air cleaner cannot display its normal per- formance and the cleaning effect decreases.
Page 319 MAINTENANCE MAINTENANCE PROCEDURE NOTICE When cleaning cover (6), do not remove vacuator valve (9). Clean the inside of the air cleaner body and cover (6). Replace outer element (7) after you have cleaned 6 times or it has been used for a year. •...
Page 320 MAINTENANCE PROCEDURE MAINTENANCE CAUTION When installing the cover (6), check O-ring (10) for scratches or damages and replace O-ring with a new one if any. Install cover (6) according to the following procedure. Set a new outer element (7). Align matchmarks (11) on the body and cover (6). Install cover (6) and fix it with clip (5).
Page 321 MAINTENANCE MAINTENANCE PROCEDURE Remove outer element (7). Do not remove inner element (8) at this time. NOTICE When cleaning cover (6), do not remove vacuator valve (9). Clean the inside of the air cleaner body and cover (6). Remove inner element (8), then quickly install the new in- ner element.
Page 322: Method For Cleaning Inside Of Cooling System
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 323 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 324 MAINTENANCE PROCEDURE MAINTENANCE Check that the coolant temperature is low enough to make it possible to touch the radiator cap surface by bare hand, turn radiator cap (7) slowly until it hits the stopper, and re- lease the pressure. Then, while pushing radiator cap (7), turn it until it touches the stopper, and remove it.
Page 325 MAINTENANCE MAINTENANCE PROCEDURE 17. Turn the fuel control dial to a point of 2/3 between Low idle (MIN) position and High idle (MAX) position. 18. Operate the work equipment control levers according to the following procedure. NOTICE When the work equipment is operated, take care that it does not interfere with the machine or ground.
Page 326: Method For Replacing Bucket Teeth
MAINTENANCE PROCEDURE MAINTENANCE 27. Drain the coolant in reservoir tank (10). 28. Clean the inside of the reservoir tank. 29. Add coolant up to the middle between FULL and LOW. 30. Stop the engine. 31. Approximately 3 minutes later, add coolant to near the mouth of the water filler port.
Page 327: Method For Adjusting Bucket Clearance
If it is impossible to remove the teeth using this procedure, for safety reasons, it is advisable to have the tooth re- moved by a Komatsu Distributor. Use a rounded bar of slightly less diameter than that of the pin to be extracted.
Page 328: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE PROCEDURE MAINTENANCE Set the work equipment in the position shown in the figure, then stop the engine and set the lock lever to LOCK posi- tion (L). A: Arm B: Bucket: Shift O-ring (1) and measure the amount of play "a". REMARK Measurement is easier if you move the bucket to one side so that all the play can be measured at one place (the right...
Page 329: Method For Checking And Maintenance Air Conditioner
MAINTENANCE MAINTENANCE PROCEDURE There are 2 types depending on the freezing temperature: –10 °C (14 °F) (general use) and –30 °C (–22 °F) (cold district use), select according to the area and season. METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER Check, maintenance items Some maintenance items of the air conditioner need to be inspected periodically and the others are performed irregularly.
Page 330: Method For Checking, Cleaning And Lubricating Slide Door Rail And Roller
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributor to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 331: Method For Checking Stopper Clearance In Opening Front Door Is Up
Check if creaks are heard from sliding door stoppers (1) and (2). If creaks are heard, wipe off dirt from the stoppers. Grease the stoppers. If the stoppers are worn, consult your Komatsu distributor. METHOD FOR CHECKING STOPPER CLEARANCE IN OPENING FRONT DOOR IS UP WARNING •...
Page 332: Method For Washing Washable Floor
MAINTENANCE PROCEDURE MAINTENANCE NOTICE For the element replacement interval, see “MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (4-11)”. Prepare a container to catch oil. Place a container to catch drained oil under the filter ele- ment. Turn filter case (1) counterclockwise and remove it. Remove element (2).
Page 333 MAINTENANCE MAINTENANCE PROCEDURE Lift the machine and position it in an inclined position by means of the rear right outrigger. Completely lower the working equipment until they are positioned on the ground. Insert the parking brake. Set the lock lever to LOCK position (L). Stop the engine.
