O&m PC 200-8
O&m PC 200-8
O&m PC 200-8
HYDRAULIC EXCAVATOR
and up
WARNING
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. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it .
NOTICE
Komatsu has Operation & Maintenance Manuals written in some other languages. if a foreign language manual is necessary, contact your local distributor for availability.
1-1
. FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points. Read this manual thoroughly and understand its contents fully. Read the safety messages and safety labels given in this manual carefully so that they should be understood fully. Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically. In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine. In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual: magazine box on the left side of the operator's seat.
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FOREWORD
FOREWORD
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. FOREWORD
FOREWORD
1-4
FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations. Signal words The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, the following signal words are used to express the potential level of hazard. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This word is used also to alert against unsafe practices that may cause property damage. Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know. This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine. This word is used for information that is useful to know.
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. SAFETY INFORMATION
FOREWORD
Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. Example of safety label using words
Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual. The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time. 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 questions regarding information in this manual. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
1-6
FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "RECOMMENDED APPLICATIONS (PAGE 3-161)" for further details.
DIRECTIONS OF MACHINE
(E) (F)
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.
Make sure that you fully understand the content of this manual, and pay careful attention to the following points when breaking in the machine. Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel control dial. Idle the engine for 5 minutes after starting it up. Avoid operation with heavy loads or at high speeds. Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and sudden changes in direction.
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. PRODUCT INFORMATION
FOREWORD
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.
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FOREWORD
PRODUCT INFORMATION
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. CONTENTS
FOREWORD
CONTENTS
FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE BREAKING-IN THE NEW MACHINE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION SAFETY MACHINE OPERATION STARTING ENGINE OPERATION TRANSPORTATION BATTERY TOWING LIFTING OBJECTS WITH BUCKET SAFETY MAINTENANCE INFORMATION OPERATION MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES MONITORING SYSTEM SWITCHES CONTROL LEVERS AND PEDALS SUN ROOF WINDSHIELD EMERGENCY ESCAPE HAMMER DOOR LOCK CAP WITH LOCK DRINK BOX MAGAZINE BOX ASHTRAY AIR CONDITIONER CONTROLS RADIO AUXILIARY ELECTRIC POWER FUSE FUSIBLE LINK CONTROLLER TOOL BOX GREASE PUMP HOLDER 1- 1 1- 2 1- 5 1- 7 1- 7 1- 7 1- 8 1- 8 1- 8 1- 9 1- 9 2- 1 2- 2 2- 4 2- 5 2- 6 2- 12 2- 21 2- 21 2- 23 2- 29 2- 30 2- 32 2- 33 2- 34 3- 1 3- 2 3- 2 3- 3 3- 5 3- 5 3- 71 3- 76 3- 79 3- 79 3- 85 3- 85 3- 86 3- 88 3- 88 3- 88 3- 89 3-102 3-107 3-108 3-109 3-109 3-109 3-109
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FOREWORD
CONTENTS
FIRE EXTINGUISHER MACHINE OPERATIONS AND CONTROLS BEFORE STARTING ENGINE STARTING ENGINE AFTER STARTING ENGINE STOPPING THE ENGINE MACHINE OPERATION STEERING THE MACHINE SWINGING WORK EQUIPMENT CONTROLS AND OPERATIONS WORKING MODE PROHIBITED OPERATIONS GENERAL OPERATION INFORMATION TRAVELING ON SLOPES ESCAPE FROM MUD RECOMMENDED APPLICATIONS BUCKET REPLACEMENT AND INVERSION PARKING MACHINE MACHINE INSPECTION AFTER DAILY WORK LOCKING TRANSPORTATION TRANSPORTATION PROCEDURE LOADING AND UNLOADING WITH TRAILER LIFTING MACHINE COLD WEATHER OPERATION COLD WEATHER OPERATION INFORMATION AFTER DAILY WORK COMPLETION AFTER COLD WEATHER SEASON LONG TERM STORAGE BEFORE STORAGE DURING STORAGE AFTER STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE TROUBLES AND ACTIONS RUNNING OUT OF FUEL PHENOMENA THAT ARE NOT FAILURES TOWING THE MACHINE LIGHTWEIGHT TOWING HOLE SEVERE JOB CONDITION DISCHARGED BATTERY OTHER TROUBLE MAINTENANCE MAINTENANCE INFORMATION OUTLINE OF SERVICE HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ELECTRIC SYSTEM MAINTENANCE WEAR PARTS WEAR PARTS LIST
3-110 3-111 3-111 3-128 3-131 3-142 3-143 3-147 3-149 3-150 3-152 3-154 3-156 3-158 3-160 3-161 3-163 3-166 3-167 3-168 3-169 3-169 3-170 3-179 3-182 3-182 3-184 3-184 3-185 3-185 3-185 3-186 3-186 3-187 3-187 3-187 3-188 3-189 3-189 3-190 3-194 4- 1 4- 2 4- 4 4- 4 4- 7 4- 8 4- 8
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. CONTENTS
FOREWORD
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE LIST SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) WHEN REQUIRED CHECK BEFORE STARTING EVERY 100 HOURS MAINTENANCE EVERY 250 HOURS MAINTENANCE EVERY 500 HOURS MAINTENANCE EVERY 1000 HOURS MAINTENANCE EVERY 2000 HOURS MAINTENANCE EVERY 4000 HOURS MAINTENANCE EVERY 5000 HOURS MAINTENANCE EVERY 8000 HOURS MAINTENANCE SPECIFICATIONS SPECIFICATIONS ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY PRECAUTIONS WHEN SELECTING READ THE INSTRUCTION MANUAL THOROUGHLY PRECAUTIONS WHEN REMOVING OR INSTALLING PRECAUTIONS WHEN USING BUCKET WITH HOOK HOOK CONDITION PROHIBITED OPERATIONS MACHINE READY FOR ATTACHMENT LOCATIONS HYDRAULIC CIRCUIT ATTACHMENT REMOVAL AND INSTALLATION ATTACHMENT OPERATIONS LONG TERM STORAGE SPECIFICATIONS ATTACHMENT GUIDE ATTACHMENT COMBINATIONS TRACK SHOES SELECTION BUCKET TEETH SELECTION HANDLING OF RUBBER PAD SHOE AND ROAD LINER TRAPEZOIDAL BUCKET HANDLING EXTENSION ARM HANDLING CLAMSHELL BUCKET
444444444444444444444455666666666666666666666666-
9 11 12 12 13 14 15 15 17 18 18 18 19 46 47 48 51 65 71 78 82 83 1 2 1 2 2 2 2 2 3 3 3 4 4 8 15 19 22 22 23 23 26 27 28 30 32 33
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FOREWORD
CONTENTS
RECOMMENDED ATTACHMENT OPERATIONS HYDRAULIC BREAKER HANDLING MACHINES EQUIPPED WITH KOMTRAX BASIC PRECAUTIONS INDEX
66667-
34 34 38 38 1
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2-1
. SAFETY INFORMATION
SAFETY
SAFETY INFORMATION
SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION Safety rules If problems are found Working wear and personal protective items Fire extinguisher and first aid kit Safety equipment Keep machine clean Keep operator's compartment clean Leaving operator's seat with lock Handrails and steps Precautions when working in high place Mounting and dismounting No persons on attachments Do not get caught in articulated portion Burn prevention Fire prevention and explosion prevention Action if fire occurs Windshield washer fluid Falling objects, flying objects and intruding objects prevention Attachment installation Attachment combinations Cab window glasses Unauthorized modifications Safety at jobsite Working on loose ground Distance to high voltage cables Ensure good visibility Ventilation for enclosed area Signalman's signal and signs Emergency exit from operator's cab Asbestos dust hazard prevention 2224 5 6
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12 12 12 12 12 13 13 13 14 14 14 14 15 15 16 17 17 17 17 17 17 18 18 18 19 19 20 20 20 20
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SAFETY
SAFETY INFORMATION
SAFETY MACHINE OPERATION STARTING ENGINE Checks before starting engine Safety rules for starting engine Starting engine in cold weather OPERATION Checks before operation Safety rules for changing machine directions Safety rules for traveling Traveling on slopes Operations on slopes Prohibited operations Operations on snow Parking machine TRANSPORTATION Loading and unloading Shipping the machine BATTERY Battery hazard prevention Starting engine with booster cables TOWING Safety rules for towing LIFTING OBJECTS WITH BUCKET Safety rules for lifting objects SAFETY MAINTENANCE INFORMATION Warning Tag Keep Work Place Clean and Tidy Appoint Leader when Working with Others Stop Engine Before Carrying Out Maintenance Two Workers for Maintenance when Engine is Running Proper Tools Accumulator, Gas spring Personnel Attachments Work Under the Machine Noise When Using Hammer Welding Works Removing Battery Terminals Safety First when Using High-pressure Grease to Adjust Track Tension Do Not Disassemble Recoil Springs Safety Rules for High-pressure Oil Precaution for High Fuel Pressure Safety Handling High-pressure Hoses Precaution for High Voltage Waste Materials Air Conditioner Maintenance Compressed Air Periodic Replacement of Safety Critical Parts
2222222222222222222222222222222222222222222222222-
21 21 21 21 22 23 23 23 24 24 25 26 27 28 29 29 29 30 30 31 32 32 33 33 34 34 34 34 35 36 36 37 37 37 37 37 38 38 38 38 39 39 39 39 40 40 40 40 40
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. SAFETY LABELS
SAFETY
SAFETY LABELS
The following warning signs and safety labels are used on this machine. Be sure that you fully understand the correct position and content of labels. To ensure that the content of labels can be read properly, be sure that they are in the correct place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to peel off. There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way. If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY
SAFETY LABELS
: if equipped
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. SAFETY LABELS
SAFETY
SAFETY LABELS
(1) Caution before operating or maintaining machine (09651-03001)
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SAFETY
SAFETY LABELS
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. SAFETY LABELS
SAFETY
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SAFETY
SAFETY LABELS
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. SAFETY LABELS
SAFETY
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SAFETY
SAFETY LABELS
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. SAFETY INFORMATION
SAFETY
SAFETY INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger. When working with another operator or with a person on worksite traffic duty, be sure that all personnel understand all hand signals that are to be used.
SAFETY EQUIPMENT
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition.
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SAFETY
SAFETY INFORMATION
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. SAFETY INFORMATION
SAFETY
To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe) to ensure that you support yourself. Do not grip the control levers or lock lever when getting on or off the machine. Never climb on the engine hood or covers where there are no non-slip pads. Before getting on or off the machine, check the handrails and steps (including the track shoe). If there is any oil, grease, or mud on the handrails or steps (including the track shoe), wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Do not get on or off the machine while holding tools in your hand.
NO PERSONS ON ATTACHMENTS
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering serious injury.
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SAFETY
SAFETY INFORMATION
BURN PREVENTION
Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap. Hot oil To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation. Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.
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. SAFETY INFORMATION
SAFETY
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SAFETY
SAFETY INFORMATION
ATTACHMENT INSTALLATION
When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact your Komatsu distributor for advice. Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual.
ATTACHMENT COMBINATIONS
Depending on the type or combination of work equipment, there is a hazard that the work equipment may hit the cab or other parts of the machine. Before using unfamiliar work equipment, check if there is any hazard of interference, and operate with caution.
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. SAFETY INFORMATION
SAFETY
UNAUTHORIZED MODIFICATIONS
If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility. Before making any modifications, please consult your Komatsu distributor. Komatsu cannot take any responsibility for accidents, failures, or damage caused by modifications not authorized by Komatsu.
SAFETY AT JOBSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating. Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks. If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines. Take action to prevent unauthorized people from approaching the jobsite. When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians. When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.
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SAFETY
SAFETY INFORMATION
Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations. To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body. Use a signalman to give warning if the machine approaches too close to the electric cables. When carrying out operations near high voltage cables, do not let anyone near the machine. If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the machine.
Voltage of Cables
100 V - 200 V 6,600 V 22,000 V 66,000 V 154,000 V 187,000 V 275,000 V 500,000 V
Safety Distance
Over 2 m (7 ft) Over 2 m (7 ft) Over 3 m (10 ft) Over 4 m (14 ft) Over 5 m (17 ft) Over 6 m (20 ft) Over 7 m (23 ft) Over 11 m (36 ft)
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. SAFETY INFORMATION
SAFETY
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SAFETY
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SAFETY
Do not allow anyone apart from the operator to ride on the machine.
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SAFETY
OPERATION
CHECKS BEFORE OPERATION
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check that the movement of the machine matches the display on the control pattern card. If it does not match, replace it immediately with the correct control pattern card. Check the operation of the work equipment, traval system and swing system. Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel. If any problem is found, carry out repairs immediately.
Before traveling, set the machine so that sprocket (1) is behind the operator's seat. If sprocket (1) is in front of the operator's cab, the machine moves in the opposite direction from the operation of the lever (front and rear travel is reversed, left and right steering is reversed). Be extremely careful when operating the machine in this situation.
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SAFETY
TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine. When traveling uphill, set the machine with the operator's seat on the uphill side; when traveling downhill, set the operator's seat on the downhill side. Check that the ground under the machine is safe when traveling.
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SAFETY
When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed. When traveling downhill, lower the engine speed, keep the travel lever close to the neutral position, and travel at low speed.
Always travel straight up or down a slope. Traveling at an angle or across the slope is extremely dangerous. Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again. Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that the machine may slip.
OPERATIONS ON SLOPES
When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded. This operation is dangerous, and may cause the machine to tip over. If the machine has to be used on a slope, pile the soil to make a platform (A) that will keep the machine as horizontal as possible.
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SAFETY
PROHIBITED OPERATIONS
Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine.
Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations.
Do not carry out demolition work under the machine. There is a hazard that the machine may become unstable and tip over. When working on or from the top of buildings or other structures, check the strength and the structure before starting operations. There is a hazard of the building collapsing and causing serious injury or damage.
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SAFETY
When carrying out demolition work, do not carry out demolition above your head. There is a hazard of broken parts falling or of the building collapsing and causing serious injury or property damage.
Do not use the impact force of the work equipment for breaking work. There is a hazard of damage to the work equipment, or a hazard of serious personal injury being caused by flying pieces of broken materials, or of the machine tipping over due to reaction from the impact. Generally speaking, the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear.
When using a breaker or other heavy work equipment, there is a hazard of the machine losing its balance and tipping over. When operating on flat ground as well as on slopes. Do not suddenly lower, swing, or stop the work equipment. Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the machine to tip over. Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment. The load may spill or the bucket may hit the dump truck and cause serious injury or property damage.
OPERATIONS ON SNOW
Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes. With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the machine to tip over. If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift. When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.
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SAFETY
PARKING MACHINE
Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground.
When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine. Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place. If it is necessary to park the machine on a slope, always do as follows. Set the bucket on the downhill side, then dig it into the ground. Put blocks under the tracks to prevent the machine from moving.
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SAFETY
TRANSPORTATION
The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out.
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SAFETY
BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line. When working with batteries, always wear safety glasses and rubber gloves. Never smoke or use any flame near the battery.
If you spill acid on your clothes or skin, immediately flush the area with large amount of water. If acid gets into your eyes, flush them immediately with large amount of water and seek medical attention.
Before working with batteries, turn the starting switch to the OFF position. As there is a hazard that sparks will be generated, always do as follows. Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other metal objects lying around near the battery. When disconnecting the battery terminals, wait for approx. one minute after turning off the engine starting switch key, and be sure to disconnect the grounding terminal (negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then the grounding (-) terminal. Make sure that all the terminals are connected securely. Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it. Tighten the battery caps securely. Install the battery securely to the determined place.
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SAFETY
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SAFETY
TOWING
SAFETY RULES FOR TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-188)". Always check that the wire rope used for towing has ample strength for the weight of the machine being towed. Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing operation.
Always wear leather gloves when handling wire rope. Never tow a machine on a slope. During the towing operation, never stand between the towing machine and the machine being towed. Operate the machine slowly and be careful not to apply any sudden load to the wire rope.
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SAFETY
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SAFETY
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SAFETY
Put blocks under the track to prevent the machine from moving.
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SAFETY
Set lock lever (1) to the LOCK position (L) to prevent the work equipment from moving. Do not touch any control levers or control pedals. If any control levers or control pedals must be operated, always give a signal to the other workers to warn them to move to a safe place.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury.
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SAFETY
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer.
ATTACHMENTS
Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.
NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
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SAFETY
WELDING WORKS
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
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SAFETY
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SAFETY
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials. Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.
COMPRESSED AIR
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.
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3-1
OPERATION
3-2
OPERATION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Radio Lock lever Left work equipment control lever One-touch power max. switch Travel pedals Travel levers Horn switch Machine monitor Cigarette Lighter Right work equipment control lever Blade control lever (if equipped) Starting switch
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Fuel control dial Lamp switch Swing lock switch Revolving warning lamp switch (if equipped) Large Capacity Airflow Air Conditioner Blower Switch (if equipped) Attachment control pedal (if equipped) Attachment control pedal (if equipped) Room Lamp Switch Swing parking brake releasel switch Emergency pump drive switch
3-3
OPERATION
Machine monitors
AA: Screen for standard BB: Screen with all lamps lighted up CC: Maintenance time warning screen
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) Wiper switch Buzzer cancel switch Auto-deceleration switch Engine coolant temperature monitor Engine coolant temperature gauge Hydraulic oil temperature gauge Service meter, Clock Hydraulic oil temperature monitor Working mode monitor Travel speed monitor Fuel gauge ECO gauge Fuel level monitor Working mode selector switch Travel speed selector switch (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) Window washer switch Air conditioner control switches Engine oil pressure monitor Charge level monitor Radiator coolant level monitor Air conditioner monitor Wiper monitor Swing lock monitor Engine pre-heating monitor or One-touch power max. monitor Auto-deceleration monitor Engine oil level monitor Air cleaner clogging monitor Water separator monitor Function switches (F1 to F6) Maintenance interval monitor
3-4
OPERATION
MONITORING SYSTEM
AA: Screen for standard BB: Screen with all lamps lighted up CC: Maintenance time warning screen
(A) (B) (C) Emergency monitors Caution monitors Basic check monitors (D) (E) Meter display portion,pilot display Monitor switches portion
REMARK One of the features of liquid crystal display panels is that there may be black spots (spots that do not light up) or white spots (spots that stay lighted up) on the screen. If there are fewer than 10 black or white spots, this is not a failure or a defect.
3-5
OPERATION
When the starting switch is turned to the ON position, the opening screen GG is displayed. After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen DD. After the check before starting screen DD is displayed for 2 seconds, the screen switches to the working mode/travel mode display screen HH. After the working mode/travel mode display screen HH is displayed for 2 seconds, the screen switches to standard screen BB. If the working mode when the engine is started is B mode, the opening screen GG is displayed for 2 seconds, and the screen then switches to the breaker mode confirmation screen II. When starting in B mode, press switch F6. If you do not want to start B mode, press switch F5. In this case, the system starts with E mode.
3-6
OPERATION
REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery condition. If this happens, the display on the machine monitor may momentarily go out, but this does not indicate any abnormality.
When the starting switch is turned to the ON position, ending screen JJ is displayed for 5 seconds, then on the display goes out.
3-7
OPERATION
If there is any abnormality when starting the engine, the check before starting screen DD changes to the maintenance interval warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance interval warning screen CC. After displaying the maintenance interval warning screen CC for 30 seconds, the screen returns to the standard screen BB. After displaying the check before starting screen DD for 2 seconds, the screen changes to the warning screen FF or error screen EE.
3-8
OPERATION
If any abnormality occurs during operation, the standard screen BB changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen
3-9
OPERATION
REMARK The colors lighting up the monitors related to the emergency stop items, caution items, and basic check items are as follows.
AA: Screen for standard BB: Screen with all lamps lighted up CC: Maintenance time warning screen
Color when monitor lights up Type of monitor (1) (2) (3) (4) (5) (6) (7) (8) (9) Engine coolant temperature monitor Hydraulic oil temperature monitor Fuel level monitor Radiator coolant level monitor Charge level monitor Engine oil pressure monitor Engine oil level monitor Air cleaner clogging monitor Water separator monitor When normal Blue Blue Blue OFF OFF OFF OFF OFF OFF OFF When abnormal Red Red Red Red Red Red Red Red Red Red At low temperature White White -
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OPERATION
Emergency Monitors
CAUTION
If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions.
These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
(1) (2)
(3)
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OPERATION
3 - 12
OPERATION
Caution Monitors
CAUTION
If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure.
These are items that should be observed while the engine is running. If any abnormality occurs, the screen displays the item that needs immediate action. If there is an abnormality, the monitor for the abnormal location lights up red.
Engine coolant temperature monitor Hydraulic oil temperature monitor Fuel level monitor
Charge level monitor Air cleaner clogging monitor Water separator monitor
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OPERATION
3 - 14
OPERATION
3 - 15
OPERATION
CAUTION
These monitors DO NOT ensure that the machine is in good condition. When performing checks before starting (daily checks), do not simply rely on the monitors. Always dismount the machine and check each item directly.
Displays basic items among the check before starting items that must be checked before starting the engine. If there is any abnormality, monitor for the location of abnormality will light up.
(1) (2)
(3)
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OPERATION
3 - 17
OPERATION
Pilot display (1) Engine pre-heating monitor (2) Swing lock monitor (3) Wiper monitor (4) Auto-deceleration monitor (5) Working mode monitor (6) Travel speed monitor (7) One-touch power max. monitor (8) Air conditioner monitor (9) Idle stop guidance
Gauge and Meter (10) Engine coolant temperature gauge (11) Hydraulic oil temperature gauge (12) Fuel gauge (13) Service meter, clock (14) ECO gauge
Pilot Display
The pilot display at the top of the screen consists of the pilot lamps to confirm the actuation of each function. When the starting switch is turned ON, the pilot lamp lights up when the display items are functioning.
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OPERATION
Wiper Monitor
Monitor (3) indicates operating ststus of the wiper. The monitor display when wiper switch is operated, as follows. When ON lights up: Wiper moves continuously When INT lights up: Wiper moves intermittently OFF: Wiper stops For details of the positions of the wiper switch, see "CONTROLS AND GAUGES (PAGE 3-3)".
Auto-deceleration Monitor
Monitor (4) shows if the auto-deceleration is being actuated. The monitor display when auto-deceleration switch is operated, as follows. Auto-deceleration monitor ON: Auto-deceleration actuated Auto-deceleration monitor OFF: Auto-deceleration canceled For details of the positions of the auto-deceleration switch, see "CONTROLS AND GAUGES (PAGE 3-3)".
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OPERATION
3 - 20
OPERATION
3 - 21
OPERATION
The overheat prevention system is actuated as follows. Red range (A) position: Engine coolant temperature monitor (E) shows abnormality display Red range (B) position: Engine speed changes to low idling, engine coolant temperature monitor (E) shows abnormality display, alarm buzzer sounds at same time The overheat prevention system continues to work until the indicator enters the green range. When the engine is started, if the indicator is at position (C), engine coolant temperature monitor (E) shows the low-temperature display. If this happens, carry out the warm-up operation. For details, see "Engine Warm Up (PAGE 3-132)". Display (G) at low temperatures: Monitor background (K) is white Display (H) at correct temperatures: Monitor background (K) is blue Display (J) when condition is abnormal: Monitor background (K) is red
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OPERATION
Display (G) at low temperatures: Monitor background (K) is white Display (H) at correct temperatures: Monitor background (K) is blue Display (J) when condition is abnormal: Monitor background (K) is red
Fuel Gauge
This meter (12) shows the amount of fuel remaining in the fuel tank. During normal operations, the indicator should be in the green range. If the indicator starts to enter red range (A) during operation, there is less than 60 liters (15.85 US gal) of fuel remaining, so carry out (A) - (B): Indicates red range (A) - (C): Indicates green range
REMARK When the indicator reaches red range (B), there is less than 41 liters (10.83 US gal) of fuel remaining. When the indicator is in red range (B), fuel level monitor (D) lights up red.
The correct fuel level may not be displayed for a short time when the starting switch is turned ON, but this is not an abnormality.
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OPERATION
When the standard screen is being displayed, if function switch F4 is pressed, it is possible to switch between the clock display and the service meter display. Clock display (12-hour or 24-hour displays are available) To set or correct the time, press function switch F6 (user mode switch).
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OPERATION
ECO Gauge
This gauge (14) shows the working load status. When the gauge is in green range A, the work load is light to medium. When the gauge is in orange range B), the load is heavy. When the gauge enters the orange range, there is no abnormality on the machine, but to protect the environment, reduce the engine output to a point where there is no adverse effect on the operation. Generally, carry out energy-saving operations in the green range. Reducing the frequency of travel also helps to save energy. Consider the best way of saving energy.
