Operation & Maintenance YEAM200201

Manual

PC200, 200LC-7,
PC210, 210LC-7,
PC220, 220LC-7
HYDRAULIC EXCAVATOR
PC200-7, DBB0001
PC200LC-7, DBE0001
SERIAL NUMBERS PC210-7, DBF0001 and up
PC210LC-7, DBG0001
PC220-7, DBH0001
PC220LC-7, DBJ0001

WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read this
manual before operating or maintaining this machine. This
manual should be kept near the machine for reference and
periodically reviewed by all personnel who will come into
contact with it.

NOTICE
Komatsu has Operation & Maintenance Manuals written in
some other languages. If a foreign language manual is
necessary, contact your local distributor for availability.
FOREWORD
11

1-1
FOREWORD FOREWORD

FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precau-
tions 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 hazard when performing operation and main-
tenance.

WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.

● Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.

● Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and speciffications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.

Storage location for the Operation and Maintenance Manual:

magazine box on the left side of the operator's seat.

1-2
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 situa-
tions.

Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.

In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
DANGER ous injury. This signal word is to be limited to most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or
WARNING serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
CAUTION erate injury. It may also be used to alert against unsafe practices.

Example of safety message using signal word

WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER
(located near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause 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 pro-
tect the machine or to give information that is useful to know.

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

This gives information that is useful to know.

REMARK

1-3
SAFETY INFORMATION FOREWORD

Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.

This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.

Example of safety label using words

Part No.

Safety labels using pictogram

Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams 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 condi-
tion at the top or left side, and the method of avoiding the haz-
ardous 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 precau-
tions. 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))

1-4
FOREWORD INTRODUCTION

INTRODUCTION
This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following works:

● Digging work

● Leveling work

● Ditching work

● Loading work

● Demolition work

See the section "RECOMMENDED APPLICATIONS (PAGE 3-97)" for further details.

DIRECTIONS OF MACHINE

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

1-5
PRODUCT INFORMATION FOREWORD

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

MACHINE SERIAL NUMBER PLATE AND ITS LOCATION

On the bottom right of the operator's cab

ENGINE SERIAL NUMBER PLATE AND ITS LOCATION

On the top of the No.1 cylinder head cover (The EPA auxiliary nameplate is on the top of the No. 5 cylinder head
cover.)

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

1-6
FOREWORD PRODUCT INFORMATION

SERVICE METER LOCATION

On top of the machine monitor

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Distributor name

Address

Service Personal

Phone/Fax

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CONTENTS FOREWORD

CONTENTS

FOREWORD
FOREWORD......................................................................................................................................................... 1-2

SAFETY INFORMATION...................................................................................................................................... 1-3

INTRODUCTION................................................................................................................................................... 1-5
DIRECTIONS OF MACHINE ...................................................................................................................... 1-5

PRODUCT INFORMATION .................................................................................................................................. 1-6

MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ...................................................................... 1-6
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ......................................................................... 1-6
SERVICE METER LOCATION ................................................................................................................... 1-7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ..................................................................... 1-7

CONTENTS .......................................................................................................................................................... 1-8

SAFETY
SAFETY INFORMATION...................................................................................................................................... 2-2

POSITION FOR ATTACHING SAFETY LABELS................................................................................................ 2-4

POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 2-4
SAFETY LABELS ....................................................................................................................................... 2-5

SAFETY INFORMATION.................................................................................................................................... 2-10

SAFETY MACHINE OPERATION ...................................................................................................................... 2-19

STARTING ENGINE ................................................................................................................................. 2-19
OPERATION............................................................................................................................................. 2-21
TRANSPORTATION................................................................................................................................. 2-27
BATTERY ................................................................................................................................................. 2-28
TOWING ................................................................................................................................................... 2-30
LIFTING OBJECTS WITH BUCKET ......................................................................................................... 2-31

SAFETY MAINTENANCE INFORMATION ........................................................................................................ 2-32

OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
GENERAL VIEW CONTROLS AND GAUGES........................................................................................... 3-3

EXPLANATION OF COMPONENTS.................................................................................................................... 3-4

MACHINE MONITOR ................................................................................................................................. 3-4

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FOREWORD CONTENTS

BASIC CHECK ITEMS................................................................................................................................ 3-5

SWITCHES ............................................................................................................................................... 3-17
CONTROL LEVERS, PEDALS ................................................................................................................. 3-22
CEILING WINDOW................................................................................................................................... 3-25
FRONT WINDOW..................................................................................................................................... 3-26
EMERGENCY EXIT FROM OPERATOR'S CAB ..................................................................................... 3-31
DOOR LOCK ............................................................................................................................................ 3-31
CAP, COVER WITH LOCK....................................................................................................................... 3-32
HOT AND COOL BOX .............................................................................................................................. 3-33
MAGAZINE BOX....................................................................................................................................... 3-33
ASHTRAY ................................................................................................................................................. 3-33
HANDLING AIR CONDITIONER .............................................................................................................. 3-34
CAR RADIO .............................................................................................................................................. 3-48
FUSE ........................................................................................................................................................ 3-53
FUSIBLELINK ........................................................................................................................................... 3-54
CONTROLLER (COMPUTER) ................................................................................................................. 3-55
TOOLBOX................................................................................................................................................. 3-55
GREASE GUN HOLDER .......................................................................................................................... 3-55
HANDLING ACCUMULATOR................................................................................................................... 3-56

MACHINE OPERATIONS AND CONTROLS..................................................................................................... 3-57

BEFORE STARTING ENGINE ................................................................................................................. 3-57
STARTING ENGINE ................................................................................................................................. 3-70
AFTER STARTING ENGINE .................................................................................................................... 3-74
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) .............................................................. 3-77
STOPPING THE ENGINE ........................................................................................................................ 3-80
CHECK AFTER SHUT OFF ENGINE....................................................................................................... 3-80
MACHINE OPERATION ........................................................................................................................... 3-81
STEERING THE MACHINE...................................................................................................................... 3-85
SWINGING ............................................................................................................................................... 3-87
WORK EQUIPMENT CONTROLS AND OPERATIONS .......................................................................... 3-88
OPERATING WORKING MODE .............................................................................................................. 3-90
PROHIBITED OPERATIONS ................................................................................................................... 3-91
GENERAL OPERATION INFORMATION ................................................................................................ 3-93
TRAVELING ON SLOPES........................................................................................................................ 3-94
ESCAPE FROM MUD............................................................................................................................... 3-96
RECOMMENDED APPLICATIONS.......................................................................................................... 3-97
REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 3-99
PARKING MACHINE .............................................................................................................................. 3-102
CHECK AFTER FINISHING WORK ....................................................................................................... 3-103
LOCKING................................................................................................................................................ 3-104

TRANSPORTATION......................................................................................................................................... 3-105
TRANSPORTATION PROCEDURE....................................................................................................... 3-105
LOADING AND UNLOADING WITH TRAILER ...................................................................................... 3-106
LIFTING MACHINE................................................................................................................................. 3-113

COLD WEATHER OPERATION ...................................................................................................................... 3-115

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CONTENTS FOREWORD

COLD WEATHER OPERATION INFORMATION................................................................................... 3-115

AFTER DAILY WORK COMPLETION .................................................................................................... 3-117
AFTER COLD WEATHER SEASON ...................................................................................................... 3-118

LONG TERM STORAGE .................................................................................................................................. 3-119

BEFORE STORAGE............................................................................................................................... 3-119
DURING STORAGE ............................................................................................................................... 3-119
AFTER STORAGE.................................................................................................................................. 3-120

TROUBLESHOOTING...................................................................................................................................... 3-121
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-121
PHENOMENA THAT ARE NOT FAILURES ........................................................................................... 3-121
TOWING THE MACHINE ....................................................................................................................... 3-122
LIGHTWEIGHT TOWING HOOK............................................................................................................ 3-122
PRECAUTIONS ON PARTICULAR JOBSITES ..................................................................................... 3-123
DISCHARGED BATTERY ...................................................................................................................... 3-124
OTHER TROUBLE ................................................................................................................................. 3-128

MAINTENANCE
MAINTENANCE INFORMATION ......................................................................................................................... 4-2

LUBRICANTS, COOLANT AND FILTERS .......................................................................................................... 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................................... 4-5
ELECTRIC SYSTEM MAINTENANCE ....................................................................................................... 4-8
HANDLING HYDRAULIC SYSTEM ............................................................................................................ 4-8

WEAR PARTS LIST ........................................................................................................................................... 4-10

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..................... 4-11

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ......................................................... 4-11

TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................... 4-15

TIGHTENING TORQUE LIST ................................................................................................................... 4-15

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-16

SAFETY CRITICAL PARTS...................................................................................................................... 4-16

MAINTENANCE SCHEDULE ............................................................................................................................. 4-17

MAINTENANCE SCHEDULE CHART ...................................................................................................... 4-17
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..................................................................... 4-19

MAINTENANCE PROCEDURE.......................................................................................................................... 4-20

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ................................... 4-20
WHEN REQUIRED ................................................................................................................................... 4-21
CHECK BEFORE STARTING .................................................................................................................. 4-46
EVERY 100 HOURS MAINTENANCE...................................................................................................... 4-47
EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-49
EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-54

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FOREWORD CONTENTS

EVERY 1000 HOURS MAINTENANCE.................................................................................................... 4-62

EVERY 2000 HOURS MAINTENANCE.................................................................................................... 4-66
EVERY 4000 HOURS MAINTENENCE.................................................................................................... 4-68
EVERY 5000 HOURS MAINTENANCE.................................................................................................... 4-69

SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2

ATTACHMENTS AND OPTIONS

GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ................................................................................................... 6-2
PRECAUTIONS WHEN INSTALLING ATTACHMENTS ............................................................................ 6-4

HANDLING BUCKET WITH HOOK ..................................................................................................................... 6-5

CHECKING FOR DAMAGE TO BUCKET WITH HOOK ............................................................................ 6-5
PROHIBITED OPERATIONS ..................................................................................................................... 6-5

MACHINES READY FOR ATTACHMENTS ........................................................................................................ 6-6

EXPLANATION OF COMPONENTS .......................................................................................................... 6-6
HYDRAULIC CIRCUIT................................................................................................................................ 6-9
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE .................................................................. 6-13
OPERATION............................................................................................................................................. 6-15
LONG-TERM STORAGE.......................................................................................................................... 6-17
SPECIFICATIONS .................................................................................................................................... 6-17

ATTACHMENT GUIDE....................................................................................................................................... 6-20

COMBINATIONS OF WORK EQUIPMENT.............................................................................................. 6-20
SELECTION OF TRACK SHOES............................................................................................................. 6-23
SELECTION OF BUCKET TEETH ........................................................................................................... 6-24
STANDARDS FOR SELECTING VERTICAL PIN TYPE
AND HORIZONTAL PIN TYPE TEETH .................................................................................................... 6-24
HANDLING OF RUBBER PAD SHOE AND ROAD LINER ...................................................................... 6-25
HANDLING TRAPEZOIDAL BUCKET...................................................................................................... 6-27
HANDLING EXTENSION ARM................................................................................................................. 6-28
HANDLING CLAMSHELL BUCKET ......................................................................................................... 6-29

RECOMMENDED ATTACHMENT OPERATIONS ............................................................................................ 6-30

HYDRAULIC BREAKER ........................................................................................................................... 6-30

INDEX .............................................................................................................................................................. 7-1

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 SAFETY
21

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

2-1
SAFETY INFORMATION SAFETY

SAFETY INFORMATION
POSITION FOR ATTACHING SAFETY LABELS ................................................................................................. 2-4
POSITION FOR ATTACHING SAFETY LABELS ............................................................................................ 2-4
SAFETY LABELS............................................................................................................................................. 2-5

SAFETY INFORMATION .................................................................................................................................... 2-10

SAFETY RULES ....................................................................................................................................... 2-10
IF ABNORMALITIES ARE FOUND .......................................................................................................... 2-10
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ................................................................... 2-10
FIRE EXTINGUISHER AND FIRST AID KIT ............................................................................................ 2-10
SAFETY EQUIPMENT.............................................................................................................................. 2-11
KEEP MACHINE CLEAN.......................................................................................................................... 2-11
KEEP OPERATOR'S COMPARTMENT CLEAN ...................................................................................... 2-11
LEAVING OPERATOR'S SEAT WITH LOCK........................................................................................... 2-11
HANDRAILS AND STEPS ........................................................................................................................ 2-12
MOUNTING AND DISMOUNTING ........................................................................................................... 2-13
NO PERSONS ON ATTACHMENTS........................................................................................................ 2-13
BURN PREVENTION ............................................................................................................................... 2-13
FIRE PREVENTION AND EXPLOSION PREVENTION........................................................................... 2-14
ACTION IF FIRE OCCURS ...................................................................................................................... 2-15
WINDSHIELD WASHER FLUID ............................................................................................................... 2-15
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION ......................... 2-15
ATTACHMENT INSTALLATION............................................................................................................... 2-15
ATTACHMENT COMBINATIONS............................................................................................................. 2-16
CAB WIDOW GLASSES........................................................................................................................... 2-16
UNAUTHORIZED MODIFICATIONS ........................................................................................................ 2-16
SAFETY AT JOBSITE .............................................................................................................................. 2-16
WORKING ON LOOSE GROUND............................................................................................................ 2-16
DISTANCE TO HIGH VOLTAGE CABLES............................................................................................... 2-17
ENSURE GOOD VISIBILITY .................................................................................................................... 2-17
VENTILATION FOR ENCLOSED AREA .................................................................................................. 2-18
SIGNALMAN'S SIGNAL AND SIGNS....................................................................................................... 2-18
EMERGENCY EXIT FROM OPERATOR'S CAB...................................................................................... 2-18
ASBESTOS DUST HAZARD PREVENTION............................................................................................ 2-18

2-2
SAFETY SAFETY INFORMATION

SAFETY MACHINE OPERATION ...................................................................................................................... 2-19

STARTING ENGINE ...................................................................................................................................... 2-19
CHECKS BEFORE STARTING ENGINE ................................................................................................. 2-19
SAFETY RULES FOR STARTING ENGINE ............................................................................................ 2-20
STARTING ENGINE IN COLD WEATHER .............................................................................................. 2-20
OPERATION.................................................................................................................................................. 2-21
CHECKS AFTER STARTING ENGINE .................................................................................................... 2-21
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS ................................................................. 2-21
SAFETY RULES FOR TRAVELING ......................................................................................................... 2-22
TRAVELING ON SLOPES........................................................................................................................ 2-23
OPERATIONS ON SLOPES..................................................................................................................... 2-24
PROHIBITED OPERATIONS ................................................................................................................... 2-24
OPERATIONS ON SNOW........................................................................................................................ 2-26
PARKING MACHINE ................................................................................................................................ 2-26
TRANSPORTATION...................................................................................................................................... 2-27
SHIPPING THE MACHINE ....................................................................................................................... 2-27
BATTERY ...................................................................................................................................................... 2-28
BATTERY HAZARD PREVENTION ......................................................................................................... 2-28
STARTING ENGINE WITH BOOSTER CABLES ..................................................................................... 2-29
TOWING ........................................................................................................................................................ 2-30
SAFETY RULES FOR TOWING............................................................................................................... 2-30
LIFTING OBJECTS WITH BUCKET.............................................................................................................. 2-31
SAFETY RULES FOR LIFTING OBJECTS .............................................................................................. 2-31

SAFETY MAINTENANCE INFORMATION......................................................................................................... 2-32

WARNING TAG ........................................................................................................................................ 2-32
KEEP WORK PLACE CLEAN AND TIDY................................................................................................. 2-32
APPOINT LEADER WHEN WORKING WITH OTHERS .......................................................................... 2-32
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................. 2-33
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ................................................. 2-34
PROPER TOOLS...................................................................................................................................... 2-34
ACCUMULATOR ...................................................................................................................................... 2-35
PERSONNEL............................................................................................................................................ 2-35
ATTACHMENTS ....................................................................................................................................... 2-35
WORK UNDER THE MACHINE ............................................................................................................... 2-35
NOISE....................................................................................................................................................... 2-36
WHEN USING HAMMER.......................................................................................................................... 2-36
WELDING WORKS................................................................................................................................... 2-36
REMOVING BATTERY TERMINALS ....................................................................................................... 2-36
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
SAFETY HANDLING HIGH-PRESSURE HOSES.................................................................................... 2-38
WASTE MATERIALS................................................................................................................................ 2-38
AIR CONDITIONER MAINTENANCE....................................................................................................... 2-38
COMPRESSED AIR ................................................................................................................................. 2-38
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................................................................. 2-39

2-3
POSITION FOR ATTACHING SAFETY LABELS SAFETY

POSITION FOR ATTACHING SAFETY LABELS

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

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

● To ensure that the content of labels can be read properly. Be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline, there may cause the labels to
peel off.

● There are also other labels in addition to the warning signes and safety labels. Handle those labels in the
same way.

● If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

POSITION FOR ATTACHING SAFETY LABELS

2-4
SAFETY POSITION FOR ATTACHING SAFETY LABELS

SAFETY LABELS

(1) Precautions for operation, inspection and (2) Precautions for before operation (09802-03000)
maintenance (09651-A0641)

(3) Warning for leaving operator's seat (4) Warnings for high voltage (09801-A0641)
(09654-A0641)

2-5
POSITION FOR ATTACHING SAFETY LABELS SAFETY

(5) Warnings when opening front window (6) Warnings when stowing front window
(09839-03000) (09308-A0481)

7) Precautions for high-temperature cooling water (8) Precautions when handling accumulator
and hydraulic oil (09653-A0481) (09659-A057B)

2-6
SAFETY POSITION FOR ATTACHING SAFETY LABELS

(9) Precautions when adjusting track tension (10) Precautions when handling cable (09808-A0881)
(09657-A0881)

(11) Stop rotation when performing testing and (12) Explanation of methods for emergency escape
adjusting (09667-A0481) (20Y-00-D1240)

2-7
POSITION FOR ATTACHING SAFETY LABELS SAFETY

(13) Roll-over precautions (09805-A0881) (14) Roll-over precautions (09805-C0881)

(15) Prohibited to enter within swing range (16) Beware of equipment (09134-A1681)
(09133-A3281)

2-8
SAFETY POSITION FOR ATTACHING SAFETY LABELS

(17) Precautions for broken or becomes dislodged to

the windiow (20U-98-21910)

2-9
SAFETY INFORMATION SAFETY

SAFETY INFORMATION

SAFETY RULES
● Only trained and authorized personnel can operate and maintain the machine.

● Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.

● If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.

● When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.

IF ABNORMALITIES ARE FOUND

If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been cor-
rected.

WORKING WEAR AND PERSONAL PROTECTIVE ITEMS

● Do not wear loose clothing and accessories. There is a
hazardthat they may catch on control levers or other pro-
truding parts.

● If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.

● Always wear a hard hat and safety shoes. If the nature of

the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.

● Check that all protective equipment functions properly

before using it.

FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.

● Be sure that fire extinguishers have been provided and

read the labels to ensure that you know how to use them in
emergencies.

● Carry out periodic inspection and maintenance to ensure

that the fire extinguisher can always be used.

● Provide a first aid kit at the storage point. Carry out periodic
checks and add to the contents if necessary.

2-10
SAFETY SAFETY INFORMATION

SAFETY EQUIPMENT
● Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately
if they are damaged.

● Understand the method of use of safety features and use them properly.

● Never remove any safety features. Always keep them in good operating condition.

KEEP MACHINE CLEAN

● If water gets into the electrical system, there is a hazard
that it will cause malfunctions or misoperation. Do not use
water or steam to wash the electrical system (sensors,
connectors).

● If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.

KEEP OPERATOR'S COMPARTMENT CLEAN

● When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you
operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious acci-
dent.

● Do not leave parts or tools lying around the operator's compartment.

● Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

● Do not use cellular telephones inside the operator's compartment when driving or operating the machine.

● Never bring any dangerous objects such as flammable or explosive items into the operator's cab.

LEAVING OPERATOR'S SEAT WITH LOCK

● Before standing up from the operator's seat (such as when
opening or closing the front window or roof window, or
when removing or installing the bottom window, or when
adjusting the operator's seat), lower the work equipment
completely to the ground, set safety lock lever (1) securely
to the LOCK position, then stop the engine. If you acciden-
tally touch the levers when they are not locked, there is a
hazard that the machine may suddenly move and cause
serious injury or property damage.

2-11
SAFETY INFORMATION SAFETY

● When leaving the machine, always lower the work equip-

ment completely to the ground, set safety lock lever (1)
securely to the LOCK position, then stop the engine. Use
the key to lock all the equipment. Always remove the key,
take it with you, and keep it in the specified place.

HANDRAILS AND STEPS

To prevent personal injury caused by slipping or falling off the machine, always do as follows.

● Use the handrails and steps marked by arrows in the dia-

gram on the right when getting on or off the machine.

● To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps (including the
track shoe) to ensure that you support yourself.

● Do not grip the control levers when getting on or off the

machine.

● Never climb on the engine hood or covers where there are

no non-slip pads.

● Before getting on or off the machine, check the handrails and steps (including the track shoe). If there is any
oil, grease, or mud on the handrails or steps (including the track shoe), wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose bolts.

● Do not get on or off the machine while holding tools in your hand.

2-12
SAFETY SAFETY INFORMATION

MOUNTING AND DISMOUNTING

● Never jump on or off the machine. Never get on or off a moving machine.

● If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.

NO PERSONS ON ATTACHMENTS
Never let anyone ride on the bucket, grapple, clamshell, or other attachments. There is a hazard of falling and suf-
fering serious injury.

BURN PREVENTION
Hot coolant
● To prevent burns from hot water or steam spurting out
when checking or draining the coolant, wait for the water to
cool to a temperature where it is possible to touch the radi-
ator cap by hand before starting the operation. Even when
the coolant has cooled down, loosen the cap slowly to
relieve the pressure inside the radiator before removing the
cap.

Hot oil
● To prevent burns from oil spurting out out or from contact
with hot parts when checking or draining the oil, wait for the
oil to cool to a temperature where it is possible to touch the
cap or plug by hand before starting the operation. Even
when the oil has cooled down, loosen the cap or plug
slowly to relieve the internal pressure before removing the
cap or plug.

2-13
SAFETY INFORMATION SAFETY

FIRE PREVENTION AND EXPLOSION PREVENTION

● Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particu-
larly flammable and can be hazardous. To prevent fire,
always observe the following:

● Do not smoke or use any flame near fuel or oil.

● Stop the engine before refueling.

● Do not leave the machine while adding fuel or oil.

● Tighten all fuel and oil caps securely.

● Do not spill fuel on overheated surfaces or on parts of

the electrical system.

● Use well-ventilated areas for adding or storing oil and

fuel.

● Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.

● After adding fuel or oil, wipe up any spilled fuel or oil.

● When carrying out grinding or welding work on the

chassis, move any flammable materials to a safe place
before starting.

● When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire, so do not
use them.

● Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.

● Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

● Fire caused by accumulation of flammable material.

● Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or
affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.

● Fire coming from electric wiring

Short circuits in the electrical system can cause fire.

● Always keep electric wiring connections clean and securely tightened.

● Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.

● Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.

If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to
the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

● Explosion caused by lighting equipment

● When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, there is danger of explosion that may
cause serious injury.

● When taking the electrical power for the lighting from the machine, follow the instructions in this manual.

2-14
SAFETY SAFETY INFORMATION

ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.

● Turn the starting switch OFF and stop the engine.

● Use the handrails and steps to get off the machine.

WINDSHIELD WASHER FLUID

Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS

PREVENTION
On jobsites where there is a hazard that falling objects, flying
objects, or intruding objects may hit or enter the operator's cab,
consider the operating conditions and install the necessary
guards to protect the operator.

● When carrying out demolition or breaker operations, install

a front guard and use a laminated coating sheet on the
front glass.

● When working in mines or quarries where there is a hazard

of falling rock, install FOPS (Falling Objects Protective
Structure) and a front guard, and use a laminated coating
sheet on the front glass.

● When carrying out the above operations, always close the

front window. In addition, always ensure that by standers
are a safe distance away and are not in hazard from falling
or flying objects.

● The above recommendations assume that the conditions

are for standard operations, but it may be necessary to add
additional guards according to the operating conditions on
the jobsite.
Always contact your Komatsu distributor for advice.

ATTACHMENT INSTALLATION
● When installing optional parts or attachments, there may be problems with safety or legal restrictions, so
please contact your Komatsu distributor for advice.

● Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.

● When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.

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SAFETY INFORMATION SAFETY

ATTACHMENT COMBINATIONS
Depending on the type or combination of work equipment, there is a hazard that the work equipment may hit the
cab or other parts of the machine. Before using unfamiliar work equipment, check if there is any hazard of interfer-
ence, and operate with caution.

CAB WIDOW GLASSES

● If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact
the operator's body directly. Stop operation immediately and replace the glass.

● If roof windows made of organic glass (polycarbonate) are damaged, they may crack and lose their protective
function. If the roof window has been damaged or cracked by falling stones or rocks, replace it with a new
part.

UNAUTHORIZED MODIFICATIONS
Any modification mode without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.

● Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications
made without authorization from Komatsu.

SAFETY AT JOBSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

● When carrying out operations near combustable materials such as thatched roofs, dry leaves or dry grass,
there is a hazard of fire, so be careful when operating.

● Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not carry out operations at places where there is a hazard of landslides or falling rocks.

● If water lines, gas lines, or high-voltage electrical lines may

be buried under the worksite, contact each utility and iden-
tify their locations. Be careful not to sever or damage any
of these lines.

● Take necessary measures to prevent any unauthorized

person from entering the operating area.

● When traveling or operating in shallow water or on soft

ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting
operations.

WORKING ON LOOSE GROUND

● Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.

● When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.

2-16
SAFETY SAFETY INFORMATION

DISTANCE TO HIGH VOLTAGE CABLES

Do not travel or operate the machine near electric cables.
There is a hazard of electric shock, which may cause serious
injury or property damage. On jobsites where the machine may
go close to electric cables, always do as follows.

● Before starting work near electric cables, inform the local

power company of the work to be performed, and ask them
to take the necessary action.

● Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.
Min. safety
Always maintain a safe distance (see the table on the right) Voltage
distance
between the machine and the electric cable. Check with
the local power company about safe operating procedure
Low 100V 200V 2m
before starting operations.
voltage 6,600V 2m
● To prepare for any possible emergencies, wear rubber
shoes and gloves. Lay a rubber sheet on top of the seat, 22,000V 3m
and be careful not to touch the chassis with any exposed
66,000V 4m
part of your body.
Very high 154,000V 5m
● Use a signalman to give warning if the machine
approaches too close to the electric cables. voltage 187,000V 6m

● When carrying out operations near high voltage cables, do 275,000V 7m

not let anyone come close to the machine.
500,000V 11m
● If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not
leave the operator's compartment until it has been con-
firmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.

ENSURE GOOD VISIBILITY

● Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.

● When working in dark places, turn on the working lamp and front lamps installed to the machine, and set
up additional lighting in the work area if necessary.

● Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.

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SAFETY INFORMATION SAFETY

VENTILATION FOR ENCLOSED AREA

If it is necessary to start the engine within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to pre-
vent gas poisoning.

SIGNALMAN'S SIGNAL AND SIGNS

● Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

● Only one signalman should give signals.

● Make sure that all workers understand the meaning of all signals and signs before starting work.

EMERGENCY EXIT FROM OPERATOR'S CAB

● If it should becomes impossible to open the cab door for any reason, open the rear window and use it as an
emergency escape. For details, see "EMERGENCY EXIT FROM OPERATOR'S CAB (PAGE 3-31)" in this
manual.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following.

● Spray water to keep down the dust when cleaning. Do not

use compressed air for cleaning.

● If there is danger that there may be asbestos dust in the

air, always operate the machine from an upwind position.
All workers should use an approved respirator.

● Do not allow other persons to approach during the operation.

● Always observe the rules and regulations for the work site and environmental standards.

This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always
use genuine Komatsu parts.

2-18
SAFETY SAFETY MACHINE OPERATION

SAFETY MACHINE OPERATION

STARTING ENGINE
If there is a warning tag hanging from the work equipment con-
trol lever, do not start the engine or touch the levers.

CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the day's work.

● Remove all dirt from the surface of the window glass to ensure a good view.

● Remove all dirt from the surface of the lens of the front lamps and working lamps, and check that they light up
correctly.

● Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.

● Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.

● Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-
trol levers are all at the neutral position.

● Before starting the engine, check that the safety lock lever is at the LOCK position.

● Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat.
When adjusting, see "ADJUSTMENT OF MIRRORS (PAGE 3-66)".

● Check that there are no persons or obstacles above, below, or in the area around the machine.

2-19
SAFETY MACHINE OPERATION SAFETY

SAFETY RULES FOR STARTING ENGINE

● When starting the engine, sound the horn as a warning.

● Start and operate the machine only while seated.

● Do not allow anyone apart from the operator to ride on the machine.

● Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause
damage to the equipment.

STARTING ENGINE IN COLD WEATHER

● Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.

● If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check for
frost and leakage of battery electrolyte before starting.

2-20
SAFETY SAFETY MACHINE OPERATION

OPERATION

CHECKS AFTER STARTING ENGINE

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.

● Always fasten your seat belt.

● Check that the movement of the machine matches the display on the control pattern card. If it does not match,
replace it immediately with the correct control pattern card.

● Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system, swing system, and steering system.

● Check for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check also that there
is no leakage of oil or fuel.

● If any abnormality is found, carry out repairs immediately.

SAFETY RULES FOR CHANGING MACHINE DIRECTIONS

● Position the upper structure so that the sprocket is at the
rear of the operator's cab before traveling.
If the sprocket is at the front of the operator's cab, the
direction of operations is reversed (for example, forward
becomes reverse, and left becomes right).

● Before travelling, check again that there is no one in the

surrounding area, and that there are no obstacles.

● Before travelling, sound the horn to warn people in the

area.

● Always operate the machine only when seated.

● Do not allow anyone apart from the operator to ride on the

machine.

● Check that the travel alarm (if equipped) works properly.

● Always lock the door and windows of the operator's com-

partment in position (open or closed).
On jobsites where there is a hazard of flying objects or of
objects entering the operator's compartment, check that
the door and windows are securely closed.

● If there is an area to the rear of the machine which cannot

be seen, position a signal person. Take special care not to
hit other machines or people when turning or swinging the
machine.

Always be sure to carry out the above precautions even when

the machine is equipped with mirrors.

A0067200

2-21
SAFETY MACHINE OPERATION SAFETY

SAFETY RULES FOR TRAVELING

● When using the machine, to prevent the machine from
overturning due to overloading and to avoid damage to the
work equipment, do not exceed the maximum permitted
load or performance of the machine.

● When traveling on level ground, pull in the work equipment

and keep it at a height of 40 to 50cm (16 to 20 in) from the
ground.

● When traveling on rough ground, travel at low speed and

do not operate the steering suddenly. There is danger that
the machine may turn over. The work equipment may hit
the ground surface and cause the machine to lose its bal-
ance, or may damage the machine or structures in the
area.

● When traveling on rough ground or steep slopes, if the

machine is equipped with auto-deceleration, always turn
the auto-deceleration switch OFF (cancel). If the auto-
deceleration is ON, the engine speed may rise and the
travel speed may suddenly increase.

● Avoid traveling over obstacles when possible. If the

machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine tilt
strongly to one side.

● When traveling or carrying out operations, always keep a

safe distance from people, structures, or other machines to
avoid coming into contact with them.

● When passing over bridges or structures, check first that

the structure is strong enough to support the weight of the
machine.
When traveling on public roads, check first with the rele-
vant authorities and follow their instructions.

● When operating in tunnels, under bridges, under electric

wires, or other places where the height is limited, operate
slowly and be extremely careful not to let the work equip-
ment hit anything.

2-22
SAFETY SAFETY MACHINE OPERATION

TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side,
always do as follows.

● When traveling on slopes, keep the work equipment

approximately 20 to 30cm (8 to 12 in) above the ground. In
case of emergency, quickly lower the work equipment to
the ground immediately to help stop the machine.

● When travel up slopes, set the operator's cab facing uphill,

when travel down slopes, set the operator's cab facing
downhill.
Always check the firmness of the ground under the front of
the machine when traveling.

● When traveling up a steep slope, extend the work equip-

ment to the front to improve the balance, keep the work
equipment approximately 20 to 30cm (8 to 12 in) above the
ground, and travel at low speed.

● When traveling downhill, lower the engine speed, keep the

travel lever close to the neutral position, and travel at low
speed.

● Always travel straight up or down a slope. Traveling at an

angle or across the slope is extremely dangerous.

● Do not turn on slopes or travel across slopes. Always go

down to a flat place to change the position of the machine,
then travel on to the slope again.

● Travel on grass, fallen leaves, or wet steel plates with low

speed. Even with slight slopes there is a hazard that the
machine may slip.

● If the engine stops when the machine is traveling on a

slope, move the control levers immediately to the neutral
position and start the engine again.

2-23
SAFETY MACHINE OPERATION SAFETY

OPERATIONS ON SLOPES
● When working on slopes, there is a hazard that the machine may lose its balance and turn over when the
swing or work equipment are operated. This may lead to serious injury or property damage, so always provide
a stable place when carrying out these operations, and operate carefully.

● Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.

● If the machine has to be used on a slope, pile the soil to

make a platform that will keep the machine as horizontal as
possible.

PROHIBITED OPERATIONS
● Never dig the work face under an overhang. There is a
hazard that rocks may fall or that the overhang may col-
lapse and fall on top of the machine.

● Do not excavate too deeply under the front of the machine.

The ground under the machine may collapse and cause
the machine to fall.

● To make it easier to escape if there is any problem, set the

trackes at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out digging operations.

2-24
SAFETY SAFETY MACHINE OPERATION

● Do not carry out demolition work under the machine. There

is a hazard that the machine may become unstable and tip
over.

● When working on or from the top of buildings or other

structures, check the strength and the structure before
starting operations.
There is a hazard of the building collapsing and causing
serious injury or damage.

● When carrying out demolition work, do not carry out demo-

lition above your head. There is a hazard of broken parts
falling or of the building collapsing and causing serious
injury or property damage.

● Do not use the impact force of the work equipment for

breaking work. There is a hazard of personal injury or prop-
erty damage being caused by flying pieces of broken mate-
rial or damage to the work equipment.

● Generally speaking, the machine is more liable to overturn

when the work equipment is at the side than when it is at
the front or rear.

