Page 1 Operation & WENAM00111 Maintenance Manual PC138US- HYDRAULIC EXCAVATOR SERIAL NUMBERS PC138US-11 F50001 and up 50001 and up WARNING ORIGINAL INSTRUCTIONS Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 2 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 3: Read This Manual
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 4: 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 5: 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 6: 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 7: 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 8 FOREWORD VIBRATION LEVELS • Do not repeatedly handle and lift loads WENAM00111...
Page 9: 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 (3-187)”.
Page 10: Directions Of Machine
FOREWORD INTRODUCTION DIRECTIONS OF MACHINE (A) Front (D) Right (B) Rear (E) Operator's seat (C) Left (F) Sprocket In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine. VISIBILITY FROM OPERATOR'S SEAT The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below.
Page 11 INTRODUCTION FOREWORD Protective structures This machine is equipped with a structure to protect the operator (ROPS) conforming to ISO12117-2: 2008. 1-10 WENAM00111...
Page 12: Engine Technology To Conform Exhaust Gas Emission
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water.
Page 13: Product Information
PRODUCT INFORMATION FOREWORD 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 It is located on the right bottom of the operator's cab.
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
SERIAL PLATE FOREWORD SERIAL PLATE SERIAL NUMBER MACHINE DESIGNATION/TYPE WEIGHT YEAR OF CONSTRUCTION PRODUCT IDENTIFICATION NUMBER ENGINE POWER MANUFACTURER 1-14 WENAM00111...
Page 16: Declaration Of Conformity
FOREWORD DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer: Komatsu Italia Manufacturing S.p.A. Via Atheste, 4 35042 Este (PD) Italy Declares that this machine: PC138US-11 Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive...
Page 17: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD ..................................1-1 READ 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 FOREWORD TABLE OF CONTENTS OPERATION ..................................3-1 GENERAL VIEW ................................ 3-2 MACHINE EQUIPMENT NAME ........................3-2 CAB EQUIPMENT NAMES..........................3-4 CONTROLS AND GAUGES NAMES ......................3-5 EXPLANATION OF COMPONENTS ........................3-9 EXPLANATION OF MACHINE MONITOR EQUIPMENT ................3-9 SWITCHES ................................ 3-85 CONTROL LEVERS AND PEDALS ......................
Page 19 OTHER TROUBLE ............................3-241 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 20 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ..................7-4 LUBRICATION CHART ............................7-4 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ................................7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-7 INDEX ....................................8-1 1-19 WENAM00111...
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. WENAM00111...
Page 22 SAFETY SAFETY SAFETY SAFETY LABELS ................................2-4 LOCATION OF SAFETY LABELS ..........................2-5 CONTENTS OF SAFETY LABELS .......................... 2-6 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........... 2-18 PRECAUTIONS BEFORE STARTING OPERATION ..................2-18 ENSURE SAFE OPERATION ......................... 2-18 UNDERSTAND THE MACHINE ........................2-18 PREPARATIONS FOR SAFE OPERATION ......................
Page 23 SAFETY SAFETY PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES ........2-34 PRECAUTIONS WHEN PARKING MACHINE ..................... 2-34 PRECAUTIONS FOR TRANSPORTATION ......................2-35 PRECAUTIONS WHEN LOADING AND UNLOADING ................2-35 TOWING AND BEING TOWED ..........................2-36 PRECAUTIONS FOR TOWING AND BEING TOWED ................2-36 LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) ......
Page 24: 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 25: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS RKA55000 (1) Combined safety information label (a) Warning against high-voltage cable WENAM00111...
Page 26: Contents Of Safety Labels
SAFETY LABELS SAFETY (b) Warning when leaving the operator's seat (14) Caution for high temperature coolant and hydraul- ic oil (c) Warning for operation, inspection and maintenance (15) Caution for adjusting track tension (2) Warning no passengers (16) Caution against falling (3) Warning danger of falling objects (17) Caution stop rotation during inspection and main- (4) Caution for blast jobsite...
Page 27 SAFETY SAFETY LABELS (b) Warning when leaving the operator's seat • Before standing up from operator's seat. • Lower the work equipment to the ground and move safety lock lever (located near seat) to lock position to avoid hit- ting unlocked operation levers. •...
Page 28 SAFETY LABELS SAFETY • Keep machine at a safe distance from blast zone and a detonator. (5) Warning for quick coupler system (20J-00-11271) • There is a danger of an exposed person being killed by falling attachment. • Read the manual for safe operation. (6) Caution for overloading machine (Machine with standard boom: 22B-00-41630) (Machine with 2-piece boom: 22B-00-R1631)
Page 29 SAFETY SAFETY LABELS (8) Combined safety information label (22B-00-21712) Follow instructions and warnings in manual and in labels on machine. Detailed explanations of the content of each label are as fol- lows: 228-00-21220 (a) Warning prohibited to enter in swing radius •...
Page 30 SAFETY LABELS SAFETY • 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 the ground, set lock lever (1) securely to the LOCK position (L), then stop the engine.
Page 31 SAFETY SAFETY LABELS (9) Warning when swinging or travelling in reverse (09833-A0881) WARNING • When swinging or backing up excavator, press button to change display mode on monitor so you can see rear and side of the machine. Before moving, look around and at mirror and monitor to confirm that no one is around the machine.
Page 32 SAFETY LABELS SAFETY (12) Caution for handling battery (09664-60001) (a) Never smoke or use any naked flame near the batteries, no sparks. (b) Always wear safety glasses when working with batteries. (c) Keep children away from batteries. KS000327 (d) Caution battery acid. WENAM00111...
Page 33 SAFETY SAFETY LABELS (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases. (13) Caution for handling cable (09808-A0881) • Sign indicates an electric hazard from handling the cable. • Read manual for safe and proper handling. (14) Caution for high temperature coolant and hydraulic oil (09653-A0481) •...
Page 34 SAFETY LABELS SAFETY (16) Caution against falling (09805-A0481) • Sign indicates a hazard of falling. • Do not stand on the place here. (17) Caution stop rotation during inspection and maintenance (09667-A0481) • Sign indicates a hazard of rotating parts such as belt, fan etc.
Page 35 SAFETY SAFETY LABELS (19) Danger do not enter within swing range (09133-A2321) • There is a danger of getting caught when upper structure swings. • Do not enter range of swing. (20) Caution for handling accumulator and gas spring (09659-A057B) •...
Page 36 SAFETY LABELS SAFETY Prohibition of short-circuit start (24) Caution for handling DEF (09632-60800) • To avoid engine damage or fire, fill with Diesel Exhaust Fluid (DEF) only. • Never use diesel fuel. (25) Caution for handling DEF (09632-61480) • To avoid engine damage or fire, fill with Diesel Exhaust Fluid (DEF) only.
Page 37 SAFETY SAFETY LABELS (25) Lock front window (22B-00-21670) 228-00-21670 2-17 WENAM00111...
Page 38: 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 39: 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 40: Prevent Fire
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 41: Precautions When Getting On Or Off Machine
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- 9,&01722 tributor to perform this work.
Page 42: Lifting Of Personnel Prohibited
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Never jump on or off the machine. Never get on or off a moving machine. • If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 43: Do Not Get Caught In Work Equipment
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 44: Protection Against Falling, Flying Or Intruding Objects
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 45: Precautions Related To Cab Glass
SAFETY NANCE • When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential problems or safety and legal requirements. • The machine weight will not exceed ROPS certified value as long as the optional attachments written in the attachment combination table of this manual are installed.
Page 46: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY 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 47: Ensure Good Visibility
SAFETY PRECAUTIONS FOR OPERATION 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 48: 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 49: Precautions When Starting Engine
SAFETY PRECAUTIONS FOR OPERATION • Before starting the engine, check that lock lever (1) is in LOCK position (L). • Adjust the mirrors to have a good rear view from the oper- ator's seat. For the adjustment, see “METHOD FOR ADJUSTING MIRRORS (3-145)”.
Page 50: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • When disconnecting the jumper cables, take care not to bring the clips in contact with each other or with the machine. • For the starting procedure with the jumper cables, see OPERATION, “START ENGINE WITH JUMPER CA- BLES (3-240)”.
Page 51: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION • Always operate the machine only when seated on the operator's seat. • Before starting to move, check again that there is no people or obstacle in the surrounding area. • Before moving, sound the horn to warn people in the surrounding area.
Page 52: Precautions When Traveling On Slopes
PRECAUTIONS FOR OPERATION SAFETY • When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate slowly and be extremely careful not to let the machine body or work equipment hit anything. PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always observe the following.
Page 53: Precautions When Operating On Slopes
SAFETY PRECAUTIONS FOR OPERATION • If the engine stops, move the control levers immediately to NEUTRAL position, set the lock lever to LOCK position, and then start the engine. PRECAUTIONS WHEN OPERATING ON SLOPES • When working on slopes, there is a hazard that the machine may lose its balance and turn over when per- forming swing or work equipment operations.
Page 54: Precautions When Operating On Snow Or Frozen Surfaces
PRECAUTIONS FOR OPERATION SAFETY • 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 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 improper 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 • Run the engine at low idle and drive the machine slowly at low speed. • When on the ramps, do not operate any lever except for the travel lever (travel forward and reverse). • Never correct your steering on the ramps. If necessary, drive off the ramps onto the ground, correct the di- rection, then enter the ramps again.
Page 57 SAFETY PRECAUTIONS FOR OPERATION NOTICE RLL (Rated Lifting Load) for the link may not be the same as the lifting capacity of the machine. Al- ways be sure to lift within the relevant lifting limits. • The lifting link RLL (Rated Lifting Load) and part number are stamped on the link as shown below. •...
Page 58: Lifting Objects With Buckets
PRECAUTIONS FOR OPERATION SAFETY • The operator or person attaching the sling should inspect the bucket link lifting device and all the components in the load line (e.g. chains, shackles etc.) visually for damage or deformation before use to ensure that they are not dam- aged or worn.
Page 59 SAFETY PRECAUTIONS FOR OPERATION • Do not swing or operate the work equipment suddenly. There is a danger that this may cause the load to swing and the machine to become unstable or tip over. • Do not leave the operator seat when there is a raised load Do not leave the operator seat when there is a raised load.
Page 60: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY 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 61: Guards
END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 62: Precautions When Installing, Removing, Or Storing Attachments
PRECAUTIONS FOR MAINTENANCE SAFETY • 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 63: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE 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 64: Handle Battery
PRECAUTIONS FOR MAINTENANCE SAFETY 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 65: Precautions For High-Temperature Coolant
SAFETY PRECAUTIONS FOR MAINTENANCE • 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 66: Precautions For High-Pressure Fuel
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 67: Precautions For High-Pressure Grease When Adjusting Track Tension
If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. HANDLE ACCUMULATOR AND GAS SPRING This machine is equipped with an accumulator.
Page 68: Precautions For Compressed Air
• When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 69 SAFETY PRECAUTIONS FOR MAINTENANCE • The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval.
Page 70: Precautions For Def
PRECAUTIONS FOR DEF SAFETY PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 71: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section. WENAM00111...
Page 72: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (9) Blade cylinder (blade specification) (2) Bucket cylinder (10) Blade (blade specification) (3) Arm (11) Idler (4) Arm cylinder (12) Track frame (5) Boom (13) Track (6) Boom cylinder (14) Sprocket (7) Additional lamp (if equipped) (15) Rear view camera (8) Working lamp...
