SEAM022902

& Maintenance
Operation
Manual

HYDRAULIC EXCAVATOR

SERIAL NUMBERS PC1800-6-10002 and

up
This material is proprietary to Komatsu Mining Systems and is not to be reproduced, used, or
disclosed except in accordance with wriien authorization from Komatsu Mining Systems.

the right to make

It is our policy to improve our products whenever it is possible and practical to do so. We reserve
to install such changes on products sold
changes or add improvements at any time without incurring any obligation
previously.

this publication.
Due to this continuous program of research and development, periodic revisions may be made to
It is recommended that customers contact their distributor for information on the latest revision.

Copyright 1999 Komatsu

December 1999 DataKom Publishing Corporation
1. FOREWORD

This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
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.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.

A __._- ____ _-
A WARNING
l Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.

l Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the luggage box behind the operator’s seat for easy reference, and have all
workers who handle the machine read it periodically.
Where to keep this manual. + “11.6 POCKET”.

l Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.

l The procedures and precautions given in this manual apply only to intended uses of the machine.
lf you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.

l Komatsu delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. lf this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. lf 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 operating the machine.

l The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page
l-l.

CALIFORNIA
Proposition 65 Warning
Dieselengine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.

O-l
2. SAFETY INFORMATION

Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.

A DANGER - This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.

A WARNING - This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.

A CAUTION - This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.

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

Safety precautions are described in SAFETY from page l-l.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact a
Komatsu distributor.

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3. INTRODUCTION

3.1 INTENDED USE

This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work:
l Digging work
l Loading work

See the section “12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.

3.2 FEATURES

l This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced
electronics system.
o The monitor panel greatly facilitates daily maintenance and self-diagnosis.
o The monitor panel and machine control system monitor greatly facilitates daily maintenance,
self-diagnosis and maintenance control.
o Working mode, travel speed and swing priority are selectable.
l Adjustable semi wrist control levers make operations smooth and easy.
l Air-conditioned operator’s cab assures comfortable operation.
l Improved operator comfort due to noise and vibration, and smart urban-style design and color,
l Enhanced safety by addition emergency stop lever, rear-view mirror and grill.
l Superb operating performance provided by powerful engine and high-performance hydraulic
pumps.
l Low fuel consumption controlled by an electronic control system provides an environment-friendly
machine.

3.3 RUNNING IN THE MACHINE

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 run in the machine for the initial 100 hours (as indicated by the service meter.)
During running in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.

The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purposes. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.

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4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR

4.1 MACHINE SERIAL NO. PLATE POSITION

On the front bottom left of the operator’s cab (side of upper

frame)

4.2 ENGINE SERIAL NO. PLATE POSITION

On the upper side of the oil cooler housing located on the left
side of the engine cylinder viewed from the fan.

4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.:

Engine serial No.:

Distributor name:

1 Address: Phone:

Service personnel for your machine:

REMARKS

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5. CONTENTS

1. Foreword .. . . .. .. . . . .... . .. . .. . .. . ... . .. . . . .. .. . . . .. .. . . . . .._.................................._................................._................... 0- 1

2. Safety information .. . . . ... . . .. . . .. .. .. .. . . .. . . . . .. . . .. . ...-..-............................~................................................... O-2

3. Introduction ..,......................................-.............................................................,................................ o- 3

4. Location of plates, table to enter serial No. and distributor ..L......._........................................... O-4

SAFETY

6. General precautions . . .. ... . . . .. . .. . . . .. . . . . . . . . . .. . .. . . . . .. . . .. .. .. .. .. . .. . .. . .. .. . . . .. .. . ... .. . . . . .. .. .._. .. .. . . . . .... . ... .. . . .. . . .. .. ... .. . I- 2

7. Precautions during operation .......................................................................................................... I- 9

7.1 Before starting engine ............................................................................................................. I- 9
7.2 After starting engine.. .............................................................................................................. l-l 1
7.3 Transportation .......................................................................................................................... l-78
7.4 Battery ....................................................................................................................................... 1-19
7.5 Towing ...................................................................................................................................... l-21
7.6 Lifting operations ..................................................................................................................... I-21

8. Precautions for maintenance ........................................................................................................... l-22

8.1 Before carrying out maintenance .......................................................................................... l-22
8.2 During maintenance ................................................................................................................ 1-26

9. Position for attaching safety labels ................................................................................................ I-31

OPERATION

10. General view ...................................................................................................................................... 2- 2

10.1 General view of machine.. ...................................................................................................... 2- 2
10.2 General view of controls and gauges ................................................................................... 2- 3

11. Explanation of components ............................................................................................................. 2- 5

11.1 Machine monitor ...................................................................................................................... 2- 5
11.2 Switches .................................................................................................................................... 2-14
11.3 Lamp ......................................................................................................................................... 2-21
11.4 Control levers, pedals.. ............................................................................................................ 2-22
11.5 Door lock.. ................................................................................................................................. 2-25
11.6 Pocket ........................................................................................................................................ 2-25
11.7 Handling air conditioner ......................................................................................................... 2-26
11.8 Emergency escape hammer ................................................................................................... 2-29
11.9 Emergency escape iadder ....................................................................................................... 2-30
11 .lO Cap, cover with lock ................................................................................................................ 2-31
11.11 Ashtray ...................................................................................................................................... 2-31
11.12 Car radio ................................................................................................................................... 2-32
11.13 Fuse ........................................................................................................................................... 2-37
11.14 Circuit-breaker .......................................................................................................................... 2-38
11.15 Controllers ................................................................................................................................ 2-38
11.16 Tool box .................................................................................................................................... 2-38
II .I7 Grease pump ............................................................................................................................ 2-39
11.18 Handling grease pump ............................................................................................................ 2-39
11 .I9 Handling accumulator ............................................................................................................. 2-41
11.20 Health monitor ......................................................................................................................... 2-43

O-5
12. Operation .........................._. ... .. .._...._.._................................................................................................ 2-54
12.1 Check before starting engine ................................................................................................. 2-54
12.2 Starting engine ......................................................................................................................... 2-68
12.3 Operations and checks after starting engine.. ...................................................................... 2-71
12.4 Moving machine off ................................................................................................................ 2-77
12.5 Steering machine ..................................................................................................................... 2-80
12.6 Stopping machine .................................................................................................................... 2-82
12.7 Swinging ................................................................................................................................... 2-83
12.8 Operation of work equipment ................................................................................................ 2-84
12.9 Handling working mode .......................................................................................................... 2-85
12.10 Prohibitions for operation ....................................................................................................... 2-86
12.11 Precautions for operation ....................................................................................................... 2-88
12.12 Precautions when traveling up or down hills ...................................................................... 2-89
12.13 How to escape from mud ....................................................................................................... 2-91
12.14 Work possible using hydraulic excavator ............................................................................. 2-92
12.15 Phenomena that are not failures ........................................................................................... 2-92
12.16 Parking machine ........................................................................................................... i.. ........ 2-93
12.17 Check after finishing work ...................................................................................................... 2-94
12.18 Stopping engine ....................................................................................................................... 2-95
12.19 Check after stopping engine ................................................................................................... 2-98
12.20 Locking ...................................................................................................................................... 2-98

13. Transportation ......................................... .......................................................................................... 2-99

13.1 Precaution for transportation ................................................................................................. 2-99
13.2 Parts for transport ................................................................................................................... 2-100

14. Cold weather operation ....................................................................................................................2-108

14.1 Precautions for low temperature ........................................................................................... 2-108
14.2 Precautions after completion of work ................................................................................... 2-110
14.3 After cold weather ................................................................................................................... 2-110

15. Long-term storage .............................................................................................................................2-111

15.1 Before storage .......................................................................................................................... 2-111
15.2 During storage ......................................................................................................................... 2-112
15.3 After storage ............................................................................................................................. 2-112
15.4 Starting machine after long-term storage ............................................................................ 2-112

16. Troubleshooting .................................................................................................................................2-l 13

16.1 When fuel runs out .................................................................................................................2-113
16.2 Phenomena that are not failures ........................................................................................... 2-l 13
16.3 Method of towing machine .................................................................................................... 2-113
16.4 Precautions on particular jobsites ......................................................................................... 2-l 13
16.5 If battery is discharged ........................................................................................................... 2-114
16.6 Other trouble ............................................................................................................................ 2-l 17

O-6
MAINTENANCE

17. Guides to maintenance .......... ......._.................. _._._

..... ....................... ....... ... ....................... .... ..... ...... 3- 2

18. Outlines of service ............................................................................................................................ 3- 6

18.1 Outline of oil, fuel, coolant.. ................................................................................................... 3- 6
18.2 Outline of electrical system .................................................................................................... 3- 9
18.3 Outline of hydraulic system .................................................................. ................................. 3-10
18.4 Releasing pressure .................................................................................................................. 3-11
18.5 Bleeding air from circuit ......................................................................................................... 3-13

19. Consumable parts list . .. . .. .. . . ... .. . .. .. . . ... _. . . . .. ._.. . ... . ._. . . .. . . . . . . .. .. . . . . . . .__.................................................... 3-19

20. Use of fuel, coolant and lubricants according to ambient temperature ....a.............................. 3-20

21. Standard tightening torques for bolts and nuts ........................................................................... 3-24
21.1 Introduction of necessary tools.. ............................................................................................ 3-24
21.2 Torque list.. ............................................................................................................................... 3-25

22. Periodic replacement of critical safety parts .. .. . . . . . . . . . . . .. . . .. . .. . .. . . . .. . . .. . .. . .. . .. . . .. . .. .. . . . . . .. .. . . . . .. . . .. . . . . .. .. 3-26

23. Maintenance schedule chart ............................................................................................................ 3-28

23.1 Maintenance schedule chart.. ................................................................................................. 3-28

24. Service Procedure .............................................................................................................................. 3-32

24.1 Initial 100 hours service .......................................................................................................... 3-32
24.2 Initial 250 hours service .......................................................................................................... 3-32
24.3 When required ......................................................................................................................... 3-33
24.4 Check before starting .............................................................................................................. 3-49
24.5 Every 70 hours service ............................................................................................................ 3-50
24.6 Every 100 hours service_. ........................................................................................................ 3-53
24.7 Every 250 hours service.. ........................................................................................................ 3-54
24.8 Every 500. hours service .......................................................................................................... 3-61
24.9 Every 1000 hours service ........................................................................................................ 3-66
24.10 Every 2000 hours service ........................................................................................................ 3-68
24.11 Every 4000 hours service.. ...................................................................................................... 3-71
24.12 Every 5000 hours service.. ...................................................................................................... 3-72

SPECIFICATIONS

25. Specifications . .. . .. . ... .. ... . . .. .. . . .. .. . . .. . . . . .. .. . . .. . .. . . .. .. .. .. .. .. . . .. . . . . ._. .. . . . .. . .. . . .. . ..- _. . .. . .. .. . . .. . . . .. . . .. . .. . . .. . . . .. . ..- 4- 2

OPTIONS, A-ITACHMENTS

26. General precautions .......................................................................................................................... 5- 2

26.1 Precautions related to safety.. ................................................................................................ 5- 2
26.2 Precautions when installing attachments ............................................................................. 5- 3

27. Introduction of attachments ............................................................................................................ 5- 4

27.1 Guards.. ..................................................................................................................................... 5 4

28. Auto-greasing system . ... . .. . . . ... .. . .. . .. . . ... .. . ... . . . .. . .. .. . .. . . . . . . . .. .. . . . .. . . . . . . .. . ... . .. .._........._.............................. 5- 5

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 SAFETY

A WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.

This safety section also contains precautions for optional equip-

ment and attachments.

l-1
 A ~~14~~~~;e~;ereasons of safety, always
6. GENERAL PRECAUTIONS ty precautions.

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.
Do not operate the machine if you are not feeling well, or if you are taking medicine which will
make you sleepy, or if you have been drinking. Operating in such a condition will adversely affect
your judgement and may lead to an accident.
When working with another operator or with a person on worksite traffic duty, be sure that all
personnel understand all hand signals that are to be used.
Always follow all rules related to safety.

l Be sure that all guards and covers are in their proper position. Have guards and covers repaired
if damaged.
l Use safety features such as safety lock levers 0 and the seat belt properly.
l Never remove any safety features. Always keep them in good operating condition.
Safety lock lever - See ‘12.16 PARKING MACHINE”.
l Improper use of safety features could result in serious bodily injury or death.

AN364156

CLOTHING AND PERSONAL PROTECTIVE ITEMS 1

Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts
1
and cause serious injury or death.
Also, do not wear oily clothes, because they are flammable.
Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the
machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering
metal chips or minute materials particularly when driving pins with a hammer and when cleaning
the air cleaner element with compressed air. Check also that there is no one near the machine.
Check that all protective equipment functions properly before using.

422
AE30.5770

Any modification made without authorization from Komatsu can create hazards. Before making a
modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or
damage caused by any unauthorized modification.

l-2
A ;tR;;Et; FaIaIic follow these safety precautions may lead
6. GENERAL PRECAUTIONS

ALWAYS APPLY LOCK

When standing up from the operator‘s seat, always place the safety lock levers @ securely in the
LOCK position. If you accidentally touch the levers when they are not locked, the work equipment
may suddenly move and cause serious injury or damage.
l When leaving the machine, lower the blade and ripper completely to the ground, set the safety
lock levers @ to the LOCK position, then stop the engine. Use the key to lock all the equipment.
Always remove the key and take it with you.
Work equipment posture + See “12.16 PARKING MACHINE”.
Locking -+ See “12.20 LOCKING”

Never jump on or off the machine. Never get on or off a moving machine.
When getting on or off the machine, always face the machine and use the handrails and steps.
Never hold any control levers or lock levers when getting on or off the machine.
To ensure safety, always maintain three-point contact (both feet and one hand, or both hands and
one foot) with the handrails and steps to ensure that you support yourself.
If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose bolts.
When getting on or off the machine, or when moving along the top of the track, if you hold the
handrail inside the door when moving on top of the track shoe, and the door lock is not locked
securely, the door may move and cause you to fall.
Always lock the door securely.
Method of locking door -) See ‘11.4 DOOR LOCK”.

AM332430 AL187320

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 a ~A&J;M~e~;ereasons qf safety, always
6. GENERALPRECAUTIONS ty precautions.

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly flammable and can be
hazardous.
Always observe the following:
l Keep any flame or lighted cigarette away from flammable fluids.
l Stop the engine and do not smoke when refueling.
l Tighten all fuel and oil caps securely.
l Use well-ventilated areas for adding or storing oil and fuel.
l Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

mnom A0055030 A0055040

lmmediateiy after operations are stopped, the engine oil and hydraulic oil are at high temperature
and are still under pressure. Attempting to remove the cap, drain the oil or water, or replace the
filters may lead to serious burns. Always wait for the temperature to go down, and folJow the
specified procedures when carrying out these operations.

To prevent hot water from spurting out, stop the engine, wait for the water to cool, then loosen
the cap slowly to relieve the pressure before removing the cap.
(When checking if the water temperature has gone down, put your hand near the front face of the
radiator and check the air temperature. Be careful not to touch the radiator.)

To prevent hot oil from spurting out, stop the engine, wait for the oil to cool, then loosen the cap
slowly to relieve the pressure before removing the cap.
(When checking if the oil temperature has gone down, put your hand near the front face of the
hydraulic tank and check the air temperature. Be careful not to touch the hydraulic tank.)

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A LVtR;;Et; Faiai~$ follow these safety precautions may lead
6. GENERAL PRECAUTIONS

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be hazardous to your health if it is inhaled.
Komatsu does not use asbestos in its products, but if you handle materials containing asbestos
fibers, follow the guidelines given below:
l Never use compressed air for cleaning.
l Use water to keep down the dust when cleaning.
l If there is danger that there may be asbestos dust in the air, operate the machine from an upwind
position whenever possible.
l Use an approved respirator if necessary.

CRUSHING OR CUTTING PREVENTION

Do not enter, or put your hand or arm or any other part of your body between movable parts such
as the work equipment and cylinders, or between the machine and work equipment.
If the work equipment is operated, the clearance will change and this may lead to serious damage
or personal injury.
If it is necessary to go between movable parts, always lock the levers and be sure that the work
equipment cannot move. For details, see ‘8. PRECAUTIONS FOR MAINTENANCE”.

AoossOso

-j FIRE EXTlNGUISHER AND FIRST AID KlT 1

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.
Provide a first aid kit at the storage point. Carry out periodic checks and add to the contents if
necessary.
Know what to do in the event of a fire or injury.
Decide the phone numbers of persons (doctor, ambulance, fire station, etc.) to contact in case of
an emergency. Post these contact numbers in specified places and make sure that all personnel
know the numbers and correct contact procedures.

A0055070

1-5
 A ~~V,“~~~lePc;,rasons cf safety, always
6. GENERAL PRECAUTIONS ty precautrons.

If there is any danger of falling or fiying objects hitting the operator, install protective guards in place
to protect the operator as required for each particular situation.

l For work in mines, tunnel or other places where there is danger of falling rocks, put FOPS (falling
object protective structure) in place. Also, place a laminate coating sheet over the windshield.

The above comments are made with regards to typical working conditions. By all means you
should put on other guards if required by conditions at your particular site.
For details of safety guards, please contact your Komatsu distributor.

Also, even for other types of work, if there is any danger of getting hit by falling or flying objects,
or of objects entering the operator’s cab, select and install a guard that matches the working
conditions.

Se sure to close the front window before commencing work.

When carrying out the above operations, make sure to keep all persons other than the operator
outside the range of falling or flying objects, Be particularly sure to maintain a proper distance when
carrying out shear operations.

FOPS
(falling object protective structure)

l-6
a WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS

l When installing and using an optional attachment, read the instruction manual for the attachment
and the information related to attachments in this manual.

l Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.

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

MACHINES WITH ACCUMULATOR

On machines equipped with an accumulator, for a short time after the engine is stopped, the work
equipment will lower under its own weight when the work equipment control lever is shifted to
LOWER. After the engine is stopped, set the safety lock lever @ to the lock position and also lock
the attachment pedal with the lock pin.

When releasing the pressure inside the work equipment circuit on machines equipped with an
accumulator, follow the procedure given in the inspection and maintenance section.
Method of releasing pressure + See “11.19 HANDLING ACCUMULATOR”.

The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is
handled in the wrong way. Always observe the following precautions.
l Never make any hole in the accumulator or expose it to flame or fire.
l Do not weld any boss to the accumulator.
l When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, it is necessary to release the gas from the accumulator. A special air bleed valve is
necessary for this operation, so please contact your Komatsu distributor.

l-7
 & E;!WN& FWereasons of safety, always
6. GENERAL PRECAUTIONS ty precautrons.

Exhaust fumes from the engine can kill.

l If it is necessary to start the engine within an enclosed area, or you handle fuel, flushing oil, or
paint, open the doors and windows to ensure that you provide adequate ventilation to prevent
gas poisoning.

l If opening the doors and windows still does not provide adequate ventilation, set up fans.

WINDOW TO ESCAPE OF OPERATOR’S CAB

l Should the door of the cab be jammed, break the left-hand
window to escape.
There is a ladder in the box on the left side of the operator’s
compartment, so use it if necessary.
For details of the method of using the ladder + see ‘11.9
EMERGENCY ESCAPE LADDER”.

l In this case, break the left-hand window using the hammer

installed to the left-hand control stand.
For details of the method of using the hammer - see “11.8
EMERGENCY ESCAPE HAMMER”.

1-8
7. PRECAUTIONS DURING A WARNING: Failure to follow these safety
OPERATION precautions may lead to a serious accident.

7.1 BEFORE STARTING ENGINE

-I SAFETY AT WORKSfTE 1
Before starting operations, thoroughly check the area for any unusual conditions that could be
dangerous.

Check the terrain and condition of the ground at the worksite. and determine the best and safest
method of operation.

Make the g,round surface as hard and horizontal as possible before carrying out operations.
If the jobsite is dusty, spray water before starting operations.

If you need to operate on a road, protect pedestrians and cars by designating a person for worksite
traffic duty or by installing fences and putting up No Entry signs around the worksite.

If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact
each utility and identify their locations. Be careful not to sever or damage any of these lines.

Check the ground condition and the depth and flow of water before operating in water or crossing
a river. NEVER be in water which is in excess of the permissible water depth.
Permissible water depth + See “12.11 PRECAUTIONS FOR OPERATION”

AE341250

CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the days work.
Failure to carry out these checks may lead to serious injury or damage.
l Completely remove all flammable materials accumulated around the engine and battery, return
all fuel containers to their proper place, remove all parts and tools from the operator’s compart-
ment, and remove any dirt from the mirrors, handrails, and steps.
Walk-around checks + See “12.1.1 WALK-AROUND CHECK”.

l Check the coolant level, fuel level, and oil level in the hydraulic tank, check for clogging of the air
cleaner, and check the electric wiring.
Checks before starting + See “12.12 CHECK BEFORE STARTING”.
l Adjust the operator’s seat to a position where it is easy to carry out operations, and check for wear
or damage to the seat belt and seat belt mounting equipment.
Adjusting operator’s seat + See ‘12.1.3 OPERATORS SEAT”.
l Check that the gauges work properly, and check that the control levers are all at the NEUTRAL
position.
Method of checking operation of gauges -
See ‘12.1.6 OPERATIONS AND CHECKS BEFORE STARTING ENGINE”.
l Check that the mirrors and window glass provide a clear view.
If the above inspections show any abnormality, carry out repairs immediately.
l If any of the machine’s mirrors are broken, replace them.
l Removal and installation of mirrors for replacement or transportation. / f
For adjustment of the mirrors + f
&
See “12.1.4 ADJUSTMENT OF MIRRORS.”
For removal and installation of the mirrors + A&
See “13.1 PRECAUTIONS FOR TRANSPORTATION.” A0055020
 A ~+i$JJie Foiereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautions.

WHEN STARTING ENGINE

I
Walk around your machine again just before mounting it, and check for people and objects that
might be in the way.
Never start the engine if a warning tag has been attached to the work equipment control lever.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
An additional worker may ride in the machine only when sitting in the passenger seat. Do not allow
anyone to ride on the machine body.
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.

DO NOT operate
When this plate is not being used
keep it in the storage compamnent.
099634WOJ

I-10
A E:;MEf; FaiJaito follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATlON

7.2 AFTER STARTfNG ENGfNE

CHECI
Failure to carry out the checks properly after starting the engine will lead to delays in discovery of
abnormalities, and this may lead to serious injury or damage to the machine.
When carrying out the checks, use a wide area where there are no obstructions. Do not allow anyone
near the machine.
l Check the operation of the gauges and equipment, and check the operation of the blade, ripper,
brakes, travel system, and steering system.
l Checks for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check
also that there is no leakage of air, oil, or fuel.
l If any abnormality is found, carry out repairs immediately.
if the machine is used when it is not improper condition, it may lead to serious injury or damage
to the machine.

-I PRECAUTIONS WHEN STARTING OFF 1

Check the direction of the track frame before operating the travel
Travel in reverse direction
lever.
When the sprocket is at the front, the operation of the travel
lever is reversed, so operate the machine carefully.
Method of steering machine + See “12.4 MOVING MACHINE
OR”.
Before moving the machine off, check again that there are no
persons or obstacies in the surrounding area.
When moving the machine off, sound the horn to warn people
in the surrounding area.
Always sit in the operator’s seat when driving the machine.
Fasten your seat belt securely.
The operator must not let any other person sit anywhere except
in the assistant’s seat.
Check that the travel alarm (option) works properly.
Always close the door of the operator’s cab and check that the
door is locked in position securely.

CHECK WHEN CHANGING DIRECTION 1

To prevent serious injury or death, always do the following before moving the machine or doing the
leveling work.
l Before changing between forward and reverse, reduce speed and stop the machine.
l Before operating the machine, sound the horn to warn people in the area.
l Check that there is no one near the machine. Be particularly careful to check behind the machine.
l When operating in areas that may be hazardous or have poor visibility, designate a person to direct
worksite traffic.
l Ensure that no unauthorized person can come within the direction of turning or direction of travel.
Always be sure to carry out the above precautions even when the machine is equipped with a backup
alarm and mirrors.

1-11
 A )Vfgl;P4?ge Foiereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautions.

PRECAUTIONSWHEN TRAVELING 1
Never turn the key in the starting switch to the OFF position when traveling.
It is dangerous if the engine stops when the machine is traveling, because it becomes impossible
to operate the steering.

It is dangerous to look around you when operating. Always concentrate on your work.

It is dangerous to drive too fast, or to start suddenly, stop suddenly, turn sharply, or zigzag.

If you find any abnormality in the machine during operation (noise, vibration, smell, incorrect
gauges, air leakage, oil leakage, etc.), move the machine immediately to a safe place and look for
the cause.

Set the work equipment to a height of 40 - 50 cm (16 - 20 in) from the ground level and travel
on level ground.

When traveling, do not operate the work equipment control levers. If the work equipment control
levers have to be operated, never operate them suddenly.

Do not operate the steering suddenly. The work equipment may hit the ground surface and cause
the machine to lose its balance, or may damage the machine or structures in the area.

When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.

Avoid traveling over obstacles as far as possible. If the machine has to travel over an obstacle,
keep the work equipment as close to the ground as possible and travel at low speed. Never travel
over obstacles which make the machine tilt strongly (10” or more).

When traveling or carrying out operations, always keep your distance from other machines or
structures to avoid coming into contact with them.

NEVER be in water which is in excess of the permissible water depth.

Permissiblewater depth + See “12.11 PRECAUTIONS FOR OPERATION”.

When passing over bridges or structures on private land, check first that the structure is strong
enough to support the mass of the machine. When traveling on public roads, check first with the
relevant authorities and follow their instructions.

Travel posture INCORRECT

AE341200

1-12
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONSDURING OPERATION

Traveling on slopes could result in the machine tipping over or slipping to the side.
When traveling on slopes, keep the blade approximately 20 - 30 cm (8 - 12 in) above the ground.
In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these
operations.
Method of traveling on slopes * See “12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN
HILLS”.
Do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes may cause the machine
to slip to the side, so travel at low speed and make sure that the machine is always traveling
directly up or down the slope.
If the engine stops on a slope, place the travel lever at the neutral position and lower the bucket
to the ground. Do not operate the steering. There is danger that the machine will turn under its
own weight.
Downhill Uphill
CORRECT

INCORRECT

A034129A AE341310

PROHIBITED OPERATIONS
Do not dig the work face under an overhang. This may cause the overhang to collapse and fall
on top of the machine.
Do not carry out deep digging under the front of the machine. The ground under the machine may
collapse and cause the machine to fall. Take emergencies into consideration and set with the travel
motor at the rear and the track (undercarriage) at right angles to the road shoulder before digging
to enable the machine to move back quickly. If the ground under the machine collapses and there
is no time to drive in reverse, do,not suddenly raise the arm and boom. In some cases, it may
in fact be safer to lower the arm and boom.
Do not swing the work equipment to the side when it is carrying a heavy load. The stability to
the side is less than the stability to the front, so there is danger that the machine may turn over.
Limits on use
To prevent accidents caused by breakage of the work equipment or tipping over of the machine
under excessive load, do not use the machine in excess of its capacity. Always be sure to keep
within the maximum specified load and safe angle determined for the structure.