● When using a breaker or other heavy work equipment, there is a hazard of the machine losing its balance and
tipping over. When operating on flat ground as well as on slopes.

● Do not suddenly lower, swing, or stop the work equipment.

● Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the machine
to tip over.

● Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other
hauling equipment. The load may spill or the bucket may hit the dump truck and cause serious injury or prop-
erty damage.

2-25
SAFETY MACHINE OPERATION SAFETY

OPERATIONS ON SNOW
● Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the
machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.

● With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.

● If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.

● When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.

PARKING MACHINE
● Park the machine on firm, level ground.

● Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.

● Lower the work equipment completely to the ground.

● When leaving the machine, set safety lock lever (1) to the
LOCK position, then stop the engine.

● Always close the operator's cab door, and use the key to
lock all the equipment in order to prevent any unauthorized
person from moving the machine. Always remove the key,
take it with you, and leave it in the specified place.

● If it is necessary to park the machine on a slope, always do

as follows.

● Set the bucket on the downhill side, then dig it into the
ground.

● Put blocks under the tracks to prevent the machine

from moving.

2-26
SAFETY SAFETY MACHINE OPERATION

TRANSPORTATION
The machine can be divided into parts for transportation, so when transportating the machine, please contact your
Komatsu distributor to have the work carried out.

SHIPPING THE MACHINE

When shipping the machine on a trailer, do as follows.

● Investigate all state and local laws governing the weight, width, and length of a load. If necessary, disassemble
the work equipment. The width, height and weight of the load differ according to the work equipment, so take
this into account when determining the shipping route.

● When passing over bridges or structures on private land, check first that the structure is strong enough to sup-
port the weight of the machine. When traveling on public roads, check first with the relevant authorities and fol-
low their instructions.

● For details of the shipping procedure, see"TRANSPORTATION (PAGE 3-105)" in the OPERATION section.

2-27
SAFETY MACHINE OPERATION SAFETY

BATTERY

BATTERY HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.

Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.

● Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may
cause an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the
electrolyte level to the UPPER LEVEL line.

● When working with batteries, always wear safety glasses and rubber gloves.

● Never smoke or use any flame near the battery.

● If you spill acid on your clothes or skin, immediately flush

the area with large amounts of water.

● If acid gets into your eyes, flush them immediately with

large quantities of water and seek medical attention.

● Before working with batteries, turn the starting switch to the OFF position.

As there is a hazard that sparks will be generated, always do as follows.

● Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.

● Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals
securely.

● Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.

● Tighten the battery caps securely.

● Install the battery securely to the determined place.

2-28
SAFETY SAFETY MACHINE OPERATION

STARTING ENGINE WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.

● When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the opera-
tor's seat and the other working with the battery).

● When starting from another machine, do not allow the two

machines to touch.

● When connecting the booster cables, turn the starting

switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.

● Be sure to connect the positive (+) cable first when install-

ing the booster cables. Disconnect the ground or negative
(-) cable (ground side) first when removing them.

● When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch
the machine.

● Always wear safety goggles and rubber gloves when start-

ing the engine with booster cables.

● When connecting a normal machine to a problem machine with booster cables, always use a normal machine
with the same battery voltage as the problem machine.

● For details of the starting procedure when using booster cables, see "STARTING ENGINE WITH BOOSTER
CABLES (PAGE 3-126)" in the OPERATION section.

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SAFETY MACHINE OPERATION SAFETY

TOWING

SAFETY RULES FOR TOWING

Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec-
tion or inspection of the wire rope.

For towing, see "TOWING THE MACHINE (PAGE 3-122)".

● Always wear leather gloves when handling wire rope.

● Fix the wire rope to the truck frame.

● During the towing operation, never stand between the tow-

ing machine and the machine being towed.

● Never tow a machine on a slope.

● Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope
may break during the towing operation.

2-30
SAFETY SAFETY MACHINE OPERATION

LIFTING OBJECTS WITH BUCKET

SAFETY RULES FOR LIFTING OBJECTS

● Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable.

● Use wire rope that conforms to the specified standard.

● Do not exceed the specified lifting load.

For details of the maximum lifting load permitted for this machine, see "HANDLING BUCKET WITH HOOK
(PAGE 6-5)"

● It is dangerous if the load hits any worker or structure. Always check carefully that the surrounding area is safe
before swinging or turning the machine.

● Do not start, swing, or stop the machine suddenly. There is a hazard that the lifted load will swing.

● Do not pull the load to the side or in towards the machine.

● Do not leave the operator's seat when there is a raised

load.

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SAFETY MAINTENANCE INFORMATION SAFETY

SAFETY MAINTENANCE INFORMATION

WARNING TAG
● Always attach the "DO NOT OPERATE" warning tag to the
work equipment control lever in the operator's cab to alert
others that you are performing service or maintenance on
the machine.
Attach additional warning tags around the machine if nec-
essary.
Warning tag Part No. 09963-A1640
Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation man-
ual pocket.

● If others start the engine, or touch or operate the work

equipment control lever while you are performing service
or maintenance, you could suffer serious injury or property
damage.

KEEP WORK PLACE CLEAN AND TIDY

● Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out opera-
tions safely.
If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure your-
self.

● Use water to clean roof windows made of organic glass (polycarbonate); do not use any organic solvent. If
benzene, toluene, methanol, or other organic solvents are used, there will be chemical reactions such as the
glass dissolving or decomposing, and the polycarbonate will deteriorate.

APPOINT LEADER WHEN WORKING WITH OTHERS

● When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.

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SAFETY SAFETY MAINTENANCE INFORMATION

STOP ENGINE BEFORE CARRYING OUT MAINTENANCE

● Stop the machine on firm, level ground.

● Select a place where there is no danger of falling rocks,

landslides, or flooding.

● Lower the work equipment completely to the ground and

stop the engine.

● Turn the starting switch to the ON position. Operate the

work equipment control lever back and forth, left and right
at the full stroke 2 to 3 times to eliminate the remaining
internal pressure in the hydraulic circuit, and then push up
safety lock lever (1) to the LOCK position.

● Put blocks under the track to prevent the machine from

moving.

2-33
SAFETY MAINTENANCE INFORMATION SAFETY

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and
do as follows.

● One worker must always sit in the operator's seat and be

ready to stop the engine at any time. All workers must
maintain contact with the other workers.

● Set safety lock lever (1) to the LOCK position.

● When carrying out operations near the fan, fan belt, or

other rotating parts, there is a hazard of being caught in the
parts, so be extremely careful.

● Do not touch any control levers. If any control lever must

be operated, always give a signal to the other workers to
warn them to move to a safe place.

● Never drop or insert tools or other objects into the fan or

fan belt.
Parts may break or be sent flying.

PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.

2-34
SAFETY SAFETY MAINTENANCE INFORMATION

ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.

When handling the accumulator, careless procedure may

cause an explosion which could lead to serious injury or prop-
erty damage. For this reason, always observe the following
precautions.

● Do not disassemble the accumulator.

● Do not bring it near flame or dispose of it in fire.

● Do not make holes in it, weld it, or use a cutting torch.

● Do not hit or roll the accumulator, or subject it to any impact.

● When disposing of the accumulator, the gas must be released.

Please contact your Komatsu distributor to have this work performed.

PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.

If necessary, employ an observer.

ATTACHMENTS
● Appoint a leader before starting removal or installation
operations for attachments.

● Place attachments that have been removed from the

machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.

WORK UNDER THE MACHINE

● If it is necessary to go under the work equipment or the
machine to carry out service and maintenance, support the
work equipment and machine securely with blocks and
stands strong enough to support the weight of the work
equipment and machine.

● It is extremely dangerous to work under the machine if the

track shoes are off the ground and the machine is sup-
ported only by the work equipment. If the control levers are
touched by mistake, or there is a hazard to the hydrauli-
cline, the work equipment or the machine may suddenly
descend. This is extremely dangerous. Never work under
the machine if the machine is not properly supported by
blocks or stands.

2-35
SAFETY MAINTENANCE INFORMATION SAFETY

NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working.

WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as fol-
lows.

● If hard metal parts such as pins, bucket teeth, cutting

edges, or bearings are hit with a hammer, there is a hazard
that pieces might be scattered and cause injury. Always
wear safety goggles and gloves.

● When hitting pins or bucket teeth, there is a hazard that

broken pieces might be sent flying and injure people in the
surrounding area. Always check that there is no one in the
surrounding area.

● If pins are hit with strong force, there is a hazard that the pin may fly out and injure people in the surrounding
area.

WELDING WORKS
Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equip-
ment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified person-
nel to carry out welding.

REMOVING BATTERY TERMINALS

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of
the battery to prevent the flow of current.

2-36
SAFETY SAFETY MAINTENANCE INFORMATION

SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST

TRACK TENSION
● Grease is pumped into the track tension adjustment sys-
tem under high pressure.
If the specified procedure for maintenance is not followed
when making adjustment, grease drain plug (1) may fly out
and cause serious injury or property damage.

● When loosening grease drain plug (1) to loosen the track

tension, never loosen it more than one turn. Loosen the
grease drain plug slowly.

● Never put your face, hands, feet, or any other part of your
body close to grease drain plug (1).

DO NOT DISASSEMBLE RECOIL SPRINGS

The recoil spring assembly is used to reduce the impact on the idler. It contains a spring under high pressure, so if
it is disassembled by mistake, the spring will fly out and cause serious injury or even death. Never disassemble the
recoil spring.

SAFETY RULES FOR HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury or property damage, so always do as follows.

● Do not carry out inspection or replacement work when the hydraulic system is under pressure.

● If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the
piping and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.

● There is a hazard that high-pressure oil leaking from small

holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately
for medical attention.

2-37
SAFETY MAINTENANCE INFORMATION SAFETY

SAFETY HANDLING HIGH-PRESSURE HOSES

● If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or property damage. If any loose bolts are found, stop work and tighten to the specified torque. If any
damaged hoses are found, stop operations immediately and contact your Komatsu distributor.

Replace the hose if any of the following problems are found.

● Damaged or leaking hydraulic fitting.

● Frayed or cut covering or exposed reinforcement layer of wire.

● Covering swollen in places.

● Twisted or crushed movable portion.

● Foreign material embedded in covering.

WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.

● Always put oil drained from your machine in containers.

Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.

● Obey appropriate laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.

AIR CONDITIONER MAINTENANCE

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite.

Never touch refrigerant.

COMPRESSED AIR
● When carrying out cleaning with compressed air, there is a hazard of serious injury or property damage
caused by flying particles.

● When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.

2-38
SAFETY SAFETY MAINTENANCE INFORMATION

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

● In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relation-
ship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Replacement of safety critical parts: See "SAFETY CRITICAL PARTS (PAGE 4-16)".

● The material of these components naturally changes over time, and repeated use causes deterioration, wear,
and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or property
damage. It is difficult to judge the remaining life of these components from external inspection or the feeling
when operating, so always replace them at the specified interval.

● Replace or repair safety critical parts if any defect is found, even when they have not reached the time speci-
fied interval.

2-39
SAFETY MAINTENANCE INFORMATION SAFETY

MEMO

2-40
 OPERATION
31

WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.

3-1
GENERAL VIEW OPERATION

GENERAL VIEW

GENERAL VIEW OF MACHINE

(1) Bucket (6) Boom cylinder

(2) Bucket cylinder (7) Sprocket
(3) Arm (8) Track frame
(4) Arm cylinder (9) Track shoe
(5) Boom (10) Idler

3-2
OPERATION GENERAL VIEW

GENERAL VIEW CONTROLS AND GAUGES

(1) Car radio (19) Emergency pump drive switch

(2) Rotating lamp switch (if equipped) (20) Travel speed selector switch
(3) Airconditioner control panel (21) Auto-deceleration switch
(4) Safety lock levers (22) Charge monitor
(5) Left work equipment control lever (23) Air cleaner clogging monitor
(6) Knob switch (24) Engine oil pressure monitor
(7) Travel pedal (25) Service meter
(8) Travel levers (26) Display
(9) Cigarette lighter / Ashtray (27) Engine water temperature gauge
(10) Machine monitor (28) Engine water temperature monitor
(11) Horn switch (29) Fuel level monitor
(12) Right work equipment control lever (30) Fuel gauge
(13) Starting switch (31) Engine oil level monitor
(14) Fuel control dial (32) Swing lock monitor
(15) Lamp switch (33) Engine pre-heating monitor
(16) Alarm buzzer stop switch (34) Engine oil replacement monitor
(17) Swing lock switch (35) Wiper switch
(18) Swing brake cancel switch (36) Working mode selector switch

3-3
EXPLANATION OF COMPONENTS OPERATION

EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for operating the machine.

To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the
equipment and the meanings of the displays.

MACHINE MONITOR

A:Basic check Items D:Meter Display Portion

B:Caution Items E:Monitor Switches

C:Emergency Stop Items

3-4
OPERATION EXPLANATION OF COMPONENTS

BASIC CHECK ITEMS

WARNING
These monitors are not a guarantee of the condition of the machine. Do not simply rely on the monitors
when carrying out checks before starting (daily checks). Always get off the machine and check each item
directly.

This displays the basic items among the check before starting items that must be checked before starting the
engine. If there is any abnormality, the monitor for the location of the abnormality will flash.

(1) Engine oil level monitor (2) Engine oil replacement monitor (only for set machines)

ENGINE OIL LEVEL MONITOR

This monitor (1) warns the operator if the oil level in the engine
oil pan has dropped.

If the oil level in the engine oil pan is low, the monitor will flash,
so check the oil level in the engine oil pan and add oil.

3-5
EXPLANATION OF COMPONENTS OPERATION

ENGINE OIL REPLACEMENT MONITOR

(only for set machines)

This monitor (2) warns the operator if the set time passes after
the engine oil was changed.

If the set time (125, 250, 500H) passes after the engine oil is
replaced, this lamp lights up. If the lamp lights up, replace the
engine oil.

If you want to change the set time for replacement of oil, please
consult your Komatsu distributor.

3-6
OPERATION EXPLANATION OF COMPONENTS

CAUTION ITEMS

CAUTION
If the warning monitor flashes or lights up, carry out inspection and maintenance of the appropriate point
as soon as possible.
If the problem is not corrected, it may lead to failure of the machine.

These are items which need to be observed when the engine is running. If any abnormality occurs, the item need-
ing immediate repair is displayed. If there is any abnormality, the abnormal location on the monitor will flash or light
up.

(1) Charge level monitor (3) Air cleaner clogging monitor

(2) Fuel level monitor

3-7
EXPLANATION OF COMPONENTS OPERATION

CHARGE LEVEL MONITOR

This monitor(1) indicates an abnormality in the charging sys-
tem while the engine is running.

If the monitor lamp flashes, check the V-belt tension. If any

abnormality is found, see "OTHER TROUBLE (PAGE 3-128)".

REMARK
● While the starting switch is ON, the lamp will remain lit and
will go off once the engine is started.
● When the engine is started or stopped with the starting
switch at the ON position, the lamp may light up and the
buzzer may sound momentarily, but this does not indicate
any abnormality.

FUEL LEVEL MONITOR

This monitor(2) warns the operator if the level of the fuel
remaining in the fuel tank goes down too low.

When the remaining fuel goes down to approx. 41 liters (10.83

US gal) , the monitor flashes, so add fuel as soon as possible.

AIR CLEANER CLOGGING MONITOR

This monitor (3) warns the operator that the air cleaner is
clogged.

If it flashes, stop the engine and carry out inspection and clean-
ing of the air cleaner.

3-8
OPERATION EXPLANATION OF COMPONENTS

EMERGENCY STOP ITEMS

CAUTION
If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point
immediately and repair the problem.

These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal
location on the monitor will flash and the buzzer will sound. Carry out the necessary repairs immediately.

(1) Engine water temperature monitor (2) Engine oil pressure monitor

ENGINE WATER TEMPERATURE MONITOR

This monitor (1) warns the operator that the temperature of the
engine coolant has risen.

If the temperature of the engine coolant becomes abnormally

high, the monitor flashes, and the overheat prevention system
is automatically actuated to reduce the engine speed.

Stop operations, and run the engine at low idling until the
engine water temperature gauge returns to the green range.

3-9
EXPLANATION OF COMPONENTS OPERATION

ENGINE OIL PRESSURE MONITOR

If the engine lubricating pressure is below the normal value,
this monitor (1) lights up and the buzzer sounds. If it lights up,
stop the engine, and check the oil level in the oil pan and lubri-
cating system.

REMARK
● While the starting switch is ON, the lamp will remain lit and
will go off once the engine is started.
● When the engine is started or stopped with the starting
switch at the ON position, the lamp may light up and the
buzzer may sound momentarily, but this does not indicate
any abnormality.

3-10
OPERATION EXPLANATION OF COMPONENTS

METER DISPLAY PORTION

Pilot Display Gauges And Meter

(1) Engine Pre-heating Monitor (3) Engine water temperature gauge

(2) Swing Lock Monitor (4) Fuel Gauge
(5) Service Meter
(6) Display

PILOT DISPLAY
When the starting switch is ON, the pilot display lights up when the display items are functioning.

ENGINE PRE-HEATING MONITOR

This monitor lamp(1) indicates the pre-heating time required
when starting the engine at an ambient temperature below 0°C
(32°F).

The monitor lamp lights when the starting switch is turned to

HEAT position and flashes after about 30 seconds to show that
the pre-heating is completed. (The monitor lamp will go off after
about 10 seconds.)

3-11
EXPLANATION OF COMPONENTS OPERATION

SWING LOCK MONITOR

This monitor (2) informs the operator that the swing lock is
being actuated.

Actuated: Lights up

When the swing lock switch is turned ON (ACTUATED), the

monitor lamp lights up.
This monitor flashes when the swing holding brake cancel
switch is turned on.

REMARK
The swing motor is equipped with a disc brake that mechani-
cally stops the rotation. When the swing lock monitor lamp is
lighted up, the brake remains applied.

GAUGES AND METER

ENGINE WATER TEMPERATURE GAUGE

This monitor (3) displays the engine coolant temperature.

During operations, the green range should be lighted up. If the

red range lights up during operations, the overheat prevention
system is actuated.

The overheat prevention system is actuated as follows.

Red range (A) lights up:Engine water temperature monitor

lamp (C) flashes.
Red range (B) lights up:Engine speed is reduced to low idling,
engine water temperature monitor
lamp (C) flashes, and alarm buzzer
sounds at the same time.

The overheat prevention system is actuated until the gauge

returns to the green range.

When red range (A) has lighted up, wait for the engine water
temperature to go down, then set the fuel control dial to low
idling to cancel the display.

FUEL GAUGE
This meter(4) shows the fuel level in the fuel tank. During nor-
mal operation, the lamp should light up in the green range.

If the lamp in the red range flashes during operation, there is

less than 60 liters (15.85 US gal) of fuel remaining, so check
and add fuel.

Red range (A) lights up: Fuel gauge monitor lamp (B) flashes.

The correct level may not be displayed for a short time after the
starting switch is turned to the ON position, but this is not an
abnormality.

With the engine stopped, turn the starting switch ON to check

that each item and meter lights up.

3-12
OPERATION EXPLANATION OF COMPONENTS

DISPLAY
This monitor (6) displays the service meter, and monitor (6) dis-
plays the content of the failure if any abnormality occurs.

REMARK
If the machine breaks down, the content of the failure is displayed when the starting switch is ON. The display
shows all the failures flashing in turn.

Monitor display Failure mode

E02 Pump control system error

E03 Swing brake system error

E05 Governor system error

E06 Electric system error

If the above displays flash, go to the item in see "ELECTRONIC CONTROL SYSTEM (PAGE 3-132)"

SERVICE METER
This meter(5) shows the total operation hours of the machine.
Set the periodic maintenance intervals using this display.
The service meter advances while the engine is running - even
if the machine is not traveling.

The meter will advance by 1 for each hour of operation regard-

less of the engine speed.

3-13
EXPLANATION OF COMPONENTS OPERATION

MONITOR SWITCHES

(1) Working mode selector switch (basic switch) (4) Wiper switch
(2) Auto-deceleration switch (selection switch) (5) Window washer switch
(3) Travel speed switch

WORKING MODE SELECTOR SWITCH (BASIC SWITCH)

This switch (1) is used to set the power and movement of the
work equipment.

Operations can be carried out more easily by selecting the

mode to match the type of operation.

A lights up: For heavy-load operations

E lights up: For operations with emphasis on fuel economy
B lights up: For breaker operations

● When starting the engine, the A mode is automatically set. Each time the switch is pressed, the next mode can
be selected.

● When starting the engine, if it is desired to set the E or B mode automatically (default option setting), please
contact your Komatsu distributor for adjustment.

NOTICE
When using the breaker, do not use A mode. There is danger that the breaker may be damaged.

3-14
OPERATION EXPLANATION OF COMPONENTS

AUTO-DECELERATION SWITCH
When this auto-deceleration switch button (2) is depressed, the
auto-deceleration is actuated, if the control levers are in the
neutral position, and the engine speed is automatically lowered
to reduce fuel consumption.

The auto-deceleration lamp "ON": The auto-deceleration is

actuated.
The auto-deceleration lamp "OFF": The auto-deceleration is
released.

Every time the switch button is depressed, actuation and

release alternate.

TRAVEL SPEED SELECTOR SWITCH

WARNING
● When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed
selector switch during the loading or unloading operation.

● If the travel speed is switched between high and low when the machine is traveling, the machine may
deviate to one side, even when traveling in a straight line. Stop the machine before switching the
travel speed.

This switch(3) is used to select high or low travel speed.

Lo lights up: Low-speed travel

Hi lights up: High-speed travel
When the engine is started,it is automatically set to Lo.

When traveling at high speed (Hi),if travel power is needed

when traveling on soft ground or slopes,the travel speed is
automatically set to low speed travel (Lo),so there is no need to
operate this switch. On the monitor display,the Hi (high speed)
lamp stays lighted up.

WIPER SWITCH
This switch (4) actuates the front window wiper.

ON lights up: The wiper works continuously.

INT lights up: The wiper works intermittently.
OFF: The wiper stops.

3-15
EXPLANATION OF COMPONENTS OPERATION

WINDOW WASHER SWITCH

This switch (5) is kept continuously pressed, window washer
fluid is sprayed out on the front glass. When the switch is
released, the spray stops.

● If switch (5) is kept pressed when the wiper is stopped,

thewindow washer fluid will spray out, and at the same
time, the wiper will be actuated continuously. When switch
(5) is released, the wiper will continue to operate continu-
ously for 2 cycles, and will then stop.

● If the wiper is moving intermittently and switch (5) is kept

pressed continuously, the window washer fluid will spray
out, and at the same time, the wiper will be actuated con-
tinuously. When switch (5) is released, the wiper will con-
tinue to operate continuously for 2 cycles, and will then
return to intermittent operation.

3-16
OPERATION EXPLANATION OF COMPONENTS

SWITCHES

(1) Starting switch (8) Knob switch

(2) Fuel control dial (9) Room lamp switch
(3) Cigarette lighter (10) Emergency pump drive switch
(4) Swing lock switch (11) Swing brake cancel switch
(5) Lamp switch (12) Rotating lamp switch
(6) Alarm buzzer stop switch
(7) Horn switch

STARTING SWITCH
This switch (1) is used to start or stop the engine.
OFF position
The key can be inserted or withdrawn. The switches for the
electric system except the room lamp, are all turned off and the
engine is stopped.
ON position
Electric current flows in the charging and lamp circuits. Keep
the starting switch key at the ON position while the engine is
running.
START position
This is the engine-start position. Keep the key at this position
during cranking. Immediately after starting the engine, release
the key. It will automatically return to the ON position.
HEAT (preheat) position
When starting the engine in winter, set the key to this position. Whenthe key is set to the HEAT position, the pre-
heating monitor lightsup. Keep the key at this position until the monitor lamp flashes.Immediately after the pre-
heating monitor flashes, release the key.The key automatically returns to the OFF position. Then, start the engine
by turning the key to the START position.

3-17
EXPLANATION OF COMPONENTS OPERATION

FUEL CONTROL DIAL

This dial(2) is used to control the engine speed and output.

(a) Low idling position: The dial is turned to the left (counter-
clockwise)
(b) High idling position: The dial is turned to the right (clock-
wise)

CIGARETTE LIGHTER
This switch (3) is used when lighting cigarettes.

When the cigarette lighter is pushed in, it will return to its origi-
nal position after several seconds, so pull it out to use it.

If the cigarette lighter is removed, it can be used as the power

source for the yellow hazard lamp. The capacity of the ciga-
rette lighter is 85W (24V x 3.5A).

3-18
OPERATION EXPLANATION OF COMPONENTS

SWING LOCK SWITCH

WARNING
● When traveling or when not using the swing operation, apply the swing lock.

● On slopes, even when the swing lock switch is at the ON position, the weight of the work equipment
may cause the upper structure to swing if the swing control lever is operated in the downhill direc-
tion.

This switch (4) is used to lock the upper structure so that it can-
not swing.

ON position (actuated): The swing lock is always applied, and

the upper structure will not swing
even if the swing is operated. In this
condition, the swing lock lamp lights
up.

OFF position (canceled): The swing lock is applied only when

all the control levers of the work
equipment are at neutral; when any of
the control levers is operated, it is
cancelled.
The swing lock is actuated approx. 5
seconds after all the control levers are
placed in the neutral position.

LAMP SWITCH
This switch (5) is used to light up the front lamps, working lamp,
additional lamp at the top front of the cab, rear lamp, and moni-
tor lighting.

ALARM BUZZER STOP SWITCH

This switch (6) is used (when the engine is running) to stop the
alarm buzzer when it has sounded to warn of an abnormality in
a warning item.

3-19
EXPLANATION OF COMPONENTS OPERATION

HORN SWITCH
When the button(7) at the tip of the right work equipment con-
trol lever is pressed, the horn will sound.

KNOB SWITCH
Knob switch (8) on the left work equipment control lever is used
to actuate the power max and slow-down functions.

Press once (single click) and keep the switch pressed. The
one-touch power max. function is actuated for a maximum of
8.5 seconds at A and E mode.

ROOM LAMP SWITCH

NOTICE
Be sure to switch the lamp to the OFF position after use.
If the switch is left at the ON position, the battery will run down.

This switch (9) is used to light up the room lamp.

ON position: Lights up
OFF position: Goes out

It will also light up even when the engine is not running.

3-20
OPERATION EXPLANATION OF COMPONENTS

EMERGENCY PUMP DRIVE SWITCH

NOTICE
This switch is installed to make it possible to carry out operation temporarily if any abnormality should
occur in the pump control system. It is not intended for permanent use. Repair the cause of the abnormal-
ity immediately.

This switch (10) is used to make it possible to carry out opera-

tions temporarily if any abnormality should occur in the pump
control system (when the display shows E02).

When normal: Move switch down

When abnormal: Move switch up

If the display shows E02, move the switch up to make it possi-

ble to carry out work.

SWING BRAKE CANCEL SWITCH

NOTICE
This switch is installed to make it possible to carry out operation temporarily if any abnormality should
occur in the swing brake system. It is not intended for permanent use. Repair the cause of the abnormality
immediately.

This switch (11) is used to make it possible to carry out opera-

tions temporarily if any abnormality should occur in the swing
brake system (when the display shows E03).

When normal: Move switch down

When abnormal: Move switch up

If the display shows E03, move the switch up to make it possi-

ble to carry out work.

ROTATING LAMP SWITCH

(if equipped)

This switch (12) is used to light up the yellow rotating lamp on

top of the cab.

3-21
EXPLANATION OF COMPONENTS OPERATION

CONTROL LEVERS, PEDALS

(1) Safety Lock Lever (3) Left Work Equipment Control Lever
(2) Travel Levers (Machines with travel pedal) (4) Right Work Equipment Control Lever

SAFETY LOCK LEVER

WARNING
● When leaving the operator's compartment, set the safety lock lever securely to the LOCK position. If
the safety lock lever is not at the LOCK position and the control levers are touched by mistake, it may
lead to serious personal injury.

● If the safety lock lever is not placed securely at the LOCK position, the control lever may move and
cause a serious accident or injury. Check that the condition of the lever is as shown in the diagram.

● When pulling the safety lock lever up, be careful not to touch the work equipment control lever.

● When pushing the safety lock lever down, be careful not to touch the work equipment control lever.

Lever (1) is a device to lock the work equipment, swing, travel,

and attachment (if equipped) control levers.

Pull the lever up to apply the lock.

This lock lever is a hydraulic lock, so even if it is in the lock

position, the work equipment control lever and travel lever will
move, but the work equipment, travel motor, and swing motor
will not work.

3-22
OPERATION EXPLANATION OF COMPONENTS

TRAVEL LEVERS

WARNING
● Do not put your foot on the pedal unless the machine
is traveling. If you leave your foot on the pedal and
press it by mistake, the machine will move suddenly,
and this may lead to a serious accident.

● With the track frame facing to the rear, the machine

will move in the reverse direction by forward traveling
and in the forward direction by reverse traveling.
When the travel lever is used, check to see if the track
frame is facing forward or backward. (If the sprocket
is located to the rear, the track frame is facing for-
ward.)

● Be extremely careful when using the pedal for opera-

tions and travel.

Thislever (2) is used to switch the direction of travel of the

machine. ( ) shows the operation of the pedal.
(a) FORWARD:
The lever is pushed forward
(The pedal is angled forward)
(b) REVERSE:
The lever is pulled back
(The pedal is angled back)

N (Neutral): The machine stops

( ): This indicates operation of the pedal.

REMARK
● Machines equipped with travel alarm (If equipped)
If the lever is shifted to the advance or reverse position from the neutral position, the alarm sounds to warnthat
the machine is starting to advance.

● The travel lever can use the auto-deceleration mechanism to change the engine speed as follows.

● When the travel lever and work equipment control levers are at the neutral position, even if the fuel control dial
is above midrange speed, the engine speed will go down to a midrange speed. If one of these levers is oper-
ated, the engine speed will rise to the speed set by the fuel control dial.

● If all the control levers are at the neutral position, the engine speed goes down approx. 100 rpm, then after
approx. 4 seconds, the engine speed goes down to the deceleration speed (approx. 1400 rpm).

3-23
EXPLANATION OF COMPONENTS OPERATION

WORK EQUIPMENT CONTROL LEVER

(with auto-deceleration device)

This Left work equipment control lever (3) is used to operate

the arm and upper structure.

Arm operation / Swing operation

(a) Arm OUT

(b) Arm IN
(c) Swing to right
(d) Swing to left

N (Neutral): The upper structure and arm are held in position

and do not move.

This Right work equipment control lever(4) is used to operate

the boom and bucket.

Boom operation / Bucket operation

(a) RAISE
(b) LOWER
(c) DUMP
(d) CURL

N (Neutral): The boom and bucket are held in position and do

not move.

REMARK
● The engine speed for all control levers (travel, work equipment, attachment) is changed as follows by the auto-
deceleration mechanism.

● When the travel lever and work equipment control levers are at the neutral position, even if the fuel control dial
is above midrange speed, the engine speed will go down to a midrange speed. If one of these levers is oper-
ated, the engine speed will rise to the speed set by the fuel control dial.

● If all the control levers are at the neutral position, the engine speed goes down approx. 100 rpm, then after
approx. 4 seconds, the engine speed goes down to the deceleration speed (approx. 1400 rpm).

3-24
OPERATION EXPLANATION OF COMPONENTS

CEILING WINDOW

WARNING
● When leaving the operator's compartment, set the
safety lock lever securely to the LOCK position.

● If the control levers are not locked, and they are

touched by mistake, this may lead to a serious acci-
dent.

When opening
1. Lock the safety lock lever securely.

2. Check for any ceiling window movement by pulling lock

knob (A) located on front side, then push up and open the
ceiling window grasping grip (B).

When closing
Close the ceiling window grasping grip (B) and lock it with lock
knob (A). If the lock cannot be applied, open and close the ceil-
ing window again.

3-25
EXPLANATION OF COMPONENTS OPERATION

FRONT WINDOW

WARNING
● When opening or closing the ceiling window, front
window, bottom window, or door, always set the
safety lock lever to the LOCK position.
If the control levers are not locked and they are
touched by accident, this may lead to a serious acci-
dent.

● When opening or closing the window at the front of

the cab, stop the machine on horizontal ground, lower
the work equipment completely to the ground, stop
the engine, then carry out the operation.

● When opening the front window, hold the grip

securely with both hands, pull up, and do not let go
until the automatic lock catch is locked.

● When closing the front window, the window will move

quicker under its own weight. Hold the grips securely
with both hands when closing it.

It is possible to store (pull up) the front window (top) in the roof
of the operator's compartment.

When opening
1. Place the work equipment on flat ground and stop the engine.

2. Securely lock the safety lock lever.

3. Check that the wiper blade is stored in the right stay.

3-26
OPERATION EXPLANATION OF COMPONENTS

4. Grip knobs (A) at the top, bottom, left, and right of the
front window, and pull lock lever (B) to release the lock at
the top of the front window. The top of the front window
will come out.

5. Hold lower knob (C) with your left hand from inside the
operator's cab, and with your right hand, grip top knob
(D), pull it up, and push it against lock catch (E) at the
rear of the cab securely to lock the window.

3-27
EXPLANATION OF COMPONENTS OPERATION

6. Check that lock lever (B) is securely at the LOCK posi-

tion.

● The lock is engaged if the arrow on lock case (F)

matches the position of the arrow on lock lever
(B).Check visually.

● If the arrow on lock case (F) does not match the posi-
tion of the arrow on lock lever (B), the lock is not
engaged. Repeat the operation in Step 5 to engage the
lock.

3-28
OPERATION EXPLANATION OF COMPONENTS

When closing

WARNING
When closing the window, lower it slowly and be careful not to get your hand caught.

1. Place the work equipment on flat ground and stop the engine.

2. Securely lock the safety lock lever.

3. Grip left and right knobs (A), and pull down lock lever (B)
to release the lock.

4. Grip knob (C) at the bottom of the front window with your
left hand and knob (B) at the top with your right hand,
push to the front, then lower slowly.

3-29
EXPLANATION OF COMPONENTS OPERATION

5. When the bottom of the window reaches the top of the

bottom window, push the top of the window to the front to
push it against left and right lock catches (G) and engage
the lock.

6. Check that lock lever (B) is securely at the LOCK posi-

tion.

● The lock is engaged if the arrow on lock case (F)

matches the position of the arrow on lock lever (B).
Check visually.