Page 73 OPERATION GENERAL VIEW (16) Fusible link (22) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator (17) System operating lamp (23) DEF pump (18) Battery disconnect switch (24) DEF tank (19) Battery (25) SCR (20) Toolbox (26) DEF injector (21) Grease pump holder...
Page 74: Cab Equipment Names
GENERAL VIEW OPERATION CAB EQUIPMENT NAMES (1) Front window (7) 12 V Power supply 2 (2) Ceiling window (8) Fire extinguisher (if equipped) (3) Door handle (9) Cup holder (4) Magazine box (10) Emergency escape hammer (5) Fuse (11) AUX (6) 12 V Power supply 1 (12) Ashtray WENAM00111...
Page 75: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES RKA55260 (1) Radio (9) Starting switch (2) Lock lever (10) Fuel control dial (3) L.H. work equipment control lever (11) Lamp switch (4) Travel pedal (12) Swing lock switch (5) Travel lever (13) Beacon switch (if equipped) (6) Machine monitor (14) Additional lamp switch (if equipped) (7) R.H.
Page 76 GENERAL VIEW OPERATION (17) Seat heater switch (if equipped) (24) Room lamp switch (18) Quick coupler switch (25) Pump secondary drive switch (19) Quick coupler switch (26) Swing parking brake cancel switch (20) 2nd attachment proportional switch (27) Lock lever automatic lock cancel switch (21) 1st attachment proportional switch (28) Cigarette lighter (22) Breaker switch...
Page 77 OPERATION GENERAL VIEW (25) Engine stop pilot lamp (32) Preheating pilot lamp (26) Work equipment lock pilot lamp (33) Auto-deceleration pilot lamp (27) Aftertreatment devices regeneration display (34) Charge level caution lamp (28) Message display (35) Engine oil pressure caution lamp (29) Air conditioner pilot lamp (36) Function switches (F1 to F6) (30) Wiper pilot lamp...
Page 78 GENERAL VIEW OPERATION (19) Window washer switch (28) Air conditioner pilot lamp (20) Air conditioner control switch (29) Wiper pilot lamp (21) Engine oil pressure caution lamp (30) Swing lock pilot lamp (22) Charge level caution lamp (31) Preheating pilot lamp (23) Seat belt caution lamp (32) Auto-deceleration pilot lamp (24) Engine stop pilot lamp...
Page 79: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. 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 The display method of the monitor is partly different when the machine is not equipped with the KomVision.
Page 80 EXPLANATION OF COMPONENTS OPERATION Displaying only meter On the standard screen (camera display, meter display), press switch F3, and only the meter is displayed. For details, see “CAMERA IMAGE SELECTOR SWITCH (3-51)”. AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display (4) Monitor switch area (2) Pilot display...
Page 81 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, opening screen GG is displayed. • After opening screen GG is displayed for 2 seconds, the screen switches to Check before starting screen •...
Page 82 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While engine shutdown secondary switch (1) is ON (engine is stopped), when the starting switch is turned to ON position, the screen shown in the figure is displayed and engine does not start.
Page 83 EXPLANATION OF COMPONENTS 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 84 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 85 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION • If there is any abnormality when starting the engine, the check before starting screen BB changes to the maintenance time warning screen CC, warning screen FF, or error screen EE. •...
Page 86 EXPLANATION OF COMPONENTS OPERATION 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. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE •...
Page 87 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 NOTICE Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab- normality of the machine.
Page 88 EXPLANATION OF COMPONENTS OPERATION (9) Caution lamp Standard screen (camera display and meter display) When 1 type of caution is generated, it is displayed on caution lamp (2). When 2 types of cautions are generated, they are displayed on caution lamps (2) and (3). When 3 types of cautions are generated, they are displayed on caution lamps (2), (3), and (4).
Page 89 OPERATION EXPLANATION OF COMPONENTS Displaying only meter On the standard screen (camera display, meter display), press switch F3, and only the meter is displayed. For details, see “CAMERA IMAGE SELECTOR SWITCH (3-51)”. (1) Seat belt caution lamp (5) Engine coolant temperature caution lamp (2) Action level display (6) Hydraulic oil temperature caution lamp (3) Caution lamp...
Page 90 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 91 OPERATION EXPLANATION OF COMPONENTS Caution lamps and display colors Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue High temperature Engine coolant temperature Low temper- Normal caution lamp ature (L02) High temperature Hydraulic oil temperature Low temper- Normal caution lamp...
Page 92 EXPLANATION OF COMPONENTS OPERATION Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue Low oil level Engine oil level caution lamp (L01) Abnormal Charge level caution lamp (L03) Clogged Air cleaner clogging caution lamp (L01) Abnormal Air conditioner system cau- tion lamp...
Page 93 OPERATION EXPLANATION OF COMPONENTS CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5. While “!” is displayed, press switch F5 to shift the monitor dis- play screen to “Current Abnormality” screen. Take appropriate remedies according to the message displayed on the monitor.
Page 94 EXPLANATION OF COMPONENTS OPERATION ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and action level “L02” is dis- played. The engine coolant temperature is abnormally high. While this lamp is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 95 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 96 The caution lamp comes on in red and the alarm buzzer oper- ates intermittently. Stop the work and move the machine to a safe area. Ask your Komatsu distributor for inspection and mainte- nance. When action level “L01” appears on screen.
Page 97 When action level “L03” appears on screen. The caution lamp comes on in red and the alarm buzzer oper- ates intermittently. Move the machine to a safe area and stop the machine, then ask your Komatsu distributor for inspection and maintenance. 3-27...
Page 98 It is not necessary to stop the machine immediately. However, it is recommended for maintenance after the end of ongoing work. Ask your Komatsu distributor for inspection and maintenance as necessary. ENGINE SUDDEN STOP BY AUTO IDLE STOP CAUTION LAMP...
Page 99 GINE OIL PAN, ADDING OIL (3-134)”. If the oil level drops again in a short time, the engine oil may be leaking. For the inspection and maintenance, ask your Komatsu distributor. ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp lights up when engine over- run occurs.
Page 100 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 101 OPERATION EXPLANATION OF COMPONENTS OVERLOAD CAUTION LAMP The overload caution lamp warns that the machine is close to tipping due to the load (an audible warning is also given), if the warning is given lower the load. Refer to the lifting capacity chart for safe load. SEATBELT CAUTION LAMP The seat belt caution lamp lights up when the seat belt is not fastened.
Page 102 EXPLANATION OF COMPONENTS OPERATION Meter display (13) Hydraulic oil temperature gauge (17) Fuel consumption gauge (14) Engine coolant temperature gauge (18) Service meter/ clock (15) Fuel gauge (19) ECO gauge (16) DEF level gauge 3-32 WENAM00111...
Page 103 OPERATION EXPLANATION OF COMPONENTS Displaying only meter On the standard screen (camera display, meter display), press switch F3, and only the meter is displayed. For details, see “CAMERA IMAGE SELECTOR SWITCH (3-51)”. Pilot display (1) Engine stop pilot lamp (7) Swing lock pilot lamp (2) Work equipment lock pilot lamp (8) Preheating pilot lamp (3) Aftertreatment devices regeneration display...
Page 104 EXPLANATION OF COMPONENTS OPERATION PREHEATING PILOT LAMP The preheating pilot lamp is displayed while the engine is pre- heated before started. When the temperature is low (in cold weather) and the auto- matic preheating function operates, the preheating pilot lamp lights up.
Page 105 Pilot lamp goes out: Air conditioner OFF MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY (3-83)”. 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 106 EXPLANATION OF COMPONENTS OPERATION ENGINE STOP PILOT LAMP The engine stop pilot lamp is displayed while the engine is stopped. It goes out when the engine is started. AFTERTREATMENT DEVICES REGENERATION DISPLAY This displays the regeneration status and automatic regenera- tion setting status of the aftertreatment devices.
Page 107 OPERATION EXPLANATION OF COMPONENTS Idling stop guidance If no operation is performed for more than 5 minutes, and the engine is idling, the idling stop message is displayed on the monitor. When waiting for work or taking short break, stop the engine to reduce unnecessary fuel consumption.
Page 108 EXPLANATION OF COMPONENTS OPERATION Low Fuel Level Guidance If the operable time estimated from the current fuel level and the latest average fuel consumption is shorter than 8 hours, the low fuel level message is displayed. The low fuel level message goes out more than 10 seconds af- ter or when switch F5 is pressed.
Page 109 OPERATION EXPLANATION OF COMPONENTS Red range (A) position: Engine coolant temperature caution lamp (E) shows abnormality display. Red range (B) position: Engine speed changes to low idle, engine coolant temperature caution lamp (E) shows abnormality display and alarm buzzer sounds at the same time The overheat prevention system continues to operate until the pointer enters the green range.
Page 110 EXPLANATION OF COMPONENTS OPERATION FUEL GAUGE Fuel gauge shows the amount of fuel in the fuel tank. The indicator should be in the green range during operations. If the indicator starts to enter red range (A) during operation, the remaining fuel is 52 ℓ or less, so perform inspection and add fuel.
Page 111 OPERATION EXPLANATION OF COMPONENTS On the standard screen, when function switch F4 is pressed, it is possible to switch between the clock display and the service meter display alternately. REMARK • If the battery is disconnected for a long period for storage etc., the time information may be lost.
Page 112 EXPLANATION OF COMPONENTS OPERATION DEF LEVEL GAUGE DEF level gauge indicates the remaining level of DEF. If the indicator is in green range during operations, it is normal. If the indicator comes close to (A) of red range during opera- tion, check and add DEF.
Page 113 OPERATION EXPLANATION OF COMPONENTS (7) Buzzer cancel switch (8) Air conditioner switch 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.
Page 114 EXPLANATION OF COMPONENTS OPERATION (D) Switch F5: ECO guidance erase switch (While ECO guidance is displayed) (E) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance icons frequently used and their functions are as follows: (F) Switch F1 or F3: Moves to the left item.
Page 115 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. How to use working mode selector switch When working mode selector switch is pressed, the Work- ing Mode selector screen is displayed on the monitor.
Page 116 EXPLANATION OF COMPONENTS OPERATION REMARK To return to the standard screen without changing the working mode, press function switch F5. After selecting the desired mode, press function switch F6 and the mode is displayed in the center of the monitor dis- play.
Page 117 OPERATION EXPLANATION OF COMPONENTS AUTO-DECELERATION SWITCH Auto-deceleration switch automatically lowers the engine speed and turns on the function to reduce fuel consumption when the control levers are at NEUTRAL position. Auto-deceleration pilot lamp lights up: Auto-deceleration ON Auto-deceleration pilot lamp goes out: Auto-deceleration OFF Each time the switch is pressed, the auto-deceleration is switched between ON and OFF.
Page 118 EXPLANATION OF COMPONENTS OPERATION TRAVEL SPEED SELECTOR SWITCH WARNING • Drive the machine at low speed (set it to Lo) always when loading to or unloading from a trailer. Never operate the travel speed selector switch during travel. • If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 119 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH Wiper switch actuates the front window windshield wiper. Each time the switch is pressed, it changes INT → ON → stop (lamp goes out). Windshield wiper pilot lamp INT lights up: Windshield wiper op- erates intermittently Windshield wiper pilot lamp ON lights up: Windshield wiper op- erates continuously...
Page 120 EXPLANATION OF COMPONENTS OPERATION WINDOW WASHER SWITCH Keep pressing this switch continuously, and window washer flu- id is sprayed out on the front glass. When releasing the switch, the spray stops. • If keep pressing the switch when the wiper is stopped, the window washer fluid is sprayed out.