INCORRECT INCORRECT

AD34132A
 a WARNING: For reasons of safety, always
7. PRECAUTIONSDURING OPERATION follow these safety precautions.

PRECAUTIONS WHEN OPERATING

l Be careful not to approach too close to the edge of cliffs.
l Carry out only work that is specified as the purpose of the machine.
Carrying out other operations will cause breakdowns.
Specifiedoperations + See “12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR”.
l Do the following to ensure good visibility.
l When operating in dark places, turn on the working lamps and front lamps, and install lighting
at the jobsite if necessary.
l Do not carry out operations in fog, mist, snow, or heavy rain, or other conditions where the
visibility is poor. Wait for the weather to clear so that visibility is sufficient to carry out work.
l Always do as follows to prevent the work equipment from hitting other objects.
l When operating in tunnels, under bridges, under electric wires, or other places where the height
is limited, be extremely careful not to -let the bucket, boom, or arm hit anything.
l To prevent accidents caused by hitting other objects, always operate the machine at a speed
which is safe for operation, particularly in confined spaces, indoors, and in places where there
are other machines.
l Never pass the bucket over the head of any worker or over the operator’s cab on a dump truck.

1-14
A E;RNN~J; FaiJaizc follow these safaty precautions may lead
7. PRECAUTIONS DURING OPERATION

DO NOT GO CLOSE TO
l Do not let the machine touch overhead electric cables. Even going close to high-voltage cables
can cause electric shock. Always maintain the safe distance given below between the machine and
the electric cable.
l To prevent accidents, always do as follows.
Cn jobsites where there is danger that the machine may touch the electric cables, consult the
electricity company before starting operations to check that the actions determined by the
relevant laws and regulations have been taken.
Wear rubber shoes and gloves. Lay a rubber sheet on top of the operatofs seat, and be careful
not to touch the chassis with any exposed part of your body.
Use a signalman to give warning if the machine approaches too close to the electric cables.
If the work equipment should touch the electric cable, the operator should not leave the
operator’s compartment.
When carrying out operations near high voltage cables, do not let anyone come close to the
machine.
Check with the electricity company about the voltage of the cables before starting operations.

Voltage Min. safety distance

3 5. 100 l 200 v 2m
2$ 6,600 v 2m
22,000 v 3m
&
2 66,000 v 4m
P 154,000 v 5m
.c
0 187,000 V 6m
E
2 275,000 V 7m AE2.41340

J
P
500,000 v 11 m

OPERATE CAREFULLY ON SNOW 1

When working on snow or icy roads, even a slight slope may cause the machine to slip to the side,
so always travel at low speed and avoid sudden starting, stopping, or turning. There is danger
of slipping particularly on uphill or downhill slopes.
With frozen road surfaces, the ground becomes soft when the temperature rises, so the travel
conditions become unstable. In such cases be extremely careful when traveling.
When there has been heavy snow, the road shoulder and objects placed beside the road are buried
in the snow and cannot be seen, so always carry out operations carefully.
When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and
use the engine as a brake while applying the foot brake intermittently (depress the brake
intermittently several times). If necessary, lower the bucket to the ground to stop the machine.
The load varies greatly according to the characteristics of the snow, so adjust the load accordingly
and be careful not to let the machine slip.

1-15
 A WARNING: For reasons of safety, always
7. PRECAUTIONS DURING OPERATION follow these safety precautions.

Do not operate the machine on soft ground. It is difficult to get the machine out again.
1
Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these
areas collapse under the mass or vibration of your machine, it could fall or tip over and this could
result in serious injury or death. Remember that the soil after heavy rain, blasting, or earthquakes
is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the mass or
vibration of your machine and cause your machine to tip over.
Install the head guard (FOPS) when working in areas where there is danger of falling stones.
Install the ROPS and wear the seat belt when working in areas where there is danger of falling
rocks or of the machine turning over.

PRECAUTIONS WHEN WORKING ON SLOPES

When working on slopes, there is danger that the machine may lose its balance and turn over
when the swing or work equipment are operated. Always carry out these operations carefully.
Do not swing the work equipment from the uphill side to the downhill side when the bucket is
loaded. This operation is dangerous.
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.
Piled soil on slope + See’“12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS”.

INCORRECT CORRECT

AD34136A

1-16
A y$RNNFs Fsisi;;~ follow these safety precautions may lead
. 7. PRECAUTIONS DURING OPERATION

Park the machine on level ground where there is no danger of falling rocks or landslides, or of
flooding if the land is low, and lower the work equipment to the ground.
If it is necessary to park the machine on a slope, set blocks under the tracks to prevent the machine
from moving, then dig the work equipment into the ground.
After stopping the engine, operate the right work equipment control lever several times to the
RAISE and LOWER positions to release the remaining pressure in the hydraulic circuit.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other
necessary signs to ensure that passing traffic can see the machine clearly, and park the machine
so that the machine, flags, and fences do not obstruct traffic.
Parking procedure + See “12.16 PARKING MACHINE”.
When leaving the machine, set the safety lock lever @to the LOCK position, stop the engine, and
use the key to lock all the equipment. Always remove the key and take it with you.
Work equipment posture -( See “12.16 PARKING MACHINE”.
Locks + See “12.20 LOCKING”.
Always close the door of the operator’s compartment.
CORRECT Method of locking

Thrust the bucket AD3413lA AN364 15E

After completing operations, remove all water, snow, or mud stuck to the wiring harness,
connector 0, switches, or sensors, and cover these parts.
If the water freezes, it will cause malfunctions of the machine when it is next used, which may
lead to unexpected accidents.

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.

Operate the control levers to relieve the hydraulic pressure (raise to above the set pressure for
the hydraulic circuit and release the oil to the hydraulic tank) to warm up the oil in the hydraulic
circuit. This ensures good response from the machine and prevents malfunctions.

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different
power source. There is danger that this will ignite the battery.
When charging or starting the engine with a different power source, melt the battery electrolyte
and check for leakage of battery electrolyte before starting.
Battery charge rate - See “14. COLD WEATHER OPERATION”.

AE305820
 a )4M&M~;e Fciereasons cf safety, always
7. PRECAUTIONSDURING OPERATION ty precautions.

7.3 TRANSPORTATION

When transporting the machine, follow the relevant rules and regulations, and take steps to ensure
safety.

When selecting the transportation route, take into consideration the maximum width, height, and
weight of the machine when loaded on the trailer.
Height, width, weight when loaded + See ‘13. TRANSPORTATION”.

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

For machines equipped with a cab, always lock the door securely.

The machine can be divided into units for transportation, so please contact your Komatsu
distributor when transporting.
Transportation posture -) See “13. TRANSPORTATION”.

1-18
A I&l;RN;INt; Fai;ai;o follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION

7.4 BATTERY
-I BATTERY HAZARD PREVENTION- 1
Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken
handling can lead to serious injury or fire. For this reason, always observe the following-. precautions.
Never bring any lighted cigarette or flame near the battery:

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

If you spill acid on your clothes or skin, immediately flush the area with large amounts of water.

Battery acid could cause blindness if splashed into the eyes. If acid gets into your eyes, flush them
immediately with large quantities of water and see a doctor at once.

if you accidentally drink electrolyte, drink a large quantity of water or milk, beaten egg or vegetable
oil. Call a doctor or poison prevention center immediately.

Before working with batteries, stop the engine and turn the starting switch to the OFF position.

Avoid short-circuiting the battery terminals (between the positive @ terminal and negative @
terminal) through accidental contact with metal objects, such as tools.

When installing the battery, connect the positive @ terminal first, and when removing the battery,
disconnect the negative @ terminal (ground side) first.

When removing or installing, check which is the positive @terminal and negative @terminal, and
tighten the nuts securely.
If the battery electrolyte is near the LOWER LEVEL, add distilled water. Do not add distilled water
above the UPPER LEVEL.

When cleaning the top surface of the battery, wipe it with a damp cloth. Never use gasoline,
thinner, or any other organic solvent or cleaning agent.

Tighten the battery caps securely.

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

Always remove the battery from the chassis before charging it.

cE9
@a dk
Qy2

@
AE305830 A0055110

1-19
 A WARNING: For reasons of safety, always
7. PRECAUTIONSDURING OPERATION follow these safety precautions.

4 STARTING WITH-1
If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always
do as .follows.
Carry out the starting operation with two workers (with one worker sitting in the operator’s seat).

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.

Be sure to connect the positive @ cable first when installing the booster cables. Disconnect the
ground or negative 0 cable first when removing them.

The final ground connection is the connection of the ground to the engine block of the problem
machine. However, this will cause sparks, so be sure to connect it as far as possible from the
battery.
Starting procedure when using booster cables - See “16.5 IF BAlTERY IS DISCHARGED”.

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.
INCORRECT

1 CHARGING-
I 1

If the battery is handled incorrectly when it is being charged, there is danger that the battery may
explode, so follow the instructions in HANDLING BATTERY and in the instruction manual for the
charger, and always observe the following precautions.
Carry out the charging in a well-ventilated place, and remove the battery caps. This disperses the
hydrogen gas and prevents explosion.
Set the voltage on the charger to match the voltage on the battery to be charged. If the voltage
setting is wrong, it will cause the charger to overheat and catch fire, and this may lead to an
explosion.
Connect the positive @ charging clip of the charger to the positive @ terminal of the battery, then
connect the negative 0 charging clip to the negative @terminal of the battery. Be sure to tighten
both terminals securely.
If the battery charge is less than l/IO of the rated charge, and high speed charging is carried out,
set to a value below the rated capacity of the battery.
If there is an excessive flow of charging current, it may cause leakage or evaporation of the
electrolyte, which may catch fire and explode.

INCORRECT

l-20
A ~;“,“~M~; Faiiaito follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION

7.5 TOWING

Injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in
the selection of the wire rope, so always do as follows.

Do not tow in a different way from the method given in the section “16.3 METHOD OF TOWING
MACHINE”.

Always wear leather gloves when handling wire rope.

When carrying out the preparation for towing with another worker, agree on signals before
starting the operation.

If the engine on the problem machine will not start or there is a failure in the brake system, please
contact your Komatsu distributor for repairs.

It is dangerous to tow a machine on a slope, so choose a place where there is a gradual slope.
If there is no place with a gradual slope, carry out work to make the slope as small as possible.

If a problem machine is towed by another machine, ALWAYS use a wire rope with a sufficient
towing capacity for the weight of the problem machine.

Do not use a wire rope which has cut strands @, kinks @, or reduced diameter 0.

7.6 LIFTING OPERATIONS

1 PROHIBITIONS FOR LIFTING OPERATIONS 1
Do not use the work equipment to carry out lifting operations.
In particular,do not do the following.
l Do not weld a hook to the bucket to lift a load.

l Do not fit a wire rope to the bucket teeth to lift a load.

l Do not wind a wire rope directly around the boom or arm to lift a load.

1-21
8. PRECAUTIONS FOR A gN!l;W&
Fc;sreasons of safety, always
MAINTENANCE ty pracautlons.

8.1 BEFORE CARRYING OUT MAINTENANCE

NOTIFICATION OF FAILURE
Carrying out maintenance not described in the Komatsu operation and maintenance manual may
lead to unexpected failures.
Please contact your Komatsu distributor for repairs.

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 working on the machine. Attach additional warning tags
around the machine if necessary.

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 death.

Warning tag Part No. 09963-03000

AE167640
J

4 CLEAN BEFORE INSPECTfoNAND

Clean the machine before carrying out inspection and maintenance. This will ensure that dirt does
not get into the machine and will also ensure that maintenance can be carried out safely.

If inspection and maintenance are carried out with the machine still dirty, it will be difficult to find
the location of problems, and there is also the danger that you will get dirty or mud in your eyes,
and that you will slip and injure yourself.

When washing the machine, always do as follows.

Wear non-slip shoes to prevent yourself from slipping on the wet surface.

When using high-pressure steam to wash the machine, always wear protective clothing.
This-will protect you from being hit by high-pressure water, and cutting your skin or getting mud
or dust into your eyes.

Do not spray water directly on to the electrical system (sensors, connectors) 0. If water gets
into the electrical system, there is danger that it will cause defective operation and malfunction.

1-22
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 8. PRECAUTIONSFOR MAINTENANCE

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other
substances that will cause you to slip. Always keep the work place clean the tidy to enable you to
carry out operations safely.
If the work place is not kept clean and tidy, there is danger that you will trip, slip, or fall over and
injure yourself.

44
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.

{ RADIATOR WATER LEVEL 1

When inspecting the radiator water level, stop the engine, and wait for the engine and radiator
to cool down. Check the water level in the sub-tank. Under normal conditions, do not open the
radiator cap.
If there is no sub-tank, or the radiator cap must be removed, always do as follows.
Wait for the radiator water temperature to go down before checking the water level.
(When checking if the water temperature has gone down, put your hand near the engine or
radiator and check the air temperature. Be careful not to touch the radiator or engine.)
Release the internal pressure before removing the radiator cap, and remove the radiator cap
slowly.

STOP ENGINE BEB

MAINTENANCE
When carrying out inspection and maintenance, park the machine on level ground where there
is no danger of failing rocks or land slides, or of flooding if the land is low, then lower the work
equipment to the ground and stop the engine.

Operate the right work equipment control lever several times to the RAISE and LOWER positions
to release the remaining pressure in the hydraulic circuit, then set safety lock lever @ to the LOCK
position.

Put blocks under the track to prevent the machine from moving.

The worker carrying out the maintenance should be extremely careful not to touch or get caught
in the moving parts.

OFF

BlOCkS 1034 13% AW34987B AN364156

1-23
 A )Vf~$J;M~e Foiereasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE ty precautions.

4 SAFETY DEVICES FOR -1

When carrying out inspection and maintenance with the work equipment raised, fit stand @ securely
to the boom to prevent the work equipment from coming down.
Place the work equipment control levers at HOLD, and set safety lock lever @ to the LOCK position.

AU'364158

PROPER TOOLS
Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause
personal injury.
Broken pieces of chisels or hammers could fly into your eyes and blind .you.
Tools -) See ‘21.1 INTRODUCTlON OF NECESSARY TOOLS”.

Hoses and other parts of the fuel, hydraulic, and brake system are critical parts for ensuring safety,
so they must be replaced periodically.
Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry out
replacement.
l Replace these components periodically with new ones, regardless of whether or not they appear
to be defective.
These components deteriorate over time, and can cause fire because of oil leakage or failure in
the work equipment system.
l Replace or repair any such components if any defect is found, even though they have not reached
the time specified.
Replacement of safety critical parts +
See “q. PERIODIC REPLACEMENT OF SAFETY CRlTlCAL PARTS”.

l-24
A E;RMMt; Fa&-t$ follow these safety precautions may lead
8. PRECAUTIONS FOR MAINTENANCE

1 USE OF LIGHTING 1
When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica-
tions.
If such lighting equipment is not used, there is danger of explosion.

If work is carried out in dark places without installing lighting, there is danger of injury, so always
install proper lighting.

Even if it is dark, do not use a lighter or flame instead of lighting. There is danger of starting a
fire, and if the battery gas ignites, it may cause an explosion.

When using the machine as the power supply for the lighting, follow the instructions in this
Operation and Maintenance Manual.

A0055160

4 PREVENTION OF FIRE 1
There is danger of the fuel and battery gas catching fire during maintenance, so always follow the
precautions below when carrying out maintenance.
Store fuel, oil, grease, and other flammable materials away from flame.

Use non-flammable materials as the flushing oil for cleaning parts. Do not use diesel oil or
gasoline. There is danger that they will catch fire.

Never smoke when carrying out inspection or maintenance. Always smoke in the prescribed place.

When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica-
tions. Never use lighters or matches as lighting.

When carrying out grinding or welding operations on the chassis, remove any flammable
materials to a safe place.

Be sure that a fire extinguisher is present at the inspection and maintenance point.

1-25
 a ;fU41;;Me Fo;ereasons of safety, always
8. PRECAUTIONSFOR MAINTENANCE ty precautrons.

8.2 DURING MAINTENANCE

1 PERSONNEL }
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel
into the area. If necessary, employ an observer.
Extra precaution should be used when grinding, welding, and using a sledge-hammer.

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

l Do not allow anyone other than the workers close to the machine or attachment.

l Place attachments that have been removed from the machine

in a safe place so that they do not fall. Put a fence around the
attachments, and set up No Entry signs to prevent unauthorized
persons from coming close.

4
A0055130

Stop the machine on firm, level ground, and always lower all work equipment to the ground before
performing service or repairs under the machine.

Always block the track shoes securely.

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

shoes are off the ground and the machine is supported only by
the work equipment. Never work under the machine if the
machine is poorly supported.

WORK ON TOP OF MACHINE

When carrying out maintenance on top of the machine, make sure that the footholds are clean
and free of obstructions, and follow the precautions below to prevent yourself from falling.
l Do not spill oil or grease.
l Do not leave tools lying around.
l Mind your step when you are walking.

Never jump down from the machine. When getting on or off the machine, always use the steps
and handrails, and maintain three-point contact (both feet and one hand or both hands and one
foot) at all times.

Use protective equipment if necessary.

1-26
A &VtR;;Et; Pa&x$ follow these safe*/ precautions may lead
8. PRECAUTIONSFOR MAINTENANCE

When carrying out maintenance with the inspection cover open, lock it securely with a lock bar.
If maintenance is carried out with the inspection cover open and not locked in position, it may close
suddenly if knocked or blown by the wind, and may cause injury to the operator.

1 MAINTENANCE WITH ENGINE RUNNING 1

To prevent injury, do not carry out maintenance with the engine running. If maintenance must be
carried out with the engine funning, 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.

When carrying out operations near rotating parts, there is danger of being caught in the parts, so
be extremely careful.

When cleaning inside the radiator, set safety lock lever @ to the LOCK position to prevent the work
equipment from moving.

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 touch the fan blade or fan belt with any tool or any part of your body. There is danger of
serious injury.

DO NOT DROP
l When opening the inspection window or tank oil filler to carry out inspection,-be careful not to
drop any nuts, bolts, or tools inside the machine.
If such parts are dropped into the machine, it will cause breakage of the machine, mistaken
operation, and other failures. If you drop any part into the machine, always be sure to remove it
from the machine.

l When carrying out inspection, do not carry any unnecessary tools or parts in your pocket.

When using a hammer, always wear safety glasses, safety helmet,

and other protective clothing, and put a brass bar between the
hammer and the part being hammered.
If hard metal parts such as pins, edges, teeth, or bearings are hit
with a hammer, there is danger that broken pieces might fly into
your eyes and cause injury.

AE3058BO

l-27
 A WARNING: For reasons of safety, always
8. PRECAUTIONSFOR MAINTENANCE follow these safety precautions.

REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with
a proper equipment. Gas is generated, and there is danger of fire or electrocution when carrying out
welding, so never allow any unqualified personnel to carry out welding.
The qualified welder must follow the precautions given below.
l Disconnect the battery terminals to prevent explosion of the battery.
l Remove the paint from the place being welded to prevent gas from being generated.
l If hydraulic equipment or piping, or places close to these are heated, flammable vapor or spray
will be generated, and there is danger of this catching fire, so avoid applying heat to such places.
l If heat is applied directly to rubber hoses or piping under pressure, they may suddenly burst, so
cover them with fireproof sheeting.
l Always wear protective clothing.
l Ensure that there is good ventilation.
l Clear up any flammable materials, and make sure that there is a fire extinguisher at the workplace.

When repairing the electrical system or when carrying out electrical welding, remove the negative
0 terminal of the battery to stop the flow of current.
Handling battery + See “16.5 IF BATTERY IS DISCHARGED”.

AE309890

4 WHEN ABNORMALITY IS LOCATED 1

l If any abnormality is found during inspection, always carry out repairs. In particular, if the machine
is used when there is any abnormality in the brakes or work equipment systems, it may lead to
serious accident.

l Depending on the type of failure, please contact your Komatsu distributor for repairs.

RULES TO FOLLOW WHEN ADDING FUEL OR OIL

If any flame is brought close to fuel or oil, there is danger that it will catch fire, so always follow the
precautions below.
l Stop the engine when adding fuel or oil.
l Do not smoke.
l Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
i l Always tighten the cap of the fuel and oil fillers securely.
l Always add fuel and oil in a well-ventilated place.

l-28
A lV$Fl;;l~; Fai;gtc~ follow these safety precautions may lead
8. PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO

ADJUST TRACK TENSION
Grease is pumped into the track tension adjustment system under high pressure.
If the specified procedure for maintenance is not followed when making adjustment, valve @ may
fly out and cause damage or personal injury.

When loosening grease drain valve 0, never loosen it more than one turn.

Never put your face, hands, feet, or any other part of your body directly in front of any grease
drain valve.
Adjusting track tension + See “24.3 WHEN REQUIRED”.

l
HANDLING HIGH-PR
-3
,’ “)
,’
,’
Aw55200

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may
lead to personal injury or damage. If any damaged hoses or loose bolts are found, stop work and
contact your Komatsu distributor for repairs.

l Replacing high-pressure hoses requires a high level of skill, and the torque is determined
according to the type of hose and size, so please do not carry out replacement yourself. Ask your
Komatsu distributor to carry out replacement.

{ PRECAUTlONS WlTH HIGH-PRESSURE]

When inspecting or replacing high-pressure 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 damage, so always do as follows.
For details of the method of releasing the pressure, see “8.1 BEFORE CARRYING OUT MAINlE-
NANCE, STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE”. Never carry
out inspection or replacement before releasing the pressure completely.

Wear safety glasses and leather gloves.

If there is any leakage from the piping or hoses, the piping, hoses, and the surrounding area will
be wet, so check for cracks in the piping and hoses and for swelling in the hoses.
If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs.

If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.

iNCORREgp COFmE;_

A0055180 A0055190

1-29
 A g41J~f;~ Foiereasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE ty precautrons.

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT

r HIGH TEMPERATURE
Immediately after stopping operations, the engine coolant, oil at all parts, the exhaust manifold, and
the muffler are at high temperature.
In this condition, if the cap is removed, or the oil is drained, or the filters are replaced, this may result
in burns or other injury. Wait for the temperature to go down, then carry out the inspection and
maintenance in accordance with the procedures given in this manual.
Cleaning inside of cooling system -) See “24.3 WHEN REQUIRED”.
Checking coolant level, oil level in hydraulic tank + see “12.12 CHECK BEFORE STARTING”.
Checking lubricating oil level, adding oil + see “12.1 CHECK BEFORE STARTING,
24.5-7 PERIODIC MAINTENANCE”.
Changing oil, replacing filters + see ‘24.7-12 PERIODIC MAINTENANCE”.

1 CHECKS AFTER INSPECTION AND MAINTENANCE 1

Failure to carry out inspection and maintenance fully. or failure to check the function of various
maintenance locations may cause unexpected problems and may even lead to personal injury or
damage, so always do as follows.
Checks when engine is stopped
l Have all the inspection and maintenance locations been checked?
l Have all the inspection and maintenance items been carried out correctly?
l Have any tools or parts dropped inside the machine? It is particularly dangerous if they get
caught in the lever linkage.
l Has water and oil leakage been repaired? Have bolts been tightened?

Checks when engine is running

For details of checks when the engine is running, see “8.2 DURING MAINTENANCE, MAINTE-
NANCE WlTH ENGINE RUNNING”, and be extremely careful to ensure safety.

Do the inspection and maintenance locations work normally?

Is there any oil leakage when the engine speed is raised and load is applied to the hydraulic
system?

WASTE MATERlALS
To prevent pollution, particularly in places where people or animals are living, always follow the
procedures given below.
Never dump waste oil in a sewer system, rivers, etc.

Always put oil drained from your machine in containers. Never INCORRECT
drain oil directly onto the ground.

Obey appropriate laws and regulations when disposing of

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

l-30
 POSITION FOR A7TACHlNG SAFETY LABELS
9.

with
them again or replace them
ls clea n. tf they are lost or damaged, attach
Always keep these labe
a new label. in the same way
d below, so handle them
r labels in add ition to the safety labels liste t labels are available;
There are othe English. To find out wha
lab& may be ava ilab le in languages other than
Safety
distributor.
contact your Komatsu
SAFETY LABELS
POSITION FOR AITACHING

l-
9. POSITION FORAlTACHfNG SAFETYLABELS

1. Warnings for operation, inspection and 3. Warnings for leaving operator’s seat
maintenance (09654-03001)
(09651-03001)
~_~~

A WARNING A WARNING
Improper operation and main-
To avoid hiing unlocked
tenance can cause serious
operationlevers, lower equipment
injuly or death. to ground and move SAFETY LOCK
LEVER (located near seat) to
Read manual and labels before LOCK position before dtanding
operation and maintenance. up from operator’s seat.
Follow instructions and wam-
Sudden and unwanted machine
ings in manual and in labels on movementcan cause serious
machine. injury or death.
09654-03001 I
Keep manual in machine cab
near operator.
Contact Komatsu distributor
for a replacement manual.
09651-03001,

2. Warnings before operating machine 4. Warnings for high voltage

(09802-03000) (09801-03001~

A WARNING A DANGER

1-32
 9. POSITION FOR ATTACHING SAFETY LABELS

5. Warnings for hot oil hazard 7. Warnings for handling accumulator

(09653-03001) (09659-53000)

a WARNING
HOtOilhazard.

To preventhot oil fromspurt-

inawt:
. Turn engineoff.
. Allow oil to cool.
l Skmly&osencaptodiie
pressurebefore removing.