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OPERATION
Working mode selector switch Auto-deceleration switch Travel speed selector switch Wiper switch
Window washer switch Buzzer cancel switch Function switches Air conditioner switch
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OPERATION
For machines ready for attachment, the attachment mode is added to the display. For details of the method for handling machines ready for attachment, see the ATTACHMENTS AND OPTIONS Section. When the monitor starts up, if the working mode setting is B mode, the confirmation message on the right is displayed and the buzzer sounds. When starting up and staying in B mode, always press function switch F6 (Yes). If you press F5 (No), the system starts up in E mode.
If you want to have automatic setting of the P, E, L, B or ATT mode when starting (optional default setting), please ask your Komatsu distributor to change the setting.
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OPERATION
If no switch is touched for more than five seconds, the selected working mode is automatically set as the working mode and the screen changes to Steps 3 and Steps 4.
REMARK To return to the standard screen without changing the working mode, press function switch F5.
3. After selecting the desired mode, press function switch F6 and the mode is displayed in the center of the monitor display. (Example: If power mode is selected: P) 4. After two seconds, the pilot monitor display at the top right of the screen is highlighted in orange.
After two seconds, the screen returns to the standard screen. The monitor display highlighted in orange in Steps 4 returns to blue.
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OPERATION
REMARK When setting the working mode to B mode, to ensure safety, the buzzer sounds and at the same time, the message in the illustration on the right is displayed. When setting to the breaker mode, always press function switch F6.
If function switch F5 is pressed, the breaker mode is not set, and the screen returns to working mode selection screen.
NOTICE When using the breaker, set to B mode. If B mode is not used, there is danger that the breaker may break.
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OPERATION
Auto-deceleration Switch
If the control levers are at neutral, this switch (2) automatically lowers the engine speed and turns on the function to reduce fuel consumption. Auto-deceleration monitor ON: Auto-acceleration ON Auto-deceleration monitor OFF: Auto-acceleration OFF Each time the switch is pressed, the auto-deceleration is switched between actuated and canceled. Auto-deceleration function When the auto-deceleration function is ON, if the work equipment and travel levers are returned to the N position, the engine speed will drop after 4 seconds from the operating speed to idling speed. This makes it possible to reduce fuel consumption. If any lever is operated when the machine is in this condition, engine speed will return to the previous operating speed to make it possible to perform operations.
1. When auto-deceleration switch (2) is pressed and the auto-deceleration function is turned ON, the mode is displayed in the center of the monitor display, and after two seconds, the screen returns to the standard screen.
2. On the standard screen, the Auto-deceleration monitor lights up. (When the auto-deceleration is OFF, it does not light up.)
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OPERATION
WARNING
When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (3) at the Lo position). Never operate travel speed selector switch (3) while loading or unloading. 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. Stop the machine before switching the travel speed.
Switch (3) is used to set the travel speed to 3 stages. Lo lights up : Low-speed travel Mi lights up : Medium-speed travel Hi lights up : Hi-speed travel When the engine is started, the speed is automatically set to Lo. Each time that the switch is pressed, the display changes Lo J Mi J Hi J Lo in turn. Even if the travel speed is set to high-speed (Hi) or a mid-range speed (Mi), when traveling on soft ground or uphill, and travel power is needed, the system automatically shifts down to low speed travel (Lo). There is no need to operate the switch. In this case, the pilot monitor on the monitor display stays lighted up at Hi (high-speed) or Mi (mid-range speed).
REMARK Each time travel speed selector switch (3) is switched, the mode is displayed on the monitor display, and after two seconds, the screen returns to the standard screen.
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OPERATION
Wiper Switch
Switch (4) operates the wiper for the front glass. Each time the switch is pressed, it changes ON INT stop (OFF). Wiper monitor INT lighted up: Wiper operates intermittently Wiper monitor ON lighted up: Wiper operates continuously Wiper monitor OFF: Wiper stops
REMARK Each time wiper switch (4) is pressed, the mode is displayed in the center of the monitor display, and after two seconds, the screen returns to the standard screen.
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OPERATION
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OPERATION
Function Switches
Function switches (7) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen. When the monitor display shows the standard screen, the functions are displayed as follows. F3: Camera screen selector switch (if equipped) F4: Service meter/time display selector switch F5: Maintenance mode switch F6: User mode switch F1 and F2 are auxiliary switches for expanded functions. For explanation of each switch, see "Handling Function Switches (PAGE 3-35)".
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OPERATION
The operation of the function switches if the initial screen is the standard screen is as follows.
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OPERATION
Press switch F1 to display all the screens for images from the No. 1 camera. Press switch F2 to display all the screens for images from the No. 2 camera.
Press switch F3 to display all the screens for images from the No. 3 camera.
REMARK If the machine is not equipped with a No. 2 camera or No. 3 camera, guidance icons (a), (b) and (c) are not displayed.
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OPERATION
Operation of Image Display Screen When Two Camera Screens are Shown Simultaneously.
The following explanation describes the method of operation when it is desired to display two camera screens at the same time on the monitor. On the No. 1 camera image display screen, if switch F4 is pressed, No. 1 camera image (d) and No. 2 camera image (e) are displayed. Even if three cameras are installed, only the images from the No. 1 camera and No. 2 camera can be displayed at the same time. When two screens are displayed at the same time, the display changes more slowly than when only one screen is displayed.
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OPERATION
It is possible to change the working mode by pressing the working mode selector switch. For details of the working mode selector switch, see "Working Mode Selector Switch (PAGE 3-26)".
If the working mode is changed, the screen returns to the standard screen. Press switch F3 again to return to the camera image display.
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OPERATION
Press the travel speed selector switch to change the travel speed mode. For details of the travel speed selector switch, see "Travel Speed Selector Switch (PAGE 3-31)".
When the travel speed mode is changed, the screen returns to the standard screen. To display the camera image, press switch F3 again.
Press the auto-deceleration switch to turn the auto-deceleration function ON/OFF. Even if the auto-deceleration switch is pressed, the camera image display screen does not switch to another screen or return to the standard screen display.
It is possible to press the buzzer cancel switch to stop the alarm buzzer for the warning item where there is an abnormality. Even if the buzzer cancel switch is pressed, the camera image display screen does not switch to another screen or return to the standard screen display.
Press the wiper switch and washer switch to operate the wipers and washer. Even if the wiper switch or washer switch is pressed, the camera image display screen does not switch to another screen or return to the standard screen display.
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OPERATION
If the error monitor or alarm monitor is displayed, press switch F6, return to the standard screen, and check the content of the error or alarm display. When the error monitor is flashing, if no lever is operated for more than 10 seconds, the screen automatically returns to the standard screen. When the screen returns to the standard screen, the error monitor at the top left of the screen goes out and the error or alarm is displayed in the center of the screen. If an error monitor is displayed, move the machine, set it in a safe posture, then have inspection carried out immediately. For details of the content of the warning displays, see "Basic Check Monitors (PAGE 3-16)", "Caution Monitors (PAGE 3-13)", "Emergency Monitors (PAGE 3-11)" and "TROUBLES AND ACTIONS (PAGE 3-187)".
3 - 40
OPERATION
When the time is being displayed, press switch F4 to switch to the service meter display. When the service meter is being displayed, press switch F4 to switch to the time display.
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OPERATION
a: Maintenance items b: Default maintenance interval settings (h) c: Time remaining until maintenance (h)
3 - 42
OPERATION
If no switch is operated for 30 seconds on the maintenance list screen, the screen automatically returns to the standard On the maintenance list screen, if the time remaining until maintenance for any item is less than 30 hours, the remaining time display is highlighted in yellow. If the time remaining until maintenance becomes 0 hours, the remaining time display is highlighted in red. If you want to change the setting for the maintenance interval, please consult your Komatsu distributor.
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OPERATION
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OPERATION
F3: Moves to next item (1 line down). When on the last line, it moves to the first line on the next page. F4: Moves to previous item (1 line up). When on the first line, it moves to the last line on the previous page.
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OPERATION
F5: Returns to standard screen. F6: Switches to 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.
The following items can be set. a: Breaker/attachment setting (machines ready for installation of attachment) b: Message display (machines equipped with KOMTRAX) c: Screen adjustment d: Clock adjustment e: Language selection f: Economy mode adjustment
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OPERATION
Breaker/Attachment Setting
On machines ready for attachment, it is possible on the breaker/attachment setting menu to adjust the oil flow in B mode and ATT mode to match the attachment. For machines that have no attachment, the breaker/attachment setting mode is not displayed.
Changing Breaker Mode Setting 1. On the standard screen, press switch F6.
2. Select Breaker/Attachment Settings on the user menu, then press switch F6.
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OPERATION
3. On the working mode selection screen shown on the right, select B Breaker and press switch F6.
On the working mode selection screen shown on the right, it is possible to carry out the following operations with switches F3 to F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to user menu screen. F6: Switches to setting screen for selected item.
4. The screen switches to the Breaker Select Menu. Breaker setting selection menu In Breaker Select (a), the oil flow to be set in B mode can be set to one of two set values. Breaker flow setting menu In the breaker flow setting menu (b), the oil flow to be set in B mode can be changed.
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OPERATION
On the Breaker Select Menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen. F6: Switches to setting screen for selected item.
Changing breaker setting selection 1. Select breaker setting selection (a) on the breaker setting menu screen, then press switch F6.
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OPERATION
2. On the Breaker Select screen, select one of the two set values for the oil flow, then press switch F6. The default values for the flow setting are both set to 180 liter/min, as shown in the illustration on the right. To select the oil flow setting, follow the procedure given in "Clock Adjustment (PAGE 3-63)". The present oil flow set for B mode is marked with a B in front of the item name as shown in the illustration on the
On the Breaker Select Menu and breaker setting selection menu, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen. F6: Switches to setting screen for selected item.
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OPERATION
Changing breaker flow setting 1. Select breaker flow setting (b) on the Breaker Select Menu screen, then press switch F6.
2. On the Breaker Oil Flow Setting screen, select one of the two set values for the oil flow, then press switch F6. The default values for the oil flow setting are both set to 180 liter/min, as shown in the illustration on the right. The present oil flow set for B mode is marked with B in front of the item name as shown in the illustration on the right.
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OPERATION
On the Breaker Select Menu and Breaker Oil Flow Setting screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen. F6: Switches to setting screen for selected item.
3. On the Breaker Oil Flow Setting screen, change the set oil After using switches F3 or F4 to change to a suitable oil flow, press switch F6 to accept the change in the oil flow and return to the previous screen. When switch F5 is pressed, no change is made in the oil flow and the screen returns to the previous screen.
(X): Present oil flow setting (Y): Min. adjusted oil flow (Z): Max. adjusted oil flow
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OPERATION
Changing Attachment Mode Setting 1. On the standard screen, press switch F6.
2. Select Breaker/Attachment Settings on the user menu, then press switch F6.
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OPERATION
3. On the working mode selection screen shown on the right, select ATT 2-Way Attachment, then press switch F6.
On the working mode selection screen shown on the right, it is possible to carry out the following operations with switches F3 to F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to user menu screen. F6: Switches to setting screen for selected item.
4. The screen switches to the 2-Way Attachment Select menu. 2-Way Attachment Select In 2-Way Attachment Select (a), the oil flow to be set in ATT mode can be set to one of two set values. 2-Way Attachment Oil Flow Setting menu In 2-Way Attachment Oil Flow Setting (b), it is possible to change the oil flow set for the ATT mode.
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OPERATION
On the 2-Way Attachment Select Menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen. F6: Switches to setting screen for selected item.
Changing attachment setting selection 1. Select attachment setting selection (a) on the attachment setting menu screen, then press switch F6.
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OPERATION
2. On the 2-Way Attachment Select Menu, select one of the two set values for the oil flow, then press switch F6. The default values for the oil flow setting are both set to 430 liters/min, as shown in the illustration on the right. To change the oil flow setting, follow the procedure given in "Adjusting Economy Mode (PAGE 3-69)". The present oil flow set for ATT mode is marked with ATT in front of the item name as shown in the illustration on the right.
If No 2-Way Attachment is selected, it becomes impossible to select the attachment mode on the working mode selection screen.
On the working mode selection screen, it is not possible to select No 2-Way Attachment.
On the 2-Way Attachment Select Menu screen and 2-way attachment select menu, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen. F6: Switches to setting screen for selected item.
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OPERATION
Changing attachment flow setting 1. Select 2-Way Attachment Oil Flow Setting (b) on the 2-Way Attachment Select menu screen, then press switch F6.
2. On the 2-Way Attachment Select Oil Flow Setting screen, select one of the two set values for the oil flow, then press switch F6.
The default values for the oil flow setting are both set to 430 liters/min, as shown in the illustration on the right. The present oil flow set for ATT mode is marked with ATT in front of the item. "No 2-Way Attachment" cannot be selected
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OPERATION
On the 2-Way Attachment Select Menu screen and 2-Way Attachment Select Menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen. F6: Switches to setting screen for selected item.
3. On the 2-Way Attachment Oil Flow Setting menu, it is possible to change the oil flow setting. After using switches F3 or F4 to change to a suitable oil flow, press switch F6 to accept the change in the oil flow and return to the previous screen. When switch F5 is pressed, no change is made in the oil flow and the screen returns to the previous screen.
(X): Present oil flow setting (Y): Min. adjusted oil flow (Z): Max. adjusted oil flow
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OPERATION
Message Display
(machines equipped with KOMTRAX) On machines equipped with KOMTRAX, it is possible to see the messages from your Komatsu distributor on this message display menu.
REMARK At present, there is no territory where it is possible to the use the message service.
In territories where it is not possible to use the message service, the message display menu functions as follows. 1. On the standard screen, press switch F6.
2. Select "User Message" on the User Menu, then press switch F6.
If you press switch F5, the screen returns to the user menu screen.
3. "No message" is displayed on the screen. Press switch F5 to return to the standard screen.
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OPERATION
Adjusting Screen
Use this screen adjustment menu to adjust the brightness, contrast, and back light of the screen.
2. Select screen adjustment on the user menu, then press switch F6. The screen switches to the selection menu screen for screen adjustment.
On machines equipped with cameras, it is possible to adjust the brightness, contrast, and back light of the cameras screen on this menu.
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OPERATION
3. Select item to be adjusted (a) or (b) from the selection menu screen for screen adjustment, then press switch F6. The screen switches to the setting screen for the selected item.
(a): Standard screen adjustment (b): Camera screen adjustment (only machines equipped with camera) On the mode selection screen shown on the right, it is possible to carry out the following operations with switches F3 to F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to user menu screen. F6: Switches to setting screen for selected item.
REMARK If the machine is not equipped with a camera, the selection menu for screen adjustment is not displayed. If screen adjustment is selected from the user menu, the adjustment screen in Step 4 is displayed.
4. Use switches F2 to F6 to adjust the brightness, contrast, and back light of the selected screen. 1) Adjustment screen for standard screen If the light switch is at night mode ON, and the standard screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode). If the light switch is at day mode ON or OFF, and the standard screen is adjusted, it is possible to adjust the brightness of the monitor screen (day mode). Adjusting camera screen 2) The background when adjusting the camera image is the image for the No. 1 camera. When displaying the camera screen, the screen may become dark if the image is on snow. In such cases, we recommend adjustment of the screen.
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OPERATION
On the screen for Items 1) and 2), it is possible to carry out the following operations with switches F2 to F6. F2: Resets all adjusted values to default value F3: Indicator of selected item moves 1 segment to left. F4: Indicator of selected item moves 1 segment to right. F5: Returns to user menu. F6: Accepts change and switches to next item setting.
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OPERATION
Clock Adjustment
On this clock adjustment menu, it is possible to change the setting of the clock displayed on the pilot monitor of the standard display.
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OPERATION
2. Select "Clock Adjustment" on the user menu, then press switch F6. The screen switches to the time adjustment selection menu screen.
The following three items can be changed. (a) Clock setting (b) 12/24 hour display mode (c) Daylight saving time
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OPERATION
3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches F3 to F6. Time Adjust the hour setting. 1) If "Time" (a) is not highlighted in yellow, press switch F6 to highlight "Time" (a) in yellow. When this is done, hour display (b) changes to orange. Adjust hour display (b) with the switches as follows. If it is not necessary to change the hour setting, press switch F6.
F3: Time advances 1 hour. F4: Time goes back 1 hour. F5: Cancels change and returns to user menu. F6: Accepts change and goes to setting for minutes.
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OPERATION
2) When minute display (c) is highlighted in orange, operate the switches as follows to adjust minute display (c). If it is not necessary to change the minute setting, press switch F6. If the time has been changed, always press switch F6.
F3: Time advances 1 minute. F4: Time goes back 1 minute. F5: Cancels change and returns to user menu. F6: Accepts change and goes to setting for 12/24 hour display mode.
12h/24h Mode Choose either a 12-hour display (am/pm) or a 24-hour display. (b): 24-hour display (c): 12-hour display (am/pm) 1) If "12h/24h Mode" (a) is not highlighted in yellow, press switch F6 to highlight "12h/24h Mode" (a) in yellow. 2) Change the "12h/24h mode" with the switches as follows. The selected display mode (b) or (c) is highlighted in green. F3: Moves 1 item to left. F4: Moves 1 item to right. F5: Cancels change and returns to user menu. F6: Accepts change and goes to setting for "Daylight Saving Time". If the setting has been changed, always press switch F6.
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OPERATION
Daylight Saving Time (Summer time) 1) If daylight saving time is turned ON (a), the clock display becomes 1 hour earlier. If daylight saving time is turned OFF (b), the clock display returns to the set time. The selected display mode is highlighted in green. 2) Change the daylight saving time with the switches as follows. F3: Moves 1 item to left. F4: Moves 1 item to right. F5: Cancels change and returns to user menu. F6: Accepts change and goes to setting for "Time". If the setting has been changed, always press switch F6.
REMARK Daylight saving time or summer time means moving the clock forward 1 hour to take advantage of the fact that the sun rises early in summer. This system is used in many countries during the summer.
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OPERATION
Language Selection
On this language selection menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. Japanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish
1. On the standard screen, press switch F6.
2. Select "Language" on the user menu, then press switch F6. The screen switches to the language selection menu screen.
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OPERATION
3. Select the language to use for the display, then press switch F6. The screen display changes to the selected language.
On the language selection screen, it is possible to carry out the following operations with switches F3 to F6. F3: Moves to item below. F4: Moves to item above. F5: Cancels change and returns to user menu screen. F6: Accepts change and returns to user menu screen.
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OPERATION
2. Select "Economy Mode Adjustment" on the user menu, then press switch F6. The screen switches to the economy mode adjustment selection menu screen.
3. Select the desired E mode from the economy mode adjustment selection menu. The levels that can be set are as follows. E0: Default E1: Economy Adjustment 1 E2: Economy Adjustment 2 E3: Economy Adjustment 3
The higher the selection is made from E0 to E3, the better the fuel consumption becomes, but the production is reduced accordingly. When the machine is shipped, it is set to E0. On the Economy Mode Adjustment menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to item below. F4: Moves to item above. F5: Cancels change and returns to user menu screen. F6: Accepts change and returns to user menu screen.
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OPERATION
SWITCHES
Starting switch Fuel control dial Cigarette lighter Swing lock switch Lamp switch Horn switch
One-touch power max. switch Room lamp switch Emergency pump drive switch Swing parking brake releasel switch Revolving warning lamp switch (if equipped) Large capacity airflow air conditioner blower switch (if equipped)
Starting Switch
Starting switch (1) is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electrical system (except room lamp), are all turned off and the engine is stopped. (B): ON position Electric current flows through the charging and lamp circuits. Keep starting switch key in the ON position while the engine is running. (C): START position This is the engine-start position. Keep the key at this position during cranking. Immediately after starting the engine, release the key. It will automatically return to the ON position (B).
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OPERATION
Cigarette Lighter
This switch (3) is used when lighting cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, so pull it out to use it. If the cigarette lighter is removed, the socket can be used as an 85W (24V x 3.5A) power source.
NOTICE This cigarette lighter is for 24V. Do not use it as the power source for 12V equipment.
WARNING
When not using the swing operation, e.g. when traveling, put the swing lock switch to the OFF position. On slopes, even when the swing lock switch is at the ON position, the weight of the work equipment may cause the upper structure to swing if the swing control lever is operated in the downhill direction.
This switch (4) is used to lock the upper structure so that it cannot swing. (a) ON position (actuated): The swing lock is always applied, and the upper structure will not swing even if the swing is operated. In this condition, the swing lock lamp lights up. (b) OFF position (canceled): The swing lock is released, when operating the swing control lever, allowing the upper structure to
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OPERATION
Lamp Switch
This switch (5) is used to light up the working lamp and monitor lighting. (a) Night position: Lamps light up and monitor illumination is set to night mode (b) Day position: Lamps light up and monitor illumination is set to day mode (c) OFF position: Lamps go out. (The monitor illumination is set to day mode.)
Horn Switch
Use this switch (6) to sound the horn. Press the switch on the right work control lever to sound the horn.
Use this switch (8) to light up the room lamp. (a) ON position: Lamp lights up (b) OFF position: Lamp goes out The room lamp lights up even when the starting switch is at the OFF position
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OPERATION
This switch (9) is used to make it possible to carry out operations temporarily if any problem should occur in the pump control system (when the display shows "E02"). (a) EMERGENCY: When abnormal (move switch up) (b) NORMAL: When normal (move switch down) If the display shows "E02", move the switch up to make it possible to carry out work.
This switch (10) is used to make it possible to carry out operations temporarily if any problem should occur in the swing parking brake system (when the display shows "E03"). (a) FREE: When abnormal (move switch up) (b) NORMAL: When normal (move switch down) If the display shows "E03", move the switch up to the FREE position, to make it possible to carry out work. When pushing this switch up to the FREE position, the swing lock monitor lamp begins to flash.
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OPERATION
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OPERATION
(1) (2)
(3) (4)
Left work equipment control lever (with auto-deceleration system) Right work equipment control lever (with auto-deceleration system)
Lock Lever
WARNING
When leaving the operator's compartment, set the lock lever securely to the LOCK position. If the lock lever is not at the LOCK position and the control levers or control pedals are touched by mistake, it may lead to serious personal injury. Check that the condition of the lever is as shown in the diagram. When pulling the lock lever up, be careful not to touch the work equipment control lever. When pushing the lock lever down, be careful not to touch the work equipment control lever.
This lever (1) is a device to lock the work equipment, swing, travel, and attachment (if equipped) control levers. (L) LOCK position: Even when levers or attachment control pedal (if equipped) are operated, machine does not move (F) FREE position: Machine moves according to operation of levers or attachment control panel (if equipped)
REMARK This lock lever is of hydraulic lock type. Accordingly, when it is in the lock position (L), the control levers or control pedals move but the machine does not move.
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OPERATION
Travel Levers
WARNING
Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may suddenly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations. When you are not using the pedal, do not rest your foot on it. If the track frame is facing the rear, the direction of travel operations will be reversed when the travel lever is operated. (The machine will travel forward when operated in reverse, and in reverse when operated forward; the left and right directions will also be reversed.) When operating the travel levers, check if the track frame is facing the front or the rear. (If the sprocket is at the rear, the track frame is facing the front.)
This lever (2) is used to change the direction of travel between forward and reverse. ( ) shows the pedal operation. (a) FORWARD: The lever is pushed forward (The pedal is angled forward) (b) REVERSE: The lever is pulled back (The pedal is angled back) N (Neutral): The machine stops
REMARK If the lever is shifted to the FORWARD or REVERSE position from the Neutral position, the alarm sounds to warn that the machine is starting to move.
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OPERATION
SUN ROOF
WARNING
When leaving the operator's seat, set the lock lever securely to the LOCK position. If the lock lever is at the FREE position and the control levers or control pedals is touched by mistake, this may lead to a serious accident.
Opening
1. Set the lock lever (1) securely to the LOCK position (L).
2. Push up lock (A) in the front center of the roof window and check that the lock is released. Then hold grip (B) and push up the roof window.
Closing
Pull the ceiling down, holding handle (B) and set locks (A). If the locks do not engage properly, open the ceiling once again and try to shut it.
WINDSHIELD
WARNING
When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK position. If the lock lever is at the FREE position and the control levers or control pedals is touched by mistake, this may lead to a serious accident. When opening or closing the front window, stop the machine on horizontal ground, lower the work equipment completely to the ground, stop the engine, then carry out the operation. When opening the front window, hold the grip securely with both hands, pull up, and do not let go until the automatic lock catch is locked. When closing the front window, the window will move quicker under its own weight. Hold the grips securely with both hands when closing it.
It is possible to stow (pull up) the front window in the roof of the operator's compartment.
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OPERATION
Opening
1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2. Set the lock lever (1) securely to the LOCK position (L).
4. Hold 2 grips (A) on the left and right top sides of the front window, and pull the 2 levers (B) to release the locks at the top of the front window. The top of the front window will come out.
