Komatsu PC800-8, PC800LC-8 Service Manual

Operation &	UEAM005400
Maintenance Manual

PC800-8

PC800LC-8

HYDRAULIC EXCAVATOR

SERIAL NUMBER

PC800-8	- 50001 and up
PC800LC-8	- 50001 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 inside the cab for reference and periodically reviewed by all personel who will come into contact with the machine.

FOREWORD

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

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.

.

DANGER

WARNING

CAUTION

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.

	NOTICE	This word is used for precautions that must be taken to avoid actions which could shorten
		the life of the machine.
	REMARKS	This word is used for information that is useful to know.

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SAFETY INFORMATION

FOREWORD

q 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	Part No.

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.

Part No.

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))

1-4

FOREWORD

SAFETY INFORMATION

Noise emission levels

Two labels indicating the machine noise level are affixed on the machine.

qSound pressure level at the operator’s station, measured according to ISO6396 (Dynamic test method, simulated working cycle).

73

qSound power level emitted by the machine, measured according to ISO 6395 (Dynamic test method, simulated working cycle). This is the guaranteed value as specified in European directive 2000/14/EC.

108

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SAFETY INFORMATION

FOREWORD

Vibration levels

When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.

The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration value for the body is less than or equal to 0.5 m/s².

These values were determined using a representative machine and measured during the typical operating condition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and ISO 5349.

Operating condition:

Excavating (Digging-loading-rotating-unloading-rotating)

Guide to Reduce Vibration Levels on Machine

The following guides can help an operator of this machine to reduce the whole body vibration levels:

1.Use the correct equipment and attachments.

2.Maintain the machine according to this manual q Tension of crawler (for crawler machines) q Brake and steering systems

q Controls, hydraulic system and linkages

3.Keep the terrain where the machine is working and traveling in good condition

q Remove any large rocks or obstacles q Fill any ditches and holes

q Site manager should provide machine operators with machine and schedule time to maintain terrain conditions

4.Use a seat that meets ISO 7096 and keep the seat maintained and adjusted

q Adjust the seat and suspension for the weight and size of the operator

q Wear seat belt

q Inspect and maintain the seat suspension and adjustment mechanisms

5.Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves smoothly

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FOREWORD

SAFETY INFORMATION

6.Adjust the machine speed and travel path to minimize the vibration level

q When pushing with bucket or blade, avoid sudden loading; load gradually

q Drive around obstacles and rough terrain conditions

q Slow down when it is necessary to go over rough terrain

q Make the curve radius of traveling path as large as possible

q Travel at low speed when traveling around sharp curves

7.Minimize vibrations for long work cycle or long distance traveling

q Reduce speed to prevent bounce

q Transport machines long distances between worksites

8.The following guidelines can be effective to minimize risks of low back pain

q Operate the machine only when you are in good health.

q Provide breaks to reduce long periods of sitting in the same posture

q Do not jump down from the cab or machine q Do not repeatedly handle and lift loads

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SAFETY INFORMATION

FOREWORD

BREAKING-IN THE NEW MACHINE

NOTICE

Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.

Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).

Make sure that you fully understand the content of this manual, and pay careful attention to the following points when breaking in the machine.

qRun the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel control dial.

q Idle the engine for 5 minutes after starting it up.

q Avoid operation with heavy loads or at high speeds.

qImmediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and sudden changes in direction.

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FOREWORD

INTRODUCTION

INTRODUCTION

This Komatsu machine is designed to be used mainly for the following work:

q Digging work

q Leveling work

q Ditching work

q Loading work

q Demolition work

See the section “RECOMMENDED APPLICATIONS (3-121)“ for further details.

DIRECTIONS OF MACHINE

(A)	Front	(E)	Operator's seat
(B)	Rear	(F)	Sprocket

(C)Left

(D)Right

In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine.

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INTRODUCTION

FOREWORD

VISIBILITY FROM OPERATOR'S SEAT

The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.