6. Warnings for hot water hazard 8. Warnings for adjusting track tension
(09668-03001) (09657-03003)

[ A WARNING 1 A WARNING13
Compressed spring lubri-
Hot water hazard. cator and grease are
under hazardous high
pressure and can cause
To prevent hot water from serious injury or death.
spurting out: . When adjusting track tension
only turn lubricator ONE TURh
l Turn engine off. tuming Iubrkator further could
0 Allow water to cool. cause lubricator and grease to
fly off and hurt you.
0 Slowly loosen cap to relieve
pressure before removing. See manual for adjustment
instructions.
. When loosening track shoe, if
it dose not loosen after turning
lubricator ONE TURN ask
Komatsu dealer or distributor
to disassemble.
096!57-v3oo3~

l-33
9. POSITION FOR ATTACHING SAFETY LABELS

9. Warnings for battery cable 12. Keep off swing area

(09808-03000) (09133-23000)

A WARNING
Improperuseofboostercables
andbatterycablescancause \ Keep off swing area /
anexpbsionresulfinginsed-
ousinjutyordeath.

l Follow instmtions in
manual when using booster
cable andbattwycables.
os60843wo-

10. Caution while engine is running 13. Warnings for battery

(09667-03001) (09664-30082)

A CAUTION A WARNING
EXPLOSIVE GASES

While engine is running:

1. Do not open cover.
2. Keep away from fan and
fan-belt.
0966743001

11 Explanation of escape method in

emergency (2OY-00-228803

_ .-. --
EMERGENCY EXIT-
'I'/~'asla.z5a4taSaa .
fiSIJ-?i3~?8<bb
PULL RING AND REMOVE RUBBER PUSH CORNER OF GLASS STORONGLY
 9. POSITION FOR ATTACHING SAFE-I-Y LABELS

9.2 CONTENT AND USE OF WARNING PLATES

1. Warning to prevent operation during maintenance (09963-03000)
Hang this warning plate on the controls in the operator’s compartment.

DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963-03000 J

1-35
OPERATION
10. GENERAL VIEW

10 1 GENERAL VIEW OF MACHINE

‘If directionsare indicatedin this section, they refer to the directions shown by the arrows in the
diagram below.

AX371450

1. Bucket 6. Boom cylinder

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

2-2
10.2 GENERAL VIEW OF CONTROLS AND GAUGES

;;

17
18
19
20
21
22
23
24
25
26
27
28

AU371460

1. Air conditioner control panel 2 16. Engine emergency stop lamp

2. Lubrication switch 77. Auto-greasing caution lamp (if equipped)
3. Safety lock lever 18. Ladder caution lamp
4. Air conditioner control panel 1 19. Fuel control dial (F. engine)
5. Swing parking brake switch 20. Starter selector switch
6. Cigarette lighter 21. Fuel control dial (R. engine)
7. Left work equipment control lever 22. Lamp switch
8. Car radio 23. Step light switch
9. Horn switch 24. Room lamp switch
10. Right work equipment control lever 25. Machine push-up switch
11. Starting switch 26. Fog lamp switch
12. Travel lever 27. Rotating lamp switch
13. Monitor 28. Shockiess boom control switch
14. Health monitor 29. Alarm buzzer stop switch
15. Preheating switch 30. Wiper switch

2-3
 ; 17
6 18
5 - _
tn
-I.

IY

20

21

22

AW371470

1. Engine water temperature, hydraulic oil 12. Display (for clock and fault indication)
temperature display selector switch 13. Service meter
2. Heavy life switch 14. Fuel gauge
3. Working mode selector switch 15. Fuel level monitor
4. Air cleaner clogging monitor (R. engine) 16. Hydraulic filter clogging monitor
5. Engine oil pressure monitor (FL engine) 17. Hydraulic oil level monitor
6. Charging level monitor (R. engine) 18. Radiator water level monitor
7. Air cleaner clogging monitor (F. engine) 19. Engine pre-heating monitor
8. Engine oil pressure monitor (F. engine) 20. Swing lock monitor
9. Charging level monitor (F. engine) 21. Engine oil level monitor
10. Engine water temperature, hydraulic oil 22. Auto-deceleration switch
temperature monitor
11. Engine water temperature gauge
hydraulic oil temperature gauge

2-4
11. EXPLANATION OF COMPONENTS

The following is an explanation of the devices needed for

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

11.l MACHINE MONITOR

An C

AW371480

This monitor system consists of monitor lamp groups (@, @N

-
and meter group Q.

A. BASIC CHECK ITEMS (11.1.1)

This displays the basic items that should be checked before
starting the engine.
If there is any abnormality, the appropriate monitor lamp will
flash.

NOTICE
If engine is started, lamp will go off even if there is an abnor-
malii.
When carrying out checks before starting, do not simply rely on
the monitor. Always refer to the periodic maintenance items or “12.
OPERATION” to carry out the checks.

2-5
11. EXPLANATION OF COMPONENTS

8. CAUTION ITEMS (11.1.2)

If these monitor items flash, checkand repair the appropriate

IAlocation as soon as possible.
CAUT’oN

These are items which need to be observed while the engine is

running. If any abnormality occurs, items which need to be repaired
as soon as possible are displayed.
If there is any abnormality, the appropriate monitor lamp will
flash to indicate the location of the abnormality.

C. EMERGENCY STOP ITEMS (11.1.31

A CAUTION
ff these monitor items flash, stop operationsimmediately,then
checkand repair the appropriate location.

These are items which need to be observed while the engine is

running. If any abnormality occurs, items which need to be repaired
immediately are displayed.

D. METER DISPLAY PORTION (11.1.4)

This portion consists of pm-heating monitor, swing lock monitor,
engine water temperature and hydraulic oil temperature gauge, fuel
gauge, service meter and display.

E. SWITCHES (11.1.5)
This selectworking mode, and time setting of clock.

2-6
 11. EXPLANATION OF COMPONENTS

--i--l
AW371490

11.1.1 A: BASIC CHECK ITEMS

NOTICE
Do not rely on the “BASIC CHECK lTEMS” only for the check
before starting
Always refer to the periodic maintenance items or “12. OPERA-
TION” to carry out the checks.

1. RADIATOR WATER LEVEL

This warns that the radiator cooling water level is too low.
I 1
If the monitor lamp flashes, check the cooling water level in the
AD314020
radiator and add water.
i
2. ENGINE OIL LEVEL

l-l
This warns that the oil level in the engine oil pan is too low.
0

cc>
If the monitor lamp flashes, check the oil level in the engine oil pan,
and add oil.
0
1 AD314030

3. HYDRAULIC OIL LEVEL

This warns that the hydraulic oil level is too low.
lf the monitor lamp flashes, check the hydraulic oil level, and add oil.
/

2-7
11. EXPLANATION OF COMPONENTS

11.1.2 B: CAUTION ITEMS

A CAUTION
If the caution monitor lamp flashes, repair the problem as soon
as possible.

1. CHARGE LEVEL
This monitor indicates an abnormality in the charging system

0
while the engine is running.
If the monitor lamp flashes, check the V-belt tension. If any
abnormality is found, see “16.6 OTHER TROUBLE”.
-+
rl
I A0313350

REMARK
While the starting switch is ON, the lamp will remain lit and will
go off once the engine is started.

2. FUEL LEVEL
If the fuel drops below 169 liters (44.6 US gal, 37.5 UK gal), the
lame will flash. TOD UD the fuel before this. I I

_I
3. AIR CLEAN CLOGGING
If the air cleaner element clogged, the monitor lamp flashes.
Stop the engine, check the air cleaner element and clean it.

A0313370

4. HYDRAULIC FILTER CLOGGING MONlTOR

I I
This monitor indicates clogging of the hydraulic filter.
If the monitor lamp flashes, stop the engine and check, clean the
filter element.

2-8
 11. EXPLANATION OF COMPONENTS

11.1.3 C: EMERGENCY STOP ITEMS

If any monitor lamp flashes, stop the engme or run It at low

idling, and take the following action.
rA cAuT’oN/

1. ENGINE WATER TEMPERATURE, HYDRAULIC OIL TEMPERA-

TURE
If the temperature of the engine cooling water and hydraulic oil
temperature become abnormally high, the monitor lamp flashes.

lf the front engine cooling water temperature is abnormally high:

The overheat prevention system is automatically actuated and
the engine speed goes down.
Lamp @ of the display selector switch lights up and the cooling
water temperature of the front engine is displayed on the engine
I 1

1 1
cooling water and oil temperature gauge.

lf the rear engine cooling water temperature is abnormally high: F R

The overheat prevention system is automatically actuated and
the engine speed goes down.
Lamp @I of the display selector switch lights up and the cooling
water temperature of the rear engine is displayed on the engine
cooling water and oil temperature gauge.

lf the hydraulic oil temperature is abnormally high:

Lamp @ of the display selector switch lights up and the hydraulic
oil temperature is displayed on the engine cooling water and oil
temperature gauge.

1 1
2. RADIATOR WATER LEVEL
If the radiator water level drops, the monitor lamp flashes. Stop

0
the engine, check the radiator water level, and add water if neces-
sary.

3. ENGINE OIL PRESSURE

If the engine oil pressure drops below the normal pressure, the @ J
monitor lamp flashes. At this item, stop the engine and inspect it
LO314020
according to “16.6 OTHER TROUBLE.*

REMARK
While the starting switch is ON, the lamp remains lit and goes
off once the engine is started. When the engine starts, the buzzer
may sound for a short time, however, this does not indicate a fault.

REMARK
l Stop the machine on level ground and check the monitor.
I A0313410 I
l Stop the engine, then turn the starting switch to the ON position
and check that the monitor lights up for 3 seconds.
If it does not light up, please contact your Komatsu distributor
to have the monitor inspected.

2-9
11. EXPLANATION OF COMPONENTS

11.1.4 D: METER DISPLAY PORTION

A1371520

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

1. ENGINE PRE-HEATING MONITOR

This monitor lamp indicates the pm-heating time required when
starting the engine at an ambient temperature below 0°C.
The monitor lamp lights when the starting switch is turned to
I n I
HEAT position and flashes after about 30 seconds to show that the
pre-heating is completed. (The monitor lamp will go off after about
IO seconds.)
I I
AD313430

2. SWING LOCK LAMP

This informs the operator that the swing lock is being actuated.

cl
Actuated: Lights up
When the swing parking brake switch is turned ON (ACTUATED), 0
the monitor lamp lights up.
When the swing parking brake release switch is turned on, this
monitor lamp flashes.

I
d!b
0
AD313440
REMARK
A disc brake is installed in the swing motor to mechanically stop
motor rotation.
The brake is always applied while the swing lock is actuated.

2-10
 11. EXPLANATION OF COMPONENTS

METERS
3. ENGINE WATER TEMPERATURE GAUGE - HYDRAULIC OIL TEM-
PERATURE GAUGE
This gauge indicates the engine cooling water temperature or
hydraulic oil temperature.

The content of the display is switched by switches a,@, and 0.

0 This displays the front engine water temperature.
0 This displays the rear engine water temperature.
0 The hydraulic oil temperature is displayed only while the switch
is being pressed.

When the switch is released, the display returns to the display

that was shown before the switch was pressed.
The green range should light up during normal operations. If the
red range lights up during operations, monitor @ will flash and the
alarm buzzer will sound at the same time.
The overheat prevention system is actuated only when the
cooling water temperature is abnormal.
If the cooling water temperature or hydraulic oil temperature is
abnormally high, applicable lamp 0, 0, or @ flash and the tempera-
ture of that item is displayed on the meter.

The overheat prevention system acts as follows.

When red range @ flash:
Engine speed is lowered further to low idling, engine water
temperature -monitor @ flashes, and alarm buzzer sounds as the
same time.

The overheat prevention system is actuated until the tempera-

ture enters the green range.

When red range @ lights, if the engine water temperature is

reduced and the fuel control dial is turned to the low idling position, 1 w4iw&wB
the overheat prevention system will be canceled.

4. FUEL GAUGE
This gauge indicates the amount of fuel in the fuel tank.
een
If the fuel level is normal during operation, the green range will
light up.
If only the red range lights up during operation, there is less than
169 liters (44.6 US gal, 37.5 UK gal) of fuel remaining in the tank, so
check and add fuel.
When red range @ lights up: Fuel gauge monitor @ flashes.

After the starting switch is turned ON, the correct level may not
be displayed for a moment, but this does not indicate any abnormal-
ity.

When stopping the engine, turn the starting switch ON and check
that the monitor lamps on items A, B, C and D and the meters light
up*

2-11
I 1. EXPLANATION OF COMPONENTS

5. DISPLAY
When the starting switch is ON, the time and service meter
reading is displayed if the condition is normal. If the condition is
abnormal, the content of the failure is displayed.
When setting the time, the 6 symbol flashes. 688~88
If there is a failure on the machine, the type of failure is displayed
when the starting switch is turned ON. The failures all flash in turn AM101350
L
on the display.

Monitor display Failure mode

E02 TVC system error
E03 Swing brake system error
E05 Governor system error
EOE Continuation of work impossible
E23 VSM controller system error

If these displays flash, see “16.5.4 ELECTRONIC CONTROL SYS-

TEM”.

6. SERVICE METER
This displays the accumulated hours of operation of the ma-
chine.
Use the display to determine the intervals for periodic mainte-
nance.
The service meter will advance while the engine is running even
B88888.8h
if the machine is not moving.
The service meter reading advances by 1 for every hour that the
AM101380
engine is running, regardless of the engine speed.

7. GREASE PRESSURE GAUGE

This indicates the grease pressure when greasing.
The gauge should indicate 4.9 - 19.6 MPa (50 - 200 kg/cm2, 710
- 2940 psi) when greasing.

REMARK
l If the pressure is below 4.9 MPa (50 kg/cm*, 710 psi), the grease
can is empty, so replace the grease can.
l If the pressure is above 19.6 MPa (200 kg/cm2, 2840 psi), there
is probably clogging. For details, see “24.5 EVERY 10 HOURS
SERVICE”.

2-12
 11. EXPLANATION OF COMPONENTS

11.1.5 E: SWITCHES

)F 2
-

AW371560

1. WORKING MODE SELECTOR SWITCH (Basic mode)

This switch is used to set the movement or power for the work
equipment. By selecting the mode to match the working conditions,
it is possible to carry out operations more easily. I

DH lights up: Powerful operation for heavy-duty operations

H lights up: Normal operations
G lights up: Light-duty operations AA307320

When starting the engine, H (heavy-duty operation) mode is

automatically selected. Each time the switch is pressed, the mode 1
selection changes. 4

2. AUTO-DECELERATION SWITCH (Selection switch)

This switch acts to activate the function that automatically low-
ers the engine speed and reduces fuel consumption when the
control lever is at neutral.
ON lights up: Auto-deceleration is actuated.
OFF: Auto-deceleration is canceled.

Each time the switch is pressed, the auto-deceleration is actu-

ated or canceled.

3. HEAVY LIFT SWITCH

Operate this switch to increase the lifting power during opera-
tions.
When the switch is turned ON during independent operations of -

the boom, the boom lifting power is increased.

2-13
Il. EXPLANATION OF COMPONENTS

11.2 SWITCHES

AU371510

1. STARTER SELECTOR SWITCH

When starting engines, select the starting operation engine.

Front enein

2-14
 11. EXPLANATION OF COMPONENTS

2. STARTING SWITCH
This switch 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 cab lamp and clock, are all turned off and the
engine is stopped.

ON position
Eiectric current flows in the charging and lamp circuits.
Keep the starting switch key at the ON position while the engine is
running.
Electricity flows to all electrical circuits except the START and HEAT
circuit.

START position
This is the engine-start position. Keep the key at this position during
cranking. Immediately after starting the engine, release the key
which will automatically return to the ON position.

3.PREHEATING SWlTCH
Use this switch when starting the engine in cold weather.
HEAT
@ When the switch is pressed, the preheating monitor lights up.
@ Keep the switch pressed until the preheating monitor goes out.
@ When the preheating monitor goes out, release the switch
immediately.
@ When the switch is released, it will return to the OFF position.
Turn the starting switch immediately to the START position to
Aw37llB
start the engine.
I
4.FUEL CONTROL DIAL (FRONT ENGINE)
(WlTH AUTO-DECELERATION MECHANISM)
This adjusts the engine speed and output.
@ Low idling (MIN): Turned fully to the left
@ Full speed (MAX): Turned fully to the right

5. FUEL CONTROL DIAL (REAR ENGINE)

This adjusts the engine speed and output.
@I Low idling (MINI: Turned fully to the left
@ Full speed (MAX): Turned fully to the right

2-15
11. EXPLANATION OF COMPONENTS

6. CIGARETTE LIGHTER
This is used to light cigarettes. To use, push the lighter in. After
a few seconds it will spring back.
Pull out the lighter and light your cigarette.
By removing the cigarette lighter, the socket is available as a
power source for the yellow flashing lamp. Max. current is 3.5 A (85
WI.

I AM069410 I

7. LAMP SWKCH
This switch is used to turn on the front lamps, working lamps,
additional lamp at the top front of the cab, rear lamps, and monitor
lighting.

8. STEP LIGHT SWlTCH

Use this switch when getting off the machine at night.
l When the switch is pressed, the step light will light up for
approx. 60 seconds.
l Even if the starting switch key is at the OFF position, the step
light will light up for approx. 60 seconds when the switch is
pressed.

9. SWlNG PARKING BRAKE SWITCH

A WARNING.
l When the machine is traveling under its own power, or when
the swing is not being operated, always set the switch to the
ON fACTUATED) position.

l On a slope, the work equipment may swing to the down side

even if the swing parking brake switch is located at the ON
position.
Be careful concerning this point.
ON
This switch is used to lock the upper structure so that it cannot

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 work equipment control
levers are at neutral; when any work equipment control lever is
operated, it is canceled.
The swing lock is actuated approx. 4 seconds after all work
equipment control lever is placed in neutral.

2-76
 11. EXPLANATION OF COMPONENTS

10. ROOM LAMP SWITCH

This is used to turn on the room lamp.
ON: Lights up
It is possible to turn on the room lamp even when the starting
switch is at the OFF position, so be careful not to forget to turn it off.

AM099420

11. MACHINE PUSH-UP SWITCH

This switch is used to switch the safety valve set pressure at the
head end of the boom cylinder to two levels.
@ Low pressure setting: The boom thrust force is weak,so the
swaying of the chassis is small during
digging operations, and digging opera-
tions can be carried out smoothly.
This is used for general digging opera-
I AM099450
tions on normal ground, soft rock, or
blasted rock.
@ High pressure setting: The thrusting force of the boom be-
comes more powerful, so it is easy to
twist and swing or escape from soft
ground. It is effective in carrying out
digging operations using the bucket and
the weight of the machine in confined
areas.

12. EGG LAMP SWITCH

This lights up the fog lamps.
ON position: Lamp lights up. ON

13. SHOCKLESS BOOM CONTROL SWITCH

This controls the shaking of the work equipment when the boom
is stopped. ON
Effect
l The shaking and spillage of load from the bucket is reduced.
l Operator fatigue when operating for long periods is reduced, so
operations can be carried out in safety.
AM099420
REMARK
When the switch is at the ON position and the boom is stopped,
the movement of the boom until it stops will increase slightly. Be
careful when using this operation until you become accustomed to it.

2-17
I 1. EXPLANATION OF COMPONENTS

14. ROTATING LAMP SWITCH

This lights up the rotating lamp.
ON position: Lamp lights up.

15. ALARM BUZZER STOP SWlTCH

This is used to stop the alarm buzzer if it sounds to warn of an
abnormality during operation.

16. WIPER SWITCH

This actuates the wiper for the front glass.
OFF: Wiper stops
ON: Wiper moves continuously
Window washer fluid is sprayed out. When switch is released it
returns to position 0.
ON: Wiper moves intermittently
Window washer fluid is sprayed out. When switch is released it
returns to position @.

17. GREASING SWlTCH

This actuates the grease pump.
0 START: Greasing is started. When the switch is released,
greasing will continue for 15 minutes and then stop.
@ STOP: This switch is used to forcibly stop the grease pump
during greasing operations.
@I Pilot lamp: This lights up when the grease pump is operating.

18. HORN SWlTCH I I

Press the switch on the right work equipment control lever to
sound the horn.
At the same time, the flashing light (option) at the top front of
the cab will flash for approx. 5 seconds to give a signal to the dump
truck.

2-18
 11. EXPLANATION OF COMPONENTS

19. ROOM LAMP SWITCH

[FOR ENGINE ROOM) OFF
This lights up the lamp inside the engine room.
ON
ON position: Lamp lights up.

AE178470
I
20. ROOM LAMP SWITCH
(FOR ROOM IN CAB) OFF
This lights up the lamp in the room of the cab.
ON
ON position: Lamp lights up.

AE178470

21. ROOM LAMP SWITCH

(FOR PUMP ROOM) OFF
This lights up the lamp inside the pump room.
ON
ON position: Lamp lights up.

AE176470
I

2-19
11. EXPLANATION OF COMPONENTS

22. PUMP CONTROL OVERRIDE SWlTCH

When normal: Switch is pushed down
When abnormal: When the monitor display shows E02 (NC
When abno
valve system error), move the switch up to make it possible to carry
out work.
The pump prolix switch is provided to make it possible to carry
out work for a short time when there is a failure in the pump control I
system (TVC valve system error). It is necessary to repair the When normal
AM089520
abnormal location as soon as possible.

SWING LOCK OVERRIDE SWlTCH

When normal: Switch is pushed down
When abno
When abnormal: When the monitor display shows E03 (Swing
brake system error), the brake is canceled, and it becomes possible
to actuate the swing and carry out normal operations. However, the
swing brake remains released. (
The swing prolix switch is provided to make it possible to carry When normal
out swing operations for a short time even when there is an
abnormality in the swing brake electric system. It is necessary to
repair the abnormality as soon as possible.

24. ENGINE EMERGENCY STOP SWllCH

Use this switch only when stopping the engine in an emergency.

A6671666

Stop switch inside en6ine mm

11666

2-20
 11. EXPLANATION OF COMPONENTS

11.3 LAMP

1. ENGINE EMERGENCY STOP LAMP

This lamp lights up when the engine emergency stop button at
the side of the left side step is pressed, or when the engine
emergency stop button inside the engine room is pressed to the OFF
position.
l If this lamp is lighted up, the engine cannot be started.
l When the engine emergency stop button is pressed again to set
it to the ON position, the lamp goes out and the engine can be
started.

For details of stopping the engine in emergencies, see “12.18.2

STOPPING IN EMERGENCY”.

2. AUTO-GREASING CAUTION LAMP (IF EQUIPPED)

This lamp lights up if an abnormality occurs in the auto-greasing
system. Check the engine from the content of the display on the
auto-greasing controller inside the cab base, then carry out repair
work.
For details, see “28. AUTO-GREASING SYSTEM”.

3. LADDER CAUTION LAMP

This lamp fights up when the ladder is lowered.
If the lamp is lighted up, the upper structure cannot be swung.
When the ladder is stored away, the caution lamp goes out and it
is possible to swing the upper structure.
For details of the method of using the ladder, see “11.9 EMERGENCY
ESCAPE LADDER”.

2-21
11. EXPLANATION OF COMPONENTS

11.4 CONTROL LEVERS, PEDALS

1

A1371680

I
1. SAFETY LOCK LEVER

I A WARNING
When leaving the operator’s compartment, set the safety lock
lever securely to the LOCK position. lf the control levers are
not locked, and they are touched by mistake, this may lead
to a serious accident.
lf the safety lock lever is not placed securely in the LOCK
position, the control levers may not be properly locked. Check
that the situation is as shown in the diagram.

When the safety lock lever is lowered, take care not to touch
the work equipment control lever. lf the safety lock lever is
not properly locked at the lower position, the work equip-
AU364178
ment and swing will move, creating a potentially dangerous
situation.

When the safety lock lever is raised, take care not to touch
the work equipment control lever.

This lever iocks the controls for the work equipment, swing,
travel, and optional attachments.
Push the lever down apply the lock.

2-22
 11. EXPLANATION OF COMPONENTS

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.

AY36416E

2. TRAVEL LEVERS {WITH PEDAL, AUTO-DECELERATION

MECHANISM)
r
a WARNING
Do not put your foot on the pedal unless the machine is
traveling. lf 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.
AM81730

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 forward.)

0 FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
0 REVERSE:
The lever is pulled back.
(The pedal is angled back)
N (Neutral): The machine stops.

( I: 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 warn that the machine is
starting to advance.

2-23
11. EXPLANATION OF COMPONENTS

3. LEFT WORK EQUIPMENT CONTROL LEVER

(with auto-deceleration device)

g WARNING
lf any lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when oper-
ating the levers.

This lever is used to operate the arm and upper structure.

Arm operation Swing operation
@ Arm OUT @ Swing to right
@ Arm IN @ Swing to left
N (Neutral)
When the lever in this position, the upper structure and the arm
will be retained in the position in which they stop.

4. RIGHT WORK EQUIPMENT CONTROL LEVER

(with auto-deceleration device)

A WARNING
lf any lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when oper-
ating the levers.

This lever is used to operate the boom and bucket.

Boom operation Bucket operation
@ RAISE @ DUMP
@ LOWER @ CURL
N (Neutral)
When the lever in this position, the boom and the bucket will be
retained in the position in which they stop.

For levers 2, 3 and 4, the engine speed changes as follows

because of the auto-deceleration mechanism.
l When the travel lever and work equipment control levers are at
neutral, even if the fuel control dial is above the mid-range
position, the engine speed will drop to a mid-range speed.
If any of the levers are operated, the engine speed will rise to the
speed set by the fuel control dial.
l If all control levers are set to neutral, the engine speed will drop
by approx. 100 rpm, and after approx. 4 seconds, the engine
speed will drop to the deceleration speed (approx. 1300 - 1500
rpm).

2-24
 11. EXPLANATION OF COMPONENTS

11.5 DOOR LOCK

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

1. Hook lock @ to portion @ to hold the door in position.

2. When opening the door, lift lock CJI up slightly and remove it
from portion 0.
When fixing the door, fix it firmly to the catch.

11.6 POCKET
Behind the operator’s seat
Ordinally, operation manual should be stored in this pocket, and
able to read the manual every time.

2-25
I I. EXPLANATION OF COMPONENTS

11.7 HANDLING AIR CONDITIONER

11.7.1 GENERAL LOCATIONS ON CONTROL PANEL

AIR CONDITIONER CONTR0.L PANEL 1 AIR CONDITIONER CONTROL PANEL 2 M371698

The pilot lamp for the switches light up to indicate that the switch
is functioning.

1. VENT SELECTOR SWITCH

This is used to select the vents which match the purpose of use.