Page 334: Method For Checking Gas Spring
Do not perform drilling, welding or flame-cutting. • Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. 4-30 WENAM00061...
Page 335: Method For Bleeding Air From Hydraulic Circuit
Gas springs are installed inside the left console (1 place), at the cab ceiling window (2 places on right and left), and inside the engine hood (1 place). In the following cases, ask your Komatsu distributor for inspec- tion, repair, and replacement. •...
Page 336 MAINTENANCE PROCEDURE MAINTENANCE Bleed air from between pump and hydraulic tank Perform it when any hydraulic component or oil is replaced. NOTICE If you run the engine at high speed without bleeding air from the piping between the pump and hydraul- ic tank, the pump may heat abnormally and may be broken in a short period.
Page 337: Method For Checking Wheel Nut Tightening
MAINTENANCE MAINTENANCE PROCEDURE NOTICE • After completing the air bleeding operation, stop the engine, leave the machine for 5 minutes, and then start the operation. This discharges the air bubbles in the oil inside the hydraulic tank. • Check for oil leakage and wipe off any spilled oil. METHOD FOR CHECKING WHEEL NUT TIGHTENING WARNING •...
Page 338: Method For Unlocking Parking Brake
MAINTENANCE PROCEDURE MAINTENANCE When bleeding the system, apply a small pipe to the screws, in order to collect the oil. Place the machine on a level ground, lower the work equipment to the ground, then apply the brake. Loosen the bleed screw (1) until no more air is present in the oil that flows out.
Page 339: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE Place the supplied lever (A) on the release device (1). Push the lever and give it a solid blow to unblock the nega- tive brake. RKA51850 After recovering the standard configuration of the circuit no more adjustments are necessary. CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING (3-126)”...
Page 340: Method For Checking Oil Level In Swing Machinery Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE Set the machine to the greasing posture shown on the fig- ure, lower the work equipment to the ground,and stop the engine. By using a grease pump, apply grease to the grease fittings marked by arrows. (1) Arm and Bucket connection pin (1 place) After greasing, wipe off any old grease that is pushed out.
Page 341: Method For Lubricating Drive Shaft
MAINTENANCE MAINTENANCE PROCEDURE Place a container to catch oil under drain valve (P). Loosen drain valve (P) and drain excessive oil. Check the oil level again. After checking oil level or adding oil, insert dipstick (G) into the hole. METHOD FOR LUBRICATING DRIVE SHAFT Perform cleaning the grease nipples.
Page 342: Every 250 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE By using a grease pump, apply grease to the grease fit- tings marked by arrows. Remove the used grease that may have spread out of the joints. METHOD FOR LUBRICATING THE FRONT AND REAR AXLE JOINTS NOTICE The lubrication points are symmetrical.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE WARNING • Do not use or charge the battery if the battery charge indicator is bright white or, if the battery does not have an indicator, if the level of the electrolyte is below the LOWER line (minimum level). This may cause an explosion.
Page 344 If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufac- turer.
Page 345: Method For Checking And Adjusting Air Conditioner Compressor Belt Tension
If distilled water is added beyond the lower point of the sleeve, use a syringe to remove the electrolyte. Neutral- ize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or your battery manufacturer. METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR...
Page 346: Method For Lubricating Outriggers Pins And Blade
Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks of the belt. Ask your Komatsu distributor for replacement of the belt. METHOD FOR LUBRICATING OUTRIGGERS PINS AND BLADE...
Page 347: Method For Checking The Oil Levels In The Front Axle
MAINTENANCE MAINTENANCE PROCEDURE Set the machine to the greasing posture shown on the fig- ure, lower the work equipment to the ground,and stop the engine. By using a grease pump, apply grease to the grease fittings marked by arrows. (1) Outrigger cylinder base pin (2 points) (2) Outrigger arm fulcrum pin (2 points) (3) Outrigger cylinder head pin (2 points) (4) Outrigger fulcrum pin (2 points)
Page 348: Method For Checking The Oil Levels In The Rear Axle
MAINTENANCE PROCEDURE MAINTENANCE Differential Check visually that the lubricant reaches the hole (1). If necessary, restore the level through the hole (1). Use a 12 mm wrench Final reduction gears This check must be carried out on each reduction gear. Place the reduction gear with the plug (2) on the horizontal axis.