● If the arrow on lock case (F) does not match the posi-
tion of the arrow on lock lever (B), the lock is not
engaged. Repeat the operation in Step 5 to engage the
lock.

Removing front window (bottom)

1. Open the front window, then hold grip (A), pull up, and
remove the bottom window.

2. After removing the bottom window, store it at the rear of

the operator's cab and lock it securely with left and right
locks (B).
● When removing, always hold the glass with one
hand and release the lock with the other hand.

3-30
OPERATION EXPLANATION OF COMPONENTS

EMERGENCY EXIT FROM OPERATOR'S CAB

● If for some reason, the cab door does not open, open the
rear window and use it as an emergency escape exit.

● Remove the rear window as follows.

1. Pull ring (1) and completely remove seal (2) from the rub-
ber core.

2. When the corner of the front window glass is pushed

strongly, it can be removed to the outside.
● Do not remove the rear window except when using it
as an emergency exit.

DOOR LOCK
Use the door lock to fix the door in position after opening it.

1. Push the door against catch (1) to fix it in position.

2. To release the lock, press knob (2) down at the left side of
the operator's seat to release the catch.

3. When fixing the door, fix it firmly to the catch.

3-31
EXPLANATION OF COMPONENTS OPERATION

CAP, COVER WITH LOCK

Locks are fitted to the fuel tank filler, hydraulic tank filler, opera-
tor's cab, engine hood, battery box cover, right side door of the
machine, and left side door of the machine. Use the starting
key to open and close the caps, doors and covers.

Insert the key as far as it will go, then turn it. If the key is turned
before it is inserted fully, it may break.

METHOD OF OPENING AND CLOSING CAP WITH LOCK

When opening
1. Insert the key into the key slot.

2. Turn the starting switch key counterclockwise, align the

key slot and counter mark on the cap, then open the cap.
REMARK
● Type A is used for the fuel tank cap. Type B is used for the
hydraulic tank cap.
● With type A, the cap is locked if it rotates freely. When it
rotates, the cap does not come off from the tank.
Turn the starting switch key counterclockwise, align the
groove in the rotor with the counter mark on the cap, then
turn the cap slowly, and when a click is heard, the lock is
released and the cap can be opened.

When locking
1. Screw in the cap, then insert the key in the key slot.

2. Turn the starting switch key clockwise, then remove the

key.

METHOD OF OPENING AND CLOSING COVER WITH LOCK

To open the cover (locked cover)
1. Insert the key into the key slot.

2. Turn the key counterclockwise and open the cover by

pulling the cover grip.

To lock the cover

1. Close the cover and insert the key into the key slot.

2. Turn the key clockwise and take the key out.

3-32
OPERATION EXPLANATION OF COMPONENTS

HOT AND COOL BOX

This is at the rear right of the operator's seat. It is intercon-
nected with the air conditioner: it warms when the heater is
being used and cools when the air conditioner is being used.

MAGAZINE BOX AND CUP HOLDER

This is on the left side of the operator's seat.

Keep the Operation and Maintenance Manual in this box so

that it can be taken out and read whenever necessary.

ASHTRAY
This is under the machine monitor at the front right of the oper-
ator's compartment.

Always make sure that you extinguish your cigarette, then put it
in the ashtray and close the lid.

3-33
EXPLANATION OF COMPONENTS OPERATION

HANDLING AIR CONDITIONER

GENERAL LOCATIONS OF CONTROL PANEL

(1) OFF switch (6) FRESH/RECIRC selector switch

(2) Fan switch (7) Display monitor
(3) Temperature control switch (8) Air conditioner switch
(4) Vent selector switch (9) Defroster selector lever
(5) Auto switch

OFF SWITCH
This switch (1) is used to stop the fan and air conditioner.

● When OFF switch (1) is pressed, the set temperature and

air flow display on display monitor (7) and the lamps above
auto switch (5) and air conditioner switch (8) go out, and
operation stops.

3-34
OPERATION EXPLANATION OF COMPONENTS

FAN SWITCH
This switch (2) is used to adjust the air flow.

The air flow can be adjusted to six levels.

● Press the ∧ switch to increase the air flow; press the ∨

switch to reduce the air flow.

● During auto operation, the air flow is automatically

adjusted.

<Monitor display and air flow>

Liquid crystal display Air flow

Air flow "low"

Air flow "medium 1"

Air flow "medium 2"

Air flow "medium 3

Air flow "medium 4"

Air flow "high"

TEMPERATURE CONTROL SWITCH

This switch (3) is used to control the temperature inside the
cab. The temperature can be set between 18°C (64.4°F) and
32°C (89.6°F).

● Press the ∧ switch to raise the set temperature; press the ∨

switch to lower the set temperature.

● The temperature is generally set at 25°C (77°F).

● The temperature can be set in stages of 0.5°C (0.9°F).

<Monitor display and the function>

Monitor display (°C) Set temperature

18.0 (64.4°F) Max. cooling

18.5 to 31.5 Adjusts temperature inside cab to

(65.3°F to 88.7°F) set temperature
32.0 (89.6°F) Max. heating

3-35
EXPLANATION OF COMPONENTS OPERATION

VENT SELECTOR SWITCH

This switch (4) is used to select the vents.

● When switch (4) is pressed, the display on monitor display

(7) switches and air blows out from the vents displayed.

● If AUTO operation is selected, the vents are selected auto-

matically.

(A): Rear vents (4 places)

(B): Face vent (1 place)
(C): Foot vent (1 place)
(D1): Front window vent (1 place)
(D2): Front window vent (1 place)

● Front window vent (D2) can be opened or closed by hand.

Liquid crystal Vent

Vent mode Remarks
display
Front and rear vents
(including defroster vent)
Front, rear, and foot vents
(including defroster vent)
Foot vent

Front, foot vents Cannot be selected for

(including defroster vent) automatic operation
Front vents Cannot be selected for
(including defroster vent) automatic operation

Note 1: Air blows out from vents marked

Note 2: The defroster vents can be opened or closed manually with the vent lever.

3-36
OPERATION EXPLANATION OF COMPONENTS

AUTO SWITCH
With this switch (5), the air flow, vents, and air source
(RECIRC/FRESH) are automatically selected according to the
set temperature.

This switch also acts as the air conditioner main switch.

● When auto switch (5) is pressed, the lamp at the top of the
auto switch lights up.

● Normally, press this switch, then use temperature control

switch (3) to set the temperature, and run the air condi-
tioner under automatic control.

● When the control is switched from automatic operation to

manual operation, it is possible to operate the switch to
change the air flow, vents, and air source (RECIRC/
FRESH). When the manual control is used, the lamp at the
top of the auto switch goes out.

The outside air is shut off and only the air inside the cab is circulated.
RECIRC
Use this position to carry out rapid cooling of the cab or when the outside air is dirty.

Outside air is taken into the cab.

FRESH
Use this position to take in fresh air or when carrying out demisting.

FRESH/RECIRC SELECTOR SWITCH

This switch (6) is used to switch the air source between recircu-
lation of the air inside the cab and intake of air from the outside.

● When switch (6) is pressed, the lamp at the top of the

selector switch lights up to show that air is being blown out.

● During automatic operation, the selection of inside air

(RECIRC) and outside air (FRESH) is carried out automat-
ically.

The outside air is shut off and only the air inside the cab is circulated.
RECIRC
Use this position to carry out rapid cooling of the cab or when the outside air is dirty.

Outside air is taken into the cab.

FRESH
Use this position to take in fresh air or when carrying out demisting.

DISPLAY MONITOR
This display monitor displays the status of temperature setting
(a), air flow (b), and vents (c).

● When OFF switch (1) is pressed, the display of tempera-

ture setting (a) and air flow (b) goes out, and operation
stops.

3-37
EXPLANATION OF COMPONENTS OPERATION

AIR CONDITIONER SWITCH

This switch (8) is used to turn the air conditioner (cooling,
dehumidifying, heating) ON or OFF.

● When the fan is acutated (the display monitor shows (b))

and air conditioner switch (8) is pressed, the air conditioner
is switched ON, the lamp at the top of the air conditioner
switch lights up, and the air conditioner starts. When it is
pressed again to the OFF position, the lamp at the top of
the air conditioner switch goes out.

● The air conditioner cannot be operated while the fan is

stopped.

DEFROSTER SELECTOR LEVER

This switch (9) is used in cold or rainy weather to remove the
mist that forms on the front glass.

Selector lever forward: To defroster (open)

Selector lever back: Closed

The defroster can be used when the vent selector switch is set
to face or face and foot.

METHOD OF OPERATION
The air conditioner can be operated automatically or manually. Select the method of operation as desired.

AUTOMATIC OPERATION
1. Turn auto switch (5) ON.
● The lamp at the top of switch (5) lights up.
● The set temperature (a) and air flow (b) are dis-
played on the monitor.

3-38
OPERATION EXPLANATION OF COMPONENTS

2. Use temperature set switch (3) to set to the desired tem-

perature. The air flow, combination of vents, and selec-
tion of fresh or recirculated air is automatically selected
according to the set temperature, and the air conditioner
is operated automatically to provide the set temperature.

REMARK
When vent display monitor (c) displays (d) or (e), and the
engine water temperature is low, the air flow is automatically
limited to prevent cold air from blowing out.

STOPPING AUTOMATIC OPERATION

Press OFF switch (1). The displays for temperature setting (a)
and air flow (b) on the display monitor, and the lamps above
auto switch (5) and air conditioner switch (8) go out, and the
operation stops.

3-39
EXPLANATION OF COMPONENTS OPERATION

MANUAL OPERATION
1. Press fan switch (2) and adjust the air flow. When doing
this, check that temperature setting (a) and air flow (b)
are displayed on the display monitor.

2. Turn air conditioner switch (8) ON. Check that the lamp
at the top of the air conditioner switch lights up.

3. Press the temperature setting switch and adjust the tem-

perature inside the cab.

3-40
OPERATION EXPLANATION OF COMPONENTS

4. Press vent selector switch (4) and select the desired

vents.
When this is done, the display for vent (c) of the display
monitor changes according to the selection.

5. Press RECIRC/FRESH selector switch (6) and select

recirculation of the air inside the cab (RECIRC) or intake
of fresh air from outside (FRESH).

STOPPING MANUAL OPERATION

Press OFF switch (1). The displays for temperature setting (a)
and air flow (b) on the display monitor, and the lamps above
auto switch (5) and air conditioner switch (8) go out, and the
operation stops.

3-41
EXPLANATION OF COMPONENTS OPERATION

OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET

To operate with cold air blowing to the face and warm air blow-
ing to the feet, set as follows.

1. Press fan switch (2) and adjust the air flow. When doing
this, check that temperature setting (a) and air flow (b)
are displayed on the display monitor.

2. Press vent selector switch (4) and set the vent display on
the display monitor to the display shown in the diagram
on the right.

3. Turn air conditioner switch (8) ON. When this is done,

the lamp above the air conditioner switch lights up.

3-42
OPERATION EXPLANATION OF COMPONENTS

4. Adjust fan switch (2), temperature setting switch (3) and

FRESH/RECIRC selector switch (6) to the desired posi-
tions.

DEFROSTER OPERATION
1. Press fan switch (2) and adjust the air flow. When doing
this, check that temperature setting (a) and air flow (b)
are displayed on the display monitor.

3-43
EXPLANATION OF COMPONENTS OPERATION

2. Press vent selector switch (4) and set the vent display on
the display monitor to the display shown in (f) or (g) in the
diagram on the right.

3. Press FRESH/RECIRC selector switch (6) and set it to

take in fresh air.

4. Press temperature setting switch (3) and set the set tem-
perature display on the display monitor to the maximum
heating temperature of 32.0.

5. Adjust vents (A), (B), and (D2) so that the air blows onto
the window glass.
(Vents (C) and (D1) are fixed and cannot be adjusted.)

3-44
OPERATION EXPLANATION OF COMPONENTS

When operating in the rainy season or when it is desired to

remove the mist from the window glass or to dehumidify the air,
turn air conditioner switch (8) ON.

PRECAUTIONS WHEN USING AIR CONDITIONER

NOTICE
1. When running the air conditioner, always start with the engine running at low speed. Never start the
air conditioner when the engine is running at high speed. It will cause failure of the air conditioner.
2. If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, so be careful
not to let water get on these parts. In addition, never bring any flame near these parts.
3. For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean
and do not leave anything around the sunlight sensor that may interfere with its sensor function.

PRECAUTIONS WHEN USING AIR CONDITIONER

Ventilate the cab from time to time when using the cooler.
● If you smoke when the cooler is on, the smoke may start to hurt your eyes, so open the window and carry out
ventilation and cooling for a short time to remove the smoke.

When running the air conditioner for a long time, carry out ventilation and cooling together once an hour.

Be careful not to make the temperature in the cab too low.

When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 - 6ºC lower than
the outside temperature). This temperature difference is considered to be the most suitable for your health, so
always be careful to adjust the temperature properly.

CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER

When carrying out inspection of a machine equipped with an air conditioner, see the "MAINTENANCE SCHED-
ULE CHART (PAGE 4-17)" and carry out inspection according to the table.

3-45
EXPLANATION OF COMPONENTS OPERATION

OTHER FUNCTIONS

SELF-DIAGNOSTIC FUNCTION
It is possible to carry out troubleshooting of the various sensors and equipment used on the air conditioner.

1. Press OFF switch (1). The temperature setting and air flow display on the liquid crystal display portion go
out and operation stops.

2. If the "∧" and "∨" parts of temperature setting switch (3) are kept pressed at the same time for at least 3 sec-
onds, the troubleshooting mode is displayed on the liquid crystal display portion.

<Monitor display and failure mode>

Display Failure mode

E-- No failure
E11 Disconnection in recirculated air sensor

E12 Short circuit in recirculated air sensor

E13 Disconnection in fresh air sensor

E14 Short circuit in fresh air sensor

E15 Disconnection in water temperature sensor

E16 Short circuit in water temperature sensor

E18 Short circuit in sunlight sensor

E21 Disconnection in vent sensor

E22 Short circuit in vent sensor

E43 Abnormality in vent damper

E44 Abnormality in air mix damper

E45 Abnormality in FRESH/RECIRC air damper

E51 Abnormality in refrigerant pressure

● When more than one failure is detected, press the "∧" or "∨" portion of temperature setting switch (3) to dis-
play the failures in turn.

● After completing the troubleshooting, press OFF switch (1) again to return to the normal display.

If any abnormality is detected by the self-diagnostic function, ask your Komatsu distributor to carry out inspection
and repair.

3-46
OPERATION EXPLANATION OF COMPONENTS

FUNCTION TO SWITCH SET TEMPERATURE DISPLAY BETWEEN °F AND °C

It is possible to switch the set temperature display between °F
and °C.

If the "∧" and "∨" portions of temperature setting switch (3) are
pressed at the same time for more than 5 seconds while the
fan is running, the temperature display will switch between °F
and °C.
(Note that the unit is not displayed.)

Liquid crystal display range

°C 18.0 to 32.0

°F 63 to 91

3-47
EXPLANATION OF COMPONENTS OPERATION

CAR RADIO

EXPLANATION OF COMPONENTS

(1) Power switch/Volume control knob/Balance knob (6) Preset buttons

(2) Tone control knob (7) Display
(3) FM/AM selector button (8) Time correction button
(4) Display selector button (9) Stereo indicator
(5) Manual tuning

POWER SWITCH/VOLUME CONTROL KNOB (SW-VOLUME)/BALANCE (Pull BAL)

Press this knob (1) to turn the power for the radio on. The fre-
quency is displayed on display (7). Press again to turn the
power off.

Turn the knob to adjust the volume as follows.

Turn CLOCKWISE to INCREASE volume

Turn COUNTERCLOCKWISE to REDUCE volume

If the knob is pulled until it locks, it can be turned to the left or

right to adjust the balance of the left and right speakers.

Turn CLOCKWISE to increase volume from RIGHT speaker

Turn COUNTERCLOCKWISE to increase volume from LEFT speaker

After adjusting the left and right balance, press lightly to return the knob to its original position. (If it is left pulled
out, the overall volume cannot be adjusted.)

3-48
OPERATION EXPLANATION OF COMPONENTS

TONE CONTROL KNOB (TONE)

Turn the knob (2) to adjust the tone as follows.

Turn CLOCKWISE to emphasize the high sounds

Turn COUNTERCLOCKWISE to suppress the high sounds

FM/AM SELECTOR BUTTON (AM/FM)

Press this button (3) and select the desired band.

Each time the button is pressed, it switches AM → FM → AM ...

DISPLAY SELECTOR BUTTON (TIME)

This equipment gives priority to the frequency display. If the
button (4) is pressed when the frequency is displayed, display
will give the present time for 5 seconds. After 5 seconds pass,
the display will automatically return to the frequency display. If
any button other than TIME SET (H, M, SET) is pressed within
the 5 seconds, the display will return to the frequency display.

MANUAL TUNING (MANUAL)

Use the buttons to (5) change the frequency.

Up button (∧): Each time the button is pressed, the frequency

will go up in steps (FM: 0.1 MHz, AM: 9 kHz).

Down button (∨): Each time the button is pressed, the fre-
quency will go down in steps (FM: 0.1 MHz, AM: 9 kHz).

For further details, see "METHOD OF OPERATION (PAGE 3-

51)"

3-49
EXPLANATION OF COMPONENTS OPERATION

PRESET BUTTONS (1, 2, 3, 4, 5, 6) (PRESET STATION)

If these buttons are set to the frequency of the desired broad-
casting station, the station can be selected at a touch.

For details of the method of presetting, see "METHOD OF

OPERATION (PAGE 3-51)".

AM090010

DISPLAY
The reception band, frequency, preset number, and time are
displayed.

TIME CORRECTION BUTTON

This is used to correct the time.

H : Hour
M : Minute
SET : Sets to start of hour (00 minutes)

STEREO INDICATOR (ST)

This lamp lights up when a stereo broadcasting is picked up
when receiving an FM broadcasting station.

3-50
OPERATION EXPLANATION OF COMPONENTS

METHOD OF OPERATION

METHOD OF SETTING PRESET BUTTONS

1. Press power switch (1) and display the frequency on dis-
play (7).

2. Turn the tuning button (5)(manual, auto) to adjust to the

desired frequency.

3. Select a preset button to use for recording the frequency

setting, and keep that button pressed for at least 1.5 sec-
onds. The sound will disappear, but when the setting is
recorded, the sound will appear and the preset number
will appear on display (7) to show that the station has
been preset.
After completion of presetting, press preset button (6),
and release it within approx. 1.5 seconds. The setting will
change to the frequency of the broadcasting station
recorded for that button. One AM station and one FM sta-
tion can be recorded for each preset button.

MANUAL TUNING
Press tuning button (5) and set to the desired frequency.

Each time the button is pressed, the frequency will move up or down in steps of 9 kHz (AM) or 0.1 MHz (FM).

∨ button: Move to a higher frequency station

∧ button: Move to a lower frequency station

● If the frequency reaches the top or bottom limit, it will automatically change as follows: top limit → bottom limit,
or bottom limit → top limit

AUTOMATIC TUNING
Keep tuning button (5) pressed for at least 0.5 seconds. When a broadcasting station is picked up, it will automati-
cally stop. To search for the next station, press tuning button (5) again for at least 0.5 seconds.

∨ button: Move to a higher frequency station

∧ button: Move to a lower frequency station

● If tuning button (5) is pressed during auto tuning, the auto tuning will be canceled and the frequency at the
point where it is canceled will be picked up.

3-51
EXPLANATION OF COMPONENTS OPERATION

SETTING CORRECT TIME

1. Press display selector button (4) to display the time.
After 5 seconds, the display will return to the frequency
display and the time cannot be corrected. If this happens,
press display selector button (4) again.

2. Press time correction button (8) and adjust the hour and
minute.
H button: Adjusts hour (advances one hour each time it
is pressed)
M button: Adjusts minute (advances one minute each
time it is pressed)
If the H or M button are kept pressed, the time will
advance continuously until the button is released.
SET button: Every time SET button is depressed, hour and minute are reset in the following manner.
If the minute display is between 0 and 05, the minute reading will return to 00.
If the minute display is between 55 and 59, the minute display will return to 00 and the hour will advance by
1.
If the minute display is between 06 and 54, no resetting can be made.
Example 10:05 → 10:00
10:59 → 11:00
10:26 → 10:26
Press the H, M, and SET buttons to set to the correct time.

ANTENNA

NOTICE
Before transporting the machine or putting it inside a
building, stored the antenna to prevent any interference.

PRECAUTIONS WHEN USING

● To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera-
tion.

● If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.

● Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a
cloth soaked in alcohol if the equipment is extremely dirty.

● When the battery is replaced, the settings for the preset buttons are all cleared, so set them again.

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OPERATION EXPLANATION OF COMPONENTS

POWER PICK-UP PORT

24V power source

NOTICE
Do not use this as the power source for 12V equipment. It
will cause damage to the equipment.

If the cigarette lighter is removed, it can be used as a power

source. The capacity of the cigarette lighter is 85W (24V x
3.5A).

12V power source

(if equipped)

This power source can be used up to a capacity of 60W (12V x

5A).

FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting
switch.

The fuses protect the electrical equipment and wiring from

burning out.

If the fuse becomes corroded, or white powder can be seen, or

the fuse is loose in the fuse holder, replace the fuse.

Replace the fuse with another of the same capacity.

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EXPLANATION OF COMPONENTS OPERATION

FUSE CAPACITIES AND CIRCUIT NAMES

Fuse
Name of circuit
capacity

(1) 10 A Controller

(2) 20 A Electromagnetic valve

(3) 10 A PPC hydraulic lock solenoid

(4) 10 A Window washer, cigarette lighter

(5) 10 A Horn

(6) 10 A 12V power source (if equipped)

(7) 10 A Rotating lamp, arm solenoid

(8) 10 A Light relay

(9) 10 A Radio, speaker, left knob switch

(10) 10 A Spare

(11) 25 A Air conditioner unit

(12) 20 A Monitor, wiper monitor

(13) 20 A Light, light relay drive

(14) 10 A Optional power source (1)

Optional power source (2), travel alarm,

(15) 10 A
12V power port

(16) 10 A Radio backup

(17) 20 A Monitor (normal power source)

(18) 10 A Starting switch

(19) 10 A Room lamp

(20) 10 A Spare

FUSIBLELINK
If the starting motor does not start even when the starting
switch is turned to the ON position, wire-shaped fusible link (1)
(2 places) has probably melted, so open the battery box cover
on the right side of the machine, check the fusible link, and
replace if necessary.

REMARK
A fusible link refers to the large-sized fuse wiring installed in
the high current flow portion of the circuit to protect electrical
components and wiring from burning, in the same way as an
ordinary fuse.

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OPERATION EXPLANATION OF COMPONENTS

CONTROLLER (COMPUTER)
An engine throttle and pump controller is installed.

NOTICE
● Be careful not to get water, mud, or juice on the con-
troller. This will cause failure.
● If any abnormality occurs in the controller, do not dis-
assemble it yourself. Contact your Komatsu distribu-
tor for repairs.

TOOLBOX
Keep the tools in this toolbox.

GREASE GUN HOLDER

This is inside the door at the rear left of the machine. When not
using the grease gun, fit it in this holder.

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EXPLANATION OF COMPONENTS OPERATION

HANDLING ACCUMULATOR

WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo-
sion which will lead to serious injury or damage. When handling the accumulator, always do as follows.

● The pressure in the control circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction that the oil spurts out when carrying out the operation.
Loosen the bolts slowly.

● Do not disassemble the accumulator.

● Do not bring it near flame or dispose of it in fire.

● Do not make holes in it or weld it.

● Do not hit it, roll it, or subject it to any impact.

● When disposing of the accumulator, the gas must be released. Please contact your Komatsu distribu-
tor to have this work carried out.

The machine is equipped with an accumulator in the control cir-

cuit. The accumulator in the control circuit is a device to store
pressure, and when this accumulator is installed, it is possible
to operate the control circuit for a short time even after the
engine is stopped. Therefore, it is possible to lower the work
equipment under its own weight by operating the control lever
in the direction to lower the work equipment.

The accumulator is installed to the position shown in the dia-

gram on the right.

METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE

EQUIPPED WITH ACCUMULATOR
1. Lower the work equipment to the ground, then close the crusher or other attachment.

2. Stop the engine.

3. Turn the key in the starting switch to the ON position again to let electric current flow in the circuits.

4. Set the safety lock lever to the FREE position, then operate the work equipment control levers and attach-
ment control pedal (if equipped) backwards and forwards, and to the right and left to the full stroke to release
the pressure in the control circuit.
5. Set the safety lock lever to the LOCK position to lock the control levers and attachment control pedal.

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OPERATION MACHINE OPERATIONS AND CONTROLS

MACHINE OPERATIONS AND CONTROLS

BEFORE STARTING ENGINE

WALK-AROUND CHECKS
Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or
leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also
for loose wiring, play, and accumulation of dust at places which reach high temperatures.

WARNING
Remove any flammable materials from around the battery or engine muffler, or other high temperature
engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to
repair any abnormalities, or please contact your Komatsu distributor.

Always check the items in this section before starting the engine each day.

1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses

Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses.
If any abnormality is found, repair it.

2. Remove dirt and dust from around engine, battery, radiator

Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flam-
mable material (dead leaves, twigs, grass, etc.) accumulated around the battery or high temperature engine
parts, such as the engine muffler or turbocharger. Remove all such dirt or flammable material.

3. Check for leakage of water or oil around engine

Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any
abnormality is found, repair it.

4. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, joints

Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking.

5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers

6. Check for damage to handrail, loose bolts

Repair any damage and tighten any loose.

7. Check for damage to gauges, monitor, loose bolts

Check that there is no damage to the gauges and monitor in the operator's cab. If any abnormality is found,
replace the parts. Clean off any dirt on the surface.

8. Clean rear view mirror, check for damage

Check that there is no damage to the rear view mirror. If it is damaged, replace it with a new mirror. Clean the
surface of the mirror and adjust the angle so that the view to the rear can be seen from the operator’s seat.

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MACHINE OPERATIONS AND CONTROLS OPERATION

9. Seat belt option and mounting clamps

Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with
new parts.

10. Check bucket with hook (if equipped) for damage.

Check the hook, catcher and hook foot for damage. If damage is found, contact your Komatsu distributor for
repair.

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OPERATION MACHINE OPERATIONS AND CONTROLS

CHECKS BEFORE STARTING

Always carry out the items of the checks in this section before starting the engine.

CHECK COOLANT LEVEL, ADD WATER

WARNING
● Do not open the radiator cap unless necessary. When checking the coolant, always wait for the
engine to cool down and check the sub tank.

● Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure.
If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the tem-
perature to go down, then turn the cap slowly to release the pressure before removing it.

1. Open the door at the rear left of the machine, and check if
the cooling water in sub-tank (1) (shown in the diagram
on the right) is between the FULL and LOW marks. If the
water level is low, add water to the FULL level through
the filler port of sub-tank (1).

2. After adding water, tighten the caps securely.

3. If the sub tank is empty, there is probably leakage of

water.
After inspecting, repair any abnormality immediately. If
there is no abnormality, check the water level in the radia-
tor. If the water level is low, add water to the radiator, then
fill the reserve tank (1).

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MACHINE OPERATIONS AND CONTROLS OPERATION

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.

1. Open the engine hood on the machine.

2. Remove dipstick (G) and wipe the oil off with a cloth.

3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.

4. The oil level should be between the H and L marks on

dipstick (G).
If the oil level is below the L mark, add engine oil through
oil filler (F).

5. If the oil is above the H line, open drain valve (P) at the
bottom of the engine oil pan, drain the excess engine oil,
then check the oil level again.

6. If the oil level is correct, tighten the oil filler cap securely
and close the engine hood.
REMARK
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine before checking.
If the machine is at an angle, make it horizontal before checking.

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OPERATION MACHINE OPERATIONS AND CONTROLS

CHECK FUEL LEVEL, ADD FUEL

WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up com-
pletely. Never bring flames near fuel because it is highly flammable and dangerous.

1. Open fuel filler cap (F) of the fuel tank.

2. When fuel filler cap (F) is opened, float gauge (G) will rise
according to the fuel level.
Check that the fuel tank is full. Check by looking into the
tank and by using float gauge (G).

3. If the tank is not full, add fuel through the fuel filler until
float gauge (G) rises to the maximum position.
Fuel tank capacity: 400 liters (105.68 US gal)
Position of tip of float gauge (G) when tank is full: Approx.
50 mm (2 in) from top surface of fuel tank

4. After adding fuel, push float gauge (G) straight down with
fuel filler cap (F). Be careful not to get float gauge (G)
caught in the tab of fuel filler cap (F), and tighten fuel filler
cap (F) securely.

REMARK
If breather hole (1) on the cap is clogged, the pressure in the
tank will drop and fuel will not flow.
Clean the hole from time to time.

DRAIN WATER, SEDIMENT FROM FUEL TANK

1. Open the pump room door on the right side of the
machine.

2. Put a container to catch the drained fuel under drain hose

(1).

3. Open drain valve (2) at the rear of the hydraulic tank and
drain the sediment and water accumulated at the bottom
of the tank together with the fuel.

4. When clean fuel comes out, close drain valve (2).

5. Close the pump room door on the right side of the

machine.

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MACHINE OPERATIONS AND CONTROLS OPERATION

CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER

1. Open the cover at the rear right of the machine.

2. Inspect the water separator, and check if the ring inside

has risen to the marked line.

3. If the ring has risen to the marked line, carry out the pro-
cedure from Step 4.

4. Set a container under the water separator to catch the

drained oil.

5. Close fuel valve (6) at the bottom of the fuel tank.

6. Remove air bleed plug (5) at the top of the water separa-
tor.

7. Loosen drain valve (1) at the bottom of the water separa-

tor, and drain the water and sediment into the container.

8. Loosen ring nut (2), then remove filter case (3).

9. Remove element (4) from the separator base.

10. Wash element (4) in clean diesel oil.

11. Check element (4), and replace it if it is damaged.

12. When installing element (4), perform Steps 6 and 7 in the

opposite order.

Tightening torque of ring nut (2): 40 ± 3 N•m {4.1 ±

0.3kgf•m}

13. Loosen air bleed plug (5) and fill inside of filter case (3)
with fuel. When fuel comes out from air bleed plug (5),
tighten air bleed plug (5).

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OPERATION MACHINE OPERATIONS AND CONTROLS

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure
before removing the cap.

1. If the work equipment is not in the condition shown in the

diagram on the right, start the engine, run the engine at
low speed, retract the arm and bucket cylinders, then
lower the boom, set the bucket teeth in contact with the
ground, and stop the engine.

2. Within 15 seconds after stopping the engine, turn the

starting switch to the ON position, and operate the control
levers (work equipment, travel) fully in each direction to
release the internal pressure.

3. Check sight gauge (G) from the right window installed to

the operator's compartment. The oil level should be
between the H and L lines.
NOTICE
Do not add oil above the H line. This will damage the
hydraulic circuit or cause the oil to spurt out. If oil has
been added to above the H level, stop the engine and wait
for the hydraulic oil to cool down, then drain the excess oil
from drain plug (P).

4. If the oil level is below the L line, add oil through oil filler
(F) at the top of the hydraulic tank.

REMARK
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:

● Before operation: between H and L level

(Oil temperature 10 to 30ºC (50 to 86ºF))
● Normal operation: around H level
(Oil temperature 50 to 80ºC (122 to 176ºF))

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MACHINE OPERATIONS AND CONTROLS OPERATION

CHECK ELECTRIC WIRINGS

WARNING
● If the fuses frequently blowor if there are traces of short circuits on the electrical wiring, locate the
cause immediately and carry out repairs, or contact your Komatsu distributor for repairs.

● Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is
clogged with dirt or dust, wash the battery cap to clean the breather hole.

Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electric wir-
ing. Check also for loose terminals and tighten any loose parts.

Check the wiring of the "battery", "starting motor" and "afternator" carefully in particular.

When carrying out walk-around checks or checks before starting, always check if there is any accumulation of
flammable material around the battery, and remove such flammable material.

Please contact your Komatsu distributor for investigation and correction of the cause.

CHECK FUNCTION OF HORN

1. Turn the starting switch to the ON position.

2. Confirm that the horn sounds without delay when the horn button is pressed. If the horn does not sound, ask
your Komatsu distributor for repair.

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OPERATION MACHINE OPERATIONS AND CONTROLS

ADJUST BEFORE OPERATION

WARNING
● Adjust the seat position before starting operations or after changing the operator.

● Adjust the seat so that the control levers and switchis can be operated freely and easily with the oper-
ator back against the backrest.

A: Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then
release the lever.
Fore-and-aft adjustment: 160 mm (6.3 in) (16 stages)

B: Adjusting reclining
NOTICE
The seat can be reclined to a large angle when the seat is
pushed fully forward, but the reclining angle is reduced
when the seat is moved back, so when moving the seat to
the rear, return the seat back to its original position.

Pull lever (2) and set the seat back to a position which is com-
fortable for operation, then release the lever.

Sit with your back against the seat back when adjusting. If your
back is not touching the seat back, the seat back may suddenly
move forward.

C:Adjusting seat tilt

● Forward tilt
Push lever (3) up to adjust the angle of the front of the seat.(4 stages)
● To raise the angle at the front of the seat, keep the lever pushed up and apply your weight to the rear of the
seat.

● To lower the angle at the front of the seat, keep the lever pushed up and apply your weight to the front of the
seat.

● Rear tilt
Pull lever (4) up to adjust the angle of the rear of the seat.(4stages)
● To raise the angle at the rear of the seat,keep the lever(3) pulled up and stand up slightly to remove your
weight from the seat.

● To lower the angle at the rear of the seat,keep the lever(3) pulled up and apply your weight to the rear of the
seat.

Amount of tilt:Up 13°,down 13°

● Adjusting seat height

It is possible to move the seat up or down by combining adjustments 1 and 2.
After setting the forward tilt or rear tilt to the desired height, operate the opposite part to set the seat horizontal
then secure in position.
Height adjustment:60 mm (2.4 in)

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MACHINE OPERATIONS AND CONTROLS OPERATION

D:Adjusting armrest angle

Armrest (5) can be made to spring up by hand approx.90°.
In addition, by turning the bottom (6) of the armrest by hand it is possible to make fine vertical adjustments of the
armrest angle.
Armrest adjustment angle:25°

REMARK
If the seat back is tipped to the front without raising the armrest(5), the armrest will rise automatically.