Page 121 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches. For explanation of each switch, see “HANDLE AIR CONDI- TIONER (3-199)”. FUNCTION SWITCHES The operation of the function switches in the standard screen CAMERA IMAGE SELECTOR SWITCH On the standard screen, you can select a display only for the camera image or a display only for the meter by pressing switch F3.
Page 122 EXPLANATION OF COMPONENTS OPERATION Operation of camera image display screen Operate the following for 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 123 OPERATION EXPLANATION OF COMPONENTS • The air conditioner can be operated. If the air conditioner switch is operated, the screen switches to the air conditioner operation screen. When the screen switches to the air conditioner operation screen, press switch F6 to return to the camera image screen. In addition, if no operation is performed for 5 seconds after the screen switches to the air conditioner operation screen, the screen automatically returns to the camera im-...
Page 124 EXPLANATION OF COMPONENTS OPERATION • It is possible to stop the alarm buzzer for the warning item where there is an abnormality, by pressing the buzzer can- cel switch. Even if the buzzer cancel switch is pressed, the camera image display screen neither switches to another screen nor returns to the standard screen.
Page 125 OPERATION EXPLANATION OF COMPONENTS When the screen returns to the standard screen, the cau- tion lamp at the top left of the screen goes out and the caution lamp and action level are displayed on the left part of the screen. •...
Page 126 EXPLANATION OF COMPONENTS OPERATION (a) “Energy Saving Guidance” • Check of “Operation Records” • Check of “ECO Guidance Records” • Check and reset of “Average Fuel Consumption Record” • “Configurations” (b) “Configurations” • “Economy Mode Adjustment” • “Breaker Setting” (if equipped) •...
Page 127 OPERATION EXPLANATION OF COMPONENTS (f) “Monitor Setting” • “Screen Adjustment” • Screen Adjustment (Camera) • “Clock Adjustment” • “Language Setting” • “Operator ID” (g) 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 128 EXPLANATION OF COMPONENTS OPERATION F5: Returns the screen to the standard screen. F6: Displays the setting screen for selected item. • If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the previous screen.
Page 129 OPERATION EXPLANATION OF COMPONENTS CHECK ECO GUIDANCE RECORD Select “ECO Guidance Records” (2) from “Energy Saving Guid- ance” menu screen, then press switch F6. On the “ECO Guidance Records” menu, display the frequency of display of the ECO guidance on a daily basis or during the split measurement period.
Page 130 EXPLANATION OF COMPONENTS OPERATION Operation on “Average Fuel Consumption Record” screen Press switch F1, F2 or F5 on “Average Fuel Consumption Re- cord” screen to perform the following operations. F1: Clears the graph data. F2: Switches graphical displays of the average fuel consump- tion.
Page 131 OPERATION EXPLANATION OF COMPONENTS Deleting “Average Fuel Consumption Record” When the switch F1 (“CLEAR”) is pressed, the reconfirma- tion 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 132 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. Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. “Average Fuel Consumption Display”...
Page 133 OPERATION EXPLANATION OF COMPONENTS REMARK When you select “Split Time” measurement, the measure- ment stop switch (“STOP”) is displayed on “Operation Re- cords” screen and “ECO Guidance Records” screen. When you stop the measurement, move from “Energy Saving Guidance” menu (a) screen to “Operation Records” (1) screen or “ECO Guidance Records”...
Page 134 EXPLANATION OF COMPONENTS OPERATION “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. On this screen, it is possible to perform the following oper- ations with switches F3 to F6.
Page 135 OPERATION EXPLANATION OF COMPONENTS Select “ECO Guidance display” (11) from “Configurations” screen, then press switch F6. “ECO Guidance Display” setting screen appears. • “ON”: Displays ECO Guidance (10) on the standard screen. • “OFF”: Does not display ECO Guidance (10) on the standard screen.
Page 136 EXPLANATION OF COMPONENTS OPERATION The setting screen for “ECO Guidance Display at Key OFF” appears. • “ON”: Displays ECO Guidance (12) on the end screen. • “OFF”: Does not display ECO Guidance (12) on the end screen. On this screen, it is possible to perform the following oper- ations with switches F3 to F6.
Page 137 OPERATION EXPLANATION OF COMPONENTS Operation on “Economy Mode Adjustment” screen On “Economy Mode Adjustment” screen, you can perform the following operations with switches F3 to F6. 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).
Page 138 EXPLANATION OF COMPONENTS OPERATION On “Breaker Setting” screen, select a breaker to change its name, then press switch F6. The “Breaker Name Setting” screen is displayed. On the “Breaker Name Setting” screen, you can perform the following operations with switches F1 to F6. F1: “CLEAR”...
Page 139 OPERATION EXPLANATION OF COMPONENTS Select “Attachment Setting” (3) on “Machine Setting” (b) screen, then press switch F6. On “Attachment Setting” screen shown in the figure, select an attachment to adjust and press switch F6. On “Attachment Setting” screen shown in the figure, you can perform the following operations with switches F1 to F1: Changes the name of the selected attachment setting.
Page 140 EXPLANATION OF COMPONENTS OPERATION Changing “2-Way Attachment Oil Flow Rate Setting” Select an attachment to change its oil flow on “Attachment Setting” screen, then press switch F2. The “2-Way Attachment Oil Flow Rate Setting” screen is displayed. On the “2-Way Attachment Oil Flow Rate Setting” screen, you can perform the following operations with switches F3 to F6.
Page 141 OPERATION EXPLANATION OF COMPONENTS Select the set time on the “Auto Idle Stop Timer Setting” screen shown in the figure, and then press switch F6. On the “Auto Idle Stop Timer Setting” screen shown in the figure, you can perform the following operations with switches F3 to F6.
Page 142 EXPLANATION OF COMPONENTS OPERATION REMARK While the auto idle stop function is ON, the number of the times that the engine was stopped when it was not at low idle (the engine speed is 1400 rpm or higher) is displayed as “L01” at and after 1000 and as “L03”...
Page 143 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE SCREEN SETTING Each item of setting menu (e) on “Maintenance” screen is used for displaying and setting the notification relevant to mainte- nance. The items on “Maintenance” display are as follows. Air Cleaner Cleaning or Change Coolant Change Fuel Prefilter Change Engine Oil Change (*1)
Page 144 • 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 “Maintenance” screen, if switch F6 is kept pressed for 1.5 seconds or more, the screen changes to “Mainte- nance Due Time Reset”...
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “Screen Adjustment” (1) on “Monitor Setting” menu screen, then press switch F6. Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one level. F4: Moves the indicator to the right by one level.
Page 146 EXPLANATION OF COMPONENTS OPERATION Screen adjustment (camera) Use “Screen Adjustment (Camera)” to adjust brightness of the camera screen. Select Screen Adjustment (Camera) (2) on “Monitor Set- ting” menu screen, then press switch F6. Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value.
Page 147 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 148 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 149 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 150 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 151 OPERATION EXPLANATION OF COMPONENTS When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID” on the “Monitor Set- ting” menu screen. Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second. The “Operator ID Change”...
Page 152 EXPLANATION OF COMPONENTS OPERATION • When you press switch F6 after inputting the ID which is not registered to the “Operator ID Change” screen, a message is displayed below and the screen returns to the “Monitor Setting” menu screen. In this case, the identified ID is not changed. •...
Page 153 In this case, the identified ID is not changed. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (g). When there is any message, the message display of the standard screen lights up.
Page 154 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 the mail confirmation menu (g) directly opens. Select the mail confirmation menu (g), and you can read the received message.
Page 155: Switches
OPERATION EXPLANATION OF COMPONENTS When “Do you send Numeric Input?” is displayed, press the switch F5, and the screen returns to the screen for replying to message. At this time, the previous input value will be cleared. SWITCHES RKA55270 (1) Starting switch (7) Wiper switch (if equipped) (2) Fuel control dial (8) Seat heater switch (if equipped)
Page 156 EXPLANATION OF COMPONENTS OPERATION (13) Breaker switch (17) Swing parking brake cancel switch (14) Horn switch (18) Lock lever automatic lock cancel switch (15) Room lamp switch (19) Cigarette lighter (16) Pump secondary drive switch (20) Engine shutdown secondary switch STARTING SWITCH Starting switch is used to start or stop the engine.
Page 157 OPERATION EXPLANATION OF COMPONENTS 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: 29% E mode: 36% Position (d) High idle...
Page 158 EXPLANATION OF COMPONENTS OPERATION BREAKER OPERATION SWITCH The breaker control switch is used to operate the breaker. For handling of the breaker control switch, see “HANDLE MA- CHINE READY FOR INSTALLATION OF ATTACHMENT (6-16)”. SWING LOCK SWITCH WARNING • When not using the swing operation, e.g. when traveling, put the swing lock switch to ON position. •...
Page 159 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH The horn switch is used to sound the horn. Press the horn switch on the R.H. work equipment control lev- er, and the horn sounds. ROOM LAMP SWITCH NOTICE If the room lamp is left to be turned on, the batteries may be exhausted.
Page 160 EXPLANATION OF COMPONENTS OPERATION If the Current Abnormality list includes any of the hydraulic sys- tem errors “DXA9KB”, “DXA8KB”, “DXA9KA” or “DXA8KA”, you can perform operation temporarily by setting this switch to "Emergency" position (a). SWING PARKING BRAKE CANCEL SWITCH NOTICE Swing operations can be performed temporarily with swing parking brake cancel switch when there is a problem in the swing parking brake system.
Page 161 • 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. REVOLVING LAMP SWITCH (if equipped) Revolving lamp switch is used to light up the yellow revolving lamp on top of the cab.
Page 162 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 163: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS SEAT HEATER SWITCH This seat heater switch is used to warm the seat. (a) ON Start the seat heating and the seat becomes warm. (b) OFF Stops the seat heating. QUICK COUPLER SWITCHES To operate the quick coupler circuit switches on RHS console and on LH PPC lever, must be operated together. Refer to “TO RELEASE A BUCKET OR ATTACHMENT (6-5)”...
Page 164 EXPLANATION OF COMPONENTS OPERATION (4) R.H. work equipment control lever (with auto-de- (6) Attachment control pedal (with auto-deceleration celeration system) system) (5) Blade control lever (with auto-deceleration system) (7) Lock pin (if equipped) LOCK LEVER WARNING • When leaving the operator's seat, set the lock lever securely to LOCK position. If the lock lever is not at LOCK position and the control levers or control switches are touched by mistake, it may lead to serious personal injury or death.
Page 165 • When the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends For the genuine hydraulic oils which Komatsu recommends, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”. • When the system has a failure •...
Page 166 EXPLANATION OF COMPONENTS OPERATION TRAVEL LEVER WARNING • If you perform operations with your foot on the pedal, the machine may suddenly start if you depress the pedal by mistake, and this may lead to serious person- al injury or death. Be extremely careful when using the pedal for travel and steering operations, and do not put your foot on the pedal when it is not necessary.
Page 167 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT CONTROL LEVER The left work equipment control lever is used to operate the arm and upper structure. Swing control (a): Swing RIGHT (b): Swing LEFT Arm control : Arm IN (d): Arm OUT N (NEUTRAL) The upper structure and arm are held in position and do not move.
Page 168: Other Equipment
EXPLANATION OF COMPONENTS OPERATION 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 169 OPERATION EXPLANATION OF COMPONENTS When opening Stop the machine on a level ground, lower the work equipment to the ground, then stop the engine. Set the lock lever securely in LOCK position (L). Check that the wiper blade is stowed in the right stay. 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 170 EXPLANATION OF COMPONENTS OPERATION 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 Handles (A) on the right and left top sides of the front win- dow are not for pulling up the front window.