Page 349: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE If necessary, move the machine slightly until reaching the specified position, which is indispensable for an accurate check. Check visually that the lubricant reaches the hole (2). If necessary, restore the level through the hole (2). Use a 12 mm wrench METHOD FOR CHECKING THE OIL LEVELS IN THE TRANSMISSION REDUC- TION GEAR WARNING...
Page 350 MAINTENANCE PROCEDURE MAINTENANCE (2) Boom cylinder base pin (1 point) (3) Boom swing support pins (2 points) Supply grease to the boom swing bracket pin according to the following procedure. Set the boom to the swing neutral position and supply grease to the pin.
Page 351 MAINTENANCE MAINTENANCE PROCEDURE (5) Boom swing cylinder base pin (1 point) (6) Fulcrum link pin (2 points) (7) Bucket cylinder rod end pin (1 point) (8) Articulation-bucket connection pin (2 points) (9) Bucket pushing lever pin (1 point) (10) Arm and bucket fulcrum lever pin (1 place) (11) Bucket cylinder base pin (1 point) (12) Boom-arm coupling pin (1 point) (13) Arm cylinder head pin (1 point)
Page 352 MAINTENANCE PROCEDURE MAINTENANCE Remove undercover (1) at the bottom of the machine. Place the container to catch oil under plug (P). Loosen drain plug (P) to drain oil. Do it slowly so that you do not get splashed with drained oil. Tighten plug (P) .
Page 353: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 354 MAINTENANCE PROCEDURE MAINTENANCE Open engine hood (3). Fix the cover with cover support lever (4). RKA47582 Place a container under the fuel prefilter cartridge to re- ceive the fuel. Loosen drain valve (5) and drain water and sediments from transparent cup (6), and also drain all the fuel from fil- ter cartridge (7).
Page 355: Method For Checking Swing Pinion Grease Level, Add Grease
Check that the grease is not milky white. Total amount of grease: 5.5 ℓ (1.45 U.S.Gal) If the grease is milky white, it needs to be replaced. Ask your Komatsu distributor to replace it. Install grease filler port cover (4) with bolts (3). Install cover (2) with bolt (1).
Page 356: Method For Checking And Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE PROCEDURE MAINTENANCE By using a grease pump, apply grease to the grease fit- tings marked by arrows (2 places). After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING AND CLEANING RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENS- ER FINS WARNING...
Page 357: Method For Cleaning Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE Check the front and rear surfaces of oil cooler fins (7), ra- diator fins (8), aftercooler fins (9), air conditioner condens- er fins (10), and fuel cooler fins (11). If there is any mud, dirt, or leaves stuck to the fins, blow it off with compressed air.
Page 358 MAINTENANCE PROCEDURE MAINTENANCE Clean recirculation air filter Open cover (1) at the front bottom left of the operator's seat. Take out recirculation air filter (2). Clean filter (2) with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash it in a neutral detergent.
Page 359: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and start the work. •...
Page 360 MAINTENANCE PROCEDURE MAINTENANCE NOTICE The tank must be drained before starting the engine, with temperatures exceeding 0°C; when the tem- perature is below 0°C, the tank must be drained at the end of work or in any case with the machine at operating temperature, in order to prevent the condensate from freezing.
Page 361: Method For Cleaning The Electric Commutator Of The Rotating Joint
JOINT WARNING Only use the product approved by Komatsu. Ask your Komatsu distributor for further information. After carrying out this maintenance, start up the engine and - before operating with the machine - check the complete working of the steering system, the speed gear and the outriggers/blade.
Page 362: Method For Checking The Brake Accumulator Precharge Pressure
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor for replacement of the belt. The low-pressure of nitrogen gas (precharge pressure) in the accumulator may cause reduction or lack of braking and may cause serious injury and even death.