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OPERATION
5. Hold lower knob (C) with your left hand from inside the operator's cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
6. Check that lever (B) is securely at the LOCK position. The lock is engaged if the arrow on lock case (F) matches the position of the arrow on lever (B). Check visually. If the arrow on lock case (F) does not match the position of the arrow on lever (B), the lock is not engaged. Repeat the operation in Step 5 to engage the lock.
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OPERATION
Closing
WARNING
When closing the window, lower it slowly and be careful not to get your hand caught.
1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2. Set the lock lever (1) securely to the LOCK position (L).
3. Grip left and right handles (A), and pull down lever (B) to release the lock.
4. Grip handle (C) at the bottom of the front window with your left hand and handle (D) at the top with your right hand, push to the front, then lower slowly.
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OPERATION
5. When the bottom of the window reaches the top of the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock.
6. Check that lever (B) is securely at the LOCK position. The lock is engaged if the arrow on lock case (F) matches the position of the arrow on lever (B). Check visually. If the arrow on lock case (F) does not match the position of the arrow on lever (B), the lock is not engaged. Repeat the operation in Step 5 to engage the lock.
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OPERATION
If sand or dust is collected at the bottom of the front window, it will be difficult to remove the window. In addition, when stowing, the sand and dust stuck to the glass will be carried inside the cab. To prevent this, clean area (A) before removing.
2. After removing the lower windshield, store it at the right rear of the operator's cab, and set lever (2) to lock position (B) to hold it securely in position. 3. When removing it, set lever (2) to release position (C), hold the glass with both hands, and pull it up.
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OPERATION
CAUTION
If it is necessary to break the window glass with the hammer, be extremely careful not to injure yourself on the flying pieces of broken glass. To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through the window. Be careful also not to slip on the broken pieces of glass.
If it should become impossible to open the cab door for any reason, and it is necessary to make an emergency escape from the operator's compartment, use hammer (A) to escape.
To escape from the operator's cab, use hammer (A) to break the glass and escape through the window.
DOOR LOCK
WARNING
Before the releasing the door lock, always stop the machine on flat ground. Never release the door lock on a slope. The door may suddenly close and cause injury. When releasing the door lock, do not extend your body or hands outside the machine and do not put your hands on the door frame. The door may suddenly close and cause injury.
Use the door lock to fix the door in position after opening it. 1. Push the door against catch (1) to lock it in position. 2. When closing the door, push down the lever (2) on the left of the operator's seat to release the catch. 3. When attaching the door in position, lock it firmly to the catch.
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OPERATION
Locking the Cap 1. Turn the cap until tight, then insert the key into the key slot. 2. Turn the starting switch key to LOCK position (B), then remove the key.
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OPERATION
Locking the Cover 1. Close the cover and insert the key into the key slot. 2. Turn the key clockwise and take the key out.
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OPERATION
DRINK BOX
This is on the right side at the rear of the operator's seat. It keeps drinks and other things hot or cold. Hot or cold air blows into the box according to the setting of the air conditioner.
MAGAZINE BOX
(The cup holder is provided separately at the front of the magazine box.) Located on left side of the operator's seat. Keep the Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary.
ASHTRAY
This is on top of the console box on the left side of the operator's seat. Always put out your cigarette before putting it in the ashtray and be sure to close the lid.
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OPERATION
OFF switch Fan switch Temperature control switch Vent selector switch Auto switch
FRESH/RECIRC selector switch Display monitor Air conditioner switch Sunlight sensor
OFF Switch
Switch (1) is used to stop the fan and air conditioner.
REMARK Even if this switch (1) is pressed, the monitor screen does not switch to the air conditioner adjustment screen.
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OPERATION
Fan Switch
Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the E switch to increase the air flow; press the R switc h to decrease the air flow. During auto operation, the air flow is automatically adjusted.
Monitor display and air flow A: Liquid crystal dispiay B: Air flow a: Air flow "low" b: Air flow "medium 1" c: Air flow "medium 2" d: Air flow "medium 3" e: Air flow "medium 4" f: Air flow "high"
REMARK If the mode is set to auto mode and the temperature setting is set to 18.0 C (64.4 F) or 32.0 C (89.6 F), the air flow from the fan is always set to HIGH and does not change even when the set temperature is reached.
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OPERATION
(A): Rear vent (4 places) (B1): Face vent (1 place) (C): Foot vent (1 place) (D): Front window glass vent (2 place) (B2): Front window glass vent (1 place)
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OPERATION
Auto Switch
With switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under automatic control. When switching from automatic operation to manual operation, it is possible to use the switches to select the vents and air source (RECIRC/FRESH).
REMARK When Auto Mode is selected, if the set temperature is set to 18.0 C (64.4 F) or 32.0 C (89.6 F), the air flow is always set to High, but this is not a problem.
RECIRC FRESH
Outside air is shut off and only air inside the cab is circulated. Use this setting to perform rapid cooling of the cab or when outside air is dirty. Outside air is taten into the cab. Use this setting to take in fresh air when performing demisting.
Display Monitor
Monitor (7) displays the status of temperature setting (a), air flow (b), and vents (c). When OFF switch (1) is pressed, the display of temperature setting (a) and air flow (b) goes out, and operation stops.
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OPERATION
Sunlight Sensor
This sensor (9) automatically adjusts the flow of air from the vents to match the strength of the sun's rays. In addition, it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun's rays beforehand and automatically adjusts the temperature.
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OPERATION
Method of Operation
The air conditioner can be operated automatically or manually. Select the method of operation as desired.
Automatic Operation
1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed.
2. Use temperature set 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 automatically to provide the set temperature.
REMARK When vent display monitor (c) displays (d) or (e), and engine coolant temperature is low, the air flow is automatically limited to prevent cold air from blowing out.
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OPERATION
Manual Operation
1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7).
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OPERATION
3. Press temperature setting switch (3) and adjust temperature inside the cab.
4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
5. Press RECIRC/FRESH selector switch (6) and select recirculation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
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2. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in the diagram on the right.
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OPERATION
4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired positions.
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OPERATION
Defroster Operation
1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7).
2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the right.
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OPERATION
3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air.
4. Press temperature setting switch (3) and set temperature on the display (7) monitor to maximum heating.
5. 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, turn air conditioner switch (8) ON.
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OPERATION
Ventilation When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry out ventilation and cooling. If you smoke when the air conditioner is on, the smoke may start to hurt your eyes, so open the window and turn the lever to FRESH for a while to remove the smoke while continuing the cooling. Temperature Control When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 or 6 C (9 or 10.8 F) lower than the outside temperature). This temperature difference is considered to be the most suitable for your health, so always be careful to adjust the temperature properly.
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OPERATION
RADIO
Control Panel
Power switch, Volume control knob, Balance control knob SEL button FM/AM selection button Display selection button
AS/PS button Preset station buttons (1,2,3,4,5,6) Display Time reset button Tuning button
SEL button
Each time this button (2) is pressed, the mode changes as follows: VOL (volume) J BAS (bass) J TRE (treble) J BAL (balance). The mode is displayed on display (7). For details of each mode, see "Method of Operating Mode (PAGE 3-105)".
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OPERATION
AS/PS button
This button (5) actuates the auto store and preset scan functions. Auto store If this button is kept pressed for at least 2 seconds during radio reception, it will automatically search for six available AM and FM stations each, starting with the lowest frequency and going up to the highest frequency. These frequencies can then be saved in the preset memory. Preset scan If this button is pressed within 2 seconds, it is possible to select one of the already preset stations. Wait for 6 sec. after pressing the button and then press the button again to select the next preset station. If it is impossible to receive the preset frequency, the selection advances after 1 second to the next preset station.
Display
In this display (7), receiving band, frequency, preset No. and time are shown.
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OPERATION
Controls of Radio
Method of Setting with Preset Button
1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. 3. With the display (7) showing the desired frequency, keep the desired Preset button No pressed for at least 1.5 seconds. The reception sound will disappear, but when the presetting operation (saving to memory) is completed, the sound will appear again and the Preset No and frequency will be shown on the display to show that the presetting operation has been completed. After completing the presetting, press Preset button (6) and release it within approx. 1.5 seconds. This will make it possible to receive the channel preset to that button. One channel each for AM and FM can be preset to each Preset REMARK It is also possible to save to the Preset button by using the auto store button.
Method of Tuning
1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. Manual tuning Press tuning button (9) until the frequency is displayed on display (7). < button: Frequency moves down > button: Frequency moves up When the frequency reaches the top or bottom frequency, it automatically continues as follows: Top J Bottom, or Bottom J Top.
Auto tuning Press tuning button (9) for at least 3 seconds. When a station is picked up, the tuning automatically stops. To search for the next station, press the tuning button again for at least 3 seconds. < button: Frequency moves down > button: Frequency moves up If this button is pressed during auto tuning, the auto tuning will be cancelled and the setting will return to the frequency in use before the button was pressed.
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OPERATION
Example 10:05 J 10:00 10:59 J 11:00 10:26 J 10:26 Use the H, M, and ADJ buttons to set to the correct time.
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OPERATION
Antenna
Before transporting the machine putting it inside a building, stored the antenna to prevent any interference. Stow the antenna as follows. 1. Loosen antenna mounting bolt (1) and store the antenna at position (A). 2. After storing the antenna, tighten bolt (1).
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OPERATION
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OPERATION
FUSE
NOTICE Before replacing a fuse, be sure to turn off the starting switch.
The fuse holder is at the rear right of the operator's seat. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. Replace the fuse with another of the same capacity.
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OPERATION
FUSIBLE LINK
If the starting motor is not cranked when the starting switch is turned START, there is probably a disconnection in fusible link (1) (2 places). Open the battery box cover on the right side of the machine and carry out inspection and replacement.
REMARK A fusible link refers to the large-sized fuse wiring installed in the high current flow portion of the circuit to protect electrical components and wiring from burning, in the same way as an ordinary fuse.
CONTROLLER
Controller installed.
NOTICE Be careful not to get water, mud, or juice on the controller. This will cause failure. If any problem occurs in the controller, do not disassemble it yourself. Contact your Komatsu distributor for repairs.
TOOL BOX
This is used for keeping the tools.
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OPERATION
FIRE EXTINGUISHER
(If equipped) A fire extinguisher is prepared at the rear part inside the operator's cab. The directions are described on the nameplate affixed to it. Just in case, carefully read and grasp them beforehand.
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OPERATION
WARNING
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor.
Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check for cracks, excessive wear, play in wotk equipment, cylinders, linkage, and hoses. If any problem is found, repair it. 2. Remove dirt and debris from around the engine, battery, and radiator. Check for dirt accumulated around the engine and radiator. Also check for flammable material (dry leaves, twigs, etc.) around the battery, engine muffler, turbocharger, or other high temperature engine parts. If any dirt or flammable materials are found, remove them. For the method of removing dirt from the radiator, see "CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner) (PAGE 4-58)". 3. Check for coolant and oil leakage around the engine Check for oil leakage from the engine and coolant leaks from the cooling system. If any problem is found, repair it. 4. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, and joints Check for oil leakage. If any problem is found, repair the area where oil is leaking. 5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers. If any problem is found, repair it. 6. Check for problems in handrails, steps, loose bolts. If any problem is found, repair it. Tighten any loose bolts. 7. Check for problem in gauges, monitor. Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts. Clean off any dirt from the surface. 8. Clean, check rear view mirror Check that there is no damage to the rear view mirror. If it is damaged repair. Clean the surface of the mirror and adjust the angle so that the area at the rear can be seen from the operator's seat.
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OPERATION
9. Seat belt and mounting clamps Check for damage or wear to the seat belt and mounting clamps. If there is any damage, replace with new parts. 10. Check bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, contact your Komatsu distributor for repairs.
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OPERATION
On this machine, a sensor is installed to detect if water is accumulated in transparent cap (2). When the water separator monitor (5) lights up red on the machine monitor, it indicates that water is accumulated in transparent cap (2). In this case also, use the procedure above to drain the water.
REMARK When only the water separator monitor lights up, it lights up in the position shown in the diagram on the right. If other monitors also light up the same time, the water separator monitor lights up at a different position. NOTICE If the water accumulated in transparent cap (2) freezes, the water separator monitor may not light up. After the engine is started, as the temperature around fuel pre-filter (1) increases, the frozen water will melt and the water separator monitor may suddenly light up. In cold areas, even if the water separator monitor does not light up, drain the water frequently. If the water inside transparent cap (2) freezes, check that the frozen water has melted completely, then use the procedure above to drain the water.
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OPERATION
REMARK If transparent cap (2) is dirty or it is difficult to see the inside, clean transparent cap (2) when replacing fuel pre-filter cartridge (1). When the drain valve (4) has been removed during the cleaning operation, coat the O-ring with grease and tighten until it contacts the bottom.
Adjustment of Drain Valve If drain valve (4) is stiff, coat the O-ring portion of the drain valve with grease to make the movement smooth. 1. Turn the valve (6) at the bottom of the fuel tank to the CLOSE position (S).
2. Set the container to catch the fuel under the pre-filter cartridge. 3. Loosen drain valve (4), then drain all the water and sediment in the transparent cap (2) and also the fuel accumulated in filter cartridge (1). 4. Check that nothing more comes out from drain hose (3), then remove drain valve (4).
5. Coat O-ring portion (7) with a suitable amount of grease. When doing this, be careful not to let the grease get stuck to the drain valve water drain port (8) or drain valve thread (9).
6. Tighten drain valve (4) by hand until it contacts the bottom of transparent cap (2). 7. Remove the fuel container. 8. Turn the valve (6) at the bottom of the fuel tank to the OPEN position (O).
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OPERATION
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Set the work equipment in the posture shown in the diagram on the right, then check the oil level and add oil if necessary. 2. If the work equipment is not in the condition shown in the diagram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinder rods fully, then lower the boom, set the bucket teeth in contact with the ground, and stop the engine. 3. Within 15 seconds after stopping the engine, move each control lever (for work equipment and travel) to the full stroke in all directions to release the internal pressure. 4. Check sight gauge (G) from the right window installed to the operator's compartment. The oil level should be between the H and L lines. NOTICE Do not add oil above the H line. This will damage the hydraulic equipment and may cause oil to spurt out. If oil is added above the H line, stop the engine, wait for the oil temperature to cool down, put a container to catch the oil under drain plug (P) at the bottom of the hydraulic tank, then drain the excess oil from the drain plug. 5. If the oil level is below the L line, add oil through oil filler (F) at the top of the hydraulic tank. REMARK The oil level will vary depending upon the oil temperature. Accordingly, use the following as a guide: Before starting operation: Between H and L levels (Oil temperature 10 to 30C (50 to 86F)) Normal operation: Around H level (Oil temperature 50 to 80C (122 to 176F))
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OPERATION
WARNING
Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.
1. Open the door at the rear left of the machine, and check if the coolant in sub-tank (1) (shown in the diagram on the right) is between the FULL and LOW marks. If the coolant level is low, add coolant to the FULL level through the filler port of sub-tank (1). 2. After adding coolant, tighten the cap securely. 3. If the sub-tank (1) is empty, there is probably leakage of coolant. After inspecting, repair any problem immediately. If there is no problem, check the coolant level in the radiator. If the coolant level is low, add coolant to the radiator, then fill the sub-tank (1). 4. If the inside of sub-tank (1) is dirty and the water level cannot be seen, use the procedure in "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)".
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OPERATION
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
1. Open the engine hood. 2. Remove dipstick (G), and wipe the oil off with a cloth. 3. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add oil through oil filler (F).
5. If the oil is above the H line, open drain valve (P) at the bottom of the engine oil pan, drain the excess engine oil, then check the oil level again. 6. If oil level is correct, securely tighten the oil filler cap and close the engine hood.
REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. If the machine is at an angle, make it horizontal before checking.
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OPERATION
CAUTION
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 and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no disconnection or trace of short-circuiting in the electric wiring and no damage to the covering. Check also that there is no loosened terminals. If any, tighten them. Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and alternator. Be sure to check that there is no inflammable material accumulated around the battery. If any is found, remove immediately.
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OPERATION
WARNING
When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous. Never bring flames near fuel.
1. Turn the engine starting switch to the ON position and check the fuel level gauge (1) on the monitor panel for fuel level. After checking, turn the switch back to the OFF position.
2. If fuel is found to be low, unscrew fuel filler cap (F) on the fuel tank and add fuel through the filler port until float gauge (G) comes up to the highest point. Fuel tank capacity: 400 liters (105.68 US gal) Position of tip (a) of float gauge (G) when fuel tank is full: Approx 50 mm (2 in) 3. After adding fuel, push float gauge (G) straight down with fuel filler cap (F). Be careful not to get float gauge (G) caught in the tab of fuel filler cap (F), and tighten fuel filler cap (F) securely.
REMARK If breather hole (3) on the cap is clogged, the pressure in the tank will drop and fuel will not flow. Clean the hole from time to time.
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OPERATION
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OPERATION
Adjustment
Seat Adjustment
WARNING
When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers.
Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's back against the backrest. (A) Fore-and-aft adjustment Pull lever (1) up, set the seat to the desired position, then release the lever. Fore-and-aft adjustment: 160 mm (6.3 in) (16 stages) (B) Adjusting reclining
REMARK The seat can be reclined more when the seat is pushed to the front. The amount of reclining decreases as the seat is pushed back, so when moving the seat back, return the seatback to the upright position.
Pull up lever (2) and set the backrest to a position that is comfortable for operation, then release the lever. Sit with your back against the seat backrest when adjusting. If your back is not against the backrest, the backrest may suddenly move forward. (C) Adjusting seat tilt Forward tilt Push lever (3) down to adjust angle of the front of seat. (4 stages) To raise the angle at front of the seat, keep the lever pushed down and apply your weight to the rear of seat. To lower the angle at front of the seat, keep the lever pushed down and apply your weight to the front of seat. Rear tilt Pull lever (4) up to adjust angle of the rear of seat. (4 stages) To raise the angle at rear of the seat, keep lever (3) pulled up, and stand up slightly to remove your weight from the seat. To lower the angle at rear of the seat, keep lever (3) pulled up, and apply your weight to the seat. Amount of tilt: Up 13, down 13 Adjusting seat height It is possible to move the seat up or down by combining adjustments forward tilt and rear tilt. After setting the forward tilt or rear tilt to the desired height, operate the opposite part to set the seat horizontal then secure in position. Height adjustment: 60 mm (2.4 in)
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OPERATION
(D) Adjusting armrest height The height of armrest (5) can be adjusted up or down by changing the position of adjustment bolt (6) at the rear of the armrest. Armrest height adjustment: 33 mm (1.3 in)
(E) Overall fore-and-aft adjustment of seat Move lever (7) to right, set to the desired position, then release the lever. In this case, the operator's seat, left and right control levers, and lock lever all slide together. Fore-and-aft adjustment:180 mm (7.1 in) (9 stages) (F) Adjusting suspension (if equipped) Turn knob (8) to the right to make the suspension harder,or to the left to make the suspension softer. Adjust the reading of the dial to match the operator's weight and select the optimum suspension.
REMARK To obtain the optimum adjustment, turn the knob (8) so that the indicator of the weight display (kg) in the transparent portion of knob (8) is the same as the operator's weight.
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OPERATION
Rearview Mirrors
WARNING
Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously.
Mirror (A) Adjust the mirror mount so that it is possible to see people at the rear left of the machine. Install the side view mirror in the location indicated in the figure at right. (L): 120 mm (4.7 in) Fix mirror securing stay (1) the way the side view mirror stretches outward to the maximum. If the side view mirror does not move smoothly when adjusting its angle, loosen mirror securing bolt (2) and mirror securing stay bolt (3). Tightening torque of bolt (2): 4.0 - 5.4 Nm (0.41 - 0.55 kgfm, 3 - 4 lbft) When adjusting the side view mirror angle, make an adjustment so that the side of the machine comes into view on the mirror as shown in the figure at right.
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OPERATION
Mirror (B) Adjust the mirror mount so that it is possible to see people at the rear right of the machine. Install the side view mirror in the location indicated in the figure at right. (M): 100 mm (3.9 in) If the side view mirror does not move smoothly when adjusting its angle, loosen mirror securing bolt (4) and mirror securing stay bolt (5). Tightening torque of bolt (4): 4.0 - 5.4 Nm (0.41 - 0.55 kgfm, 3 - 4 lbft) When adjusting the side view mirror angle, make an adjustment so that the side of the machine comes into view on the mirror as shown in the figure at right.
Mirrors (C), (D) Adjust the side view mirrors so that people around 1 m away from the machine can be seen. (W): 1 m (3 ft 3 in)
If side view mirror (C), (D) does not move smoothly when adjusting its angle, loosen mirror securing screw (6). Tightening torque of screw (6): 0.98 - 1.47 Nm (0.10 - 0.15 kgfm, 0.7 - 1.1 lbft)
When installing mirrors (C) and (D), make sure to leave clearance (V) to prevent contact between the mirror and mirror stay. (V): Min. 10 mm (0.4 in)
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OPERATION
Seat Belt
WARNING
Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt. Always wear the seat belt during operations. Fit the seat belt so that it is not twisted.
Removing Belt Press button (5) in buckle (4), and remove tongue (3) from buckle (4). The belt is automatically wound in, hold grip (2) and return the belt slowly to wind-in device (1).
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OPERATION
WARNING
When starting the engine, check that the lock lever is securely at the LOCK position. If the lock lever is not locked securely and the control levers or control pedal are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
1. Check that lock lever (1) is at the LOCK position (L). 2. Check that each control lever and control pedal is at the Neutral position. If the control levers and control pedal are not being touched, they will be at the Neutral position.
3. Insert the key in starting switch (2), turn the key to the ON position (B), then carry out the following checks.
If a password has been set, the input display screen will be displayed on the monitor screen. After inputting the password, press Enter switch F6 (3).
REMARK For details of the method of setting, changing, or canceling the password, see separate "PROCEDURE FOR SETTING, CHANGING, OR CANCELING PASSWORD".
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OPERATION
1) The buzzer sounds for approx. 2 seconds, then the monitor or meter lights up for approx. 2 seconds. Radiator coolant level monitor (4) Charge level monitor (5) Engine oil pressure monitor (6) Engine oil level monitor (7) Air cleaner clogging monitor (8) Water separator monitor (9) Engine coolant temperature gauge (10) If any monitor does not light up or the buzzer does not sound, there is probably a failure in the monitor, so please contact your Komatsu distributor for repairs. 2) After approx. 2 seconds, the screen will change to the working mode/travel speed display monitor. Next, it will switch to the standard screen. Engine coolant temperature gauge (10) Engine coolant temperature monitor (11) Fuel gauge (12) Fuel level monitor (13) Hydraulic oil temperature gauge (14) Hydraulic oil temperature monitor (15) 3) If the hydraulic oil temperature gauge is out or caution lamp (16) stays lighted up red, immediately check the item that lights up red.
4) If the maintenance interval has passed, maintenance interval monitor (17) lights up for 30 seconds. Press maintenance switch F5 (18), check the item, and carry out maintenance immediately.
For details of the method of checking the maintenance interval, see "Maintenance Selector Switch (PAGE 3-42)" in the explanation for each component.
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OPERATION
STARTING ENGINE
WARNING
Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explosions. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
NOTICE Before starting the engine, check that fuel control dial (2) is at the low idling (MIN) position. If the fuel control dial is at the full speed (MAX) position, the engine will accelerate suddenly and cause damage to the engine parts. Do not keep the key in starting switch (3) at the START position continuously for more than 20 seconds. If the engine does not start, wait for at least 2 minutes, then start again from the beginning. After the engine starts, wait for the engine oil pressure monitor to go out. Do not touch the control levers or control pedal while the engine oil pressure monitor is lighted up.
This machine is equipped with an engine automatic preheating device that functions to start the engine preheating automatically. If the ambient temperature is low, the preheating monitor will light up when the key in starting switch (3) is turned to the ON position to inform the operator that preheating has been started automatically. 1. Check the lock lever (1) is in the LOCK position (L). If the lock lever is in the FREE position (F), the engine does not start.
2. Set fuel control dial (2) to the low idling (MIN) position.
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OPERATION
If the ambient temperature is low, the preheating monitor lights up and automatic preheating is carried out. Keep the key in starting switch (3) at the ON position until the preheating monitor goes out.
The time that the preheating monitor stays lighted up depends on Ambient temperature the ambient temperature as shown in the table on the right.