Page 171 OPERATION EXPLANATION OF COMPONENTS When closing CAUTION When closing the window, lower it slowly and be careful not to get your hand caught. Stop the machine on a level ground, lower the work equipment to the ground, then stop the engine. Set the lock lever securely in LOCK position (L).
Page 172 EXPLANATION OF COMPONENTS OPERATION When the bottom of the window reaches the top of lower side window, push the top of the window to the front to push it against right and left lock catches (G) and engage the lock. Check that lever (B) is securely in LOCK position.
Page 173 OPERATION EXPLANATION OF COMPONENTS After removing the bottom window, store it at the rear of the operator's cab and lock it securely with lock (2). The procedure for stowing is as follows. Set it with the protruding part of grip (1) on the glass on the inside and insert the bottom of the glass into the groove in seat (3).
Page 174 EXPLANATION OF COMPONENTS OPERATION SLIDE DOOR CAUTION • Be sure to check that the sliding door is locked in po- sition both when it is open and when it is closed. • Always place the machine on a level ground when opening or closing the door.
Page 175 OPERATION EXPLANATION OF COMPONENTS Insert the key as far as it will go to the shoulder (A) and turn it. If the key is turned when it is not inserted all the way to the end, it may break. MAGAZINE BOX A pocket is provided the rear inside the cab for keeping Opera- tion and Maintenance Manual and oil chart.
Page 176 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 ca- pacity larger than above value, consult your Komatsu distributor.
Page 177 OPERATION EXPLANATION OF COMPONENTS M type housing (2 poles) Terminal Body Rear holder AVS 0.5 AVS 0.85 to 2 AVS 3 Komatsu part No. 08056-00211 08056-00230 08056-00050 08056-00051 08056-00052 Left connector No.: M10 X type housing (2 poles) Terminal Grommet AVS 0.5 to...
Page 178 EXPLANATION OF COMPONENTS OPERATION Fuse capacities and circuit names Fuse Name of circuit Secondary switch, working lamp relay 30 A Solenoid valve PPC hydraulic lock solenoid 10 A Window washer, cigarette lighter 10 A Horn Spare 10 A Revolving lamp (if equipped) 10 A Radio, speaker, L.H.
Page 179 OPERATION EXPLANATION OF COMPONENTS REMARK • Spare fuses are installed in the back of the fuse holder lid at the rear left of the operator's seat. • After using spare fuses, replenish them immediately. • One spare fuse is installed for each 5 A, 10 A, 20 A, 25 A, and 30 A.
Page 180 EXPLANATION OF COMPONENTS OPERATION GREASE PUMP HOLDER Open the tool box cover on the left side of the machine, and you see the grease pump storage place. When storing the grease pump, pass its nozzle through the hole at the end until it stops. FIRE EXTINGUISHER (if equipped) A fire extinguisher is prepared at the rear part inside the opera-...
Page 181 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. 3-111 WENAM00111...
Page 182 Urea SCR systems. Alerts in Induce- ment of the Komatsu Urea SCR System progress step by step. It starts with visual indications on the machine monitor with audible sounds to engine power deration to avoid dangerous conditions.
Page 183 OPERATION EXPLANATION OF COMPONENTS To prevent deterioration of the aftertreatment devices, the ex- haust gas temperature rises automatically, which is regenera- tion. During regeneration, the aftertreatment devices regenera- tion display (1) comes on in the indicator lamp. When the engine is idled for long periods of time, regeneration will occur more frequently.
Page 184 EXPLANATION OF COMPONENTS OPERATION Low-level requirement for regeneration • When caution lamp (2) comes on in yellow (action level (3): “L01”, screen (A) is displayed first. • The action level goes out after 2 seconds and the screen changes to standard screen (B). •...
Page 185 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION When the manual stationary regeneration is required, check if the caution lamp (1) is lit. During manual stationary regeneration, there are times when engine low idle speed increases automatically. Move the machine to a safe area and stop it with the en- gine running.
Page 186 EXPLANATION OF COMPONENTS OPERATION When manual stationary regeneration is not activated even af- ter you push the switch F6, return to the normal screen. Then push the switch F5, and follow the instructions shown on the screen. Manual stationary regeneration may continue for over 40 mi- nutes.
Page 187 OPERATION EXPLANATION OF COMPONENTS Even if regeneration is disabled, the aftertreatment device re- generation display (1) may come on under certain condition. In this case, it is impossible to disable regeneration. Procedures to stop the regeneration When aftertreatment device regeneration display (1) is lit on the standard screen, push F6 on the standard screen to open the “Aftertreatment Devices Regeneration”...
Page 188 EXPLANATION OF COMPONENTS OPERATION Push F6 on the normal screen, to open the “Aftertreatment Devices Regeneration” screen. If this screen does not show, push F1 and F2 to toggle to this screen. Select Yes to cancel regeneration disable and push F6. ABOUT THE OPERATION OF UREA SCR SYSTEM The Urea SCR System automatically starts operating as soon as the engine is started.
Page 189 OPERATION EXPLANATION OF COMPONENTS The Inducement strategy progressed in 5 levels from Warning, Escalated Warning, Mild inducement, Severe In- ducement and Final Inducement. The DEF level caution lamp (1) on the machine monitor will light up, audible alert will start, then Action level will be dis- played on the machine monitor, and engine power will be derat- ed in steps.
Page 190 EXPLANATION OF COMPONENTS OPERATION Inducement status (4): “1 DEF low level warning appears.” Add DEF to the DEF tank immediately. • Escalated Warning: The audible alert sounds in repetition of “three beeps and a pause”. 2 gradations of the DEF level gauge light up in the red range.
Page 191 Add DEF to the DEF tank immediately. In case the system does not come out of Inducement even if DEF is added in the tank, contact your Komatsu Distribu- tor. INDUCEMENT STRATEGY WHEN ABNORMALITIES ARE DETECTED IN THE...
Page 192 EXPLANATION OF COMPONENTS OPERATION The inducement strategy progresses in 5 levels, “Warning”, “Escalated Warning”, “Mild Inducement”, “Severe Inducement” and “Final Inducement”. The Inducement strategy includes vis- ual alert by the DEF caution lamp (1), and Action Level dis- played on the machine monitor (2), and the audible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle.
Page 193 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (4): “1 Please inspect and maintain SCR system.” Move the machine to the safe place and contact your Ko- matsu Distributor. If operation continues for 1 hour after “Warning” started without taking any actions instructed by the Action Level table, Inducement advances to “Escalated Warning”.
Page 194 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Mild Inducement”.
Page 195 OPERATION EXPLANATION OF COMPONENTS abnormalities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of “Mild Inducement” through the machine monitor. Note that “Tem- porary Restoration from Inducement” does not regain full engine power. “Temporary Restoration from Inducement”...
Page 196 EXPLANATION OF COMPONENTS OPERATION Press F6 while the “Engine power Recovery” window is displayed. Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of “Mild Inducement” for the maximum of 30 minutes as long as there is sufficient remaining time to “Final Inducement”.
Page 197 If a recurrence occurs, “Severe Inducement” will be activated. If this occurs, utilize “Temporary Restoration from Inducement” and move the machine to a safe place, and contact your Komatsu distributor. The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not cor- rected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final Inducement”...
Page 198 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 199: Machine Operations And Controls
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Always perform the following inspections and cleaning every day before starting engine for the day's work.
Page 200 13. Check the bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, ask your Komatsu distribu- tor for repair. 14. Check and clean the camera Check the camera for any abnormality.
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE If the water inside transparent cup (2) freezes, wait until the frozen water has melted completely, then follow the procedure to drain the water. REMARK • If transparent cup (2) is dirty or it is difficult to see the inside, clean transparent cup (2) when replacing fuel prefilter cartridge (1).
Page 202 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 203 OPERATION MACHINE OPERATIONS AND CONTROLS Add oil through oil filler port (F) of the hydraulic tank until the oil level comes between levels H and L of sight gauge (G). NOTICE Do not add oil above H line. It may damage the oil cir- cuit and cause the oil to spurt out.
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check it with the reservoir tank when the engine is cold. • Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in the radiator.
Page 205 • 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 206 MACHINE OPERATIONS AND CONTROLS OPERATION When the fuel level caution lamp lights up in red, check the fuel level with fuel level gauge (1) on the machine monitor. When the fuel gauge pointer (2) reads the red range, the fuel amount is 52 ℓ or less. The fuel level is low.
Page 207 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 208 MACHINE OPERATIONS AND CONTROLS OPERATION Refuelling can be stopped at any time by turning off the master switch (5). **NO SIGNAL** If more fuel is needed in the fuel tank after the float switch has stopped the pump, press and hold switch (6). When switch (6) is pressed and held, the refuel pump will fill the tank.
Page 209 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may need to be replaced.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION After checking, turn the starting switch back to OFF posi- tion (A). Open the machine right front cover, turn the filler cap (2) counterclockwise. Open the filler cap. The caps of DEF tanks are blue, as required by emission regulations.
Page 211 After checking, turn the starting switch back to OFF posi- tion. If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. METHOD FOR CHECKING HORN Turn the starting switch to ON position.
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION 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 malfunction due to accidental contact with the control levers. •...
Page 213 OPERATION MACHINE OPERATIONS AND CONTROLS Pull up reclining adjustment lever (2) and set the seat back to a position which is comfortable for operation, then release reclin- ing adjustment lever (2). REMARK Sit with your back against the backrest when adjusting. If your back is not touching the backrest, it may suddenly move for- ward.
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION Operate the tilt adjustment lever (4) upward or the tilt ad- justment lever (3) downward, and set the seat tilt angle to the desired position. Set the seat horizontally by the opposite inclination opera- tion, and release the tilt adjustment lever. Adjustment amount: 60 mm METHOD FOR ADJUSTING ARMREST ANGLE •...
Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION Pull fore-aft adjustment lever (7) to the right, adjust the seat to the desired position, then release fore-aft adjustment lever (7). The operator's seat, right and left control levers, and lock lever all slide (move) together.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION Mirror (A): Machine L.H. front mirror Mirror (B): Machine rear mirror PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) Adjust the mirror so that the operator can see a person at the rear left of the machine. If the mirror is removed, install it to the position shown in the figure.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS If the mirror is removed, install it to the position shown in the figure. (E): 360 mm (H): 15 ° If mirror does not move smoothly when adjusting its angle, loosen mirror fixing screw (4) and mirror fixing bolt (5). Tightening torque of screw (4): 3.0 to 3.5 Nm Check that you can see a person within 1 m away from around the machine.
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION 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. If the image on the monitor is not aligned correctly, adjust mounting angle (A) of the rear view camera in the following procedure.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS Remove bolts (4) (2 places). Remove cover (1). Loosen mounting bolts (5) (3 places) of the camera, and adjust camera installing angle (A) so that the side of cam- era matches the edge of bracket (B). After adjusting, tighten bolts (5).
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION 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 221 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. 3-151...
Page 222 MONITOR WHEN STARTING SWITCH IS ON WHILE OPERATOR ID INPUT IS SET (3-13)”. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identification function. Perform the following inspection on the machine monitor.
Page 223: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS If the maintenance due time has passed for certain items, maintenance time caution lamp (15) is lit in red for 30 seconds. Press user menu display switch (16), check the item which has exceeded the maintenance interval, and perform maintenance immediately.