Page 363: Every 1000 Hours Maintenance
WARNING If the braking pressure is not correct, the braking system doesn't work correctly and may cause serious injury and even death. Ask your Komatsu distributor for the checking. METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Page 364 MAINTENANCE PROCEDURE MAINTENANCE Open dirt cover (1). Lock securely with hood support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). Remove the cap of oil filler port (F) gradually to release the internal pressure.
Page 365: Method For Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGE OIL IN SWING MACHINERY CASE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. Refill capacity: 2.8 ℓ...
Page 366: Method For Changing The Front Axle Oil
MAINTENANCE PROCEDURE MAINTENANCE Use a 17 mm wrench Put back the plug (1) and pour oil of the prescribed type through the hole (2), until reaching the lower edge of the hole itself. Put back the filler cap (2). Carry out some travel movements, stop the machine and check the level again.
Page 367: Method For Changing The Rear Axle Oil
MAINTENANCE MAINTENANCE PROCEDURE Use a 12 mm wrench Move the machine until the plug (3) is positioned on the horizontal axis. Add oil of the prescribed type until reaching the lower edge of the hole itself. Put back the filler cap (3) and carry out some travel move- ments;...
Page 368: Method For Adjusting The Parking Brake
Put back the filler cap (3) and carry out some travel move- ments; stop the machine and check the levels again. METHOD FOR ADJUSTING THE PARKING BRAKE Ask your Komatsu distributor for the adjusting. METHOD FOR CHECKING OIL LEVEL IN PTO GEAR CASE, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Page 369: Method For Replacing Fuel Main Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE Swing the upper structure so that PTO gear case is at the center between wheels. Set the lock lever to LOCK position (L). Stop the engine. Remove undercover (1) at the bottom of the machine. Remove oil level check plug (G) and check the oil level. If the oil level is near the lower edge of the hole of plug, the oil amount is proper.
Page 370 The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 371: Every 2000 Hours Maintenance
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR CHECKING FAN BELT TENSION AND REPLACING FAN BELT Special tools are required for the inspection and replacement.
Page 372: Method For Changing Oil In Hydraulic Tank, Cleaning Hydraulic Tank Strainer
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER (for machines in which synthetic biodegradable oil HEES is used) WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 373 MAINTENANCE MAINTENANCE PROCEDURE Open dirt cover (1). Lock securely with hood support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). Loose the cap of oil filler port (F) gradually to release the internal pressure.
Page 374 MAINTENANCE PROCEDURE MAINTENANCE 14. Loosen the bolts (4 pieces) and remove cover (7). At this time, cover (7) may jump out under the force of spring (8). Remove the bolts while pressing the cover (7) down a. 15. Hold the top of rod (9), pull it up, and remove spring (8) and strainer (10).
Page 375: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tors (For Control Circuit)
• Do not hit or roll them, or subject them to any impact. • When disposing, the gas must be released. Ask your Komatsu distributor for replacement of the belt. NOTICE If the nitrogen gas charge pressure in the accumulators is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 376 MAINTENANCE PROCEDURE MAINTENANCE Method for checking function of accumulators CAUTION When performing the inspection, check that there is no person or obstacle in the surrounding area. Replace the accumulators every 2 years or every 4000 hours, whichever comes sooner. Check the nitrogen gas charge pressure as follows. Stop the machine on a firm and level place.
Page 377 If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulators for the hy- draulic circuit has probably dropped. Ask your Komatsu distrib- utor for inspection. This completes the inspection. After completion of the inspection, set the lock lever to LOCK position and turn the starting switch to OFF position.
Page 378 MAINTENANCE PROCEDURE MAINTENANCE Turn the starting switch to OFF position (A), and then stop the engine. Turn the starting switch to ON position (B). Set lock lever to FREE position (F), then operate the work equipment control levers and the attachment control switch fully to the front, rear, left, and right to release the pressure in the control circuit.
Page 379: Method For Checking Alternator And Starting Motor
MAINTENANCE PROCEDURE METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for in- spection and repairs. If the engine is started frequently, have this inspection performed every 1000 hours.