PROXIMITY VISIBILITY

The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be seen when operating the machine.

12M CIRCUMFERENCE VISIBILITY

The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be seen when operating the machine.

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FOREWORD

PRODUCT INFORMATION

PRODUCT INFORMATION

When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

On the bottom right of the operator's cab

The design of the nameplate differs according to the territory.

EPA REGULATIONS, ENGINE NUMBER PLATE

On the upper side of the engine cylinder head cover.

EPA: Environmental Protection Agency, U.S.A.

1-11

PRODUCT INFORMATION

FOREWORD

SERVICE METER LOCATION

On top of the machine monitor

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Product Identification Number
Manufacturers name:	KOMATSU UK Ltd.
Address:	Durham Road
	Birtley
	Chester-Le street
	County Durham DH32QX
Distributor	United Kingdom
Address

Phone

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FOREWORD

PRODUCT INFORMATION

MACHINE SERIAL PLATE

MANUFACTURING YEAR

MODEL

SERIAL

WEIGHT

ENGINE POWER

PRODUCT IDENTIFICATION NUMBER

MANUFACTURER

MODEL
SERIAL No.
MANUFACT. YEAR
MASS	kg
ENGINE POWER	kW

Product Identification Number

MANUFACTURER Manufactured by Komatsu UK Ltd. for Komatsu Ltd.,Tokyo,Japan

205-00-K1291

Komatsu UK Ltd, Birtley, Co Durham, United Kingdom

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PRODUCT INFORMATION

FOREWORD

1-14

	CONTENTS
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................	1-2
SAFETY INFORMATION......................................................................................................................................	1-3
Noise emission levels .................................................................................................................................	1-5
Vibration levels............................................................................................................................................	1-6
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............................................................	1-6
BREAKING-IN THE NEW MACHINE .........................................................................................................	1-8
INTRODUCTION...................................................................................................................................................	1-9
DIRECTIONS OF MACHINE ......................................................................................................................	1-9
VISIBILITY FROM OPERATOR'S SEAT..................................................................................................	1-10
PROXIMITY VISIBILITY ..................................................................................................................	1-10
12M CIRCUMFERENCE VISIBILITY ..............................................................................................	1-10
PRODUCT INFORMATION................................................................................................................................	1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE .....................................	1-11
EPA REGULATIONS, ENGINE NUMBER PLATE ...................................................................................	1-11
SERVICE METER LOCATION .................................................................................................................	1-12
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ...................................................................	1-12
MACHINE SERIAL PLATE .......................................................................................................................	1-13
SAFETY
SAFETY INFORMATION......................................................................................................................................	2-2
SAFETY LABELS.................................................................................................................................................	2-4
LOCATION OF SAFETY LABELS..............................................................................................................	2-5
SAFETY LABELS .......................................................................................................................................	2-6
SAFETY INFORMATION....................................................................................................................................	2-13
SAFETY MACHINE OPERATION......................................................................................................................	2-22
STARTING ENGINE .................................................................................................................................	2-22
OPERATION.............................................................................................................................................	2-23
TRANSPORTATION.................................................................................................................................	2-29
BATTERY .................................................................................................................................................	2-30
TOWING ...................................................................................................................................................	2-31
LIFTING OBJECTS WITH BUCKET.........................................................................................................	2-32
SAFETY MAINTENANCE INFORMATION ........................................................................................................	2-33