-4 C to -15 C -15 C or less 4. If the preheating monitor does not light up, or it lights up and then goes out to inform that the engine preheating has been completed, turn the key in starting switch (3) to the START position (C) and start the engine. REMARK If the ambient temperature is low, the engine may not start even when the key in the starting switch (3) is kept at the START position for 20 seconds. If this happens, wait for at least 2 minutes, then start again from the beginning. 5. After the engine starts, release the key in starting switch (3). The key will automatically return to the ON position (B). REMARK When the engine is started, depending on the ambient temperature or the condition of the battery, the battery voltage may suddenly drop. If this happens, the display on the machine monitor will momentarily disappear, but this does not indicate any 6. Even if the engine starts, wait for the engine oil pressure monitor to go out. Do not touch the control levers or control pedal while the engine oil pressure monitor is lighted up. NOTICE If the engine oil pressure monitor does not go out even after 4 to 5 seconds have passed, stop the engine immediately. Check the oil level, check for leakage of oil, and take the necessary action.
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OPERATION
REMARK Regardless of the ambient temperature, it is possible to start the engine preheating manually. 1. Turn the key in starting switch (3) to the left from OFF position (A). The preheating monitor lights up and engine preheating starts. (Preheating continues while the key in starting switch (3) is held at the left position.) 2. The preheating monitor starts lighting about 30 seconds after preheating starts and then goes off in about 10 seconds. 3. After the preheating monitor goes off, turn the key in starting switch (3) to START position (C). The engine will start.
If the engine cannot be started with the above procedure, wait for at least two minutes, then start again from Step 1.
Turbo protect function The turbo protect function is a function to protect the turbocharger by keeping the engine speed at less than 1000 rpm immediately after the engine is started. When the turbo protect function is actuated, the engine speed is held at less than 1000 rpm, regardless of the position of the fuel control dial. When the turbo protect function is actuated, the engine speed is held at less than 1000 rpm, even if the fuel control dial is operated. When the turbo protect function is canceled, the engine speed is set to the speed for the position of the fuel control dial. The relationship between the length of time of actuating the Coolant Turbo protect turbo protect function and the temperature of the engine coolant temperature time (sec.) is as shown in the table. Above 10C (50F) 0 10 to -30C Change 0 to 20 (50 to -22F) below -30C (22F) 20
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OPERATION
WARNING
To stop the engine in emergencies or when the actuation of the engine is abnormal or there is any other trouble, turn the key in the starting switch to the OFF position. Do not carry out operations or operate the levers or pedal suddenly while the hydraulic oil is at low temperature. Always carry out the warm-up operation for the hydraulic equipment until the hydraulic oil temperature monitor displays the correct temperature. (When the hydraulic oil temperature is low, the low temperature display shown on the right is given. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white) If the warm-up operation for the hydraulic equipment is not carried out thoroughly, and the machine is moved, the reaction of the control levers and pedals will be slow and the movement may not be what the operator intended. Always warm up the hydraulic equipment. In particular, in cold areas, always warm up the hydraulic equipment thoroughly.
There are two types of warm-up operation: warm up the engine and warm up the hydraulic equipment. In addition, depending on the environment, the method of carrying out the warm-up operation may differ, so carry out the warm-up operation according to the items given in the appropriate section. (When only the engine is warmed up, the hydraulic equipment is not warmed up, so always carry out the warm-up operation for the hydraulic equipment separately from the warm-up operation for the engine. Warm up the hydraulic equipment thoroughly ensures that the hydraulic oil is warmed up and that warm hydraulic oil circulates in all the control circuits.)
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OPERATION
Engine Warm Up
NOTICE Do not accelerate the engine suddenly until the warm-up operation has been completed. Do not run the engine at low idling or high idling under no load for more than 20 minutes. This will have an adverse effect on the environment, and will also have an adverse effect on the internal structure of the engine. If it is necessary to run the engine at idling for more than 20 minutes, apply a load from time to time or run at a mid-range speed.
After the engine starts, do not start operating the machine immediately. First, carry out the following operations and checks. 1. This machine is equipped with an automatic engine warm-up system, so if the engine water temperature is below 30 C after the engine is started, the engine warm-up operation starts automatically. When the engine automatic warm-up operation starts, the engine speed is maintained at a speed higher than the normal low idling speed. If the engine water temperature goes above 30 C or if the warm-up operation has been continued for more than 10 minutes, the automatic warm-up operation is cancelled and the engine speed drops to the normal low idling speed.
2. Check that engine coolant temperature monitor (1) displays the correct temperature. If it displays low temperature, use the procedure in Step 3 to carry out additional warm up of the engine until the monitor displays the correct temperature. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white 3. Turn fuel control dial (2) to a point midway between low idling (MIN) and full speed (MAX), run the engine under no load at a mid-range speed until engine coolant temperature monitor (1) displays the correct temperature.
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OPERATION
(A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white
If the engine coolant temperature monitor displays the correct temperature, the engine warm-up operation is completed. After checking that the engine coolant temperature monitor displays the correct temperature, carry out the warm-up operation for the hydraulic equipment.
NOTICE Canceling automatic warm-up operation If it becomes necessary in an emergency to cancel the automatic warm-up operation or to lower the engine speed to low idle, do as follows. 1) Turn fuel control dial (2) to the full speed (MAX) position and hold it for 3 seconds.
2) When fuel control dial (2) is returned to the low idle (MIN) position, the engine speed will drop.
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OPERATION
WARNING
Before carrying out the warm-up operation for the hydraulic equipment, turn the swing lock switch ON, check on the monitor that the swing lock monitor lights up to show that the swing lock is actuated, then start the warm-up operation. When warm up the hydraulic equipment, check that there is no person or obstacle in the surrounding area, then sound the horn and start the operation. Carry out the warm-up operation for the hydraulic equipment until the hydraulic oil temperature monitor displays the correct temperature. (When the hydraulic oil temperature is low, the low temperature display shown on the right is given. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white) The warm-up operation for the hydraulic equipment is necessary not only for the circuit between the pump and cylinders and between the pump and motor, but also for all the control circuits. Do not carry out the operation just for one cylinder or motor, or the operation just in one direction. Carry out the operation in both directions for the work equipment (boom, arm, bucket), swing, travel, and attachment (if equipped).
1. Check that engine coolant temperature monitor (1) displays the correct temperature. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white If it displays low temperature, carry out additional warm up of the engine until engine coolant temperature monitor (1) displays the correct temperature. For details of the procedure, see "Engine Warm Up (PAGE 3-132)".
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OPERATION
2. Turn swing lock switch (2) ON and check that the swing lock monitor lights up.
3. To complete the warm-up operation of the hydraulic equipment more quickly, set the working mode to P mode (heavy-duty mode). For details of the procedure for setting the working mode, see "Working Mode Selector Switch (PAGE 3-26)".
4. Move lock lever (3) slowly to the FREE position (F), then raise the bucket from the ground.
5. Turn fuel control dial (4) to a point midway between low idling (MIN) and full speed (MAX).
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OPERATION
NOTICE When the work equipment is retracted, take care that it does not interfere with the machine body or ground. 6. Move right work equipment control lever (5) slowly in the direction to pull in the bucket (D). Operate the lever to the end of its travel and hold it in position for 30 seconds. 7. Move right work equipment control lever (5) slowly in the direction to push out the bucket (C). Operate the lever to the end of its travel and hold it in position for 30 seconds. 8. Next, move left work equipment control lever (6) slowly in the direction to pull in the arm (B). Operate the lever to the end of its travel and hold it in position for 30 seconds. 9. Move left work equipment control lever (6) slowly in the direction to push out the arm (A). Operate the lever to the end of its travel and hold it in position for 30 seconds. 10. Repeat the operation in Steps 6 to 9 for 5 minutes. 11. Check that hydraulic oil temperature monitor (7) is displaying the correct temperature. If the hydraulic oil temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 6 to 10 until the display is the correct temperature.
(A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white Check that engine coolant temperature monitor (1) displays 12. the correct temperature. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white If it displays low temperature, carry out additional warm up of the engine until engine coolant temperature monitor (1) displays the correct temperature. For details of the procedure, see "Engine Warm Up (PAGE 3-132)".
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OPERATION
13. Check that the hydraulic oil temperature monitor and engine coolant temperature monitor are displaying the correct temperature, then check that all the gauges and caution monitors on the machine monitor are in the following status. Radiator coolant level monitor (8): OFF Charge level monitor (9): OFF Engine oil pressure monitor (10): ON Engine oil level monitor (11): OFF Air cleaner clogging monitor (12): OFF Water separator monitor (13): OFF Engine pre-heating monitor (14): OFF Engine coolant temperature gauge (15): Indicator in green range Engine coolant temperature monitor (1): Displays correct temperature Hydraulic oil temperature gauge (16): Indicator in green range Hydraulic oil temperature monitor (7): Displays correct temperature Fuel gauge (17): Indicator in green range Fuel level monitor (18): Displays appropriate level 14. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor.
In cold temperatures (ambient temperature below 0 C (32 F)), even when the hydraulic oil temperature monitor displays the correct temperature, carry out additional Step 15 to warm up all the hydraulic equipment. 15. Turn fuel control dial (4) to the full speed (MAX) position, repeat Steps 6 to 9 for 3 to 5 minutes, then check again that the hydraulic oil temperature monitor is displaying the correct temperature. If it is not displaying the correct temperature, repeat Steps 6 to 9 for 3 to 5 minutes until hydraulic oil temperature monitor (7) displays the correct temperature. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white
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OPERATION
For both normal temperatures and cold temperatures, carry out the following operation. 16. Check that fuel control dial (4) is at a point midway between low idling (MIN) and full speed (MAX). If it is not at the midway position, set it to the midway position and run the engine at a mid-range speed before operating.
17. Before starting operations, repeat the following operations slowly 3 to 5 times to circulate warm oil through the control circuits.
Boom operation RAISE (E) LOWER (F) Arm operation IN (B) OUT (A) Bucket operation CURL (D) DUMP (C) When carrying out swing operations, release swing lock switch (2), check that swing lock monitor (19) goes out, then operate the swing. Swing operation Left (G) Right (H)
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OPERATION
For attachment operations (if equipped), change the working mode to the attachment mode.
Attachment operation
18. Check that hydraulic oil temperature monitor (7) is displaying the correct temperature. If the hydraulic oil temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 6 to 10 until the display is the correct temperature.
(A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white If the hydraulic oil temperature monitor displays the correct temperature, the hydraulic equipment warm-up operation is completed. After confirming that the hydraulic oil temperature monitor displays the correct temperature, carry out the following procedure.
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OPERATION
(A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white
2. Push working mode selector switch (20) of the machine monitor to select the working mode to be used. For details of the procedure for selecting the working mode, see "Working Mode Selector Switch (PAGE 3-26)".
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OPERATION
5) ATT mode For operations with crusher or other double-acting action attachment
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OPERATION
1. Run the engine at low idle for about 5 minutes to cool down gradually. 2. Turn the key in starting switch (1) to the OFF position (A) and stop the engine. 3. Remove the key from starting switch (1).
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OPERATION
MACHINE OPERATION
WARNING
Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction from the operation of the travel levers or travel pedals (front and rear travel is reversed, left and right steering is reversed). Before starting the machine off, check that the area around the machine is safe, and sound the horn. Do not allow anyone to enter the area around the machine. Clear any obstacles from the travel path. There is a blind spot at the rear of the machine, so be particularly careful when traveling in reverse. If the travel levers or travel pedals is operated when the auto deceleration is being actuated, the engine speed will suddenly rise, so be careful when operating. When traveling, check that the alarm sounds normally.
2. Turn fuel control dial (3) towards the full speed (MAX) position to increase the engine speed.
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OPERATION
2. Operate the right and left travel levers (5), or the right or left travel pedals (6) as follows: When sprocket (A) is situated at the rear of the machine; Start the machine either by pushing lever (5) forward slowly or by stepping on the front part of pedal (6) slowly.
When sprocket is situated at the front of the machine; Start the machine either by pulling lever (5) back slowly or by stepping on the rear part of pedal (6) slowly.
3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair. REMARK In cold temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation. In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil and mud from the undercarriage.
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OPERATION
2. Operate the right and left travel levers (5), or the right or left travel pedals (6) as follows: When sprocket (A) is at the rear of the machine: Slowly pull the levers (5) backward, or slowly depress the rear part of the pedals (6) to move the machine backward.
When sprocket (A) is at the front of the machine: Slowly push the levers (5) forward, or slowly depress the front part of the pedals (6) to move the machine backward.
3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair. REMARK In cold temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation. In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil and mud from the undercarriage.
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OPERATION
Stopping Machine
Avoid stopping suddenly. Give yourself ample room when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine.
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OPERATION
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 direction of operation of the travel levers or control pedals is the opposite from the direction of movement of the machine.
Use the travel levers to change direction. Avoid sudden changes of direction as much as possible. Especially when performing counter-rotation (spin turn), stop the machine before turning. Operate two travel levers (1) as follows.
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OPERATION
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OPERATION
SWINGING
WARNING
The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully.
1. Before starting the swing operation, turn swing lock switch (1) OFF and check that swing lock monitor (2) has gone out. (a): ON position (b): OFF position
2. Operate left work equipment control lever (3) to swing the upper structure. (A): Left swing (B): Right swing
3. When not using the swing, turn swing lock switch (1) ON. Check that swing lock monitor (2) lights up. (a): ON position (b): OFF position
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OPERATION
WARNING
If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully.
Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position. Arm control Move the left work equipment control lever to the front or rear to operate the arm.
Swing control Move the left work equipment control lever to the left or right to swing the upper structure.
Boom control Move the right work equipment control lever to the front or rear to operate the boom.
Bucket control Move the right work equipment control lever to the left or right to operate the bucket.
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OPERATION
If the work equipment control levers are returned to the neutral position when the machine is stopped, even if the fuel control dial is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a mid-range speed.
REMARK The control circuit on this machine is equipped with an accumulator. Even if the engine is stopped, if the starting switch key is turned to the ON position within 15 seconds after stopping the engine, and the lock lever is set to the FREE position, it is possible to use the lever operation to lower the work equipment to the ground. This procedure can also be used for releasing the remaining pressure in the hydraulic cylinder circuits or for lowering the boom after loading the machine onto a trailer.
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OPERATION
WORKING MODE
Working Mode
Use working mode selector switch (1) to select the working mode that matches the operating conditions or purpose. This will make it possible to carry out operations efficiently. Use the following procedure to select the most efficient working mode. When the starting switch is turned ON, the working mode is set to the mode that was in operation when the starting switch was last turned OFF. Use the working mode switch to set the mode to the most efficient mode to match the type of work.
Applicable operations Normal digging or loading operations (operations with emphasis on production) Normal digging or loading operations (operations with emphasis on fuel consumption) Aligning position (fine control operations) Breaker operations Operations with the crusher or other double-acting action attachment
NOTICE If breaker operations are carried out in a mode other than the breaker mode, there is danger of breakage of the hydraulic equipment. Do not carry out breaker operations in any mode except the breaker mode. 1. If working mode selector switch (1) is pressed, the working mode selection screen is displayed on the monitor.
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2. Press switches F3 or F4 at the bottom of the screen or the working mode selector switch to select the appropriate mode.
3. After selecting the desired mode, press switch F6 to accept the change. The screen returns to the standard screen. If switch F5 is pressed, the screen returns to the standard screen without changing the mode. If a working mode is selected, and nothing is done for 5 seconds, the selected working mode is automatically accepted and the screen returns to the standard screen. If a working mode is selected and working mode switch (1) is kept pressed, the selected mode is accepted and the screen returns to the standard screen.
If the breaker mode is selected, "Really Set Breaker Mode?" is displayed on the screen. To set to the breaker mode, press switch F6. If switch F5 is pressed, the screen returns to the working mode selection screen.
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PROHIBITED OPERATIONS
WARNING
If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
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OPERATION
Do not drive the machine in water deeper than the center of carrier roller (1). Supply grease to the parts which have been under water for a long time until the used grease is projected out of the bearings (around the bucket pin, in particular).
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OPERATION
TRAVELING ON SLOPES
WARNING
Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be performed, pile soil to make a platform (A) on the slope so the machine is kept horizontal during operation. Do not travel up or down steep slopes. There is a danger that the machine may turn over. When traveling, raise the bucket approx. 20 to 30 cm (8 to 12 in) from the ground. Do not travel downhill in reverse. Never turn on slopes or travel across slopes. Always go down to a flat place to perform these operations. It may be longer, but it will ensure safety. Always operate or travel in such a way that it is possible to stop safely at any time if the machine slips or becomes unstable. When traveling uphill, if the shoes slip or it is impossible to travel uphill using only the force of the tracks, do not use the pulling force of the arm to help the machine travel uphill. There is danger that the machine may
1. When traveling down steep hills, use the travel lever and fuel control dial to keep the travel speed low. When traveling down a steep hill of more than 15, set the work equipment to the posture shown in the diagram on the right, and lower the engine speed.
2. When traveling up a steep hill of more than 15, set the work equipment to the posture shown in the diagram on the right.
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When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.
Traveling Downhill
Put the travel lever in the neutral position. This will cause the brake to be automatically applied.
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When only one side is stuck in mud, use the bucket to raise the track, then lay boards or logs and drive the machine out.
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RECOMMENDED APPLICATIONS
In addition to the following, it is possible to further increase the range of applications by using various attachments.
Backhoe Work
A backhoe is suitable for excavating areas that are lower than the machine. When the condition of the machine is as shown in the diagram on the right (angle between [bucket cylinder and link] and [arm cylinder and arm] is 90), the maximum excavation force is obtained from the pushing force of each cylinder. When excavating, use this angle effectively to optimize your working efficiency. The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle towards the machine. There may be some differences depending on the excavation depth, but try to stay within the above range rather than operating the cylinder to the end of its stroke.
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 reverse direction.
Ditching Work
Ditching work can be performed efficiently by attaching a bucket which matches the digging operation and then setting the tracks parallel to the line of the ditch to be excavated. To excavate a wide ditch, first dig both sides and then finally remove the center portion.
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Loading Work
In places where the swing angle is narrow, work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator. Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.
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OPERATION
WARNING
When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition. If pins are hit with a strong force, there is a hazard that the pin may fly out and injure people in the surrounding area. Make sure that there is no one in the surrounding area before starting the operation. When removing the pins, do not stand behind the bucket. In addition, be extremely careful not to put your foot under the bucket while standing at the side for the work. When removing or inserting pins, be extremely careful not to get your fingers caught. Never insert your fingers into the pin holes when aligning the holes.
Stop the machine on a firm and flat surface and do the work. When performing joint work, appoint a lead and follow that person's instructions and signals.
Replacement
1. Place the bucket in contact with a flat surface. REMARK When removing the pins, place the bucket so that it is in light contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins. NOTICE After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, be careful not to damage them. 2. Remove the double nut on the stopper bolt for arm pin (A) and link pin (B), remove the bolt, pull out arm pin (A) and link pin (B), and then remove the bucket. 3. Align the arm (5) with holes (1) of the replacement bucket and the link (6) with holes (2), then insert grease-coated pins (A) and (B) into hole (1) and hole (2) respectively.
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REMARK When installing the bucket, for arm pin portion (A), fit O-ring (3) to bucket (4) in the position shown in the diagram on the right. After inserting the pin, fit it in the standard groove. For link pin portion (B), install the bucket with O-ring (3) fitted in the standard groove. 4. Install the stopper bolts and nuts for each pin, then grease the pin. REMARK Lubricate with grease thoroughly until the grease comes out from the end face. When replacing the bucket, replace the dust seal if it has been damaged. If a damaged seal is used without being replaced, sand and dirt may enter the pin portion and cause abnormal wear of the pin.
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OPERATION
Inversion
1. Place the bucket in contact with a flat surface. REMARK When removing the pins, place the bucket so that it is in light contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.
NOTICE After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, be careful not to damage them. 2. Remove the double nut on the stopper bolt for arm pin (A) and link pin (B), remove the bolt, pull out arm pin (A) and link pin (B), and then remove the bucket. 3. After removing the bucket, reverse it. 4. Align arm (5) with replacement bucket hole (1), then align link (6) with hole (2), coat pins (A) and (B) with grease, and install.
REMARK When reversing, do not install an O-ring. Keep the O-ring in a safe place until using it next. 5. Install the stopper bolts and nuts for each pin, then grease the pin. REMARK Lubricate with grease thoroughly until the grease comes out from the end face. When replacing the bucket, replace the dust seal if it has been damaged. If a damaged seal is used without being replaced, sand and dirt may enter the pin portion and cause abnormal wear of the pin.
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OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure, thrust the bucket into the ground. If the control lever is touched by accident, the machine may move suddenly, and this may lead to a serious accident. Before leaving the operator's compartment, always set the lock lever securely to LOCK position.
1. Put left and right travel levers (1) in the neutral position. The machine stops.
2. Turn fuel control dial (2) to low idling position (MIN) and lower the engine speed.
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3. Lower the bucket horizontally until the bottom touches the ground.
5. Check the engine cooling water temperature and engine oil pressure with the machine monitor. If the coolant temperature gauge is in the red range, allow it to cool until the indicator enters the green range, then stop the engine. For details of the inspection and action to take, see "TROUBLES AND ACTIONS (PAGE 3-187)". If the engine oil pressure monitor lights up, stop the engine immediately. For details of the inspection and action to take, see "TROUBLES AND ACTIONS (PAGE 3-187)". 6. Stop the engine. For details on the procedure for stopping the engine, see "STOPPING THE ENGINE (PAGE 3-142)".
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OPERATION
LOCKING
Always lock the following places. (1) Operator's cab door Always close the window. (2) Fuel tank filler port (3) Engine hood (4) Battery box cover (5) Left side door of the machine (6) Right side door of the machine (7) Hydraulic tank filler port (8) Air conditioner FRESH filter intake port
REMARK Use the starting switch key to lock and unlock all these places.
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OPERATION
TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
Select the method of transportation to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)". Note that the weight and dimensions given in SPECIFICATIONS may differ according to the type of shoe or arm, or other attachments. Please consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard installed for the operator's cab.
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. TRANSPORTATION
OPERATION
WARNING
Always obey the following when loading or unloading the machine from a trailer. Select firm, level ground when loading or unloading the machine. Maintain a safe distance from the edge of the road. Always turn the auto-deceleration switch OFF (cancel). If the auto-deceleration switch is left ON, the machine may suddenly start moving. Always set the travel speed switch to low speed (Lo), run the engine at low idling, and operate the machine slowly when loading or unloading. In cold areas, carry out the warming-up operation thoroughly and make sure that the engine speed is stable before carrying out the loading or unloading operation. Never correct your steering on the ramps. There is danger that the machine may tip over. If necessary, drive off the ramps or back on to the trailer and correct the direction. It is dangerous to use the work equipment for loading and unloading operations. Always use ramps. When on the ramps, do not operate any lever except the travel lever. The center of gravity of the machine will change suddenly at the joint between the ramps and the trailer, and there is danger of the machine losing its balance. Travel slowly over this point. If it is necessary to swing the work equipment on the trailer platform, the footing is unstable, so be extremely careful that the machine does not tip over. If the work equipment is installed to the machine, pull the work equipment in, and operate slowly to prevent the machine from losing its balance. Position a flagman to give guidance to prevent the machine from coming off the ramps and to ensure safety in the operation. Always observe the following regarding the ramps and trailer platform. Use ramps with ample width, length, thickness, and strength and install them at a maximum slope of 15. When using piled soil, compact the piled soil fully to prevent the slope face from collapsing. Clean the machine tracks and ramps before starting in order to prevent the machine from slipping on the ramps. There is danger of the machine slipping if there is water, snow, grease, oil, or ice on the ramp surface.
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TRANSPORTATION
Loading
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer. Make angle of installation (4) a maximum of 15. If the ramps bend a large amount under the weight of the machine, put blocks under the ramps to prevent them from bending.
3. Turn the travel speed selector switch to low speed travel (Lo lamp lights up). Press travel speed selector switch (5) to switch the travel speed. The travel speed (Lo, Mi, Hi) is displayed on the travel speed monitor (6). 4. Turn auto-deceleration switch (7) OFF and operate the fuel control dial to set the engine speed to low idling. Each time auto-deceleration switch (7) is pressed, it switches OFF J ON J OFF in turn. When auto-deceleration switch (7) is turned OFF, the auto-deceleration monitor (8) goes out.
5. Turn the swing lock switch ON to apply the swing lock. When the swing lock switch is turned to the ON position, the swing lock monitor (9) lights up. (a): ON position (b): OFF position
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OPERATION
6. If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it; if it has no work equipment, travel in reverse to load it. Follow instructions and signals of a conductor particularly when traveling in reverse. 7. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer. Align the direction of travel with the ramps and travel slowly. Lower the work equipment as far as possible without causing interference. When on the ramps, operate only the travel lever. Do not operate any other lever.
8. When loading or unloading a machine with the work equipment installed, at the point where the tracks are on both the ramps and the ground surface, turn the swing lock switch OFF, then swing the upper structure slowly 180. After doing that, drive slowly in reverse and load the machine onto the trailer.