Page 380 MAINTENANCE PROCEDURE MAINTENANCE By using tools, loosen bolt (3) and nut (4) of elbow (2) above KCCV ventilator (1). Move loosened bolt (3) and nut (4) along the groove of el- bow (2) to position (A) shown in the figure. By using the filter wrench, loosen cover (7) of KCCV venti- lator (1).
Page 381 MAINTENANCE MAINTENANCE PROCEDURE After removing cover (7) from ventilator body (8), remove element (9). Oil may be accumulated in or sticking to cover (7) and ele- ment (9). When replacing the element, take care that the oil will not spill out. REMARK When the ambient temperature is low, water or emulsified matter may stick to the inside of KCCV because of con-...
Page 382: Every 4000 Hours Maintenance
Boom foot connection hose • Boom cylinder hose • Arm connection hose • Arm cylinder hose • Ask your Komatsu distributor 1st and 2nd boom connection hose • for replacement. 2-piece boom hose • Bucket cylinder hose • Travel line hose •...
Page 383: Method For Checking Water Pump
• Do not hit or roll them, or subject them to any impact. • When disposing it, the gas must be released. Ask your Komatsu distributor for replacement of the belt. NOTICE If the nitrogen gas charge pressure in the accumulators is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 384: Every 5000 Hours Maintenance
(6 places) for the high-pressure piping between the supply pump and the common rail. If there are any problems, the replacement must be performed. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,...
Page 385: Method For Changing Oil In Hydraulic Tank, Cleaning Hydraulic Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and start the work. •...
Page 386 MAINTENANCE PROCEDURE MAINTENANCE Open dirt cover (1). Lock securely with hood support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). Loose the cap of oil filler port (F) gradually to release the internal pressure.
Page 387 MAINTENANCE MAINTENANCE PROCEDURE 14. Loosen the bolts (4 pieces) and remove cover (7). At this time, cover (7) may jump out under the force of spring (8). Remove the bolts while pressing the cover (7) down a. 15. Hold the top of rod (9), pull it up, and remove spring (8) and strainer (10).
Page 388 WENAM00061...
Page 389: Specifications
SPECIFICATIONS WENAM00061...
Page 390 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS With tyres 18-19.5 Overall dimensions Dimensions Element Unit Arm L= 1650 Arm L= 1900 Total length with rear outriggers 5830 5960 Total length with rear blade 5940 6070 Overall height 3860 3900 Total width with blade 2350 2350 Wheelbase 2200...
Page 391 SPECIFICATIONS SPECIFICATIONS Working ranges (mm) Unit Arm L= 1650 mm Arm L= 1900 mm Max. digging height mm 8400 8630 Max. dumping height mm 6330 6525 Max. digging depth mm 4055 4305 Max. vertical wall digging depth mm 3415 3650 Max.
Page 392 SPECIFICATIONS SPECIFICATIONS RKA55390 WENAM00061...
Page 393 6800 Maximum load on rear axle 6000 Bucket capacity (ISO 7451) Bucket L= 650 mm m³ 0.235 Engine model Engine diesel Komatsu SAA4D95LE-6 SAE J1995 (Gross) 50.7/1950 Rated horsepower kW / rpm ISO 9249/ SAE J1349 (Net) 48.8/1950 Turret swing speed 10.0...
Page 394: Lifting Capacities
LIFTING CAPACITIES SPECIFICATIONS LIFTING CAPACITIES WARNING The excavator used in handling operations must conform with current local regulations and be equip- ped with safety valves and an overload alarm in compliance with EN 474-5. For detail see “METHOD FOR LIFTING OBJECTS WITH LIFTING DEVICE (3-185)”. EXPLANATION OF LIFT CAPACITY CHART Legend A: Reach from swing centre...
Page 395 SPECIFICATIONS LIFTING CAPACITIES RKA52790 Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping). LIFTING CAPACITIES TABLES WITH BLADE/OUTRIGGERS RAISED Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping).
Page 396 LIFTING CAPACITIES SPECIFICATIONS 4.5 m 1150 1220 *1550 1200 *1720 *1720 3.0 m 1200 1650 1110 *2370 1610 1.5 m 1140 1540 1010 1020 1130 1490 2110 1350 - 1,5m *1290 1530 1000 2170 1400 With rear blade, arm L=1900, twin tyre - Unit: kg Max.
