KOMATSU PC88MR-8 HYDRAULIC EXCAVATOR Operation and Maintenance Manual (SN:A90001 and UP) – PDF DOWNLOAD

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KOMATSU PC88MR-8 HYDRAULIC EXCAVATOR Operation and Maintenance Manual (SN:A90001 and UP)

KOMATSU PC88MR-8 HYDRAULIC EXCAVATOR OPERATION AND MAINTENANCE MANUAL (SN:A90001 AND UP) – PDF DOWNLOAD:

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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 while operating or performing 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.

Make sure that you fully understand the content of this manual, and pay careful attention to the following 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 operating 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 except in cases of emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user. Operations that are prohibited in this manual must never be performed under any circumstances.

TABLE OF CONTENTS:

COVER................................................................................................................................  1
INTRODUCTION.........................................................................................................................  3
	FOREWORD.........................................................................................................................  4
	SAFETY INFORMATION...............................................................................................................  5
		Signal Words.................................................................................................................  5
		Other Signal Words...........................................................................................................  5
		Safety Labels................................................................................................................  6
			Safety Label Using Words.................................................................................................  6
			Safety Label Using Pictogram.............................................................................................  6
	INTRODUCTION.....................................................................................................................  7
		Directional Reference of Machine.............................................................................................  7
		Visibility from Operator's Seat..............................................................................................  7
	BREAKING IN THE MACHINE..........................................................................................................  8
	PRODUCT INFORMATION..............................................................................................................  9
		Product Identification Number (PIN) - Machine Serial No. Plate...............................................................  9
		EPA* Regulations, Engine Serial Number Plate and its Location................................................................  9
		Service Meter Location....................................................................................................... 10
		Your Machine Serial Numbers and Distributor.................................................................................. 10
	TABLE OF CONTENTS................................................................................................................ 11
SAFETY............................................................................................................................... 23
	SAFETY AND WARNING DECALS........................................................................................................ 24
		Location of Safety Decals.................................................................................................... 25
	GENERAL SAFETY RULES AND PRECAUTIONS............................................................................................. 32
		General Safety Rules......................................................................................................... 32
		General Safety at Job Site................................................................................................... 33
		Working on Loose Ground...................................................................................................... 33
		Safety Features.............................................................................................................. 34
		Personal Protective Equipment................................................................................................ 34
		Fire and Explosion Prevention................................................................................................ 35
			Fire Caused by Fuel or Oil............................................................................................... 35
			Fire Caused by Accumulation of Flammable Material........................................................................ 35
			Fire Coming From Electric Wiring......................................................................................... 36
			Fire Coming From Hydraulic Line.......................................................................................... 36
			Windshield Washer Fluid.................................................................................................. 36
		Action if Fire Occurs........................................................................................................ 36
		Fire Extinguisher and First Aid Kit.......................................................................................... 36
		Fire Prevention and Suppression.............................................................................................. 37
			Fire Prevention Steps.................................................................................................... 37
			Fixed Fire Detection System.............................................................................................. 37
			Fixed Fire Suppression System............................................................................................ 37
			Fire Prevention Procedures............................................................................................... 37
		Dust Hazard Precautions...................................................................................................... 38
		Keep Operator's Cab Clean.................................................................................................... 38
		Unauthorized Modifications................................................................................................... 38
		Leaving Operator’s Compartment............................................................................................... 39
		Mounting and Dismounting..................................................................................................... 40
		Crush or Pinch Point Dangers................................................................................................. 40
		Inside Operator’s Compartment................................................................................................ 41
		Precautions When Using ROPS.................................................................................................. 41
		Protection Against Falling or Flying Objects................................................................................. 42
		Precautions for Attachments.................................................................................................. 43
		Quick Coupler Attachment..................................................................................................... 43
		Large Attachments............................................................................................................ 43
	PRECAUTIONS BEFORE STARTING OPERATIONS........................................................................................... 44
		Pre-Operational Checks....................................................................................................... 44
		Seat Belt Inspection......................................................................................................... 45
		Starting Your Work Operations................................................................................................ 46
		Work Site Hazards............................................................................................................ 46
		Avoiding Dangerous Situations................................................................................................ 47
		Working Clearances........................................................................................................... 51
		Operations on Slopes......................................................................................................... 52
		Operating on Snow or Icy Surfaces............................................................................................ 52
		Asbestos Hazard Alert........................................................................................................ 52
	RULES FOR ROAD TRAVEL............................................................................................................ 53