E:Overall fore-and-aft adjustment of seat

Move lever (7) to right, set to the desired position, then release the lever. In this case, the operator's seat, left and
right control levers, and safety lock lever all slide together.
Fore-and-aft adjustment:180 mm (7.1 in) (9 stages)

F:Adjusting suspension
Turn knob (8) to the right to make the suspension harder,or to the left to make the suspension softer. Adjust the
reading of the dial to match the operator's weight and select the optimum suspension.

REMARK
To obtain the optimum adjustment,turn the knob (8) so that the indicator of the weight display (kg) in the transpar-
ent portion of knob (8) is the same as the operator's weight.

ADJUSTMENT OF MIRRORS
Loosen nut (1) and bolt (2) mounting the mirror, and adjust to
the position which gives the best view from the operator's seat
of the blind spot to the left and right sides at the rear of the
machine.

● Adjust the mirror mount so that it is possible to see any

person (or object of height 1 m (3 ft 3 in) and diameter 30
cm (11.8 in)) at the rear left and right of the machine.

● Install the mirror to the mounting position and dimensions

shown. The values given below are reference values for
the range of view.

Mounting position X : 100 mm (3.9 in)

Range of view Y (right side) : 1500 mm (4 ft 11in)
Range of view Z. (left side) : 1830 mm (6 ft)
Mirror A : Must be able to see hatched area (A)
Mirror B : Must be able to see hatched area (B)
Mirror C : Must be able to see hatched area (C) (if equipped)

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OPERATION MACHINE OPERATIONS AND CONTROLS

SEAT BELT

WARNING
● Before fitting the seat belt, check that there is no abnormality in the belt mount bracket or mounting
belt. If it is worn or damaged, replace the seat belt.

● Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manu-
facture of the belt is shown on the back of the belt.

● Always wear the seat belt during operations.

● Fit the seat belt so that it is not twisted.

FASTENING AND REMOVING SEAT BELT

This seat belt has a wind-in device, so it is not necessary to
adjust the length.

Fastening seat belt

Hold grip (2) and pull the belt out from wind-in device (1), check
that the belt is not twisted, then insert tongue (3) into buckle (4)
securely.
When doing this, pull the belt lightly to check that it is properly
locked.

Removing belt
Press button (5) in buckle (4), and remove tongue (3) from
buckle (4).
The belt is automatically wound in, so hold grip (2) and return
the belt slowly to wind-in device (1).

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MACHINE OPERATIONS AND CONTROLS OPERATION

OPERATIONS BEFORE STARTING ENGINE

WARNING
● When starting the engine, check that the safety lock
lever is securely at the LOCK position.
If the control levers are not locked and they are
touched by accident when starting the engine, the
work equipment may move unexpectedly, and this
may lead to a serious accident.

● When standing up from the operator's seat, always set

the safety lock lever to the LOCK position, regardless
of whether the engine is running or stopped.

1. Check that safety lock lever (1) is at the LOCK position.

2. Check the position of each lever.

Set the control lever to the neutral position.

When starting the engine, never touch the knob switch.

3. Insert the key in starting switch (2), turn the key to the ON
position, then carry out the following checks.

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OPERATION MACHINE OPERATIONS AND CONTROLS

1) The buzzer will sound for approx. 1 sec, and the fol-
lowing monitors and gauges will light up for approx.
3 sec.

● Engine oil level monitor (3)

● Charge level monitor (4)
● Fuel level monitor (5)
● Engine water temperature monitor (6)
● Engine oil pressure monitor (7)
● Engine water temperature gauge (8)
● Fuel gauge (9)
● Engine pre-heating lamp(10)
● Air cleaner clogging monitor(11)
● Swing lock lamp (12)
● Replacement monitor of engine oil (13)

If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or discon-
nection in the monitor wiring, so contact your Komatsu distributor for repairs.

After approx. 3 sec, the following gauges will remain on and the other monitors will go out.

● Charge level monitor (4)

● Engine oil pressure monitor (7)
● Engine water temperature gauge (8)
● Fuel gauge (9)

2) Press lamp switch (14) and check that the front lamp
lights up.

If it does not light up, there is probably a blown bulb

or disconnection, so contact your Komatsu distribu-
tor for repairs.

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MACHINE OPERATIONS AND CONTROLS OPERATION

STARTING ENGINE

NORMAL STARTING

WARNING
● Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.

● Exhaust gas is toxic. When starting the engine in con-

fined spaces, be particularly careful to ensure good
ventilation.

NOTICE
● Before starting the engine, check that the fuel control dial is at the low idling (MIN) position.
● Do not crank the starting motor continuously for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes before trying again.
● If the fuel control dial is at the FULL position, the engine will accelerate suddenly and cause damage
to the engine parts, so set it to an intermediate or low speed position.

1. Check that safety lock lever (1) is at LOCK position. If

safety lock lever (1) is at the FREE position, the engine
will not start.

2. Set fuel control dial (2) at the low idling (MIN) position.
If it is at the high idling (MAX) position, always change it
to the low idling (MIN) position.

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OPERATION MACHINE OPERATIONS AND CONTROLS

3. Turn the key in starting switch (3) to the START position.

The engine will start.

4. When the engine starts, release the key in starting switch

(3).
The key will return automatically to the ON position.

5. Even after the engine is started, do not touch the work

equipment control levers and the travel pedals, while the
engine hydraulic pressure monitor lamp is still lighted.
NOTICE
If the engine oil pressure monitor does not go out even
after 4 to 5 seconds have passed, stop the engine immedi-
ately. Check the oil level, check for leakage of oil, and take
the necessary action.

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MACHINE OPERATIONS AND CONTROLS OPERATION

STARTING ENGINE IN COLD WEATHER

WARNING
● Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.

● Never use starting aid fluids as they may cause explo-

sions.

NOTICE
● Before starting the engine, check that fuel control dial (2) is at the low idling (MIN) position.
● Do not keep the strating motor rotating continuously for more than 20 seconds.
If the engine fails to start,wait for about 2 minutes and repeat from Step 2.
● If the fuel control dial is at the FULL position, the engine will accelerate suddenly and cause damage
to the engine parts, so set it to an intermediate or low speed position.

When starting in low temperatures, do as follows.

1. Check that safety lock lever (1) is in the LOCK position. If

it is in the FREE position, the engine cannot be started.

2. Set fuel control dial (2) at a low idling (MIN) position.

Do not set fuel control dial (2) at the high idling (MAX)
position.

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OPERATION MACHINE OPERATIONS AND CONTROLS

3. Hold the key in starting switch (3) at the HEAT position,

and check that preheating monitor (4) lights up.
After about 18 seconds, preheating monitor lamp (4) will
flash to indicate that preheating is finished.

REMARK
The monitors and gauges will light up also when the key is
turned to the HEAT position, but this is not an abnormality.

4. When preheating monitor (4) goes out, turn the key in

starting switch (3) to the START position to start the
engine.

5. When the engine starts, release the key in starting switch

(3).
The key will return automatically to the ON position.

6. Even after the engine is started, do not touch the work

equipment control levers and the travel pedals, while the
engine hydraulic pressure monitor lamp is still lighted.

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MACHINE OPERATIONS AND CONTROLS OPERATION

AFTER STARTING ENGINE

WARNING
● Emergency stop
If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position.

● If the work equipment is operated without warming the machine up sufficiently, the response of the
work equipment to the movement of the control lever will be slow, and the work equipment may not
move as the operator desires, so always carry out the warming-up operation. Particularly in cold
areas, be sure to carry out the warming-up operation fully.

BREAKING-IN THE NEW MACHINE

CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating
the machine under severe conditions at the beginning can adversely affect the performance and shorten
the machine life.
Be sure to running-in the machine for the initial 100 hours (as indicated by the service meter).
During running-in operations, follow the precautions described in this manual.

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

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

● Avoid operation with heavy loads or at high speeds.

● Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.

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OPERATION MACHINE OPERATIONS AND CONTROLS

WARMING-UP OPERATION
NOTICE
● When the hydraulic oil is at a low temperature, do not
carry out operations or move the levers suddenly.
Always carry out the warming-up operation. This will
help to extend the machine life.
● Do not suddenly accelerate the engine before the
warming-up operation is completed.
Do not run the engine at low idling or high idling con-
tinuously for more than 20 minutes. This will cause
leakage of oil from the turbocharger oil supply piping.
If it is necessary to run the engine at idling, apply a
load from time to time or run the engine at a mid-range
speed.

REMARK
● If the engine water temperature is above 30ºC, to protect the turbocharger, the engine speed does not rise for
2 seconds after starting, even if the fuel control dial is turned.
● If the hydraulic oil temperature is low, the hydraulic oil temperature monitor display will be white.

After starting the engine, do not immediately start operations. First, carry out the following operations and checks.

1. Turn fuel control dial (2) to the center position between

LOW IDLING and HIGH IDLING and run the engine at
medium speed for about 5 minutes with no load.

2. Set safety lock lever (1) to the FREE position, and raise
the bucket from the ground.

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MACHINE OPERATIONS AND CONTROLS OPERATION

3. Operate bucket control lever (3) and arm control lever (4)
slowly to move the bucket cylinder and arm cylinder to
the end of the stroke.

4. Carry out bucket and arm operation for 5 minutes at full

stroke, alternating between bucket operation and arm
operation at 30 second intervals.
REMARK
If swing lock switch (5) is operated to the ON position, it is pos-
sible to raise the oil temperature faster.

NOTICE
When the work equipment is retracted, take care that it
does not interfere with the machine body or ground.

5. After carrying out the warming-up operation, check that

each gauge and monitor lamp is in the following condi-
tion.
● Engine oil level monitor (6): OUT
● Charge level monitor (7): OUT
● Fuel level monitor (8): OUT
● Engine water temperature monitor (9): OUT
● Engine oil pressure monitor (10): OUT
● Engine water temperature gauge (11): Inside green
range
● Fuel gauge (12): Inside green range
● Engine pre-heating lamp(13): OUT
● Air cleaner clogging monitor (14): OUT
● Replacement monitor of engine oil (15): OUT

6. Check that there is no abnormal exhaust gas color, noise,

or vibration. If any abnormality is found, repair it.

7. Use the working mode switch on monitor panel (16) to set

to the desired working mode.

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OPERATION MACHINE OPERATIONS AND CONTROLS

IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)

When starting the engine in cold areas,carry out the automatic warming-up operation after starting the engine.

When the engine is started,if the engine water temperature is low (below 30°C (86°F)),the warming-up operation is
carried out automatically.

The automatic warming-up operation is canceled if the engine water temperature reaches the specified tempera-
ture (30°C (86°F))or if the warming-up operation is continued for 10 minutes.If the engine water temperature or
hydraulic oil temperature are low after the automatic warming-up operation,warm the engine up further as follows.

NOTICE
● Never carry out operations or operate the levers sud-
denly when the hydraulic oil is still at low temperature.
Always continue the warming-up operation until the
work equipment monitor display is green. This will
extend the service life of the machine.
● Do not suddenly accelerate the engine before the
warming-up operation is completed.
Do not run the engine at low idling or high idling con-
tinuously for more than 20 minutes.This will cause
leakage of oil from the turbocharger oil supply pip-
ing.If it is necessary to run the engine at idling,apply a
load from time to time or run the engine at a mid-range
speed.

REMARK
If the hydraulic oil temperature is low, the hydraulic oil temperature monitor display will be white.

1. Turn fuel control dial (2) to the medium speed position.

2. Set safety lock lever (1) to the FREE position and raise
the bucket from the ground.

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MACHINE OPERATIONS AND CONTROLS OPERATION

3. Operate bucket control lever (3) and arm control lever (4)
slowly to move the bucket cylinder and arm cylinder to
the end of their stroke.

4. Operate the bucket for 30 seconds and the arm for 30

seconds in turn fully for 5 minutes.

REMARK
Turn swing lock switch (5) ON (ACTUATED)and operate the
lever to make the oil temperature rise more quickly.

NOTICE
When the work equipment is retracted,take care that it
does not interfere with the machine body or ground.

5. After carrying out the warming-up operation, check that

each gauge and monitor lamp is in the following condi-
tion.
● Engine oil level monitor (6): OUT
● Charge level monitor (7): OUT
● Fuel level monitor (8): OUT
● Engine water temperature monitor (9): OUT
● Engine oil pressure monitor (10): OUT
● Engine water temperature gauge (11): Inside green
range
● Fuel gauge (12): Inside green range
● Engine pre-heating lamp(13): OUT
● Air cleaner clogging monitor (14): OUT
● Replacement monitor of engine oil (15): OUT

6. Check that there is no abnormal exhaust gas color, noise,

or vibration. If any abnormality is found, repair it.

7. If air cleaner clogging monitor (14) is lighted up, clean or

replace the element immediately.
For details of the method of cleaning the element, see
"CHECK, CLEAN AND REPLACE AIR CLEANER ELE-
MENT (PAGE 4-21)".

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OPERATION MACHINE OPERATIONS AND CONTROLS

8. Turn fuel control dial (2) to the full speed (MAX)position

and carry out the operation is Step 5 for 3 to 5 minutes.

9. Repeat the following operation 3 to 5 times and operate

slowly.
Boom operation RAISE ↔ LOWER
Arm operation IN ↔ OUT
Bucket operation CURL ↔ DUMP
Swing operation LEFT ↔ RIGHT
Travel (Lo) operation FORWARD ↔ REVERSE
REMARK
In the above operation is not carried out, there may be a delay
in response when starting or stopping each actuator, so con-
tinue the operation until it becomes normal.

10. Use working mode switch 2 on the monitor panel to

select the working mode to be used.
NOTICE
Canceling automatic warming-up operation
If it becomes necessary in an emergency to lower the
engine speed to low idling,cancel the automatic warming-
up operation as follows.

1) Turn fuel control dial (2) to the full speed (MAX)posi-

tion and hold it for 3 seconds.

2) When fuel control dial (2) is returned to the low idling

(MIN) position,the engine speed will drop.

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MACHINE OPERATIONS AND CONTROLS OPERATION

STOPPING THE ENGINE

NOTICE
If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Conse-
quently, do not abruptly stop the engine apart from an emergency.

In particular, if the engine has overheated, do not abruptly stop it but run it at mediumspeed to allow it to
cool gradually, then stop it.

1. Run the engine at low idling speed for about 5 minutes to

allow it to gradually cool down.

2. Turn the key in starting switch (1) to the OFF position and
stop the engine.

3. Remove the key from starting switch (1).

CHECK AFTER SHUT OFF ENGINE

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, and check
also for leakage of oil or water. If any abnormalities are found, repair them.

2. Fill the fuel tank.

3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.

4. Remove any mud affixed to the undercarriage.

REMARK
After stopping the engine, if the starting switch is turned within approx. 10 seconds to the ON or START position to
start the engine again, the monitor display is not reset, and the screen before the starting switch was turned OFF
is displayed.

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OPERATION MACHINE OPERATIONS AND CONTROLS

MACHINE OPERATION

PREPARATIONS FOR MOVING THE MACHINE OFF

WARNING
● Before operating the steering levers, check the direc-
tion of the track frame.
If the sprocket is at the front, the operation of the
travel levers is reversed.

● When moving off, check that the area around the

machine is safe, and sound the horn before moving.

● Do not allow anyone in the area around the machine.

● Remove all obstacles from the travel path of the

machine.

● The rear of the machine is a blind spot, so be particu-

larly careful when travel in reverse.

● If the lever is moved inside the deceleration range,

engine speed will rise suddenly. Operate the levers
carefully.

● For machines equipped with a travel alarm (if

equipped), check that the warning equipment works
properly.

1. Set swing lock switch (1) to the ON (actuated) position

and confirm that swing lock monitor lamp (2) lights up.

2. Turn fuel control dial (3) towards the full speed position to
increase the engine speed.

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MACHINE OPERATIONS AND CONTROLS OPERATION

MOVING MACHINE FORWARD

1. Set safety lock lever (4) in the FREE position, fold the
work equipment, and raise it 40 to 50 cm (16 to 20 in)
from the ground.

2. Operate right and left travel levers (5) or right and left
travel pedals (6) as follows.
● When the sprocket is at the rear of the machine

Push levers (5) forward slowly or depress the front part of

pedals (6) slowly to move the machine off.

● When the sprocket is at the front of the machine

Pull levers (5) backward slowly or depress the rear part of

pedals (6) slowly to move the machine off.

3. For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, please
contact your Komatsu distributor for repairs.

REMARK
In cold temperatures, if the machine travel speed is not normal, carry out the warming-up operation thoroughly.
In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil
and mud from the undercarriage.

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OPERATION MACHINE OPERATIONS AND CONTROLS

MOVING MACHINE BACKWARD

1. Set safety lock lever (4) in the FREE position, fold the
work equipment, and raise it 40 to 50 cm (16 to 20 in)
from the ground.

2. Operate right and left travel levers (5) or right and left
travel pedals (6) as follows.
● When the sprocket is at the rear of the machine

Pull levers (5) backward slowly or depress the rear part of

pedals (6) to move the machine off.

● When the sprocket is at the front of the machine

Push levers (5) forward slowly or depress the front part of

pedals (6) to move the machine off.

3. For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, please
contact your Komatsu distributor for repairs.

REMARK
In cold temperatures, if the machine travel speed is not normal, carry out the warming-up operation thoroughly.
In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil
and mud from the undercarriage.

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MACHINE OPERATIONS AND CONTROLS OPERATION

STOPPING MACHINE

WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.

1. Put the left and right travel levers (1) in the neutral posi-
tion, then stop the machine.

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OPERATION MACHINE OPERATIONS AND CONTROLS

STEERING THE MACHINE

Steering

WARNING
Before operating the travel levers, check the position of the sprocket. If the sprocket is at the front, the
operation of the travel levers is reversed.

Use the travel levers to change direction.

Avoid sudden changes of direction as far as possible. In partic-

ular, when carrying out counter-rotation (spin turn), stop the
machine first before turning.

Operate two travel levers (1) as follows.

Steering the Machine when Stopped

When turning to the left:

Push the right travel lever forward to turn to the left when trav-
eling forward; and pull it back to turn left when traveling in
reverse.

REMARK
When turning to the right, operate the left travel lever in the
same way.

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MACHINE OPERATIONS AND CONTROLS OPERATION

Changing Direction of the Machine

When turning to the left:

If the left travel lever is returned to the neutral position, the

machine will turn to the left.

REMARK
When turning to the right, operate the right travel lever in the
same way.

Counter-rotation Turn (Spin Turn)

When using counter-rotation (spin turn) to turn left, pull the left
travel lever back and push the right travel lever forward.

REMARK
When using counter-rotation to turn right, pull the right travel
lever back and push the left travel lever forward.

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OPERATION MACHINE OPERATIONS AND CONTROLS

SWINGING

WARNING
● The rear of the machine extends outside the track
width. Check that the surrounding area is safe before
swinging be upper structure.

● Check that swing lock monitor is not lighted up.

● If the swing control lever is operated quickly, the

upper structure will move quickly; if it is operated
slowly, the upper structure will move slowly.

1. Before starting the swing operation, turn swing lock

switch (1) OFF and check that swing lock monitor (2) has
gone out.

2. Operate left work equipment control lever (3) to operate

the swing.
At the N position, the spring brake is applied.

3. When not using the swing, turn swing lock switch (1) ON.
Check that swing lock monitor (2) lights up.

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MACHINE OPERATIONS AND CONTROLS OPERATION

WORK EQUIPMENT CONTROLS AND OPERATIONS

WARNING
● If the lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly
rise, so be careful when operating the lever.

● If the work equipment control lever is operated quickly, the work equipment will move quickly; if the
lever is operated slowly, the work equipment will move slowly.

The work equipment is operated by the left and right work equipment control levers. The left work equipment con-
trol lever operates the arm and swing, and the right work equipment control lever operates the boom and bucket.

The movements of the lever and work equipment are as shown in the diagrams on the right. When the levers are
released, they automatically return to the neutral position and the work equipment is held in place

● When the machine is at a standstill, and the work equipment levers are put in neutral, the engine speed is kept
at medium speed due to the function of the auto-deceleration, even if the fuel control dial is set at the MAX
position.

REMARK
If the levers are operated within 15 seconds after stopping the engine,it is possible to lower the work equipment to
the ground.
In addition, the levers can also be operated to release any remaining pressure inside the hydraulic cylinder circuit
and to lower the boom after loading the machine on a trailer.

● Arm control

Move the left work equipment control lever to the front or

rear to operate the arm.

● Swing control

Move the left work equipment control lever to the left or

right to swing the upper structure.

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OPERATION MACHINE OPERATIONS AND CONTROLS

● Boom control

Move the right work equipment control lever to the front or

rear to operate the boom.

● Bucket control

Move the right work equipment control lever to the left or

right to operate the bucket.

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MACHINE OPERATIONS AND CONTROLS OPERATION

OPERATING WORKING MODE

Working mode
By using the working mode selector switch to select a working mode that matches the operating condition, it is
possible to carry out operations efficiently.

Use the following procedure to make effective use of each working mode.

When the starting switch is turned ON, the working mode is set to A mode (digging).

Use the working mode switch to set the mode to the most effi-
cient mode to match the type of work.

Working mode Applicable operations

A mode Normal digging, loading operations

(Operations with emphasis on productivity)

E mode Normal digging, loading operations

B mode Breaker operations

NOTICE
If breaker operations are carried out in the heavy digging
mode, the hydraulic equipment may be dam-aged. Operate
the breaker only in B mode.

ONE-TOUCH POWER MAX. SWITCH

The one-touch power max. switch can be used during operations to increase the power. Make effective use of this
function whenever necessary in combination with the working mode.

1. Press the left knob switch and keep it pressed. The

power is increased as long as the switch is being
pressed. However, the increased power is automatically
canceled after 8.5 seconds.
● This function is not actuated when the working mode
is set to L mode or B mode.

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OPERATION MACHINE OPERATIONS AND CONTROLS

PROHIBITED OPERATIONS

WARNING
● If it is necessary to operate the work equipment control lever when the machine is traveling, be
extremely careful when operating.

● If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly
increase, so be careful when operating.

OPERATIONS USING SWING FORCE

Do not use the swing force to compact soil or break objects.
This is not only dangerous, but will also markedly reduce the
life of the machine.

OPERATIONS USING TRAVEL FORCE

Do not dig the bucket into the ground and use the travel force
to carry out excavation. This will damage the machine or work
equipment.

OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS

If the cylinder is used when the cylinder rod has been operated
to the end of its stroke during operations, external force will
cause impact to the work equipment, and this will damage the
hydraulic cylinders. Avoid carrying out operations with the
hydraulic cylinder fully retracted or fully extended.

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MACHINE OPERATIONS AND CONTROLS OPERATION

OPERATIONS USING BUCKET DROPPING FORCE

Do not use the dropping force of the machine for digging, or
use the dropping force of the bucket as a pickaxe, breaker, or
pile driver.

This will markedly reduce the life of the machine.

OPERATIONS USING MACHINE DROPPING FORCE

Do not use the dropping force of the machine for digging.

DIGGING HARD ROCKY GROUND

It is better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce dam-
age to the machine but make for better economy.

SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL

(1) Never carry out sudden lever shifting as this may cause
sudden starting.

(2) Avoid sudden lever shifting from forward to reverse (or

from reverse to forward).

(3) Avoid sudden lever shifting change such as sudden stop-

ping from near top speed (lever release operation).

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OPERATION MACHINE OPERATIONS AND CONTROLS

GENERAL OPERATION INFORMATION

TRAVELING
When traveling over obstacles such as boulders or tree
stumps, the machine (in particular, the undercarriage) is sub-
jected to a large shock, so reduce the travel speed and travel
over the obstacle at the center of the tracks. As far as possible,
remove such obstacles or avoid traveling over them.

HIGH SPEED TRAVEL

On uneven roadbeds such as rock beds or uneven roads with
large locks, travel at Lo speed. When Hi-speed traveling, set
the idler in the forward direction.

PERMISSIBLE WATER DEPTH

CAUTION
When driving the machine out of water, if the angle of the
machine exceeds 15º, the rear of the upper structure will
go under water, and water will be thrown up by the radia-
tor fan. This may cause the fan to break.
Be extremely careful when driving the machine out of
water.

Do not drive the machine in water deepen than of the center of

carrier roller(1).

Supply grease to the parts which have been under water for a
long time until the used grease is projected out of the bearings
(around the bucket pin, in particular).

3-93
MACHINE OPERATIONS AND CONTROLS OPERATION

TRAVELING ON SLOPES

WARNING
When traveling, raise the bucket approx. 20 to 30cm (8 to
12 in) from the ground.

Do not travel downhill in reverse.

● When traveling over ridges or other obstacles, keep

the work equipment close to the ground and travel
slowly.

● Never turn on slopes or travel across slopes.

Always go down to a flat place to perform these oper-
ations. It may be longer, but it will ensure safety.

● Always operate or travel in such a way that it is possi-

ble to stop safely at any time if the machine slips or
becomes unstable.

● Turning or operating the work equipment when work-

ing on slopes may cause the machine to lose it bal-
ance and turn over, so avoid such operations.
It is particularly dangerous to swing downhill when
the bucket is loaded.
If such operations have to be carried out, pile soil to
make a platformon the slope so that the machine can
be kept horizontal when operating.

● Do not travel up or down steep slopes. There is dan-

ger that the machine may turn over.

● When traveling uphill, if the shoes slip or it is impossi-

ble to travel uphill using only the force of the tracks,
do not use the pulling force of the arm to help the
machine travel uphill. There is danger that the
machine may turn over.

1. When traveling down steep hills, use the travel lever and
fuel control lever to keep the travel speed low. When trav-
eling down a steep hill of more than 15º, set the work
equipment to the posture shown in the diagram on the
right, and lower the engine speed.
REMARK
Travel down fills with the sprocket side down.
If the machine travels down with the sprocket side up, the track
tends to become loose, and that can cause skipping pitches.

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OPERATION MACHINE OPERATIONS AND CONTROLS

2. When traveling up a steep hill of more than 15º, set the

work equipment to the posture shown in the diagram on
the right.

● When traveling up steep slopes, to ensure the balance,

extend the work equipment to the front, keep it raised 20 -
30cm (10 - 20in) from the ground surface, and travel at low
speed.

TRAVELING DOWNHILL
To brake the machine during downhill runs, put the travel lever in the neutral position. This will cause the brake to
be automatically applied.

ENGINE STOPPED ON SLOPE

If the engine stops when traveling uphill, move the all levers to the neutral position, then start the engine again.

PRECAUTIONS ON SLOPES
● If the engine stops when the machine is on a slope, never use the left work equipment control lever to carry
out swing operations. The upper structure will swing under its own weight.

● Be extremely careful when opening or closing the door on slopes. The weight of the door may cause the door
to open or close suddenly.
Always set the door so that it is firmly locked in position.

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MACHINE OPERATIONS AND CONTROLS OPERATION

ESCAPE FROM MUD

Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to
get the machine out.

STUCK ONE SIDE OF TRACK

NOTICE
When using the boom or arm to raise the machine, always
havethe bottom of the bucket in contact with the ground.
(Never pushwith the teeth). The angle between the boom
and arm should be 90º to 110º. The same applies when
using the inverting bucket.

When only one side is stuck in mud, use the bucket to raise the
track, then lay boards or logs and drive the machine out. If nec-
essary, put a board under the bucket also.

STUCK BOTH SIDES OF TRACKS

If the track on both sides are in mud and the machine slips and
cannot move, use the procedure given above to lay logs or tim-
ber. dig the bucket into the ground at the front, operate the arm
in the same way as when digging, and set the travel lever to
FORWARD to pull the machine out.

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OPERATION MACHINE OPERATIONS AND CONTROLS

RECOMMENDED APPLICATIONS
In addition to the following, it is possible to further increase the range of applications by using various attachments.

BACKHOE WORK
A backhoe is suitable for excavating at a position lower than
the machine.

When the condition of the machine is as shown in the diagram

at right, each cylinder's maximum pushing excavation force is
obtained when the bucket cylinder and link, arm cylinder and
arm are at 90º.

When excavating, use this angle effectively to optimize your

work efficiency.

The range for excavating with the arm is from a 45º angle away
from the machine to a 30º angle toward the machine.

There may be some differences depending on the excavation

depth, but try to stay within the above range rather than operat-
ing the cylinder is the end of its stroke.

SHOVEL WORK
A shovel is suitable for excavating at a position higher than the
machine. Shovel work is performed by attaching the bucket in
the reverse direction.

DITCHING WORK
Ditching work can be performed efficiently by attaching a
bucket to match the width of the ditch and then setting the
tracks parallel to the line of the ditch to be excavated.

To excavate a wide ditch, first dig out both sides and then
finally remove the center portion.

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MACHINE OPERATIONS AND CONTROLS OPERATION

LOADING WORK
In places where the swing angle is small, work can be carried
out more efficiently by stopping the dump truck in a place
where it can be seen easily by the operator.

Loading is easier and the capacity is greater if you load from

the rear of the dump truck body than if you load from the side.

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OPERATION MACHINE OPERATIONS AND CONTROLS

REPLACEMENT AND INVERSION OF BUCKET

WARNING
● When the pin is knocked in with a hammer, pieces of metal may fly into your eyes and cause serious
injury.
When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equip-
ment.

● When the bucket is removed, place it in a stable condition.

● If the pins are hit with force, the pin may fly and injure people in the surrounding area, so check that
the surrounding area is safe.

● When removing the pin, be extremely careful not to stand behind the bucket or to put your foot or any
part of your body behind the bucket from the side.

● When removing or installing the pin, be extremely careful not to get your hands caught.

● Never put your fingers in the pin holes when aligning the holes.

Stop the machine on a firm, flat surface. When performing joint work, make clear signals to each other and work
carefully for safety's sake.

REPLACEMENT
1. Place the bucket in contact with a flat surface.
REMARK
When removing the pins, place the bucket so that it is in light
contact with the ground.
If the bucket is lowered strongly to the ground, the resistance
will be increased and it will be difficult to remove the pins.

NOTICE
After removing the pins, make sure that they do not
become contaminated with sand or mud and that the seals
of bushing on both sides do not become damaged.

2. Remove the double nut from the stopper bolt of each pin
of the arm and link, remove the bolts, then take out arm
pin (A) and link pin (B), and remove the bucket.

3. Align the arm with holes (1) and the link with holes (2),
then coat with grease and install pins (A) and (B).

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MACHINE OPERATIONS AND CONTROLS OPERATION

REMARK
● Carry out installation in the reverse order to removal.
● When installing the bucket: For arm pin portion (A), fit an
O-ring at the position on the bucket shown in the diagram
on the right. After inserting the pin, fit it into the proper
groove. For link pin portion (B), install the bucket with the
O-ring fitted in the proper groove.

4. Install the stopper bolts and nuts for each pin, then
grease the pin.

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OPERATION MACHINE OPERATIONS AND CONTROLS

INVERSION
1. Place the bucket in contact with a flat surface.
REMARK
When removing the pins, place the bucket so that it is in light
contact with the ground.
If the bucket is lowered strongly to the ground, the resistance
will be increased and it will be difficult to remove the pins.

NOTICE
After removing the pins, make sure that they do not
become contaminated with sand or mud and that the seals
of bushing on both sides do not become damaged.

2. Remove the double nut from the stopper bolt of each pin
of the arm and link, remove the bolts, then take out arm
pin (A) and link pin (B), and remove the bucket.

3. Reverse the bucket.

After reversing the bucket, align the mounting pin hole
with the arm and link, align the arm with the link mounting
hole, then align the link with the arm mounting hole and
install the bucket.

4. Align the arm with holes (1) and the link with holes (2),
then coat with grease and install pins (A) and (B).

REMARK
When reversing, do not install an O-ring. Keep the O-ring in a
safe place until using it next.

5. Install the stopper bolts and nuts for each pin, then
grease the pin.

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MACHINE OPERATIONS AND CONTROLS OPERATION

PARKING MACHINE

WARNING
● Avoid sudden stops. Leave as much room as possi-
ble when stopping.

● Park the machine on firm level ground.

Avoid parking the machine on a slope.
If the machine must be parked on a slope, put blocks
under tracks and dig the work equipment into the
ground to prevent the machine from moving.

● If the work equipment lever is touched by mistake, the

work equipment or machine may suddenly move and
cause serious personal injury or accident. Always set
the safety lock lever securely to the LOCK position
before standing up from the operator's seat.

1. Put left and right travel levers (1) in the neutral position.
The machine stops.

2. Lower the engine speed to low idling by fuel control dial

(2) .

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OPERATION MACHINE OPERATIONS AND CONTROLS

3. Lower the bucket horizontally until the bottom touches

the ground.

4. Set safety lock lever (3) in the LOCK position.

CHECK AFTER FINISHING WORK

Check the engine water temperature gauge (1), engine oil
pressure monitor (2), and fuel gauge (3) on the machine moni-
tor.

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MACHINE OPERATIONS AND CONTROLS OPERATION

LOCKING
Always lock the following places.

(1) Door of operator’s cab

Always remember to close the window.
(2) Fuel tank filler port
(3) Engine hood
(4) Battery box cover
(5) Left side door of the machine
(6) Right side door of the machine
(7) Hydraulic tank filler port
REMARK
Use the starting switch key to open and close all these places.

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OPERATION TRANSPORTATION

TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.

TRANSPORTATION PROCEDURE
As a basic rule, transport the machine by trailer.

Select the trailer to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)" .

Note that the value for the weight and transportation dimensions given in SPECIFICATIONS may differ according
to the type of shoe or type of arm or other attachments.

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TRANSPORTATION OPERATION

LOADING AND UNLOADING WITH TRAILER

WARNING
● Always turn the auto-deceleration switch OFF (can-
cel)during loading and unloading operations.
If the auto-deceleration switch is left ON,the machine
may suddenly start moving.

● Always drive the machine at low speed when loading

or unloading the machine on a trailer. Do not operate
the travel speed selector switch.

● Run the engine at low idling, set to low speed, and

operate the machine slowly when loading or unload-
ing.

● Do not load or unload the machine during the auto-

matic warming-up operation.
If the automatic warming-up operation is canceled
during the loading or unloading operation, the speed
will suddenly change.

● Select firm, level ground when loading or unloading

the machine.
Maintain a safe distance from the edge of the road.

● Use ramps with ample width, length, thickness, and

strength and install them at a maximum slope of 15º.
When using piled soil, compact the piled soil fully and
take action to prevent the slope face from collapsing.