9. Turn the swing lock switch ON to apply the swing lock. When the swing lock switch is turned to the ON position, the swing lock monitor (9) lights up. (a): ON position (b): OFF position
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TRANSPORTATION
10. When the machine travels over the rear wheels of the trailer, it becomes unstable, drive slowly and carefully. (Never operate the steering.) 11. At the moment the machine passes the rear wheels, it tilts forward, be careful not to let the work equipment hit the trailer body. Drive the machine forward to the specified position, then stop the machine. 12. Lower the work equipment on top of wooden blocks.
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OPERATION
Securing Machine
NOTICE Stow the radio antenna. Reassemble the mirrors so that they are within the width of the machine. To prevent damage to the bucket cylinder during transportation, put a wooden block under the tip of the bucket link to prevent the bucket cylinder from touching the floor. Check that the engine hood catch is locked. Hold the grip of the engine hood and raise it slightly. If it does not open, the catch is locked. If the engine hood catch is not locked, there is danger that the engine hood may open during transportation.
Load the machine onto a trailer as follows: 1. Extend the bucket and arm cylinders fully, then lower the boom slowly.
2. Set the lock lever securely to the LOCK position (L). 3. Stop the engine, then remove the key from the starting switch. 4. Close all doors, windows, and covers. Lock the covers, caps, and doors fitted with locks.
5. Place blocks under both ends of the tracks to prevent the machine from moving during transportation, and secure the machine with chains or wire rope of suitable strength. Be particulary careful to secure the machine in position so it does not slip to the side.
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OPERATION
TRANSPORTATION
Rearview Mirrors
The mirrors are at the positions shown in the diagram on the right. If they are damaged, or are to be removed for shipment, or are to be installed again, use the following procedure. After installing the mirrors, be sure to adjust them, referring to "Rearview Mirrors (PAGE 3-123)".
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OPERATION
Removal Mirrors (A), (B) 1. Loosen mounting bolt (2), then remove mirror (1) from support (3). 2. Loosen bolt (4) and remove support (3) and clamp (5) from the handrail.
Mirrors (C), (D) 3. Loosen locknut (2), then remove mirror (1) from bracket (3). 4. Remove bolt (4), then remove bracket (3) from the machine.
Installation Mirrors (A), (B) 1. Install support (3) and clamp (5) to the handrail,then tighten with bolt (4). 2. Install mirror (1) to support (3),then tighten lock bolt (2).
Mirrors (C), (D) 3. Install bracket (3) to the machine with bolt (4). 4. Install mirror (1) to bracket (3),then tighten locknut (2).
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OPERATION
TRANSPORTATION
Unloading
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer. Make angle of installation (4) a maximum of 15. If the ramps bend a large amount under the weight of the machine, put blocks under the ramps to prevent them from bending.
3. Remove the chains and wire ropes fastening the machine. 4. Start the engine. Warm the engine up fully. 5. Set the lock lever to FREE position (F).
6. Turn the travel speed selector switch to low speed travel (Lo lamp lights up). Press travel speed selector switch (5) to switch the travel speed. The travel speed (Lo, Mi, Hi) is displayed on the travel speed monitor (6). 7. Turn auto-deceleration switch (7) OFF and operate the fuel control dial to set the engine speed to low idling. Each time auto-deceleration switch (7) is pressed, it switches OFF J ON J OFF in turn. When auto-deceleration switch (7) is turned OFF, the auto-deceleration monitor (8) goes out.
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OPERATION
8. Raise the work equipment, pull in the arm under the boom, then move the machine slowly. 9. When the machine is horizontal on top of the rear wheels of the trailer, stop the machine.
NOTICE When unloading the machine, always keep the arm and boom at an angle of 90 - 110. If the machine is unloaded with the arm pulled in, it will cause damage to the machine. When moving onto the ramps, do not thrust the bucket into the ground. This will cause damage to the hydraulic cylinders. 10. When moving from the rear of the trailer on to the ramps, set the angle of the arm and boom to 90 to 110, lower the bucket to the ground, then move the machine slowly. 11. When moving down the ramps, operate the boom and arm slowly to lower the machine carefully until it is completely off the ramps.
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OPERATION
TRANSPORTATION
LIFTING MACHINE
WARNING
The operator carrying out the lifting operation using a crane must be a properly qualified crane operator. Never raise the machine with any worker on it. Always make sure that the wire rope is of ample strength for the weight of this machine. When lifting, keep the machine horizontal. When carrying out lifting operations, set the lock lever to the LOCK position to prevent the machine from moving unexpectedly. Never enter the area under or around a raised machine. Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting equipment other than in the procedure below. There is a hazard that the machine may lose its balance.
NOTICE The lifting procedure applies to machines with standard specifications. The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor.
For details of the weight, see "SPECIFICATIONS (PAGE 5-2)". When lifting the machine, carry out the operation on flat ground as follows.
4. Stop the engine, check that there is nothing around the operator's compartment, then get off the machine. Close the cab door and front glass securely.
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OPERATION
5. Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. However, for machines equipped with a full roller guard for the track roller, pass the wire rope under the track. 6. Set the lifting angle (A) of the wire rope to 30 to 40, then lift the machine slowly. 7. After the machine comes off the ground, check the hook condition and the lifting posture, and then lift slowly.
2. Start the engine and set the work equipment to the posture shown in the diagram on the right. (Boom fully raised, arm, bucket fully pulled in) set the upper structure facing straight to the front. (Idler end)
3. Set the lock lever securely to the LOCK position. 4. Stop the engine, check that the area around the operator's cab is safe, then get down from the machine. Close the cab door, front glass, left and right doors, and engine hood securely. 5. Install shackles to the lifting hooks on top of the boom and counterweight, then fit wire rope.
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OPERATION
TRANSPORTATION
6. As shown in the diagram on the right, select the wire rope so that lifting point (A) is directly above the center of gravity (B) (a point 490 mm (19.3 in) to the rear of the swing center). (A): Lifting point (B): Center of gravity (C): Swing center (D): 490 mm (19.3 in) (E): Min. 8 m (26 ft 3 in) (F): Min. 3.5 m (11 ft 6 in) (G): Min. 6.3 m (20 ft 8 in)
7. When lifting the machine, check that there is no change in the posture of the work equipment caused by leakage of oil from the hydraulic circuit at the boom cylinder head end. 8. When the machine comes off the ground, stop the lifting operation, check that the machine is balanced, and when the machine stabilizes, lift it slowly. 9. After completing the lifting operation, always install cover (1) on top of the counterweight.
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OPERATION
WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash it off with large amounts of fresh water and see a doctor at once. When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface. Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE Use Komatsu Supercoolant (AF-NAC) wherever available, or use permanent type antifreeze coolant. Never use methanol, ethanol, or propanol-based antifreeze. Do not use any water leakage prevention agent, either alone, or in combination with antifreeze. Do not mix one brand of antifreeze with a different brand. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. For details, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)".
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)".
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OPERATION
Battery
WARNING
The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger that the battery may explode. Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold temperature to ensure the machine can be started easily the next morning.
REMARK Measure the specific gravity and calculate the charging rate from the following conversion table.
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store the battery in a warm place, and install it again the next morning. If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the day's work to prevent diluted electrolyte in the battery from freezing during the night.
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OPERATION
WARNING
Performing idle-running of the tracks is dangerous, stay well away from the tracks.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions. Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal. Park the machine on hard, dry ground. If this is impossible, park the machine on boards. The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next morning. Open the drain valve and drain any water collected in the fuel system to prevent it from freezing. Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops. After operation in water or mud, remove water from undercarriage as described below to extend undercarriage service life. 1. Swing 90 with engine at low idle and bring the work equipment to the side of the track. 2. Jack up the machine until the track is raised slightly from the ground. Rotate the track under no load. Repeat this procedure on both the left and right sides.
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OPERATION
When putting the machine in storage for a long time (more than one month), do as follows. Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level ground and cover the machine with canvas. Completely fill the fuel tank. This prevents moisture from collecting. Lubricate and change the oil before storage. Coat the exposed portion of the hydraulic cylinder piston rod with grease. Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it Set the attachment control pedal to the lock position on machines ready for attachments. Set the stop valve to the LOCK position on machines ready for attachments. Install the blind plugs to the elbows. For details of the LOCK and FREE positions of the stop valve, see "ATTACHMENT REMOVAL AND INSTALLATION (PAGE 6-15)". To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type antifreeze (density between 30% and 68%).
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve ventilation and prevent gas poisoning.
During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts. At the same time, also charge the battery. When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods. If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In addition, check the refrigerant level twice a year.
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OPERATION
AFTER STORAGE
NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it.
When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods. Add oil and grease at all lubrication points. When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after starting the engine. If there is water in the oil, change all the oil.
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OPERATION
When the bucket control lever is operated to the CURL position and the work equipment is lowered under no load from a high position, the bucket speed will drop momentarily when the bucket teeth are more or less at the horizontal position. The bucket or arm will fluctuate by itself during heavy-duty digging operations.
When starting or stopping the swing, noise will be emitted from the brake valve. When going down a steep slope at low speed, a noise will be emitted from the travel motor brake valve.
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OPERATION
WARNING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed. Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing operation. Always wear leather gloves when handling wire rope. Never tow a machine on a slope. During the towing operation, never stand between the towing machine and the machine being towed. Operate the machine slowly and be careful not to apply any sudden load to the wire rope.
NOTICE The permissible pulling power of this machine is as follows. PC200: 142,000 N (14,600 kgf) PC220: 168,000 N (17,100 kgf) Always carry out towing operations within the maximum towing capacity.
If the machine sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram on the right. Place pieces of wood between wire ropes and body to prevent damage to ropes and body. Hold the wire rope level and direct it straight to the track frame. When towing a machine, travel at a speed of less than 1 km/h for a distance of only a few meters to a place that is suitable for carrying out repairs. This is for use only in emergencies.
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OPERATION
WARNING
The shackle must always be used. Hold the wire rope level and direct it straight to the track frame. Move the machine slowly and be careful not to apply any sudden load to the wire rope.
There is a hole in the track frame to fit the shackle when towing light objects. Permissible towing load: PC200 Max. 58,800N (6,000 kgf) PC220 Max. 78,400 N (8,000 Kgf)
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OPERATION
DISCHARGED BATTERY
WARNING
It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks. Battery electrolyte is dilute sulfuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, immediately wash it off with a large amount of water. If it gets in your eyes, wash it out with fresh water and consult a doctor. When handling batteries, always wear safety glasses and rubber gloves. When removing the battery, first disconnect the cable from the ground (normally the negative (-) terminal). When installing, install the positive (+) terminal first. If a tool touches the positive terminal and the chassis, there is danger that it will cause a spark, so be extremely careful. If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion. When removing or installing the terminals, check which is the positive (+) terminal and which is the negative (-) terminal.
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OPERATION
Battery Charges
When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-190)" and the instruction manual accompanying the charger, and do as follows.
Set the voltage of the charger to match the voltage of the battery to be charged. If the correct voltage is not selected, the charger may overheat and cause an explosion. Connect the positive (+) charger clip of the charger to the positive (+) terminal of the battery, then connect the negative (-) charger clip of the charger to the negative (-) terminal of the battery. Be sure to attach the clips securely. Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set it to less than the rated battery capacity. If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and explode. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a danger that this will ignite the battery electrolyte and cause the battery to explode. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.
3 - 191
OPERATION
WARNING
When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses. Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. If hydrogen gas explodes, it could cause serious injury. Be careful not to make a mistake when connecting a booster cable. In the last connection (to the upper structure frame), a spark will be caused, connect the cable to a spot as far away from the battery as possible. (Avoid the work equipment, however, because it is not a good conductor) When removing the booster cable, exercise good care so that the booster cable clips may not contact each other, or they contact the chassis.
NOTICE The starting system for this machine uses 24V. For the normal machine, also use a 24V battery. The size of the booster cable and clip should be suitable for the battry size. The battery of the normal machine must be the same capacity as that of the engine to be started. Check the cables and clips for damage or corrosion. Make sure that the cables and clips are firmly connected. Check that the lock levers and parking brake levers of both machine are in the LOCK position. Check that each lever is in the NEUTRAL position.
3 - 192
OPERATION
WARNING
Always check that the lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in the HOLD or neutral position.
1. Make sure the clips are firmly connected to the battery terminals. 2. Start engine of the normal machine and run it at high idle speed. 3. Turn the starting switch of the problem machine to the START position and start the engine. If the engine doesn't start at first, try again after 2 minutes or so.
3 - 193
OPERATION
OTHER TROUBLE
Electrical System
( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Lamp does not glow brightly even when the engine runs at high speed Lamp flickers while engine is running Charge level monitor does not go out even when engine is running Abnormal noise is generated from alternator Starting motor does not turn when starting switch is turned to ON Pinion of starting motor keeps going and out Starting motor turns engine sluggishly Starting motor disengages before engine starts Engine pre-heating monitor does not light Oil pressure monitor does not light up when engine is stopped (starting switch at ON position) Outside of electrical heater is not warm when touched by hand Main causes Defective wiring, deterioration of ( battery Loose fan belt Defective alternator Defective alternator Defective wiring Defective starting motor Insufficient battery charge Insufficient battery charge Defective wiring, defective ring gear pinion Defective wiring Defective heater relay Defective monitor Defective caution lamp switch Defective wiring Disconnection in electric heater ( ( ( ( ( ( Remedy Check, repair loose terminals, disconnections, replace battery) Replace fan belt, Check Replace) Replace) Check, repair) Replace) Charge Charge Check, repair)
( ( ( ( ( (
3 - 194
OPERATION
Chassis
( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Speed of travel, swing, boom, arm, bucket is slow Pump generates abnormal noise (sucking in air) Excessive rise in hydraulic oil temperature Main causes Lack of hydraulic oil Clogged element in hydraulic Loose fan belt Dirty oil cooler Lack of hydraulic oil Track comes off Abnormal wear of sprocket Boom rises slowly, does not rise Does not swing Track too loose Lack of hydraulic oil ( Remedy Add oil to specified level, see Clean, see EVERY 2000 Check fan belt tension, replace) Clean, see EVERY 500 HOURS SERVICE Add oil to specified level, see Adjust track tension, see WHEN REQUIRED Add oil to specified level,
3 - 195
OPERATION
Engine
( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Engine oil pressure monitor lights up Main causes Engine oil pan oil level is low (sucking in air) Clogged oil filter cartridge Defective tightening of oil pipe, pipe joint, oil leakage from damaged point Defective engine oil pressure Steam spurts out from top of radiator (pressure valve) Coolant level low, leakage of water Loose fan belt Dirt or scale accumulated in cooling system Radiator coolant level monitor lights up Clogged radiator fins or damaged fins Defective thermostat Loose radiator filler cap (high-altitude operations) Engine does not start when starting motor is turned Lack of fuel Air in fuel system ( ( ( Remedy Add oil to specified level, see CHECK BEFORE STARTING Replace cartridge, see EVERY 500 HOURS SERVICE Check, repair)
Replace sensor) Check, add coolant, repair, see CHECK BEFORE STARTING Check fan belt tension, replace) Change coolant, flush inside of cooling system, see WHEN REQUIRED Clean or repair, see EVERY 500 HOURS SERVICE Replace thermostat) Tighten cap or replace packing Add fuel, see CHECK BEFORE STARTING Repair place where air is sucked in, see EVERY 500 HOURS SERVICE
Defective fuel injection pump or defective nozzle Starting motor cranks engine sluggishly Engine pre-heating monitor does not light up Exhaust gas is white or blue Too much oil in oil pan
Replace pump or nozzle) See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM Set oil to specified level, see CHECK BEFORE STARTING Clean or replace, see WHEN REQUIRED
Defective nozzle
3 - 196
OPERATION
Main causes Low-grade fuel being used Overheating Damage inside muffler (
Remedy Change to specified fuel Refer to "Radiator coolant level monitor lights up" as above Replace muffler)
3 - 197
OPERATION
E03
Engine controller power source error Engine controller drive system circuit error (engine stopped) Engine controller system error Output reduced to protect engine Abnormality in throttle system Engine sensor (coolant temperature, fuel pressure, oil pressure) system error Network error
(*): For details of handling the emergency pump drive switch and swing brake cancel switch, see "Emergency Pump Drive Switch (PAGE 3-74)" and "Swing Parking Brake Release Switch (PAGE 3-74)".
3 - 198
4-1
. MAINTENANCE INFORMATION
MAINTENANCE
MAINTENANCE INFORMATION
Do not perform any inspection and maintenance operation that is not found in this manual.
Fuel Strainer
If your machine is equipped with a fuel strainer, do not remove it while fueling.
Welding Instructions
Cut off power. Wait for approx. one minute after turning off the engine starting switch key, and then disconnect the negative (-) terminal of the battery. Do not apply more than 200 V continuously. Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near instruments, connectors, etc., the instruments may malfunction. If a seal or bearing happens to come between the part being welded and grounding point, change the grounding point to avoid such parts. Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
4-2
MAINTENANCE
MAINTENANCE INFORMATION
Dusty Jobsite
When working at dusty worksites, do as follows: 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. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. When checking and replacing the oil or filters, move the machine to a place where there is no dust and take care to prevent dust from entering the system.
4-3
. OUTLINE OF SERVICE
MAINTENANCE
OUTLINE OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil. When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the small amount of oil remaining in the piping mixes with the new oil.) Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed in the table below.
Item Engine oil pan Damper case Swing machinery case Final drive case Hydraulic oil system Radiator Powertrain oil TO10 (Komatsu genuine parts) Supercoolant AF-NAC (density: 30% or above) (Komatsu genuine parts) Powertrain oil TO30 (Komatsu genuine parts) Type Engine oil EO15W40DH (Komatsu genuine parts)
4-4
MAINTENANCE
OUTLINE OF SERVICE
FUEL
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work. The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly. Be extremely careful not to let impurities get in when storing or adding fuel. Always use the fuel specified for the temperature in the Operation and Maintenance Manual. If the fuel is used at temperatures lower than the specified temperature (particularly at temperatures below -15C (5F), the fuel will solidify. If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and this may result in problems such as a drop in output. Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank. If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit. If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE Always use diesel oil for the fuel. To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly.
4-5
. OUTLINE OF SERVICE
MAINTENANCE
GREASE
Grease is used to prevent seizure and noises at the joints. This construction equipment is used under heavy-duty conditions. Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual. The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease. If any part becomes stiff after being used for long time, add grease. Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts.
Measurement of quantity of particles This uses a particle quantifier index measurement machine to measure the quantity of iron particles of 5 or more, enabling early detection of failures.
Others Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
4-6
MAINTENANCE
OUTLINE OF SERVICE
OIL SAMPLING
Sampling interval 250 hours: Engine 500 hours: Other components Precautions when sampling Make sure that the oil is well mixed before sampling. Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor.
FILTERS
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems. Replace all filters periodically. For details, see the Operation and Maintenance Manual. However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used. Never try to clean the filters (cartridge type) and use them again. Always replace with new filters. When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are found, contact your Komatsu distributor. Do not open packs of spare filters until just before they are to be used. Always use Komatsu genuine filters.
4-7
. WEAR PARTS
MAINTENANCE
WEAR PARTS
Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, always use 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 for the latest part number when ordering parts.
4-8
MAINTENANCE
* If using these fuels, serious troubles may occur because of early deterioration of engine oil or early wear of engine internal parts. If using them by necessity for local situations, be sure to inform customers about the following. 1) Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil based on the result. 2) Always be aware that oil change interval is extremely shorter than standard. 3) Be sure to carry out periodic engine inspection by distributor's expert since change interval of periodic replacement parts and overhaul interval are also shorter.
4-9
MAINTENANCE
Engine oil pan Specified capacity liter US gal liter US gal 25.4 6.71 23.1 6.10
Refill capacity
Swing machinery case 7.1 (PC200) 8.2 (PC220) 1.88 (PC200) 2.17 (PC220) 7.1 (PC200) 8.2 (PC220) 1.88 (PC200) 2.17 (PC220)
Final drive case (each) 3.5 (PC200) 5.4 (PC220) 0.92 (PC200) 1.43 (PC220) 3.3 (PC200) 5.2 (PC220) 0.87 (PC200) 1.37 (PC220)
Hydraulic system 232 (PC200) 239 (PC220) 61.29 (PC200) 63.14 (PC220) 135 35.67
Cooling system
Fuel tank
21.0 (PC200) 400 20.4 (PC220) 5.55 (PC200) 105.68 5.39 (PC220) 21.0 (PC200) 20.4 (PC220) 5.55 (PC200) 5.39 (PC220)
NOTICE Always use diesel oil for the fuel. To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly.
4 - 10
MAINTENANCE
Note 1: HTHS ( High-Temperature High-Shear Viscosity 150C), specified by ASTM D4741 must be equal to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils. Note 3: Hyper grease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended. Note 4: Supercoolant (AF-NAC) 1) Coolant has the important function of anticorrosion as well as antifreeze. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant AF-NAC is strongly recommended wherever available. 2) For details of the ratio when diluting super coolant with water, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)". Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution. (never dilute with water) 3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
4 - 11
MAINTENANCE
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation. Always pay careful attention when tightening parts.
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, always use a Komatsu genuine part of the same size as the part that was replaced.
Tightening torque Target value Nm 13.2 31 66 113 172 260 360 510 688 883 1295 1720 2210 2750 3280 kgfm 1.35 3.2 6.7 11.5 17.5 26.5 37 52.3 70.3 90 132.5 175.0 225.0 280.0 335.0 lbft 9.8 23.1 48.5 83.2 126.6 191.7 267.6 378.3 508.5 651 958.4 1265.8 1627.4 2025.2 2423.1 Nm 11.8-14.7 27-34 59-74 98-123 153-190 235-285 320-400 455-565 610-765 785-980 1150-1440 1520-1910 1960-2450 2450-3040 2890-3630 Service limit kgfm 1.2-1.5 2.8-3.5 6.0-7.5 10.0-12.5 15.5-19.5 23.5-29.5 33.0-41.0 46.5-58.0 62.5-78.0 80.0-100.0 118.0-147.0 155.0-195.0 200.0-250.0 250.0-310.0 295.0-370.0 lbft 8.7-10.8 20.3-25.3 43.4-54.2 72.3-90.4 112.1-141 170.0-213.4 238.7-296.6 336.3-419.5 452.1-564.2 578.6-723.3 853.5-1063.3 1121.1-1410.4 1446.6-1808.3 1808.3-2242.2 2133.7-2676.2
lbft
103 10.5
157 16.0 115.7 128-186 13.0-19.0 94.0-137.4 216 22.0 159.1 177-245 18.0-25.0 130.2-180.8
4 - 12
MAINTENANCE
4 - 13
MAINTENANCE
10 Work equipment hose (bucket cylinder inlet port 11 Work equipment hose (arm cylinder line, boom foot) 12 Work equipment hose (arm cylinder inlet port) 13 Attachment additional line hose (boom foot) 14 Attachment additional line hose (boom top) 15 Swing line hose (swing motor inlet port) 16 Main suction hose 17 Heater hose 18 Travel line hose (control valve - swivel joint) 19 Travel line hose (swivel joint - travel motor) 20 Pump branch hose 21 Pump LS hose 22 Pump pressure hose 23 Accumulator(for control circuit ) Accumulator 24 (For additional attachment low pressure, high pressure) 25 High-pressure piping clamp 26 Fuel spray prevention cap 27 Seat belt
4 - 14
MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" to confirm the correct maintenance schedule when carrying out maintenance.
4- 68
444444444444-
19 25 29 30 32 35 37 38 39 40 43 44
4- 47
4- 48 4- 50
4444444444-
51 52 53 55 57 58 60 62 63 64
4 - 15
. MAINTENANCE SCHEDULE
MAINTENANCE
EVERY 1000 HOURS MAINTENANCE REPLACE HYDRAULIC OIL FILTER ELEMENT CHANGE OIL IN SWING MACHINERY CASE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL REPLACE FULE MAIN FILTER CARTRIDGE CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS REPLACE CORROSION RESISTOR CARTRIDGE CHECK FAN BELT TENSION AND REPLACE FAN BELT CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER) EVERY 2000 HOURS MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE CLEAN HYDRAULIC TANK STRAINER CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) CHECK ALTERNATOR CHECK ENGINE VALVE CLEARANCE, ADJUST EVERY 4000 HOURS MAINTENANCE CHECK WATER PUMP CHECK VIBRATION DAMPER CHECK STARTING MOTOR REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER CHECK OPERATING CONDITION OF COMPRESSOR EVERY 5000 HOURS MAINTENANCE CHANGE OIL IN HYDRAULIC TANK EVERY 8000 HOURS MAINTENANCE REPLACE HIGH-PRESSURE PIPING CLAMP REPLACE FUEL SPRAY PREVENTION CAP
44444444-
65 66 67 68 70 70 70 70
4- 71 4- 72 4- 73 4- 77 4- 77
4444444-
78 78 78 79 80 80 81
4- 82
4- 83 4- 83
4 - 16
MAINTENANCE
MAINTENANCE SCHEDULE
4 - 17
. MAINTENANCE PROCEDURE
MAINTENANCE
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
Carry out the following maintenance only after the first 250 hours of operation on new machines. REPLACE FUEL PRE-FILTER CARTRIDGE For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS SERVICE.