		Precautions When Traveling................................................................................................... 53
		Traveling with Carriage Reversed............................................................................................. 53
		Travel on Slopes............................................................................................................. 54
		Parking the Machine.......................................................................................................... 56
	PRECAUTIONS DURING MAINTENANCE OPERATIONS........................................................................................ 57
		Warning Tags................................................................................................................. 57
		Equipment Storage............................................................................................................ 57
		Working Under the Machine.................................................................................................... 58
		Using Drop Lamps............................................................................................................. 58
		Keeping the Machine Clean.................................................................................................... 58
		Performing General Maintenance Procedures.................................................................................... 59
		Running the Engine During Maintenance........................................................................................ 60
		Proper Tools................................................................................................................. 60
		Engine System High-Voltage................................................................................................... 60
		Welding, Grinding or Cutting................................................................................................. 61
		Adjusting Track Tension...................................................................................................... 61
		DO NOT Disassemble Recoil Springs............................................................................................ 61
		When Using Hammer............................................................................................................ 61
		Refueling the Machine........................................................................................................ 62
		Cooling System Precautions................................................................................................... 62
		Battery Precautions.......................................................................................................... 63
		Starting the Machine......................................................................................................... 64
		High-Pressure Hoses.......................................................................................................... 64
		Handling High-Pressure Hoses................................................................................................. 64
		Precaution for High Fuel Pressure............................................................................................ 65
		High Temperatures Areas...................................................................................................... 65
		Disposal of Waste Materials.................................................................................................. 65
		Accumulator.................................................................................................................. 66
		Critical Parts............................................................................................................... 66
	TRANSPORTING THE MACHINE......................................................................................................... 67
		Loading and Unloading a Trailer.............................................................................................. 67
		Loading the Machine.......................................................................................................... 68
		Securing the Machine......................................................................................................... 70
	TOWING........................................................................................................................... 71
		Safety Rules for Towing...................................................................................................... 71
OPERATION............................................................................................................................ 73
	MACHINE VIEW ILLUSTRATIONS....................................................................................................... 74
		Overall Machine View......................................................................................................... 74
		Controls and Gauges.......................................................................................................... 75
		Machine Monitor.............................................................................................................. 76
	DETAILED CONTROLS AND GAUGES..................................................................................................... 77
		Monitoring System............................................................................................................ 77
		Basic Operation of Machine Monitor........................................................................................... 78
			Starting Engine When Situation is Normal................................................................................. 78
			Stopping Engine When Situation is Normal................................................................................. 79
			If There Is Abnormality When Starting Engine............................................................................. 80
			If Any Abnormality Occurs During Operation............................................................................... 80
		Emergency Monitors........................................................................................................... 82
			Engine Coolant Temperature Monitor....................................................................................... 82
			Hydraulic Oil Temperature Monitor........................................................................................ 82
			Engine Oil Pressure Monitor.............................................................................................. 83
		Caution Monitors............................................................................................................. 84
			Engine Coolant Temperature Monitor....................................................................................... 84
			Hydraulic Oil Temperature Monitor........................................................................................ 85
			Fuel Level Monitor....................................................................................................... 85
			Charge Level Monitor..................................................................................................... 85
		Basic Check Monitors......................................................................................................... 86
			Maintenance Interval Monitor............................................................................................. 86
		Meter Display Portion........................................................................................................ 87
			Pilot Display............................................................................................................ 87
			Engine Pre-heating Monitor............................................................................................... 87
			Swing Lock Monitor....................................................................................................... 88
			Wiper Monitor............................................................................................................ 88
			Auto-deceleration Monitor................................................................................................ 88
			Working Mode Monitor..................................................................................................... 88
			Travel Speed Monitor..................................................................................................... 89
			Air Conditioner Monitor.................................................................................................. 89
			Message Monitor.......................................................................................................... 89
			Idle Stop Guidance....................................................................................................... 89
		Gauges and Meter............................................................................................................. 90
			Engine Coolant Temperature Gauge......................................................................................... 90