Control
panel
Purpose
r AIR CONDITIONER
Sending breeze
CONTROL PANEL 1
Sending breeze to
r AIR CONDlTlONER CONTROL PANEL 2
Sending breeze to Sending breeze
1
of ‘use from front feet upper part of body from rear

Switch GD LD
AN1 13550 Ar4113560 AN1135M AN113560

Vent

2-26
 11. EXPLANATION OF COMPONENTS

2. FRESH/RECIRC SELECTOR SWlTCH (AIR CONDlTlONER CON-

TROL PANEL 1 AND 2 THE SAME)
This switch is used to intake fresh air or recirculate the internal
air.

--_
or cool the operator’s cab taking in clean fresh air

Switch

AN1 13590 AN113600

3. TEhPERATURE CONTROL SWlTCH (AIR CONDlTlONER CON-

TROL PANEL 1 AND 2 THE SAME)
This switch is used to adjust the temperature steplessly between
low and high.

Purpose
Cooling Heating
of use

COOL WARM
a D

AN113610 AN113620

Switch

The more lamps in the blue range light up, the lower
the temperature becomes; the more lamps in the red
range light up, the higher the temperature becomes.
The range is divided into 7 levels, and each range is
divided further steplessly.

4. WIND FLOW SELECTOR SWlTCH (AIR CONDlTlONER CONTROL

PANEL 1 AND 2 THE SAME)
The wind flow can be adjusted to 3 levels.

Purpose Low wind Medium wind High wind

of use flow flow flow

Switch
(a [01 i

AN113640 ANl13ma AN113660

2-27
11. EXPLANATION OF COMPONENTS

5. AIR CONDlTlONER SWlTCH

0
@
CONTROL PANEL 1 AND 2 THE SAME)
(AIR CONDITIONER

This is used to switch the air conditioner ON/OFF.

6. OFF SWlTCH (AIR CONDlTlONER CONTROL PANEL

1 AND 2 THE SAME)

This switch is use to stop the fan.

7. DEFROSTER
This is used to clear the mist from the front glass in cold or rainy
conditions.
l Open the defroster vent and adjust the direction so that the air
blows on the front glass. (During normal operations, use with the
defroster vent closed.)
l If it is desired to remove the mist quickly, close the other vents
when using the defroster vent.
The defroster can be used under the following conditions:
When air conditioner control panel 1 vent selector is at ~2
When air conditioner control panel 2 vent selector is at p”

I !

11.7.2 PRECAUTIONS WHEN USING AIR

CONDITIONER
Carry out ventilation from time to time when using the cooler.
l If you smoke when the cooler is on, the smoke may start to hurt
your eyes, so turn the lever to FRESH to remove the smoke while
continuing the cooling.

l When running the air conditioner for a long time, turn the lever
to the FRESH position once an hour to carry out ventilation and
cooling.

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

l When the cooler is on, set the temperature so that it feels slightly
cool when entering the cab (5 - 6°C 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.

2-28
 11. EXPLANATION OF COMPONENTS

11.8 EMERGENCY ESCAPE HAMMER

NOTICE
When escaping, remove the broken pieces of the glass from the
sash so that you will not cut yourself with them. Take care not to
slip on the broken and scattered pieces.

In case it becomes impossible to open the door, a hammer to be

used for escape from the cab is installed.

When escaping, break the left-hand window glass with hammer.

2-29
11. EXPLANATION OF COMPONENTS

11.9 EMERGENCY ESCAPE LADDER

There is a rope ladder in the box by the passage of the left side
of the operator’s compartment. Use it for escape in emergencies.

When using the ladder to escape, fit the hooks at the end of the
ladder to the handrail, then lower the ladder. Check that the condi-
tion of the ladder is normal before going down it.

Hook
When /

Han

\
When ladder
iB ^.^_^A
A-A .’ D’y’=u

2-30
 11. EXPLANATION OF COMPONENTS

11.10 CAP, COVER WITH LOCK

The fuel filler, operator’s cab, engine hood, battery box cover,
right side door and left side door of the machine body are fitted with
locks.
Use the starting switch key to lock or unlock these places.

11.10.1 METHOD OF OPENING AND CLOSING CAP

WITH LOCK (For the fuel tank filler port)
To open the cap
1. Insert the key into the cap.
2. Turn the key clockwise, align the match mark on the cap with the
rotor groove, then remove the cap.

To lock the cap i

1. Turn the cap into place.
2. Turn the key counterclockwise and take the key out.

Match mark
on the cap

ADO53820

Insert the key as far as it will go. If the key is turned before it is
inserted all the way, it may break.

Shoulder
11.102 METHOD OF OPENING AND CLOSING
AL067870
COVER WITH LOCK (For the cover with lock)
To open the cover
1. Insert the key in the key hole of the cover.
2. Turn the key counterclockwise and pull out the cover glip, then
open the cover.

To close the cover

1. Close the cover, and insert the key in the key hole.
2. Turn the key counterclockwise and take the key out.

11.11 ASHTRAY
This is on the left side of the operator’s seat.
Always make sure that you extinguish the cigarette before
closing the lid.

2-31
11. EXPLANATIONOF COMPONENTS

11.12 CAR RADIO

11.12.1 EXPLANATION OF COMPONENTS

I
I
I I I I

f 1 L o SW-VOLUME PU BAL

I I \ I
C’TONE
JJ
\ \ I \
I I . .

1. POWER SWITCH/VOLUME CONTROL KNOB (SW-VOLUME)

BALANCE CONTROL KNOB /Pull BALI
Press this knob to turn the power for the radio on. The frequency
is displayed on display 0. 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.)

2. TONE CONTROL KNOB (TONE)

Turn the knob to adjust the tone as follows.
Turn CLOCKWISE to emphasize the high sounds
Turn COUNTERCLOCKWISE to suppress the high sounds
-1

AMOwl

2-32
 11. EXPLANATION OF COMPONENTS

3. FM/AM SELECTOR BUlTON (AM/FM)

Press this button and select the desired band.
Each time the button is pressed, it switches AM + FM + AM . . .

AM099390

4. DISPLAY SELECTOR BUTTON (TIME)

This equipment gives priority to the frequency display. If the
button 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.
AM099990
I

5. TUNING BUlTONS (TUNING)

MANUAL TUNING (MANUAL)
Use the buttons to change the frequency.
Up button (A): Each time the button is pressed, the frequency
will go up in steps (FM: 0.1 MHz, AM: 9 kHz).
Down button WI: Each time the button is pressed, the fre-
quency will go down in steps (FM: 0.1 MHz, AM: 9 kHz).

I AMO9OQOO

6. PRESET BUlTONS (I, 2, 3, 4, 5,6) (PRESET STATION) 1

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 “11.12.2 METHOD
OF OPERATION”.

AM090010

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

I AM90020 1

8. TIME CORRECTIONBUITON
This is used to correct the time.
H : Hour
M : Minute
SET: Sets to start of hour (00 minutes)

2-33
11. EXPlANATiON OF COMPONENT’S

9. STEREO INDICATOR (ST)

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

11.122 METHOD OF OPERATION

METHOD OF SETTING PRESET BUTTONS
1. Press power switch @I and display the frequency on display 0.
2. Turn the tuning button (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 seconds. The sound
will disappear, but when the setting is recorded, the sound will
appear and the preset number will appear on display QI to show
that the station has been preset.
After completion of presetting, press preset button @, and
release it within approx. 1.5 seconds. The setting wili change to
the frequency of the broadcasting station recorded for that
button. One AM station and one FM station can be recorded for
each preset button.

MANUAL TUNING
Press tuning button @ 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).
V button: Move to a higher frequency station
A button: Move to a lower frequency station
l If the frequency reaches the top or bottom limit, it will automati-
cally change as follows: top limit + bottom limit, or bottom limit
+ top limit _

AUTOMATIC TUNING
Keep tuning button @I pressed for at least 0.5 seconds. When a
broadcasting station is picked up, it will automatically stop. To
search for the next station, press tuning button @I again for at least
0.5 seconds.
V button: Move to a higher frequency station
A button: Move to a lower frequency station
l If tuning button @ 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.

2-34
 11. EXPLANATION OF COMPONENTS

SETTING CORRECT TIME

1. Press display selector button @ 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 @ again.
2. Press time adjustment button @I 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: Sets to start of hour (when it is pressed, the minute
returns to 00)
If the minute display is between 0 and 29, and the SET button
is pressed, the minute reading will return to 00. If it is pressed
when the minute display is between 30 and 59, the minute
display will return to 00 and the hour will advance by 1.
Example lo:29 - IO:00
10:30 -) 1 l:oo
Press the H, M, and SET buttons to set to the correct time.

ANTENNA
In areas where the reception is weak or there is interference,
extend the antenna. If the radio is set to a station with strong radio
waves, retract the antenna to set to a weaker input.

NOTICE
Always retract the antenna before transporting the machine or
driving the machine into a work shop or garage.

2-35
1I. EXPLANATION OF COMPONENTS

11.12.3 PRECAUTIONS WHEN USING

l To ensure safety, always keep the sound to a level where it is
possible to hear outside sounds during operation.
l If water gets into the speaker case or car radio (auto tuning), it
may lead to an unexpected failure, so be careful not to get water
on the equipment.
l 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.
l When the battery is replaced, the settings for the preset buttons
are all cleared, so set again.

11.12.4 SPECIFICATIONS
Tuning method: PLL synthesizer method
Reception frequency: AM 522 kHz - 1629 kHr (in 9 kHz steps)
FM 76.0 MHz - 90.0 MHz (in 0.1 MHz steps)
Actual max. sensitivity: AM 30 dB
FM 75 dB
Actual max. output: lOWx2
Current consumption: Max. 2 A
External dimensions: Width 184 mm (7.24 in),
Height 56 mm (2.20 in),
Depth 116 mm (4.57 in)
Weight: 0.65 kg (1.43 lb)

2-36
 Il. EXPLANATION OF COMPONENTS

11.13 FUSE
This forms one unit with the circuit breaker.

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 a fuse with another of the same capacity.

If there is a surge of current, the circuit breaker cuts the circuit

to protect the wiring. To restore the circuit that has been cut off by
the breaker, press in the button that has popped out.

If the electrical circuit is working normally, the button will stay

pushed in. If it springs out immediately after it is pushed in, it is
necessary to check the electrical circuit.

Fuse, breaker capacity and name of circuit

Circuit

2-37
11. EXPLANATION OF COMPONENTS

11.14 CIRCUIT-BREAKER (Installed outside cab)

If the engine does not start even when the starting switch is
turned to the ON position, the electrical circuit has probably been cut
by the circuit breaker. Open the side door closest to the front of the
machine on the left side and check the breaker button under the
battery.

If the button is protruding, push it in.

If the electrical circuitis working normally, the button will stay
pushed in. If it springs out immediately after it is pushed in, it is I 1
necessary to check the electrical circuit.

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

11 .15 CONTROLLERS Governor Puma controller

The engine throttle and pump controller and the VHMS control-
front
ler are installed inside the cab base.
ine

I
r rear
sine

NOTICE (VHWS controller) VHMS.

l Never splash or spill water, mud or drink over the controllers as
thii may cause a fault.
l lf a fault occurs in the controller, do not attempt repair, but
consult your Komatsu distributor.

11.16 TOOL BOX

This is used for keeping the tools.

2-38
 Il. EXPLANATION OF COMPONENTS

11.17 GREASE PUMP

The pump is instituted by the inlet of the cab lower room on the
machine.

11.18 HANDLING GREASE PUMP

11.18.1 INSTRUCTIONS FOR USE
1. When the lever of grease gun @ is pulled, grease is forced out
and the pump also begins to work automatically.
2. When greasing is finished, release the lever of grease gun @ and
pumping of grease will stop.

REMARKS
When greasing with grease gun, close stop valve, to close the
other line.
After finished the greasing work, open stop valve.
Use the special handle when opening or closing stop valve.
When greasing with the grease gun, run the front engine at a
mid-range speed.
Turn the starting switch ON, then set the greasing switch to
START.
(The greasing operation stops after 15 minutes, but if it is desired
to carry out more greasing, press the START button again.
During auto-greasing, the lamp in the hatched portion (center of
switch) will light up.)

11.18.2 PRECAUTIONS FOR USE

l When greasing the machine, set the grease gun so that the
nozzle is vertical to the nipple.

l When removing the grease gun nozzle from the nipple, bend the
end of the nozzle over slightly, then remove the end of the nozzle
carefully.
l If there is too little grease the pump will run dry, so move the
grease to the center or refill the grease can.

2-39
11. EXPLANATIONOF COMPONENTS

11.18.3 RERLLING GREASE CAN

1. Loosen wing bolts @ at 3 places on grease can 0, and then
remove cover @ and pump as one unit.
2. Take out follow plate @ from inside can.
3. Pack grease can @ with new grease and set follow plate @ on
top of grease in grease can.

REMARK
Fit the cone in the center of the follow plate with grease before
insertion.

4. Install cover @ while carefully passing suction tube through hole

in follow plate @.
Tighten 3 wing bolts @ equally.

REMARK
When the pump is used, it will function for a short time, then
stop.
However, the grease pumped out first is not suitable for use, as
it contains air and is a whitish color.

5. Open check valve @ and pump all the grease containing air out
of small hole @ at the bottom of the check valve.
6. After bleeding air, tighten check valve @ securely.

7. Pull the grease gun lever to force all grease containing air out of
the grease gun and hoses.

REMARK
l When refilling with grease, be very careful not to let sand or dirt
stick to the suction tube or follow plate.
l If the pump runs dry even when there is sufficient grease, it
means the follow plate may not be installed correctly. Stop
greasing and set the follow plate correctly.
l When not using the grease gun for a long time, close valve 0
and shut off the air supply, relieve the inner pressure in the gun,
the hose and the pump.

2-46
 11. EXPLANATION OF COMPONENTS

11.19 HANDLING ACCUMULATOR

A WARNING
On machines equipped with an accumulator, for a short time
after the engine is stopped, if the work equipment control lever
is moved to the LOWER position, the work equipment will move
down under its own weight.
After stopping the engine, always place the safety lock lever in
the LOCK position.

The accumulator is filled with high-pressure nitrogen gas, and

it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions.
l lf accumulators break down or have trouble, immediately ask
your Komatsu distributor to carry out repairs.
l Only Komatsu personnel and those licensed to service high
pressure equipment may recharge an accumulator with nitro-
gen.
l Never overhaul or dispose of an accumulator without first
bleeding out all the nitrogen through the air bleeder valve.
l Have your Komatsu distributor check the gas pressure once
a year.
l Never make any hole in the accumulator or expose it to flame
or fire.
l Do not weld any boss or make any hole in to the accumulator.
l When overhauling or disposing of the accumulator, it is
necessary to release the gas from the accumulator, so please
contact your Komatsu distributor.

This machine is equipped with the accumulator in the control Inside of track frame
circuit.
The accumulator is a device to store the pressure in the control
circuit, and when it is installed, the control circuit can be operated
for a short time even after the engine is stopped. Therefore, if the
control lever is moved in the direction to lower the work equipment,
it is possible for the work equipment to move under its own weight.

The accumulator is installed to inside of track frame (1 point) and IInside of left de&
inside of left deck (1 point).

2-41
11. EXPLANATIONOF COMPONENTS

11.19.1 METHOD OF RELEASING PRESSURE IN

CONTROL CIRCUIT ON MACHINE
EQUIPPED WITH ACCUMULATOR
Place the work equipment on the ground.

Stop the engine.

Move the safety lock lever to the free position. Move the work
equipment control lever and forth, right and left so as to release
the pressure in the control circuit.

Move the safety lock lever to the lock position. Lock the control
lever. The pressure, however, will not be completely released, so
when the accumulator is removed in the control circuit, gradu-
ally loosen the screws. Never stand in the oil ejection direction.

2-42
 11. EXPLANATION OF COMPONENTS

11.20 HEALTH MONITOR

1. Health monitor
The health monitor displays the condition of the machine, the
maintenance status, and messages to the operator and service
man, and is also used to input the necessary data.
The surface of screen 0 is equipped with touch switches to
switch the screen and input the data.

REMARK
When the starting switch is turned ON, the opening screen is
displayed for approx. 5 seconds. The condition of the machine is not
displayed.
If the ambient temperature of the monitor goes below -30°C or
above 55”C, the back light is turned off to protect the screen. The
display cannot be seen, but this is not an abnormality.
When the temperature returns to the operating range, the dis-
play will appear again, so carry out operations according to the
machine monitor.

2-43
17. EXPLANATION OF COMPONENTS

2. Switching screens
There are 5 screens. The screen can be switched bv ooeratina‘ the touch switch on the surface.
Opening screen: it takes approx. 5 second; after the-starting switch is turned ON for the
condition of the machine to be displayed. During this time, the opening
screen is shown.
Normal screen: The screen automatically switches to the normal screen approx. 5 seconds
after the starting switch is turned ON. The oil temperatures, water tem-
peratures, and oil pressures are displayed on the meters.
It is possible to switch from this screen to screens @I and @I, by pressing
the touch switch.
Maintenance screen: This displays the time remaining until the next maintenance is to be
performed.
Setting screen: This screen is used to set the date and time.
With this screen, it is possible to set the user ID.
Abnormality screen: If any abnormality occurs, the screen switches automatically to this
display.
When the abnormality is removed, the screen automatically returns to the
display shown before the abnormality occurred.

A CAUTION
As far as possible, set the data and time to the local time. lf it is not set, the operating data will
not be correctly recorded.
)

\
/ I 1
1Starting switch ON 1
1

After approx. 5 seconds

2-44
 11. EXPLANATION OF COMPONENTS

3. Explanation of screen
3.1 Opening screen
It takes approx. 5 seconds from the time the staning switch is
turned ON until the condition of the machine is displayed.
During this time, the opening screen is displayed.
Hello !
3.2 Normal screen Welcome to VHMS system
The srstem is nowbuildino UP
The screen automatically switches to the normal screen approx. Please wait a moment.
30 seconds after the starting switch is turned ON. The oil tempera- -
tures, water temperatures, and oil pressures are displayed on the
meters.

I- -J
R COOLANT R PTO OIL

AU364470

Meter display:The oil temperatures, water temperatures, and oil pressures are displayed. The display
item screen can be changed by touching switch 0.
Brightness control
button: This adjusts the brightness. For details of the method of adjusting the brightness, see
Section 3.3.
Operating hours/ tachometer display
button: This switches to the operating hours and tachometer display screen.
Setting screen display
button: This switches to the setting screen.
Display selector
button: This switches the display to the next screen. Each time it is pressed, the display screen
switches in the following cycle: @ + @I - @ + @
@ Front engine water temperature, rear engine water temperature, front PTO oil
temperature, rear PTO oil temperature
@I Front engine oil temperature, rear engine oil temperature, front engine oil
pressure, rear engine oil pressure
@ Front PTO oil temperature, rear PTO oil temperature, hydraulic oil temperature
Maintenance screen display
button: This switches to the maintenance screen.
The color of the letters on the panel for each item changes according to the remaining
time.
(40 h remaining: Yellow; 0 h remaining: Red)
Time display: This displays the present time.

2-45
11. EXPLANATION OF COMPONENTS

3.3 Brightness control screen

When the brightness control button is pressed, brightness con-
trol sub-panel @ is displayed on top of the present screen. If the sub-
screen is not touched within 5 seconds, it will disappear and the
original screen will be displayed.

P3
I

II /
I
II
II Brightness and C ntrast
P
Settings
II

Contrast
r;“lpq

01-Q m next maint

I , I I I J AW364430

@ Contrast control slide: This is used to adjust the contrast of the screen.
Press the desired position on the slide bar.

@ Brightness control slide: This is used to adjust the brightness of the screen.
Press the desired position on the slide bar.

2-46
 11. EXPLANATION OF COMPONENTS

3.4 Maintenance screen

This displays the items to be performed up the next time for each
maintenance item.
When the remaining time becomes short, the color of the letters
on the screen and the color of the maintenance screen selector
button on the normal screen change.
40h remaining: Yellow
Oh remaining: Red

P I

MAINTENANCE MONITOR-1 250/500h

1
@N___
Change engine oil 170H

II/
J

Chance enoine oil filter 170H

Change hydraulic filter 170H

Change hydraulic drain filter 170H

hW37IBlE

Standard maintenance
interval display: This displays the standard maintenance interval.

Maintenance item
display: . This displays the maintenance items.

Remaining time
display: This displays the time remaining until the next time of maintenance.

Maintenance item
selector button (back): This switches the maintenance item display to the previous display.
Each time it is pressed, the display changes @ + @ + @ + @.

0 Maintenance item
selector button (next): This switches the maintenance item display to the next display.
Each time it is pressed, the display changes @ + @ + @ - @.
@ Maintenance items for every 250 h
@ Maintenance items for every 500 h
@ Maintenance items for every 1000 h
@ Maintenance items for every 2000 h

2-47
11. EXPLANATION OF COMPONENTS

@ Maintenance items for every 250 h

l Change oil in engine oil pan
l Replace engine oil filter cartridge
l Replace hydraulic filter element
l Replace drain filter cartridge
l Replace hydraulic tank breather filter element
@ Maintenance items for every 500 h
l Replace fuel filter
@ Maintenance items for every 1000 h
l Change oil in swing machinery case
l Change oil in PTO case
l Replace corrosion resistor cartridge
@I Maintenance items for every 2000 h
l Change oil in hydraulic tank
l Wash engine breather element
l Change oil in final drive case

This screen displays typical change and replacement items, but

there are also other inspection and adjustment items. When carrying
out maintenance, see the inspection and maintenance schedule
chart in Section 23 of this manual.

@ Normal screen
display button: This switches to the normal screen. The item
previously displayed on the normal screen is
displayed.

2-48
 11. EXPLANATION OF COMPONENTS

3.5 Setting screen

Use this screen to input the date, time, display unit, and user ID.

DATE SETTING

4 5 6

7 8 6

0 BS Enter
USERID

Au372720

@ Date setting button: Press this button when inputting the date.
Screens @to @Jare displayed. When the item to be changed is pressed,
the screen for ten-key pad @ used for the input is displayed and data
can be input.

@ Data display: The present settings are displayed.

@ Time setting button: Press this button when inputting the time.
The input procedure is the same as for item 0.

@ Unit setting button: Only metric units can be set.

METRIC: Metric units are displayed (km/h, kg/cm*, “C, J?,Metric TON)

2-49
11. EXPLANATION OF COMPONENTS

@ User ID: This is used when giving an ID number to the machine.

A maximum of IO alphanumeric characters can be input.

@ input sub-screen : Input with ten-key pad then confirm by pressing ENTER key.
(ten-key pad) If any mistake is made in the input, press the backspace key. Each time
it is pressed, the last character on the right is deleted. When the ENTER
key is pressed to confirm the input, the sub-screen will go out, the
display will return to the setting screen, and the input data will be
displayed.

@I Normal screen display

button : This switches to the normal screen. The item previously being dis-
played is displayed again.

@ Time setting button : The clock will start when this button is pressed. If the button is not
pressed, the time will not be updated.

2-50
 11. EXPLANATION OF COMPONENTS

3.6 Abnormality screen

If any abnormality occurs on the machine, the screen automatically changes to display the type of
failure and the action to take. Carry out the action given on the screen.
When the abnormality screen is being displayed, press CANCEL button @to view the other screens. The
screen will go out. Even when the screen is cancelled, if the abnormality still exists, if the starting switch
is not turns OFF and then ON again, the screen will not be displayed.

G1.F engine coolant temp. hioh

-Stop work and run engine idle at low sDeed

until Pointer enters oreen range.
-StOD engine and check cooling water level
in the reserve tank and add.

Order of occurrence of Toial number of

Proble now being displayed. existing Problems. AU371828

3.6.1 Basic check items

NOTICE
Even if this screen is not displayed, the items for check before starting must never be omitted.
Always carry out the basic checks according the MAINTENANCE section, or “12. OPERATION”.

bo 6 R. enaine oil level low

‘Stoo engine and check engine oil level

in oil Dan and add.

El CANCEL

AN371838

This screen displays typical basic check items, but there are also other check items. For details, see
section 3.6.4 Abnormality display item table.

2-51
1I. EXPLANATION OF COMPONENTS

3.6.2 CAUTION items

A CAUTION
lf thii scraenis displayed, carry out inspectionand maintenanceof the problem locationas soon
as possible. ,

‘Check the battery chargino system.

‘Chatoine volt is

This screen displays typical caution items, but there are also other CAUTION items. For details, see
section 3.6.4 Abnormality display item table.

3.6.3 Emergency stop items

A CAUTION
lf this screenis displayed,stop the engine immediatelyor run at low idling and carryout the action
given on the monitor display.

OPI 6 R PTO oil temperature hioh

‘Stop enoine and check PTO oil level and

add oil.

This screen displays typical emergency stop items, but there are also other emergency stop items.
For details, see section 3.6.4 Abnormality display item table.

2-52
 11. EXPLANATION OF COMPONENTS

3.6.4 Abnormality display item table

The following abnormalities are displayed on the health monitor.

@ Basic check items

Drop in front oil level
Front radiator water level (before starting)
Drop in rear oil level
Rear radiator water level (before starting)
Hydraulic oil level

@ CAUTION items
Clogging of front air cleaner
Abnormality in front battery charge
Abnormality in front water temperature sensor system
Clogging of rear air cleaner
Abnormality in rear battery charge
Abnormality in rear water temperature sensor system

0 Emergency stop items

Abnormality in front PTO oil temperature
Error in front NC valve system
Drop in front engine oil pressure
Abnormality in front engine oil temperature
Front overheating
Error in front governor system
Abnormality in front radiator water level
Abnormality in front engine oil pressure
Abnormality in rear PTO oil temperature
Error in rear TVC valve system
Abnormality in rear engine water temperature
Drop in rear engine oil pressure
Abnormality in rear engine oil temperature
Error in rear governor system
Abnormality in rear radiator water level
Abnormality in rear engine oil pressure
Error in swing brake system
Error in network system
Hydraulic oil temperature
Hydraulic oil clogging
Abnormality in #l relief pressure
Abnormality in #2 relief pressure
Abnormality in #3 relief pressure
Abnormality in #4 relief pressure
Abnormality in #5 relief pressure
Abnormality in gear pump pressure

2-53
12. OPERATION

12.1 CHECK BEFORE STARTING ENGINE

Perform following checks for operator safety and maintenance of
machine performance.