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CONTENTS

OPERATION

MACHINE VIEW ILLUSTRATIONS .....................................................................................................................	3-2
OVERALL MACHINE VIEW........................................................................................................................	3-2
CONTROLS AND GAUGES .......................................................................................................................	3-3
DETAILED CONTROLS AND GAUGES..............................................................................................................	3-5
MONITORING SYSTEM.............................................................................................................................	3-5
BASIC OPERATION OF MACHINE MONITOR ................................................................................	3-6
EMERGENCY MONITORS ...............................................................................................................	3-9
CAUTION MONITORS ....................................................................................................................	3-11
BASIC CHECK MONITORS ............................................................................................................	3-13
METER DISPLAY PORTION...........................................................................................................	3-15
MONITOR SWITCHES PORTION ..................................................................................................	3-19
SWITCHES ...............................................................................................................................................	3-34
CONTROL LEVERS AND PEDALS .........................................................................................................	3-41
SUN ROOF ...............................................................................................................................................	3-43
OPENING ........................................................................................................................................	3-44
CLOSING.........................................................................................................................................	3-44
WINDSHIELD ...........................................................................................................................................	3-44
EMERGENCY EXIT FROM OPERATOR'S CAB......................................................................................	3-49
DOOR LOCK ............................................................................................................................................	3-49
CAP WITH LOCK......................................................................................................................................	3-49
HOT AND COOL BOX ..............................................................................................................................	3-51
MAGAZINE BOX.......................................................................................................................................	3-51
ASHTRAY .................................................................................................................................................	3-51
AIR CONDITIONER CONTROLS.............................................................................................................	3-52
AIR CONDITIONER CONTROL PANEL .........................................................................................	3-52
METHOD OF OPERATION .............................................................................................................	3-56
USE AIR CONDITIONER WITH CARE ...........................................................................................	3-62
AIR CONDITIONER MAINTENANCE .............................................................................................	3-63
OTHER FUNCTIONS ......................................................................................................................	3-63
RADIO-CASSETTE (OPTION)-65
USE RADIO WITH CARE................................................................................................................	3-65
AUXILIARY ELECTRIC POWER..............................................................................................................	3-66
24V POWER SOURCE ...................................................................................................................	3-66
12V POWER SOURCE ...................................................................................................................	3-67
FUSE ........................................................................................................................................................	3-68
CIRCUIT BREAKER .................................................................................................................................	3-69
CONTROLLER .........................................................................................................................................	3-70
TOOL BOX................................................................................................................................................	3-70
GREASE PUMP........................................................................................................................................	3-71
METHOD OF USE...........................................................................................................................	3-71
PRECAUTIONS WHEN USING ......................................................................................................	3-72
SUPPLYING GREASE ....................................................................................................................	3-73
ACCUMULATOR HANDLING...................................................................................................................	q-75
RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN
ACCUMULATOR ............................................................................................................................	Q-75

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	CONTENTS
MACHINE OPERATIONS AND CONTROLS.....................................................................................................	3-76
BEFORE STARTING ENGINE .................................................................................................................	3-76
WALK-AROUND CHECKS..............................................................................................................	3-76
CHECKS BEFORE STARTING.......................................................................................................	3-77
ADJUSTMENT.................................................................................................................................	3-85
SEAT BELT .....................................................................................................................................	3-88
OPERATIONS BEFORE STARTING ENGINE ...............................................................................	3-89
STARTING ENGINE .................................................................................................................................	3-92
AFTER STARTING ENGINE ....................................................................................................................	3-95
ENGINE WARM UP.........................................................................................................................	3-95
HYDRAULIC EQUIPMENT WARM UP ...........................................................................................	3-97
OPERATION AFTER COMPLETION OF WARM-UP OPERATION .............................................	3-102
STOPPING THE ENGINE ......................................................................................................................	3-104
MACHINE OPERATION .........................................................................................................................	3-105
PREPARATIONS FOR MOVING THE MACHINE.........................................................................	3-105
MOVING MACHINE FORWARD ...................................................................................................	3-106
MOVING MACHINE BACKWARD.................................................................................................	3-107
STOPPING MACHINE...................................................................................................................	3-108
STEERING THE MACHINE....................................................................................................................	3-109
STEERING ....................................................................................................................................	3-109
SWINGING .............................................................................................................................................	3-111
WORK EQUIPMENT CONTROLS AND OPERATIONS ........................................................................	3-112
WORKING MODE...................................................................................................................................	3-114
PROHIBITED OPERATIONS .................................................................................................................	3-115
GENERAL OPERATION INFORMATION ..............................................................................................	3-117
TRAVELING ON SLOPES......................................................................................................................	3-118
ESCAPE FROM MUD.............................................................................................................................	3-120
TRACK ON ONE SIDE STUCK.....................................................................................................	3-120
TRACKS ON BOTH SIDES STUCK..............................................................................................	3-120
RECOMMENDED APPLICATIONS........................................................................................................	3-121
BACKHOE WORK .........................................................................................................................	3-121
DITCHING WORK .........................................................................................................................	3-121
LOADING WORK ..........................................................................................................................	3-121
BUCKET REPLACEMENT .....................................................................................................................	3-122
REPLACEMENT............................................................................................................................	3-122
PARKING MACHINE ..............................................................................................................................	3-124
MACHINE INSPECTION AFTER DAILY WORK ....................................................................................	3-126
LOCKING................................................................................................................................................	3-126
TRANSPORTATION.........................................................................................................................................	3-127
TRANSPORTATION PROCEDURE.......................................................................................................	3-127
LIFTING MACHINE.................................................................................................................................	3-127
SHIPPING MACHINE INFORMATION ...................................................................................................	3-129
TRANSPORTATION POSTURE ............................................................................................................	3-130
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE......................................	3-135