			Hydraulic Oil Temperature Gauge.......................................................................................... 91
			Fuel Gauge............................................................................................................... 91
			Service Meter, Clock..................................................................................................... 92
			ECO Gauge................................................................................................................ 93
		Monitor Switches Portion..................................................................................................... 94
			Working Mode Selector Switch............................................................................................. 94
			Auto-deceleration Switch................................................................................................. 97
			Travel Speed Selector Switch............................................................................................. 98
			Wiper Switch............................................................................................................. 99
			Window Washer Switch.....................................................................................................100
			Buzzer Cancel Switch.....................................................................................................100
			Function Switches........................................................................................................101
			Air Conditioner Switch...................................................................................................101
			Handling Function Switches...............................................................................................102
			Service Meter/Clock Display Selector Switch..............................................................................103
			Maintenance Selector Switch..............................................................................................104
			Operations on Maintenance List Screen....................................................................................105
			Operations on Maintenance Interval Reset Screen..........................................................................106
			User Mode Selector Switch................................................................................................107
			Breaker/Attachment Setting...............................................................................................109
			Message Display..........................................................................................................122
			Adjusting Screen.........................................................................................................124
			Clock Adjustment.........................................................................................................127
			Language Selection.......................................................................................................133
			Adjusting Economy Mode...................................................................................................135
		Switches.....................................................................................................................137
			Ignition Switch..........................................................................................................137
			Fuel Control Dial........................................................................................................138
			Cigarette Lighter........................................................................................................138
			1st-Line Attachment Proportional Switch..................................................................................139
			Breaker Operation Switch.................................................................................................139
			Horn Switch..............................................................................................................139
			Room Lamp Switch.........................................................................................................139
			Emergency Pump Drive Switch..............................................................................................140
			Swing Parking Brake Release Switch.......................................................................................140
			Revolving Warning Lamp Switch (If Equipped)..............................................................................140
			Lamp Switch..............................................................................................................141
			Quick Coupler Switches...................................................................................................141
		Control Levers and Pedals....................................................................................................142
			Lock Lever...............................................................................................................143
			Travel Levers............................................................................................................144
			Work Equipment Control Lever.............................................................................................145
			Blade Control Lever......................................................................................................146
			Swing Lock Cover.........................................................................................................146
			Boom Swing Control Pedal.................................................................................................146
	SUN ROOF.........................................................................................................................147
	WINDSHIELD.......................................................................................................................148
		Opening......................................................................................................................148
		Closing......................................................................................................................152
		Removing Lower Windshield....................................................................................................154
	SLIDING DOOR.....................................................................................................................155
	EMERGENCY ESCAPE HAMMER..........................................................................................................156
	COVER WITH LOCK..................................................................................................................157
		Opening and Closing Covers with Lock.........................................................................................157
			Opening the Cover........................................................................................................157
			Locking the Cover........................................................................................................157
	ENGINE HOOD......................................................................................................................158
	MUD COVER........................................................................................................................160
	BATTERY INSPECTION COVER.........................................................................................................161
	AIR CONDITIONER CONTROLS.........................................................................................................162
		Air Conditioner Control Panel................................................................................................162
			OFF Switch...............................................................................................................162
			Fan Switch...............................................................................................................163
			Temperature Control Switch...............................................................................................163
			Vent Selector Switch.....................................................................................................164
			Auto Switch..............................................................................................................165
			FRESH/RECIRC Selector Switch.............................................................................................165
			Display Monitor..........................................................................................................165
			Air Conditioner Switch...................................................................................................166
			Sunlight Sensor..........................................................................................................166
		Method of Operation..........................................................................................................167
			Automatic Operation......................................................................................................167