12.1.1 WALK-AROUND CHECK

A WARNING
l Leakage of oil or fuel, or accumulation of flammable material
around high temperature parts, such as the engine muffler or
turbocharger, may cause fire.
Check carefully, and if any abnormality is found, repair it or
I-- contact your Komatsu distributor.

Before starting the engine, look around the machine and under
the machine to check for loose nut 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 collection
of dust at places which reach high temperatures.

Always carry out 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 flammable 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 dam-

age, wear, loose bolts, or leakage of oil from rollers and final
drive case

6. Check for damage to handrail, loose bolts

Repair any damage and tighten any loose bolts.

2-54
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.

REMARK
Check monitor system
Before starting the engine, turn the starting switch to ON and
check that the alarm buzzer sounds and all monitor and gauge lamps
light up for about three seconds.

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.

9. Check seat belt and mount fittings

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

10. Check tightness of air cleaner mounting bolts.

11. Check oil level in PTO case

Check the oil level in PTO case.
The oil level should be between the L and H marks.

12. Check oil level in swing machinery case

Check the oil level in swing machinery case.
The oil level should be between the L and H marks.

13. Drain water and sediment from fuel tank

Loosen drain valve and drain the water and sediment at the
bottom of the tank together with fuel.

2-55
12.1.2 CHECK BEFORE STARTING
Always carry out the items in this section before starting the
engine each day.

CHECK COOLANT LEVEL, ADD WATER

A WARNING
0 Do not open the radiator cap unless necessary. When check-
ing the coolant, always check the radiator reserve tank when
the engine is cold.
0 Do not remove the cap when the radiator water is hot. Boiling
water may spurt out. After the water temperature goes
down, turn the cap slowly to release the pressure, then
remove it.

Open the left rear cover on the machine and check that the
cooling water level is between the FULL and LOW marks on F. ENi I NE R. Ek I NE
11111~11
radiator reserve tank @ (shown in the diagram on the right).
If the water level is low, add water through the water filler of
reserve tank 0 to the FULL level.

After adding water, tighten the caps securely.

If the reserve tank becomes empty, first inspect for water leaks
and then fill the radiator and the reserve tank with water.

REMARK
l When adding water to the radiator, remove cover 0, then loosen
radiator cap @I slowly. After checking that the pressure has been
released, push in the cap, keep it pushed in, then loosen it further
and remove it.
l Check that the level of the coolant is above the hatched portion
in the diagram on the right. If the water level is low, add water
through the water filler port.
AEo82160
l After adding water, install radiator cap 0.
When operating in cold areas, see “14. COLD WEATHER OPERA-
TION”.

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

I. Open the left cover (rear engine) and the front cover (front
engine) at the center of the engine hood.

2. Remove dipstick @ and wipe the oil off with a cloth.

3. Insert dipstick @ fully in the oil filler pipe, then take it out again. I]

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

0.
If the oil level is belowthe L mark, add engine oil through oil filler
0.

NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

2-56
 12. OPERATION

5. If the oil is above the H mark, drain the excess engine oil from
drain plug 81, @Z and 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 check-
ing.
If the machine is at an angle, make it horizontal before checking.

,
CHECK FUEL LEVEL, ADD FUEL

g WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. lf you spill fuel, thoroughly clean up any spillage.

1. Use sight gauge f@ on the side of the fuel tank to check that the
tank is full.

2. If the fuel level is not within the sight gauge, add fuel through
filler port @ while watching sight gauge 0.

Fuel capacity: 2300 e (608 US gal, 506 UK gal)

NOTICE
For details of the fuel to use, see ‘20. USE OF FUEL, COOlANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
AEl76690

3. After adding fuel, tighten the cap securely.

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

2-57
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

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

l lf oil has been added to above the H mark, stop the engine
and wait for the hydraulic oil to cool down, then drain the
excess oil from the drain plug 8.

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, move each control 1

lever (for work equipment and travel) to the full stroke in all
directions to release the internal pressure.

3. Check sight gauge 0. The oil level is normal if between the H and
L marks.

NOTICE
Do not add oil if the level is above the H line. This will damage
the hydraulic equipment and cause the oil to spurt out.

4. If the level is below the L mark, remove the upper cover of the
hydraulic tank and add oil through oil filler 0.

NOTlCE
For details of the oil to use, see ‘20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

REMARK
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:
l Before operation: around L level
(Oil temperature 10 to 30°C (50 to 86°F))
o Normal operation: around H level
(Oil temperature 50 to 80°C (122 to 176°F))
 r
CHECK FOR CLOGGING OF AIR CLEANER
1. Confirm that the air cleaner clogging monitor does not flash.

2. If it flashes, immediately clean or replace the element.

For details of method of cleaning the element, see “24.3.1

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT”.

CHECK ELECTRIC WlRlNGS

I A WARNING
lf fuses are frequently blown or if there are traces of short
circuit on the electrical wiring, locate the cause and carry out
repair.
Accumulation of flammable material (dead leaves, twigs,
grass, etc.) around the battery may cause fire, so always
check and remove such material.
Keep the top surface of the battery clean and check the
breather hole in the battery cap. If it is clogged with dirt or
dust, wash the battery cap to clear the breather hole.
I
Check for damage and wrong capacity of the fuse and any sign
of disconnection or short circuit in the electric wiring. Check also for
loose terminals and tighten any loose parts.
Check the wiring of the “battery”, “starting motor” and “alter-
nator” 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. Press the horn switch and check that the horn sounds immedi-
ately.
If the horn does not sound, please contact your Komatsu dis-
tributor for repairs.

2-59
CHECK OIL LEVEL IN PTO CASE
1. Open the left side cover and use dipstick @ to check the oil level.
2. The oil level should be between the L and H marks. If necessary,
add oil at the dipstick guide hole.

NOTICE
For details of the oil to use, see ‘20. USE OF FUEL, COOLANT
AND LUBRlCANTS ACCORDING TO AMBIENT TEMPERATURE”.

Check the oil level with the engine stopped or running at low
idling.
When the engine stopped, wait for at least 15 minutes after
stopping the engine before checking.
When checking at idling, run the engine at idling for at least 15
minutes before checking.

DRAIN WATER AND SEDIMENT FROM FUEL TANK

1. Pull out the hose from holder @ at the bottom of the tank.
2. Loosen drain valve @ and drain the water and sediment at the
bottom of the tank together with fuel.
3. After draining, tighten drain valve @ securely and set the hose
at the original position.

2-50
CHECK CENTRAL MONITOR
Carry out the following checks to prevent loss of warning ability
caused by defective operation of the buzzer or broken lamps on the
monitor panel.
1. Before starting the engine, turn the starting switch to ON and
check that the alarm buzzer sounds and all monitor and gauge
lamps light up for about 3 seconds.
If any lamp does not light up or the buzzer does not sound, the
cause is probably a broken bulb or disconnection, so contact
your Komatsu distributor.

2-61
 .
12. OPERATION

12.1.3 ADJUST OPERATOR’S SEAT

l Adjust the seat position before starting operations or after

A: Fore-and-aft adjustment
Move lever @ to right. After the seat is set to the desired
position, release the lever.
Adjustable distance: 100 mm (3.9 in) in IO steps

B: Adjusting reclining

NOTICE
The seat can be reclined to a large angle when the seat is
AM364200
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 @ and set the seat back to a position which is

comfortable 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

1. Forward tilt @I
Push lever @I down to adjust the angle of the front of the seat.
(4 stages)
I. To raise the angle at the front of the seat, keep the lever pushed
down and apply your weight to the rear of the seat.
2. To lower the angle at the front of the seat, keep the lever pushed
down and apply your weight to the front of the seat.
2. Rear tilt @I
Pull lever @ up to adjust the angle of the rear of the seat. (4
stages)
To raise the angle at the rear of the seat, keep the lever 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 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)

2-62
D: Adjusting armrest angle
Armrest @ can be made to spring up by hand approx. 90”.
In addition, by turning the bottom @ 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,
the armrest will rise automatically.

E: Overall fore-and-aft adjustment of seat

Pull up lever @, 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: 120 mm (4.8 in)

F: Adjusting suspension
Turn knob 0 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 so that the
indicator of the weight display (kg) in the transparent portion of knob
0 is the same as the operator’s weight.

ADJUSTMENT OF MONITOR PANEL ANGLE

Turn the monitor panel so that the operator can view the monitor
with ease. When adjusting the angle, the panel should be set to the
desired position using both hands. The panel is automatically locked
at that position.
Amount of adjustment: 30” (stepless)

2-63
12. OPERATION

12.1.4 ADJUSTMENT OF MIRRORS

ADJUSTMENT OF MIRRORS
Loosen nut @ of each mirror and adjust the mirror angle at
which you can see the reflected view most easily from the operator’s
seat.
In particular, adjust the mirrors so that you can see persons on
both side of the rear end of the machine.

INSTALLATION PROCEDURE OF MIRRORS

install and adjust mirror so that anyone in both LHS and RHS of
machine rear position (or any object of dimension approximately 1
m high and 30 cm diameter) is clearly visible.
Refer to dimensions shown in right chart for position of mirror.
Field of visibility reference value is shown below.

Mirror @: Hatched @ area (opposite side of @I to be visible

(option)
Mirror @: Hatched @I area to be visible.

2-64.
12.1.5 USING SEAT BELT

I A WARNING
Before fastening the seat belt, inspect the securing brackets
and belt for abnormal conditions.
Replace any worn or damaged seat belt or the securing
brackets.

Adjust and fasten the seat belt before operating the machine.

Always use seat belt when operating the machine.

Do not use seat belt with either half of the belt kinked.

FASTEN THE BELT AND REMOVE lT

1. Sit in the seat and adjust the seat to a position where it is easy
to carry out operations with your back against the backrest.

2. For machines with a suspension seat, adjust the position of the

seat, then adjust tether belt 0. Install the tether belt so that it is
tensed when no one is sitting in the seat. (Only machines
equipped with suspension seat)
I--%--
3. After adjusting the seat position, sit in the seat. Grip buckle @
and tongue @ in each hand and insert tongue @ into buckle 0.
Confirm by pulling the belt that the tongue is securely locked to
the buckle.

4. When removing the belt, raise the tip of buckle @ lever to release
it.

Fasten belt along your body without kinking it. Adjust the lengths of
the belt on both the buckle and the tongue sides so that the buckle
is located at the mid-point of your body front.
AH364210

ADJUST THE BELT LENGTH

To shorten the belt

Pull the free end of the belt on either the buckle body or tongue
side.

AM091850
To lengthen the belt
Pull the belt while holding it at a right angle to buckle or tongue.

Inspect bolts and fittings on the chassis for tightness. Retighten any
loose bolts to 20 to 29 Nm (2 to 3 kgm, 15 to 20 Ibft) torque.

If the seat is scratched or frayed or if any of the fittings are broken

or deformed from long service, replace the seat belt immediately.
AMOS1860
NOTICE 1
Even if there appears to be no abnormality in the belt, always
replace the seat belt once every 3 years. The date of manufacture
is shown on the back of the belt.

2-65
12.1.6OPERATIONS AND CHECKS BEFORE STARTING
ENGINE

ff the control lever is touched by accident, the work equipment

or the machine may move suddenly. When feavmg the opera
tor’s compartment, always set the safety lock fever securely to
the LOCK position. A WARNfNG :]

1. Check that safety lock lever @I 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 button.

3. Insert the key in starting switch 0, turn the key to the ON

position, then carry out the following checks.

(I) The buzzer will sound for approx. 1 set, and the following
OFF
monitors and gauges will light up for approx. 3 sec. I
4 Radiator water level monitor @
0 Engine oil level monitor @
4 Hydraulic oil level monitor @
0 Charge level monitor @
0 Fuel level monitor 0
4 Engine water temperature, hydraulic oil temperature moni-
tor @
0 Engine oil pressure monitor @I
0 Engine water temperature gauge @I
0 Fuel gauge @
0 Engine pm-heating monitor @I
0 Air cleaner clogging @I
l Swing lock lamp @
0 Hydraulic filter clogging monitor @

If the monitors or gauges do not light up or the buzzer does not

sound, there is probably a broken bulb or disconnection in the
monitor wiring, so contact your Komatsu distributor for repairs.

After approx. 3 set, the following gauges will remain on and the
other monitors will go out.
0 Engine water temperature gauge @I
4 Fuel gauge @

(2) Press lamp switch @I to turn on the head lamps.

If the lamps do not light up, there is probably a broken bulb or
disconnection in the wiring, so contact your Komatsu distributor
for repairs. ON

2-66
3. Check that engine emergency stop lamp @ is off. If it is lighted
up, engine stop switch @ inside the engine room or engine stop
switch @ at the side of the left side step is at the OFF position,
or there is a disconnection.
If the switch is OFF, press the engine stop switch ON. If there
is a disconnection, please contact your Komatsu distributor for
repairs.

2-67
12.2 STARTING ENGINE
12.2.1 NORMAL STARTING

area, then sound the horn and start the engine.

NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine will not start, wait for at least 2 minutes before
trying to start the engine again.

1. Turn the staner motor selector switch @ to FRONT engine.

Front ene in

2. Set fuel control dial @ at the low idling (MIN) position.

Low idling _o34o

3. Turn the key in starting switch @ to the START position. The

engine will start. OFF
1

4. When the engine starts, release the key in starting switch 0. The
key will return automatically to the ON position. OFF
I

5. Turn the starter selector switch @ to REAR engine.

Set fuel control dial @ at the low idling (MINI position, and
repeat steps 3 - 4 to start the engine.

2-68
122.2 STARTING IN COLD WEATHER

Check that there are no persons or obstacles in the surround-

l Never use starting aid fluids as they may cause explosions.

NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine fails to start, repeat from step 3 and af’ter waiting
for about 2 minutes.

When starting in low temperatures, do as follows.

1. Turn the starter motor selector switch @ to FRONT engine. Rear engine

Front enein

2. Set fuel control dial @ at 3 notch from the low idling (MINI
position.

REMARK
There are 10 notches for the dial rotation, and the click can be
felt by hand.
Low idling
3. Hold the preheating switch @ at the HEAT position, and check AM096510
that preheating monitor @ lights up.
After about 30 seconds, preheating monitor lamp @will flash for
about 10 seconds to indicate that preheating is finished.
When the preheating switch is released, it will go off automati-
HEAT
cally.

REMARK
The monitor and gauge also light up when the key is at the HEAT
position, but this does not indicate any abnormality.

2-69
12. OPERATION

4. When preheating monitor flashes, turn the key in starting switch

@ to the START position to start the engine.

5. When the engine starts, release the key in starting switch 0. The
key will return automatically to the ON position. OFF
I
6. Turn the starter selector switch @ to REAR engine.
Set fuel control dial @ at the low idling (MIN) position, and
repeat steps 3. - 5. to start the engine. 2
-zD
5p
-4
AW350040

SPECIAL STARTING
When starting after running out of fuel, fill with fuel, then fill the
fuel filter cartridge with clean fuel and bleed the air from the fuel
system before starting. .

2-70
12.3 OPERATIONS AND CHECKS AFTER
STARTING ENGINE
7 a WARNING I
l Emergency stop
If there has been any abnormal actuation or trouble, turn the
starting switch key to the OFF position.
l 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

cold areas, be sure to carry out the warming-up operation

12.3.1 WHEN NORMAL

NOTICE
l 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.
l Do not suddenly accelerate the engine before the warming-up
operation is completed.
Do not run the engine at low idling or high idling continuously
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.
o The hydrauiic oil temperature should ideally lie within the range
60 to 80°C (122 to 176°F). lf the machine is operated after raising
the oil temperature to 20°C (68°F). the life of the machine will
be extended.

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

Turn fuel control dial @ and @ to the center position between

r
low idling (MINI and high idling (MAX) and run the engine at
medium speed for about 5 minutes with no load.

Low idling
AMO¶O410

2. While running the engine at medium speed, press working mode

switch @ until the heavy-duty operation mode lamp is turned on.

2-71
 Push greasing switch @ to START side and carry out greasing
of the work equipment and swing circle. Grease will be supplied
automatically for 15 minutes. If you wish to stop before complet-
ing the 15 minutes, push greasing switch @ to STOP side.
During greasing, the lamp in the hatched portion (center of
switch) will light up.

Carry out greasing around the bucket.

For details see “11.17 GREASE PUMP”.

5. Set the safety lock lever @ to the FREE position, and raise the
bucket from the ground.

6. Operate bucket control lever @I and arm control lever @ slowly

to move the bucket cylinder and arm cylinder to the end of the Arm operation Bucket operation
stroke.
g:“RLK

AMo9oua

7. Carry out bucket and arm operation for 5 minutes at full stroke,
Le*
alternating between bucket operation and arm operation at 30
second intervals.
If the swing lock switch @I is set to the ON (actuated) position and
swing control lever @I is operated at full stroke, oil temperaturerise
can be increased earlier.

NOTICE
When the work equipment is retracted, take care that it does
not interfere with the machine body or ground.

2-72
 12. OPERATION

8. After carrying out the warming-up operation, check that each

gauge and monitor lamp is in the following condition.
l Engine water temperature gauge @I: Inside green range
0 Fuel gauge 0: Inside green range
0 Engine water temperature
hydraulic oil temperature monitor 0: OUT
Radiator water level monitor @I: OUT
Engine oil pressure monitor @I: OUT
Charge level monitor @: OUT
Fuel level monitor 0: OUT
Air cleaner clogging monitor @: OUT
Engine pre-heating monitor @I: OUT
Engine oil level monitor @I: OUT
Hydraulic oil level monitor 0: OUT
Hydraulic filter clogging monitor @: OUT

9. Check that there is no abnormal exhaust gas color, noise, or

vibration. If any abnormality is found, repair it.

10. Press working monitor mode switch @ until required operation

mode lamp is turned on.

2-73
12.3.2 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 30X), the warming-up operation is carried out automatically.

The automatic warming-up operation is canceled if the engine water

temperature reaches the specified temperature (30°C) 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
0 When the hydraulicoil is at a low temperature,do not carryout
operations or move the leverssuddenly. Always carry out the
warming-up operation.This will help to extendthe machinelife.
0 Do not suddenly acceleratethe engine before the warming-up
operation is completed.
Do not run the engine at low idling or high idling continuously
for more than 20 minutes.This will causeleakageof oil from the
turbocharger oil supply piping. lf it is necessaryto run the
engine at idling, apply a load from time to time or run the engine
at a mid-range speed.
11572040

1. Set fuel control dial @ and @to the low idling (MINI position and I I
run the engine for about 5 minutes without load.

I Low idling
AMO9EWl

2. Press working mode switch @ on the monitor panel until the H.0
(heavy-duty operation) mode lamp lights up.
I .

3. Turn fuel control dial @ and @ to the medium speed position.

Low idling
AM090410

2-74
4. Set safety lock lever 0 to the FREE position and raise the bucket
from the ground.

AW364166

5. Operate bucket control lever @I and arm control lever @ slowly

to move the bucket cylinder and arm cylinder to the end of their Arm operation Bucket operation
stroke.

6. Operate the bucket for 30 seconds and the arm for 30 seconds
in turn fully for 5 minutes.

NOTICE
When the work equipment is retracted, take care that it does
not interfere with the machine body or ground.

7. Turn fuel control dial @ and @ to the full speed (MAX) position
and carry out the operation is Step 6. for 3 - 5 minutes.

8. Repeat the following operation 3 - 5 times and operate slowly.

0 Boom operation RAISE c) LOWER
0 Arm operation IN ti OUT
l Bucket operation CURL c) DUMP
l Swing operation LEFT t) RIGHT
0 Travel (Lo) operation FORWARD t) REVERSE

REMARK
In the above operation is not carried out, there may be a delay
in response when starting or stopping each actuator, so continue the
operation until it becomes normal.

9. Use working mode switch @ on the monitor pane! to select the 11

working mode to be used.

1 AA307550

2-75
NOTICE
Canceling automatic warming-up operation
lf it becomes necessary in an emergency to lower the engine speed
to low idling, cancel the automatic warming-up operation as fol-
lows.

1. Turn fuel control dial @to the full speed (MAX) position and hold
it for 3 seconds.

2. When fuel control dial 0 is returned to the low idling (MINI

position, the engine speed will drop.

Low idling AM090340

2-76
12.4 MOVING MACHINE OFF

12.4.1 MOVING MACHINE FORWARD

A WARNING
Before operating the travel levers, check the direction of the
track frame. lf 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.

Clear all personnel from the machine and the area.

Clear all obstacles from the path of the machine.

ff the lever is moved inside the deceleration range, engine

speed will rise suddenly. Operate the levers carefully.

For machines equipped with the travel alarm (option), check

that the alarm works properly.

1. Set swing lock switch @ to the ON (actuated) position and

confirm that swing lock monitor lamp @ lights up.

2. Turn fuel control dial @ towards the full speeed position to

increase the engine speed.

3. Set safety lock lever @ in the FREE position, fold the work
equipment, and raise it 40 - 50 cm (16 to 20 in) from the ground.

2-77
4. Operate right and left travel levers @ or right and left travel
pedals @ as follows.

l When the sprocket is at the rear of the machine

Push levers @ forward slowly or depress the front part of pedals
@ slowly to move the machine off.

l When the sprocket is at the front of the machine

Pull levers @ backward slowly or depress the rear part of pedals
@ slowly to move the machine off.

5. For machines equipped with the travel alarm (option), check that
the alarm sounds.
If the alarm does not sound, please contact your Komatsu
distributor for repairs.

124.2 MOVING MACHINE BACKWARD

A WARNING
Before operating the travel levers, check the direction of the
track frame. lf 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.

Clear all personnel from the machine and the area.

Clear all obstacles from the path of the machine.

Use extreme care when reversing the machine. Note there is

an blind spot behind the machine.

if the lever is moved inside the deceleration range, engine

speed will suddenly rise. Operate the levers carefully.

For machines equipped with the travel alarm (option), check

that the alarm works properly.

1. Set swing lock switch @ to the ON (actuated} position and

confirm that swing lock monitor lamp @ lights up.

2-78
2. Turn fuel control dial @I towards the full speed (MAX) position
to increase the engine speed.

Full
M

I AMwow)

3. Set safety lock lever @ in the FREE position, fold the work
equipment, and raise it 40 - 50 cm (16 to 20 in) from the ground.

4. Operate right and left travel levers @ or right and left travel
pedals @ as follows.

0 When the sprocket is at the rear of the machine

Pull levers @ backward slowly or depress the rear part of pedals
@ to move the machine off.

0 When the sprocket is at the front of the machine

Push levers @forward slowly or depress the front part of pedals
@ to move the machine off.

Sprocket mnoas

5. For machines equipped with the travel alarm (option), check that
the alarm sounds.
If the alarm does not sound, please contact your Komatsu
distributor for repairs.

2-79
72.5 STEERING MACHINE

12.5.1 STEERING (CHANGING DIRECTION)

a WARNING
l Before operating the travel levers, check the position of the
I sprocket.
l if the sprocket is at the front, the operation of the travel levers
I is reversed.
l When turning in places where there is big resistance to
1 turning, turn at low speed using the LO (low) position.

Use the travel levers to change direction.

Avoid sudden changes of direction as far as possible. In particu-
lar, when carrying out counter-rotation (spin turn), stop the machine
first before turning.
Operate two travel levers @ as follows.

Changing direction of machine when stopped

When turning to the left: Turning left
Push the right travel lever forward to travel left when traveling when traveline
forward: and pull it back to turn left when traveling in reverse.

REMARK Turning left

when traveling
When turning to the right, operate the left travel lever in the in reverse
same way.

Steering when traveling (left and right travel levers both operated
in same direction)
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.

2-80
 12. OPERATION

When making counter-rotation turn (spin turn)

When turning lef? using counter-rotation, pull the left travel lever
back and push the right travel lever forward.

REMARK
When turning right using counter-rotation, pull the right travel
lever back and push the left travel lever forward.

2-81
12.6 STOPPING MACHINE

a WARNING
I
Avoid stopping suddenly. Give yourself ample room when
stopping.
When stopping the machine, select flat hard ground and avoid
dangerous places. lf it is unavoidably necessary to park the
machine on a slope, insert blocks underneath the track shoes.
As an additional safety measure, thrust the bucket into the
ground.
If the control lever is touched by accident, the work equipment Thrust the bucket

or the machine may move suddenly, and this may lead to a

serious accident. Before leaving the operator’s compartment,
always set the safety lock lever securely to the LOCK position.

AW36416B

1. Put the left and right travel levers @ in the neutral position, then
stop the machine.

2. Lower the engine speed using fuel control dial 0.

3. Lower the bucket horizontally until its underside touches the

ground.

4. Place lock lever @ to the lock position.

Low idling AMo903u)

, ,

2-82
 12. OPERATION

12.7 SWINGING I

A WARNING
l When operating the swing, check that the area around the
machine is safe.

l During swing operatins, do not put swing parking brake

i switch @ to ON.

1. Before swing operations, put swing parking brake switch @ to

OFF and confirm that swing lock lamp @ goes off.

NOTICE
Check that swing lock monitor @ goes out at the same time.

2. Operate left work equipment control lever @ to swing the upper

Leftswing
structure.

3. When not operating

@ ON (ACTUATED).
the swing, turn swing parking brake switch

2-83
12.8 OPERATION OF WORK EQUIPMENT

If any lever is operated when in the auto-deceleration actuated

The work equipment is operated by the left and right work

equipment control levers. The left work equipment control 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.

l If the work equipment control lever is returned to the neutral

position when the machine is stopped, even if the fuel control
lever is set to FULL, the auto-deceleration mechanism will act to
reduce the engine speed to a mid-range speed.

Swine owmtion

I
r
Boom oeerrtioo

Bucketo,eration

2-84
12.9 HANDLING WORKING MODE
WORKING MODE
The mode selector switch can be used to switch the mode to
match the operating conditions and purpose, thereby enabling work
to be carried out efficiently.
Make effective use of each mode as follows.

When the starting switch is turned ON, the working mode is set
to the most commonly used general operation mode, so normal
operations can be carried out without setting the mode.

Use the working mode switch to set the mode to the most -
efficient mode to match the type of work.

AA307550

Working mode Applicable operation

Powerful digging and loading for short

DH mode
time in quarry

H mode Normal digging and loading operations

Leveling, finishing operations, hauling
G mode
operations

NOTICE
Do not use the heavy-duty operation mode for breaker opera-
tions. If breaker operations are carried out in the heavy-duty opera-
tion mode, there is danger that the hydraulic equipment may be
damaged or broken.