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (3) to Low idle (MIN) position. Turn starting switch key (2) to START position (C). The engine starts. When the engine starts, release the starting switch key (2). The key will return automatically to ON position (B). REMARK When the engine is started, the battery voltage may sud- denly drop depending on the temperature and the battery...
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING ENGINE IN COLD WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious personal injury or death. •...
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (3) to Low idle (MIN) position. Hold starting switch key (2) in HEAT (preheating) position (D). Preheating pilot lamp (4) lights up, and approximately 30 seconds later it flashes for 10 seconds to notify completion of preheating.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS • After the engine starts, wait for the engine oil pressure caution lamp to go out. Do not touch the control levers or control pedal while the engine oil pressure caution lamp is lit. • If the engine oil pressure caution lamp does not go out even after 4 to 5 seconds have passed, stop the engine immediately.
Page 228: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 229 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 230 MACHINE OPERATIONS AND CONTROLS OPERATION Turn fuel control dial (2) to the middle between Low idle (MIN) and High idle (MAX) to run the engine at a medium speed. Run the engine with no load until engine coolant temperature caution lamp (1) displays correct temperature. •...
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS 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 232 MACHINE OPERATIONS AND CONTROLS OPERATION Check that engine coolant temperature caution lamp (1) displays the correct temperature. • Display (A) when temperature is correct: Caution lamp background (C) is blue. • Display (B) when temperature is low: Caution lamp background (C) is white. If it displays low temperature, perform additional warm up of the engine until engine coolant temperature caution lamp (1) displays the correct temperature.
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS Operate the work equipment to warm up the hydraulic components. NOTICE When the work equipment is operated, take care that it does not interfere with the machine or ground. Move R.H. work equipment control lever (5) slowly in the direction of bucket CURL position (D).
Page 234 • Fuel level caution lamp (16): Displays appropriate level 12. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 13. Hydraulic system warm-up operation in cold weather NOTICE In cold temperatures (ambient temperature below 0 °C), even when the hydraulic oil temperature caution lamp displays the correct temperature, perform the "Hydraulic system warm-up operation in...
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS 14. Before starting the work, check that fuel control dial (4) is at a 2/3 position between Low idle (MIN) position and High idle (MAX) position. If it is not at the 2/3 point, set it to the 2/3 point and run the engine at 2/3 speed between MIN and MAX before operat- ing.
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION For attachment operations (if equipped), change the work- ing mode to the attachment mode. 16. Check that hydraulic oil temperature caution lamp (7) dis- plays correct temperature. • Display (A) when temperature is correct: Caution lamp background (C) is blue.
Page 237: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Display of working mode P mode E mode For heavy-duty operations For fuel economy conscious operations L mode B mode For operations requiring fine control and lifting operation For breaker operations ATT/P mode ATT/E mode For operations of 2-way attachment such as crusher For operations of 2-way attachment such as crusher (fuel economy conscious operations)
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE Do not stop the engine abruptly except in an emergency. Otherwise, the service lives of component parts of the en- gine will be reduced. If the engine is overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradu- ally, and then stop it.
Page 239: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE WARNING • Check the direction of the track frame before operating the travel lever and travel pedal. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction to the direction of the operation of the travel levers or travel pedals (front and rear travel are reversed, right...
Page 240 (6) slowly. When traveling, check that the alarm sounds normally. If the travel alarm does not sound, contact your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warm-up operation.
Page 241 (6) slowly. When traveling, check that the alarm sounds normally. If the travel alarm does not sound, contact your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warm-up operation.
Page 242: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS Change direction of machine When turning left, return the left travel lever to the neutral posi- tion. : Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.
Page 244: Method For Swinging Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SWINGING MACHINE WARNING • The tail of the machine extends outside the tracks. Check that there is no one around the machine before operating the swing. • If the travel levers are operated when the engine speed is decreased by the auto-deceleration function, the en- gine speed will suddenly increase.
Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS • Arm operation Move the L.H. work equipment control lever back and forth. You can operate the arm. • Swing operation Move the L.H. work equipment control lever to the right and left. The upper structure swings. •...
Page 246: Handle Working Mode
MACHINE OPERATIONS AND CONTROLS OPERATION REMARK This machine is equipped with an accumulator in the control circuit. Even if the engine is stopped, if the starting switch key is turned to ON position within 15 seconds after stopping the engine, and the lock lever is set to FREE position, it is possible to use the lever operation to lower the work equipment to the ground.
Page 247: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS Press the working mode selector switch or, function switch F3 or F4 to select the appropriate mode. Select a desired working mode and press function switch The change is entered and the screen returns to the stand- ard screen.
Page 248 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects. This is not only dangerous, but also drastically reduces the life of the machine. PROHIBITION OF OPERATIONS USING TRAVEL FORCE Do not use the travel force to perform excavation by digging the bucket into the ground.
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig. This can apply an excessive force to the chassis and buck- et, and the machine may break.
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION 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 251 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF SWINGING OR TRAVELING WHEN ROCK IS ON TOP OF TRACK ASSEMBLY If the machine travels or swings with crushed stones, soil, or sand on the track, they hit and damage the undercover and frame.
Page 252: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION When driving on rough ground (rock-bed, etc.), direct the idler (1) having the cushion mechanism in the travel direction and drive the machine at low speed. 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.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS • Press travel speed selector switch (1) to switch the travel speed. The travel speed (“Lo”, “Hi”) is displayed on travel speed display (2). PRECAUTIONS FOR FOLDING WORK EQUIPMENT (Machine with blade) When folding in the work equipment to the travel or transporta- tion posture, be careful not to let the bucket hit the blade.
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION When performing the backhoe operation near the blade, take care that the boom cylinder does not touch the blade. Dig with the blade at the rear usually, and dig in front of the blade only when required.
Page 255: Precautions For Working On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR WORKING ON SLOPE WARNING • Swinging operations or operating the work equipment on slopes machine may lose its balance and tip over. Avoid such operations as much as possible. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 256: Method For Escaping From Mud
MACHINE OPERATIONS AND CONTROLS OPERATION • When traveling up a steep hill of more than 15 °, set the work equipment to the posture shown in the figure. (a) : 20 to 30 cm Braking on downhill slope Set the travel lever in NEUTRAL position, and the brake is applied automatically. If engine stops If the engine stops when traveling uphill, move the travel levers to NEUTRAL position, lower the bucket to the ground, stop the machine, then start the engine again.
Page 257: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ESCAPING WHEN TRACKS ON BOTH SIDES ARE STUCK When the tracks on both sides get stuck, pull out the machine according to the following procedure. Place logs, wooden blocks, etc. under the tracks according to the above procedure.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION SHOVEL WORK A shovel is suitable for excavating at a position higher than the machine. Shovel work is performed by attaching the bucket in the re- verse direction. DITCHING WORK Ditching work can be performed efficiently by attaching a buck- et which matches the digging operation and then setting the tracks parallel to the line of the ditch to be excavated.
Page 259: Method For Replacing And Inverting Bucket
OPERATION MACHINE OPERATIONS AND CONTROLS 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 protective eyeglasses, hard hat, gloves, and other protective equipment.
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • Perform installation in the reverse order to removal. • Fit O-ring (3) to arm (5) as shown in the figure since it is damaged easily when bucket (4) is installed. After inserting the pin, fit it in the regular groove. Install the lock bolt and nut of each pin.
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS Invert the removed bucket. Align arm (5) with mounting portion (1). Align link (6) with mounting portion (2). Insert grease-coated pins (A) and (B) into mounting por- tion (1) and mounting portion (2) respectively. REMARK Fit O-ring (3) to mounting portion (1) of arm (5) and bucket (4).
Page 262: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION 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, block the tracks from movement. As an addi- tional safety measure, thrust the work equipment into the ground.
Page 263: Method For Checking After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS Set the lock lever (2) 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 264: Lock
MACHINE OPERATIONS AND CONTROLS OPERATION LOCK Position to be locked Always lock the following places. (1) Fuel tank filler cap (2) Hydraulic tank oil filler cap (3) Operator's cab door (4) Toolbox and grease pump storage cover (5) Left front cover of the machine (6) Battery inspection cover (7) Engine hood (8) Machine right front cover...
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK Insert the key into the key slot. Turn the key counterclockwise, and pull the cover handle. Position (A): OPEN Position (B): CLOSE (LOCK) If it is equipped with stay for supporting the cover, open the cover wide until the stay is set in LOCK position.
Page 266 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE Always keep the hood locked unless you need to open it. METHOD FOR OPENING ENGINE HOOD Insert the key into the key slot. Turn the key counterclockwise (A) and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) Unlock the lock by pulling the engine hood open lever (1) to your side.
Page 267 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key clockwise (B) and remove it. (A): OPEN : CLOSE METHOD FOR OPENING AND CLOSING CAB DOOR METHOD FOR OPENING CAB DOOR Insert the key into the key slot. Turn the key counterclockwise (A) and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) 3-197...
Page 268 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR LOCKING CAB DOOR Close the door and insert the key into the key slot. Turn the key clockwise (B) and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) 3-198 WENAM00111...
Page 269: Handle Air Conditioner
If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner system cau- 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 •...
Page 270: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (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 271 OPERATION HANDLE AIR CONDITIONER 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 272 HANDLE AIR CONDITIONER OPERATION (A): Rear vent (2 places) (B1): Face vent (1 place) (B2): Foot vent (1 place) (C): Foot vent (1 place) : Front window glass vent (2 places) Air blows out from the vents marked with ○. Vent Monitor display Air vent mode...
Page 273 OPERATION HANDLE AIR CONDITIONER 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 274: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION 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 275 OPERATION HANDLE AIR CONDITIONER 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 276 HANDLE AIR CONDITIONER OPERATION 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 277 OPERATION HANDLE AIR CONDITIONER 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 278 HANDLE AIR CONDITIONER OPERATION 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. At this time, check that set temperature (a) and air flow rate (b) are displayed on “A/C Setting”...
Page 279 OPERATION HANDLE AIR CONDITIONER 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 280 HANDLE AIR CONDITIONER OPERATION 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.) When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, press air conditioner switch (8) to turn it ON.
Page 281: Handle Radio
OPERATION HANDLE RADIO 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 282 HANDLE RADIO OPERATION PRESET BUTTON If you register desired stations to the preset button beforehand, you can select each station by touching this but- ton once. It is possible to preset 6 stations each for both AM and FM. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display.
Page 283: Method For Controlling Radio
OPERATION HANDLE RADIO Open cap (A) at the rear right of the operator's seat. Connect a portable audio equipment by using an commer- cially available audio cable. Press band/AUX selector button (1) to select “AUX”. METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM.
Page 284 HANDLE RADIO OPERATION METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING) Press band/AUX selector button (1) and select FM or AM. Hold down sound control button (2). When a proper frequency is picked up, it is automatically registered to preset memories 1 to 6. METHOD FOR CALLING PRESET Press band/AUX selector button (1) and select FM or AM.
Page 285 OPERATION HANDLE RADIO METHOD FOR ADJUSTING SOUND BALANCE Press sound control button (1) to light up “BAL” on the dis- play. You can adjust the sound (balance). Press tuning/time adjustment button (2) to adjust the sound (balance). Press the △ button, and the speaker output on the R •...
Page 286: Stow Antenna
HANDLE RADIO OPERATION Press display selector button (1) to cancel time adjustment. The screen returns to clock display. STOW ANTENNA Before transporting the machine putting it inside a building, store the antenna to prevent any interference. Loosen antenna mounting bolt (1) and store the antenna at position (A).