			Stopping Automatic Operation.............................................................................................168
			Manual Operation.........................................................................................................168
			Stopping Manual Operation................................................................................................170
			Operation with Cold Air to Face and Warm Air to Feet.....................................................................170
			Defroster Operation......................................................................................................172
		Use Air Conditioner with Care................................................................................................174
			Ventilation..............................................................................................................174
			Temperature Control......................................................................................................174
			Inspection and maintenance of Air Conditioner Equipped Machine...........................................................174
	RADIO............................................................................................................................176
		Control Panel................................................................................................................176
			Power Switch, Volume Control Knob, Balance Control Knob..................................................................176
			Sel Button...............................................................................................................176
			FM/AM Selection Button (AM/FM)...........................................................................................176
			Display Selection Button (TIME)..........................................................................................176
			AS/PS button.............................................................................................................177
			Preset Station Buttons (1, 2, 3, 4, 5, 6)................................................................................177
			Display..................................................................................................................177
			Time Reset Button........................................................................................................177
			Tuning Button (TUNING)...................................................................................................177
		Controls of Radio............................................................................................................178
			Method of Setting with Preset Button.....................................................................................178
			Method of Tuning.........................................................................................................178
			Method of Operating Mode.................................................................................................178
			Setting Correct Time.....................................................................................................179
		Antenna......................................................................................................................179
		Use Radio with Care..........................................................................................................179
	FUSE.............................................................................................................................180
		Fuse Capacities and Circuit Names............................................................................................180
		Fusible Link.................................................................................................................181
	AUXILIARY ELECTRIC POWER.........................................................................................................182
	CONTROLLERS......................................................................................................................183
	OPERATION MANUAL STORAGE.........................................................................................................184
	CUP HOLDER.......................................................................................................................184
	TOOL BOX.........................................................................................................................184
	GREASE PUMP HOLDER...............................................................................................................184
	ASHTRAY..........................................................................................................................185
	FIRE EXTINGUISHER (IF EQUIPPED)..................................................................................................185
	MACHINE OPERATIONS AND CONTROLS..................................................................................................186
		Before Starting Engine.......................................................................................................186
			Walk-Around Checks.......................................................................................................186
		Checks Before Starting.......................................................................................................187
			Check Coolant Level, Add Coolant.........................................................................................187
			Check Oil Level in Engine Oil Pan, Add Oil...............................................................................188
			Check Fuel Level, Add Fuel...............................................................................................190
			Check Oil Level in Hydraulic Tank, Add Oil...............................................................................192
			Check Dust Indicator.....................................................................................................193
			Check for Water and Sediment in Water Separator, Drain Water.............................................................194
		Check Electric Wiring........................................................................................................196
			Check Working Lamp Switch................................................................................................196
			Check Function of Horn...................................................................................................196
		Adjustments..................................................................................................................197
			Seat Adjustment..........................................................................................................197
			Rear View Mirrors........................................................................................................198
			Wind-in Type Seat Belt...................................................................................................200
		Operations Before Starting Engine............................................................................................201
	STARTING ENGINE..................................................................................................................204
		Normal Starting..............................................................................................................204
		Starting Engine in Cold Weather..............................................................................................206
		Turbo protect function.......................................................................................................208
		Breaking-in the New Machine..................................................................................................208
	AFTER STARTING ENGINE............................................................................................................209
		Checking Engine Startability and Noise.......................................................................................209
		Checking Engine Acceleration and Deceleration................................................................................209
		Engine Warm Up...............................................................................................................210
		Hydraulic Equipment Warm Up..................................................................................................212
		Operation After Completion of Warm-Up Operation..............................................................................218
	STOPPING THE ENGINE..............................................................................................................220
	MACHINE OPERATION................................................................................................................221
		Preparations for Moving the Machine..........................................................................................221
		Moving Machine Forward.......................................................................................................222