2-85
12.10 PROHlBlTlONS FOR OPERATION

A WARNING
lf it is necessary to operate the work equipment control lever
when the machine is traveling, stop the machine before
operating the work equipment control lever.
lf the lever is moved inside the deceleration range, engine
speed will suddenly rise. Operate the levers carefully.
Never operate the machine on a rock bed (hard or soft rock).
Never carry out digging operations with the track gauge
retracted.
It is dangerous to travel over obstacles, so avoid such opera-
tions.
lf it is necessary for the machine to travel over boulders or
tree stumps, a large shock will be brought to bear on the
machine (particularly the undercarriage), so lower the travel
speed and travel so that the center of the tracks passes over
the obstacle.
When doing this, keep the work equipment close to the
INCORRECT
ground.

Prohibited operations using swing force

Do not use the swing force to compact soil or break earth
mounds or walls.
When swinging, do not dig the bucket teeth into the soil.
These operations will damage the work equipment.
AE171030

Prohibited operations using travel force

Do not leave the bucket dug into the ground and use the travel
force to excavate. This will bring excessive force to bear on the rear
of the machine.

Precautions when operating hydraulic cylinders to end of stroke

If the cylinder is operated to the end of its stroke during opera- : Margin
tions, force will be brought to bear on the stopper inside the cylinder,
and this will reduce the life of the machine. To prevent this, always
leave a small safety margin when operating the cylinders.

Prohibited operations using dropping force of bucket

Do not use the dropping force of the bucket as a pickaxe, breaker,
or pile driver. This will bring excessive force to bear on the rear of
the machine, and will not only damage the machine, but is also
dangerous.

2-86
Prohibited operations using dropping force of machine
Do not use the dropping force of the machine for digging. INCORRECT

INCORRECT

AE171080

Digging rocky ground

It is better to excavate hard rocky ground after breaking it up by
some other means. This will not only reduce damage to the machine
but make for better economy.

2-87
12.11 PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN TRAVELING

When traveling over obstacles such as boulders or tree stumps,
the machine (in particular, the undercarriage) is subjected 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.

PERMISSIBLE WATER DEPTH

NOTlCE
When driving the machine out of water, if the angle of the
machine exceeds 15”, the rear of the upper structure will go under
water, and water will be thrown up by the radiator fan. This may
cause the fan to break.
Be extremely careful when driving the machine out of water.

Do not immerse the machine in water by more than the permis- 1

sible depth (under swing circle 0).
In addition, for parts that have been immersed in water for a long
time, pump in grease until the old grease comes out from the
bearings. (Around the bucket pins, and swing circle)
12.12 PRECAUTIONS WHEN TRAVELING UP OR
DOWN HILLS

db WARNING
When traveling, raise the bucket approx. 20 - 30 cm (8 - 12
in) from the ground.
Do not travel downhill in reverse.
AE34152A

lt is dangerous to turn on slopes or to travel across slopes.

Always go down to a flat place to perform these operations.
It may be longer, but it will ensure safety.

lf the machine starts to slide or loses stability, lower the

bucket immediately and brake the machine.

Turning or operating the work equipment when working on

slopes may cause the machine to lose its balance and turn
over, so avoid such operations. It is particularly dangerous to INCORRECT CORRECT
swing downhill when the bucket is loaded.
lf such operations have to be carried out, pile soil to make a
platform on the slope so that the machine can be kept
horizontal when operating.

Do not travel on slopes of over 30’ as there is danger that the

machine may overturn.

1) When traveling down steep hills, use the travel lever and fuel
control lever to keep the travel speed low.
When traveling down slopes of more than 15”, set the work
equipment in the posture shown in the figure on the right, and
lower the engine speed.

AD34129A

2) When traveling up a steep hill of more than 15’, set the work
equipment in the posture shown in the diagram on the right.

2-83
Braking when 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.

lf shoes slip
When traveling uphill, if the shoes slip or it is impossible to travel
uphill using the force of the track only, it is possible to use the pulling
force of the arm to help the machine travel uphill.

Ii engine stops
l If the engine stops when traveling uphill, move the travel levers
to the neutral position, lower the bucket to the ground, stop the
machine, then start the engine again.

l When engine trouble causes the engine to stop with the work
equipment (boom) raised, place the traveling and steering levers
in NEUTRAL and immediately (within 2 or 3 minutes) operate the
boom lever fully to the LOWER side and lower the work equip-
ment until it is in contact with the ground.

Precautions on slopes
l If the engine stops when the machine is on a slope, never use
the left work equipment control lever to carry out swing opera-
tions. The upper structure will swing under its own weight.
l Do not open or close the door on the cab if the machine is on
a slope. This may cause a sudden change in the operating force.
Always keep the door locked.

2-90
 12. OPERATION

12.13 HOW TO ESCAPE FROM MUD

Always operate carefully to avoid getting stuck in mud. If the
machine does get stuck in mud, use the following procedures to get
the machine out.

l Place the machine push-up switch at position 0. This will

increase the pushing power of the boom and make it easier to
escape.

12.13.1 WHEN ONE SIDE IS STUCK

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 neces-
sary, put a board under the bucket also.

NOTICE
When using the boom or arm to raise the machine, always have
the bottom of the bucket in contact with the ground. (Never push
with the teeth). The angle between the boom and arm should be 90’
to 110”.

12.13.2 WHEN BOTH SIDES ARE STUCK

When the tracks on both sides are stuck in mud and the machine
will not move, lay boards as explained above, and dig the bucket into
the ground in front. Then pull in the arm as in normal digging
operations and put the travel levers in the FORWARD position to pull
the machine out.

2-91
12.14 WORK POSSIBLE USING HYDRAULIC
EXCAVATOR
In addition to the following, it is possible to further increase the
range of applications by using various attachments.

12.14.1 DIGGING WORK

This machine is designed to dig places lower than the level of
the machine.
If the arm digging angle is set to a range of 30” to the rear and 45”
to the front, the arm cylinder can be used effectively to carry out
work efficiently.

12.14.2 LOADING WORK

In places where the swing angle is small, work efficiency can be
enhanced by locating the dump truck in a place easily visible to the
operator.
Loading is easier and capacity greater if you begin from the front
of the dump truck body than if loading is done from the side.

1 AEO82730

12.15 PHENOMENA THAT ARE NOT FAILURES

Note that the following phenomena are not failures:
1. When the arm is pulled in, the speed of movement will drop
momentarily when the arm is more or less vertical.

2. The arm speed will drop momentarily when the bucket teeth are
more or less horizontal.

3. When starting or stopping the swing, noise will be emitted from

the brake valve.

4. When going down a steep slope at low speed, a noise will be

emitted from the travel motor.

2-92
12.16 PARKING MACHINE

I A WARNING
1
Avoid stopping suddenly. Give yourself ample room when
stopping.

When stopping the machine, select flat hard ground and

avoid dangerous places. lf it is unavoidably necessary to park
the machine on a slope, insert blocks underneath the track
shoes. As an additional safety measure, thrust the bucket into
the ground. Thrust the bucket

If the control lever is touched by accident, the work equip-

ment or the machine may move suddenly, and this may lead
to a serious accident, Before leaving the operator’s compart-
ment, always set the safety lock lever securely to LOCK
position.

1. Put left and right travel levers @ in the neutral position.

The machine stops.

2. Turn fuel control dial @ to lower the engine speed to low idling.

Low idling AM0903401

2-93
3. Lower the bucket horizontally until the bottom touches the
ground.

I AD34 1570

4. Set safety lock lever @ in the LOCK position.

AU364168

12.17 CHECK AFTER FINISHING WORK

Check the engine water temperature, engine oil pressure and
fuel level on the monitor gauge.

2-94
12.18 STOPPING ENGINE
12.18.1 NORMAL STOPPING

NOTICE
If the engine is abruptly stopped before it has cooled down,
engine life may be greatly shortened. Consequently, 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 medium speed to allow it to cool gradually, then stop
it.

1. Run the engine at low idling speed for about 5 minutes to allow
it go gradually cool down.

2. Turn the key in starting switch @ to the OFF position and stop
the engine. OFF
I
3. Remove the key from starting switch @_

2-95
12.182 STOPPING IN EMERGENCY

a CAUTION
Use the engine stop switch only when stopping the engine in
an emergency. When stopping normally, use the procedure in
12.18.1.

Using engine stop switch, fuel cut knob from ground

1. Press the red switch @ immediately beside the left steps.

I M372220 I

2. Turn fuel cut knob @ to the left to release the lock.

3. Pull the knob and turn it to the right to lock it and stop the engine.

l When starting the engine again after stopping it, turn the
fuel cut knob to the leti to release the lock, then press the
knob back in, and press the engine stop switch. Check that
engine emergency stop lamp @ on the panel on the right
side of the operator’s seat inside the cab is OFF, then start
the engine.

l Turn the fuel cut knob to the right to lock it.

P
OFF

2-96
Using engine stop switch inside engine room

NOTICE
The switch inside the engine room is provided to make it
impossible to start the engine from inside the cab when carrying
out inspection and maintenance inside the engine room. Normally,
keep this switch at the ON position (red lamp lighted up).

l Press red switch @ at the side of the steps for the engine room
in the center of the engine hood to stop the engine.

l When starting the engine again after stopping it, press the switch m
again. Check that engine emergency stop lamp @ on the p
on the right side of the operator’s seat inside the cab is OFF,
start the engine. I IcmXon\ I

2-97
12. OPERATION

12.19 CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, paint-
work, 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 stuck to the undercarriage.

12.20 LOCKING
Always lock the following places.
@ Door of operator’s cab
Always remember to close the window.
@ Fuel tank filler port
@ Battery box cover
@ Left side door of the machine (7 positions)
@ Right side door of the machine (2 positions)
@ Operator cab under box door
@ Engine hood (3 positions)
@ Box for storing emergency escape ladder

REMARK
Use the starting switch key to open and close all these places.

2-98
13. TRANSPORTATION

When transporting the machine, observe all related laws and

regulations, and be careful to assure safety.

13.1 PRECAUTIONS FOR TRANSPORTATION

g WARNING
l Determine the route for transporting the machine by taking
into account the width, height and weight of the machine.

l Ahnrays check that the door on the cab is closed and locked
before transporting the machine.

NOTICE
Always retract the radio antenna.

Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.

REMOVAL AND INSTALLATION OF MIRRORS

Mirrors are installed to the positions shown at right (The one
marked with % is optional). When removing and installing them for
replacement or transportation, observe the following procedure.

Removal
1. Loosen nut @ of mirror 0, and remove the latter from support
0.
2. Loosen bolt 0, and remove support @ and clamp @ from the
..
handrail.

Installation
1. Install support @ and clamp @ to the handrail, then secure it
with bolt 0.
2. Install mirror @ to support 0. then tighten nut 0.

2-99
13. TRANSPORTATION

13.2 PARTS FOR TRANSPORT

The dimensions in the diagrams are given in millimeters.

For ease of transport, the machine may be disassembled into the parts shown in the diagrams: the
body, operator‘s cab, track frames, ladder, platform, attachments and counterweight.
Ask your Komatsu distributor to carry out the disassembly work.

PC1800-6

Weight:
s0 : Lifting position

21000 kg x 2 = 42000 kg
(46200 lb x 2 = 92400 lb)

I-- 7436
w AU372310

Weight: 44000 kg
(96800 lb)

c 8731

Am372320

2-100
 13. TRANSPORTATION

Weight: 1230 kg
(2712 lb)

2100 1606. 7 J
AU372330

Weight: 1000 kg
(2200 lb)

AE179190

Weight: 50 kg
(110 lb)

I 650
c 596
AU372340

2-101
13. TRANSPORTATION

Weight: 12000 kg
(26500 lb)

AU372350

Weight: 22000 kg
(46400 lb)

i!i
700

Weight:
A1312360

17500 kg
(36500 lb)

AU372370

2-102
 13. TRANSPORTATION

Weight: 11600 kg
(25520 lb)

Weight: 9370 kg (11m3)

(20657 lb)
9985 kg ( 12m3)
(22013 lb)

I - I

Weight: 1288 kg x 2 = 2750 kg

(2834 lb x 2 = 5668 lb)

Weight: 1928 kg x 2 = 3856 kg

(4242 lb x 2 = 8484 lb)

Ml80460

2-103
13. TRANSPORTATION

Weight: 135 kg Weight: 80 kg

(298 lb) (187 lb)

AEl79270 AE179280

Weight: 70 kg Weight: 16 kg
(154 lb) (35 lb)

AE179290 AE179300

Weight: 45 kg
(99 lb)
T- Weight: 215 kg
(474 lb)

2-104
e
, 1037 1 c 667 A

AE179310
1 1”_?.
I.-

I
r
Y
\ n n
-
5310

u
-
u
I
 Weight: 9 kg Weight: 20 kg Weight: 21 kg
(20 lb) (44 lb) (46 lb)

AE179330 AEl79350

Weight: 35 kg Weight: 35 kg
(77 lb) (77 lb)

I-

llld? ,”
03

I-_

2464
B
1 2464 j
I- -I

AE179360 AEl79370

Weight: 24 kg Weight: 30 kg
(53 lb) (66 lb)

I 1070 1 1 786 _/

AEl79390

2-105
13. TRANSPORTATION

Weight: 28 kg Weight: 17 kg
(62 lb) (37 lb)

Weight: 8 kg
(18 lb)
I 90
AW364340

Weight: 8 kg
(18 lb)

11354350 A1364360

Z-106
 13. TRANSPORTATION

Weight: 31 kg Weight: 16 kg
(68 lb) (35 lb)

AE179400 AE179410

Weight: 20 kg Weight: 37 kg
(44 lb) (82 lb)

46

AE179420 AE179430

Weight: 29 kg Weight: 45 kg
(64 lb) (99 lb)

3823

1892
r ‘1

AU364380

2-107
14. COLD WEATHER OPERATION

14.1 PRECAUTIONS FOR LOW TEMPERATURE

If the temperature is low, it becomes difficult to start the engine,
and the coolant may freeze, so do as follows.

14.1.1 FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components. For
details of the specified viscosity, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

14.1.2 COOLANT

NOTICE
l Never use methanol, ethanol or propanol based antifreeze.
l Absolutely avoid using any water leak preventing agent irre-
spective of whether it is used independently or mixed with an
antifreeze.
l Do not mix one antifteeze with a different brand.

For details of the antifreeze mixture when changing the coolant,

see “24.3 WHEN REQUIRED”.
Use a Permanent Antifreeze (ethylene glycol mixed with corro-
sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements, ask the supplier of that
antifreeze for information.
Standard requirements for permanent antifreeze
l SAE .... ....... .... .............. ......... ........... ... ...... .............................. . 31034
l FEDERAL STANDARD ... ................. .............. ................. O-A-548D

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.

2-108
 14. COLD WEATHER OPERATION

14.1.3 BATTERY

A WARNING
l To avoid gas explosions, do not bring fire or sparks near the
battery.

l 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.

When the ambient temperature drops, the capacity of the battery

will also drop. If the battery charge ratio is low, the battery electro-
lyte may freeze. Maintain the battery charge as close as possible to
lOO%, 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.

100% 1.28 1.29 130 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

l When electrolyte level is low, add distilled water in the morning

before work instead of after the day’s work. This is to prevent
fluid from freezing at night.

2-109
14. COLDWEATHEROPERATION

14.2 F;‘RE;UTIONS AFTER COMPLETION OF

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.

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 electrolyte level is found low, add distilled water in the morn-

ing 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.

14.3 AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as

follows.
l Replace the fuel and oil for all parts with oil of the viscosity
specified.
For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE”.

l If for any reason permanent antifreeze cannot be used, and an

ethyl glycol base antifreeze (winter, one season 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 water.

2-110
15. LONG-TERM STORAGE

15.1 BEFORE STORAGE

NOTICE
To protect the cylinder rod when the machine is not being used,
set the work equipment in the posture shown in the diagram.
(This prevents rusting of the cylinder rod)

When putting the machine in storage for a long time, do as

A0341570
follows.
After washing and cleaning each portion, store the machine
indoors. When you must leave the machine outdoors, park the
machine on a level place where it will not suffer from flooding
or other natural disasters, and cover it with canvas, etc..

Completely fill the fuel tank, lubricate and change the oil before
storage.

Apply a thin coat of grease to 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 separately.

If the ambient temperature is expected to drop below 0°C.

always add antifreeze to the cooling water.

Set the fuel control dial to the engine low idling position and
place the other control levers and switches at the N or OFF
position.
Set the lock lever to the LOCK position.

2-111
15. LONG-TERM STORAGE

15.2 DURING STORAGE

A 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.

Operate the engine and move the machine for a short distance
once a month so that a new film of oil will be coated over movable
parts and component surfaces. At the same time, also charge the
battery.

l Also carry out cooler operation in the case of machines equipped

with an airconditioner.

l Before operating the working equipment, wipe off the grease on

the hydraulic piston rod.

15.3 AFTER STORAGE

NOTKZE
If the machine was stored without carrying out the monthly rust
prevention operation, request your Komatsu distributor for service.

Carry out the following procedure when taking the machine out
of long-term storage.

l Wipe off the grease from the hydraulic cylinder rods.

l Add oil and grease to all places.

l Bleed air from hydraulic cylinder circuit.

Refer to the item of BLEEDING AIR FROM CIRCUIT.

15.4 ~;W&l~~ MACHINE AFTER LONG-TERM

When starting the machine after a long-term storage, first cancel

the automatic warming-up function as follows.
1. Turn the starring switch key to the ON position.

2. Turn the fuel control dial from the low idling (MINI position to
the full (MAX) position, hold it there for 3 seconds, then return
it to the low idling (MINI position and start the engine.

2-112
16. TROUBLESHOOTING

16.1 WHEN FUEL RUNS OUT

Once the fuel runs out, supply fuel and bleed air from the fuel
piping, then start the engine. For air bleeding method, see “24.8
EVERY 500 HOURS SERVICE”.

16.2 PHENOMENA THAT ARE NOT FAILURES

Note that the following phenomena are not failures:

1. The arm speed will drop momentarily when the bucket teeth are
more or less horizontal.

2. When starting or stopping the swing, noise will be emitted from

the brake valve.

3. When going down a steep slope at low speed, a noise will be

emitted from the travel motor.

16.3 METHOD OF TOWING MACHINE

A WARNING
When towing the machine, use a wire rope that has ample
strength for the weight of the machine that is being towed.

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.

16.4 PRECAUTIONS ON PARTICULAR JOBSITES

1. 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.

2. For heavy-duty operations and deep digging, carry out greasing

of the work equipment mounting pins every time before opera-
tion.

After greasing, operate the boom, arm and bucket several times,
then grease again.

2-113
16. TROUBLESHOOTING

16.5 IF BATTERY IS DISCHARGED

A WARNING
When checking or handling the battery, stop the engine and
turn the starting switch key to the OFF position before
starting.

The battery generates hydrogen gas, so there is danger of

explosion. Do not bring lighted cigarettes near the battery, or
do anything that will cause sparks.
When removing,
disconnect the
Battery electrolyte is dilute sulphuric acid, and it will attack cable from the
your clothes and skin. lf it gets on your clothes or on your ground terminal
first
skin, wash it immediately off with large amounts of water. lf
it gets in your eyes, wash it out with fresh water, and consult
a doctor.

When handling battery, always wear protective goggles.

When removing the battery, first disconnect the cable from

the ground (normally, from the negative 0 terminal). When
installing, install the positive @ terminal first. lf a tool touches
the cable connecting the positive terminal and the chassis,
there is danger that it will cause sparks.

lf 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, check which is the positive CiJ

terminal and negative @ terminal.

16.51 PRECAUTIONS FOR CHARGING BATTERY

When charging the battery without removing it from the ma-
chine.

l Before charging, disconnect the wiring of the battery terminals,

since abnormal voltage may be applied to the alternator to break
it.
l Keep all battery caps removed while charging to release the gas
produced.
l If the battery is overheated (the battery fluid temperature ex-
ceeds 45”CL stop charging for a while.
l After the battery is charged fully, stop charging immediately.
Overcharging can cause the following.
1) Overheating of battery
2) Reduction of battery fluid
3) Battery trouble
l Do not connect the cables to the battery inversely (connect the
@ cable to the 0 terminal, and the @ cable to the @ terminal).
If they are connected so, the alternator, etc. may be broken.
l When handling the battery for a purpose other than check of the
battery fluid level or measurement of specific gravity of the
battery fluid, disconnect the cables from it.

2-114
 16. TROUBLESHOOTING

16.5.2 STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:

Precautions when connecting and disconnecting booster cable

a WARNING
When connecting the cables, never contact the positive @
and negative 0 terminals.

When starting the engine with a booster cable, always wear

safety glasses.

Be careful not to let the normal machine and problem ma-

chine contact each other. This prevents sparks from generat-
ing near the battery which could ignite the hydrogen gas
given off by the battery. lf 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 revolving 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. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.

NOTICE
l The size of the booster cable and clip should be suitable for the
battery size.

l The battery of the normal machine must be the same capacity

as that of the engine to be started.

l Check the cables and clips for damage or corrosion.

l Make sure that the cables and clips are firmly connected.

2-115
16. TROUBLESHOOTING

Connecting the booster cables

Keep the starting switch 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 position.

2. Connect one clip of booster cable @ to the positive @ terminal

of the problem machine.

3. Connect the other clip of booster cable @ to the positive @

terminal of the normal machine.

4. Connect one clip of booster cable @I to the negative 0 terminal

of the normal machine.

5. Connect the other clip of booster cable @I to the engine block of

the problem machine.

Starting the engine

1. Make sure the clips are firmly connected to the battery terminals.

2. Start the engine of the normal machine and keep it running 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.

Disconnecting the booster cables

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 @I from the engine block of the
Batten/ of the
problem machine. normal machine@J problem machhne
I I
c v
-Ql
2. Remove the other clip of booster cable @ from the negative 0 Engine blodc ofthe problem machine Awu98,
terminal of the normal machine.

3. Remove one clip of booster cable @from the positive @terminal

of the normal machine.

4. Remove the other clip of booster cable @ from the positive @

terminal of the problem machine.

Z-116
 16. TROUBLESHOOTING

16.6 OTHER TROUBLE

16.6.1 ELECTRICAL SYSTEM
0 ( ): Always contact your Komatsu distributor when dealing with these items.
l 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 l Defective wiring (o Check, repair loose terminals,
when the engine runs at high disconnections)
speed l Defective adjustment of fan belt l Adjust fan belt tension

tension For details, see EVERY 260

Lamp flickers while engine is HOURS SERVICE
running

Charge level monitor flashes even l Defective alternator (o Replace)

when engine is running l Defective wiring (o Check, repair)

Abnormal noise is generated from l Defective alternator (0 Replace)

alternator

Starting motor does not turn when l Defective wiring (o Check, repair)
starting switch is turned to ON l Defective starter (o Replace)
l Insufficient battery charge l Charge

l Defective safety relay (o Replace)

Pinion of starting motor keeps going l Insufficient battery charge l Charge

in and out

Starting motor turns engine l Insufficient battery charge l Charge

sluggishly l Defective starting motor (o Replace)

Starting motor disengages before l Defective wiring (o Check, repair)

engine starts l Insufficient battery charge l Charge

l Disconnection heater plug (o Replace)

Pm-heating monitor does not light l Defective wiring (o Check, repair)

l Defective heater relay (o Replace)
l Defective monitor (o Replace)

Oil pressure monitor does not l Defective monitor (o Replace)

light up when engine is stopped l Defective caution lamp switch (o Replace)
(starting switch at ON position)

Charge level monitor does not l Defective monitor (o Replace)

light up when engine is stopped l Defective wiring (o Check, repair)

2-117
16. TROUBLESHOOTING

16.6.2 CHASSIS
0 ( ): Always contact your Komatsu distributor when dealing with these items.
l 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, l Lack of hydraulic oil l Add oil to specified level,
boom, arm, bucket is slow see CHECK BEFORE
STARTING

Pump generates abnormal l Clogged element in hydraulic l Clean, see EVERY 2000
noise tank strainer HOURS SERVICE

Excessive rise in hydraulic l Loose fan belt l Adjust fan belt tension,
oil temperature see EVERY 250 HOURS
SERVICE
l Dirty oil cooler l Clean, see EVERY 566
HOURS SERVICE
l Lack of hydraulic oil l Add oil to specified level,
see CHECK BEFORE
STARTING
I

Track comes off l Track too loose l Adjust track tension, see
WHEN REQUIRED

l Add oil to specified level,

see CHECK BEFORE
STARTING

2-118
16.6.3 ENGINE
l ( 1: Always contact your Komatsu distributor when dealing with these items.
l 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 l Engine oil pan oil level is low l Add oil to specified level, see
lights up (sucking in air) CHECK BEFORE STARTING
Clogged oil filter cartridge l Replace cartridge, see EVERY
250 HOURS SERVICE
Defective tightening of oil pipe (e Check, repair)
joint, oil leakage from damaged
part
Defective engine oil pressure (e Replace sensor)
sensor
Defective monitor (e Replace monitor)

Steam is emitted from top part l Cooling water level low, water l Add cooling water, repair, see
of radiator (pressure valve) leakage CHECK BEFORE STARTING
l Loosen fan belt l Adjust fan belt tension, sea

EVERY 250 HOURS SERVICE

l Dirt or scale accumulated in l Change cooling water, clean

cooling system inside of cooling system, see

WHEN REQUIRED
Clogged radiator fin or l Clean or repair, see EVERY

damaged fin 500 HOURS SERVICE

Radiator water level monitor l Defective thermostat (e Replace thermostat)
lights up l Loose radiator filler cap (high a Tighten cap or replace packing
altitude operation)
l Defective water level sensor (e Replace sensor)
l Defective monitor te Replace monitor)

Engine does not start when l Lack of fuel a Add fuel, see CHECK
starting motor is turned BEFORE STARTING
l Air in fuel system l Repair place where air is

sucked in, see EVERY 500

HOURS SERVICE
Defective fuel injection pump or le Replace pump or nozzle)
nozzle
Starting motor cranks engine
sluggishly
See ELECTRICAL SYSTEM
Preheating monitor does not
light up I-
Defective compression
0 Defective valve clearance [O Adjust valve clearance)

2-119
16. TROUBLESHOOTING

ENGINE kont’d) (16.6.3)

Problem Main causes Remedy

Exhaust gas is white or blue l Too much oil in oil pan l Add oil to specified level,
see CHECK BEFORE
STARTING
0 Improper fuel l Change to specified fuel

Exhaust gas occasionally turns Clogged air cleaner element l Clean or replace, see WHEN
black REQUIRED
Defective nozzle (0 Replace nozzle)
Defective compression (0 See defective compression
above)
Defective turbocharger l Clean or replace turbocharger
Clogged air cooled after cooler l Clean or replace, see WHEN

fin REQUIRED

Combustion noise occasionally l Defective nozzle (e Replace nozzle)

makes breathing sound

Abnormal noise generated l Low grade fuel being used l Change to specified fuel
(combustion or mechanical) l Overheating l Refer to “Radiator water level
monitor lights up” as above
l Damage inside muffler (o Replace muffler)
l Excessive valve clearance (o Adjust valve clearance)

2-120
16.6.4 ELECTRONIC CONTROL SYSTEM
If an error code is displayed on the machine monitor display
(normally this displays the time), follow the self-diagnostic remedy
table below.