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CONTENTS

COLD WEATHER OPERATION ......................................................................................................................	3-137
COLD WEATHER OPERATION INFORMATION...................................................................................	3-137
FUEL AND LUBRICANTS .............................................................................................................	3-137
COOLING SYSTEM COOLANT ....................................................................................................	3-137
BATTERY ......................................................................................................................................	3-138
MONITOR......................................................................................................................................	3-138
AFTER DAILY WORK COMPLETION....................................................................................................	3-140
AFTER COLD WEATHER SEASON ......................................................................................................	3-140
LONG TERM STORAGE..................................................................................................................................	3-141
BEFORE STORAGE...............................................................................................................................	3-141
DURING STORAGE ...............................................................................................................................	3-142
AFTER STORAGE..................................................................................................................................	3-142
STARTING MACHINE AFTER LONG-TERM STORAGE ......................................................................	3-142
TROUBLES AND ACTIONS ............................................................................................................................	3-143
RUNNING OUT OF FUEL ......................................................................................................................	3-143
PHENOMENA THAT ARE NOT FAILURES...........................................................................................	3-144
TOWING THE MACHINE .......................................................................................................................	3-144
SEVERE JOB CONDITION ....................................................................................................................	3-145
DISCHARGED BATTERY ......................................................................................................................	3-146
BATTERY REMOVAL AND INSTALLATION ................................................................................	3-146
BATTERY CHARGES ...................................................................................................................	3-147
STARTING ENGINE WITH BOOSTER CABLES ..........................................................................	3-148
OTHER TROUBLE .................................................................................................................................	3-150
ELECTRICAL SYSTEM.................................................................................................................	3-150
CHASSIS .......................................................................................................................................	3-151
ENGINE .........................................................................................................................................	3-152
ELECTRONIC CONTROL SYSTEM .............................................................................................	3-154
POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS ............................................	3-155

MAINTENANCE

MAINTENANCE INFORMATION .........................................................................................................................	4-2
OUTLINE OF SERVICE........................................................................................................................................	4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................	4-4
OIL .....................................................................................................................................................	4-4
FUEL..................................................................................................................................................	4-5
COOLANT AND WATER FOR DILUTION.........................................................................................	4-5
GREASE............................................................................................................................................	4-6
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS).........................................................	4-6
STORING OIL AND FUEL.................................................................................................................	4-7
FILTERS ............................................................................................................................................	4-7
ELECTRIC SYSTEM MAINTENANCE .......................................................................................................	4-8
EXPLANATION OF LUBRICATION CHART DECAL .................................................................................	q-9