		Moving Machine Backward......................................................................................................223
		Stopping Machine.............................................................................................................224
	STEERING THE MACHINE.............................................................................................................225
		Steering.....................................................................................................................225
			Steering the Machine When Stopped........................................................................................225
			Changing Direction of the Machine........................................................................................226
			Counter-rotation Turn (Spin Turn)........................................................................................226
	SWINGING.........................................................................................................................227
	WORK EQUIPMENT CONTROLS AND OPERATIONS...........................................................................................228
	WORKING MODE.....................................................................................................................230
	PROHIBITED OPERATIONS............................................................................................................232
		Operations Using Swing Force.................................................................................................232
		Operations Using Travel Force................................................................................................232
		Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends...........................................................232
		Operations Using Bucket Dropping Force.......................................................................................233
		Operations Using Machine Dropping Force......................................................................................233
		Digging Hard Rocky Ground....................................................................................................233
		Prohibition of Lifting Operation.............................................................................................234
		Sudden Lever or Pedal Shifting High Speed Travel.............................................................................234
		Support Blade on Both Sides..................................................................................................234
	GENERAL OPERATION INFORMATION....................................................................................................235
		Traveling....................................................................................................................235
		High Speed Travel............................................................................................................235
		Folding in Work Equipment....................................................................................................235
		Avoid Hitting Blade..........................................................................................................236
		Blade During Backhoe Operations..............................................................................................236
		Permissible Water Depth......................................................................................................236
	TRAVELING ON SLOPES..............................................................................................................237
		Traveling Downhill...........................................................................................................238
		Engine Stopped on Slope......................................................................................................238
		Cab Doors on Slope...........................................................................................................238
	ESCAPE FROM MUD..................................................................................................................239
		Track on One Side Stuck......................................................................................................239
		Tracks on Both Sides Stuck...................................................................................................239
	RECOMMENDED APPLICATIONS.........................................................................................................240
		Backhoe Work.................................................................................................................240
		Shovel Work..................................................................................................................240
		Ditching Work................................................................................................................240
		Loading Work.................................................................................................................241
		Refill and Finishing Work....................................................................................................241
		Side Ditching Work...........................................................................................................241
	BUCKET REPLACEMENT AND INVERSION.................................................................................................242
		Replacement..................................................................................................................242
		Inversion....................................................................................................................243
	PARKING MACHINE..................................................................................................................246
	MACHINE INSPECTION AFTER DAILY WORK..............................................................................................248
		Before Stopping Engine.......................................................................................................248
		After Stopping Engine........................................................................................................248
	LOCKING..........................................................................................................................248
	ROAD LINERS AND RUBBER SHOES.....................................................................................................249
		Road Liners and Rubber Shoes Information.....................................................................................249
		Warranty for Road Liners and Rubber Shoes....................................................................................249
		Using Road Liners and Rubber Shoes...........................................................................................250
			Prohibited Works.........................................................................................................250
			Long Life Operations.....................................................................................................250
	MACHINE READY FOR ATTACHMENT.....................................................................................................254
		Locations....................................................................................................................254
			Selector Valve...........................................................................................................254
			1st-Line Attachment Proportional Switch..................................................................................255
			Breaker Operation Switch.................................................................................................255
			Breaker Circuit Additional Oil Filter....................................................................................255
			Accumulator (For Low Pressure)...........................................................................................255
		Hydraulic Circuit............................................................................................................256
			Hydraulic Circuit Connection.............................................................................................256
		Attachment Removal And Installation..........................................................................................258
			Attachment Installation..................................................................................................258
			Attachment Removal.......................................................................................................260
		Attachment Operations........................................................................................................262
			When Using Breaker.......................................................................................................262
			When Using General Attachment Such As Crusher............................................................................264
		Long Term Storage............................................................................................................264
		Hydraulic Specifications.....................................................................................................264