Page 397 SPECIFICATIONS LIFTING CAPACITIES With rear outriggers, arm L=1650, twin tyre - Unit: kg Max. 6.0 m 5.0 m 4.0 m 4.5 m 1200 1270 *1550 1130 *1720 *1720 3.0 m 1020 1250 1720 1030 *2370 1510 1.5 m 1200 1610 1070 1180 1560...
Page 398 LIFTING CAPACITIES SPECIFICATIONS 4.5 m 1060 1240 *1460 1200 *1580 *1580 3.0 m 1200 1660 1100 *2230 1610 1.5 m 1140 1540 1110 1470 2080 1290 - 1,5m 1180 1490 2120 1330 With front and rear outriggers, arm L=1650, twin tyre - Unit: kg Max.
Page 399 SPECIFICATIONS LIFTING CAPACITIES With rear blade, arm L=1900, twin tyre, turret rotated at 180° - Unit: kg Max. 6.0 m 5.0 m 4.0 m 4.5 m *1470 *1440 *1500 1360 *1620 *1620 3.0 m *1400 *1550 *1810 1260 *2290 1840 1.5 m *1420 *1720...
Page 400 LIFTING CAPACITIES SPECIFICATIONS 4.5 m *1570 *1540 *1600 1290 *1760 *1760 3.0 m *1520 *1620 *1890 1190 *2430 1740 1.5 m *1500 *1760 *2220 1090 *1470 *1740 *2290 1040 *3140 1470 - 1,5m *1330 *1900 1080 *2620 1520 With front blade, arm L=1900, twin tyre - Unit: kg Max.
Page 401 SPECIFICATIONS LIFTING CAPACITIES With front and rear outriggers, arm L=1650, twin tyre - Unit: kg Max. 6.0 m 5.0 m 4.0 m 4.5 m *1570 1070 *1540 1140 *1600 *1600 *1760 *1760 3.0 m *1520 *1620 1110 *1890 1540 *2430 2230 1.5 m *1500...
Page 402 WENAM00061...
Page 403: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section. WENAM00061...
Page 404: Precautions For Using Attachment And Options
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any not authorized by Komatsu. Any personal injury, failure, or property damage caused by the use of unauthorized attachments or options will not be the responsibility of Komatsu.
Page 405 ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS • The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight when it is stopped in a raised position) also becomes greater. Do not stop the work equipment in air.
Page 406: Quick Coupler System
Pressure regulation valve (2) allows the attachment pressure and the release pressure for the quick coupler to be limited according to the coupler manufacturer's recommendation respectively. Check that the valve is correctly set. • Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu dealer. LOCATIONS RKA52800...
Page 407 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM OPERATION OF QUICK COUPLER TO RELEASE A BUCKET OR ATTACHMENT WARNING Pressure in the system can cause injury. Follow all instructions in “METHOD FOR REMOVING AND IN- STALLING ATTACHMENT (6-11)”. If the bucket or attachment has any hydraulic connections to the machine these must be disconnected before proceeding.
Page 408 This machine has a system installed to give a warning if there is a failure to maintain pressure in the quick coupler system. Whenever the alarm indicator for the hydraulic attachment and level is displayed on the monitor “L03”, stop the machine immediately and contact your Komatsu dealer to get an inspection carried out.
Page 409 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM When the switch (1) is on “a” the monitor displays the quick coupling activation indicator and the warning signal emits a continuous sound. RKA54680 Position the quick coupler over the new bucket or attachment. With switch (1) in position “a”...
Page 410: Handle Bucket With Hook
ATTACHMENTS AND OPTIONS HANDLE BUCKET WITH HOOK When using the bucket with hook, check that there is no damage to the hook, stopper, or hook mount. If there is any problem, ask your Komatsu distributor. PRECAUTIONS FOR OPERATION PRECAUTIONS FOR LIFTING OPERATIONS •...