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
Carry out the following maintenance only after the first 500 hours of operation on new machines. Replace fuel main filter cartridge For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE.
4 - 18
MAINTENANCE
MAINTENANCE PROCEDURE
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
WARNING
When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
NOTICE Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel light up. If the element is cleaned frequently before the air cleaner clogging monitor light up, the air cleaner will not be able to display its performance fully, and the cleaning efficiency will also go down. In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element. If inspection, cleaning, or maintenance is carried out with the engine running, dirt will enter the engine and cause damage to the engine. Always stop the engine before carrying out these operations.
Checking
If air cleaner clogging monitor (1) of the monitor panel flashes, clean the air cleaner element.
Replacing Replace element, O-ring If the element has been used for one year, or air cleaner clogging monitor (1) on the monitor panel lights up after the element has been cleaned, replace outer element (5), inner element (6), and O-ring (8). Replacing vacuator valve Replace vacuator valve (4) if it is damaged or if the rubber is markedly deformed.
4 - 19
. MAINTENANCE PROCEDURE
MAINTENANCE
NOTICE Never remove the inner element (6). It will allow dirt to enter and cause failure of the engine. Do not use a screwdriver or other tool. 2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out. 3. When the outer element (5) has been removed, check that the inner element has not come out of position and is not at an angle. If is is at an angle, insert your hand and push it in straight. 4. After removing the outer element (5), cover the inner element (6) with a clean cloth or tape to prevent dirt or dust from entering. 5. Wipe off or brush off the dirt stuck to cover (3) and the inside of the air cleaner body (7). 6. Remove any dirt or dust that is accumulated to evacuator valve (4) installed to cover (3). NOTICE When cleaning the element, do not hit or beat it against anything. 7. Direct dry compressed air (less than 0.69 MPa (7 kgf/cm2, 99.4 PSI)) to the outer element from inside along its folds, then direct it from outside along its folds and again from inside. 1) Replace the outer element which has been cleaned 6 times repeatedly or used throughout a year. Replace the inner element at the same time. 2) Replace both inner and outer elements when the air cleaner clogging monitor (1) lights up soon after installing the cleaned outer element even though it has not been cleaned 6 times.
4 - 20
MAINTENANCE
MAINTENANCE PROCEDURE
3) Remove one seal from the element whenever the element has been cleaned.
8. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element.
9. Remove the cloth or tape covering inner element (6). NOTICE Do not use an element whose folds or gasket or seal are damaged. If the element or O-ring are cleaned and used again after they have been used for more than one year, it will cause problems. Do not use them again. 10. Check that there is no dirt or oil stuck to the seal portion of the new element or cleaned element. Wipe off any dirt or oil. 11. Push the outer element in straight with your hand when installing it to the air cleaner body. If the outer element is held and rocked lightly up and down and to the left and right while pushing it in, the outer element can be inserted easily. NOTICE Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element cylinder (face where no hole is drilled) (B), (C) is at cover (3) end. If the direction of installation is mistaken, there is danger that it will cause breakage of the air cleaner element or serious damage to the engine.
4 - 21
. MAINTENANCE PROCEDURE
MAINTENANCE
NOTICE When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling. 12. Install cover (3) as follows. 1) Align cover (3) with the element. 2) Hook the tip of hook (2) to the protruding part of the air cleaner body and lock it in position. 3) When locking hooks (2) in position, apply the hooks in turn on opposite sides (top, bottom, left, right) in the same way as when tightening bolts. 4) Always install cover (3) so that the evacuator (4) is facing the ground (A). 5) When cover (3) is installed, check that the clearance between the air cleaner body and cover (3) is not too large. If it is too large, install again.
4 - 22
MAINTENANCE
MAINTENANCE PROCEDURE
Replacing Element
1. Open the rear door at the left side of the machine, remove 4 hooks (2), then remove cover (3).
2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out. Do not remove inner element (6) when doing this. 3. When the outer element (5) has been removed, check that the inner element has not come out of position and is not at an angle. If is is at an angle, insert your hand and push it in straight. 4. Wipe off or brush off the dirt stuck to cover (3) and the inside of the air cleaner body (7). 5. Remove any dirt or dust that is accumulated to evacuator valve (4) installed to cover (3).
NOTICE The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the same time. If the inner element is not installed properly and the outer element and cover are installed, there is danger that the outer element will be damaged. The seal portion on imitation parts lacks precision, and allows the entry of dust, which leads to damage of the engine. Do not use such imitation parts. 6. Remove inner element (6), then quickly install the new inner element. Insert the inner element securely so that it does not move. 7. Push the new outer element (5) in straight with your hand when installing it to the air cleaner body. If the element is held and rocked lightly up and down and to the left and right while pushing it in, the element can be inserted easily.
4 - 23
. MAINTENANCE PROCEDURE
MAINTENANCE
NOTICE Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element cylinder (face where no hole is drilled) (B), (C) is at cover (3) end. If the direction of installation is mistaken, there is danger that it will cause breakage of the air cleaner element or serious damage to the engine.
NOTICE When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling. 9. Install cover (3) as follows. 1) Align cover (3) with the element. 2) Hook the tip of hook (2) to the protruding part of the air cleaner body and lock it in position. 3) When locking hooks (2) in position, apply the hooks in turn on opposite sides (top, bottom, left, right) in the same way as when tightening bolts. 4) Always install cover (3) so that the evacuator (4) is facing the ground (A). 5) When cover (3) is installed, check that the clearance between the air cleaner body and cover (3) is not too large. If it is too large, install again.
10. Replace seal (9) on the cover (3) with a new seal.
4 - 24
MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it. When starting the engine while cleaning the machine, set the lock lever in the lock position to prevent the machine from moving. For details of starting the engine, see "BEFORE STARTING ENGINE (PAGE 3-111)" and "STARTING ENGINE (PAGE 3-128)" in the OPERATION section. There is danger of touching the fan if the undercover is left removed. Never enter behind the machine when the engine is running.
Stop the machine on level ground when cleaning or changing the coolant. Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below.
Antifreeze coolant Komatsu supercoolant (AF-NAC) Permanent type antifreeze (All-season type, *) Interval of cleaning inside of cooling system and changeing antifreeze coolant Every two years or every 4000 hours whichever comes first Every year (autumn) or every 2000 hours whichever comes first Replacing corrosion resistor unnecessary Every 1000 hours and when cleaning the inside of the cooling system and when changing coolant
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03. The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. When no corrosion resistor is used, use the special cover (600-411-9000). Please consult your Komatsu distributor about the method of installing.
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To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30% and 68%. When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10C (18F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100). The freezing temperature of undiluted antifreeze is -15C (5F). Do not store undiluted antifreeze at a temperature of below -15C (5F).
PC220, 220LC
Min. atmospheric temperature Amount of antifreeze Amount of water C F liter US gal liter US gal -10 14 6.1 1.61 14.3 3.78 30 -15 5 7.3 1.93 13.1 6.46 36 -20 -4 8.4 2.22 12.0 3.17 41 -25 -13 9.4 2.48 11.0 2.91 46 -30 -22 10.2 2.695 10.2 2.695 50 -35 -31 11.0 2.91 9.4 2.48 54 -40 -40 11.8 3.12 8.6 2.27 58
WARNING
Antifreeze is flammable, so keep it away from flame. Antifreeze is toxic. When open the drain valve, be careful not to get water containing antifreeze on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. When changing the coolant or draining the coolant from the radiator before carrying out repairs, ask a specialist company to handle any coolant containing antifreeze, or contact your Komatsu distributor. Antifreeze is toxic, so never pour it into drainage water ditches or drain it onto the ground surface.
Use antifreeze and appropriate water for diluting. (for details, see "COOLANT AND WATER FOR DILUTION (PAGE 4-5)") We recommend use of an antifreeze density gauge to control the mixing proportions. Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant. Prepare a hose to supply antifreeze coolant and water.
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1. Stop the machine on level ground, then stop the engine. 2. Tighten valve (1) of the corrosion resistor (only for machines equipped with a corrosion resistor).
3. Check that the cooling water temperature has gone down enough to make it possible to touch the radiator cap surface by hand, then turn radiator cap (2) slowly until it contacts the stopper to release the pressure. 4. Following this, push radiator cap (2), turn it until it contacts the stopper, then remove it.
5. Remove the undercover, then set the container under drain valve (3) to catch the coolant mixture. Open drain valve (3) at the bottom of the radiator and drain the coolant. 6. After draining the coolant, close drain valve (3), and fill with city water. When the radiator is full, start the engine and run at low idling to raise the temperature to at least 90C (194F), then continue to run for approx. 10 minutes. 7. Stop the engine and open drain valve (3) to drain the water. 8. After draining the water, clean the radiator with detergent. For the cleaning method, follow the instruction of detergent. 9. Close drain valve (3). 10. Replace the corrosion resistor, and open valve (1).(Only machines equipped with corrosion resistor) For details of replacement of the corrosion resistor cartridge, see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-70)". 11. Install the undercover. 12. Add coolant mixed with antifreeze until it overflows from the water filler. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze. 13. Run the engine at low idling for 5 minutes to remove the air from the water, then run at high idling for 5 minutes. (Leave radiator cap (2) removed when doing this.)
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14. Drain the coolant from sub-tank (4), clean the inside of the sub-tank, then add water until the coolant level is between the FULL and LOW marks. If the sub-tank is extremely dirty and it is difficult to clean, replace it with a new part. 15. Stop the engine, wait for approx. 3 minutes, add city water up to near the mouth of the filler port, then tighten radiator cap (2).
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Tightening
Triple shoe, swamp shoe, flat shoe, rubber pad shoe 1. First tighten to a tightening torque of 490 49 Nm (50 5 kgfm, 360 36 lbft) then check that the nut and shoe are in close contact with the link contact surface. 2. After checking, tighten a further 120 10. Road liner Tighten to a tightening torque of 550 60 Nm (56 6 kgfm, 405.0 43.4 lbft). After tightening, check that the nut and shoe are in close contact with the link contact surface.
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Checking
1. Run the engine at low idle, then move the machine forward for a distance equal to the track length on ground, and slowly stop the machine. 2. Put on the track shoe straight wooden bar (3) which stretches from idler (1) to upper carrier roller (2). 3. Measure the maximum deflection between bottom surface of the wooden bar and top surface of the track shoe. Deflection "a" should be 10 - 30 mm (0.4 - 1.2 in).
If the track tension is not at the standard value, adjust it in the following manner.
Adjustment
WARNING
There is danger of plug (1) flying out under the high internal pressure of the grease. Never loosen plug (1) more than 1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor.
Increasing Track Tension Prepare a grease pump. 1. Pump in grease through grease fitting (2) with a grease pump. (Grease fitting (2) forms one part with plug (1).) 2. To check if the tension is correct, run the engine at low idle, move the machine slowly forward (by an amount equal to the length of track on ground), then stop the machine. 3. Check the track tension again, and if the tension is not correct, adjust it again.
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4. Continue to pump in grease until dimension (S) becomes zero (0). If the tension is still loose, the pin and bushing are excessively worn, so they must be either turned or replaced. Please contact your Komatsu distributor for repairs.
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs.
1. Loosen plug (1) gradually to release the grease. 2. When loosening plug (1), turn it a maximum of one turn. 3. If the grease does not come out smoothly, move the machine forwards and backwards a short distance. 4. Tighten plug (1). 5. To check if the tension is correct, run the engine at low idle, move the machine slowly forward (by an amount equal to the length of track on ground), then stop the machine. 6. Check the track tension again, and if the tension is not correct, adjust it again.
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WARNING
It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out. Check that there is no one in the surrounding area. There is a hazard that fragments will fly during the replacement work, so always wear protective equipment like safety glasses and gloves.
1. To make it possible to knock out pin of tooth (1), put block (5) under the bottom of the bucket, and set so that the bottom surface of the bucket is horizontal.
2. Check that the work equipment is in a stable condition, then set the lock lever to the LOCK position (L).
3. Use a hammer and drift to knock out lock pin (2). (If the drift is set against rubber pin lock (3) when it is hit, the rubber pin lock may break. Set it against the back of the pin.) 4. After removing lock pin (2) and rubber pin lock (3), check them.
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If lock pin (2) and rubber pin lock (3) are used in the condition below, it will cause tooth (1) to come off during operation. Always replace them with new parts. The lock pin (2) is too short. Dimension (B) is 1/3 or more of dimension (A) when locking pin (2) is aligned with bottom face (C).
Rubber (6) of the rubber pin lock is cut and the steel ball is about to come out.
5. Clean the surface of adapter (4) and remove the soil with a knife. 6. Use your hand or a hammer to push rubber pin lock (3) into the hole of the adapter. When doing this, be careful that the rubber pin lock (3) does not fly out from the adapter surface.
7. Clean the inside of teeth (1), then install it to adapter (4). If there is mud affixed to it or if there are protrusions, the teeth (1) will not enter the adapter properly, and there will not be proper contact at the mating portion.
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8. Fit tooth (1) to adapter (4), and confirm that when the pointer is pressed strongly, the rear face of the hole for the pin of the teeth (1) is at the same level as the rear face of the hole for the pin of the adapter (4). If the rear face of the pin hole of tooth (1) protrudes in front of the rear face of the pin hole of adapter (4), do not knock the pin in. If this happens, there is something (C) preventing the tooth (1) from fitting completely in adapter (4), locate the problem and remove the obstruction. When tooth (1) fits completely in adapter (4), knock in lock pin (2). 9. Insert lock pin (2) in the pin hole in the tooth (1), and knock it in so that the top surface of lock pin (2) is the same height as the surface of tooth (1). 10. After replacing a bucket tooth, always check the following. 1) After the lock pin (2) has been knocked in completely, check that it is secured by the teeth (1) and surface. 2) Lightly hit lock pin (2) in the reverse direction from which it was hit in. 3) Lightly hit the tip of the teeth (1) from above and below, and hit its sides from right and left. 4) Confirm that rubber pin lock (3) and lock pin (2) are set as shown in the figure.
REMARK If the tooth is turned, the wear will become uniform. This will extend the service life of the tooth and reduce the frequency of replacement. When replacing the tooth, replace the rubber pin lock and lock pin with new parts at the same time. This will prevent the tooth from falling out.
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WARNING
It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out. Check that there is no one in the surrounding area. There is a hazard that fragments will fly during the replacement work, so always wear protective equipment like safety glasses and gloves.
1. To make it possible to knock out pin (1) of tooth (2), put block (5) under the bottom of the bucket, and set so that the bottom surface of the bucket is horizontal.
2. Check that the work equipment is in a stable condition, then set the lock lever to the LOCK position (L).
3. Place a bar on the head of pin (1), hit the bar with a hammer to knock out the pin, then remove tooth (2). REMARK If the bucket teeth cannot be safely removed by this mothod, have your Komatsu distributor replace the bucket teeth.
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4. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket.
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WARNING
It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance. Set the work equipment in a stable condition, stop the engine, then set safety lock lever securely to the LOCK position (L).
1. Set the work equipment in the position shown in the diagram on the right, then stop the engine and set the lock lever to the LOCK position (L). 2. Shift O-ring (1) and measure the amount of play "a". Measurement is easier if you move the bucket to one side so that all the play can be measured at one place (the right side in the diagram). Use a clearance gauge for easy and accurate measurement. 3. Loosen 4 plate mounting bolts (2), and loosen plate (3). The shim is a split type, so the operation can be carried out without removing the bolts. 4. Remove shim (4) corresponding to the amount of play "a" measured above.
[Example] In the case of play of 3 mm (0.118 in), remove two 1.0 mm (0.039 in) shims and one 0.5 mm (0.020 in) shim. Play becomes 0.5 mm (0.020 in). For shim (4), two types of 1.0 mm (0.039 in) and 0.5 mm (0.020 in) are used. When play "a" is smaller than one shim, do not carry out any maintenance. 5. Tighten the four bolts (2). If the bolts (2) are too stiff to tighten, pull out pin stopper bolt (5) for easier tightening.
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When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
Area, season Normal Winter in cold area Winter in extremely cold area Proportions Washer fluid 1/3: water 2/3 Washer fluid 1/2 : water 1/2 Pure washer fluid Freezing temperature -10C (14F) -20C (-4F) -30C (-22F)
There are two types depending on the freezing temperature: -10C (14F) (general use) and -30C (-22F) (cold area use), select according to the area and season.
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WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.
If the refrigerant (gas) level is low, the cooling effect will become poor. When the engine is running at full throttle and the cooler is running at high speed, look at the sight glass (1) (inspection window) in the refrigerant hose mouthpiece to check the condition of the refrigerant gas (Freon 134a) flowing in the refrigerant circuit. (A) No bubbles in refrigerant flow: Suitable (B) Some bubbles in flow (bubbles pass continuously): Lack of refrigerant (C) Colorless, transparent: No refrigerant
REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
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WARNING
When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation. If the control levers are touched by mistake, the machine may suddenly move, and this may lead to a serious accident. Always set the lock lever securely to the LOCK position before standing up from the operator's seat.
NOTICE When carrying out this operation, be careful not to get water on the monitor and connectors inside the operator's cab. Never spray water above the pedestal of the operator's seat (2). If any water splashes on the surrounding equipment, be sure to wipe it off.
With the washable floor, it is possible to flush out the dirt on the cab floor directly with water.
Method of Washing
1. Set the machine at an angle. For details, see "Method of Setting Machine at Angle (PAGE 4-42)" 2. Swing the upper structure slowly so that water drain holes (3) in the cab floor are at a low position.
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3. Lower the work equipment to the ground and set the machine in a stable condition.
4. Set lock lever (1) to LOCK position (L) and stop the engine.
5. Remove the floor mat holder plate (4). 6. Pull the knob of floor mat holder clip (5) and remove clip (5). 7. Remove the floor mat. 8. Remove the cap from water drain hole (3). 9. Flush out the dirt on the floor directly with water through water drain hole (3). 10. After completing the washing operation, install the cap in water drain hole (3). 11. Fit the floor mat, then secure it with floor mat holder plate (4). 12. Secure the floor mat in position with the floor mat holder clip (5).
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WARNING
Select a solid and smooth slope. Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground.
1. Stop the machine so that the work equipment is on the downhill side. 2. Put blocks under the track and dig the work equipment into the ground.
WARNING
Select a firm flat place. Put strong blocks under the undercarriage to stabilize the machine and be extremely careful when carrying out the operation.
1. Raise the chassis with the boom and arm. When doing this, operate the levers slowly. 2. Insert block (5) under the raised track to make the machine stable.
3. Raise the boom slowly and lower the machine. When doing this, check that the machine is always stable.
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WARNING
The gas spring is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to serious injury or damage. When handling the gas spring, always do as follows. Do not disassemble the accumulator. Do not bring it near flame or dispose of it in fire. Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
The gas springs are located at the engine hood (left, right: two places) and the cab roof (left, right: two places). In the following cases, please ask your Komatsu distributor to carry out inspection, repair, and replacement. When the engine hood or cab ro of window cannot be opened with light effort. When the engine hood or cab roof window do not stay open. When oil or gas is found to be leaking from the gas spring.
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NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. When replacing the travel motor safety valve, please contact your Komatsu distributor to have it replaced and to have the air bled. 5. Bleeding air from travel motor (Bleed the air only when the oil inside the travel motor case has been drained.) 1) Run the engine at low idling, loosen air bleeder (4), and tighten it when oil flows out.
2) Run the engine at low idle and swing the work equipment 90 to bring it to the side of the track. 3) Jack up the machine until the track is raised slightly from the ground.Rotate the track under no load for 2 minutes. Repeat this procedure on both the left and right sides, and rotate the track equally both forward and in reverse.
6. Bleeding air from attachment (when installed) If a breaker or other attachment has been installed, run the engine at low idle and operate the attachment pedal repeatedly (approx. 10 times) until the air has been bled from the attachment circuit. NOTICE If the method of bleeding the air from the attachment itself is specified by the manufacturer, bleed the air according to the specified procedure. After completing the air bleeding operation, stop the engine, and leave the machine for 5 minutes before starting operations. This will remove the air bubbles in the oil inside the hydraulic cylinders. Check that there is no leakage of oil and wipe off any oil that has been spilled. After completing the air bleeding operation, inspect the oil level, and if the oil level is low, add oil.
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(1) Arm-Link coupling pin (1 place) (2) Arm-Bucket coupling pin (1 place)
(3) Link coupling pin (2 places) (4) Bucket cylinder rod pin (1 place) (5) Bucket-Link coupling pin (1 place)
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WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
NOTICE When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts. When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below. Open cover (1) at the rear left side of the machine. The batteries are installed at (A) part.
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2. If the electrolyte level is below the midway point between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines, remove cap (2) and add distilled water to the U.L. line. 3. After adding distilled water, tighten cap (2) securely. REMARK If distilled water is added to above the UPPER LEVEL (U.L.) line, use a syringe to lower the level to the UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.
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Adjustment
1. Loosen bolts (1) and (2). Compressor (3) is installed to bracket (4), so when bolts (1) and (2) are loosened, it becomes possible to move bracket (4) with the mounting position of bolt (2) as the fulcrum.
2. Loosen bolt (1) and bolts (2), then move compressor (3) to adjust. 3. When the position of the compressor is determined, tighten bolts (1) and (2) to hold it in position.
NOTICE Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones. The fan belt has elongated, leaving little allowance for adjustment. A cut or crack is found on the belt. Slipping or creaking sound is heard coming from the belt. When the new V-belt is set, readjust it after one hour of operation.
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LUBRICATING
NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval. Carry out greasing every 10 hours for the first 50 hours on a new machine. Carry out the greasing also at 250 hours and 500 hours on a new machine. After the machine was subjected to jobs in the water, be sure to grease the wet pins. When carrying out heavy-duty operations, such as hydraulic breaker operations, carry out the greasing every 100 hours. 1. Set the machine to the greasing posture shown on the right, lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out.
(2) Boom foot pin (2 places) (3) Boom cylinder rod end pin (2 places) (4) Arm cylinder foot pin (1 place)
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(5) Boom - Arm coupling pin (1 place) (6) Arm cylinder rod end (1 place) (7) Bucket cylinder foot pin (1 place)
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CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
Refill capacity of oil pan: 23.1 liters (6.10 US gal) Prepare a filter wrench 1. Remove the undercover directly under the engine at the bottom of the machine, then set a container in position to catch the drained oil. 2. To prevent getting oil on yourself, lower the lever of drain valve (P) slowly, drain the oil, then raise the lever to close the valve.
3. Open the cover at the rear right, then use a filter wrench to turn filter cartridge (1) to the left to remove it.
4. Clean filter holder (2), fill the new filter cartridge with clean engine oil, coat the thread and packing surface of the new filter cartridge with clean engine oil (or coat it thinly with grease), then install it to the filter holder. REMARK Check that there is no old packing stuck to filter holder (2). If there is any old packing stuck to the filter, it will cause leakage of oil. 5. When installing, tighten until the packing surface contacts the seal surface of filter holder (2), then tighten it a further 3/4 to 1 turn.
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6. After replacing the filter cartridge, open the engine hood and add engine oil through oil filler (F) to between the H and L marks on dipstick (G). 7. Run the engine at idle for a short time, then stop the engine, and check that the oil level is between the H and L marks on the dipstick. For details, see "Check Oil Level in Engine Oil Pan, Add Oil (PAGE 3-117)". 8. Install the undercover.
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WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts to cool down before starting the operation. High pressure is generated inside the engine fuel piping system when the engine is running. When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter. Do not bring any fire or flame close.
NOTICE Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Komatsu part. The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts. When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.
2. Open the cover on the right side of the machine. 3. Set the container to catch the fuel under the pre-filter cartridge. 4. Loosen drain valve (2), then drain all the water and sediment in the transparent cap (3) and also the fuel accumulated in filter cartridge (4). 5. Remove connector (5). Wrap the removed connector in a vinyl bag to prevent water from getting on it. 6. Using a filter wrench, turn transparent cap (3) to the left to remove it. (This cap is used again.) 7. Using a filter wrench, turn cartridge (4) to the left to remove it. 8. Install transparent cap (3) to the bottom of the new filter cartridge. (When doing this, always replace O-ring (6).) 9. When installing, apply oil to the packing surface and bring the packing surface into contact with the seal surface of filter cartridge (4) and then tighten it further by 1/4 - 1/2 turns. If the transparent cap is tightened too much, the O-ring will be damaged and this will cause leakage of fuel; if it is not tightened enough, fuel will leak through the gap at the O-ring. To prevent these problems, always tighten securely to the fixed tightening angle.