	TRANSPORTATION...................................................................................................................264
		Transportation Procedure.....................................................................................................264
		Loading and Unloading with Trailer...........................................................................................265
			Loading..................................................................................................................266
			Securing Machine.........................................................................................................267
			Unloading................................................................................................................268
	LIFTING MACHINE..................................................................................................................271
	COLD WEATHER OPERATION...........................................................................................................272
		Fuel and Lubricants..........................................................................................................272
		Cooling System Coolant.......................................................................................................272
		Battery......................................................................................................................273
		After Daily Work Completion..................................................................................................274
		After Cold Weather Season....................................................................................................274
	LONG TERM STORAGE................................................................................................................275
		Before Storage...............................................................................................................275
		During Storage...............................................................................................................275
		After Storage................................................................................................................275
		Starting Machine After Long-term Storage.....................................................................................275
	TROUBLES AND ACTIONS.............................................................................................................276
		Running Out of Fuel..........................................................................................................276
		Phenomena That Are Not Failures..............................................................................................276
		Towing the Machine...........................................................................................................277
		Severe Job Condition.........................................................................................................277
		Discharged Battery...........................................................................................................278
			Battery Removal and Installation.........................................................................................279
			Battery Charges..........................................................................................................280
		Starting Engine with Booster Cables..........................................................................................281
			Connecting and Disconnecting Booster Cables..............................................................................281
			Booster Cable Connection.................................................................................................282
			Starting the Engine......................................................................................................282
			Booster Cable Disconnection..............................................................................................282
	TROUBLESHOOTING..................................................................................................................284
		Electrical System............................................................................................................284
		Chassis......................................................................................................................285
		Engine.......................................................................................................................286
		Electronic Control System....................................................................................................288
		Point of Contact to Telephone when Error Occurs..............................................................................288
MAINTENANCE..........................................................................................................................289
	GUIDES TO MAINTENANCE............................................................................................................290
		Check Service Meter..........................................................................................................290
		Komatsu Genuine Replacement Parts............................................................................................290
		Komatsu Genuine Oils.........................................................................................................290
		Always Use Clean Washer Fluid................................................................................................290
		Always Use Clean Oil and Grease..............................................................................................290
		Checking Foreign Materials in Drained Oil and on Filters.....................................................................290
		Fueling......................................................................................................................290
		Welding Instructions.........................................................................................................290
		Do Not Drop Things Inside Machine:...........................................................................................290
		Dusty Work Sites.............................................................................................................291
		Avoid Mixing Oil.............................................................................................................291
		Locking Inspection Covers....................................................................................................291
		Bleeding Air From Hydraulic Circuit..........................................................................................291
		Precautions When Installing Hydraulic Hoses..................................................................................291
		Checks After Inspection and Maintenance......................................................................................291
	OUTLINES OF SERVICE..............................................................................................................292
		Handling Oil, Fuel, Coolant, and Performing Oil Clinic.......................................................................292
			Oil......................................................................................................................292
			Fuel.....................................................................................................................292
			Coolant and Water for Dilution...........................................................................................293
			Grease...................................................................................................................293
			Performing KOWA (Komatsu Oil Wear Analysis)..............................................................................294
			Storing Oil and Fuel.....................................................................................................295
			Filters..................................................................................................................295
		Outline of Electric System...................................................................................................295
	WEAR PARTS LIST..................................................................................................................296
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................................................297
	USE OF FUEL, COOLANT AND LUBRICANTS..............................................................................................298
		Selection According to Ambient Temperature...................................................................................298
		Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil..........................................299
	STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................................................300
		Torque List..................................................................................................................300
	PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................................302
		Safety Critical Parts........................................................................................................302
	REGULAR SCHEDULED MAINTENANCE....................................................................................................304
		Maintenance Schedule Chart...................................................................................................304
	MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.......................................................................................305
	WHEN REQUIRED....................................................................................................................306
		Check, Clean and Replace Air Cleaner Element.................................................................................306
			Checking.................................................................................................................306
			Cleaning Outer Element...................................................................................................306
			Replacing Element........................................................................................................308
		Clean Inside of Cooling System...............................................................................................310
			Mixing Rate of Water and Antifreeze......................................................................................311
		Check and Tighten Track Shoe Bolts...........................................................................................313
			Method for Further Tightening of Steel Shoe..............................................................................313
			Method for Further Tightening of Road Liner..............................................................................313
			Order for tightening.....................................................................................................313
		Check and Adjust Track Tension...............................................................................................314
			Checking.................................................................................................................314
			Adjustment...............................................................................................................314
			Increasing Track Tension.................................................................................................314
			Loosening Track Tension..................................................................................................315
		Check Road Liners or Rubber Shoes............................................................................................316
			Lug Height...............................................................................................................316
			Rubber Shoe Steel Code Cuts..............................................................................................316
			Rubber Shoe Core Separations.............................................................................................317
			Rubber Shoe Tension......................................................................................................317
			Rubber Shoe Cracks.......................................................................................................317
		Check and Adjust Rubber Shoe Tension.........................................................................................318
			Checking.................................................................................................................318
			Adjustment...............................................................................................................318
			Increasing Track Tension.................................................................................................318
			Loosening Track Tension..................................................................................................319
		Replace Road Liners..........................................................................................................319
		Replace Rubber Shoes.........................................................................................................320
			Rubber Shoes Removal.....................................................................................................320
			Rubber Shoes Installation................................................................................................321
		Change Steel Shoes or Road Liner to Rubber Shoes.............................................................................322
			Changing from Steel Shoes or Road Liners to Rubber Shoes.................................................................322
			Changing from Rubber Shoes to Steel Shoes or Road Liners.................................................................322
		Replace Bucket Teeth (Vertical Pin Type).....................................................................................323
		Replace Bucket Teeth (Horizontal Pin Type)...................................................................................326
		Adjust Bucket Clearance......................................................................................................328
		Check Window Washer Fluid Level, Add Fluid...................................................................................329
		Check and Maintenance of Air Conditioner.....................................................................................330
			Check Level of Refrigerant (Gas).........................................................................................330
			Inspection During Off Season.............................................................................................330
			Inspection and Maintenance Items.........................................................................................330
		Check, Clean and Lubricate Cab Slide Door Rail and Roller....................................................................331
			Checking.................................................................................................................331
			Cleaning.................................................................................................................331
			Greasing.................................................................................................................331
		Replace Breaker Circuit Additional Oil Filter Element........................................................................332
		Wash Washable Floor..........................................................................................................333
			Method of Washing........................................................................................................333
			Method of Setting Machine at Angle.......................................................................................334
		Check Gas Spring.............................................................................................................336
		Bleeding Air From Hydraulic System...........................................................................................337
	CHECK BEFORE STARTING............................................................................................................340
	EVERY 100 HOURS MAINTENANCE......................................................................................................341
		Lubricating..................................................................................................................341
		Check Swing Machinery Case Oil, Add Oil......................................................................................342
	EVERY 250 HOURS MAINTENANCE......................................................................................................343
		Check Oil Level in Final Drive Case, Add Oil.................................................................................343
		Check Level of Battery Electrolyte...........................................................................................343
			When Checking Electrolyte Level from Side of Battery.....................................................................344
			When it is Impossible to Check Electrolyte Level from Side of Battery....................................................345
			When it is Possible to Use Indicator to Check Electrolyte Level..........................................................345
		Check and Adjust Cooling Fan Belt Tension....................................................................................346
			Checking.................................................................................................................346
			Adjustment...............................................................................................................347
		Check Air Conditioner Compressor Belt Tension, Adjust........................................................................348
			Checking.................................................................................................................348