● Remove all mud and dirt from the machine tracks

before starting in order to prevent the machine from
slipping on the ramps.
Be sure that the ramp surface is clean and free of
water, snow, ice, grease, or oil.

● Never correct your steering on the ramps. There is

danger that the machine may turn over.
If necessary, drive off the ramps, correct the direction,
then enter the ramps again.

● Do not use use the work equipment for loading and

unloading operations. It is dangerous.

● When on the ramps, do not operate any lever except

the travel lever.

● The center of gravity of the machine will change sud-

denly at the joint between the ramps and the track or
trailer, and there is danger of the machine losing its
balance. Travel slowly over this point.

● When swinging the upper structure on the trailer, the

trailer is unstable, so pull in the work equipment and
swing slowly.

When loading or unloading, always use ramps or a platform and carry out the operation as follows.

3-106
OPERATION TRANSPORTATION

LOADING
1. Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of a road.

2. Properly apply the brakes on the trailer and put blocks

under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer
and the machine.
Be sure that the two sides are at the same level as one
another.
Make the slope of the ramps a maximum of 15º.
Set the distance between the ramps to match the center
of the tracks.

3. Set the travel speed selector switch to the LOW position.

4. Turn the auto-deceleration switch OFF.

5. Lower the engine speed to low idling fuel control dial.

3-107
TRANSPORTATION OPERATION

6. If the machine is equipped with work equipment, set the

work equipment at the front, and travel forward to load it;
if it has no work equipment, travel in reverse to load it.

7. When the machine travels over the rear wheels of the

trailer, it will become unstable, so travel slowly and care-
fully. (Never change the direction of the machine under
any circumstances.)

8. Turn the swing lock switch OFF to release the swing lock,
then swing the upper structure slowly 180°.
When the machine passes the raised area above the rear
wheels, it will tilt to the front, so be extremely careful not
to let the work equipment hit the body of the trailer, then
travel forward to the specified position.

9. Stop the machine at the specified position on the trailer.

10. Turn the swing lock switch ON to lock the swing lock.

3-108
OPERATION TRANSPORTATION

SECURING MACHINE

NOTICE
● Stow the car radio antenna. In addition, remove the mirrors.
Tie the removed parts securely to the trailer.
● To prevent damage to the bucket cylinder during transportation, fit a wooden block at one end of the
bucket cylinder to prevent it from touching the floor.

After loading the machine on the trailer, secure the machine as follows.

1. Extend the bucket and arm cylinders fully, then lower the
boom slowly.

2. Stop the engine, then remove the key from the starting
switch.

3. Lock the control levers securely with the safety lock lever.

4. Lock the operator's cab, side cover, battery box cover

and engine hood.

5. Put blocks under both ends of the tracks to prevent the

machine from moving during transportation, and tie the
machine down securely with chains or wire rope of suit-
able strength.
Be particularly careful to fix the machine in position
securely so that it does not slip to the side.

3-109
TRANSPORTATION OPERATION

REMOVING, INSTALLING MIRRORS

The mirrors are at the positions shown in the diagram on the
right. ( : if equipped)
If they are damaged, or are to be removed for shipment, or are
to be installed again, use the following procedure.

Removal
1. Loosen locknut (2) of mirror (1), then remove mirror (1)
from support (3).

2. Loosen bolt (4), then remove support (3) and clamp (5)
from the handrail.

Installation
1. Install support (3) and clamp (5) to the handrail, then
tighten bolt (4).

2. Install mirror (1) to support (3), then tighten locknut (2).

3-110
OPERATION TRANSPORTATION

UNLOADING
1. Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of a road.
2. Properly apply the brakes on the trailer and put blocks
under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer
and the machine.
Be sure that the two sides are at the same level as one
another.
Make the slope of the ramps a maximum of 15º.
Set the distance between the ramps to match the center
of the tracks.

3. Remove the chains or wire rope holding the machine.

4. Start the engine.

Carry out the warming-up operation thoroughly in cold
weather.

5. Set the safety lock lever (1) to the FREE position.

6. Set the travel speed selector switch to the LOW position.

7. Turn the auto-deceleration switch OFF.

3-111
TRANSPORTATION OPERATION

8. Set fuel control dial (1) at the LOW ILDING position.

9. Turn the swing lock switch OFF to release the swing lock.

10. Raise the work equipment, pull in the arm under the
boom, then move the machine slowly.

11. When the machine is horizontal on top of the rear wheels

of the trailer, stop the machine.
NOTICE
● If the machine is unloaded with the arm pulled in, the
work equipment will be damaged.
● When moving on to the ramps, to prevent damage to
the hydraulic cylinders, do not let the bucket hit the
ground.

12. When moving from the rear of the trailer on to the ramps,
set the angle of the arm and boom to 90 - 110º, lower the
bucket to the ground, then move the machine slowly.

13. When moving down the ramps, operate the boom and
arm slowly to lower the machine carefully until it is com-
pletely off the ramps.

14. Turn the swing lock switch ON to apply the swing lock

3-112
OPERATION TRANSPORTATION

LIFTING MACHINE

WARNING
● Never raise the machine with any worker on it.

● Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of
the machine.

● Never try to lift the machine in any posture other than the posture given in the procedure below.
There is a hazard that the machine may lose its balance.

● Never lift the machine with the upper structure swung to the side. Swing the work equipment so that it
is at the sprocket end and set the undercarriage and upper structure parallel before lifting.

● When lifting, keep the machine horizontal.

● It is dangerous to go under the machine when it is raised.

Never go under the machine in such cases.

STANDARD SPECIFICATION MACHINE

NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases,
please contact your Komatsu distributor for information.

For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".

When lifting the machine, carry out the operation on flat ground as follows.

1. Swing the upper structure so that the work equipment is

at sprocket end.

2. Extend the bucket cylinder and arm cylinder fully, then

lower the work equipment to the ground as shown in the
diagram on the right using the boom cylinder.

3. Stop the engine, check that there is nothing around the

operator's compartment, then get off the machine.
Close the cab door and front glass securely.

3-113
TRANSPORTATION OPERATION

4. Pass wire ropes between the 1st and 2nd track rollers
from the front and between the 1st and 2nd track rollers
from the rear.
However, for machines equipped with a full roller guard
for the track roller, pass the wire rope under the track.

5. Set the lifting angle of the wire rope to 30º to 40º, then lift
the machine slowly.

6. After the machine comes off the ground, check carefully

that the machine is balanced, then lift slowly.

REMARK
For machines equipped with lifting hooks, raise the machine as
follows.

1) Start the engine and set the work equipment to the

posture shown in the diagram on the right. (Boom
raised fully, arm, bucket pulled in fully.) Set the
upper structure facing directly to the front (idler end).

2) Set the safety lock lever to the LOCK position.

3) Stop the engine, check that the area around the

machine is safe, then get down from the machine.
Close the cab door window and front window, left
and right doors, and engine hood securely.

4) Install shackles to the lifting hooks on the boom and

the top of the counterweight, then fit the wire rope.

5) Select the wire rope so that lifting position P is imme-

diately above the center of gravity of the machine (a
point 400 mm (15.8 in) behind the swing center) as
shown in the diagram on the right.

6) When lifting, check that leakage of oil in the hydrau-

lic circuit at the head end of the boom cylinder does
not cause the posture to change.

7) When the machine leaves the ground, stop the lifting

operation and check that the machine is balanced.
When the machine becomes stable, continue the lift-
ing operation.

3-114
OPERATION COLD WEATHER OPERATION

COLD WEATHER OPERATION

COLD WEATHER OPERATION INFORMATION

If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol-
lows.

FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see "USE OF
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-11)".

COOLING SYSTEM COOLANT

WARNING
● Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes
or on your skin, wash it off with large quantities of fresh water and see a doctor at once.

● Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing anti-
freeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask
your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to
the ground surface.

● Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.

NOTICE
● Never use methanol, ethanol or propanol based antifreeze.
● Absolutely avoid using any water leak preventing agent irrespective of weather it is used indepen-
dently or mixed with an antifreeze.
● Do not mix one antifreeze with a different brand.

For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-26)".

REMARK
Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be used
only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn). When refilling
the cooling system, add antifreeze in autumn, but do not add any in spring.

For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-26)".

3-115
COLD WEATHER OPERATION OPERATION

BATTERY

WARNING
● The battery generates flammable gas, so do not bring fire or sparks near the battery.

● Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts
of water, and consult a doctor.

● Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with water.

● If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.

When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low,
the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%, and insulate it
against cold temperature so that the machine can be started easily the next morning.

REMARK
Measure the specific gravity and calculate the rate of charge from the following conversion table.

Temp. of fluid
20ºC 0ºC -10ºC -20ºC
Rate of charge

100 1.28 1.29 1.30 1.31

90 1.26 1.27 1.28 1.29

80 1.24 1.25 1.26 1.27

75 1.23 1.24 1.25 1.26

● As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine,
keep it in a warm place, and install it again the next morning.

● If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add the water
after the day's work so as to prevent fluid in the battery from freezing in the night.

3-116
OPERATION COLD WEATHER OPERATION

AFTER DAILY WORK COMPLETION

WARNING
● Performing idle-running of the tracks is dangerous, so stay well away from the tracks.

● After completion of operations, fill the fuel tank to prevent the formation of water caused by conden-
sation of moisture in the empty space in the tank when the temperature goes down.

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, always observe the following precautions.

● Mud and water on the machine body should be completely removed. This is to prevent damage to the seal
caused by mud or dirt getting inside the seal with frozen drops of water.

● Park the machine on hard, dry ground.

If this is impossible, park the machine on wooden boards.

The boards help protect the tracks from being frozen in soil and the machine can start next morning.

● Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.

● After operation in water or mud, remove water from undercarriage as described below to extend undercarriage
service life.

1. Swing 90º with engine at low idling and bring the work
equipment to the side of the track.

2. Jack up the machine until the track is raised slightly from

the ground. Rotate the track under no load. Repeat this
procedure on both the left and right sides.

3-117
COLD WEATHER OPERATION OPERATION

AFTER COLD WEATHER SEASON

When season changes and the weather becomes warmer, do as follows.

● Replace the fuel and oil for all parts with oil of the viscosity specified.

For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE (PAGE 4-11)".

● If for any reason permanent antifreeze cannot be used, and an ethyl glycol base antifreeze (winter, one sea-
son type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the
inside of the cooling system thoroughly, and fill with fresh soft water.

3-118
OPERATION LONG TERM STORAGE

LONG TERM STORAGE

BEFORE STORAGE
NOTICE
When storing the machine, set the machine in the posture
shown in the diagram on the right to protect the cylinder
rod.
(To prevent rusting of the cylinder rod)

When putting the machine in storage for a long time, do as follows.

● Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select
level ground and cover the machine with a sheet.

● Completely fill the fuel tank, lubricate and change the oil before storage.

● Apply a thin coat of grease to the metal surface of the hydraulic piston rods.

● Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it sepa-
rately.

● If the ambient temperature is expected to drop below 0ºC (32ºF), always add antifreeze to the cooling water.

● Lock each control lever and pedal with the lock lever and pedal lock.

● Set the stop valve to the LOCK position on machines which can install attachments. Install a plug in the elbow.

● Set the selector valve on the machines which can install attachments to the "Where no attachment is
mounted" position.

DURING STORAGE

WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors,
open the doors and windows to improve ventilation and prevent gas poisoning.

● During storage, always operate the machine once a month so that a new film of oil will be coated over mov-
able parts and component surfaces. At the same time, also charge the battery.

● For machines equipped with an air conditioner, run the air conditioner.

● Rotate the tracks.

3-119
LONG TERM STORAGE OPERATION

AFTER STORAGE
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please
contact your Komatsu distributor.

When using the machine after long-term storage, do as follows before using it.

● Wipe off all the grease coating the hydraulic cylinder rods.

● Add oil and grease to all places.

● When the machine has been stored for a long time, the moisture in the atmosphere will get into the oil. Check
the oil at all parts before and after starting the engine. If there is water in the oil, change all the oil.

STARTING MACHINE AFTER LONG-TERM STORAGE

When starting the engine after long-term storage, cancel the automatic warming-up operation as follows.

1. Turn the starting switch key to the ON position.

2. Turn the fuel control dial from the low idling (MIN) position to the full (MAX) position, hold it there for 3 sec-
onds, then return it to the low idling (MIN) position and start the engine.

3-120
OPERATION TROUBLESHOOTING

TROUBLESHOOTING

AFTER RUNNING OUT OF FUEL

When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.

For details of bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-56)".

PHENOMENA THAT ARE NOT FAILURES

Note that the following phenomena are not failures:

● When the arm is pulled in, the speed of movement will drop
momentarily when the arm is more or less vertical.

● The arm speed will drop momentarily when the bucket

teeth are more or less horizontal.

● Bucket or arm shakes during heavy-duty digging opera-

tions.

● When starting or stopping the swing, noise will be emitted from the brake valve.

● When going down a steep slope at low speed, a noise will be emitted from the travel motor.

3-121
TROUBLESHOOTING OPERATION

TOWING THE MACHINE

WARNING
● When towing the machine, use a wire rope that has ample strength for the weight of the machine that
is being towed.

● Do not apply a sudden load to the wire rope.

If the machine sinks in mud and cannot get out under its own
power, or if the drawbar pull of the excavator is being used to
tow a heavy object, use a wire rope as shown in the diagram
on the right.

Place pieces of wood between wire ropes and body to prevent

damage to ropes and body.

At this time, never use the hook for light-weight towing.

LIGHTWEIGHT TOWING HOOK

WARNING
● The shackle must always be used.

● Hold the rope level and direct it straight to the track

frame.

● Move the machine slowly.

The track frame has been equipped with a hook to pass the
shackle for towing light objects.

Permissible towing load:

PC200 : Max. 58800 N (6000 kgf)
PC220 : Max. 78400 N (8000 kgf)

3-122
OPERATION TROUBLESHOOTING

PRECAUTIONS ON PARTICULAR JOBSITES

● When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry
out greasing every time the operation is carried out.

● For heavy-duty operations and deep digging, carry out greasing of the work equipment mounting pins every
time before operation.

After greasing, operate the boom, arm, bucket, and blade several times, then grease again.

3-123
TROUBLESHOOTING OPERATION

DISCHARGED BATTERY

WARNING
● It is dangerous to charge the battery while it is still
mounted on the machine. Always remove the battery
before charging it.

● When checking or handling the battery, stop the

engine and turn the starting switch key to the OFF
position.

● The battery generates hydrogen gas, so there is a haz-

ard of explosion.
Do not bring lighted cigarettes near the battery, or do
anything that will cause sparks.

● Battery electrolyte is dilute sulphuric acid, and it will

attack your clothes and skin. If it gets on your clothes
or on your skin, wash it immediately off with large
amounts of water. If it gets in your eyes, wash it out
with fresh water, and consult a doctor.

● When handling batteries, always wear protective gog-

gles and rubber gloves.

● When removing the battery, first disconnect the cable

from the ground (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis,
there is danger that it will cause a spark, so be
extremely careful.

● If the terminals are loose, there is danger that the

defective contact may generate sparks that will cause
an explosion.

● When installing the terminals, install them tightly.

When removing or installing the terminals, check
which is the positive (+) terminal and which is the neg-
ative (-) terminal.

● Green rust around the terminals is a cause of self-dis-

charge of the battery. Polish the terminals with sand-
paper. After removing the rust, coat the terminals
thinly with grease before installing.

3-124
OPERATION TROUBLESHOOTING

REMOVAL AND INSTALLATION OF BATTERY

NOTICE
After fixing the battery in position, check that it does not move. If it moves, install it again.

● When removing, remove from the ground side first (normally the (-) terminal).
Be careful not to touch between the (+) terminal and the machine with any tool. Letting a tool touch is danger-
ous as it causes sparks.
● When installing, connect the ground side last.
● When replacing the battery, fix the battery securely with the battery mount clamp.
● Tightening torque of mounting bolts : 9.8 to 14.7 N•m (1 to 1.5 kgf•m, 7.2 to 10.8 lbft)

BATTERY CHARGES
When charging the battery, there is danger that the battery may
explode if it is handled wrongly, so follow the instructions in
"OTHER TROUBLE (PAGE 3-128)" and the instruction manual
supplied with the charger, and be sure to observe the following
precautions.

● Set the voltage of the charger to match the voltage of the

battery to be charged. If the voltage is not selected cor-
rectly, the charger may overheat and cause an explosion.

● Connect the positive (+) charger clip of the charger to the

positive (+) terminal of the battery, then connect the nega-
tive (-) charger clip of the charger to the negative (-) termi-
nal of the battery. Be sure to fix the clips securely.

● Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire
and explode.

● If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery electrolyte and cause the battery to explode.

● Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may
cause an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the
electrolyte level to the UPPER LEVEL line.

3-125
TROUBLESHOOTING OPERATION

STARTING ENGINE WITH BOOSTER CABLES

When starting the engine with a booster cable, do as follows:

CONNECTING AND DISCONNECTING BOOSTER CABLES

WARNING
● When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.

● When starting the engine with a booster cable, always

wear safety glasses.

● Be careful not to let the normal machine and problem

machine contact each other. This prevents sparks
fromgenerating near the battery which could ignite the
hydrogen gas given off by the battery. If hydrogen gas
explodes, it could cause serious injury.

● Make sure that there is no mistake in the booster

cable connections.
The final connection is to the upper structure frame,
but sparks will be generated when this is done, so
connect to a place as far as possible from the battery.
(However, avoid connecting the cable to the work
equipment, as conduction is poor.)

● Use care when removing the cables from the machine

that has been started. To avoid hydrogen explosion,
do not allow the cable ends to contact each other or
the machine.

NOTICE
● The starting system for this machine uses 24 V. For the normal machine, also use a 24V battery.
● The size of the booster cable and clip should be suitable for the battry size.
● The battry of the normal machine must be the same capacity as that of the engine to be started.
● Check the cables and clips for damage or corrosion.
● Make sure that the cables and clips are firmly connected.
● Check that the safety lock levers and parking brake levers of both machine are in the LOCK position.
● Check that each lever is in the NEUTRAL position.

3-126
OPERATION TROUBLESHOOTING

BOOSTER CABLE CONNECTION

Keep the starting switch of the nornal machine and problem
machine are both at the OFF position.

Connect the booster cable as follows, in the order of the num-

bers marked in the diagram.

1. Make sure that the starting switches of the normal

machine and problem machine are both at the OFF posi-
tion.

2. Connect one clip of booster cable (A) to the positive (+)

terminal of the problem machine.

3. Connect the other clip of booster cable (A) to the positive

(+) terminal of the normal machine.

4. Connect one clip of booster cable (B) to the negative (-)

terminal of the normal machine.
5. Connect the other clip of booster cable (B) to the upper structure of the problem machine.

STARTING THE ENGINE

CAUTION
Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is
working normally or has failed. Check also that all the control levers are at the HOLD or neutral position.

1. Make sure the clips are firmly connected to the battery terminals.

2. Start the engine of the normal machine and keep it to run at high idling speed.

3. Turn the starting switch of the problem machine to the START position and start the engine. If the engine
doesn't start at first, try again after 2 minutes or so.

BOOSTER CABLE DISCONNECTION

After the engine has started, disconnect the booster cables in
the reverse of the order in which they were connected.

1. Remove one clip of booster cable (B) from the upper

structure of the problem machine.

2. Remove the other clip of booster cable (B) from the nega-
tive (-) terminal of the normal machine.

3. Remove one clip of booster cable (A) from the positive

(+) terminal of the normal machine.

4. Remove the other clip of booster cable (A) from the posi-
tive (+) terminal of the problem machine.

3-127
TROUBLESHOOTING OPERATION

OTHER TROUBLE

ELECTRICAL SYSTEM
● ( ): Always contact your Komatsu distributor when dealing with these items.

● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem Main causes Remedy

Lamp does not glow brightly even ● Defective wiring, deterioraion of ( ● Check, repair loose terminals,
when the engine runs at high battery disconnections, replace battery)
speed

Lamp flickers while engine is run- ● Loose fan belt ● Check fan belt tension, replace
ning

Charge level monitor does not go ● Defective alternator ( ● Replace)

out even when engine is running ● Defectivr wiring ( ● Check, repair)

Abnormal noise is generated from ● Defective alternator ( ● Replace)

alternator

Starting motor does not turn when ● Defective wiring ( ● Check, repair)
starting switch is turned to ON ● Defective starting motor ( ● Replace)
● Insufficient battery charge ● Charge

Pinion of starting motor keeps ● Insufficient battery charge ● Charge

going and out ● Defective safety relay ( ● Replace)

Starting motor turns engine slug- ● Insufficient battery charge ● Charge

gishly ● Defective starting motor ( ● Replace)

Starting motor disengages before ● Defective wiring, defective ring ( ● Check, repair)
engine starts gear pinion
● Insufficient battery charge ● Charge

Pre-heating monitor does not light ● Defective wiring ( ● Check, repair)

● Defective heater relay ( ● Replace)
● Defective monitor ( ● Replace)

Oil pressure monitor does not light ● Defective monitor ( ● Replace)

up when engine is stopped (start- ● Defective caution lamp switch ( ● Replace)
ing switch at ON position)

Outside of electrical heater is not ● Defective wiring ( ● Check, repair)

warm when touched by hand ● Disconnection in electric heater ( ● Replace)
● Defective operation of heater ( ● Replace)
relay switch

3-128
OPERATION TROUBLESHOOTING

CHASSIS
● ( ): Always contact your Komatsu distributor when dealing with these items.

● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem Main causes Remedy

Speed of travel, swing, boom, arm, ● Lack of hydraulic oil ● Add oil to specified level, see
bucket is slow CHECK BEFORE STARTING
Pump generates abnormal noise ● Clogged element in hydraulic ● Clean, see EVERY 2000
(sucking in air) tank strainer, lack of oil HOURS SERVICE

Excessive rise in hydraulic oil tem- ● Loose fan belt ● Check fan belt tension, replace
perature ● Dirty oil cooler ● Clean, see EVERY 500 HOURS
SERVICE
● Lack of hydraulic oil ● Add oil to specified level, see
CHECK BEFORE STARTING

Track comes off ● Track too loose ● Adjust track tension, see WHEN
REQUIRED
Abnormal wear of sprocket

Bucket rises slowly, does not rise ● Lack of hydraulic oil ● Add oil to specified level,
CHECK BEFORE STARTING

Does not swing ● Swing lock switch still applied ● Turn swing lock switch OFF

3-129
TROUBLESHOOTING OPERATION

ENGINE
● ( ): Always contact your Komatsu distributor when dealing with these items.

● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem Main causes Remedy

Engine oil pressure monitor lights ● Engine oil pan oil level is low ● Add oil to specified level, see
up (sucking in air) CHECK BEFORE STARTING
● Clogged oil filter cartridge ● Replace cartridge, see EVERY
500 HOURS SERVICE
● Defective tightening of oil pipe, (● Check, repair)
pipe joint, oil leakage from dam-
aged point
● Defective engine oil pressure ( ● Replace sensor)
sensor
● Defective monitor ( ● Replace)

Steam spurts out from top of radia- ● Cooling water level low, leakage ● Check, add water, repair, see
tor (pressure valve) of water CHECK BEFORE STARTING
● Loose fan belt ● Check fan belt tension, adjust,
replace
● Dirt or scale accumulated in ● Change coolant, flush inside of
cooling system cooling system, see WHEN
REQUIRED

Radiator water level monitor lights ● Clogged radiator fins or dam- ● Clean or repair, see EVERY
up aged fins 500 HOURS SERVICE
● Defective thermostat (● Replace thermostat)
● Loose radiator filler cap (high- ● Tighten cap or replace packing
altitude operations)
● Defective water level sensor ( ● Replace sensor)
● Defective monitor ( ● Replace sensor)

Engine does not start when starting ● Lack of fuel ● Add fuel, see CHECK BEFORE
motor is turned STARTING
● Air in fuel system ● Repair place where air is
sucked in, see EVERY 500
HOURS SERVICE
● Defective fuel injection pump or (● Replace pump or nozzle)
defective nozzle
● Starting motor cranks engine ● See ELECTRICAL SYSTEM
sluggishly
● Preheating monitor does not ● See ELECTRICAL SYSTEM
light up
● Defective compression
❍ Defective valve clearance ( ● Adjust valve clearance)
Exhaust gas is white or blue ● Too much oil in oil pan ● Set oil to specified level, see
CHECK BEFORE STARTING
● Improper fuel ● Change to specified fuel

3-130
OPERATION TROUBLESHOOTING

Problem Main causes Remedy

Exhaust gas occasionally turns ● Clogged air cleaner element ● Clean or replace, see WHEN
black REQUIRED
● Defective nozzle (● Replace nozzle)
● Defective compression (● See defective compression
above)
● Defective turbocharger ● Clean or replace turbocharger

Combustion noise occasionally ● Defective nozzle ( ● Replace nozzle)

make breathing sound
Abnormal noise generated (com- ● Low-grade fuel being used ● Change to specified fuel
bustion or mechanical) ● Overheating ● Refer to "Radiator water level
monitor lights up" as above
● Damage inside muffler ● Replace muffler
● Excessive valve clearance (● Adjust clearance)

3-131
TROUBLESHOOTING OPERATION

ELECTRONIC CONTROL SYSTEM

If an error code appears on the machine monitor display (normally displays TIME), follow the countermeasure
table as shown below in the self-diagnosis.

Machine monitor trouble display

Monitor display Error mode Countermeasure

E02 PC-EPC valve sys- If the pump override switch is set to the ON posi-
tem error tion, operation can be carried out.However,imme-
diately have the TVC valve system inspected by
your Komatsu distributor.(*)
E03 Swing brake system Turn the swing prolix switch ON to cancel the
error brake.
When applying the swing brake, operate the
swing lock switch manually. Depending on the
cause of the failure, it may be impossible to
release the brake.In any case, have the system
inspected immediately by your Komatsu distribu-
tor.(*)

E05 Governor system Governor will not execute the control function.
error Manually operate the governor-lever.To fix the
governor lever at the full stroke position,use the
retaining bolt holes on bracket.In this case, imme-
diately have the governor system inspected by
your Komatsu distributor.

In the case where the monitor will not display error codes
Have the machine inspected immediately by your
and work equipment operation and swing operation can-
Komatsu distributor.
not be carried out.

(*): For details of handling the emergency pump drive switch, swing holding brake cancel switch, and emergency
work equipment actuation switch, see "SWITCHES (PAGE 3-17)".

3-132
 MAINTENANCE
41

WARNING
Please read and make sure that you understand the safety
volume before reading this section.

4-1
MAINTENANCE INFORMATION MAINTENANCE

MAINTENANCE INFORMATION
Do not carry out any inspection and maintenance operation that is not found in this manual.

SERVICE METER READING

Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.

KOMATSU GENUINE REPLACEMENT PARTS

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE LUBRICANTS

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.

WINDSHIELD WASHER FLUID

Use automobile windshield washer fluid, and be sure not to let any dirt get into it.

FRESH AND CLEAN LUBRICANTS

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.

CHECK DRAINED OIL AND USED FILTER

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantities of metal particles or foreign materials are found, always report to the person in charge, and carry
out suitable action.

FUEL STRAINER
If your machine is equipped with a fuel strainer, do not remove it while fueling.

WELDING INSTRUCTIONS
● Turn off the engine starting switch.

● Do not apply more than 200V continuously.

● Connect grounding cable within 1m (3.3 ft) from the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may have troubles.

● Avoid seals or bearings from being between the area to be welded and the position of grounding point.

● Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

4-2
MAINTENANCE MAINTENANCE INFORMATION

DO NOT DROP THINGS INSIDE MACHINE

● When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.

● Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

DUSTY JOBSITE
When working at dusty worksites, do as follows:

● Check the clogging of the air cleaner more frequently with the dust indicator. Clean the air cleaner element
more frequently.

● Clean the radiator core frequently to avoid clogging.

● Clean and replace the fuel filter frequently.

● Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

● When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from get-
ting into the oil.

AVOID MIXING LUBRICANTS

Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with
the new type of oil.

LOCKING THE INSPECTION COVERS

When carrying out maintenance with the inspection cover open, lock it in position securely with a lock bar. If
inspection or maintenance is carried out with the inspection cover open and not locked in position, there is a haz-
ard that it may be suddenly blown shut by the wind and cause injury to the worker.

HYDRAULIC SYSTEM - AIR BLEEDING

When hydraulic equipment has been repaired or replaced, or the hydraulic piping has been removed and installed
again, the air must be bled from the circuit. For details, see "BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE
4-43)".

HYDRAULIC HOSE INSTALLATION

● When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.

When doing this, be careful not to forget to assemble the O-rings and gaskets.

● When installing the hoses, do not twist them or bend them into loops with a small radius.

This will cause damage to the hose and markedly reduce its service life.

4-3
MAINTENANCE INFORMATION MAINTENANCE

CHECKS AFTER INSPECTION AND MAINTENANCE WORKS

If you forget to carry out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injuly or property damage. Always do as follows.

● Checks after operation (with engine stopped)

● Have any inspection and maintenance points been forgotten?

● Have all inspection and maintenance items been carried out correctly?

● Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside machine and get caught in the lever linkage mechanism.

● Is there any leakage of water or oil? Have all the bolts been tightened?

● Checks when operating engine

● For details of the checks when operating the engine, see "TWO WORKERS FOR MAINTENANCE WHEN
ENGINE IS RUNNING (PAGE 2-34)" and pay careful attention to safety.

● Are the inspection and maintenance items working properly?

● Is there any leakage of oil when the engine speed is raised and load is applied to the oil pressure?

SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE

It is necessary to use fuel and lubricants that match the ambient temperature.

For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
(PAGE 4-11)".

4-4
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS

LUBRICANTS, COOLANT AND FILTERS

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
● Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres-
sure), and is deteriorates with use.

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Man-
ual.

Even if the oil is not dirty, always change the oil after the specified interval.

● Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.

The majority of problems with machine are caused by the entry of such impurities.

Take particular care not to let any impurities get in when storing or adding oil.

● Never mix oils of different grades or brands.

● Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.

● If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.

● When changing the oil, always replace the related filters. In particular, when replacing the engine oil filter, fill
the new filter with fresh, clean specified oil before installing.

● We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.

FUEL
● The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

● Be extremely careful not to let impurities get in when storing or adding fuel.

● Always use the fuel specified in the Operation and Maintenance Manual.

Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15ºC
(5ºF)), so it is necessary to change to a fuel that matches the temperature.

● To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank after completing the day's work.

● Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water
from the fuel tank.

● If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

4-5
LUBRICANTS, COOLANT AND FILTERS MAINTENANCE

COOLING SYSTEM COOLANT

● River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the
engine and radiator, and this will cause defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

● When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

● Komatsu machines are supplied with Komatsu specified anti-freeze in the coolant.

This anti-freeze is effective in preventing corrosion of the cooling system.

The anti-freeze can be used continuously for 2 years or 4000 hours. Therefore, it can be used as it is even in
hot areas.

● Anti-freeze is flammable, so be extremely careful not to expose it to flame or fire.

● The ratio for the mixture of water and anti-freeze differs according to the ambient temperature.

For details of the ratio, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-26)".

● If the engine overheats, wait for the engine to cool before adding coolant.

● In addition to causing overheating, lack of cooling water also causes corrosion of the cooling circuit due to
entry of air.

GREASE
● Grease is used to prevent twisting and noise at the joints.

● The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not
need grease.

If any part becomes stiff or generates noise after being used for a long time, grease it.

● Always wipe off all of the old grease that is pushed out when greasing.

Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.

CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and down-time. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other abnormalities.

Periodic use of KOWA makes the following possible:

● It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.

● It enables repair schedules to be planned, leading to improved machine availability.

4-6
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS

KOWA ANALYSIS ITEMS

● Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.

● Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of large iron particles in the oil.

● Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.

OIL SAMPLING
● Sampling interval
250 hours: Engine
500 hours: Other components
● Precautions when sampling
● Make sure that the oil is well mixed before sampling.
● Carry out sampling regularly at fixed intervals.
● Do not carry out sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.

OIL AND FUEL STORAGE

● Keep indoors to prevent any water, dirt, or other impurities from getting in.

● When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at
the side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.

● To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).

4-7
LUBRICANTS, COOLANT AND FILTERS MAINTENANCE

FILTERS
● Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.

Replace all filters periodically. For details, see the Operation and Maintenance Manual.

However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.

● Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

● When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are
found, please contact your Komatsu distributor.

● Do not open packs of spare filters until just before they are to be used.

● Always use Komatsu genuine filters.

ELECTRIC SYSTEM MAINTENANCE

● It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged.
This will cause electrical leakage and may lead to malfunction of the machine. Do not wash the inside of the
operator's cab with water. When washing the machine, be careful not to let water get into the electrical compo-
nents.

● Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and
check of battery fluid level.

● Never install any electric components other than there specified by Komatsu.

● External electrical interference may cause malfunction of the control system controller, so before installing a
radio receiver or other wireless equipment, please contact your Komatsu distributor.

● When working at the seashore, carefully clean the electric system to prevent corrosion.

● When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power
source connector. The optional power source must never be connected to the fuse, starting switch, or battery
relay.

HANDLING HYDRAULIC SYSTEM

● During and after operations, the hydraulic system is at high temperature. During operations, it is also under
high pressure, so always pay careful attention to the following when carrying out inspection and maintenance
of the hydraulic system.

● Stop the machine on level ground, lower the bucket to the ground, and set so that there is no pressure on the
cylinder circuit.

● Always stop the engine.

● Immediately after operations, the hydraulic oil and lubricating oil are under pressure and at high temperature,
so always wait for the temperature to go down before starting maintenance.

● Even when the temperature goes down, there may still internal pressure, so when loosening plugs, screws, or
hose connections, do not stand directly in front, and loosen gradually to release the internal pressure before
removing.

4-8
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS

● When carrying out inspection or maintenance of the hydraulic circuits, always bleed the air to release the inter-
nal pressure.

● Inspection or maintenance consists of checking the hydraulic oil level, replacing the filters, and changing the
hydraulic oil.

● When removing high-pressure hoses, check that the O-ring is not damaged. If it is damaged, replace it.

4-9
WEAR PARTS LIST MAINTENANCE

WEAR PARTS LIST

Wear parts such as the filter element, bucket tooth, etc. are to be replaced at the time of periodic maintenance or
before their abrasion limits.

The wear parts should be changed correctly in order to use the machine economically.

For part change, Komatsu genuine parts of excellent quality should be used.

When ordering parts, please check the part number in the parts book.