Machine monitor failure display

Monitor display Failure mode Remedy

E02 lVC valve system error When pump prolix switch is turned ON, normal
operations become normal, but carry out inspection
immediately. (%_)

E03 Swing brake system Turn swing prolix switch ON and release brake.
error When applying swing brake, operate swing lock
switch manually. In this case, carry out inspection
immediately. (Z)

E05 Governor system error The governor cannot carry out control. Operate the
I governor lever manually. To secure at the full
position, there is a mounting hole for the lock bolts
in the bracket. In this case, carry out inspection
immediately.

Stop the engine, check the engine oil level and

PTO oil level.

Normal operation is possible, but carry out

inspection immediately.

EOE Abnormality in network If the engine can be run, move the machine to
(pump absorption torque a safe posture, then carry out inspection
reduced or engine immediately.
stopped) If the engine is started and then stalls, turn the
TVC prolix switch ON, move the machine to
a safe posture, then carry out inspection
immediately.
If the engine is stopped, also carry out inspection
immediately.

If no error code is displayed but work Carry out inspection immediately.

equipment or swing cannot be operated

%: For details of handling the pump prolix switch and swing prolix switch, see “11.2 SWITCHES”.

2-121
MAINTENANCE
17. GUIDES TO MAINTENANCE

Do not carry out any inspection and maintenance operation that is not given in this manual.
Perform maintenance work on hard, flat ground.

Check service meter:

Check the service meter reading every day to see if the time has come for any necessary maintenance
to be carried out.

Komatsu genuine replacement parts:

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

Komatsu genuine oils:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for
ambient temperature.

Always use clean washer fluid:

Use automobile window washer fluid and be careful not to let any dirt get into it.

Always use clean oil and grease:

Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away
from oil and grease.

Wipe off the old grease:

After greasing, up, always wipe off the old grease that was forced out.

Keeping the machine clean:

Always keep the machine clean. This makes is easier to find parts causing problems. Keep in particular
grease fittings, breathers and oil level gauges clean and avoid foreign matters from getting in them.

Be careful of hot water and oil:

Draining hot oils and coolants and removing their filters immediately after the engine stops are
hazardous. Allow the engine to cool.
If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 40°C)
before draining it.

Checking for foreign materials in drained oil and on filter:

After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign
materials. If large quantities of metallic particles or foreign materials are found, consult your Komatsu
distributor.

Fuel strainer:
If your machine is equipped with a fuel strainer, do not remove it while fueling.

Oil change:
Check or change oils in the places where dust is scarce to keep foreign materials away from oils.

Adding fuel:
When adding fuel, be careful not to allow the water collected at the top or bottom of the drum to get
into the fuel.

3-2
 17. GUIDES TO MAINTENANCE

Warning tag:
Attach warning tag to the starting switch or other appropriate control lever to prevent any person who
is not aware of the circumstances from starting the engine.

Obey precautions:
During the operation, always obey the precautions on the safety label attached to the machine.

Welding instructions:
l Turn off the engine starting switch.
l Do not apply more than 200 V continuously.
l Connect the grounding cable within 1 m from the area to be welded.
l Avoid seals or bearings from being between the area to be welded and the position of grounding
point.
l Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding
point.

Fire prevention:
Use nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from light
oil.

Clamp faces:
When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with
new ones. Be sure to fit O-rings and gaskets when assembling.

Objects in your pockets:

Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when
you bend over the machinery while working on it.

Checking undercarriage:
When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and
damage to bolts and nuts. Loosen the track tension a little when working in such areas.

Precautions when washing machine:

l Never spray steam or water directly on the connectors or mechatronics parts.
l Do not allow water to get on the monitors and controllers inside the operator’s cab.
l Never spray steam or water directly at the radiator or oil cooler portions.

3-3
17. GUIDES TO MAINTENANCE

Pre-and post-work checks:

Before starling work in mud, rain, snow or at the seashore, check plugs and valves for tightness.
Wash the machine immediately after the work to protect components from rusting.
Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they
are submerged in water.

Dusty worksites:
When working at dusty worksites, do as follows:
l Inspect the dust indicator to see whether the air cleaner is blocked up. Clean the air cleaner at shorter
intervals than specified.
l Clean the radiator core frequently to avoid clogging.
l Clean and replace the fuel filter frequently.
l Clean electrical components, especially the starting motor and alternator, to avoid accumulation of
dust.

Avoid mixing oils:

Never mix oils of different brands. If you have only oil which is a different brand from the one that is
used in the machine, do not add it but replace all the oil.

Check oil level:

When adding oil or checking the oil level, ensure that the oil is at the correct level.

Electrical equipment:
When washing the machine, take care not to splash water over the electrical equipment. If it is soaked
with water, it may not operate normally.

Working at seashore:
When working at seashore, check that the various plugs and valves, etc., are tightened up properly. After
completion of work, thoroughly wash the machine and carefully clean all electrical equipment to ensure
that is does not corrode.

3-4
 17. GUIDESTO MAINTENANCE

Precautions when carrying out maintenance on hydraulic equipment, circuit, and hvdraulii system:
Stop the machine on level ground, lower the bucket to the ground, and set so that there is no pressure
in the cylinder circuit.
Stop the engine.
Immediately after operations, the hydraulic oil and lubricating oil is at high temperature and
pressure, so wait for the oil temperature to cool down before starting maintenance.
Even when the temperature has gone down, the circuits may be under internal pressure, so when
loosening the plugs, bolts, or hose connections, do not stand directly in front, and loosen gradually
to release the internal pressure.
When carrying out inspection or maintenance of the hydraulic circuit, always release the internal
pressure inside the hydraulic tank before starting.

Bleed air:
After changing the oil, replacing the filter element, or cleaning the strainer, bleed the air from the circuit.
After changing the oil in the hydraulic tank, replacing the element, removing the hydraulic cylinders or
work equipment piping, or replacing or cleaning the line filter element, bleed the air from the circuit after
completing the operation. For details of the method of bleeding the air, see BLEEDING AIR FROM
CIRCUIT.

3-5
18. OUTLINES OF SERVICE

l Use Komatsu genuine parts for replacement.

l When changing or adding oil, do not use a different type of oil.

l Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as
shown in the table below.

Swing machinery case

Final drive case SAE 30
API classification CD
Damper case

Hydraulic tank
I SAE low
API classification CD

ASTM D975 No. 2

(However, ASTM D975 No. 1 is
Fuel tank used for the winter season
(October to March)

Komatsu Super Coolant

Radiator
I (AF-ACL) 41% added to water

18.1 OUTLINE OF OIL, FUEL, COOLANT

18.1.1 OIL
Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and
Maintenance Manual. Even if the oil is not dirty, always replace it 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 machines 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 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 at the same time.

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.

3-6
 18. OUTLINES OF SERVICE

18.1.2 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 -15°C (VF)), 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.

18.1.3 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 original anti-freeze in the coolant when the machine
is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.

Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing proportions, see 24.3.2 CLEAN INSIDE OF COOLING SYSTEM.

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from
the air in the coolant.

3-7
18. OUTLINES OF SERVICE

18.1.4 GREASE
l Grease is used to prevent twisting and noise at the joints.

l The nipples not included in the maintenance section are those for overhaul, so they do not need
grease.
If any part becomes stiff after being used for long time, add grease.

l 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.

18.1.5 STORING OIL AND FUEL

l Keep indoors to prevent any water, dirt, or other impurities from getting in.

l 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.

l 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).

18.1.6 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, it is necessary to consider replacing 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 stuck 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.

8-8
18.2 OUTLINE OF ELECTRICAL SYSTEM

If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result
in hazardous malfunction of the machine.

Services relating to the electric system are (1) check of fan belt tension, (2) check of damage or wear
of the fan belt and (3) check of battery fluid levef.

Never remove or disassemble any electric components installed in the machine.

Never install any electric components other than those specified by Komatsu.

Be careful to keep water away from the electric system when washing the machine or when it rains.

Since the controller for the control system may cause malfunction due to external wave interference,
before installing a radio receiver and a walkie-talkie or citizen band, consult your Komatsu distributor.

When working at the seashore, carefully clean the electric system to prevent corrosion.

When installing a car 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.

3-9
18.3 OUTLINE OF HYDRAULIC SYSTEM

During operation and immediately after operation is ended, the temperature of the hydraulic system
still remains high.
In addition, high hydraulic pressure is applied to the system. Take care when inspecting and
maintaining the hydraulic system.
o Stop the machine on level ground, lower the bucket to the ground, then set so that there is no
pressure applied to the cylinder circuit.
o Always stop the engine.
o Immediately after operations, the hydraulic oil and lubricating oil are at high temperature and
high pressure, so wait for the oil temperature to go down before starting maintenance.
Even when the temperature goes down, the circuit may still be under internal pressure, so when
loosening the plug or screw, or the hose joint, do not stand in front of the part. Loosen it slowly
to release the internal pressure before removing it.
o When carrying out inspection or maintenance of the hydraulic circuit, always bleed the air from
the hydraulic tank to remove the internal pressure.

Periodic maintenance includes the inspection of the hydraulic oil level, replacement of the filter and
refilling of hydraulic oil.

When the high pressure hose, etc., is removed, check the O-ring for damage. If necessary, replace
it.

After the hydraulic filter element and strainer are cleaned or replaced, or after the hydraulic system
is repaired or replaced or the hydraulic piping is removed, bleed air from the hydraulic circuit.

The accumulator is charged with high-pressure nitrogen gas. Incorrect handling may be dangerous.
For the handling procedure, see “11.19 Handling accumulator”.

3-10
18.4 RELEASING PRESSURE

When disassembling the machine or removing the piping during

inspection or maintenance, always release the pressure as follows.

RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUlT, SWING

CIRCUlT, TRAVEL ClRCUlT

A WARNING
When removing the oil filler cap of the hydraulic tank, turn it
slowly to release the internal pressure before taking off the cap.

1. Lower the work equipment to the ground in a stable flat place

as shown in the diagram, then stop the engine.
Set the lock lever to the FREE position.
:. After stopping the engine, move each work equipment control
lever to the end of its travel within 5 to 6 seconds.
Leave the starting switch ON.
:. Remove the cap of the hydraulic tank.
4. Start the engine, run it for approx. 10 seconds, then stop the
engine again.
l When running the engine, do not raise the speed above 1000
rpm.
Set the work equipment control levers to neutral.
:. After stopping the engine, move each work equipment control
lever to the end of its travel within 5 to 6 seconds.
0 Repeat Steps 4 to 5 three times.
I 1

A CAUTION
When the piping for the work equipment circuits is removed, for
safety, insert a hose with quick coupler into the coupler installed
to each circuit to completely remove the remaining pressure.

1. Boom cylinder head end

2. Boom cylinder bottom end
3. Arm cylinder head end
4. Arm cylinder bottom end
5. Bucket cylinder head end
6. Bucket cylinder bottom end

RELEASING PRESSURE IN ACCUMULATOR CIRCUIT

Pilot circuit
Stop the engine, set lock lever @ to the FREE position, then move
each work equipment control lever 3 to 4 times to the end of its
travel. After 1 minute passes, the pressure is relieved.
l Do not loosen the piping less than 1 minute after releasing
pressure.

3-11
18. OUTLINES OF SERVICE

Hydraulic idler cushion circuit

Slowly loosen stop valve @ installed on the inside of the axle,
and after one minute the pressure is released.
l Do not loosen the valve quickly.
This will generate high pressure inside the tank circuit.
l Use the special knob to open and close stop valve 0.

Specialhandle Ml 69680

3-12
 18. OUTLINES OF SERVICE

18.5 BLEEDING AIR FROM CIRCUIT

After assembling piping disconnected during inspection and

maintenance, always bleed the air from the circuit as follows.

PRECAUTIONS WHEN BLEEDING AIR

Bleed the air in order as follows.
1. Pump (for swing, for travel, work equipment)
2. Motor (for swing, for travel)
3. Idler cushion circuit
4. Work equipment circuit
Run the engine at less than 1000 rpm and operate the cylinders
slowly.
Do not raise the pressure inside the cylinder by suddenly oper-
ating the cylinder, and do not operate the cylinder to the end of
its stroke.
For the first return movement of each cylinder, be particularly
careful to operate the cylinder slowly.
During the first stroke of the cylinder, there is a large amount of
air inside the circuit, so the work equipment will not move for
more than 10 seconds.
However, do not move the lever to the end of its travel.

3-13
18. OUTLINES OF SERVICE

BLEEDING AIR FROM PUMP

Bleed the air at the same time from the swing, travel, hydraulic,
and pilot pumps.
If the pump assembly has been removed, or the oil in the
hydraulic tank has been changed, bleed the air from the pump as
follows to prevent the pump from seizing.

Rear ene ine

Front engine

AU’372428
L
Name of pump Front engine Rear engine
Hydraulic pump Pl, P2 P3. P4
Swing pump PSl PS2
Gear pump PGl PG2

l Install tube @I to the plug to prevent the discharge oil from

spurting out.

1. Loosen bleeders @ - @I (14 places) of each pump one or two

turns.

2. Add oil to fill the hydraulic tank to the specified level.

Keep the oil filler cap @ off after adding oil to the hydraulic tank.

3. Sheck that oil flows out from gear pump @ and @ and hydraulic
oump bleeders 0, 0, 0, and 0, then temporarily tighten plugs
TJ,@, 0, 0, 0, and @.

4. Check that the air has stopped spurting out from swing pump
plugs @ and 8, then temporarily tighten rear engine plug 8.
Leave front engine plug @ loosened.

I I r \I\ Y AEl78710 I

3-14
18. OUTLINES OF SERVICE

BLEEDING AIR FROM MOTOR

Travel motor
1. Start the engine and run at low idling.

2. Loosen plug @ of the travel motor 1 - 2 turns.

Loosen the plugs for all four motors.

3. When no more cloudy white oil comes out frm the tip of plug 0,
the air bleeding is completed.

4. Tighten plug 0.
Tightening torque: 8.8 f 1 Nm (0.9 -c 0.1 kgm, 6.5 A 0.7 Ibft)

Swing motor
Loosen plug @ of the swing motor 1 - 2 turns.

Start the engine and run at low idling.

When no more cloudy white oil comes out from the port of plug
0, the air bleeding is completed.

Tighten plug 0.
Tightening torque: 8.8 r 1 Nm (0.9 t 0.1 kgm, 6.5 + 0.7 Ibft)
Carry out the same procedure for the front and rear motors.

3-16
 18. OUTLINES OF SERVICE

BLEEDING AIR FROM IDLER CUSHION CIRCUlT

Before pumping grease into the grease cylinder, always bleed
the air.
/
1. Loosen grease fitting @ of the greae cylinder one turn. (left and
right, 2 places)
Grease fitting @I can be loosened until it contacts the stopper,
but do not remove the stopper and loosen it any further.

2. Open stop valves @ and @ on the inside of the accelerator fully.

3. Loosen air bleed plug @I of the cushion cylinder approx. one

turn. (left and right, 2 places)

4. Start the engine and run at idling for 2 to 3 minutes.

5. When no more cloudy white oil comes out from air bleed plug
@ of the cushion cylinder, close stop valve 0.
Leave stop valve @ open.

6. Operate the right travel lever 2 or 3 times to the FORWARD and

REVERSE position.

7. Check that oil comes out from air bleed plugs @ (left and right,
2 places) and 0, then close stop valve @ and air bleed plugs @
and 0.
AE179HO

8. Tighten grease fittings @ (left and right, 2 places).

REMARKS
l Always tighten grease fitting @ last.
This completes bleeding of the air and pumping in of pressure
oil.
l Check that all the stop valves and air bleed plugs are closed.
AEl79550
l Check that protrusion @ of the cushion cylinder plunger is 135
-c 5 mm (5.3 * 0.2 in).

Hydrauric cushion i.i-

-_-
CYI inder
AE176570

3-17
18. OUTLINES OF SERVICE

BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT

After changing the oil in the hydraulic tank or replacing the line
filter, after reassembling the cylinders or piping, or after reassem-
bling the pumps or suction piping, always bleed the air from the
hydraulic circuit.
Run the engine at low idling and do as follows:

1. Operate each cylinder 4 - 5 times to a point 100 mm from the end

of its stroke.

When operating for the first time, there is a large amount of air
in the circuit, so the work equipment will not move for approx. 10
seconds. Be careful not to operate the lever to the full stroke.

2. Keep the engine at low idling and operate each cylinder from the Do not contact ground surface
I ADZ.41
59A
point 100 mm from the end of its stroke slowly (take at least 10
seconds) to extend the cylinder to the end of its stroke. Hold the
work equipment control lever for 3 minutes at the full stroke.

3. Run the engine at high idling and operate each cylinder from the
point 100 mm from the end of its stroke slowly (take at least 10
seconds) to extend the cylinder to the end of its stroke. Hold the
work equipment control lever for 1 minute at the full stroke.

l The operation in Steps 1. - 3. will bleed the air from inside the
cylinders.

0 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.

3-18
19. CONSUMABLE PARTS LIST

Consumable 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 consumable parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts 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.

Replacement
Item Part No. Part Name Qw frequency

07063-01210 Element
Every 250 hours service
(07009-15180) (O-ring)
Hydraulic oil filter
07063-51210 Element
Every 500 hours service
(07000-15180) (O-ring)

Drain filter 113-60-23160 Cartridge 2 Every 250 hours service

Engine oil filter 600-211-1231 Cartridge 4 Every 250 hours service

Engine bypass filter 600-212-1511 Cartridge 2 Every 250 hours service

Fuel filter 600-311-7732 Cartridge 2 Every 250 hours service

209-60-63210 Element 2
Line filter
209-60-63310 Element I 4 I
Corrosion resistor 600-41 l-l 171 Cartridge 2 Every 1000 hours service

Hydraulic oil tank

breather element
285-62-17320 Element
I I 2 Every 1000 hours service

6128-81-7042 Element assembly 2

Air cleaner
600-181-4400 Outer element assembly 2

Komatsu tooth
Point
Bucket 21T-72-74311
(Pin)
(21T-72-74320)

3-19
 IEL, COOLANT AND LUBRICANTS ACCORDING
UT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY

KINDOF
RESERVOIR
FLUID 2 -4 14 32 50 68 86 104-F
0 -20 -10 0 IO
Specified Refill
20 30 4O’C

38 Q 33.5 e
Engine oil pan zront & rear) (Front & rear)
10.0 US gal 8.9 US gal

20 e 20 e
PTO case ‘rant & rear) (Front & rear)
5.3 US gal 5.3 US gal

30 e 30 e
Swing machinery case Engine oil Front & rear) (Front & rear)
7.9 US gal 7.9 US gal

85 Q 85 Q
Final drive case 22.5 US gal 22.5 US gal
(each) (each)

2400 Q 1600 Q
Hydraulic system 634 US gal 396 US gal

2300 Q
Fuel tank Diesel fuel
608 US gal

Grease fitting Grease

85 Q
Cooling system Water Front & rear) -
22.4 US gal

% ASTM D975 No. 1

3-20
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan at every periodic maintenance
interval given 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 l/2 of regular interval

Above 1.0% 1 l/4 of regular interval

When starting the engine in an atmospheric temperature of under O’C (32“F), be sure to use engine
oil of SAElOW, SAElOW-30 and SAE15W-40, even though 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 (SAElOW-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

3-21
20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil
Anti-freeze
[CD or CEI
Coolant
SAEIOW, 30, 40 Gear Oil Grease
rl0. Supplier [Ethylene Glycol
lOW30, 15W40 [GL4 or GL-51 [Lithium-Base1
Base1
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked l is CE.)
EOIO-CD AF-ACL
E030-CD GO90 G2-LI AF-PTL
1 KOMATSU
EOIO-30CD GO140 GZ-LI-S AF-PT (Winter, one
E015-40CD season type

Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP
grade
*Sigma turbo

Multi-purpose gear RYKON premium

3 AMOCO *Amoco 300
oil grease

Litholine HEP 2
4 ARC0 *Arcofleet S3 plus 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 HYP~Y Anti-freeze
Spheerol EPL2
CRD HYP~Y B
HYP~Y C

8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2

Universal gear
9 CONOCO *Fleet motor oil Super&a grease
lubricant

Multiperformance 3C Tranself EP
10 ELF Glacelf
Performance 3C Tranself EP type 2

Essolube D3
*Essolube X0-3
EXXON Gear oil GP
lEssolube XD-3 Extra Beacon EP2 All season coolant
” (ESSO) Gear oil GX
lEsso heavy duty
Exxon heavy duty

Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolan

Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77
Mobilube HD
1ow-30, 15w-40 Mobilgrease special

3-22
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENTTEMPERATURE

Engine Oil
Anti-freeZ
[CD or CEI
Coolant
SAElOW, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
1ow30, 15w40 IGL-4 or GL-51 [Lithium-Base]
Base1
(The 15W46 oil SAE80, 90, 140 NLGI No. 2
Permanent Tvpe
marked * is CE.)

Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White - bearing summer coolant
grease

15 1 PETROFINAI FINA kappa TD / Liii ~~:~~~~ :E 1 FINA marson EPL2 TFINA tamidor

Spirax EP
16 1 SHELL / Rimula X Albania EP grease
Spirax heavy duty

Sunoco ultra prestige Sunoco antifreeze

Sunoco GL5
17 SUN 2EP and summer
gear oil
Sun prestige 742 coolant

Multifak EP2 Code 2055 startex

/ Multigear
Starplex 2 antifreeze coolant

Total EP
Rubia S
19 TOTAL Total transmission Multis EP2 Antigel/antifreeze
*Rubia X
TM

20 UNION *Guard01 MP gear lube LS Unoba EP

*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B Antifreeze
MDC Multigear C

3-23
21. &lililDARD TIGHTENING TORQUES FOR BOLTS AND

21.1 INTRODUCTION OF NECESSARY TOOLS

The following tools are needed when carrying out maintenance.

No. Name of tool Part No. Remarks

1 Wrench Applicable width across flats (S1-S2)

0900240810 8mm-IOmm
09002-01214 12mm-14mm
09002-01317 13mm-17mm
09002-01922 19mm-22mm
09002-02427 24mm-27mm
09002~3032 30mm-32mm

0903340190 Interchangeable flat-head and cross-head type

3 Socket wrench 09020-l 0284 Applicable width across flats

set 10 mm, 13 mm, 14 mm, 17 mm, 19 mm, 22 mm,
24 mm, 27 mm, 30 mm, 32 mm, 36 mm
Extension, Handle joint bar

09019-08035

07952-80002 For nreasinn work

07951-21045
07951-l 1400

07950-80403 (Lithium base grease, 400 g)

09038-00150

09055-l 0390

09036-00150

195-98-I 1590

178-96-11120

09054-00009 9 leave 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.10,

0.15, 0.20

If any of the above tools are broken, please order them from your Komatsu distributor.

3-24
 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

21.2 TORQUE LIST

Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.
The tightening torque is determined by the width across the fiats
b
@ 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.
Nm (newton meter): 1Nm + 0.1 kgm
+ 0.74 Ibft

Thread diameter Width across

of bolt (mm) flats (mm)
Ia) (b)
Nm kgm Ibft

6 10 13.2 + 1.4 1.35 f 0.15 3.73f 1.03

8 13 31.4 -c2.9 3.2 2 0.3 23.2 + 2.1

10 17 65.7 + 6.8 6.7 t 0.7 48.5 5 5.0

12 19 112 f 9.8 11.5 + 1.0 62.6 + 1.2

14 22 177*19 18.0 t 2.0 131 + 14

16 24 279 + 29 28.5 +i3 206 z 21

18 27 383239 39 f 3 282 i 29
20 30 549258 56 2 6 405 t 43
22 32 745 578 76 + 8 549 + 58

24 36 927 +-98 94.5 f 10 684~ 72

27 41 1320 2 140 135 + 15 973 2 100

30 46 1720 2 190 175 t 20 1270 2 140

33 50 2210 + 240 225 2 25 1630 + 180

36 55 2750 = 290 280 r 30 !030 f 210

39 60 3280% 340 335 f 35 !42Oz 250

NOTICE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tightening
torque: doing so will damage the plastic parts.

3-25
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY 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 passes, 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 conditipn. 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 time 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 critical safety parts.