			Adjustment...............................................................................................................349
	EVERY 500 HOURS MAINTENANCE......................................................................................................350
		Lubricating..................................................................................................................350
		Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge............................................................352
		Replace Fuel Pre-Filter Cartridge............................................................................................353
		Check Swing Pinion Grease Level, Add Grease..................................................................................355
		Lubricate Swing Circle.......................................................................................................355
		Clean and Inspect Radiator Fins, Oil Cooler Fins, After Cooler Fins, Fuel Cooler Fins, and Air Conditioner Condenser Fins....356
		Clean Air Conditioner Fresh/Recirc Filters...................................................................................357
			Cleaning Recirculated Air Filter.........................................................................................357
			Cleaning Fresh Air Filter................................................................................................357
		Replace Breather Element In Hydraulic Tank...................................................................................358
	EVERY 1000 HOURS MAINTENANCE.....................................................................................................359
		Change Oil in Swing Machinery Case...........................................................................................359
		Change Oil in Final Drive Case...............................................................................................360
		Replace Hydraulic Oil Filter Element.........................................................................................361
		Replace Fuel Main Filter Cartridge...........................................................................................363
		Check All Tightening Points of Engine Exhaust Pipe Clamps....................................................................365
		Check Oil Level in PTO Gear Case, Add Oil....................................................................................365
	EVERY 2000 HOURS MAINTENANCE.....................................................................................................366
		Check Alternator, Starting Motor.............................................................................................366
		Check Engine Valve Clearance, Adjust.........................................................................................366
		Checking Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit)................................................366
			Function of Accumulator..................................................................................................366
			Checking Function of Accumulator.........................................................................................367
			Method of Releasing Pressure In Hydraulic Circuit........................................................................369
	EVERY 4000 HOURS MAINTENANCE.....................................................................................................370
		Check Water Pump.............................................................................................................370
		Replace Accumulator (For Control Circuit)....................................................................................370
	EVERY 5000 HOURS MAINTENANCE.....................................................................................................371
		Change Oil in Hydraulic Tank, Clean Strainer.................................................................................371
SPECIFICATIONS.......................................................................................................................375
	SPECIFICATIONS...................................................................................................................376
OPTIONS, ATTACHMENTS.................................................................................................................379
	ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....................................................................................380
		Safety First.................................................................................................................380
		Attachment Installation......................................................................................................381
	BUCKET WITH HOOK.................................................................................................................382
		Hook Condition...............................................................................................................382
		Prohibited Operations........................................................................................................382
			Operations with Care.....................................................................................................382
	CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)..............................................................383
		Control Pattern Change Procedure.............................................................................................383
		Machine Control Patterns.....................................................................................................384
	HYDRAULIC QUICK COUPLER PIPING...................................................................................................385
		Locations....................................................................................................................385
		Operation....................................................................................................................386
			To Release a Bucket or Attachment........................................................................................386
			To Pick Up a New Bucket or Attachment....................................................................................386
	POWER ANGLE BLADE................................................................................................................387
		Blade Control Lever..........................................................................................................387
			Lifting Control..........................................................................................................387
			Angling Control..........................................................................................................387
		Maintenance..................................................................................................................388
			When Required............................................................................................................388
			Every 500 Hours Service..................................................................................................388
		Wear Parts List..............................................................................................................389
		Specifications...............................................................................................................389
	ATTACHMENT GUIDE.................................................................................................................390
		Attachment Combinations......................................................................................................390
		Track Shoes Selection........................................................................................................391
	RECOMMENDED ATTACHMENT OPERATIONS................................................................................................392
		Hydraulic Breaker............................................................................................................392
			Main Applications........................................................................................................392
			Prohibited Works.........................................................................................................394
			Greasing.................................................................................................................397
		Crusher......................................................................................................................398
			Main Applications........................................................................................................398
			Prohibited Works.........................................................................................................398
	HANDLING MACHINES EQUIPPED WITH KOMTRAX..........................................................................................402
		Basic Precautions............................................................................................................402

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.