The parts in parentheses are to be replaced at the same time.

Item Part No. Part Name Q’ty Replacement frequency

Engine oil filter 6736-51-5142 Cartridge 1 Every 500 hours service

Fuel filter 6732-71-6111 Cartridge 1 Every 500 hours service

Additional fuel filter 600-311-9121 Filter 1 Every 500 hours service

Hydraulic tank breather 20Y-60-21470 Element 1 Every 500 hours service

207-60-71180 Element 1
Hydraulic oil filter Every 1000 hours service
(07000-15160) (O-ring) (1)

Anti-corrosion filter 600-411-1191 filter 1 Every 1000 hours service

600-185-3100
(PC200/210)
Air cleaner Element assembly 1 -
600-185-4100
(PC220)

Additional filter for 20Y-970-1820 Element 1

-
breaker (if equipped) (07000-12115) (O-ring) (1)

Electric heater
6732-11-4811 Gasket 2 -
(optional)

205-70-19570 Horizontal pin type

(PC200/210) Tooth 5
(09244-02496) (Pin) (5)

20Y-70-D1310 Cutter (left) 1

20Y-70-D1320 Cuttler(right) 1
Bucket -
(176-32-11210) (Bolt) (8)
(01803-02430) (Nut) (8)

206-70-48610 Horizontal pin type 4

(PC220) Tooth
(09244-02516) (Pin) (4)

4-10
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

USE OF FUEL, COOLANT AND LUBRICANTS

ACCORDING TO AMBIENT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE
KIND OF CAPACITY
RESERVOIR FLUID Specified Refill

26.3 liters 24 liters

6.95 US gal 5.28 US gal

6.6 liters 6.6 liters

1.74 US gal 1.74 US gal

4.7 liters 4.5 liters

1.24 US gal 1.19 US gal

0.75 liters -
0.20 US gal

240 liters
63.14 US gal
(PC200) 143 liters
247 liters 33.29 US gal
65.26 US gal
(PC220)

400 liters
105.68 US gal -

- -

22.8 liters
6.02 US gal
(PC200)
-
30.9 liters
8.16 US gal
(PC220)

For HO46-HM,use the oil recomended by komatsu.

∗ASTM D975 No. 1

4-11
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

REMARK
● When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours
described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.

Change interval of oil in

Fuel sulphur content
engine oil pan

0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval

● When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or
less in the day time.
● Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to
half.
● There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature in the table.
● We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine
and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute

4-12
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil
[CD or CE] Anti-freeze Coolant
Gear Oil Grease
SAE10W, 30, 40 [Ethylene Glycol
No. Supplier [GL-4 or GL-5] [Lithium-Base]
10W30, 15W40 Base]
SAE80, 90, 140 NLGI No.2
(The 15W40 oil Permanent Type
marked * is CE.)

EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)

Diesel sigma S super

2 AGIP dieselmulti- grade Rotra MP GR MU/EP -
*Sigma turbo

Multi-purpose gear PYKON premium

3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D

Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP

*RPM delo 400 Universal thuban Marfak all purpose 2

6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C

8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -

Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant

Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2

Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty

Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant

Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special

Multi-purpose white
*Superme duty fleet Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease

4-13
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

Engine Oil
[CD or CE] Anti-freeze Coolant
Gear Oil Grease
SAE10W, 30, 40 [Ethylene Glycol
No. Supplier [GL-4 or GL-5] [Lithium-Base]
10W30, 15W40 Base]
SAE80, 90, 140 NLGI No.2
(The 15W40 oil Permanent Type
marked * is CE.)

FINA potonic N
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
FINA potonic NE

Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty

Sunoco ultra pres- Sunoco antifreeze

Sunoco GL5
17 SUN - tige 2EP and summer cool-
gear oil
Sun prestige 742 ant

*Ursa super plus Multifak EP2 Coda 2055 startex

18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant

Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM

20 UNION *Guardol MP gear lube LS Unoba EP -

*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C

4-14
MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE LIST

CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.

The tightening torque is determined by the width across the flats of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.

Tightening torque
Width
Thread across Target value Service limit
diameter flat
a(mm) b(mm) N•m kgf•m lbft N•m kgf•m lbft
6 10 13.2 1.35 9.8 11.8 - 14.7 1.2 - 1.5 8.7 - 10.8

8 13 31 3.2 23.1 27 - 34 2.8 - 3.5 20.3 - 25.3

10 17 66 6.7 48.5 59 - 74 6.0 - 7.5 43.4 - 54.2

12 19 11 11.5 83.2 98 - 123 10.0 - 12.5 72.3 - 90.4

14 22 177 18 130.2 157 - 196 16.0 - 20.0 115.7 - 144.7

16 24 279 28.5 206.1 245 - 309 25.0 - 31.5 180.8 - 227.8

18 27 382 39 282.1 343 - 425 35.0 - 43.5 253.2 - 314.6

20 30 549 56 405.0 490 - 608 50.0 - 62.0 361.7 - 448.4

22 32 745 76 549.7 662 - 829 67.5 - 84.5 488.2 - 611.2

24 36 927 94.5 683.5 824 - 1030 84.0 - 105.0 607.6 - 759.5

27 41 1320 135.0 976.5 1180 - 1470 120.0 - 150.0 868.0 - 1085.0

30 46 1720 175.0 1265.8 1520 - 1910 155.0 - 195.0 1121.1 - 1410.4

33 50 2210 225.0 1627.4 1960 - 2450 200.0 - 250.0 1446.6 - 1808.3

36 55 2750 280.0 2025.2 2450 - 3040 250.0 - 310.0 1808.3 - 2242.2

39 60 3280 335.0 2423.1 2890 - 3630 295.0 - 370.0 2133.7 - 2676.2

● The torques marked ✩ indicate the tightening torques for

the hoses at the top of the swivel joint.

Apply the following table for Hydraulic Hose.

Nominal - Width Tightening torque

No. of across Target value Permissible range
threads flat (b)
(a) (mm) N•m kgf•m lbft N•m kgf•m lbft
9/16 - 18UNF 19 44 4.5 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0
11/16 - 16UN 22 74 7.5 54.2 54 - 93 5.5 - 9.5 39.8 - 68.7
13/16 - 16UN 27 103 10.5 75.9 84 - 132 8.5 - 13.5 61.5 - 97.6
1 - 14UNS 32 157 16.0 115.7 128 - 186 13.0 - 19.0 94.0 - 137.4
13/16 - 12UN 36 216 22.0 159.1 177 - 245 18.0 - 25.0 130.2 - 180.8
✩1 -7/16 - 12UN
41 215 22.0 159.1 176 - 234 18.0 - 24.0 130.2 - 180.8
- 2B

4-15
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL

PARTS
To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out
periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of
the parts given in the table. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passed, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely.

However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.

If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the
hoses.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

Ask your Komatsu distributor to replace the safety critical parts.

SAFETY CRITICAL PARTS

No. Safety critical parts for periodic replacement Q’ty Replacement interval

1 Fuel hose (Fuel tank - Water separator) 1

2 Fuel hose (water separaror - Additional fuel filter) 1

3 Fuel hose (Additional fuel filter - Fuel pump) 1

4 Fuel return hose (Fuel injection pump - Fuel tank) 2

5 Spill hose (Engine output connector - Fuel tank) 1

6 Pump outlet hose (Pump - Control valve) 2

7 Work equipment hose (Boom cylinder inlet) 4

8 Work equipment hose (Bucket cylinder line - Boom foot section) 2

9 Work equipment hose (Bucket cylinder inlet) 2 Every 2 years or 4000
hours, whichever comes
10 Work equipment hose (Arm cylinder line - Boom foot section) 2 sooner
11 Work equipment hose (Arm cylinder inlet) 2
12 Additional attachment line hose (Boom foot section) 2

13 Additional attachment line hose (Boom top section) 2

14 Swing line hose (Swing motor inlet) 2

15 Main suction hose 1

16 Heater hose(Optional) 2

17 Travel line hose (Control valve - Swivel joint) 4

18 Travel line hose (Swivel joint - Travel motor) 4

19 Seat belt 1 Every 3 years

4-16
MAINTENANCE MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE
If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For
details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-19)" to confirm the correct main-
tenance schedule when carrying out maintenance.

MAINTENANCE SCHEDULE CHART

Initial 250 Hours Maintenance (Only after the first 250 hours)
REPLACE FUEL FILTER CARTRIDGE.............................................................................................................. 4-56
CHECK ENGINE VALVE CLEARANCE, ADJUST.............................................................................................. 4-67

When Required
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ............................................................................ 4-21

CLEAN INSIDE OF COOLING SYSTEM............................................................................................................ 4-26

CHECK AND TIGHTEN TRACK SHOE BOLTS ................................................................................................. 4-29

CHECK AND ADJUST TRACK TENSION.......................................................................................................... 4-30

CHECK ELECTRICAL INTAKE AIR HEATER .................................................................................................... 4-32

REPLACE BUCKET TEETH (VERTICAL PIN TYPE)......................................................................................... 4-33

REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) ................................................................................... 4-36

ADJUST BUCKET CLEARANCE........................................................................................................................ 4-37

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ................................................................................. 4-38

CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER) ....... 4-39

WASHING WASHABLE FLOOR......................................................................................................................... 4-40

METHOD OF SETTING MACHINE ANGLE ....................................................................................................... 4-42

BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................................................................. 4-43

METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT............................................. 4-45

Checks Before Starting

Every 100 Hour Maintenance

LUBRICATING .................................................................................................................................................... 4-47

4-17
MAINTENANCE SCHEDULE MAINTENANCE

Every 250 Hours Maintenance

CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL ...................................................................................... 4-49

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...................................................................................... 4-50

CHECK LEVEL OF BATTERY ELECTROLYTE ................................................................................................. 4-51

CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT................................................... 4-53

Every 500 Hours Maintenance

LUBRICATE SWING CIRCLE (2 POINTS) ......................................................................................................... 4-54

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........................................ 4-55

REPLACE FUEL FILTER CARTRIDGE .............................................................................................................. 4-56

CHECK SWING PINION GREASE LEVEL, ADD GREASE ............................................................................... 4-57

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS................................ 4-58

CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM ................................... 4-59
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK ................................................................................ 4-61

Every 1000 Hours Maintenance

REPLACE HYDRAULIC FILTER ELEMENT....................................................................................................... 4-62

CHANGE OIL IN SWING MACHINERY CASE ................................................................................................... 4-64

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ............................................................................................ 4-65

CHECK ALL TIGHTENING PARTS OF TURBOCHARGER............................................................................... 4-65

CHECK PLAY OF TURBOCHARGER ROTOR .................................................................................................. 4-65

CHECK FAN BELT TENSION AND REPLACE FAN BELT................................................................................. 4-65

Every 2000 Hours Maintenance

CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................... 4-66

CLEAN HYDRAULIC TANK STRAINER ............................................................................................................. 4-67

CLEAN, CHECK TURBOCHARGER .................................................................................................................. 4-67

CHECK ALTERNATOR, STARTING MOTOR ..................................................................................................... 4-67

CHECK ENGINE VALVE CLEARANCE, ADJUST.............................................................................................. 4-67

CHECK VIBRATION DAMPER ........................................................................................................................... 4-67

Every 4000 Hours Maintenance

CHECK WATER PUMP....................................................................................................................................... 4-68

Every 5000 Hours Maintenance

CHANGE OIL IN HYDRAULIC TANK ................................................................................................................. 4-69

4-18
MAINTENANCE MAINTENANCE SCHEDULE

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER

For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging
operations, so set the maintenance intervals as follows.

REPLACING HYDRAULIC ELEMENT

● On new machines, replace the element after the first 100 to
150 hours, then carry out further replacement of the ele-
ment according to the table on the right.

CHANGING OIL IN HYDRAULIC TANK

● Change the oil according to the table on the right.

REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER

● Use a guideline of 250 hours for use of the breaker (operating ratio for the breaker: 50 % or more), and replace
the element according to the table on the right.

4-19
MAINTENANCE PROCEDURE MAINTENANCE

MAINTENANCE PROCEDURE

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250

HOURS)
Carry out the following maintenance only after the first 250 hours of operation on new machines.

● Replace Fuel Filter Cartridge

● Check and adjust engine valve clearance,adjust

Special tools are needed for inspection and maintenance, so contact your Komatsu distributor.

For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS and 2000 HOURS
SERVICE.

4-20
MAINTENANCE MAINTENANCE PROCEDURE

WHEN REQUIRED

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

WARNING
● If inspection, cleaning, or maintenance is carried out with the engine running, dirt will enter the
engine and cause damage to the engine. Always stop the engine before carrying out these opera-
tions.

● When using compressed air, there is danger of dirt flying and causing personal injury.
Always wear protective glasses, dust mask, or other protective equipment.

● When removing the outer element from the air cleaner body, it is dangerous to pull it out by force.
When working at high places or where the foothold is poor, be careful not to fall because of the reac-
tion when pulling out the outer element.

Checking
If air cleaner clogging monitor(1) of the monitor panel flashes,
clean the air cleaner element.

Replacing
● Replacing element, O-ring
If one year has passed since installing the element or if air
cleaner clogging monitor (1) on the monitor panel flashes
immediately after the element is cleaned, replace the outer
element, inner element, and O-ring.

● Replacing evacuator valve

Replace it if it is damaged or the rubber is markedly
deformed.

NOTICE
Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel flashes. If
the element is cleaned frequently before the clogging monitor flashes, the air cleaner will not be able to
display its performance fully, and the cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element.

Outer Element - Clean

1. Open the rear door at the left side of the machine,
remove 3 hooks (2), then remove cover (3).
NOTICE
Before and after cleaning the element, do not leave or keep
it in direct sunlight.

2. Hold the outer element, rock it lightly up and down and to the left and right, and rotate the element to the left
and right to pull it out.

4-21
MAINTENANCE PROCEDURE MAINTENANCE

NOTICE
● Never remove the inner element. It will allow dirt to
enter and cause failure of the engine.
● Do not use a screwdriver or other tool.

3. After removing the outer element, cover the air connector

inside the air cleaner body with a clean cloth or tape to
prevent dirt or dust from entering.

4. Wipe off or brush off the dirt stuck to cover (3) and the
inside of the air cleaner body.

5. Remove any dirt or dust that is accumulated to evacuator

valve (4) installed to cover (3).

6. Direct dry compressed air (less than 0.69MPa (7kgf/cm2,

99.4PSI)) to the outer element from inside along its folds,
then direct it from outside along its folds and again from
inside.
1) Remove one seal from the element whenever the
element has been cleaned.
2) Replace the outer element which has been cleaned
5 times repeatedly or used throughout a year.
Replace the inner element at the same time.

4-22
MAINTENANCE MAINTENANCE PROCEDURE

3) Replace both inner and outer elements when the

monitor lamp (1) flashed soon after installing the
cleaned outer element even though it has not been
cleaned 5 times.
4) When replacing the element, stick on seal (A)
packed in the same box as the element. Stick the
seal in the position shown in the diagram on the
right.

7. Remove the cloth or tape cover installed in Step 3.

8. If small holes or thinner parts are found on the element

when it is checked by shining a light through it after
cleaning, replace the element.
NOTICE
● When cleaning the element, do not hit or beat it
against anything.
● Do not use an element whose folds or gasket or seal
are damaged.

4-23
MAINTENANCE PROCEDURE MAINTENANCE

Air Cleaner Element - Install

NOTICE
● Do not use any damaged gasket or seal or element with damaged pleats.
● Cleaning the element or O-ring after one year has passed and using them again will cause problems.
Always replace them with new parts.
● The seal portion on imitation parts lacks precision, and allows the entry of dust, which leads to dam-
age of the engine. Do not use such imitation parts.
● Do not run the engine with the inner element removed. It will cause damage to the engine.

1. Check that there is no dirt or oil stuck to the seal portion of the new element or cleaned element. Wipe off
any dirt or oil.

2. When the outer element has been removed, check that the inner element has not come out of position and is
not at an angle. If is is at an angle, insert your hand and push it in straight.

3. Push the outer element in straight with your hand when installing it to the air cleaner body.
If the element is held and rocked lightly up and down and to the left and right while pushing it in, the element
can be inserted easily.
NOTICE
When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in
straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner
body may be damaged, so be careful when assembling.

4. Install cover (3) as follows.

1) Align cover (3) with the element.
2) Hook the tip of hook (2) to the protruding part of the
air cleaner body and lock it in position.
3) When locking hooks (2) in position, apply the hooks
in turn on opposite sides (top, bottom, left, right) in
the same way as when tightening bolts.
4) Always install cover (3) so that the evacuator is fac-
ing the ground.
5) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too
large.
If it is too large, install again.

4-24
MAINTENANCE MAINTENANCE PROCEDURE

Air Cleaner Inner Element - Replace

1. First remove the outer element, and then remove the inner element.
2. Cover the air connector side (outlet side) with a clean cloth or tape.
3. Clean the air cleaner body interior, then remove the cover from the air intake port in Step 2.
4. Install a new inner element to the connector, then tighten the nut.
NOTICE
The inner element must not be cleaned and used again. When replacing the outer element, replace the
inner element at the same time.

5. Set the outer element in position, then lock cover (3) with
hooks (2).

4-25
MAINTENANCE PROCEDURE MAINTENANCE

CLEAN INSIDE OF COOLING SYSTEM

WARNING
● Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure.
If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the tem-
perature to go down, then turn the cap slowly to release the pressure before removing it.

● Cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set
the safety lock lever to the LOCK position.

● For details of starting the engine, see "BEFORE STARTING ENGINE (PAGE 3-57)" and "STARTING
ENGINE (PAGE 3-70)" in the OPERATION section.

● There is danger of touching the fan if the undercover is left removed.

Never enter behind the machine when the engine is running.

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor agent KI according to
the table below.

Cleaning inside of cooling system

Kind of coolant Adding corrosion resistor agent KI
and changing coolant

Permanent type anti- Every year (autumn)or every 2000

freeze (All season type) hours whichever comes first

Nom permanent type Every 1000 hours and when

Every 6 months (spring, autumn)
antifreeze containing cleaning the inside of the cooling
(Drain antifreeze in spring, add
ethylene glycol (winter, system and when changine cool-
antifreeze in autumn)
one season type) ant.
When not using anti- Every 6 months or every 1000
freeze hours whichever comes first

Stop the machine on level ground when cleaning or changing the coolant.

Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.

Super Coolant (AF-NAL) has an anti-corrosion effect as well as an antifreeze effect.

The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.

In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corro-
sion resistor agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liters (0.065 oz/US
gal).

When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing rate table given below.

It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate.

4-26
MAINTENANCE MAINTENANCE PROCEDURE

Mixing rate of water and antifreeze

PC200

°C -10 -15 -20 -25 -30

Min. atmospheric temperature
°F 14 5 -4 -13 -22

liters 6.9 8.2 9.3 10.5 11.4

Amount of antifreeze
US gal 1.82 2.17 2.46 2.77 3.01

liters 15.9 14.6 13.5 12.3 11.4

Amount of water
US gal 4.20 3.86 3.57 3.25 3.01

PC220

°C -10 -15 -20 -25 -30

Min. atmospheric temperature
°F 14 5 -4 -13 -22

liters 9.3 11.1 12.7 14.2 15.4

Amount of antifreeze
US gal 2.46 2.93 3.36 3.75 4.07

liters 21.6 19.8 18.2 16.7 15.5

Amount of water
US gal 5.71 5.23 4.81 4.41 4.10

WARNING
Antifreeze is flammable, so keep it away from flame.

Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on
you. I If it gets in your eyes, flush your eyes with large quantities of fresh water and see a doctor at once.

Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.

We recommend use of an antifreeze density gauge to control the mixing proportions.

● Prepare a container to catch drained coolant: Min 21.5 liters (5.68 US gal) capacity.

Prepare a hose to supply water.

1. Turn radiator cap (1) slowly and remove it.

2. Remove the undercover, then set the container under

drain valve (2) to catch the coolant mixture.
Open drain valve (2) at the bottom of the radiator and
drain the coolant.

3. After draining the coolant, close drain valve (2), and fill
with city water. When the radiator is full, start the engine
and run at low idling to raise the temperature to at least
90°C, then continue to run for approx. 10 minutes.

4-27
MAINTENANCE PROCEDURE MAINTENANCE

4. Stop the engine, open drain valve (2), and drain the
water.

5. After draining the water, clean the radiator with detergent.

For the cleaning method, follow the instruction of deter-
gent.

6. Close drain valve (2).

7. Install the undercover.

8. Add water through the water filler up to the filler port.

9. Run the engine idle at a low speed for 5 minutes, then at

a high speed for 5 minutes to bleed air mixed in the cool-
ing water. (At this time, keep the radiator cap (1)
removed.)

10. After draining off the cooling water of reserve tank (3) ,
clean the inside of the reserve tank and refill the water
between FULL and LOW level.

11. Stop the engine. About 3 minutes later, supply city water
up to the water filler, then close radiator cap.

4-28
MAINTENANCE MAINTENANCE PROCEDURE

CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts (1) loose, they will
break, so tighten any loose bolts immediately.

Method for tightening

● Track shoe

1. First tighten to a tightening torque of 490 ± 49 N•m (50 ± 5 kgf•m, 360 ± 36 lbft) then check that the nut and
shoe are in close contact with the link contact surface.

2. After checking, tighten a further 120º ± 10º.

● Road liner

1. Tighten to a tightening torque of 549 ± 59 N•m (56 ± 6 kgf•m, 405 ± 43 lbft).

After tightening, check that the nut and shoe are in close contact with the link contact surface.

Order for tightening

Tighten the bolts in the order shown in the diagram on the right.
After tightening, check that the nut and shoe are in close con-
tact with the link mating surface.

AD053090

4-29
MAINTENANCE PROCEDURE MAINTENANCE

CHECK AND ADJUST TRACK TENSION

WARNING
For details of starting the engine and operating the work equipment, see "BEFORE STARTING ENGINE
(PAGE 3-57)", "STARTING ENGINE (PAGE 3-70)", "AFTER STARTING ENGINE (PAGE 3-74)", and "WORK
EQUIPMENT CONTROLS AND OPERATIONS (PAGE 3-88)" in the OPERATION section.

The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil, so
inspect the track tension frequently in order to maintain the standard tension.
Stop the machine on firm, horizontal ground when carrying out the inspection and maintenance.

Checking
1. Run the engine at low idling, move the machine forward a
distance equal to the length of track on ground, then stop
the machine.

2. Choose wooden block (3) that will reach from idler (1) to
carrier roller (2), then place it on top of the track.

3. Measure the maximum deflection between the top sur-

face of the track and the bottom surface of the wooden
block.
● Standard deflection
Deflection "a" should be 10 to 30 mm (0.4 to 1.2 in).

If the track tension is not at the standard value, adjust it in the following manner.

4-30
MAINTENANCE MAINTENANCE PROCEDURE

Adjustment

WARNING
There is danger of plug (1) flying out under the high inter-
nal pressure of the grease. Never loosen plug (1) more
than 1 turn.

Never loosen any part other than plug (1). Never put your
face in the mounting direction of plug (1).

If the track tension cannot be loosened with the proce-

dure given here, please contact your Komatsu distributor.

When increasing tension

Prepare a grease gun.

1. Pump in grease through grease fitting (2) with a grease

gun.
(Grease fitting (2) forms one unit with plug (1).)

2. To check that the tension is correct, move the machine

slowly forward (7 - 8 m (23 ft - 26 ft 3 in)).

3. Check the track tension again, and if the tension is not

correct, adjust it again.

4. Continue to pump in grease until dimension S becomes

zero (0). If the tension is still loose, the pin and bushing
are excessively worn, so they must be either turned or
replaced.
Please contact your Komatsu distributor for repairs.

4-31
MAINTENANCE PROCEDURE MAINTENANCE

When loosening tension

WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.

If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs.

1. Loosen plug (1) gradually to release the grease.

2. Turn plug (1) a maximum of one turn.

3. If the grease does not come out smoothly, move the

machine forwards and backwards a short distance.

4. Tighten plug (1).

5. To check that the tension is correct, move the machine

slowly forward (7 - 8 m (23 ft - 26 ft 3 in).

6. Check the track tension again, and if the tension is not

correct, adjust it again.

CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air
heater repaired or checked for dirt or disconnections.

4-32
MAINTENANCE MAINTENANCE PROCEDURE

REPLACE BUCKET TEETH (VERTICAL PIN TYPE)

Replace the point before the adapter starts to wear.

WARNING
● It is dangerous if the work equipment moves by mis-
take when the teeth are being replaced. Set the work
equipment in a stable condition, then stop the engine
and apply the locks securely to the levers.

● If the locking pin is knocked out with excessive force,

there is a hazard that the pin may fly out. Check that
there is no one in the surrounding area.

● Pieces will often fly during the replacement operation,

so always wear safety glasses, gloves, and other pro-
tective equipment.

1. To make it possible to knock out the pin of tooth (1), set

the bottom surface of the bucket on a block, check that
the work equipment is in a stable condition, then set the
safety lock lever to the LOCK position.
Set so that thebottom face of the bucket is horizontal.

2. Use a hammer and drift to knock out lock pin (2). (If the
drift is set against rubber pin lock (3) when it is hit, the
rubber pin lock may break. Set it against the back of the
pin.)

3. After removing lock pin (2) and rubber pin lock (3), check
them.
If lock pins and rubber pin locks with the following defects
are used, the teeth may come off the bucket. Replace
them with new ones.

● The lock pin is too short.

4-33
MAINTENANCE PROCEDURE MAINTENANCE

● The rubber of the rubber pin lock is torn, and the steel balls
may come out.

● The steel balls are buried when they are pressed by hand.

4. Clean the surface of adapter (4) and remove the soil with
a knife.
5. Use your hand or a hammer to push rubber pin lock (3)
into the hole of the adapter.
When doing this, be careful that the rubber pin lock does
not fly out from the adapter surface.

6. Clean the inside of teeth (1), then install it to adapter (4).

If there is mud affixed to it or if there are protrusions, the
teeth will not enter the adapter properly, and there will not
be proper contact at the mating portion.

7. Fit teeth (1) to adapter (4), and confirm that when the
pointer is pressed strongly, the rear face of the hole for
the pin of the teeth (1) is at the same level as the rear
face of the hole for the pin of the adapter.
If the rear face of the hole for the pin of teeth (1) is pro-
truding to the front from the rear face of the pin hole for
adapter (4), do not try to knock the pin in.

There is something preventing teeth (1) from entering

adapter (4) fully, so remove the obstruction. When teeth
(1) enters adapter (4) fully, knock in lock pin (2).

4-34
MAINTENANCE MAINTENANCE PROCEDURE

8. Insert lock pin (2) in the hole of the teeth and hit it until its
top is the same level as the surface of teeth (1).

9. After replacing a bucket tooth, always check the follow-

ing.

1) After the lock pin has been knocked in completely,

check that it is secured by the point and surface.

2) Lightly hit lock pin (2) in the reverse direction from

which it was hit in.

3) Lightly hit the tip of the point from above and below,
and hit its sides from right and left.

4) Confirm that rubber pin lock (3) and lock pin (2) are
set as shown in the figure.

The life of the teeth can be lengthened and the frequency

of its replacement can be reduced by turning it upside
down so that it will wear evenly.

Replace the rubber pin lock and locking pin at the same
time as replacing the teeth. This makes it possible to pre-
vent the teeth from falling out.

4-35
MAINTENANCE PROCEDURE MAINTENANCE

REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)

Replace the teeth before the wear reaches the adapter.

WARNING
● It is dangerous if the work equipment moves by mis-
take when the teeth are being replaced. Set the work
equipment in a stable condition, then stop the engine
and apply the locks securely to the levers.

● If the locking pin is knocked out with excessive force,

there is a hazard that the pin may fly out. Check that
there is no one in the surrounding area.

● Pieces will often fly during the replacement operation,

so always wear safety glasses, gloves, and other pro-
tective equipment.

1. Set the bottom of the bucket on a block to make it possi-

ble to remove pin (1), check that the work equipment is
stable, then set the safety lock lever to the LOCK posi-
tion.
Set so that the bottom of the bucket is horizontal.

2. Place a bar on the pin head and strike the bar with a
hammer to knock out pin (1). Remove tooth (2).

REMARK
Use a round bar with a smaller diameter than that of the pin.

3. Clean the mounting face. Fit a new tooth (2) in the

adapter, push in pin (1) partially by hand, then lock it with
a hammer to install the tooth to the bucket.

4-36
MAINTENANCE MAINTENANCE PROCEDURE

ADJUST BUCKET CLEARANCE

WARNING
It is dangerous if the work equipment moves by mistake
when the clearance is being adjusted.

Set the work equipment in a stable condition, then stop

the engine and lock the safety lock lever securely.

1. Set the work equipment to the position shown in the dia-

gram at right, stop the engine and set the lock lever to the
locked position.

2. Shift O-ring (1) of the linkage and measure the amount of

play "a".
Measurement is easier of you move the bucket to one
side or the other so all the play can be measured in one
place. (In the diagram this is on the left-hand side)

Use a gap (clearance) gauge for easy and accurate mea-

surement.

3. Loosen the four plate fixing bolts (2) and loosen plate (3).
Because it uses split shims, you can carry out the opera-
tion without removing the bolts entirely.

4. Remove shim (4) corresponding to the amount of play "a"

measured above.
[Example]
In the case of play of 3 mm, remove two 1.0 mm shims
and one 0.5 mm shim. Play becomes 0.5 mm. For shim
(4), two types of 1.0 mm and 0.5 mm are used.
When play a is smaller than one shim, do not carry out
any maintenance.

5. Tighten the four bolts (2).

If the bolts (2) are too stiff to tighten, pull out pin stopper
bolt (5) for easier tightening.

4-37
MAINTENANCE PROCEDURE MAINTENANCE

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

If there is air in the window washer fluid, check the level of the
fluid in window washer tank (1). Add automobile window
washer fluid if necessary.

When adding fluid, be careful not to let any dust get in.

Mixture ratio of pure washer fluid and water

Since the ratio should be varied depending on atmospheric temperature, replenish washer fluid at the following
mixture ratio, taking temperature into account.

Operation area Freezing

Mixture ratio
and season temperature

Pure washer fluid 1/3:

Normal - 10ºC (14ºF)
water 2/3

Winter in cold Pure washer fluid 1/2:

- 20ºC (- 4ºF)
region water 1/2

Winter in
extremely cold Pure washer fluid - 30ºC (- 22ºF)
region

Pure washer fluid comes in two types: for -10ºC (14ºF) (for general use) and for -30ºC (-22ºF) (cold regions).

Use pure washer fluid according to operation area and season.

4-38
MAINTENANCE MAINTENANCE PROCEDURE

CHECK AND ADJUST AIR CONDITIONER

(ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)

CHECK LEVEL OF REFRIGERANT (GAS)

WARNING
If the refrigerant used in the cooler gets into your eyes or
on your hands, it may cause loss of sight or frostbite. Do
not touch the refrigerant. Never loosen any part of the
refrigerant circuit.
Do not bring any flame close to any point where the refrig-
erant gas is leaking.

If there is a lack of refrigerant (Freon 134a), the cooling perfor-

mance will be poor.

When operating the cooler at high speed, there should be no

bubbles in the sight glass (inspection window) mounted on the
condenser unit receiver.

● No bubbles in refrigerant flow: Correct

● Bubbles in refrigerant flow (bubbles continuously pass

through): Refrigerant level low

● Colorless, transparent: No refrigerant

REMARK
When there are bubbles, the refrigerant gas level is low, so
contact your refrigerant dealer to have refrigerant added. If the
air conditioner is run with the refrigerant gas level low, it will
cause damage to the compressor.

Check in off-season
When not being used for a long period, operate the cooler for 3 to 5 minutes once a month to supply lubricant to
each component of the compressor.

Inspection and maintenance items list for cooler

Inspection and
Contents Maintenance interval
maintenance items

Twice a year; spring

Refrigerant (gas) Filling quantity
and autumn

Condenser Clogging of fin Every 500 hours

Compressor Function Every 4000 hours

V belt Damage and tension Every 250 hours

Blower motor and fan Function (Check for abnormal sound) When required

Control mechanism Function (Check for normal function) When required

Installation condition looseness of tightening

Piping for connection When required
connection portions gas leakage, damage

4-39
MAINTENANCE PROCEDURE MAINTENANCE

WASHING WASHABLE FLOOR

WARNING
● When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely
careful when carrying out the operation.

● If the control levers are touched by mistake, the work equipment or machine may suddenly move, and
this may lead to a serious accident. Always set the safety lock lever securely to the LOCK position
before standing up from the operator's seat.

NOTICE
● When carrying out this operation, be careful not to get water on the monitor and connectors inside the
operator's cab.
● Never spray water above the pedestal of the operator's seat (2).
● If any water splashes on the surrounding equipment, be sure to wipe it off.

With the washable floor, it is possible to flush out the dirt on the cab floor directly with water.

WASHING WASHABLE FLOOR MAT

1. Stop the machine on horizontal ground, lower the bucket to the ground, then stop the engine.

2. When washing the floor mat, use a brush to remove the dust, or direct the water onto the mat and wash it
with a brush.

Method of washing
1. Set the machine at an angle.
2. Swing the upper structure slowly so that water drain
holes (3) in the cab floor are at a low position.

4-40
MAINTENANCE MAINTENANCE PROCEDURE

3. Lower the work equipment to the ground and set the

machine in a stable condition.

4. Set the safety lock lever to the LOCK position, then stop
the engine.

5. Remove the floor mat holder plate (4).

6. Remove the floor mat.

7. Remove the cap from water drain port (3).

8. Flush out the dirt on the floor directly with water through
water drain port (3).

9. After completing the washing operation, install the cap in

water drain port (3).

10. Fit the floor mat, then secure it with floor mat holder plate
(4).

4-41
MAINTENANCE PROCEDURE MAINTENANCE

METHOD OF SETTING MACHINE ANGLE

Method Using Slope

WARNING
Select a firm flat place.

Always put blocks under the track to prevent the machine from moving, and dig the work equipment into
the ground.

1. Stop machine so that the work equipment is on the down-

hill side.

2. Put blocks under the track and dig the work equipment
into the ground.

Method Using Block

WARNING
Select a firm flat place.

Put strong blocks under the undercarriage to stabilize the machine and be extremely careful when carry-
ing out the operation.

1. Raise the chassis with the boom and arm.

When doing this, operate the levers slowly.