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10. Clean the filter holder, fill the new filter cartridge with clean fuel, coat the packing surface thinly with oil, then install to the filter holder. NOTICE When adding fuel, do not remove cap (B). Always add fuel from the 8 small holes (A) on the dirty side. After adding fuel, remove cap (B) and install the fuel filter. Always fill with clean fuel. Be careful not to let any dirt or dust get into the fuel. In particular, center portion is the clean side, so do not remove cap (B) when adding fuel. Be careful not to let dirt or dust get into center portion on the clean side.
11. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount. When tightening with a filter wrench, be extremely careful not to dent or damage the filter. Check that the drain valve (2) is tightened securely. 12. 13. Remove the vinyl bag covering connector (5), then connect connector (5). REMARK If water gets on the connector (5), the sensor may malfunction and the water separator monitor may light up. When removing connector (5), be extremely careful not to let water get on the connector. If water gets on connector (5), dry it completely before connecting it.
14. Turn the valve (1) at the bottom of the fuel tank to the OPEN position (O). 15. After completing the replacement of filter cartridge (4), bleed the air.
Bleed the air as follows: 16. Fill the fuel tank with fuel (to the position where the float is at the highest position). 17. Loosen the knob of feed pump (7), pull it out, then pump it in and out until the movement becomes heavy.
REMARK It is not necessary to remove the plug at the top of the fuel pre-filter and fuel main filter. After the engine runs out of fuel, use the same procedure to operate feed pump (7) and bleed the air. 18. After finishing to bleed air, push in the knob of feed pump (7) and tighten it. 19. After replacing the filter cartridge, start the engine and run it at low idling for 10 minutes. Check for leakage of oil from the filter seal surface and tranparent cap mounting. If any oil is leaking, check the tightening of the filter cartridge. If there is still oil leakage, repeat Steps 1 - 7 to remove the filter cartridge, and if any damage or embedded foreign material in the packing surface is found, replace it with a new cartridge and repeat Steps 8 - 19 to install it.
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MAINTENANCE
MAINTENANCE PROCEDURE
2. Insert scale (3) into the grease through inspection and adjustment hole (A). Check that the height of grease (S) in the area passing the pinion is at least 9 mm (0.355 in). Add grease if the level is low. 3. Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Please contact your Komatsu distributor.
Total amount of grease PC200: 14.6 liters (3.86 US gal) PC220: 15.8 liters (4.17 US gal)
4. Install cover (2) with bolts (1).
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. MAINTENANCE PROCEDURE
MAINTENANCE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner)
WARNING
If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment.
NOTICE When using compressed air for cleaning, blow it keeping some distance to avoid damaging the fins. Damage on the fins can cause water leakage and overheating. In a dusty job site, check the fins every day, regardless of the maintenance interval. 1. Open engine hood (1).
2. Loosen screw (3) and pull up net (2). 3. After pulling up net (2), clean it. (Install it again in Step 7.) 4. Check the front and rear surfaces of oil cooler fins (4), radiator fins (5), aftercooler fins (6), Air conditioner condenser fins (7), and fuel cooler fins (8). If there is any mud, dirt, or leaves stuck to the fins, blow the dirt off with compressed air. Steam or water may be used instead of compressed air. However, when carrying out powerful steam cleaning (high-pressure machine wash) of the heat exchange equipment (radiator, oil cooler, aftercooler, fuel cooler, air conditioner condenser), maintain sufficient distance from the machine when carrying out the operation. If steam cleaning (high-pressure machine wash) is carried out at close range, there is danger that the internal fins of the heat exchange equipment may be deformed, and this will cause early clogging and breakage. 5. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by aging. In addition, check the hose clamps for looseness.
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MAINTENANCE
MAINTENANCE PROCEDURE
6. Remove undercover (9) and blow the mud, dirt, and leaves that have been cleaned off to the outside. 7. Push in cleaned net (2) back to the original place and secure it with screw (3).
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. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear protective glasses, dust mask, and other protective equipment.
NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. REMARK If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner unit.
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MAINTENANCE
MAINTENANCE PROCEDURE
REMARK The FRESH filter must be installed facing in the correct direction. When installing, insert the long (L) end of filter (3) into the filter case first. If the short (S) end is installed first, cover (2) will not
4 - 61
. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Remove the cap of oil filler (F) at the top of the hydraulic tank.
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MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
1. Remove dipstick (G) and wipe the oil from the dipstick with a cloth. 2. Fully insert dipstick (G) into the filler pipe. 3. Pull out dipstick (G) and check that the oil level is between the (H) and (L) marks on the dipstick. 4. If the oil does not reach the (L) mark on dipstick (G), remove the cap of oil filler port (F) and add oil. Remove dipstick (G) when adding oil. 5. If the oil level is above the (H) mark on dipstick (G), loosen drain valve (P) and drain the excess oil. Set a container to catch the oil under drain valve (B) before draining the oil. 6. After checking oil level or adding oil, insert the dipstick (G) into the hole and install oil filler (F) cap.
4 - 63
. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure. Please do not stand in front of the plug when you loosen the plug.
Prepare a handle. 1. Set the TOP mark at the top, with the UP mark and plug (P) perpendicular to the ground surface. 2. Remove plug (F) using the handle. When the oil level reaches a point 10 mm (0.4 in) below the bottom of the plug hole, the correct amount of oil has been added. 3. If the oil level is too low, install plug (F), operate the travel levers, and drive forward or in reverse to rotate the sprocket one turn. Then repeat Step 2 to check again. 4. If the oil level is low, add oil through the hole of plug (F). Add oil until oil overflows from the hole of plug (F). 5. After checking, install plug (F). Tightening torque for plugs (F): 68.6 9.8 Nm (7 1 kgfm, 50.6 7.2 lbft)
REMARK There are two plugs (F). Add oil through the one easier to fill oil and through which no internal gears are to be seen.
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MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
NOTICE If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than during normal bucket operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" when carrying out maintenance. 1. Set the work equipment on the hard and flat ground in the maintenance posture as shown in the figure, then lower it to the ground and stop the engine.
2. Remove the cap from oil filler (F), and release the internal pressure. 3. Loosen 6 bolts, then remove cover (1). When doing this, the cover may fly out under the force of spring (2), so hold the cover down when removing the bolts. 4. After removing spring (2), valve (3) and strainer (4), take out element (5). Inspect the bottom of the filter case for dirt, and remove it, if any. Take good care then not to let fall the dirt into the hydraulic tank. 5. Clean the removed parts in flushing oil. 6. Install the new element in the place where old element (5) was installed. 7. Set valve (3), strainer (4) and spring (2) on top of the element. 8. Set cover (1) in position, push it down by hand, and install the cover with the mouning bolts. 9. Screw in the oil filler cap and install the cover. 10. To bleed the air, start the engine according to "STARTING ENGINE (PAGE 3-128)" and run the engine at low idle for 10 minutes. 11. Stop the engine.
4 - 65
. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
Refill capacity PC200: 7.1 liters (1.88 US gal) PC220: 8.2 liters (2.17 US gal)
1. Remove cover (A) of the inspection hole.
2. Set a container under drain valve (P) under the machine body to catch the oil. 3. Loosen drain valve (P) under the body, drain the oil, then tighten the drain valve again. REMARK If the oil forms thin threads, there is no problem in stopping the draining operation. In low temperatures, swing the work equipment to raise the oil temperature slightly before starting the operation to drain the oil. However, never swing the work equipment during the draining operation. This will cause breakage of the swing 4. Remove the cap of oil filler (F), then add the replacement amount of oil through oil filler (F). 5. Check the oil level. For details, see "CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL (PAGE 4-63)".
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MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
NOTICE Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the oil level. 1. Open the cover on the right side of the machine. 2. Remove plug (G) and check the oil level. if the oil level is near the bottom of the plug hole, the oil amount is at a proper level. If found short, remove plug (F) and replenish oil through plug (F) filler port up to the bottom of plug (G) hole. NOTICE If excess oil is supplied, drain it to the specified amount to avoid overheating. 3. Install plugs (G) and (F). 4. Close the door.
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. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts to cool down before starting the operation. High pressure is generated inside the engine fuel piping system when the engine is running. When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter. Do not bring any fire or flame close.
NOTICE Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Komatsu part. The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts. When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.
2. Open the engine hood. 3. Set the container to catch the fuel under the filter cartridge. 4. Using a filter wrench, turn filter cartridge (2) counterclockwise to remove it. 5. Clean the filter holder, coat the packing surface of the new filter cartridge thinly with oil, then install the filter cartridge to the filter holder.
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MAINTENANCE
MAINTENANCE PROCEDURE
NOTICE Do not fill the new filter cartridge with fuel. Remove cap (B) and install the filter cartridge.
6. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount. 7. Turn the valve (1) at the bottom of the fuel tank to the OPEN position (O). 8. After completing the replacement of filter cartridge (2), bleed the air.
Bleed the air as follows: 9. Fill the fuel tank with fuel (to the position where the float is at the highest position). 10. Loosen the knob of feed pump (4), pull it out, then pump it in and out until the movement becomes heavy.
REMARK It is not necessary to remove the plug at the top of the fuel pre-filter and fuel main filter. After the engine runs out of fuel, use the same procedure to operate feed pump (4) and bleed the air. 11. Push in the knob of feed pump (4) and tighten it. 12. After replacing the filter cartridge, start the engine and run it at low idling for 10 minutes. Check for leakage of oil from the filter seal surface. If any oil is leaking, check the tightening of the filter cartridge. If there is still oil leakage, repeat Steps 1 - 4 to remove the filter cartridge, and if any damage or embedded foreign material in the packing surface is found, replace it with a new cartridge and repeat Steps 5 - 12 to install
4 - 69
. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
1. Screw in valve (1) at the top of the corrosion resistor. 2. Using a filter wrench, turn cartridge (2) to the left to remove it. 3. Install a new filter cartridge after coating oil on its sealing face. In the installation, turn the cartridge by two-thirds of one turn after the packing surface comes to contact with the sealing face of the cartridge stand. A genuine Komatsu filter cartridge is recommended for use. 4. Open valve (1). 5. Run the engine and check that there is no leakage of water from the seal surface.
4 - 70
MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
Immediately after the engine is stopped, the oil and parts are at high temperature. For this reason, if you touch the oil or parts immediately after the engine is stopped, you will suffer burns. Wait for the temperature to go down before starting the operation. If there is pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure. To avoid danger, do not stand directly in front of the plug.
Refill capacity PC200 (each): 3.3 liters (0.87 US gal) PC220 (each): 5.2 liters (1.37 US gal) Prepare a handle.
1. Set the TOP mark at the top, with the TOP mark and plug (P) perpendicular to the ground surface. 2. Set a container under plug (P) to catch the oil. 3. Remove plugs (P) and (F) with the handle and drain the oil. REMARK Check the O-rings in the plugs for damage. If necessary, replace with new ones. 4. Tighten plug (P). 5. Add oil through the hole of plug (F). 6. When oil begins to overflow from the plug (F) hole, install plug (F). Tightening torque of plugs (P) and (F): 68.6 9.8 Nm (7 1 kgfm, 50.6 7.2 lbft) REMARK There are two plugs (F). Add oil through the one easier to fill oil and through which no internal gears are to be seen.
4 - 71
. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Remove the cap from oil filler (F), and release the internal pressure. 2. Loosen 6 bolts, then remove cover (1). When doing this, the cover may fly out under the force of spring (2), so push the cover down when removing the bolts. 3. Hold the top of rod (3) and pull up to remove spring (2) and strainer (4). 4. Remove all the dirt stuck to strainer (4), then wash it in flushing oil. If strainer (4) is damaged, replace it with a new part. 5. When installing, insert strainer (4) into protruding part (5) of the tank, and assemble. 6. Assemble so that the protruding part at the bottom of cover (1) holds spring (2), then tighten with the bolt.
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MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to serious injury or damage. When handling the accumulator, always do as follows. The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition, loosen the bolts slowly when carrying out the operation. Do not disassemble the accumulator. Do not bring it near flame or dispose of it in fire. Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the machine.
FUNCTION OF ACCUMULATOR
The accumulator stores the pressure in the control circuit. Even after the engine is stopped, the control circuit can be operated, so the following actions are possible. If the control lever is operated in the direction to lower the work equipment, it is possible for the work equipment to go down under its own weight. The pressure in the hydraulic circuit can be released. The accumulator is installed to the position shown in the diagram on the right.
4 - 73
. MAINTENANCE PROCEDURE
MAINTENANCE
CAUTION
When carrying out the inspection, check first that there is no person or obstacle in the surrounding area.
Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm, level ground. 2. Hold the work equipment in the maximum reach posture (arm fully out, bucket fully dumped) at a height (A) 1.5 m (4 ft 11 in) from the ground.
Carry out Steps 3 - 5 within 15 seconds. When the engine is stopped, the pressure in the accumulator gradually goes down. For this reason, the check can only be carried out immediately after the engine is stopped.
3. Keep the work equipment at the maximum reach, turn the starting switch to the OFF position (A), and stop the engine.
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MAINTENANCE
MAINTENANCE PROCEDURE
5. With the lock lever at the FREE position (F), operate the work equipment control levers fully in the LOWER direction and check that the work equipment is lowered to the ground.
6. If the work equipment goes down under its weight and contacts the ground, the accumulator is normal. If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulator for the hydraulic circuit has probably dropped. Please contact your Komatsu distributor for inspection.
7. This completes the inspection. After completion of the inspection, set the lock lever to the LOCK position and turn the starting switch to the OFF position.
4 - 75
. MAINTENANCE PROCEDURE
MAINTENANCE
Carry out Steps 4 - 6 within 15 seconds. When the engine is stopped, the pressure in the accumulator gradually goes down. For this reason, the release can only be carried out immediately after the engine is stopped.
4. Stop the engine. 5. Turn the starting switch to the ON position (B).
6. Set lock lever to FREE position (F), then operate the work equipment control levers and the attachment control pedal (if equipped) fully to the front, rear, left, and right to release the pressure in the control circuit.
7. Set the lock lever to the LOCK position, then turn the starting switch to the OFF position. 8. Insert the lock pin in position (a) so that the attachment control pedal cannot be operated. (If equipped)
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MAINTENANCE
MAINTENANCE PROCEDURE
CHECK ALTERNATOR
Contact your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection carried out every 1000 hours.
4 - 77
. MAINTENANCE PROCEDURE
MAINTENANCE
4 - 78
MAINTENANCE
MAINTENANCE PROCEDURE
WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to serious injury or damage. When handling the accumulator, always do as follows. The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition, loosen the bolts slowly when carrying out the operation. Do not disassemble the accumulator. Do not bring it near flame or dispose of it in fire. Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
If operations are continued after the performance of the accumulator has dropped, it will be impossible to release the remaining pressure in the hydraulic circuit if there should be a failure on the machine. Please ask your Komatsu distributor to replace the accumulator. The accumulator is installed to the position shown in the diagram on the right.
4 - 79
. MAINTENANCE PROCEDURE
MAINTENANCE
Check visually and touch by hand to check that there is no hardening of the rubber and no loose bolts of the mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail. If there are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out replacement.
The fuel spray prevention caps (14 places) on the fuel injection piping and both ends of the high-pressure piping act to prevent the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the fuel should leak or spray out. Check visually and touch by hand to check that there are no missing caps, loose bolts or hardening of the rubber. If there are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out replacement.
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MAINTENANCE
MAINTENANCE PROCEDURE
4 - 81
. MAINTENANCE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
NOTICE If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than during normal bucket operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" when carrying out maintenance.
Refill capacity: 135 liters (35.67 US gal) Prepare a handle (for the socket wrench). 1. Swing so that the drain plug at the bottom of the hydraulic tank is in the middle between the left and right tracks. 2. Retract the arm and bucket cylinders, then lower the boom and put the teeth in contact with the ground. 3. Set the lock lever to the LOCK position and stop the engine.
4. Remove the cap of oil filler port (F) at the top of the hydraulic tank. 5. Set a container directly under the drain plug under the machine to catch the oil that is drained. Remove drain plug (P) and drain the oil. Check that the O-ring installed to plug (P) is not damaged. If it is damaged, replace the O-ring. After draining the oil, tighten drain plug (P). The specified tightening torque is 68.6 9.81 Nm (7 1 kgfm, 50.6 7.2 lbft) Take care not to get oil on yourself when you remove drain plug (P). 6. Fill with the specified amount of oil through oil filler port (F). Check that the oil level is between the H - L lines on the sight gauge. For details of the suitable oil, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-9)".
For details of the method of checking the oil level, see "Check Oil Level in Hydraulic Tank, Add Oil (PAGE 3-115)". 7. Bleed the air from the hydraulic circuit. For details of the method of bleeding the air from the hydraulic circuit, see "BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE 4-44)".
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MAINTENANCE
MAINTENANCE PROCEDURE
4 - 83
5-1
. SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
Item Operating weight Bucket capacity Name of engine Engine horsepower A Overall length B Overall height C Overall width D Track width E Height of cab F Radius of upper structure G Length of track H Tumbler center distance Min. ground clearance Travel speed (Lo/Mi/Hi) Swing speed Unit kg (lb) m3 (cu.yd) kW (HP)/rpm mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) km/h (MPH) rpm 2,750 (9' 0") 4,070 (13' 4") 440 (1' 5") 12.4 PC200-8 19,500 (42,998) PC200LC-8 20,900 (46,085) PC220-8 22,900 (50,495) PC220LC-8 24,330 (53,648)
0.8 (1.05) 110 (148)/2,000 2,970 (9' 9") 2,800 (9' 2") 600 (1' 12") 2,970 (9' 9") 3,080 (10' 1") 700 (2' 4") 2,750 (9' 0")
1.0 (1.3) 125 (168)/2,000 9,885 (32' 5") 3,185 (10' 5") 3,280 (10' 9") 700 (2' 4") 2,940 (9' 8") 3,845 (12' 7") 440 (1' 5") 11.7 3,185 (10' 5") 2,980 (9' 9") 600 (1' 12") 2,940 (9' 8")
KOMATSU SAA6D107E-1 diesel engine 9,425 (30' 11") 9,425 (30' 11") 9,885 (32' 5")
3,040 (9' 12") 4,450 (14' 7") 4,260 (13' 12") 4,640 (15' 3") 440 (1' 5") 440 (1' 5")
3,275 (10' 9") 3,655 (11' 12") 3,460 (11' 4") 3.0/4.1/5.5 (1.9/2.5/3.4)
3.1/4.2/5.3 (1.9/2.6/3.3)
5-2
SPECIFICATIONS
SPECIFICATIONS
Working ranges A Max. digging reach B Max. digging depth C Max. digging height D Max. vertical wall depth E Max. dumping height F Min. dumping height G Max. digging reached at ground level
Unit mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in)
PC200-8 9,875 (32' 5") 6,620 (21' 9") 5,980 (19' 7") 7,110 (23' 4") 2,645 (8' 8")
PC200LC-8 9,875 (32' 5") 6,620 (21' 9") 5,980 (19' 7") 7,110 (23' 4") 2,645 (8' 8")
PC220-8
PC220LC-8
10,180 (33' 5") 10,180 (33' 5") 6,920 (22' 8") 6,010 (19' 9") 7,035 (23' 1") 2,530 (8' 4") 6,920 (22' 8") 6,010 (19' 9") 7,035 (23' 1") 2,530 (8' 4")
mm (ft in) 10,000 (32' 10") 10,000 (32' 10") 10,000 (32' 10") 10,000 (32' 10")
mm (ft in) 9,700 (31' 10") 9,700 (31' 10") 9,700 (31' 10") 9,700 (31' 10")
5-3
6-1
6-2
PROHIBITED OPERATIONS
Operations with Care
During lifting operations, reduce the engine speed and carry out the operation in L mode. Depending on the posture of the work equipment, there is the danger that the wire or load may slip off the hook. Always be careful to maintain the correct hook angle to prevent this from happening. Never travel the machine while lifting a load. If the bucket with hook is turned and used for operations, it will hit the arm during dumping operations, be careful when using it. If you are planning to newly install a hook, contact your Komatsu distributor.
6-3
Breaker circuit additional oil filter Accumulator(for low pressure) Accumulator(for high pressure: if equipped)
Stop Valve
This valve (1) stops the flow of the hydraulic oil. (a) FREE: Hydraulic oil flows. (b) LOCK: Hydraulic oil stops. When removing or installing attachments, set this valve to the LOCK position.
6-4
Selector Valve
This valve (2) switches the flow of 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. For details of switching the working mode, see "HYDRAULIC CIRCUIT (PAGE 6-8)".
NOTICE If a service circuit from the attachment maker has been added, the return circuit may not switch automatically.
WARNING
Do not carry out operations with your foot on the pedal. If the pedal is depressed by mistake, the attachment may suddenly move and cause a serious accident. Lock the pedal with the lock pin when you are not operating the attachment.
This pedal (3) is used to control the attachment. When the front, center (neutral), and rear of the pedal are depressed, the movement of the attachment is as follows. Hydraulic breaker Front of pedal (A): Actuated Center of pedal (N): Stopped Rear of pedal (B): Stopped Regarding other attachments, hold a meeting with the attachment maker at the time of installation to confirm the operation of the pedal and attachment before using it.
6-5
Lock Pin
This pin (4) locks the control pedal. Position (a): Locked Position (b): Only front of pedal can be operated to full position (rear is locked) Position (c): Both front and rear of pedal can be operated to full position When not using the attachment, set the lock pin to position (a). When using the breaker, use the working mode selector switch on the monitor switch portion to set the working mode to B mode, and set the lock pin to position (b) when using the pedal. 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 When using the breaker, if the lock pin is set to position (c) and the pedal is operated in direction (D), it will cause damage or defective operation of the breaker. To prevent this, when using the breaker, always set the lock pin to position (b). Before changing the position of the lock pin, stop the engine.
6-6
Accumulator
WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to serious injury or damage. When handling the accumulator, always do as follows. The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition, loosen the bolts slowly when carrying out the operation. Do not disassemble the accumulator. Do not bring it near flame or dispose of it in fire. Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
These accumulators (6) and (7) are installed to reduce the peak pressure in the hydraulic circuit when the breaker is being used. Normally, do not touch them.
NOTICE On machines equipped with a breaker, it is necessary to install an accumulator to the breaker piping to match the model number of the breaker manufacturer. If no accumulator is installed and the breaker is operated, the service life of the machine will be reduced. For questions about the breaker, please contact your Komatsu distributor. If the pressure of the nitrogen gas charging the accumulator drops, it will be impossible to release the remaining pressure in the control circuit after the engine is stopped. In addition, if operations are continued with the nitrogen gas at low pressure, it will cause damage to the hydraulic circuit or machine. Check the nitrogen charge pressure periodically.
For details, see "CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker) (PAGE 4-70)" or "CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) (PAGE 4-73)".
6-7
HYDRAULIC CIRCUIT
NOTICE The return circuit when a breaker is installed must return directly to the return filter, so do not use it except in B mode. The standard set pressure for the safety valve in the service valve is set when the machine is shipped from the factory. When B mode is selected, it is set to 20.6 MPa (210 kgf/cm2, 2980 PSI); when ATT mode is selected, it is set to 27.4 MPa (280 kgf/cm 2 , 3980 PSI). Depending on the attachment, adjustment may be necessary. In such a case, please ask your Komatsu distributor to carry out the adjustment.
ATT mode
6-8
When setting the FREE or LOCK position of the stop valve rotor, remove bolt (2), turn over plate (1), then turn the rotor. After setting, install plate (1) again with bolt (2).
2. Remove plug (3) at the tip of the stop valve piping. (Left and right, 2 places) Be careful not to lose or damage the removed parts.
3. After removing plug (3), connect the attachment piping (4) is provided by the attachment manufacturer. For the mouthpiece size and accumulator add-on, the action to take differs according to the attachment manufacturer, so please consult your Komatsu distributor.
6-9
When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the rear of the pedal is depressed, oil flows to the piping on the right side of the work equipment. (When a breaker is installed, only the front of the pedal can be used.)
6 - 10
WARNING
Immediately after operating the engine, all parts still retain high temperature. Never replace the filter in such condition. Replace it only after each part has sufficiently cooled.
NOTICE For details of the replacement interval for the element, "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)".
Prepare a container to catch the oil. 1. Lower the work equipment to the ground and stop the engine.
2. Turn the starting switch to the ON position (B), then set the lock lever to the FREE position (F). 3. After carrying out Step 2, operate each work equipment control lever and attachment control pedal fully to the front, rear, left, and right 2 or 3 times within 15 seconds to release the internal pressure in the hydraulic circuit.
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5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit.