1-18

	CONTENTS
WEAR PARTS....................................................................................................................................................	4-11
WEAR PARTS LIST..................................................................................................................................	4-11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................	4-12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL...........................................................................................................................................	4-14
TIGHTENING TORQUE SPECIFICATIONS ......................................................................................................	4-15
TIGHTENING TORQUE LIST...................................................................................................................	4-15
SAFETY CRITICAL PARTS ...............................................................................................................................	4-16
SAFETY CRITICAL PARTS LIST .............................................................................................................	4-16
MAINTENANCE SCHEDULE.............................................................................................................................	4-17
MAINTENANCE SCHEDULE CHART......................................................................................................	4-17
MAINTENANCE PROCEDURE..........................................................................................................................	4-19
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) ...................................	4-19
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) ...................................	4-19
WHEN REQUIRED ...................................................................................................................................	4-19
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.........................................................	4-19
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................	4-24
CHECK AND TIGHTEN TRACK SHOE BOLTS..............................................................................	4-27
CHECK AND ADJUST TRACK TENSION ......................................................................................	4-28
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................	4-30
REPLACE BUCKET TEETH (KMAX) ..............................................................................................	4-31
ADJUST BUCKET CLEARANCE ....................................................................................................	4-32
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ..............................................................	4-34
CHECK AND MAINTENANCE AIR CONDITIONER .......................................................................	4-35
CLEAN LINE FILTER, REMOVE DIRT ...........................................................................................	4-36
CHECK GAS SPRING.....................................................................................................................	4-36
BLEEDING AIR FROM HYDRAULIC SYSTEM ..............................................................................	4-37
CHECK BEFORE STARTING ..................................................................................................................	4-40
EVERY 10 HOURS MAINTENANCE........................................................................................................	4-41
LUBRICATING.................................................................................................................................	4-41
EVERY 100 HOURS MAINTENANCE......................................................................................................	4-43
LUBRICATING SWING CIRCLE .....................................................................................................	4-43
EVERY 250 HOURS MAINTENANCE......................................................................................................	4-44
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..................................................................	4-44
CHECK LEVEL OF BATTERY ELECTROLYTE .............................................................................	4-44
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS ...............................	4-46
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST ............................................................	4-47
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST .....................................	4-48
EVERY 500 HOURS MAINTENANCE....................................................................................................	.. 4-49
REPLACE FUEL PRE-FILTER CARTRIDGE..................................................................................	4-49
CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................................	4-51

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH

AIR CONDITIONER) .......................................................................................................................

4-52

1-19

CONTENTS

CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED

WITH AIR CONDITIONER) .............................................................................................................	4-53
REPLACE PILOT FILTER ...............................................................................................................	4-54
CLEAN STRAINER OF COUPLING LUBRICATING OIL FILTER...................................................	4-55
REPLACE DRAIN FILTER CARTRIDGE ........................................................................................	4-55
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ....................	4-56
EVERY 1000 HOURS MAINTENANCE....................................................................................................	4-58
REPLACE FUEL MAIN FILTER CARTRIDGE ................................................................................	4-58
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.............................................................	4-61
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT...........................................	4-62
REPLACE HYDRAULIC OIL FILTER ELEMENT ............................................................................	4-62
CHANGE OIL IN SWING MACHINERY CASE................................................................................	4-63
CHANGE OIL IN COUPLING CASE ...............................................................................................	4-65
REPLACE CORROSION RESISTOR CARTRIDGE .......................................................................	4-66
CHECK WELDED STRUCTURE.....................................................................................................	4-66
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER) ............	4-68
EVERY 2000 HOURS MAINTENANCE....................................................................................................	4-69
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................	4-69
CLEAN HYDRAULIC TANK STRAINER .........................................................................................	4-70
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT) .........................................................................................................................................	4-71
CHECK ALTERNATOR ...................................................................................................................	4-74
CHECK ENGINE VALVE CLEARANCE, ADJUST..........................................................................	4-74
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS................................	4-74
EVERY 4000 HOURS MAINTENANCE....................................................................................................	4-75
CHECK WATER PUMP...................................................................................................................	4-75
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) ..............................................................	4-75
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER 4-76
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..............	4-76
CHECK OPERATING CONDITION OF COMPRESSOR................................................................	4-77
CHECK STARTING MOTOR...........................................................................................................	4-77
EVERY 5000 HOURS MAINTENANCE....................................................................................................	4-78
CHANGE OIL IN HYDRAULIC TANK..............................................................................................	4-78
EVERY 8000 HOURS MAINTENANCE....................................................................................................	4-80
REPLACE HIGH-PRESSURE PIPING CLAMP ..............................................................................	4-80
REPLACE FUEL SPRAY PREVENTION CAP................................................................................	4-80