2. Insert a block securely between the ground surface and

the raised track and make sure that the machine is sta-
ble.

3. Raise the boom slowly and lower the machine.

When doing this, check that the machine is always sta-
ble.

4-42
MAINTENANCE MAINTENANCE PROCEDURE

BLEEDING AIR FROM HYDRAULIC SYSTEM

For details, see "STARTING ENGINE (PAGE 3-70)". If it is necessary to refer to the items for starting the engine,
moving the machine off, steering, or stopping, see the OPERATION section.

1. Bleeding air from pump

1) Loosen air bleed plug (1) and check if oil oozes out.

2) If the oil does not ooze out, remove the drain hose
from the hydraulic pump case and fill the pump case
completely with hydraulic oil through drain port (2).
Hold the removed hose firmly, keeping the mouth-
piece higher than the oil level in the hydraulic tank so
that oil will not spill out of the hose.

3) After air bleeding is completed, first tighten air bleed

plug (1) and then install the drain hose.

NOTICE
If the drain hose is installed first, oil will spurt out of air bleed plug (1).
If the pump is run when the pump case is not full of oil, there will be abnormal generation of heat, and this
will lead to premature failure of the pump.

2. Starting engine
Start the engine. For details, see "STARTING ENGINE (PAGE 3-70)".
Run the engine at low idling for 10 minutes after starting, then start operations.

3. Bleeding air from cylinders

1) Run the engine at a low idling and extend and retract the cylinders 4 to 5 times to a point 100 mm(3.9in)
from the end of the stroke. (Be careful not to operate to the end of the stroke.)

2) Next, operate each cylinder 3 to 4 times to the end of its stroke.

3) Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air.

NOTICE
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air
inside the cylinder may cause damage to the piston packing.

4. Bleeding air from swing motor

1) Run the engine at low idling, loosen hose (1) at port
S, and check that oil oozes out from port S hose (1).

NOTICE
Do not operate the swing under any circumstances.

2) If oil does not ooze out, stop the engine, remove port
S hose (1), and fill the inside of the motor case with
hydraulic oil.

3) After completely bleeding the air, tighten port S hose (1).

4) Run the engine at low idling and slowly swing at least two times uniformly to the left and right. This will
automatically bleed the air.

NOTICE
● If the air is not bled from the swing motor, there is danger that the motor bearings will be damaged.
● If the swing motor safety valve is to be replaced, ask your Komatsu distributor to carry out the
replacement and air bleed operation.

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MAINTENANCE PROCEDURE MAINTENANCE

5. Bleeding air from travel motor (only when oil inside travel motor case has been drained)
1) Run the engine at low idling and loosen air bleed
plug (1). If oil spills out, tighten the plug.

2) Run the engine at low idling and swing the work

equipment 90º to bring it to the side of the track.

3) Jack up the machine until the track is raised slightly

from the ground.Rotate the track under no load for 2
minutes.
Repeat this procedure on both the left and right
sides, and rotate the track equally both forward and
in reverse.

6. Bleeding air from attachment (when installed)

If a breaker or other attachment has been installed, run the engine at low idling and operate the attachment
pedal repeatedly (approx. 10 times) until the air has been bled from the attachment circuit.
NOTICE
● If the method of bleeding the air from the attachment itself is specified by the manufacturer, bleed the
air according to the specified procedure.
● After completing the air bleeding operation, stop the engine, and leave the machine for 5 minutes
before starting operations. This will remove the air bubbles in the oil inside the hydraulic cylinders.
● Check that there is no leakage of oil and wipe off any oil that has been spilled.
● After completing the air bleeding operation,inspect the oil level,and if the oil level is low, add oil.

4-44
MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT

WARNING
● The hydraulic circuit is always under pressure, so release the pressure inside the circuit before
inspecting or replacing the piping or hoses. If the pressure is not released, high-pressure oil will
spurt out and may cause serious personal injury.

● The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Wait for the temperature to go down before starting the operation.

● When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal
pressure before removing the cap.

1. Stop the machine on horizontal, firm ground.

2. Within 15 seconds after stopping the engine, turn the

starting switch to the ON position, and operate the control
levers (work equipment, travel) fully in each direction to
release the internal pressure.

3. Sowly loosen oil filler cap (F) at the top surface of the
hydraulic tank to release the internal pressure.

4-45
MAINTENANCE PROCEDURE MAINTENANCE

CHECK BEFORE STARTING

For details of the following items, see "CHECKS BEFORE STARTING (PAGE 3-59)" in the OPERATION section.

● Check coolant level, add water

● Check oil level in engine oil pan, add oil

● Check fuel level, add fuel

● Drain water, sediment from fuel tank

● Check for water and sediment in water separator, drain water

● Check oil level in hydraulic tank, add oil

● Check electric wirings

● Check function of horn

4-46
MAINTENANCE MAINTENANCE PROCEDURE

EVERY 100 HOURS MAINTENANCE

LUBRICATING

NOTICE
● If any abnormal noise is generated at the greasing point, carry out greasing regardless of the mainte-
nance interval.
● When operating the machine for the first 50 hours, carry out the greasing every 10 hours.
● After carrying out digging work in water, always greasing the pins that were under water.

1. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and
stop the engine.

2. Using a grease pump, pump in grease through the grease fittings shown by arrows.

3. After greasing, wipe off any old grease that was pushed out.

4-47
MAINTENANCE PROCEDURE MAINTENANCE

(1) Boom cylinder foot pin (2 points)

(2) Boom foot pin (2 points)

(3) Boom cylinder rod end (2 points)

(4) Arm cylinder foot pin (1 point)

(5) Boom-Arm coupling pin (1point)

(6) Arm cylinder rod end (1 point)

(7) Bucket cylinder foot pin (1 point)

(8) Arm-Link coupling pin (1 point)

(9) Arm-Bucket coupling pin (1 point)

(10) Link coupling pin (2 points)

(11) Bucket cylinder rod end (1 point)

(12) Bucket-Link coupling pin (1 point)

4-48
MAINTENANCE MAINTENANCE PROCEDURE

EVERY 250 HOURS MAINTENANCE

CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.

1. Remove dipstick (G) and wipe the oil from the dipstick
with a cloth.

2. Insert dipstick (G) fully in the guide.

3. When dipstick (G) is pulled out, if the oil level is between

the H and L marks of the gauge, oil level is proper.

4. If the oil does not reach the L mark on dipstick (G),

remove oil filler (F), and add engine oil.

5. If the oil level exceeds the H mark on the dipstick, loosen

drain plug to drain the excess oil.

6. After checking oil level or adding oil, insert the dipstick

into the hole and install oil filler cap.

4-49
MAINTENANCE PROCEDURE MAINTENANCE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

WARNING
● The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Wait for the temperature to go down before starting the operation.

● If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.

● Prepare a hexagonal wrench.

1. Set the final drive so that TOP mark comes to the top and
the mark and plug (P) are perpendicular to the ground.

2. Using a hexagonal wrench, remove plug (F) and check

that the oil level is within a range from the bottom of the
plug hole to a point 10 mm(0.4 in) below it.

3. If the oil level is too low, install plug (F), operate the travel
levers, and drive forward or in reverse to rotate the
sprocket one turn. Then repeat Step 2 to check again.

4. If the oil level is still too low, add engine oil through the
hole in plug (F) until the oil overflows.

5. After checking, install plug (F).

REMARK
There are two plugs (F). Add oil through the one easier to fill oil
and through which no internal gears are to be seen.

4-50
MAINTENANCE MAINTENANCE PROCEDURE

CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this check before operating the machine.

WARNING
● Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accel-
erate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may also cause an explosion.

● The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks
near the battery.

● Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amount
of water and consult a doctor.

● When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.

NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.

Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.

1. Open cover (1) at the rear left side of the machine. The
batteries are installed at (A) part.

When Checking Electrolyte Level from side of Battery

If it is possible to check the electrolyte level from the side of the battery, check as follows.

1. Use a wet cloth to clean the area around the electrolyte

①
level lines and check that the electrolyte level is between
the UPPER LEVEL (U.L) and LOWER LEVEL (L.L) lines.
If the battery is wiped with a dry cloth, static electricity
may cause a fire or explosion.

4-51
MAINTENANCE PROCEDURE MAINTENANCE
2. If the electrolyte level is below the midway point between
the U.L and L.L lines, remove cap (1) and add distilled
water to the U.L line.

3. After adding distilled water, tighten cap (1) securely.

REMARK
If distilled water is added to above the U.L line, use a pipette to
lower the level to the U.L line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a
large amount of water or consult your Komatsu distributor or
battery maker.

Electric eye inclicator

Check the condition of battery with indicator.
The working condition of battery can be judged by the
electric eye indicator on the upper surface of battery. Under
normal condition, the electric eye indicator indicates blue. If
c eye indicator indicates white or red, it means the
the electric
battery is under the condition of lack of electricity or elec-
trohlyte, and need to change electricity or add elec c trolyte
immediately.

4-52
MAINTENANCE MAINTENANCE PROCEDURE

CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT

Checking
Press the belt at a point midway between the drive pulley and
compressor pulley with a finger force of approx. 58.8 N (6 kgf)
and check that the deflection is 5 - 8 mm (0.20 in - 0.31 in).

Adjusting
1. Loosen bolts (1) and (2).
● Bracket (4) holds the compressor in place. When
bolts (1) and (2) are loosened, bracket (4) moves
with the securing position of bolt (2) as a fulcrum.

2. Loosen nut (5) attached to the fixed bracket (3) and then
tighten bolt (6).
● Tighten bolt (6) so that the deflection of the belt will
be 5 - 8 mm (approx. 58.8N (6 kgf)).

3. Tighten bolts (1) and (2) to secure bracket (4).

4. Loosen bolt (6) to remove from bracket (4).

5. Tighten nut (5).

6. Check each pulley for damage, wear of the V-groove,

and wear of the V-belt. In particular, be sure to check that
the V-belt is not touching the bottom of the V-groove.

7. Replace belt if it has stretched, leaving no allowance for

adjustment, or if there is a cut or crack on V-belt.

8. When the new V-belt is set, readjust it after operation for

an hour.

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MAINTENANCE PROCEDURE MAINTENANCE

EVERY 500 HOURS MAINTENANCE

Maintenance for every 100 and 250 hours service should be carried out at the same time.

LUBRICATE SWING CIRCLE (2 POINTS)

1. Lower the work equipment to the ground.

2. Using a grease gun, pump in grease through the grease

fittings shown by arrows.

3. After greasing, wipe off all the old grease that was
pushed out.

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MAINTENANCE MAINTENANCE PROCEDURE

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER

CARTRIDGE

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.

Prepare the following:

● Refill capacity of oil pan: 24 liters (5.28 US gal)

● Filter wrench

1. Remove undercover (1) at the bottom of the machine,

then set a container under drain valve (P) to catch the
drained oil.

2. To prevent getting oil on yourself, lower the lever of drain

valve (P) slowly, drain the oil, then raise the lever to close
the valve.

3. Open the cover at the rear right, then use a filter wrench
to turn filter cartridge (1) to the left to remove it.

4. Clean the filter holder, fill the new filter cartridge with
clean engine oil, coat the packing surface and thread of
the filter cartridge with engine oil (or coat it thinly with
grease), then install the filter cartridge to the filter holder.
REMARK
Check that there is no old packing stuck to the filter holder. If
there is any old packing remaining, it will cause oil leakage.

5. When installing, bring the packing surface into contact

with the seal surface of the filter holder, then tighten a fur-
ther 3/4 - 1 turn.

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MAINTENANCE PROCEDURE MAINTENANCE

6. After replacing the filter cartridge, open the engine hood

and add engine oil through oil filler (F) to between the H
and L marks on dipstick (G).

7. Run the engine at idling for a short time, then stop the
engine and check again that the oil level is between the H
and L marks on dipstick (G).
For details, see "CHECK OIL LEVEL IN ENGINE OIL
PAN, ADD OIL (PAGE 3-60)".

8. Install the undercover.

REPLACE FUEL FILTER CARTRIDGE

WARNING
● The parts are at high temperature immediately after the engine has been operated. Wait for all parts to
cool down before replacing the filter.

● Do not bring fire or sparks near the fuel.

Prepare a filter wrench and a container to catch the fuel.

1. Set the container to catch the fuel under the filter car-
tridge.

2. Using a filter wrench, turn filter cartridge (1) counterclock-

wise to remove it.

3. Clean the filter holder, fill a new filter cartridge with clean
fuel, coat the packing surface with engine oil, then install
it to the filter holder.

4. After bringing the packing surface into contact with the

seal surface of the filter holder, tighten it a further 1/2
turns.
If the filter cartridge is tightened too far, the packing will
be damaged and this will lead to leakage of fuel. If the fil-
ter cartridge is too loose, fuel will also leak from the pack-
ing, so always tighten to the correct amount.

5. After replacing the fuel filter cartridge, bleed the air from
the system. Bleed the air as follows.

6. Fill the fuel tank with fuel (to the position where the float
is at the highest position).

7. After replacing filter cartridge (1), loosen air bleed plug (3).

8. Loosen the knob of feed pump (2), pump it up and down, and continue to make the fuel overflow until no
more bubbles come out from air bleed plug (3). Then tighten the knob of feed pump.

9. Tighten air bleed pug (3).

Always use a genuine Komatsu filter cartridge.
After replacing the filter cartridge, start the engine and check for any leakage of oil from the filter seal sur-
face.
REMARK
Use the feed pump to bleed air from the fuel system, when the machine has run out of fuel, too.

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MAINTENANCE MAINTENANCE PROCEDURE

REPLACE ADDITIONAL FUEL FILTER

WARNING
● The engine is at high temperature after machine operation. wait for the engine to cool down before
replacing filter.

● Do not bring any fire or flame close to the fuel.

Prepare a filter wrench and an oil container.

1. Place the container under filter to receive oil.

2. Rotate filter (2) counter-clockwise with filter wrench to

remove the filter .

3. Clean the filter head, and use clean fuel to clean new fil-
ter, and apply engine oil to the matching surface. Then,
install it to filter head.

4. Tighten to make the sealing surface contact the sealing

surface of filter head while installing, then tighten
another 1/2 turn.
If the filter is excessively tightened, the matching surface
will be damaged, causing oil leak
If the filter is to loose, fuel will leak from the matching sur-
face, so tigheten it properly.

5. Bleeding air after additional fuel filter is replaced.

RCHECK SWING PINION GREASE LEVEL,

ADD GREASE
Prepare a scale.

1. Remove bolts (1) (2 bolts) on the top of the revolving

frame and remove cover (2).

2. Insert a scale into the grease and check that the height of
the grease in the portion where the pinion passes is at
least 14 mm (0.6 in). Add more grease if necessary.

3. Check if the grease is milky white. If it is milky white, it is

necessary to change the grease. Please contact your
Komatsu distributor.

The total amount of grease

PC200,PC210 : 14.6 liters (3.86 US gal)
PC220 : 15.8 liters (4.17 US gal)

4. Install cover (2) with bolts (1).

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MAINTENANCE PROCEDURE MAINTENANCE

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND

CONDENSER FINS

WARNING
If compressed air, high-pressure water, or steamhit your body directly, or they cause dirt or dust to be
blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective
equipment.

NOTICE
When using compressed air, if the nozzle is brought too near the fins, the fins may be damaged. Carry out
the cleaning from a reasonable distance to prevent damage to the fins.
Do not direct the jet directly at the core. If the fins are damaged, it will cause leakage of water and over-
heating. On dusty jobsites, carry out this inspection every day, regardless of the maintenance interval.

1. Open engine hood (1).

2. Loosen screw (3) and pull up net (2).

3. Clean net (2). (it is to be installed again, as instructed in

the item 8)

4. Loosen screw (5) and detach net (6) between the radiator
and the oil cooler.

5. Inspect the front and rear of oil cooler fins (4), radiator
fins (7), after-cooler fins (8) and condenser fins (9) for
dirt, dust, dry leaves, etc. Blow them away with com-
pressed air, if any. Steam or water may be used instead
of compressed air.

6. Check the rubber hose. Replace with a new one, if the

hose is found to have cracks or to be hardened by aging.
Further, check the hose cramps for looseness.

7. Remove cover (10) of the under cover and dispose of the

dirt, dust, dry leaves, etc. fallen on it.

8. Push in cleaned net (2) back to the original place and

secure it with screw (3).

9. Secure net (6) with screw (5).

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MAINTENANCE MAINTENANCE PROCEDURE

CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER

SYSTEM

WARNING
If compressed air, high-pressure water, or steamhit your body directly, or they cause dirt or dust to be
blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective
equipment.

NOTICE
The guide for cleaning the filter is 500 hours, but if the machine is used on an extremely dusty jobsite,
reduce the maintenance interval and clean the filter more frequently.

REMARK
If the filter is clogged, the air flow is reduced and a muffled sound can be heard from the air conditioner unit.

CLEANING RECIRCULATED AIR FILTER

1. Remove wing bolts (1) from the inspection window at the
bottom rear left on the inside of the operator's cab, then
take out the recirculated air filter.

2. Clean the filter with compressed air. If there is oil on the

filter, or if the filter is extremely dirty, wash it in a neutral
agent. After rinsing it in water, dry it thoroughly before
using it again.
If the clogging of the filter cannot be removed by blowing
with air or washing in water, replace the filter with a new
part.

CLEANING FRESH AIR FILTER

1. Open the side door of air cleaner on the left outside cab
using a key.

2. Open the side door on the left lower of cab by hand, to

draw out element fron air cleaner.

3. Clean the filter with compressed air. If there is oil on the

filter, or if the filter is extremely dirty, wash it in a neutral
agent. After rinsing it in water, dry it thoroughly before
using it again.
If the clogging of the filter cannot be removed by blowing
with air or washing in water, replace the filter with a new
part.

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MAINTENANCE PROCEDURE MAINTENANCE

4. After cleaning, insert the filter in filter case (3) again, open the cover at the bottom left of the operator's cab
by hand, return the filter case to its original position, then close the cover. When doing this, check that the
lock is applied.

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MAINTENANCE MAINTENANCE PROCEDURE

REPLACE BREATHER ELEMENT IN HYDRAULIC TANK

WARNING
● The parts and oil are still at high temperature after the engine is stopped, and may cause serious
burns. Wait for the temperature to go down before cleaning the breather element in the hydraulic tank.

● When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal
pressure, then remove it carefully.

1. Remove the cap from oil filler (F) at the top of the hydrau-
lic tank.

2. Replace internal element (1).

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MAINTENANCE PROCEDURE MAINTENANCE

EVERY 1000 HOURS MAINTENANCE

Maintenance for every 100, 250 and 500 hours service should be carried out at the same time.

REPLACE HYDRAULIC FILTER ELEMENT

WARNING
● The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Wait for the temperature to go down before cleaning the hydraulic tank strainer.

● When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal
pressure,then remove it carefully.

NOTICE
If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than dur-
ing normal bucket operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
(PAGE 4-19)" when carrying out maintenance.

1. Set the work equipment on the hard and flat ground in the
maintenance posture as shown in the figure, then lower it
to the ground and stop the engine.

2. Remove the cap from oil filler (F), and release the internal
pressure.

3. Loosen 6 bolts, then remove cover (1). When doing this,

the cover may fly out under the force of spring (2), so
hold the cover down when removing the bolts.

4. After removing spring (2), valve (3) and strainer (4), take
out element (5).
● Inspect the bottom of the filter case for dirt, and
remove it, if any. Take good care then not to let fall
the dirt into the hydraulic tank.

5. Clean the removed parts in diesel oil.

6. Install the new element in the place where old element

(4) was installed.

7. Set valve (3), strainer (4) and spring (2) on top of the ele-
ment.

8. Set cover (1) in position, push it down by hand, and

install the cover with the mounting bolts.

9. Install the oil filler cap.

4-62
MAINTENANCE MAINTENANCE PROCEDURE

10. To bleed the air, start the engine according to "START-

ING ENGINE (PAGE 3-70)" and run the engine at low
idling for 10 minutes.

11. Stop the engine.

4-63
MAINTENANCE PROCEDURE MAINTENANCE

CHANGE OIL IN SWING MACHINERY CASE

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.

● Refill capacity: 6.6 liters (1.74 US gal)

1. Remove cover (A) of the inspection hole.

2. Set an oil container under drain valve (P) under the

machine body.

3. Loosen drain valve (P) under the body, drain the oil, then
tighten the drain valve again.

4. Remove the cap of oil filler (F), then add the specified
amount of engine oil through oil filler (F).

5. Pull out dipstick (G) and wipe off oil on the dipstick with
cloth.

6. Insert dipstick (G) into the gauge pipe thoroughly and

then pull out it again.

7. When the oil level is between the H and L marks, on dip-

stick (G), it is normal. If the oil does not reach the L mark,
add more oil through oil filler (F).

8. If the oil level exceeds the H mark, drain the excess

engine oil from drain valve (P), and check the oil level
again.
● When draining the excess engine oil, pull out hose
(1) from the check hole and then open the drain
valve.

4-64
MAINTENANCE MAINTENANCE PROCEDURE

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
the temperature to go down before starting the work.

NOTICE
For the oil level check, park the machine on a flat ground and start the work more than 30 minutes after
the engine was stopped.

1. Open the cover on the right side of the machine.

2. Remove oil inspection plug (G) and check that the oil is
near the bottom of the check hole. If the oil level is low,
remove the plug from oil filler (F), and add oil through oil
filler (F) until the oil level is close to the bottom of the hole
of oil inspection plug (G).
NOTICE
If the oil level is found too high, be sure to drain the oil to
the specified level. The excess oil may cause overheating.

3. Install oil inspection plug (G) and the plug of oil filler (F).

4. Close the cover.

CHECK ALL TIGHTENING PARTS OF TURBOCHARGER

Contact your Komatsu distributor to have the tightening portions checked.

CHECK PLAY OF TURBOCHARGER ROTOR

Ask Komatsu distributor to check the play of the turbocharger rotor.

CHECK FAN BELT TENSION AND REPLACE FAN BELT

Special tools are required for inspection and replacement of the fan belt. Contact your Komatsu distributors for
inspection and replacement.

REMARK
An installed auto fan belt tension adjuster, "Auto Tensional Fan Belt", dispenses with the belt deflection adjust-
ment.

4-65
MAINTENANCE PROCEDURE MAINTENANCE

EVERY 2000 HOURS MAINTENANCE

Maintenance for every 100, 250, 500 and 1000 hours service should be carried out at the same time.

CHANGE OIL IN FINAL DRIVE CASE

WARNING
● The oil is at high temperature after the engine is stopped. Wait for the temperature to go down before
starting the operation.

● If there is pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to
release the pressure.

● Refill capacity (each): 4.5 liters (1.19 US gal)

● Hexagon wrench

1. Set the final drive the way TOP mark comes to the top
and the mark and plug (P) are perpendicular to the
ground.

2. Set a container under plug (P) to catch the oil.

3. Remove plugs (P) and (F) with the hexagon wrench and
drain the oil.
REMARK
Check the O-rings in the plugs for damage. If necessary,
replace with new ones.

4. Tighten plug (P).

5. Add engine oil trough the hole of plug (F).

6. When the oil overflows from the hole of plug (F), install
plug (F).
P lugs (P) and (F ) are tightened to the torque of
68.6±9.8N•m (7±1 kgf•m).

REMARK
There are two plugs (F). Add oil through the one easier to fill oil and through which no internal gears are to be
seen.

4-66
MAINTENANCE MAINTENANCE PROCEDURE

CLEAN HYDRAULIC TANK STRAINER

WARNING
● The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Wait for the temperature to go down before cleaning the hydraulic tank strainer.

● When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal
pressure,then remove it carefully.

1. Loosen 6 bolts, then remove cover (1).

When doing this, the cover may fly out under the force of
spring (2), so push the cover down when removing the
bolts.

2. Pull up the top of rod (3), and remove spring (2) and
strainer (4).

3. Remove the dirt stuck to strainer (4), then wash it in clean

diesel oil or flushing oil.
If strainer (4) is damaged, replace it with a new one.

4. Refit strainer (4) by inserting it into tank projecting part

(5).

5. Assemble so that the protruding part at the bottom of

cover (1) holds spring (2), then tighten with the bolt.

CLEAN, CHECK TURBOCHARGER

Contact your Komatsu distributor for cleaning or inspection.

CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for
inspection or repair.

If the engine is started frequently, carry out inspection every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for service.

CHECK VIBRATION DAMPER

As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for service.

4-67
MAINTENANCE PROCEDURE MAINTENANCE

EVERY 4000 HOURS MAINTENENCE

Maintenance for every 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.

CHECK WATER PUMP

Since the pulley may have play, oil may leak, water may leak
and the drain hole (A) may be clogged, contact your Komatsu
distributor for inspection, overhaul or replacement.

4-68
MAINTENANCE MAINTENANCE PROCEDURE

EVERY 5000 HOURS MAINTENANCE

Maintenance for every 100, 250, 500 and 1000 hours service should be carried out at the same time.

CHANGE OIL IN HYDRAULIC TANK

WARNING
● The parts and oil are still at high temperature after the engine is stopped, and may cause serious
burns. Wait for the temperature to go down before cleaning the breather element in the hydraulic tank.

● When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal
pressure, then remove it carefully.

NOTICE
If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than dur-
ing normal bucket operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
(PAGE 4-19)" when carrying out maintenance.

Prepare the following.

● Refill, capacity: 115 liters (30.38 US gal)

● Prepare a handle for the socket wrench set.

1. Swing the upper structure so that drain plug at the lower

part of the suction tube comes to the middle of the left or
right track.

2. Retract the arm and bucket cylinders to the stroke end,

then lower the boom and put the bucket teeth in contact
with the ground.

3. Lock the safety lock lever and stop the engine.

4. Remove the cap of oil filler (F) over the hydraulic tank.

5. Set the oil container under the drain plug under the
machine. Using the handle, remove drain plug (1) and
drain the oil.
Check the O-ring installed to plug (1), and if it is dam-
aged, replace the O-ring. After draining the oil, tighten
drain plug (1).
Tightening torque: 69 ± 10 N•m (7 ± 1 kgf•m, 51 ± 7 lbft).

When removing drain plug (1), be careful not to get oil on your-
self.

6. Add the specified amount of engine oil through oil filler

port (F).
Check that the oil level is between H and L on the sight
gauge.

For details of the method of bleeding the air, see "CHECK OIL
LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 3-63)".

4-69
MAINTENANCE PROCEDURE MAINTENANCE

MEMO

4-70
SPECIFICATIONS
51

5-1
SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS

Item Unit PC200-7 PC200LC-7 PC220-7 PC220LC-7

kg 19,700 21,100 22,800 25,050

Operating weight
(lb) (43,439) (46,526) (50,294) (55,236)

Bucket capacity m3 (cu.yd) 0.8(1.05) 0.8(1.05) 1(1.31) 1(1.31)

Name of engine KOMATSU SAA6D102E diesel engine

Engine horsepower kW (HP)/rpm 107(145)/1950 125(168)/2000

mm 9425 9,425 9,885 9,885

A Overall length
(ft in) (30’11") (30’11") (32’5") (32’5")

B Overall height mm (ft in) 2,970(9’9") 2,970(9’9") 3,160(9’9") 3,160(9’9")

C Overall width mm (ft in) 2,800(9’2") 3,080(10’1") 2,980(0’0") 3,280(10’9")

D Track width mm (ft in) 600(1’12") 700(2’2") 600(1’12") 700(2’2")

E Height of cab mm (ft in) 3,000(9’10") 3,000(9’10") 3,015(9’11") 3015(9’11")

F Radius of upper structure mm (ft in) 2750(9’) 2750(9’) 2,940(5’6") 2,940(5’6")

G Length of track mm (ft in) 4,080(13’5") 4,450(14’7") 4,250(13’11") 4,640(15’3")

H Tumbler center distance mm (ft in) 3,270(10’9") 3,640(11’11") 3,460(11’4") 3,845(12’7")

Min. ground clearance mm (ft in) 440(1’5") 440(1’5") 440(1’5") 440(1’5")

3.0/5.5 3.0/5.5 3.1/5.5 3.1/5.5

Travel speed (Low/High) km/h (MPH)
(1.9/3.4) (1.9/3.4) (1.9/3.4) (1.9/3.4)

Swing speed rpm 12.4 12.4 11.7 11.7

5-2
SPECIFICATIONS SPECIFICATIONS

Working ranges Unit PC200-7 PC200LC-7 PC220-7 PC220LC-7

A Max. digging reach mm (ft in) 9,875(32’5") 10,180(33’5")

B Max. digging depth mm (ft in) 6620(21’9") 6920(22’8")

C Max. digging height mm (ft in) 10,000(32’10") 10,000(32’10")

D Max. vertical wall depth mm (ft in) 5,980(19’7") 6,010(19’9")

E Max. dumping height mm (ft in) 7,110(23’4") 7,035(23’1")

F Min. dumping height mm (ft in) 2,645(8’8") 2,530(8’4")

G Max. reach at ground level mm (ft in) 9,700(31’10") 10,020(32’10")

5-3
SPECIFICATIONS SPECIFICATIONS

MEMO

5-4
 ATTACHMENTS
AND
OPTIONS
61

WARNING
Please read and make sure that you understand the safety
volume before reading this section.

6-1
GENERAL PRECAUTIONS ATTACHMENTS AND OPTIONS

GENERAL PRECAUTIONS

PRECAUTIONS RELATED TO SAFETY

If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of
the machine, but will also cause problems with safety.

When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu-
tor first.

If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.

WARNING
General precautions

● Attachments are powerful tools. To prevent serious injury or damage, use the attachment correctly.

● Read the instruction manual for the attachment thoroughly, and do not use this attachment unless
you are sure that you have understood the guides completely.
If you lose the instruction manual, always ask the manufacturer or attachment sales company for a
new copy.

● Depending on the attachment, install the necessary front guard to the machine.

● Depending on the attachment, the impact noise may make it difficult for fellow workers to transmit
instructions for the operation. Before starting operation, decide a leader and determine the signals to
be used.

● Do not carry out swinging operations to the side with a heavy load on the attachment. This is particu-
larly dangerous on slopes.

● Compared with a machine equipped with a bucket, a machine equipped with a breaker has a heavy
load at the front of the work equipment and is unstable. To avoid the danger of tipping over, do not
carry out operations with the attachment swung to the side.

● When an attachment is installed, the swing range and center of gravity of the machine are different,
and the machine may move in an unexpected way. Be sure that you understand the condition of the
machine properly.

● Before starting operations, set up a fence around the machine to prevent people from entering.
Never operate the machine when there are people near the machine.

● To prevent serious accidents caused by misoperation, do not put your foot on the pedal except when
operating the pedal.

6-2
ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS

WARNING
Precautions for removal and installation operations

When removing or installing the attachment, always do as follows to ensure safety in the operation.

● Carry out the removal and installation operation on firm, level ground.

● When carrying out the operation with two or more workers, determine the signals and follow these
during the operation.

● Always use a crane when you lift or carrying heavy objects (more than 25kg or 55 lb).

● When removing heavy components, always support the component before removing it.
When lifting with a crane, be particularly careful about the position of the center of gravity.

● It is dangerous to carry out operations with a load left raised by a crane. Always prepare a stand and
ensure that the condition is safe.

● When leaving an attachment removed or when installing the attachment, make sure that it is in a sta-
ble condition and cannot fall over.

● Never go under a load raised by a crane.

Stay in a safe place where there is no danger if the load should fall.

NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per-
son.
For details of removal and installation operations, contact your Komatsu distributor.

6-3
GENERAL PRECAUTIONS ATTACHMENTS AND OPTIONS

PRECAUTIONS WHEN INSTALLING ATTACHMENTS

WARNING
Long work equipment reduces the stability of the
machine, so if the swing is operated on a slope, or when
going down a steep hill, the machine may lose its balance
and overturn.

The following operations are particularly dangerous, so

never operate the machine in these ways.

● If heavy work equipment is installed, the overrun of

the swing becomes greater (the distance from the
point where the operator operates the control levers
to stop the swing to the point where the upper struc-
ture stops completely), so there is danger of mistak-
ing the distance and hitting something.
Always operate so that there is an ample margin to the
stopping point.
Furthermore, the hydraulic drift also becomes larger
(when the work equipment is stopped in mid-air, it will
gradually move down under its own weight).

● Always follow the correct procedure when installing

the boom and arm.
If the correct procedure is not followed, this may lead
to serious damage or injury, so consult your Komatsu
distributor before carrying out installation.

● If long work equipment is installed, the working range

will suddenly become larger, so there is danger of
mistaking the distance and hitting something.
Always operate the work equipment so that there is
ample space from any obstacles in the area.

6-4
ATTACHMENTS AND OPTIONS HANDLING BUCKET WITH HOOK

HANDLING BUCKET WITH HOOK

CHECKING FOR DAMAGE TO BUCKET WITH HOOK

Check that there is no damage to the hook, stopper, or hook mount. If there is any abnormality, contact your
Komatsu distributor.

PROHIBITED OPERATIONS

PRECAUTIONS DURING OPERATIONS

● When carrying out lifting operations, reduce the engine
speed and use the lifting operation mode.

● Depending on the posture of the work equipment, there is

the danger that the wire or load may slip off the hook.

Always be careful to maintain the correct hook angle to

prevent this from happening.

● Never steer the machine while lifting a load.

● If the bucket with hook is turned and used for operations, it

will hit the arm during dumping operations, so be careful
when using it.

● If you are planning to install a hook, contact your Komatsu distributor.

6-5
MACHINES READY FOR ATTACHMENTS ATTACHMENTS AND OPTIONS

MACHINES READY FOR ATTACHMENTS

EXPLANATION OF COMPONENTS

(1) Stop valve (4) Lock pin

(2) Selector valve (5) Additional filter for breaker
(3) Attachment control pedal (6) Accumulator

STOP VALVE
This valve (1) stops the flow of the hydraulic oil.

(a) FREE: Hydraulic oil flows

(b) LOCK: Hydraulic oil stops

Set this valve to the LOCK position when removing or installing

attachments.

6-6
ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS

SELECTOR VALVE
This valve (2) switches the flow of hydraulic oil.

It is automatically switched according to the selected working

mode. It is necessary to switch the working mode to match the
attachment that is installed. For details of switching the work-
ing mode, see "HYDRAULIC CIRCUIT (PAGE 6-9)".

NOTICE
If a service circuit from the attachment maker has been
added, the return circuit may not switch automatically.