6. Place a container under the filter element to catch the oil. 7. Set a container in position to catch the drained oil, then remove plug (3) and drain the oil accumulated in filter case (1). 8. After checking that the hydraulic oil temperature has gone down, turn filter case (1) to the left, remove it, then take out element (2). 9. Clean the removed parts, then install new element (2). Element (2) must be installed facing in the correct direction. Set direction Y with the holes in it facing up, and insert the hole in element (2) on the protruding portion inside filter head (6). 10. Install new O-ring (4) to filter case (1), then screw filter case (1) into filter head (6). When the top of filter case (1) comes into contact with the filter head, tighten it at least a further 1/2 turns. 11. Clean plug (3), then fit a new O-ring (5) to plug (3). 12. Install plug (3) to filter case (1). Tightening torque: 27.4 - 58.8 Nm (2.8 - 6.0 kgfm, 20.3 - 43.4 lbft)
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WARNING
Immediately after operating the engine, all parts still retain high temperature. Never replace the filter in such condition. Replace it only after each part has sufficiently cooled.
NOTICE For details of the replacement interval for the element, "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)".
Prepare a container to catch the oil. 1. Lower the work equipment to the ground and stop the engine.
2. Turn the starting switch to the ON position (B), then set the lock lever to the FREE position (F). 3. After carrying out Step 2, operate each work equipment control lever and attachment control pedal fully to the front, rear, left, and right 2 or 3 times within 15 seconds to release the internal pressure in the hydraulic circuit.
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5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit.
6. Place a container under the filter element to catch the oil. 7. After checking that the hydraulic oil temperature has gone down, turn filter case (1) to the left, remove it, then take out element (2). 8. Clean the removed parts, then install new element (2). Element (2) must be installed facing in the correct direction. Set direction Y with the holes in it facing up, and insert the hole in element (2) on the protruding portion inside filter head (6). 9. Install new O-ring (3) to filter case (1), then tighten filter case (1) to a tightening torque of 25 - 35 Nm (2.6 - 3.6 kgfm, 18.8 - 26.0 lbft).
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5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit.
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6. After checking that the hydraulic oil temperature has gone down, set the rotor of the stop valve (installed to the piping for the outlet port and inlet port on the side face of the arm) to LOCK position (b). (a) FREE: Hydraulic oil flows (direction of arrow is parallel to long direction of arm) (b) LOCK: Hydraulic oil does not flow (direction of arrow is at right angles to long direction of arm)
When setting the FREE or LOCK position of the stop valve rotor, remove bolt (2), turn over plate (1), then turn the rotor. After setting, install plate (1) again with bolt (2). Remove the hoses on the attachment side. Install the plugs to 7. the two outlets. The plugs are used to prevent the attachment from incorrect operation caused by mixing in of foreign matter. After the plugs are correctly installed, store the attachment.
8. Pull out the mounting pins (2 places), remove the attachment, then install the bucket. For details of the procedure for installing the bucket, see "BUCKET REPLACEMENT AND INVERSION (PAGE 3-163)". 9. After installing the bucket, check the oil level in the hydraulic tank.
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Attachment Installation
1. Remove the bucket. For bucket dismounting procedure, see "BUCKET REPLACEMENT AND INVERSION (PAGE 3-163)". 2. Place the attachment in a horizontal position, then install to the arm with pin (A) and then pin (B).
3. Lower the attachment to the ground and stop the engine. 4. Turn the starting switch to the ON position (B), then set the lock lever to the FREE position (F). 5. After carrying out Step 4, operate each work equipment control lever and attachment control pedal fully to the front, rear, left, and right 2 or 3 times within 15 seconds to release the internal pressure in the hydraulic circuit.
6 - 17
7. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit.
8. After checking that the hydraulic oil temperature has gone down, remove the plugs from 2 places at the outlet port and inlet port. Be careful not to get any dirt or mud on the hose mouthpiece. If the O-ring is damaged, replace it with a new part. 9. Connect the hose at the attachment side. When doing this, check the direction of flow of the oil and be careful not to make any mistake. 10. Set the rotor of the stop valve installed to the inlet port on the side face of the arm and the outlet port piping to FREE position (a).
(a) FREE: Hydraulic oil flows (direction of arrow is parallel to long direction of arm) (b) LOCK: Hydraulic oil does not flow (direction of arrow is at right angles to long direction of arm) When setting the FREE or LOCK position of the stop valve rotor, remove bolt (2), turn over plate (1), then turn the rotor. After setting, install plate (1) again with bolt (2).
11. After installing the attachment, check the oil level in the hydraulic tank.
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ATTACHMENT OPERATIONS
WARNING
If the pedal is operated when the auto-deceleration is being actuated and the engine speed has dropped, the engine speed will suddenly rise, so be careful when operating. If you leave your foot resting on the pedal and depress the pedal by mistake, there is danger that the attachment may suddenly move and cause serious personal injury. If you do not need to operate the pedal, do not rest your foot on the pedal. When the attachment is not being used, set the lock pin of the pedal to the LOCK position to prevent the pedal from being operated.
When changing the oil flow setting for the breaker mode, see "Breaker/Attachment Setting (PAGE 3-47)", "Changing Breaker Mode Setting (PAGE 3-47)" for details. When changing the oil flow setting for the attachment mode for the crusher or other attachment, see "Breaker/Attachment Setting (PAGE 3-47)", "Changing Breaker Mode Setting (PAGE 3-47)" for details. The method of operating the attachment is as follows.
If the working mode pilot monitor does not display B for the breaker mode, press working mode selector switch (1) and set to the breaker mode as follows. When working mode selector switch (1) is pressed, the screen switches to the working mode selection screen.
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1. Press working mode selector switch (1) or press switches F3 or F4 to select breaker mode B. 2. With breaker mode B highlighted in yellow, do one of the following to accept the selection. Keep working mode selector switch (1) pressed. Press switch F6. Leave as it is for 5 seconds. 3. If the breaker mode is selected, "Really Set Breaker Mode?" is displayed on the screen. To set to the breaker mode, press switch F6.
If switch F5 is pressed, the screen returns to the working mode selection screen without changing to the breaker mode. If a slide arm or other special attachment is installed and the mode is switched to the breaker mode by mistake, it may lead to serious danger, such as the work equipment suddenly dropping. If breaker operations are carried out in a mode other than the breaker mode, the warning screen is displayed. Always carry out breaker operations in the breaker mode. Precautions when using Check that the stop valve is at the FREE position. Check that the working mode is B mode. For details of the path of the oil, see "HYDRAULIC CIRCUIT (PAGE 6-8)". When considering whether it is necessary to install an accumulator for the attachment circuit, contact the attachment manufacturer and then decide. For other precautions when handling the breaker, follow the instruction manual from the breaker manufacturer and use the breaker correctly. The deterioration of the hydraulic oil when using the breaker is much faster than for normal operations, so reduce the maintenance interval for the hydraulic oil and element. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)".
6 - 20
If the working mode pilot monitor does not display ATT for the attachment mode, press working mode selector switch (1) and set to the attachment mode as follows. If P, E, or L mode are selected, the attachment is not actuated.
1. Press working mode selector switch (1) or press switches F3 or F4 to select attachment mode ATT. 2. With attachment mode ATT highlighted in yellow, do one of the following to accept the selection. Keep working mode selector switch (1) pressed. Press switch F6. Leave as it is for 5 seconds.
On the user menu attachment setting, it is possible to make the attachment mode inactive. When using the attachment mode, check that the attachment mode is active before starting operations. Precautions when using Check that the stop valve is at the FREE position. Check that the working mode is ATT mode. For details of the path of the oil, see "HYDRAULIC CIRCUIT (PAGE 6-8)". For other precautions when handling the attachment, follow the instruction manual from the attachment manufacturer and use the attachment correctly.
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SPECIFICATIONS
Hydraulic specifications Max. merging oil flow 214 x 2 liters / min Safety valve of service valve relief setting pressure 27.4 MPa (280 kgf/cm2, 3980 PSI)(except B mode) Safety valve of service valve cracking pressure 24.5 MPa (250 kgf/cm2, 3550 PSI)(except B mode) Safety valve of service valve relief setting pressure 20.6 MPa (210 kgf/cm2, 2980 PSI)(B mode) Safety valve of service valve cracking pressure 15.2 MPa (155 kgf/cm2, 2200 PSI)(B mode) In addition, valves with a safety valve relief set pressure of 24.5 MPa (250 kgf/cm2, 3550 PSI) and relief valve cracking pressure of 20.1 MPa (205 kgf/cm2, 2911 PSI) are also avilable so please contact your Komatsu
6 - 22
ATTACHMENT GUIDE
ATTACHMENT GUIDE
WARNING
Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing. Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment. Any injuries, accidents, or damage resulting from the use of unauthorized attachments or options will not be the responsibility of Komatsu.
ATTACHMENT COMBINATIONS
WARNING
Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
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. ATTACHMENT GUIDE
PC200, 200LC This table lists the combination of attachments which can be installed to the long arm (standard), short arm and extension arm. {: Can be used U: Can be used only for light duty work : Cannot be used
NOTICE When the extension arm is equipped, if the bucket is drawn to the machine body, the arm interferes with the body. Operate the extension arm carefully. When the boom is fully lowered during oblique digging, the boom interferes with the undercarriage. Operate the boom carefully.
Categories of use For general digging: Digging or loading sand, gravel, clay etc. For light duty digging: Digging or loading dry, uncaked earth and sand, mud etc. For loading work: Loading dry, loose earth and sand For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durability and high wear resistance be employed. *:Equipped with side cutter
Capacity m3 (cu.yd) 0.50 (0.65) 0.60 (0.78) 0.8 (1.05) 0.9 (1.18) 1.0 (1.3) 1.17 (1.5) 0.40 (0.52) 0.55 (0.72) 0.61 (0.80) 0.66 (0.86) 0.8 (1.05) Outside width mm (ft in) 750 (2' 6") 970 (3' 2") 1,150 (3' 9") 1,200 (3' 11") 1,330 (4' 4") 1,450 (4' 9") 950 (3' 1") 866 (2' 10") 1,800 (5' 11") Extension Short Short Standard arm arm arm arm 1.1 m 1.8 m 2.4 m 2.9 m (9 ft 6 in) (7 ft 10 in) (5 ft 11 in) (3 ft 7 in) { { { U U { { { { U U { { { { { { { { { { { { { { { { { U U { { { { { { { {
Name of bucket
Use
*Narrow bucket *Narrow bucket *Standard bucket *Light duty bucket Light duty bucket Light duty bucket Slope finishing bucket Trapezoidal bucket (Variable slope type) Ripper bucket Clamshell bucket Ditch cleaning bucket One tooth ripper Three teeth ripper
Narrow digging Narrow digging General digging Light duty digging Loading Loading Slope finishing Trapezoidal shaped diching Digging rocks Ditching, loading Ditching, cleaning Digging, removing rocks Digging, removing rocks
6 - 24
ATTACHMENT GUIDE
PC220, 220LC This table lists the combination of attachments which can be installed to the standard arm, long arm and short arm. {: Can be used U: Can be used only for light duty work : Cannot be used
NOTICE When the boom is fully lowered during oblique digging, the boom interferes with the undercarriage. Operate the boom carefully.
Categories of use For general digging: Digging or loading sand, gravel, clay etc. For light duty digging: Digging or loading dry, uncaked earth and sand, mud etc. For loading work: Loading dry, loose earth and sand For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durability and high wear resistance be employed. *: Equipped with side cutter. *1 is available only during loading
Capacity m3 (cu.yd) 0.72 (0.94) 1.0 (1.3) 1.14 (1.5) 1.26 (1.6) 0.40 (0.52) 0.55 (0.72) 0.61 (0.80) 0.66 (0.86) 0.80 (1.05) Outside width mm (ft in) 900 (2' 11") 1,260 (4' 2") 1,300 (4' 3") 1,400 (4' 7") 950 (3' 1") 866 (2' 11") 1,800 (5' 11") Long Standard arm arm 3.5 m 3.2 m (10 ft 6 in) (11 ft 6 in) { { U U { { { { { { { { { { { { U *1 Short Short arm arm 2.0 m 2.5 m (8 ft 2 in) (6 ft 7 in) { { U U { { { { { { { { { U U { { { { { { {
Name of bucket
Use
*Narrow bucket *Standard bucket *Light duty bucket Light duty bucket Slope finishing bucket Trapezoidal bucket (Variable slope type) Ripper bucket Clamshell bucket Ditch cleaning bucket One tooth ripper Three teeth ripper
Narrow digging General digging Light duty digging Loading For triming of a slope and rolling compaction Trapezoidal shaped diching Digging rocks Ditching, loading Ditching, cleaning Digging, removing rocks Digging, removing rocks
6 - 25
. ATTACHMENT GUIDE
Selection
Check the category from the uses in the table below, then select the shoes from the table below that. Category of use B and C are the wide shoe, so there are limits on the use. Check the precautions for use, examine the conditions of use thoroughly, and use the optimum shoes for the situation. When selecting the shoe width, choose the narrowest shoes possible to bring the machine within the range where there is no problem regarding the machine flotation and ground contact pressure. If wider shoes than necessary are used, the load on the shoe will increase, this may cause problems such as bending of the shoe, cracking of the link, damage of the pin, and looseness of the shoe bolts.
Category A Use Rocky ground, riverbeds, normal soil Normal soil, soft ground Precautions when using On rough ground with large obstacles such as boulders or fallen These shoes cannot be used on rough ground where there are large obstacles such as boulders or fallen trees. Travel at Hi or Mi speed only on flat ground, and if it is impossible to Use the shoes only in places where the machine sinks and it is impossible to use A or B shoes. These shoes cannot be used on rough ground where there are large obstacles such as boulders or fallen trees. Travel at Hi or Mi speed only on flat ground, and if it is impossible to D E Paved road Paved road To protect the rubber shoes, always follow precautions in
PC200 Specifications Category mm (ft in) 600 (1' 12") A Triple 700 (2' 4") B Triple 800 (31.5") C Triple 860 (2' 10") C Swamp 600 (1' 12") D Flat 600 (1' 12") E Road liner
PC200LC Specifications Category mm (ft in) 700 (2' 4") B Triple 600 (1' 12") A Triple 800 (2' 7") C Triple 900 (2' 11") C Triple 860 (2' 10") C Swamp 600 (1' 12") D Flat 600 (1' 12") E Road liner
PC220 Specifications Category mm (ft in) 600 (1' 12") A Triple 700 (2' 4") B Triple 800 (2' 7") C Triple 600 (1' 12") D Flat 600 (1' 12") E Road liner
PC220LC Specifications Category mm (ft in) 700 (2' 4") B Triple 600 (1' 12") A Triple 800 (2' 7") C Triple 600 (1' 12") D Flat
6 - 26
ATTACHMENT GUIDE
Teeth Selection
Vertical Pin Type Tooth
General digging: Digging and loading normal soil, such as sand, gravel, clay, etc. Light-duty digging: digging and loading dry and loose sandy soil, or muddy soil. Loading: loading of dry and loose earth.
Long-life Tooth
Jobsites where long wear life is demanded, such as when loading hard rocks. Jobsites where no penetration is needed, such as when working with crushed rocks after blasting or ripping. Jobsites where heavy-duty operations are carried out, such as hitting or pulling up rocks with the tips of the teeth.
Self-sharpening Tooth
Jobsites demanding penetration such as digging and loading sandy or clayey soil.
Rock LightHeavy Work Contents Digging with hammering work Scraping down General excavation Loading
Sand
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. ATTACHMENT GUIDE
Working Environment
Use a machine equipped with rubber pad shoes or Road Liner mainly for jobs on the paved roads. If used oth-erwise, breakage or chipping will occur on the rubber and the service life will be considerably reduced. Particularly the following jobsites must be avoided. Jobsite strewn with crushed concrete or on sand Jobsite with protruding edged objects like steel bar, glass and the like Jobsite on rocky terrain or in a river with many rocks A ride over a concrete road shoulder or above all the tip of sheet piles driven into the ground must be avoided. Be careful of machine skidding on the road covered with water, ice, snow or gravel. Pay special attention when unloading a machine from a truck. Use a machine equipped with rubber pad shoes or Road Liner in the ambient temperature range of -25C to 65 C due to the properties of rubber.
Working Conditions
A job using the undercarriage as a fulcrum, side digging job, digging job on a slope and a job requiring frequent steering, as shown in the picture, cause an excessive load on the rubber and there is danger that it may be damaged. Durability of rubber pad shoes may not be covered with warranty, if a special work equipment is mounted.
6 - 28
ATTACHMENT GUIDE
The rubber is still usable, even if it does not look in good shape with part of the rubber chipped or cuts developed on the surface, so long as damage has not developed all over the shoe or it does not damage a road surface.
Height of Lug
If lug height "a" is reduced by wear, the drawer pull will drop. If "a" is less than 5 mm (0.2 in), replace with a new part.
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. ATTACHMENT GUIDE
TRAPEZOIDAL BUCKET
Use the trapezoidal bucket when digging trapezoidal ditches in fields. By installing the variable plate, it is possible to excavate three angles of ditch slope face (45, 40, 38). The position of installation of the variable plate is different for each ditch slope face angle (45, 40, 38).
Digging Work
Operate the boom, arm, and bucket so that line A of the side plate of the bucket is always perpendicular, then carry out digging. Horizontal calculation plate B is welded to the bucket pin hole portion, so when digging, operate so that the plate is horizontal during the digging operation.
Ditch slope face 45 degrees Use the bucket only or install the variable plate using the ditch slope angle holes, and use the method above for digging.
6 - 30
ATTACHMENT GUIDE
Ditch slope face 40 degrees, 38 degrees Install the variable plate using the respective ditch slope angle holes, and use the method above for digging. Even when the variable plate is fitted, keep the line on the bucket side plate perpendicular during the digging operation.
6 - 31
. ATTACHMENT GUIDE
6 - 32
ATTACHMENT GUIDE
Digging Method
Digging is carried out with the clamshell pushed by the boom, but when operating the bucket, raise the boom slightly and carry out digging. When the clamshell bucket rotates, relieve the hydraulic pressure in the bucket cylinder, then return the lever to the HOLD position. The rotation is locked for a short time.
Lubrication
Prepare a grease gun 1. Lower the work equipment to the ground and set it in a stable condition before stopping the engine. 2. Using a grease gun, apply grease to the grease fittings marked by arrows (12 places). 3. After greasing, wipe off any old grease that was pushed out.
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HYDRAULIC BREAKER
Main Applications
Crushed rock Demolition work Road construction This attachment can be used for a wide range of applications including demolition of buildings, breaking up road surfaces or slag, tunnel work, rock crushing and breaking operations in quarries.
Keep the chisel pushed perpendicularly against the impact surface when carrying out breaking operations.
When applying impact, push the chisel against the impact surface and operate so that the chassis rises approx. 5 cm (2 in) off the ground. Do not let the machine come further off the ground than this amount.
6 - 34
When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge.
The direction of penetration of the chisel and the direction of the breaker body will gradually move out of line with each other, always adjust the bucket cylinder to keep them aligned.
Always keep the chisel pressed against the impact surface properly to prevent using the impact force when there is no resistance.
Prohibited Works
To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. Do not operate all cylinders to the end of their strokes. Always leave approx. 5 cm (2 in) to spare. Using the mount to gather in pieces of rock
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Holding the chisel horizontal or pointed up when carrying out impacting operations
Pecking operations
6 - 36
Extending the bucket cylinder fully and thrusting to raise the machine off the ground
Greasing
Supply grease in the correct position.
NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic components, while the breaker is in use. Therefore, be sure to grease the breaker, holding it in the right posture.
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BASIC PRECAUTIONS
WARNING
Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This may cause failure or fire on the KOMTRAX equipment or the machine itself. (Your Komatsu distributor will carry out removal and installation of KOMTRAX.) Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected wires may cause failure or fire on the KOMTRAX equipment or the machine itself. For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm (8.7 in) from the pacemaker. The radio waves may have an adverse effect on the operation of the pacemaker.
NOTICE Even when the key in the starting switch of the KOMTRAX system is at the OFF position, a small amount of electric power is consumed. When putting the machine into long-term storage, take the action given in "LONG TERM STORAGE (PAGE 3-185)". Please contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof. Be careful not to get water on the communications terminal or wiring.
REMARK The KOMTRAX system uses wireless communications, so it cannot be used inside tunnels, underground, inside buildings, or in mountain areas where radio waves cannot be received. Even when the machine is outside, it cannot be used in areas where the radio signal is weak or in areas outside the wireless communication service area. There is absolutely no need to inspect or operate the KOMTRAX communications terminal, but if any abnormality is found, please consult your Komatsu distributor.
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INDEX
INDEX
<A> Air Conditioner Controls Ashtray Attachment Guide Attachment Combinations Bucket Teeth Selection Handling Clamshell Bucket Handling Extension Arm Handling of Rubber Pad Shoe and Road Liner Trapezoidal Bucket Auxiliary Electric Power <B> Breaking-In The New Machine Bucket Replacement and Inversion Bucket with Hook Hook Condition Prohibited Operations <C> Cap with Lock Cold Weather Operation After Cold Weather Season After Daily Work Completion Cold Weather Operation Information Control Levers and Pedals Controller Controls and Gauges <D> Detailed Controls and Gauges Directions of Machine Door Lock <E> Electric System Maintenance Emergency Escape Hammer Engine, After Starting Engine, Before Starting Engine, Starting Engine, Stopping the EPA Regulations, Engine Number Plate Escape from Mud <F> Fire Extinguisher 336666689 88 23 23 27 33 32 Foreword Fuse Fusible Link <G> General Operation Information General Precautions for Safety Precautions when Removing or Installing Precautions when Selecting Precautions when Using Read the Instruction Manual Thoroughly Grease Pump Holder <H> Handling Machines Equipped With KOMTRAX Basic Precautions Handling Oil, Fuel, Coolant, and Performing Oil Clinic <I> Introduction <L> Locking Long Term Storage After Storage Before Storage During Storage Starting Machine After Long-Term Storage <M> Machine Inspection After Daily Work Machine Operation Machine Operations and Controls Machine Ready for Attachment Attachment Operations Attachment Removal and Installation Hydraulic Circuit Locations Long Term Storage Specifications Machine View Illustrations Machine, Steering the 1- 2 3-108 3-109
3-156 6- 2 6662 2 2
6- 28 6- 30 3-107
6- 2 3-109
1- 7 3-163 6- 3 6- 3 6- 3
6- 38 6- 38 44
1-
3- 5 1- 7 3- 85
3-110
7-1
INDEX
Magazine Box Maintenance Information Maintenance Procedure Check Before Starting Every 100 Hours Every 250 Hours Every 500 Hours Every 1000 Hours Every 2000 Hours Every 4000 Hours Every 5000 Hours Every 8000 Hours Initial 250 Hours (First 250 Hours Only) Initial 500 Hours When Required Maintenance Schedule Maintenance Interval for Hydraulic Breaker Maintenance Schedule Chart Monitoring System <O> Outline of Service Overall Machine View <P> Parking Machine Product Identification Number (PIN)/Machine Serial No. Plate Product Information Prohibited Operations <R> Radio Recommended Applications Recommended Attachment Operations Hydraulic Breaker Recommended Fuel, Coolant, and Lubricant Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil <S> Safety Critical Parts Safety Critical Parts List Safety Information Safety Information Safety Information Safety Labels
3444444444444444-
88 2 18 46 47 48 51 65 71 78 82 83 18 18 19 15
Location of Safety Labels Safety Labels Safety Machine Operation Battery Lifting Objects with Bucket Operation Starting Engine Towing Transportation Safety Maintenance Information Service Meter Location Specifications Sun Roof Swinging Switches <T> Tightening Torque Specifications Tightening Torque List Tool Box Transportation Lifting Machine Loading and Unloading with Trailer Transportation Procedure Traveling on Slopes Troubles and Actions Battery, Discharged Lightweight Towing Hole Other Trouble Phenomena That are Not Failures Running Out of Fuel Severe Job Condition Towing the Machine <W> Wear Parts Wear Parts List Windshield Work Equipment Controls and Operations Working Mode <Y> Your Machine Serial Numbers And Distributor
2- 5 2- 6 2- 21 2- 30 2- 33 2- 23 2- 21 2- 32 2- 29 2- 34 1- 9 5- 2 3- 79 3-149 3- 71
4- 17 4- 15 3- 5
43-
4 2
3-166 1- 8 1- 8 3-154
4- 12 4- 12 3-109 3-169 3-179 3-170 3-169 3-158 3-187 3-190 3-189 3-194 3-187 3-187 3-189 3-188
3-102 3-161 6- 34 6- 34 49
4- 8 4- 8 3- 79 3-150 3-152
4- 11
1-
4- 13 4- 14 1- 5 2- 2 2- 12 2- 4
7-2