Page 411: Handle Machine Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS RKA52820 (1) Selector valve (4) 2nd-line attachment proportional switch (2) 1st-line attachment proportional switch (5) Additional filter for breaker (3) Breaker operation switch (6) Accumulator (for low pressure) SELECTOR VALVE...
Page 412 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS ATTACHMENT 1 PROPORTIONAL SWITCH The 1st-line attachment proportional switch is on the right PPC valve lever and it is used to operate the attachment. The 1st-line attachment proportional switch is a roller propor- tional control switch.
Page 413: Hydraulic Circuit
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT You can increase or decrease the flow rate by controlling the switch stroke. The attachment does not operate unless the attachment mode is set on the machine monitor. RKA48510 HYDRAULIC CIRCUIT METHOD FOR CONNECTING HYDRAULIC CIRCUIT When installing the attachment, connect the hydraulic circuit as follows.
Page 414 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS METHOD FOR REMOVING ATTACHMENT Lower the attachment to the ground and stop the engine. Turn the starting switch to ON position (B). Set the lock lever to FREE position (F). Operate each control lever (work equipment, travel) and attachment control switch fully in each direction within 15 seconds after the engine is stopped to release the internal...
Page 415 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Turn the starting switch to OFF position (A). Open dirt cover (1). Lock securely with hood support lever (2). Loosen bolt (3) and remove plate (4) on the top of oil filler port (F).
Page 416 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS METHOD FOR INSTALLING ATTACHMENT Remove the bucket. For the removal procedure of the bucket, see “METHOD FOR REPLACING AND INVERTING BUCKET (3-186)”. Place the attachment on a horizontal place, install pin (A) and then pin (B) in this order to the arm.
Page 417 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Operate each control lever (work equipment, travel) and attachment control switch fully in each direction within 15 seconds after the engine is stopped to release the internal pressure in the hydraulic circuit. RKA52830 RKA48500 Set the lock lever to LOCK position (L).
Page 418: Method For Operating Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Open dirt cover (1). 10. Lock securely with hood support lever (2). 11. Loosen bolt (3) and remove plate (4) on the top of oil filler port (F). 12. Remove the cap of oil filler port (F) gradually to release the internal pressure.
Page 419 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Operate the breaker operation switch. RKA48504 The breaker operates. METHOD FOR OPERATING MACHINE WHEN WORKING MODE IS NOT IN BREAKER MODE If the breaker mode is not indicated as the working mode, enter it according to the following procedure. Press working mode selector switch (1).
Page 420: Long-Term Storage
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS • Is the selector valve in the dirt cover set to the position for the breaker? • Is lock bar (2) for the selector valve in the dirt cover instal- led to the position for the breaker? •...
Page 421: Specifications
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Set the selector valve to the position for general attachment such as crusher. SPECIFICATIONS Hydraulic specifications Flow rate Attachment mode: 125 ℓ/ min Breaker mode: 80 ℓ/ min Cracking pressure of safety valve When breaker is used: 17.2 MPa {175 kg/cm When another attachment is used: 19.6 MPa {200 kg/cm 6-19 WENAM00061...
Page 422: Attachments And Options
• Installing attachments or optional equipment without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the ma- chine and the life of the equipment.
Page 423: Recommended Attachment Operations
Select the optimum attachment model for the hydraulic excavator body. The attachments and models ready for installation differ according to the machine body. For details of the selection of the attachments or the models, consult your Komatsu distributor. HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows.
Page 424 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm off the ground. Do not raise it off the ground unnecessarily. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 425 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not use the mount to gather in pieces of rock. Do not work by using the swing force. Do not move the chisel while performing breaking operation. Do not perform breaker operation in horizontal or upward direc- tion.
Page 426 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Do not perform the operation with bucket cylinder rod extended fully to raise the machine off the ground. Do not perform the breaker work with any cylinder at the stroke end.
Page 427 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Grease the breaker while holding it in the right posture shown below. • Lower the chisel perpendicularly to the ground. • Insert the grease gun perpendicularly to the greasing point. Wrong posture 6-25 WENAM00061...
Page 428 WENAM00061...
Page 429: Replacement Parts
REPLACEMENT PARTS WENAM00061...
Page 430: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Retighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. WENAM00061...