SPECIFICATIONS

SPECIFICATIONS ................................................................................................................................................

5-2

1-20

	CONTENTS
ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS FOR SAFETY..........................................................................................................	6-2
PRECAUTIONS WHEN SELECTING.........................................................................................................	6-2
READ THE INSTRUCTION MANUAL THOROUGHLY..............................................................................	6-2
PRECAUTIONS WHEN REMOVING OR INSTALLING .............................................................................	6-2
PRECAUTIONS WHEN USING..................................................................................................................	6-3
ATTACHMENT GUIDE.........................................................................................................................................	6-4
COMBINATIONS OF WORK EQUIPMENT................................................................................................	6-5
WORKING RANGE DIAGRAM..........................................................................................................	6-6
TRACK SHOES SELECTION.....................................................................................................................	6-7
HANDLING MACHINES EQUIPPED WITH KOMTRAX ......................................................................................	6-8
BASIC PRECAUTIONS ..............................................................................................................................	6-8

INDEX

COLOPHON

1-21

CONTENTS

1-22

SAFETY

WARNING

Please read and make sure that you fully understand the precautions discribed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.

SAFETY INFORMATION	SAFETY
SAFETY INFORMATION
SAFETY LABELS................................................................................................................................................	2-4
Location of safety labels...............................................................................................................................	2-5
Safety labels.................................................................................................................................................	2-6
SAFETY INFORMATION
Safety rules ................................................................................................................................................	2-13
If problems are found .................................................................................................................................	2-13
Working wear and personal protective items .............................................................................................	2-13
Fire extinguisher and first aid kit ................................................................................................................	2-13
Safety equipment .......................................................................................................................................	2-14
Keep machine clean...................................................................................................................................	2-14
Keep operator's compartment clean ..........................................................................................................	2-14
Leaving operator's seat with lock ...............................................................................................................	2-14
Handrails and steps ...................................................................................................................................	2-15
Mounting and dismounting .........................................................................................................................	2-16
No persons on attachments .......................................................................................................................	2-16
Do not get caught in articulated portion .....................................................................................................	2-16
Burn prevention..........................................................................................................................................	2-16
Fire prevention and explosion prevention ..................................................................................................	2-17
Action if fire occurs.....................................................................................................................................	2-18
Windshield washer fluid .............................................................................................................................	2-18
Falling objects, flying objects and intruding objects prevention .................................................................	2-18
Attachment installation ...............................................................................................................................	2-18
Attachment combinations...........................................................................................................................	2-19
Cab window glasses ..................................................................................................................................	2-19
Unauthorized modifications........................................................................................................................	2-19
Safety at jobsite..........................................................................................................................................	2-19
Working on loose ground ...........................................................................................................................	2-19
Distance to high voltage cables .................................................................................................................	2-20
Ensure good visibility .................................................................................................................................	2-20
Ventilation for enclosed area......................................................................................................................	2-21
Signalman's signal and signs.....................................................................................................................	2-21
Emergency exit from operator's cab ..........................................................................................................	2-21
Asbestos dust hazard prevention...............................................................................................................	2-21
SAFETY MACHINE OPERATION ....................................................................................................................	2-22
STARTING ENGINE ..................................................................................................................................	2-22
Checks before starting engine ............................................................................................................	2-22
Safety rules for starting engine ...........................................................................................................	2-22
Starting engine in cold weather...........................................................................................................	2-23
OPERATION ..............................................................................................................................................	2-23
Checks before operation.....................................................................................................................	2-23
Safety rules for changing machine directions .....................................................................................	2-23
Safety rules for traveling .....................................................................................................................	2-24
Traveling on slopes.............................................................................................................................	2-25
Operations on slopes ..........................................................................................................................	2-26
Prohibited operations ..........................................................................................................................	2-26
Operations on snow ............................................................................................................................	2-28
Parking machine .................................................................................................................................	2-28
TRANSPORTATION ..................................................................................................................................	2-29
Loading and unloading........................................................................................................................	2-29
Shipping the machine .........................................................................................................................	2-29
BATTERY...................................................................................................................................................	2-30
Battery hazard prevention...................................................................................................................	2-30