Page 287: Handle Road Liners
OPERATION HANDLE ROAD LINERS HANDLE ROAD LINERS (Road liner specification) RECOMMENDED USE OF ROAD LINERS The road liners have good features the steel shoes do not have. However, if they are used in the same manner as the steel shoes are, the features are not used fully. Perform the optimum operation according to the condition of the site and contents of work.
Page 288 HANDLE ROAD LINERS OPERATION • Install to all the links of the right and left tracks always when installing the road liner. If it is installed partially or to only one portion, its service life is shortened remarkably. Precautions during operation When operating, observe the following.
Page 289: 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”.
Page 290: 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 291 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 292 TRANSPORTATION OPERATION Turn the swing lock switch ON to apply the swing lock. When the swing lock switch is turned to ON position, swing lock pilot lamp (9) lights up. : ON position (B): OFF position If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it;...
Page 293 OPERATION TRANSPORTATION 10. Drive the machine slowly in reverse to load it onto the trail- When the machine travels over the rear wheels of the trail- er, it becomes unstable. Drive the machine carefully and slowly. (Never operate the steering.) When the machine passes over the rear wheels, it inclines backward.
Page 294 TRANSPORTATION OPERATION • Securing the machine when using tie-down point (1) Tie one end of each chain or wire rope of appropriate strength to the tie-down holes on the track frame. X : 50 to 100 mm (Keep the chains off the track frame.) 3-224 WENAM00111...
Page 295 OPERATION TRANSPORTATION (Machine with blade) • Method for securing the machine without tie-down point Prevent the machine from moving during transporta- tion, by putting wooden blocks on the front and rear sides of the tracks, and secure the machine with chains or wire ropes of suitable strength.
Page 296 TRANSPORTATION OPERATION Apply the trailer brakes securely, then put chocks (1) under the tires to prevent the trailer from moving. Set right and left ramps (2) parallel to each other and equally spaced to the right and left of center (3) of the trail- er.
Page 297: Method For Lifting Machine
This lifting method 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 298 TRANSPORTATION OPERATION When lifting the machine, perform the operation on a flat ground according to the following procedure. Start the engine. Swing the upper structure in order for the position of the work equipment to come to the sprocket (1) side if the ma- chine is equipped with a blade.
Page 299: Cold Weather Operation
If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 300: Precautions After Daily Work Completion
COLD WEATHER OPERATION OPERATION When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be started easily in the next morning.
Page 301: After Cold Weather Season
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM- MENDED FUEL, COOLANT, AND LUBRICANT (7-4)”. If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-231 WENAM00111...
Page 302: 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. 3-232...
Page 303 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 304: Troubles And Actions
TROUBLES AND ACTIONS OPERATION TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill it up with fuel and bleed air from the fuel system before stating. Always check the fuel level to prevent running out of fuel. For the method of bleeding air, see “METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE (4-50)”...
Page 305: Precautions For Towing Machine
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR TOWING MACHINE WARNING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death. •...
Page 306: Precautions For Severe Job Condition
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR USING LIGHTWEIGHT TOWING HOLE WARNING • Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to seri- ous personal injury or death.
Page 307: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS 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 308 TROUBLES AND ACTIONS OPERATION METHOD FOR REMOVING BATTERY Open the battery inspection cover. Open the battery inspection cover wide until the stay is set in LOCK position. Remove the wing nuts (1) (2 places). Remove the rubber cover (2). Remove the cable (3) on the negative (-) terminal side (ground side) first.
Page 309 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Follow the instruction manual accompanying the battery charger, and observe the following. •...
Page 310 TROUBLES AND ACTIONS OPERATION 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 311: 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 312 TROUBLES AND ACTIONS OPERATION 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 313 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 314 Improper oil is used. (Viscosity is im- Replace oil. See METHOD FOR US- proper.) ING FUEL, COOLANT AND LUBRI- CANTS ACCORDING TO AMBIENT TEMPERATURE and KOMATSU GENUINE LUBRICANTS. Clogged oil filter cartridge Replace cartridge. See EVERY 500 HOURS MAINTENANCE. Oil leakage due to improper connec- Check, repair.
Page 315 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Starting motor rotates but engine Add fuel. See CHECKS BEFORE Lack of fuel does not start. STARTING. Repair place where air is sucked in. Air in fuel system See EVERY 500 HOURS MAINTE- NANCE.
Page 316 For the method of replacement, see “METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE (4-50)”, “METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE (4-60)”. If “CA2249” or “CA559” is not cleared even after the replacement, ask your Komatsu distributor for inspec- tion immediately, even though the machine can perform normal operation.
Page 317: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section. WENAM00111...
Page 318: 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 319: Dusty Jobsites
MAINTENANCE PRECAUTIONS FOR MAINTENANCE DUSTY JOBSITES When working at dusty jobsites, observe the following. • Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. • Replace the fuel filter more frequently.
Page 320: 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 321 Always use ultra-low-sulfur diesel fuel. 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 322 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 323 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 324: Handle Electrical Components
Komatsu recommends installing electric components 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. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 325: 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 326 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Width Tightening torque Nominal - No. of across Target value Allowable range threads "a" flats "b" (mm) 9/16-18UNF 35 to 54 3.5 to 5.5 11/16-16UN 54 to 93 5.5 to 9.5 13/16-16UN 10.5 84 to 132 8.5 to 13.5...
Page 327: Maintenance Schedule
250 hours. For details, see the oil part number and note in “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE WHEN REQUIRED ................................4-13 METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER ..........
Page 328: Maintenance Interval For Hydraulic Breaker
MAINTENANCE SCHEDULE TABLE MAINTENANCE METHOD FOR REPLACING DEF TANK BREATHER ELEMENT ..............4-62 METHOD FOR CHECKING FAN BELT TENSION AND REPLACING FAN BELT ........4-63 EVERY 2000 HOURS MAINTENANCE........................4-63 METHOD FOR CLEANING HYDRAULIC TANK STRAINER ................4-64 METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR CONTROL CIRCUIT) ........................
Page 329: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING • If inspection, cleaning, or maintenance is performed while the engine is running, dust enters into the engine and damages it. Be sure to stop the engine before performing these works. •...
Page 330 MAINTENANCE PROCEDURE MAINTENANCE Hold the outer element (5), rock it lightly up and down and to the right and left, and pull it out while turning it to the right or left. When outer element (5) is removed, check that the inner element does not come out of position and is not at an an- gle.
Page 331 MAINTENANCE MAINTENANCE PROCEDURE 11. After cleaning, illuminate the inside of the element with an electric bulb to check. If any holes or thin places are found, replace the inner and outer elements. 12. Remove the cover of cloth or tape attached to inner ele- ment (6).
Page 332 MAINTENANCE PROCEDURE MAINTENANCE Lock the tip of hook (2) on the protrusion of the air cleaner body. Always install the cover (3) so that vacuator (4) faces right below (A). When cover (3) is installed, check that the clearance between the air cleaner body and cover (3) is not too large.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE Do not remove inner element (6) at this time. When outer element (5) is removed, check that the inner element does not come out of position and is not at an an- gle. If the inner element is inclined, push it in straight by hand to the end.
Page 334: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 335 When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the 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 336 MAINTENANCE PROCEDURE MAINTENANCE Place the containers to catch the coolant under the drain hose installed to drain valve (6) and under coolant drain plug (7) of the engine cylinder block. Open the drain valve (6) at the bottom of the radiator. Remove the drain plug (7) of the cylinder block and drain the coolant.
Page 337 MAINTENANCE MAINTENANCE PROCEDURE 16. 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. Move the R.H. work equipment control lever slowly in the direction to the bucket CURL side (D).
Page 338: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE 25. Drain the coolant in reservoir tank (8). 26. Clean the inside of reservoir tank. 27. Add Non-Amine Engine Coolant to the middle between FULL and LOW. 28. Stop the engine. 29. After approximately 3 minutes, add Non-Amine Engine Coolant (AF-NAC) up to the mouth of the coolant filler port.
Page 339: Method For Checking Looseness And Tightening Road Liner Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING LOOSENESS AND TIGHTENING ROAD LINER SHOE BOLTS NOTICE If the machine is used with road liner shoe bolts loose, they will break. Tighten any loose shoe bolts immediately. Check for looseness of the road liner shoe bolt (1). If any looseness of the bolt is found, tighten it in order shown in the figure.
Page 340: Method For Checking Road Liner
Check the track tension again, and if the tension is not correct, adjust it again. METHOD FOR CHECKING ROAD LINER (Road liner specification) If the road liners are in the following condition, they must be replaced. Ask your Komatsu distributor for replace- ment. 4-24...
Page 341: Method For Replacing Road Liner
(Road liner specification) • When all the road liners of the machine need to be replaced, ask your Komatsu distributor to replace them. • When replacing only part of the road liner, use the special road liner removal tool. Order the tool from your Komatsu distributor.
Page 342 MAINTENANCE PROCEDURE MAINTENANCE Check that the work equipment is in a stable condition, then set the lock lever to LOCK position (L). Use a hammer and bar to drive out lock pin (2). If the bar is set against rubber pin lock (3) when it is hit, the rubber pin lock may break.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE Use your hand or a hammer to push rubber pin lock (3) in- to the hole of adapter (4). When doing this, be careful that rubber pin lock (3) does not fly out from the adapter surface. Clean the inside of tooth (1), then install it to adapter (4).
Page 344: Method For Replacing Bucket Teeth (Horizontal Pin Type)
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the bucket teeth before the adapter starts to wear. WARNING • It is dangerous if the work equipment moves by mistake when the tooth is being replaced. Set the work equipment in a stable condition, set the lock lever securely to LOCK position, and stop the engine.
Page 345: Method For Adjusting Bucket Clearance
MAINTENANCE MAINTENANCE PROCEDURE Clean the mounting face and fit new tooth (2) to the adapt- Insert pin (1) halfway, and drive it with the hammer to in- stall it to the bucket. METHOD FOR ADJUSTING BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance.
Page 346: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID If air is in the window washer fluid, check the fluid level in window washer tank (1). Check the fluid level in window washer tank (1). If the level is low, add window washer fluid for automobile. Take the following precautions when filling.
Page 347 (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 348: Method For Checking, Cleaning And Lubricating Slide Door Rail And Roller
Spray rail (1) and roller (2) thoroughly with lubricant. After spraying with lubricant, slide the door and check that the door opens and closes smoothly. If the movement is not smooth, consult your Komatsu distributor. METHOD FOR CHECKING, CLEANING AND LUBRICATING SLIDE DOOR STOP- Prepare lubricant.
Page 349: Method For Checking Stopper Clearance In Opening Front Door Is Up
Rubber stopper (1) may be worn partially, but it does not affect the function as long as there is no backlash or clearance. If there is any clearance, consult your Komatsu distributor. METHOD FOR REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER...
Page 350: Method For Washing Washable Floor
MAINTENANCE PROCEDURE MAINTENANCE Place a container to catch drained oil under the filter ele- ment. Turn filter case (1) counterclockwise and remove it. Remove element (2). Remove plug (3) from filter case (1). After checking that the hydraulic oil temperature has drop- ped, turn filter case (1) counterclockwise, remove it, then take out element (2).
Page 351 MAINTENANCE MAINTENANCE PROCEDURE Swing the upper structure slowly so that water drain holes (1) in the cab floor are at a low position. Lower the work equipment to the ground and set the ma- chine in a stable condition. Set the lock lever to LOCK position (L). Stop the engine.
Page 352: 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 perform this work. 4-36 WENAM00111...