Page 431: Defined Life Parts List
REPLACEMENT PARTS PERIODIC REPLACEMENT OF DEFINED LIFE PARTS DEFINED LIFE PARTS LIST Parts for periodic replacement Replacement interval Fuel system Fuel hose Spill hose Engine lubrication system Turbocharger lubrication hose Engine oil filter hose Work equipment hydraulic Main pump delivery hose system Main pump LS hose Swing line hose...
Page 432: Consumable Parts
When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check the latest part number when ordering parts. CONSUMABLE PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 433: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 434: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient Temperature, degrees Celsius Recommended Komatsu Tank Fluid Type Fluids WENAM00061...
Page 435 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT Engine oil for EOS5W30-LA KDPF used in -25 °C 35 °C (KES Diesel Engine Oil) cold terrain (Oil (Note 1) Change interval EOS5W40-LA 250 hours) -25 °C 40 °C (KES Diesel Engine Oil) Engine oil pan (Note 1) EO10W30-LA Engine oil for -20 °C...
Page 436: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Non-Amine Engine Coolant (AF-NAC) is supplied in diluted state, so always fill up with it. (Never dilute it with water) RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. WENAM00061...
Page 437: Index
INDEX INDEX Symbols "Autocruise" switch..........3-91 Backhoe work............. 3-182 12H24H display mode - Switch......3-82 Basic operation of machine monitor......3-10 2WS/4WS-R switch..........3-94 Basic operation of machine monitor when starting en- 4WS-C switch............3-94 gine while engine shutdown secondary switch is ON..............3-11 Battery - Handle............
Page 438 INDEX Check signs and signalman's signals....2-26 Checks after inspection and maintenance....4-3 ECO gauge............3-34 Checks and adjustment before starting engine.... ECO gauge - Set target fuel consumption value...3-68 .............2-27,3-125 ECO guidance............3-30 Checks before starting........2-28,4-35 ECO guidance record - Check......3-63 Cigarette lighter.............3-95 Economy mode - Adjust........3-71 Clock - Adjust............3-80...
Page 439 3-178 Keep machine clean..........2-16 Guide to reduce vibration levels on machine..1-6 Keep work place clean and tidy......2-39 Komatsu Closed Crankcase Ventilation (KCCV) 3-123 Komatsu genuine lubricants........4-2 Handle electrical components.........4-7 Komatsu genuine replacement parts...... 4-2 Handling bucket with hook........6-8 KOMTRAX............
Page 440 Parking brake relay deactivation switch....3-99 Machine ready for installation of attachment - Handle. Parking brake switch..........3-95 .................6-9 Perform KOWA (Komatsu Oil Wear Analysis)..4-5 Machine settings........... 3-70 Periodic replacement of defined life parts..2-47,7-2 Magazine box............3-115 Permissible depth of water, soil and dirt..... 3-180...
Page 441 INDEX Phenomena and actions for chassis....3-234 Precautions to prevent fire........2-17 Phenomena and actions for engine related parts..Precautions when installing hydraulic hoses..4-3 ..............3-234 Precautions when leaving machine...... 2-21 Phenomena that are not failures......3-225 Precautions when loading and unloading..... 2-35 Pilot display............3-26 Precautions when operating on snow or frozen surfa- Pilot display and meter display......
Page 442 INDEX Rear axle - Change oil.......... 4-63 Stopper - Check clearance in opening front door is up Rear axle - Check oil level........4-44 ...............4-27 Rear mirror (C) - Adjusting........3-141 Store oil and fuel............. 4-6 Rear view camera - Adjust angle......3-142 Street mode pilot lamp..........
Page 443 INDEX Vent selector switch..........3-201 Vibration levels............1-6 Visibility from operator's seat........1-9 Warning display for abnormalities and faults..3-15 Washable floor - Wash..........4-28 Water pump - Check..........4-79 Water separator Check / Drain water and sediment.................3-128 Wear well-fitting clothes and protective equipment................2-16 Wheel nut tightening - Check........4-33 When handling accumulator and gas spring..2-46...

Komatsu PW98MR-10 Operation & Maintenance Manual

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