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SAFETY

SAFETY INFORMATION

Starting engine with booster cables....................................................................................................	2-31
TOWING ....................................................................................................................................................	2-31
Safety rules for towing ........................................................................................................................	2-31
LIFTING OBJECTS WITH BUCKET..........................................................................................................	2-32
Safety rules for lifting objects ..............................................................................................................	2-32
SAFETY MAINTENANCE INFORMATION.......................................................................................................	2-33
Warning Tag ..............................................................................................................................................	2-33
Keep Work Place Clean and Tidy ..............................................................................................................	2-33
Appoint Leader when Working with Others................................................................................................	2-33
Stop Engine Before Carrying Out Maintenance.........................................................................................	2-34
Two Workers for Maintenance when Engine is Running ...........................................................................	2-34
Proper Tools ..............................................................................................................................................	2-35
Accumulator, Gas spring............................................................................................................................	2-35
Personnel...................................................................................................................................................	2-35
Attachments ...............................................................................................................................................	2-36
Work Under the Machine ...........................................................................................................................	2-36
Noise..........................................................................................................................................................	2-36
When Using Hammer.................................................................................................................................	2-36
Welding Works...........................................................................................................................................	2-36
Removing Battery Terminals......................................................................................................................	2-37
Safety First when Using High-pressure Grease to Adjust Track Tension..................................................	2-37
Do Not Disassemble Recoil Springs ..........................................................................................................	2-37
Safety Rules for High-pressure Oil ............................................................................................................	2-37
Precaution for High Fuel Pressure.............................................................................................................	2-38
Safety Handling High-pressure Hoses.......................................................................................................	2-38
Precaution for High Voltage .......................................................................................................................	2-38
Waste Materials .........................................................................................................................................	2-39
Air Conditioner Maintenance......................................................................................................................	2-39
Compressed Air .........................................................................................................................................	2-39
Periodic Replacement of Safety Critical Parts ...........................................................................................	2-39

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SAFETY LABELS

SAFETY

SAFETY LABELS

The following warning signs and safety labels are used on this machine.

q Be sure that you fully understand the correct position and content of labels.

qTo 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.

qThere are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way.

qIf 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

LOCATION OF SAFETY LABELS

2-5

SAFETY LABELS

SAFETY

SAFETY LABELS

(207-00-K1951)

q Warnings for operation, inspection and maintenance

qImproper operation and maintenance can cause serious injury or death.

qRead the manual and labels before operation and maintenance.

Follow instructions and warnings in manual and in labels on machine.

(1) Keep the manual in machine cab near operator.

If this manual is lost, please contact your Komatsu distributor for a replacement.

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