Page 353: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE PROCEDURE The gas springs are installed inside the left console (1 place) and at the cab ceiling window (2 places). In the following cases, ask your Komatsu distributor for inspec- tion, repair, and replacement. • The lock lever cannot be pulled up lightly or the cab ceiling window cannot be opened lightly.
Page 354 MAINTENANCE PROCEDURE MAINTENANCE NOTICE If the engine runs at high speed immediately after startup or a cylinder is pushed up to its stroke end, air mixed into the cylinder may cause damage to the piston packing or etc. Run the engine and keep it at low idle speed. Extend and retract each cylinder 4 to 5 times, taking care that a cylinder is not moved to the stroke end.
Page 355: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE Run the engine at low idle and swing the upper structure 90 ° to bring the work equipment to the side of the track. Push up the machine until the track is raised slightly from the ground. Perform idle rotation of track for 2 minutes. Repeat this procedure on both the right and left sides.
Page 356: 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. Pump in grease through the grease fittings shown by arrows by using a grease pump. (1) Arm and Bucket connection pin (1 place) After greasing, wipe off any old grease that is pushed out.
Page 357: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Place a container to receive the oil under drain valve (P). Loosen drain valve (P) and drain excessive oil. Check the oil level again. After the oil level check and the adding the oil, insert the oil level gauge so that the stamping mark (T) of it faces the center of the swing machinery.
Page 358: Method For Changing Oil In Large Capacity Final Drive Case
MAINTENANCE PROCEDURE MAINTENANCE Set the plug (F) at the top so that the line running on the plug (F) and plug (P) is perpendicular to the ground sur- face. Place the container to catch oil under plug (P). Remove plug (G) with the hexagonal wrench. Check the oil level.
Page 359: Method For Checking Battery Electrolyte Level
MAINTENANCE MAINTENANCE PROCEDURE Set the plug (G) at the top so that the line running on the plug (G) and plug (P) is perpendicular to the ground sur- face. Place the container to receive the oil under plug (P). Remove the plug (G) with the hexagonal wrench. Check the oil level.
Page 360 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 361: Method For Checking And Adjusting Air Conditioner Compressor Belt Tension
If purified water is added to above the bottom tip of the sleeve, use a syringe to remove electrolyte. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If nec- essary, consult your Komatsu distributor or your battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 362 MAINTENANCE PROCEDURE MAINTENANCE Press the center between compressor pulley (A) and fan pulley (B) with a finger (approximately 60 N). If deflection (C) is 6 to 9 mm, the belt tension is normal. If the deflection is out of the standard, adjust it to the standard value.
Page 363: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE After adjusting the belt tension properly, tighten the nut (2) until it touches the boss (5) and tighten it further in direc- tion B so that it does not become loose. Tightening torque: 108 to 132 Nm Tighten the bolts (1) (4 pieces) to fix them.
Page 364 MAINTENANCE PROCEDURE MAINTENANCE (2) Boom foot pin (2 places) (3) Boom cylinder rod end pin (2 places) (4) Arm cylinder foot pin (1 place) (5) Boom and arm connection pin (1 place) (6) Arm cylinder rod end (1 place) (7) Bucket cylinder foot pin (1 place) (8) Arm-Link connection pin (1 place) (9) Link connection pin (1 places) (10) Bucket cylinder rod end (1 place)
Page 365 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Refill capacity of oil pan: 11.5 ℓ...
Page 366: 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 367 MAINTENANCE MAINTENANCE PROCEDURE Place a container under the fuel prefilter cartridge to re- ceive the fuel. Loosen the drain valve (2) and drain water and sediments from transparent cup (3), and also drain all the fuel from fil- ter cartridge (4). Turn the transparent cup (3) counterclockwise to remove it by using the filter wrench.
Page 368: Method For Checking Swing Pinion Grease Level, Adding Grease
Check that the grease is not milky white. Total amount of grease: 10 ℓ If the grease is milky white, it needs to be replaced. Ask your Komatsu distributor to replace it. Install cover (2) with bolt (1). METHOD FOR LUBRICATING SWING CIRCLE Prepare a grease pump.
Page 369: Method For Checking And Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND CLEANING RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENS- ER FINS WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the com- pressed air, high-pressure water, or steam, there is a danger of personal injury.
Page 370: Method For Cleaning Air Conditioner Fresh/Recirc Air Filters
MAINTENANCE PROCEDURE MAINTENANCE Check the rubber hoses and check the hose clamps for looseness. If the rubber hoses are cracked or fragile, replace them. If the hose clamps are loosened, tighten them. After inspecting and cleaning, install nets (2) and(3) as they were. METHOD FOR CLEANING AIR CONDITIONER FRESH/RECIRC AIR FILTERS WARNING •...
Page 371: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Open cover (1) with the hand. Fix the cover with cover support lever (3). Remove fresh air filter (2). Clean fresh air 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 372: Method For Change Oil In Swing Machinery Case
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (1) (4 pieces), and open hydraulic tank top cover (2). Remove the cap of oil filler port (F) gradually to release the internal pressure. Remove the cap of oil filler port (F). Loosen the bolts (3) (3 pieces) and remove cover (4). Cover (4) may jump out under the force of spring (5), so hold cover (4) down when removing the bolts.
Page 373: Method For Changing Oil In Final Drive Case
MAINTENANCE MAINTENANCE PROCEDURE Prepare a container to receive the oil. Swing the upper structure so that drain plug (P) on the un- derside of the machine is in the middle between the right and left tracks. Place the oil container to receive the oil under drain plug (P).
Page 374: Method For Changing Oil In Large Capacity Final Drive Case
MAINTENANCE PROCEDURE MAINTENANCE Set the plug (G) at the top so that the line running on the plug (G) and plug (P) is perpendicular to the ground sur- face. Place the oil container to catch oil under plug (P). By using a hexagonal wrench, remove plugs (P), (G), and (F) , and drain the oil.
Page 375: Method For Checking Oil Level In Pto Gear Case, Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE Set the plug (G) at the top so that the line running on the plug (G) and plug (P) is perpendicular to the ground sur- face. Place the container to receive the oil under plug (P). Remove plugs (P), (G), and (F) by using a hexagonal wrench, and drain the oil.
Page 376: Method For Replacing Fuel Main Filter 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 377 MAINTENANCE MAINTENANCE PROCEDURE Turn the valve (1) to CLOSE position (S). Place the container to receive the oil under filter cartridge (2). Turn the filter cartridge (2) counterclockwise by using the filter wrench, and remove it. Clean the filter head. Thinly apply oil to the packing surface of the new filter cartridge, then install the filter cartridge to the filter head.
Page 378: Method For Checking All Tightening Points Of Engine Intake Pipe Clamps
5 to 10 to install 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 REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING •...
Page 379: Every 2000 Hours Maintenance
If the machine is operated without DEF tank breather element attached, or with the element other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without DEF tank breather element at- tached, nor use the element other than Komatsu genuine parts.
Page 380: Method For Cleaning Hydraulic Tank Strainer
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR 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 then start the work. •...
Page 381: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
• 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. NOTICE If the nitrogen gas charge pressure in the accumulator 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 382 If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulator 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 383 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR RELEASING PRESSURE IN ACCUMULATOR Lower the work equipment to the ground. REMARK Close the crusher attachment jaws, etc. Set the lock lever to LOCK position (L). Perform the following procedure within 15 seconds. REMARK After the engine stops, the accumulator pressure decreas- es gradually.
Page 384: Method For Checking Alternator And Starting Motor
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 385 MAINTENANCE MAINTENANCE PROCEDURE 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 386 MAINTENANCE PROCEDURE MAINTENANCE 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 387: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 388 MAINTENANCE PROCEDURE MAINTENANCE Remove the filter cap (1) at the bottom of the DEF pump, and remove equalizing element (2). Turn the cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5). Insert the filter removal tool (3) into the bottom of the DEF pump and thrust in with hand.
Page 389: Every 4000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Slide the filter (6) down, and remove spacer (5) from filter removal tool (3). Pull the filter (6) up while pushing in the tip of filter removal tool (3), and remove it. Return the removed spacer (5) to filter removal tool (3), and keep them.
Page 390: Method For Checking Water Pump
• 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. NOTICE If the nitrogen gas charge pressure in the accumulator 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 391: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
(2 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 392: Every 4500 Hours Maintenance
Check visually and touch by hand to check that there are no missing fuel spray prevention cap, loose bolts or hardening of the rubber. If there is any problem, the replacement must be performed. Ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours should be performed at the same time.
Page 393 MAINTENANCE MAINTENANCE PROCEDURE Set the lock lever to LOCK position (L) and stop the en- gine. Remove the bolts (1) (4 pieces), and remove the hydraulic tank top cover (2). Remove the cap of oil filler port (F). Remove the undercover (3). Place the oil container under the drain plug (P1) at the bot- tom of the machine.
Page 394: Every 8000 Hours Maintenance
Maintenance for every 100, 250, 500, 1000 and 4500 hours service should be performed at the same time. METHOD FOR REPLACING DEF HOSE Ask your Komatsu distributor for replacement of the DEF hose. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-78 WENAM00111...
Page 395: Specifications
SPECIFICATIONS WENAM00111...
Page 396: Specifications: Pc138Us-11
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: PC138US-11 Item Unit PC138US-11 Machine weight 13800 Bucket capacity 0.50 Engine model Komatsu SAA4D95LE-7 diesel engine SAE J1995 72.6/2050 (gross) Rated horsepower kW / rpm 9249/SAE 72.5/2050 J1349 (net) A Overall length (standard specification) 7280 A' Overall length (blade specification)
Page 397 SPECIFICATIONS SPECIFICATIONS Working range drawing Working ranges Unit PC138US-11 A Max. digging reach 8300 B Max. digging depth 5480 C Max. digging height 9340 D Max. vertical wall digging depth 4900 E Max. dumping height 6840 Min. swing radius of work equip-...
Page 398: Explanation Of Lift Capacity Chart
EXPLANATION OF LIFT CAPACITY CHART SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART 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. Legend A: Reach from swing centre B: Bucket hook height...
Page 399 SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping). RKA55300 WENAM00111...
Page 400 WENAM00111...
Page 401: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section. WENAM00111...
Page 402: 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 403 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 404: 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 RKA55290...
Page 405 This machine has a system installed to give a warning if there is a failure to maintain pressure in the quick coupler system. If the buzzer sounds in the cab make sure that the cause is clarified be- fore continuing work. In particular check for leaks in the system. If in doubt call your Komatsu dis- tributor.
Page 406 QUICK COUPLER SYSTEM ATTACHMENTS AND OPTIONS Operate switch (1), and with switch (1) in position “B” press and hold button (2) on the left hand lever, to activate quick coupler. NOTICE The switch has a safety lock mechanism to prevent ac- cidental operation.
Page 407: 2-Piece Boom
ATTACHMENTS AND OPTIONS 2-PIECE BOOM 2-PIECE BOOM 2-PIECE BOOM COMPONENTS RKA60710 (1) Arm (4) First boom raise cylinder (2) Second boom (5) First boom (3) Second boom adjust cylinder 2-PIECE BOOM CONTROL PEDAL The 2-piece boom control pedal is situated at the left of travel levers.
Page 408: Method For Lubricating 2-Piece Boom
2-PIECE BOOM ATTACHMENTS AND OPTIONS METHOD FOR LUBRICATING 2-PIECE BOOM NOTICE Perform greasing every 500 hours. If any unusual noise is generated from any greasing point, perform greasing regardless of the greasing interval. Perform greasing every 10 hours for the first 50 hours operation on a new machine. After the machine is subjected to digging work in the water, be sure to grease the wet pins.