ATTACHMENT CONTROL PEDAL

This pedal (3) is used to control the attachment.

When the front, center (neutral), and rear of the pedal are
depressed, the movement of the attachment is as follows.

Hydraulic breaker
Front of pedal (A) : Actuated
Center of pedal N : Stopped
Rear of pedal (B) : Stopped

Regarding other attachments, hold a meeting with the attach-

ment maker at the time of installation to confirm the operation
of the pedal and attachment before using it.

REMARK
This pedal cover (3) differs in thickness at both ends. It can be stalled facing in either direction, so install it accord-
ing to your own preference.

LOCK PIN
This pin (4) locks the control pedal.

Position (a) : Locked

Position (b) : Only front of pedal can be operated to full posi-
tion (rear is locked)
Position (c) : Both front and rear of pedal can be operated to
full position

● When using a breaker, select B mode on the monitor and

set the lock pin to position (b).
When not using the attachment, set the lock pin to position
(a).

● When using a breaker, select A or E mode on the monitor and set the lock pin to position (c).

NOTICE
When using a breaker, if the lock pin is set to position (c) and the rear portion (B) of the pedal is
depressed, it will cause defective operation or breakage of the breaker, so always set the lock pin to posi-
tion (b) when using the breaker.

6-7
MACHINES READY FOR ATTACHMENTS ATTACHMENTS AND OPTIONS

ADDITIONAL FILTER FOR BREAKER

This filter (5) prevents deterioration of the hydraulic oil when
using a breaker.

Oil only flows when B mode is selected on the monitor.

NOTICE
Always install an additional filter in the return circuit on
machines equipped with a hydraulic breaker.

ACCUMULATOR

WARNING
The accumulator is charged with high-pressure nitrogen
gas, so it is extremely dangerous if it is handled incor-
rectly.
For details of handling, see “HANDLING ACCUMULATOR
(PAGE 3-56)”.

This accumulator (6) is installed to reduce the peak pressure in

the hydraulic circuit when a breaker is used. Normally, do not
touch it.

NOTICE
The need to install an accumulator depends on the breaker
manufacturer. When installing a breaker made by another
manufacturer, please consult your Komatsu distributor.
Depending on the breaker manufacturer, it may be neces-
sary to install the accumulator at the inlet or outlet port of
the breaker.

6-8
ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS

HYDRAULIC CIRCUIT
NOTICE
● When a breaker is installed, it is necessary to connect the return circuit directly to the return filter, so
use only B mode. Do not use any other mode.
● The standard set pressure of the service valve safety valve depends on the mode selected when the
machine is shipped from the factory.
If B mode is selected: 20.6 MPa (210 kgf/cm2, 2980 PSI)
If A or E mode is selected: 27.4 MPa (280 kgf/cm2, 3980 PSI)
Adjustment may be needed depending on the attachment, so in such a case, please contact your
Komatsu distributor.

SWITCHING HYDRAULIC CIRCUIT

● Depending on the type of attachment, set the working mode on the monitor as follows.

● The set pressure of the service valve safety valve and the hydraulic circuit switch is according to the working
mode selected.

Working Set pressure of service safety

Attachment Hydraulic circuit
mode valve

Return circuit automatically

Breaker or other attachment When shipped from factory :
B mode switched so that it does not
with one-way circuit 20.6 MPa (210 kgf/cm2, 2980 PSI)
pass through control valve

Return circuit automatically

Crusher or other attachment A mode or When shipped from factory :
switched so that it passes
with two-way circuit E mode 27.4 MPa (280 kgf/cm2, 3980 PSI)
through control valve

ADJUSTING OIL FLOW

Depending on the attachment, it is necessary to change the oil flow in the service circuit.

For details of setting the oil flow, see "OPERATION (PAGE 6-15)".

SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT

● When a possible attachment (if equipped) is installed and B mode is selected:

1) The circuit becomes a circuit for breaker operation (1-way circuit).

2) The hydraulic oil flowing in the breaker circuit flows to the additional filter for the breaker.
3) The relief valve is set to a lower pressure.
When shipped from factory: 20.6 MPa (210 kgf/cm2, 2980 PSI)
4) It is possible to adjust the maximum flow with the select mode.

● When a possible attachment (if equipped) is installed and A mode or E mode is selected:

1) The circuit becomes a circuit for crusher operation (2-way circuit).

2) The hydraulic oil flowing in the crusher circuit does not flow to the additional filter for the breaker.
3) The relief valve is set to a higher pressure.
When shipped from factory: 27.4 MPa (280 kgf/cm2, 3980 PSI)
4) It is possible to adjust the maximum flow with the select mode.

6-9
MACHINES READY FOR ATTACHMENTS ATTACHMENTS AND OPTIONS

HYDRAULIC CIRCUIT CONNECTION

When connecting the attachment, connect the hydraulic circuit
as follows.

1. Remove blind plugs (1) at the end of the stop valve pip-
ing. (Two spots on the left and right) Be careful not to lose
or damage any part that has been removed.

2. Connect attachment piping (2) provided by the attach-

ment manufacturer to the hole for the plug removed in
Step 1.
For the mouthpiece size and accumulator add-on, the
action to take differs according to the attachment manu-
facturer, so please consult your Komatsu distributor.

6-10
ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS

PATH OF OIL
The direction of operation of the pedal and the path of the oil are as shown in the diagram below.

When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the
rear of the pedal is depressed, oil flows to the piping on the right side of the work equipment. (When a breaker is
installed, only the front of the pedal can be used.)

6-11
MACHINES READY FOR ATTACHMENTS ATTACHMENTS AND OPTIONS

REPLACE ADDITIONAL BREAKER FILTER ELEMENT

WARNING
Immediately after operating the engine, all parts still retain
high temperature. Never replace the filter in sucn condi-
tion. Replace it only after each part has sufficiently
cooled.

● Prepare a container for draining off oil.

1. Place the container under the filter element.

2. Turn filter case (1) counterclockwise to remove it.

Remove element (2) from the case.

3. Unscrew plug (3) from filter case (1).

4. Clean the removed parts. Mount a new element (2) and

O-ring (4).

5. After the case reaches the filter holder, additionally

tighten the case by more than a 1/2 turn.
NOTICE
For the element replacement interval, see “MAINTENANCE
INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-19)”.

6-12
ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS

ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE

DISMOUNTING PROCEDURE
1. Place the attachment on the ground and stop the engine.
2. Turn the starting switch to ON position and push down
the safety lock lever to FREE position.

3. Operate each work equipment control lever and the

attachment control pedal back and forth, left and right at
full stroke 2 to 3 times to eliminate the internal pressure
in the hydraulic circuit.

4. Loosen slowly oil filler cap (F) on top of the hydraulic tank
to eliminate the internal pressure in the hydraulic circuit.

5. After confirming low oil temperature, turn the rotor of the

stop valve connected to the inlet and outlet piping on the
arm side face toward the lock side.

6. Remove the hoses on the attachment side. Install the

blind plugs to the two outlets.

The blind plugs are used to prevent the attachment from incor-
rect operation caused by mixing in of foreign matter. After the
plugs are correctly installed, store the attachment.

6-13
MACHINES READY FOR ATTACHMENTS ATTACHMENTS AND OPTIONS

7. Dismount the attachment by removing the retaining pins

(2 pins). Then, mount the bucket.
For the bucket mounting procedure, see "REPLACE-
MENT AND INVERSION OF BUCKET (PAGE 3-99)".

8. After the bucket is mounted, check the hydraulic oil level.

MOUNTING PROCEDURE
1. Remove the bucket.
For bucket dismounting procedure, see "REPLACEMENT AND INVERSION OF BUCKET (PAGE 3-99)".

2. Place the attachment on a flat place, install pins (A) and

(B) to the arm in that order.

3. After confirming low oil temperature, remove the blind

plug from the outlet and inlet port respectively.
Take care that no dust, mud etc. adheres to the hose
mousepiece portions.
If O-ring is damaged, replace it with a new one.

4. Connect the hose at the attachment side.

When doing this, check the direction of flow of the oil and
be careful not to make any mistake.

5. Turn the rotor of the stop valve connected to the inlet and
outlet piping on the arm side face toward the free side.

6. Confirm that oil level in the hydraulic oil tank is cor-

rect,after mounting the attachment.

6-14
ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS

OPERATION

WARNING
● Do not rest the foot on the pedal and depress it, when the auto deceleration switch is in ON position.
The engine speed rises all of sudden and the attachment will move suddenly and cause serious dam-
age or injury.

● Do not put your foot on the pedal except when operating the pedal. If rest your foot on the pedal dur-
ing operations, and it is depressed by accident, the attachment may move suddenly and cause seri-
ous damage or injury.

The operation of the attachment is as follows.

WHEN USING BREAKER

When the B mode control switch is ON and the lock pin position
makes only the front of the pedal free, if the front of the pedal is
depressed, the breaker is actuated.

Check that the operation mode selector is at the position of B

Mode.

Precautions when using

● Check that the stop valve is at the FREE position.

● Check of the selector valve is installed to the breaker posi-

tion.
For details of the path of the oil, See “HYDRAULIC CIR-
CUIT (PAGE 6-9)”.

● Consult with the attachment manufacturer as to whether

the accumulator is required for the attachment circuit or
not.

● For other precautions when using the breaker, see the

instruction manual provided by the breaker manufacturer.

● When the breaker is used, the hydraulic oil degrades faster

than in normal operation. Shorten the maintenance interval
of the hydraulic oil and filter element.
See "MAINTENANCE INTERVAL FOR HYDRAULIC
BREAKER (PAGE 4-19)".

6-15
MACHINES READY FOR ATTACHMENTS ATTACHMENTS AND OPTIONS

WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER

Set the lock pin to FREE position and depress the pedal for-
ward or backward to operate the attachments.

Precautions when using

● Check that the stop valve is at the FREE position.

● Confirm that the selector valve is set to the position for

general attachments such as the crusher.
Free
For details of the oil path, see "HYDRAULIC CIRCUIT (PAGE
6-9)".

● For other precautions when using the attachment, see the

instruction manual provided by the attachment manufac-
turer.

6-16
ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS

LONG-TERM STORAGE
If the equipment is not to be used for a long period, do as follows.

● Set the stop valve to the LOCK position.

● Install the blind plugs and O-rings to the valves.

● Set the selector valve to the "when not use" position.

● Lock the lock pin to the lock position.

If the pedal is operated when there is no breaker or general attachment installed, it will cause overheating and
other problems.

SPECIFICATIONS
Hydraulic specifications
● Max. merging oil flow 214×2 liters / min

● Safety valve of service valve Relief setting pressure 27.47MPa (280kgf / cm²) (except B mode)

● Safety valve of service valve Cracking pressure 24.53MPa (250kgf / cm²) (except B mode)

● Safety valve of service valve Relief setting pressure 20.60MPa (210kgf / cm²) (B mode)

● Safety valve of service valve Cracking pressure 15.21MPa (155kgf / cm²) (B mode)

In addition to the valves listed above, a safety valve with relief setting pressure of 24.53 MPa (250kgf / cm²) and a
safety valve with cracking pressure of 20.11 MPa (205 kgf / cm² )are available. Consult the Komatsu distributor in
the territory.

6-17
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS

ATTACHMENT GUIDE

WARNING
● Please read the instruction manual for the attachment and the sections of this manual related to
attachments and options.

● When installing any attachment or option, there may be problems with safety, so please contact your
Komatsu distributor before installing.

● Installing attachments or options without consulting your Komatsu distributor may not only cause
problems with safety, but may also have an adverse effect on the operation of the machine and the life
of the equipment.

● Any injuries, accidents, or damage resulting from the use of unauthorized attachments or options will
not be the responsibility of Komatsu.

COMBINATIONS OF WORK EQUIPMENT

WARNING
Depending on the type or combination of work equipment, there is danger that the work equipment may
hit the cab or machine body.
When using unfamiliar work equipment for the first time, check before starting if there is any danger of
interference, and operate with caution.

PC200,220
This table lists the combination of attachments which can be installed to the long arm (standard), short arm and
extension arm.

: Can be used
: Can be used only for light-duty work
: Cannot be used

NOTICE
● When the extension arm is equipped, if the bucket is drawn to the machine body, the arm interferes
with the body. Operate the extension arm carefully.
● When the boom is fully lowered during oblique digging, the boom interferes with the undercarriage.
Operate the boom carefully.

Categories of use

For general digging : Digging or loading sand, gravel, clay etc.

For light duty digging : Digging or loading dry, uncaked earth and sand, mud etc.
For loading work : Loading dry, loose earth and sand

● For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durabil-
ity and high wear resistance be employed.

6-20
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE

*: Equipped with side cutter

Capacity Outside Standard Short Short Extension

Name of bucket (m3) width Use arm arm arm arm
SAE (CECE) (mm) (2.9 m) (2.4 m) (1.8 m) (1.1 m)

* Narrow bucket 0.50 (0.45) 750 (30") Narrow digging

* Narrow bucket 0.60 (0.55) 970 (38") Narrow digging

* Standard bucket 0.8 (0.7) 1150 (45") General digging

* Light duty bucket 0.9 (0.8) 1200 (47") Loading

Light duty bucket 1.0 (0.9) 1330 (52") Loading

Light duty bucket 1.17 (1.0) 1450 (57") Loading

Slope finishing bucket 0.40 (0.35) – Slope finishing

Trapezoidal bucket Trapezoidal

0.55 (0.5) –
(Variable slope type) shaped diching

Ripper bucket 0.61 (0.56) 950 (37") Digging rocks

Clamshell bucket 0.66 (0.6) 866 (34") Ditching, loading

Ditch cleaning bucket 0.8 (0.7) 1800 (71") Ditching, cleaning

One tooth ripper – – Digging, removing rocks

Three teeth ripper – – Digging, removing rocks

6-21
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS

PC220,220LC
For trimming of a slope and rolling compaction.

: available
: available only for light-duty work
: not available

NOTICE
When the boom is fully lowered during oblique digging, the boom interferes with the undercarriage.
Operate the boom carefully.

Categories of use

For general digging : Digging or loading sand, gravel, clay etc.

For light duty digging : Digging or loading dry, uncaked earth and sand, mud etc.
For loading work : Loading dry, loose earth and sand

● For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durabil-
ity and high wear resistance be employed.

*: Equipped with side cutter. *1 is available only during loading operation.

Capacity Outside Standard Long Short Short

Name of bucket (m3) width Use arm arm arm arm
SAE (CECE) (mm) (3.0 m) (3.5 m) (2.5 m) (2.0 m)

*Narrow bucket 0.72 (0.65) 900 (35") Narrow digging

*Standard bucket 1.0 (0.9) 1260 (50") General digging *1

*Light duty bucket 1.17 (1.0) 1300 (51") Light duty digging

Light duty bucket 1.26 (1.1) 1400 (55") Loading

For triming of a slope

Slope finishing bucket 0.40 (0.35) –
and rolling compaction

Trapezoidal bucket Trapezoidal

0.55 (0.5) –
(Variable slope type) shaped diching

Ripper bucket 0.61 (0.56) 950 (37") Digging rocks

Clamshell bucket 0.66 (0.6) 866 (34") Ditching, loading

Ditch cleaning bucket 0.8 (0.7) 1800 (71") Ditching, cleaning

One tooth ripper – – Digging, removing rocks

Three teeth ripper – – Digging, removing rocks

6-22
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE

SELECTION OF TRACK SHOES

Select suitable track shoes to match the operating conditions.

METHOD OF SELECTING SHOES

Confirm the category from the list of uses in Table 1,then use Table 2 to select the shoe.

Categories B and C are wide shoes, so there are limitations on their use.When using these shoes,check the pre-
cautions, then investigate and study fully the conditions of use to confirm that these shoses are suitable.

When selecting the shoe width, select the narrowest shoe possible that will give the required flotation and ground
pressure. If a wider shoe than necessary is used, the load on the track will increase,and this will cause the shoes
to bend, links to crack, pins to break, shoe bolts to come loose, and various other problems.

Table 1

Category Use Precautions when using

Rocky ground, riverbeds, ● On rough ground with large obstacles such as boulders or fallen trees,
A
normal soil travel at low speed.
● These shoes cannot be used on rough ground where there are large
obstacles such as boulders or fallen trees.
B Normal soil, soft ground
● Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid
going over obstacles, shift down and travel at half speed in Lo.
● Use the shoes only in places where the machine sinks and it is impossible
to use A or B shoes.
Extremely soft ground ● These shoes cannot be used on rough ground where there are large
C
(swampy ground) obstacles such as boulders or fallen trees.
● Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid
going over obstacles, shift down and travel at half speed in Lo.
● Take note of low gradeability due to the flat shoes and exercise a due
D Paved road
care.
● Be sure to follow the instructions set forth in the "Handling of Road Liner"
E Paved road
section for the protection of the rubber pad shoes.

Table 2

PC200, 220-7 PC200LC, 220LC-7

Specifications Category Specifications Category

Standard 600mm Triple A 700mm Triple B

600mm Road Liner 600mm Road Liner
Option E E
(Rubber pat type) (Rubber pat type)
Option 610mm Flat D 610mm Flat D
Option 700mm Triple B 600mm Triple A
Option 800mm Triple C 800mm Triple C
Option 860mm Swamp C 860mm Swamp C

6-23
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS

SELECTION OF BUCKET TEETH

Depending on the working conditions, there is danger that an adapter and teeth may break, so select from the ver-
tical pin and horizontal pin teeth to give teeth that are suitable for the purpose.
While the standard teeth of both vertical and horizontal pin types may be used widely, the following kinds of teeth
are recommended depending on the working conditions.

METHOD OF SELECTING TEETH

Use of vertical pin teeth

General digging: Digging and loading normal soil, such as sand, gravel, clay, etc.
Light-duty digging: digging and loading dry and loose sandy soil, or muddy soil
Loading: loading of dry and loose earth

Use of horizontal pin teeth

Heavy-duty digging: digging hard soil, soil with rocks involving hammering work, scraping and the like

● The heavy-duty bucket is of a horizontal pin type and as such, use it for heavy duty-digging.

Use of long-life teeth

● Jobsites where long wear life is demanded, such as when loading hard rocks.

● jobsites where no penetration is needed, such as when working with crushed rocks after blasting or ripping

● Jobsites where heavy-duty operations are carried out, such as hitting or pulling up rocks with the tips of the
teeth

Self-sharpening teeth (both vertical pin type and horizontal pin type)
● Jobsites demanding penetration such as digging and loading sandy or clayey soil

STANDARDS FOR SELECTING VERTICAL PIN TYPE

AND HORIZONTAL PIN TYPE TEETH
Applicable Work Site

Clayey soil,
Rock Crushed stone Decompressed Sand
weathered granite

Digging with
Heavy ←

Horizontal pin type teeth

hammering Horizontal pin type teeth
Vertical pin type teeth
work
Work Contents

Horizontal pin type teeth

Scraping down Horizontal pin type teeth
Vertical pin type teeth
General exca- Horizontal pin type teeth
vation Vertical pin type teeth
→ Light

Horizontal pin type teeth

Loading
Vertical pin type teeth

6-24
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE

HANDLING OF RUBBER PAD SHOE AND ROAD LINER

Be sure to observe the following instructions, when using a machine equipped with rubber pad shoes or Road
Liner.

WORKING ENVIRONMENT
● Use a machine equipped with rubber pad shoes or Road Liner mainly for jobs on the paved roads. If used oth-
erwise, breakage or chipping will occur on the rubber and the service life will be considerably reduced.
Particularly the following jobsites must be avoided.
● Jobsite strewn with crushed concrete or on sand

● Jobsite with protruding edged objects like steel bar, glass and the like

● Jobsite on rocky terrain or in a river with many rocks

A ride over a concrete road shoulder or above all the tip of sheet piles driven into the ground must be avoided.

● Be careful of machine skidding on the road covered with water, ice, snow or gravel. Pay special attention when
unloading a machine from a truck.

● Use a machine equipped with rubber pad shoes or Road Liner in the ambient temperature range of -25°C -
65°C due to the properties of rubber.

WORKING CONDITIONS
● A job using the undercarriage as a fulcrum, side digging
job, digging job on a slope and a job requiring frequent
steering, as shown in the picture, cause an excessive load
on the rubber and there is danger that it may be damaged.

● Durability of rubber pad shoes may not be covered with

warranty, if a special work equipment is mounted.

6-25
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS

STORAGE AND MAINTENANCE

● Take care that no oil or grease sticks to the rubber. If it
does, wipe it off immediately.

● Install rubber pad shoes and Road Liner (A) corresponding

to the number of the links. If there is any missing pad or
liner, the rubber will be greatly deformed and damaged.

● If rubber pad shoes or Road Liner (A) has to be stored for a

long period, keep it indoors to avoid direct sunlight and
rain.

EXTENT OF DAMAGE TO RUBBER

● When traveling on a concrete pavement, rubber may stick
to the road surface, leaving a dark track behind. It is the
time for replacement.

● The rubber is still usable, even if it does not look in good shape with part of the rubber chipped or cuts devel-
oped on the surface, so long as damage has not developed all over the shoe or it does not damage a road sur-
face.

CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)

If the road liner are in the following condition, they must be repaired or replaced, so please contact your Komatsu
distributor for repair or replacement.

Height of lug
● If lug height "a" is reduced by wear, the drawbar pull will
drop. If "a" is less than 5 mm (0.2 in), replace with a new
part.

When making judgement whether to replace, repair, or

contiune using road liner, please contact your Komatsu dis-
tributor.

Replace road liner

● When all the road liners of the machine need to be
replaced, ask your Komatsu distributor to replace them.

● When only some of the road liners need to be replaced,

replace them by using the road liner replacing tools. Order
the tools from your Komatsu distributor.

6-26
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE

HANDLING TRAPEZOIDAL BUCKET

This bucket is used to dig trapezoidal ditches in paddy fields,
farmland etc. and it can dig 3 types of ditch gradients (45°, 40°
and 38°) when a movable plate is attached.

● The mounting position of the movable plate varies depend-

ing on whether the ditch gradient is 45°, 40° or 38°.

HOW TO PERFORM EXCAVATION

Operate the boom, the arm and the bucket to make the line (A)
of the side-plate of the bucket vertical.

The guide plate (B) to check this position is installed beside the
bucket pins. Accordingly, hold this plate horizontal when dig-
ging.

Ditch gradient of 45°

Attach the bucket only or the movable plate by selecting the
related ditch holes. Perform digging by the above method.

6-27
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS

Ditch gradient of 40° and 38°

Attach the movable plate by selecting the related ditch holes.
Perform digging according to the above method.

Even if the trapezoidal bucket is provided with the movable

plate, always perform digging with the bucket side face perpen-
dicular to the ground.

HANDLING EXTENSION ARM

When the extension arm is equipped, if the arm is retracted, the bucket interferes with the boom cylinder foot and
the revolution frame. Be careful at operation and transportation.

● When the extension arm is equipped, use the narrow bucket (bucket width:750 mm (30")and 560 mm (22"))
without the side cutter.
Since the standard bucket causes body instability and the bucket interferes with the operator's cab when
retracting the arm, do not mount the standard bucket.

● Work in hard soil or rocky terrain will shorten the life of the extension arm, the boom and the arm.
It is better not to use the extension arm in such conditions.

6-28
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE

HANDLING CLAMSHELL BUCKET

This bucket is used for digging and loading in side-ditches or the confined spaces.

How to perform excavation

This clamshell digs by pushing the boom against the ground.

However, when perform bucket operation, perform digging while gradually raising the boom.

If the clamshell bucket rotates, relieve the bucket cylinder pressure then set the lever to the neutral position.
This can temporarily stop the rotation.

PRECAUTIONS WHEN USING

● For safety, always avoid abrupt traveling, swing and stopping.

● Make the teeth of the bucket vertical in digging.

● Do not swing the bucket to crush the rock or to cut through soil.

● Do not use the bucket for hammering or pulling out piles etc.

● Before leaving the machine, open the bucket and lower it to the ground.

REMARK
Remove the bucket from the arm when transporting the machine.

LUBRICATING
● Prepare a grease pump.

1. Stop the machine on firm horizontal ground, lower the

work equipment to the ground, then stop the engine.

2. Using a grease pump, pump in grease through grease fit-

tings (12 points) shown by arrows.

3. After greasing, wipe off any old grease that was pushed
out.

6-29
RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS

RECOMMENDED ATTACHMENT OPERATIONS

This section describes the necessary precautions to be observed when operating a hydraulic excavator equipped
with an attachment.

NOTICE
Select the attachment most suited to the machine body.

● The machine models to which attachments can be mounted vary. For selection of attachment and
machine model, consult your Komatsu distributor.

HYDRAULIC BREAKER

MAIN APPLICATIONS
● Crushed rock

● Demolition work

● Road construction

This attachment can be used for a wide range of work including

demolition of buildings, breaking up of road surfaces, tunnel
work, breaking up slag, rock crushing, and breaking operations
in quarries.

Keep the chisel pushed perpendicularly against the impact sur-

face when carrying out breaking operations.

6-30
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS

When applying impact, push the chisel against the impact sur-
face and operate so that the chassis rises approx. 5 cm (2 in)
off the ground. Do not let the machine come further off the
ground than this amount.

When applying continuous impact to the same impact surface,

if the chisel does not penetrate or break the surface within 1
minute, change the point of impact and carry out breaking
operations closer to the edge.

The direction of penetration of the chisel and the direction of

the breaker body will gradually move out of line with each
other, so always adjust the bucket cylinder to keep them
aligned.

Always keep the chisel pressed against the impact surface

properly to prevent using the impact force when there is no
resistance.

6-31
RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS

PROHIBITED WORKS
To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate
the machine in any of the following ways.

● Do not operate all cylinders to the end of their strokes. Always leave approx. 5 cm (2 in) to spare.

Using the mount to gather in pieces of rock

Operations using the swing force

Moving the chisel while carrying out impacting operations

Applying impact horizontally or in upward direction

6-32
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS

Twisting the chisel when it has penetrated the rock

Pecking operations

Extending the bucket cylinder fully and thrusting to raise the

machine off the ground

6-33
RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS

GREASING POSITION FOR HYDRAULIC BREAKER

Supply grease in the correct position.

NOTICE
If grease is supplied in an incorrect position, the breaker is
filled with more grease than necessary. As a result, soil
and sand will enter the hydraulic circuit and can damage
the hydraulic devices while the breaker is used. Accord-
ingly, be sure to supply grease in the correct position.

6-34
INDEX

INDEX
8

A E
AFTER COLD WEATHER SEASON ................ 3-118 ELECTRIC SYSTEM MAINTENANCE ................. 4-8
AFTER DAILY WORK COMPLETION .............. 3-117 ENGINE HOOD .................................................. 3-33
AFTER RUNNING OUT OF FUEL .................... 3-121 ENGINE SERIAL NUMBER PLATE AND ITS
AFTER STARTING ENGINE ..............................3-74 LOCATION ....................................................... 1-8
AFTER STORAGE ............................................ 3-120 ESCAPE FROM MUD ........................................ 3-96
ASHTRAY ........................................................... 3-33 EVERY 1000 HOURS MAINTENANCE ............. 4-62
ATTACHMENT GUIDE ....................................... 6-20 EVERY 2000 HOURS MAINTENANCE ............. 4-66
ATTACHMENT MOUNTING/DISMOUNTING EVERY 4000 HOURS MAINTENENCE ............. 4-68
PROCEDURE ................................................. 6-13 EVERY 500 HOURS MAINTENANCE ...... 4-54, 6-18
EVERY 5000 HOURS MAINTENANCE ............. 4-69
EXPLANATION OF COMPONENTS ............. 3-4, 6-6
B
BASIC CHECK ITEMS ..........................................3-5
BATTERY ............................................................ 2-28 F
BEFORE STARTING ENGINE ...........................3-57 FOREWORD ........................................................ 1-2
BEFORE STORAGE ......................................... 3-119 FRONT WINDOW ............................................... 3-26
FUSE .................................................................. 3-53
FUSIBLELINK ..................................................... 3-54
C
CAP, COVER WITH LOCK ................................. 3-32
CAR RADIO ........................................................ 3-48 G
CARRYING OUT KOWA GENERAL OPERATION INFORMATION .......... 3-93
(Komatsu Oil Wear Analysis) ............................ 4-6 GENERAL PRECAUTIONS .................................. 6-2
CEILING WINDOW ............................................. 3-25 GENERAL VIEW .................................................. 3-2
CHECK AFTER FINISHING WORK .................3-103 GENERAL VIEW CONTROLS AND
CHECK AFTER SHUT OFF ENGINE ................. 3-80 GAUGES .......................................................... 3-3
CHECK BEFORE STARTING ............................. 4-46 GENERAL VIEW OF MACHINE ........................... 3-2
CHECKING FOR DAMAGE TO GREASE GUN HOLDER .................................... 3-55
BUCKET WITH HOOK ..................................... 6-5
COLD WEATHER OPERATION ....................... 3-115
COLD WEATHER OPERATION H
INFORMATION ............................................ 3-115 HANDLING ACCUMULATOR ............................ 3-56
COMBINATIONS OF WORK EQUIPMENT ........ 6-20 HANDLING AIR CONDITIONER ........................ 3-34
CONTROL LEVERS, PEDALS ........................... 3-22 HANDLING BUCKET WITH HOOK ...................... 6-5
CONTROLLER (COMPUTER) ............................ 3-55 HANDLING CLAMSHELL BUCKET ................... 6-29
HANDLING EXTENSION ARM .......................... 6-28
HANDLING OF RUBBER PAD SHOE AND
D ROAD LINER ................................................. 6-25
DIRECTIONS OF MACHINE ................................ 1-7 HANDLING OIL, FUEL, COOLANT, AND
DISCHARGED BATTERY ................................. 3-124 PERFORMING OIL CLINIC ............................. 4-5
DOOR AT FRONT OF TOOL BOX ..................... 3-33 HANDLING SCSH BUSHING ............................. 6-18
DOOR LOCK ....................................................... 3-31 HANDLING TRAPEZOIDAL BUCKET ................ 6-27
DURING STORAGE ......................................... 3-119 HYDRAULIC BREAKER ..................................... 6-30

I
IN COLD AREAS (AUTOMATIC
WARMING-UP OPERATION) ........................ 3-77
INITIAL 250 HOURS MAINTENANCE (ONLY
AFTER THE FIRST 250 HOURS) .................. 4-20
INTRODUCTION .................................................. 1-7

7-1
 INDEX

L S
LIFTING MACHINE ...........................................3-113 SAFETY CRITICAL PARTS ............................... 4-16
LIFTING OBJECTS WITH BUCKET ...................2-31 SAFETY INFORMATION ......................1-5, 2-2, 2-10
LIGHTWEIGHT TOWING HOOK ......................3-122 SAFETY LABELS ................................................. 2-5
LOADING AND UNLOADING WITH TRAILER..3-106 SAFETY MACHINE OPERATION ...................... 2-19
SAFETY MAINTENANCE INFORMATION ........ 2-32
LOCKING ..........................................................3-104 SELECTION OF BUCKET TEETH ..................... 6-24
LONG TERM STORAGE ..................................3-119 SELECTION OF TRACK SHOES ....................... 6-23
LONG-TERM STORAGE ....................................6-17 SERVICE METER LOCATION ............................. 1-9
LUBRICANTS, COOLANT AND FILTERS ............4-5 SPECIFICATIONS ....................................... 5-2, 6-17
STANDARDS FOR SELECTING
VERTICAL PIN TYPE AND
M HORIZONTAL PIN TYPE TEETH .................. 6-24
MACHINE MONITOR ............................................3-4 STARTING ENGINE ..................................2-19, 3-70
MACHINE OPERATION .....................................3-81 STEERING THE MACHINE ................................ 3-85
MACHINE OPERATIONS AND STOPPING THE ENGINE .................................. 3-80
CONTROLS ....................................................3-57 SWINGING ......................................................... 3-87
MACHINE SERIAL NUMBER PLATE AND SWITCHES ......................................................... 3-17
ITS LOCATION .................................................1-8
MACHINES READY FOR ATTACHMENTS .........6-6
MAGAZINE BOX .................................................3-33 T
MAINTENANCE INFORMATION ..........................4-2 TIGHTENING TORQUE LIST ............................. 4-15
MAINTENANCE INTERVAL FOR HYDRAULIC TIGHTENING TORQUE SPECIFICATIONS ...... 4-15
BREAKER ......................................................4-19 TOOLBOX .......................................................... 3-55
MAINTENANCE PROCEDURE ..........................4-20 TOWING ............................................................. 2-30
MAINTENANCE SCHEDULE .............................4-17 TOWING THE MACHINE ................................. 3-122
MAINTENANCE SCHEDULE CHART ................4-17 TRANSPORTATION ................................2-27, 3-105
TRANSPORTATION PROCEDURE ................. 3-105
TRAVELING ON SLOPES .................................. 3-94
O TROUBLESHOOTING ...................................... 3-121
OPERATING WORKING MODE .........................3-90
OPERATION .......................................................2-21
OPERATION AND MAINTENANCE MANUAL U
HOLDER .........................................................3-57 USE OF FUEL, COOLANT AND
OTHER TROUBLE ............................................3-128 LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE ........................... 4-11

P
PARKING MACHINE ........................................3-102 W
PERIODIC REPLACEMENT OF WEAR PARTS LIST ........................................... 4-10
SAFETY CRITICAL PARTS ...........................4-16 WHEN REQUIRED ............................................. 4-21
PHENOMENA THAT ARE NOT FAILURES .....3-121 WORK EQUIPMENT CONTROLS AND
POSITION FOR ATTACHING SAFETY LABELS .2-4 OPERATIONS ................................................ 3-88
PRECAUTIONS ON PARTICULAR JOBSITES 3-123
PRECAUTIONS RELATED TO SAFETY ..............6-2
PRECAUTIONS WHEN INSTALLING Y
ATTACHMENTS ...............................................6-4 YOUR MACHINE SERIAL NUMBERS AND
PRODUCT IINFORMATION .................................1-8 DISTRIBUTOR ................................................. 1-9
PROHIBITED OPERATIONS .......................3-91, 6-5
PROPER SELECTION OF FUEL,
COOLANT AND LUBRICANTS ......................4-11

R
RECOMMENDED APPLICATIONS ....................3-97
RECOMMENDED ATTACHMENT
OPERATIONS ................................................6-30
REPLACEMENT AND
INVERSION OF BUCKET ..............................3-99

7-2
MEMO

7-3
Printed in P.R. China
2004 - 05 (50) S