Page 409 ATTACHMENTS AND OPTIONS 2-PIECE BOOM (8) 2-piece boom cylinder rod end pin (1 place) RKA45240 (9) Boom and arm connection pin (1 place) (10) Arm cylinder rod end pin (1 place) (11) Bucket cylinder foot pin (1 place) RKA60770 (12) Arm-link connection pin (1 place) RKA60780 (13) Link connection pin (1 place) (14) Bucket cylinder rod end pin (1 place)
Page 410: Preparation For Storage And Lifting Machine
2-PIECE BOOM ATTACHMENTS AND OPTIONS PREPARATION FOR STORAGE AND LIFTING MACHINE Preparation for storage machine When leaving the operator's cab, set the machine in the following posture for safety reason. When leaving the machine for a long time. RKA60720 When leaving the machine for a short time. RKA60730 Preparation for lifting machine WARNING...
Page 411: Specifications
ATTACHMENTS AND OPTIONS 2-PIECE BOOM SPECIFICATIONS RKA60810 Item Unit 2500 mm arm specification Overall length 8100 Overall height 3050 6-11 WENAM00111...
Page 412 2-PIECE BOOM ATTACHMENTS AND OPTIONS 6-12 WENAM00111...
Page 413: Explanation Of Lift Capacity Chart
ATTACHMENTS AND OPTIONS 2-PIECE BOOM Working ranges (mm) Unit 2500 mm arm specification Max. digging height 9130 Max. dumping height 6750 Max. digging dept 5680 Max. vertical wall digging depth 4440 Max. digging depth of cut for 2440 5570 mm level Max.
Page 414 2-PIECE BOOM ATTACHMENTS AND OPTIONS Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping). RKA60820 6-14 WENAM00111...
Page 415: Handle Bucket With Hook
HANDLE BUCKET WITH HOOK 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 416: Handle Machine Ready For Installation Of Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS RKA55380 (1) Stop valve (6) Accumulator (for low pressure) (2) Selector valve (7) 2nd attachment proportional switch (3) Attachment control pedal (8) 1st attachment proportional switch (4) Lock pin (9) Breaker switch...
Page 417 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT SELECTOR VALVE The selector valve switches the flow of the hydraulic oil. It is automatically switched according to the selected working mode. It is necessary to switch the working mode to match the attachment that is installed.
Page 418 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS • When using the crusher, use the working mode selector switch on the monitor switch portion to set the working mode to ATT mode, and set the lock pin to position (c) when using the pedal. NOTICE •...
Page 419: Method For Changing Over And Connecting Hydraulic Circuit Of Machines Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ACCUMULATOR (FOR LOW PRESSURE) The accumulator (for low pressure) is installed to protect the oil cooler when the breaker is used. For necessity of this accumulator, consult the attachment man- ufacturer.
Page 420: Method For Removing And Installing Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Connect the attachment piping provided by the attachment manufacturer. The dimensions on the machine body side are shown in the figure. As for the dimensions on the attachment side, consult the attachment manufacturer. (A): Plug After connecting the piping, bleed air from the circuit ac- cording to the following procedure.
Page 421 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 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 pedal fully in each direction within 15 seconds after the engine is stopped to release the internal...
Page 422 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Turn the starting switch to OFF position (A). Remove the bolts (1) (4 pieces), and open hydraulic tank top cover (2). Remove the cap of oil filler port (F) gradually to release the internal pressure.
Page 423 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 12. Remove the hoses on the attachment side. Install the plugs to outlets (2 places). The plugs are used to prevent the attachment from making incorrect operation caused by mixing in of foreign matter. After the plugs are correctly installed, store the attach- ment.
Page 424 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Set the lock lever to FREE position (F). Operate each control lever (work equipment, travel) and attachment control pedal fully in each direction within 15 seconds after the engine is stopped to release the internal pressure in the hydraulic circuit.
Page 425 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Remove the bolts (1) (4 pieces), and open the hydraulic tank top cover (2). 10. Remove the cap of oil filler port (F) gradually to release the internal pressure. 11. Remove the cap of oil filler port (F). 12.
Page 426: Method For Operating Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS METHOD FOR OPERATING ATTACHMENT WARNING • If the travel levers or travel pedals are operated when the engine speed is decreased by the auto- deceleration function, the engine speed will suddenly increase. Be careful. •...
Page 427 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Press working mode selector switch (1). The screen changes to Working Mode screen. Press working mode selector switch (1) or press switches F3 or F4 to select Breaker Mode B. With breaker mode B highlighted in yellow, do one of the following to enter the selection.
Page 428 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS When considering whether it is necessary to install an accumulator for the attachment circuit, contact the attachment manufacturer and then decide. When handling the breaker, follow the instruction manual from the breaker manufacturer and use the break- er correctly.
Page 429: Long-Term Storage
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT REMARK Even if P, E, or L mode is selected, the attachment is not operated. When using the Attachment Mode, check that the Attachment Mode is active before starting operations. On Attachment Setting of the user menu, it is possible to make the attachment mode inactive.
Page 430: 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 431: Track Shoes Selection
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS Opening Capacity Opening Standard width Tooth Long arm Short arm width Name mounting (Side cut- specifica- specifica- (Body) specifi- SAE/ ter) tion tion cation CECE Vertical 0.29 / Narrow dig- Narrow bucket ○ ○ ○...
Page 432 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS Classifi- Specification cation Standard 600 mm Triple Optional 500 mm Triple Optional 500 mm Flat Precaution for track shoe selection • Since working conditions “B” and “C” are for wide shoe, their use is limited. Check the precautions for use and the using condition, and then use a suitable shoe.
Page 433: 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 434 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 435 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 436 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 437 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 6-37 WENAM00111...
Page 438: Komvision
KomVision is the CCTV system for Komatsu machines. PRECAUTIONS WHEN USING KomVision • In these cases, it is necessary for a Komatsu distributor to adjust the monitor screen. • When you cannot confirm the normal range of the camera visibility •...
Page 439: Explanation Of Machine Monitor Equipment
ATTACHMENTS AND OPTIONS KomVision (7)Engine coolant temperature caution lamp (23)Work equipment lock pilot lamp (8)ECO gauge (24)Aftertreatment devices regeneration display (9)Fuel consumption gauge (25)Message display (26)Air conditioner pilot lamp (10)Service meter (11)Working mode display (27)Engine oil level caution lamp (12)Travel speed display (28)Air cleaner clogging caution lamp (13)Clock (29)Charge level caution lamp...
Page 440: Warning Display
KomVision ATTACHMENTS AND OPTIONS REMARK • The liquid crystal panel may show some black spots or bright spots. It is not defect unless there are 10 or more of them. • When the temperature in the cab is high, the brightness of monitor may reduce automatically to protect the LCD.
Page 441: Camera System Caution Lamp
The machine monitor will not show the image from the defec- tive camera. Physically make sure the adjacent safety around the machine. Consult your Komatsu distributor for inspection and mainte- nance. CAMERA CONTROLLER CAUTION LAMP The caution lamp comes on in yellow with action level "L01"...
Page 442 KomVision ATTACHMENTS AND OPTIONS (3) Camera image display (4) Camera switch display Komvision provides a Bird’s eye view display of the machine with composite images from three onboard cam- eras to create a 240° view of the machine. Since the image is a composite of three cameras, the shaded areas in the images to the right may be doubled, distorted, or misaligned.
Page 443 Swing radius of the right and Yellow left ends of the blade + 2.0 m If the blade type or the overall length of the track is changed, consult your Komatsu distributor for adjustment of the camera image display. 6-43...
Page 444: Monitor Display Selector Switch
KomVision ATTACHMENTS AND OPTIONS MONITOR DISPLAY SELECTOR SWITCH To switch the monitor display screen, perform these operations. AA: Start screen, BB: Enlarged screen from the top, CC: Camera image screen, DD: Guidance screen, EE: Me- ter display screen • On the start screen AA, the area around the machine appears on the left side of the monitor. The image of the selected camera appears on the right side of the monitor.
Page 445: Camera Image Selector Switch
ATTACHMENTS AND OPTIONS KomVision • Press the switch F3 while the start screen AA appears to show the enlarged image from the top. • Press the switch F3 on the enlarged screen BB from the top to show the screen CC of the camera image. •...
Page 446: Method For Checking Camera Visibility
If the traffic cone can be seen on the monitor screen, it is nor- mal. If the traffic cone cannot be seen on the monitor screen, ask your Komatsu distributor for adjustment of the cam- era image. TROUBLES AND ACTIONS When the monitor does not respond or displays no camera image, consult your Komatsu distributor.
Page 447: Replacement Parts
REPLACEMENT PARTS WENAM00111...
Page 448: 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. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 449: 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 450: 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 451 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication chart are explained as follows. Symbol Meaning of symbol Symbol Meaning of symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check engine oil level Change hydraulic oil Check hydraulic oil level Change power train oil...
Page 452: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient Temperature, degrees Celsius Recommended Komatsu Reservoir Fluid Type Fluids Engine oil for EOS5W30-LA KDPF used in -25 °C 35 °C (KES Diesel Engine Oil)
Page 453: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Note 6: DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after the engine is started. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. WENAM00111...
Page 454: Index
INDEX INDEX Symbols Antenna - Stow ............3-216 Appoint leader when working with others ....2-40 12H24H display mode - Switch ........3-78 Armrest angle - Adjust ..........3-144 2-piece - Preparation for storage and lifting machine.. Ashtray..............3-105 ............... 6-10 Attachment - Install........
Page 455 INDEX Bucket - Replace / Invert......... 3-189 Declaration of conformity .......... 1-15 Bucket clearance - Adjust ......... 4-29 DEF...............3-229,4-5 Bucket tooth (horizontal pin type) - Replace ..4-28 DEF - Check level / Add......... 3-139 Bucket tooth (vertical pin type) - Replace ....4-25 DEF - Store..............4-7 Burn prevention ............
Page 456 INDEX Engine - Start..........3-153,3-241 Fuel................4-4 Engine - Start in cold weather ........ 3-155 Fuel - Check level / Add......3-135,3-136 Engine - Start in normal weather ......3-153 Fuel and lubricants ........... 3-229 Engine - Start with jumper cables ......3-240 Fuel and lubricants to match ambient temperature.4-3 Fuel consumption gauge ..........
Page 457 Komatsu Closed Crankcase Ventilation (KCCV).3-112 Machine - Store long-term ........6-29 Komatsu genuine lubricants ........4-2 Machine - Swing ............3-174 Komatsu genuine replacement parts ......4-2 Machine - Travel forward ........3-170 KOMTRAX ..............3-128 Machine - Travel reverse ........3-170 KomVision.
Page 458 Precautions for towing and being towed ....2-36 Precautions for towing machine ......3-235 Precautions for transportation ........2-35 Perform KOWA (Komatsu Oil Wear Analysis)..4-6 Precautions for traveling ......... 3-182 Periodic replacement of defined life parts..2-48,7-2 Precautions for traveling on slopes ......2-32 Permissible depth of water, soil and dirt ....
Page 459 INDEX Precautions for working at high places ....2-42 Prohibition of operations when machine is not stable.. Precautions for working on slopes......3-185 ..............3-180 Precautions for working under machine or work Prohibition of sudden lever or pedal shift during high equipment ............

Komatsu PC138US-11 Operation & Maintenance Manual

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