3-26
 22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

CRITICAL SAFETY PARTS

No. Part name Unit Replacement intervals

@ Fuel hose (fuel tank - fuel strainer) 2

@ Fuel hose (fuel strainer - injection pump) 2

@ Fuel hose (injection pump - fuel filter) 4

@I Fuel return hose (fuel pump - adapter) 2

@/F ue I ret urn hose (adapter - fuel tank) 12 I

@ Spill hose (between nozzles) 4

0 Spill hose (nozzle -fuel tank) 2

@ 1 Turbocharger lubricating hose 12 I

@ No.1 pump discharge port hose 2

@I No.2 pump discharge port hose 2

@I Swing No.1 pump discharge port hose 1 Every 4000 hours or

every 2 years, whichever
@ Swing No.1 pump outlet branch hose 1
comes sooner
@I No.3 pump discharge port hose 2

@I No.4 pump discharge port hose 2

0 Branch hose 4

@ ] Swing No.2 pump discharge port hose II I

@I I Swing No.2 pump outlet branch hose II I
@I Heater hose (engine - heater) 8

@ Pump suction hose 8

@J 1 Swing line hose I 4 I

@ I Boom cylinder line hose (B/H) 18 I

@ Arm cylinder line hose (B/H) 8

@I Bucket cylinder line hose (B/H) 8

@ Bucket suction coupling 3

@ Seat belt (option) 1 Every 3 years

3-27
23. MAINTENANCE SCHEDULE CHART

23.1 MAINTENANCE SCHEDULE CHART

SERVICE l-l-EM PAGE

INITIAL 100 HOURS SERVICE (only after the first 100 hours)

Clean strainer of PTO lubricating oil filter 3-62

INITIAL 250 HOURS SERVICE (only after the first 250 hours)

Replace fuel filter cartridge 3-63

Change oil in swing machinery case 3-66

Change oil in PTO case 3-67

Change oil in final drive case 3-68

Check engine valve clearance, adjust 3-70

WHEN REQUIRED

Check, clean and replace air cleaner element 3-33

Clean inside of cooling system 3-35

Check and tighten track shoe bolts 3-39

Check and adjust track tension 3-40

Check electrical intake air heater 3-42

Replace bucket teeth (horizontal pin type) (KOMATSU TOOTH) 3-43

Adjust bucket clearance 3-44

Check window washer fluid level, add fluid 3-45

Check and adjust airconditioner 3-46

Cleaning, removing dirt from line filter 3-47

Replacement of fan belt and adjustment of auto tensioner 3-48

CHECK BEFORE STARTING

Check coolant level, add water 2-56

Check oil level in engine oil pan, add oil 2-56

Check fuel level, add fuel 2-57

Check oil level in hydraulic tank, add oil 2-58

3-28
 23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

(CHECK BEFORE STARTING)

Check for clogging of air cleaner 2-59

Check electric wiring 2-59

Check function of horn 2-59

Check oil level in PTO case, add oil 2-60

Drain water and sediment from fuel tank 2-60

Check central monitor 2-61

CHECK EVERY 10 HOURS SERVICE

Lubricating 3-50

l Arm - Bucket coupling pin (2 points) 3-50

l Arm - Link coupling pin (2 points) 3-50

l Bucket cylinder rod end pin (2 points) 3-51

l Link coupling pin (4 points) 3-51

l Bucket - Link coupling pin (2 points) 3-51

l Boom cylinder foot pin 3-52

l Boom foot pin 3-52

l Boom cylinder rod end pin 3-52

l Arm cylinder foot pin 3-52

l Bucket cylinder foot pin 3-52

l Boom - Arm coupling pin 3-52

l Arm - Link coupling pin 3-52

0 Swing circle 3-52

EVERY 100 HOURS SERVICE

Check oil level in swing machinery case 3-53

EVERY 250 HOURS SERVICE

Lubricating 3-54

l Fan pulley assembly (2 points) 3-54

l Tension pulley assembly (2 points) 3-54

3-29
23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

Check oil level in final drive case, add oil 3-54

Change drain filter cartridge 3-55

Change oil in engine oil pan, replace engine oil filter cartridge and bypass filter 3-55
cartridae (Front and rear enaine)
Check alternator drive belt tension, adjust 3-56
Check air conditioner compressor belt tension, adjust (Only for machines equipped with 3-57
air conditioner)
Check level of battery electrolyte 3-58

Check, clean fuel strainer 3-59

Check and tighten track shoe bolts 3-59

Check and tighten track frame and axle connecting bolts 3-59

Replace filter element of hydraulic tank breather 3-60

EVERY 566 HOURS SERWCE

Clean and inspect radiator fins, oil cooler fins, after cooler fins, condenser fins 3-61
(Only for machines equipped with air conditioner)
Clean pilot filter strainer 3-62

Clean strainer of PTO lubrication oil filter 3-62

Replace fuel filter cartridge 3-63

Clean fresh/recirc air filters of air conditioner (Only for machines equipped with 3-64
air conditioner)
Check fan belt 3-64

Change hydraulic filter element 3-65

EVERY 1000 HOURS SERVICE

Change oil in swing machinery case 3-66

Check turbocharger clamping joint 3-66

Change oil in PTO case 3-67

Replace corrosion resistor cartridge 3-67

Check inspection of welding structure (Color check) 3-67

EVERY 2000 HOURS SERVICE

Change oil in final drive case 3-68

Clean, check turbocharger 3-68

Check turbocharger rotor play 3-69

Check swing pinion grease level, add grease 3-69

Clean engine breather 3-69

Clean hydraulic tank strainer 3-70

3-30
 23. MAINTENANCE SCHEDULECHART

SERVICE ITEM PAGE

(EMRY 2000 HOURS SERVICE1

Check alternator, starting motor 3-70

Check engine valve clearance, adjust 3-70

EVERY 4000 HOURS SERVICE

Check water pump 3-71

Check vibration damper 3-71

Check fan pulley and tension pulley 3-71

Check air compressor, adjust 3-71

EVERY 5000 HOURS SERVICE

Channe oil in hvdraulic tank, clean strainer 3-72

3-31
24. SERVICE PROCEDURE

24.1 INITIAL 100 HOURS SERVICE

Maintenance for every 10 hours service should be carried out at

the same time.
Carry out the following maintenance only after the first 100
hours.

l CLEAN STRAINER OF P-TO LUBRICATING OIL FILTER

for detail of method of replacing or maintaining, see the section

on EVERY 500 HOURS SERVICE.

24.2 INITIAL 250 HOURS SERVICE

Maintenance for every 10 hours service should be carried out at

the same time.
Carry out the following maintenance only after the first 250
hours.

l CHANGE FUEL FILTER CARTRIDGE

l CHANGE OIL IN SWlNG MACHINERY CASE
l CHANGE OIL IN PTO CASE
l CHANGE OIL IN FlNAl DRfVE CASE
l CHECK ENGINE VALVE CLEARANCE, ADJUST

For details of the method of replacing or maintaining, see the

section on EVERY 500 HOURS, 1000 HOURS and 2000 HOURS
SERVICE.

3-32
 24. SERVICE PROCEDURE

24.3 WHEN REQUIRED

24.3.1 CHECK, CLEAN AND REPLACE AIR

CLEANER ELEMENT

Never clean or replace the air cleaner element with the engine

l When using pressure air to clean the element wear safety

glasses or goggles to protect the eyes.

CHECK
If the air cleaner clogged warning lamp @ lights up, clean the air
cleaner element.

CLEAN. REPLACE OUTER ELEMENT

1. Open the engine hood, loosen wing nut 0, then remove the
outer element 0.
To prevent entry of dirt and dust, cover the air connector side of
the rear end of the air cleaner with a clean cloth and adhesive
tape.

2. Clean the air cleaner body interior

3. Direct dry compressed air (less than 700 kPa (7 kg/cmz, 100 psi)),
to element @ from inside along its folds, then direct it from
outside along its folds and again from inside.
1) Remove one seal from the outer element. The number of
times the outer element has been cleaned can be seen by the
number of removed seals.
2) Replace an outer element which has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace the element when the air cleaner clogged warning
lamp lights up soon after installing a cleaned element even
though it has not been cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if
necessary, retighten.
5) Replace seal washer @ or wing nut @ with new parts if they
are broken.

4. If small holes or thinner parts are found on the element when it

is checked with an electric bulb after cleanina. reolace the
1. .

element.

NOTICE
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against
something.
Wrap up unused elements and store them in a dry area.
1
5. Remove the cloth and tape used for cover in Step 1.

6. Install the cleaned element and fix it with the wing nut.

3-33
24. SERVICE PROCEDURE

Replacing inner element

1. First remove the outer element, and then remove the inner
element.

2. Place the cover over the air intake part to prevent dust entering.

3. Clean the air cleaner body interior, then remove the cover from
the air intake port.

4. Fit a new inner element and tighten it with nuts.

5. Install the new outer element.

Push the dust indicator reset button.

NOTICE
l Do not attempt to reinstall a cleaned inner element.
l Do not attempt the air cleaner replacing, while engine running.
l When replacing the inner element, also replace the outer ele-
ment new one.

3-34
 24. SERVICE PROCEDURE

24.3.2 CLEAN INSIDE OF COOLING SYSTEM

a WARNING
Soon after the engine has been stopped, the coolant is hot
and can cause personal injury. Allow the engine to cool
before draining water.

Since cleaning is performed while the engine is running, it is

very dangerous to enter the rear side of the machine as the
machine may suddenly start moving. lf the under cover is left
removed, it may interfere with the fan. While the engine is
running, never enter the rear side of the machine.

Never remove the radiator cap when the engine is at operat-

ing temperature. At operating temperature, the coolant is
under pressure. Steam blowing up from the radiator could
cause personal injury. Allow the engine to cool until the
radiator filler cap is cool enough to touch with your hand.
Remove the filler cap slowly to allow pressure to be relieved.

l Clean the inside of the cooling system, change the coolant and
replace the corrosion resistor according to the table below.

1 Cleaning inside of / Replacing corrosion

Kind of coolant cooling system and resistor
changing coolant

Every year (autumn) or

Permanent type antifreeze
every 2000 hours,
(All season type)
whichever comes first
Every 1000 hours and
Every 6 months (spring,
Non permanent type autumn) when cleaning
antifreeze containing
ethylene glycol Winter,
(Drain antifreeze in spring, tshetinnd~n~f~~eoo’ing
one season type)
add antifreeze in autumn)
changing coolant.
Every 6 months or every
When not using antifreeze 1000 hours, whichever
comes first

l Stop the machine on level ground when cleaning or changing

the coolant.
0 Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type
antifreeze, use an antifreeze containing ethylene glycol.

3-35
24. SERVICE PROCEDURE

l When deciding the ratio of antifreeze to water, check the lowest

temperature in the past, and decide from the mixing rate table
given below.
It is actually better to estimate a temperature about 70°C lower
when deciding the mixing rate.

Mixing rate of water and antifreeze

A WARNING
Antifreeze is flammable, so keep it away from any flame.

l Use city water for the cooling water.

If river water, well water or other such water supply must be
used, contact your Komatsu distributor.
l We recommend use of an antifreeze density gauge to control the
mixing proportions.

A WARNING
When removing drain plug, avoid pouring coolant on yourself.

3-36
 24. SERVICE PROCEDURE

0 Prepare a container to catch drained coolant: Min. 85 f?capacity

0 Refill capacity: Each 85 I? (22.5 US gal) capacity.
1. Stop the engine, close valves @ on corrosion resistor.

2. Turn cap @ slowly until it comes off.

3. Loosen drain valve @ and @ at the bottom of engine and drain

off the cooling water.

4. Close up drain valves @ and @ and pour in clean water (ex. city
water) up to the vicinity of the water filler.

5. When the water reaches the vicinity of the water filler, put the
engine at low idling, open drain valves @ and 0, then pass water
- Ml79690
through the cooling system for 10 minutes.
When doing this, keep the radiator filled up to the filler with
water.

6. After washing the cooling system, stop the engine. Open drain
valves @ and @to drain water and close drain valves @ and 0.

7. After draining off the cooling water, wash out the cooling system
using commercially available detergent.
Follow the instructions on the detergent container.

8. After washing the cooling system, drain off all the water, then
close up drain valves @ and @ and pour in clean water (ex. city
water) slowly up to the vicinity of the water filler.

9. When the water reaches the vicinity of the water filler, put the
engine at low idling, open drain valves @ and 0, then pass water
through the cooling system until clean water comes out from the
drain valves.
When doing this, keep the radiator filled up to the filler with
water.

3-37
24. SERVICE PROCEDURE

IO. When the water becomes completely clean, stop the engine and
close drain valves @ and 0.

11. Replace the corrosion resistor cartridge.

For details of replacement of the corrosion resistor, see “24.8
EVERY 1000 HOURS SERVICE”.

12. Open valve @ of corrosion resistor.

13. Supply water until it overflows from the water filler.

14. Run the engine for 5 minutes at low idling and then for another
5 minutes at high idling to eliminate air trapped in the cooling
system (leave the water filler cap off during the operation).

15. After draining off the cooling water of reserve tank, clean the
inside of the reserve tank and refill the water between FULL and
front eneine’zenoine Au364396
LOW level.

16. Stop the engine and wait for about 3 minutes. Supply cooling
water up to the vicinity of the water filler. Tighten the cap.

3-38
 24. SERVICE PROCEDURE

24.3.3 CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts @ loose, they will
break, so tighten any loose bolts immediately.

Method for tightening

1. First tighten to a tightening torque of 687 2 69 Nm (70 = 7 kgm,
507 + 51 lb ft) then check that the nut and shoe are in close
contact with the link contact surface.

2. After checking, tighten a further 120” f IO”.

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 contact with
the link mating surface.

3-39
24. SERVICE PROCEDURE

24.3.4 CHECK AND ADJUST TRACK TENSION

A WARNING
Carry out this operation with two workers. The operator must
move the machine in accordance with the signals from the other
worker. The track tension is checked with the chassis raised, so
it is extremely dangerous if the machine is lowered by mistake
during the inspection. Never move the machine while anyone is
carrying out measurements.

The wear of pins and bushings on the undercarriage will vary

with the working conditions and soil properties. It is thus necessary
to continually inspect the track tension so as to maintain the stand-
ard tension.
Carry out the check and adjustment under the same conditions
as when operating (on jobsites where the track becomes clogged
with mud, measure with the track clogged with mud).

Inspection
1. Raise the chassis with the boom and arm.
When doing this, operate the levers slowly.
2. Measure the clearance between the tread of the fourth track
roller from the sprocket and the roller contact face of track link
at a position that is safe even if the chassis should come down.

Standard clearance: 100 to 150 mm (3.9 to 5.9 in)

100; 150 mm
(3.9 - 5.9 in)
AC383140

If the track tension is not at the standard value, adjust it in the

following manner.

3-40
 24. SERVICE PROCEDURE

Adjusting Hit cylinder

1. Check that stop valve @ is copietely closed.

2. Open stop valve 0.

'CC cccnl

3. Start engine and run at a medium speed.

Low idling
AMO?30410

4. Operate the right control lever to the FORWARD position inter-

mittently (2 - 3 seconds) 3 - 4 times to relieve the travel motor.

NOTICE
0 Do not carry out this operation on a slippery road surface (steel
plate, etc.).

l Even when protrusion amount @ of the hydraulic cushion is

within the standard value, the HIC charge pressure may be low,
so always carry out the above operation exactly.

5. Check that the protrusion @ of the plunger of the hydraulic

cushion cylinder is 135 f 5 mm (5.3 k 0.2 in) on both the left and
right.

6. Close stop valve @ completely.

3-41
24. SERVICE PROCEDURE

Adjusting grease cylinder

1
A WARNING
3
l Do not loosen grease fitting @ more than one turn. There is
danger that it may fly out under the high internal pressure.
iE!XI!? 0 Ic
a
l Never loosen any part other than grease fMing 0. lf the
grease does not come out, move the machine backwards and
AEl79730
forwards slightly.
I 1
NOTICE
Before pumping in grease, check that the protrusion @ of the
plunger of the hydraulic cushion cylinder is 135 + 5 mm (5.3 + 0.2
in) on both the left and right.
Check again after pumping in grease.
lf the protrusion is not within this range, loosen grease fitting
@ one turn and let grease out to adjust. If the protrusion cannot be Cushion cylinder
AV364400
adjusted to 135 d 5 mm (5.3 + 0.2 in), the hydraulic cushion must L
be adjusted, so please contact your Komatsu distributor for adjust-
ment.

If the track tension is adjusted only by using grease and not by

hydraulic pressure, excessive load may be brought to bear on
the undercarriage and this may cause damage.
AcAmloN7

When increasing tension prepare a grease gun.

1. Pump in grease through grease fitting @ with a grease gun.

2. To check that the correct tension has been achieved, move the
machine backwards and forwards.

3. Check the tension again, and if it is not correct, adjust it again.

4. Continue to pump in grease until @ becomes 190 mm (6.1 in).

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.

0 Always use the special knob when opening or closing stop

valves @ and 0.

l Please ask your Komatsu distributor to check once a year for any
abnormality.

24.3.5 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.

Remove the electrical intake air heater from the engine intake
connection, and check it for possible open-circuits and dirt.
When inspecting and replacing the electrical intake air heater,
replace the gasket with new one.

3-42
 24. SERVECE PROCEDURE

24.3.6 REPLACE BUCKET TEETH

(HORIZONTAL PIN TYPE) (KOMATSU TOOTH)
Replace the teeth before the wear reaches the adapter.

It is dangerous if the work equipment moves by mistake when

the teeth are being replaced. Set the work equipment in a stable
condition, then stop the engine and apply the locks securely to
the levers.

AW364166

1. Place a block under the bucket bottom so that the pin of tooth
@ can be knocked out with a hammer. Carry out full stroke
operation of the control levers within 15 seconds after the engine
has stopped. After confirming that the work equipment is in a
stable condition, lock the safety lock lever.
Set so that the bottom face of the bucket is horizontal.

2 Place a bar on the pin head and strike the bar with a hammer to
knock out pin 0. Remove tooth @_

REMARK
Use a round bar with a smaller diameter than that of the pin.

AEO83270

3. Clean the mounting face. Fit a new tooth @ in the adapter, push
in pin @ partially by hand, then lock it with a hammer to install
the tooth to the bucket.

3-43
24. SERVICE PROCEDURE

24.3.7 ADJUST BUCKET CLEARANCE

A 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 lever securely.

AU364166
i

if there is excessive free play on the coupling section of the

bucket and arm, adjust the bucket clearance in the following manner.

1. Set the work equipment to the position shown in the diagram at

right, stop the engine and set the lock lever to the locked
position.

2. Loosen 3 bolts 0, 6 bolts 0, plate @ and plate 0.

3. Take out shims @I equivalent in size to free play 0.

Thickness of shim @I is 0.5 mm or 1.0 mm (0.02 or 0.04 in).
When free play @ is less than a thickness of shim, do not
compress the shims by tightening bolt 0.

4. Tighten 3 bolts @ and 6 bolts 0.

With this adjustment, clearance @ becomes larger, but play @I

is removed.

3-44
 24. SERVICE PROCEDURE

24.3.8 CHECK WINDOW WASHER FLUID LEVEL, ADD

FLUID
If air is ejected with the window washer fluid, check the fluid
level in window washer tank 0. If showing under the level, fill with
automobile window washer fluid.

When adding fluid, be careful not to let dirt or dust get in.

l Mixture ratio of pure washer fluid and water

Since the ratio should be varied depending on atmospheric tempera-
\ tank
ture, replenish washer fluid at the following mixture ratio, taking
temperature into account. \

Operation area Freezing

Mixture ratio
and season temperature
I I
I I AE179760
Pure washer fluid I
Normal - 10-C (14’F)
l/3: water 2f3

Pure washer fluid

Winter in cold region - 2O’C (- 4-F)
l/2: water l/2

Winter in extremely
Pure washer fluid - 30-C (- 22-F)
cold region

Pure washer fluid comes in two types: for -1o’C (14’F) (for general
use) and for -3OC (-22°F) (cold regions).
Use pure washer fluid according to operation area and season.

3-45
24.3.9 CHECK AND ADJUST AIRCONDITIONER

CHECK LEVEL OF REFRIGERANT (GAS)

lf the liquid gets into your eyes or on your hands, it may cause
loss of sight or frostblte, so never loosen any part of the
~AwARN’NG

If there is a lack of refrigerant (Freon 134aL the cooling perform-

ance 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.
l No bubbles in refrigerant flow: Correct
l Bubbles in refrigerant flow (bubbles continuously pass through):
Refrigerant level low
l 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 No refrigerant
damage to the compressor. 1 Colorless.
iranspamit )

Check in off-season
When not being used for a long period, operate the cooler for 3 to
5 minutes once a week to supply lubricant to each component of the
compressor.

Inspection and maintenance items list for cooler

Inspection and Maintenance

Contents
maintenance items interval
Twice a year;
Refrigerant (gas) Filling quantity
spring and autumn

Condenser Clogging of fins Every 500 hours

Compressor T Function Every 4000 hours

V belt I Damage and tension Every 250 hours

Blower motor Function (Check for

When required
and fan abnormal sound)

Function (Check for

Control mechanism normal function) When required
II
Piping for Instaflation condition
connection looseness of tightening When required
connection oortions
1 gas leakage; damage ]

3-46
 24. SERVICE PROCEDURE

24.3.10 CLEANING, REMOVING DIRT FROM LINE FILTER

I

As seen from left of chassis As seen from rear of chassis

AU332550

If there is any abnormality in the pumps or other hydraulic

equipment, do as follows, and remove the dirt from inside the line
filter.

1. Loosen the air suctin plug KiJ - 0) corresponding to the line filter
to be removed 1 - 2 turns.

l Relationship of line filter and air suction plug

Line filter A -_) plug 0

Line filter B + duo (7,
Line filter C + plug 0
Line filter D + plug 0
Line filter E + plug 0
Line filter F + plug 0

2. Remove 4 bolts @, and flange 0, then temporarily insert 2 of

bolts @ into cover 0.
Temporarily insert bolts @ on diagonally opposite sides.

3. Loosen clamp 0.

4. Remove cover @, and clean filter @I.

(1) When cleaning the filter, also clean off the dirt and dust stuck
to the side face of the case.
(2) When assembling the case again, replace O-ring @ and
backup ring @ together.
(3) Tightening torque for cover: 108 + 10 Nm
(11 f 1 kgm, (79 f 7 Ibft))
(4) After assembling the line filter again, bleed the air from the
system. (For details, see “18.5 BLEEDING AIR FROM CIR-
CUIT”)

3-47
24. SERVICEPROCEDURE

243.11 REPLACEMENT OF FAN BELT AND

ADJUSTMENT OF AUTO TENSIONER
As this machine is provided with a device which keeps a constant
fan belt tension without regard to elongation of the V-belt, no
adjustment is required until the belt is broken.

Replacement
1. Loosen lock nut @ and completely release the spring.
2. Press tension pulley @ in the direction indicated by the arrow to
remove the V-belt.
Then install a replacement.
Replace three V-belts at the same time.

Adjustment
Check the size A to see that it is maintained at 54 f 3 mm (2.1
* 0.1 in).
If not, adjust the fan belt as follows:
Tighten adjusting bolt @ until size A becomes 54 f 3 mm (2.1 &
0.1 in), and tighten lock nut @ securely.

3-45
 24. SERVICE PROCEDURE

24.4 CHECKS BEFORE STARTING

24.4.1 CHECK COOLANT LEVEL, ADD WATER
See 12. OPERATION, 12.1 Check before starting engine.

24.4.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

See 12. OPERATION, 12.1 Check before starting engine.

24.4.3 CHECK FUEL LEVEL

See 12. OPERATION, 12.1 Check before starting engine.

24.4.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

See 12. OPERATION, 12.1 Check before starting engine.

24.4.5 CHECK FOR CLOGGING OF AIR CLEANER

See 12. OPERATION, 12.1 Check before starting engine.

24.4.6 CHECK ELECTRICAL WIRING

See 12. OPERATION, 12.1 Check before starting engine.

24.4.7 CHECK FUNCTION OF HORN

See 12. OPERATION, 12.1 Check before starting engine.

24.4.8 CHECK OIL LEVEL IN PTO CASE, ADD OIL

See 12. OPERATION, 12.1 Check before starting engine.

24.4.9 DRAIN WATER, SEDIMENT FROM FUEL TANK

See 12. OPERATION, 12.1 Check before starting engine.

24.4.10 CHECK CENTRAL MONlTOR

See 12. OPERATION, 12.1 Check before starting engine.

3-49
24. SERVICE PROCEDURE

24.5 EVERY 10 HOURS SERVICE

A WARNING
if any abnormal noise comes from the greasing points of the
work equipment, apply grease regardless of the service interval.

24.5.1 LUBRICATING
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.

AW372460

1. Arm-Bucket coupling pin (2 points)

2. Arm-Link coupling pin (2 points)

3-50
 24. SERVICE PROCEDURE

3. Bucket cylinder rod end pin (2 points)

4. Link coupling pin (4 points)

5. Bucket-Link coupling pin (2 points)

AE130420

Method for greasing with grease gun

1. Tighten stop valve @ in the room below the operator’s cab to the
CLOSED position.
Use the special handle when opening or closing stop valve 0.

2. Pull the hose out from the reel, and pump in grease through the
grease fitting.
Operate the engine at low speed or midrange speed to carry out
the greasing.
It is efficient to carry out the greasing while warming up the
engine before starting operation.

Special handle AEl69680 1

3-51
24. SERVICE PROCEDURE

Other greasing
The following reasing points can be greased by operating the
greasing switch in the operator’s compartment.

6. Boom cylinder foot pin

7. Boom foot pin
8. Boom cylinder rod end pin
9. Arm cylinder foot pin
10. Bucket cylinder foot pin
11. Boom-Arm coupling pin
12. Arm-Link coupling pin
13. Swing circle

1. Set stop valve @ of the grease pump outlet port in the room
under the operator’s cab to the OPEN position.

2. Turn the greasing switch START

Continue greasing for approx. 15 minutes. When doing this, run
the engine at low speed or midrange speed.

When greasing, grease pressure gauge @ should indicate 4.9 -

19.6 MPa (50 - 200 kg/m*, 710 - 2840 psi).
If the pressure is below 4.9 MPa (50 kg/cm*, 710 psi), the grease
can is empty, so replace the grease can.

AE178280

If the pressure is above 19.6 MPa (200 kg/cm*, 2840 psi), check
the distributor indicator at the top face of the boom foot. If the
plunger is protruding, that line is clogged, so check and repair.

3-52
 24. SERVICE PROCEDURE

24.6 EVERY 100 HOURS SERVICE

Maintenance for every 10 hours should be carried out at the
same time.

24.6.1 CHECK OIL LEVEL IN SWING MACHINERY CASE

1. Use dipstick @ to check the oil level.
2. The oil level should be between the L and H marks. If necessary,
add oil at the dipstick guide hole.

NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3-53
24. SERVICE PROCEDURE

24.7 EVERY 250 HOURS SERVICE

Maintenance for every 10 hours should be carried out at the
same time.
Carry out the following maintenance only after the first 250
hours.

l FUEL FILTER, REPLACE CARTRIDGE

l SWING MACHINERY CASE CHANGE OIL
l PTO CASE, CHANGE OIL
l FINAL DRIVE CASE, CHANGE OIL
l ENGINE VALVE CLEARANCE, CHECK AND ADJUST

For detail of the method of replacing or maintaining, see the

section on EVERY 100 HOURS, 500 HOURS, 1000 HOURS AND 2000
HOURS SERVICE.

24.7.1 GREASE FAN PULLEY ASSEMBLY, TENSION

F. ENGINE F. ENGINE R. ENGINE
PULLEY ASSEMBLY FAN PULLEY TENSI ON FAN PULLEY
Add grease through the fittings marked by arrows.
1. Fan pulley assembly (2 points)
2. Tension pulley assembly (2 points)

24.7.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

A WARNING 7
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
starting the operation.

lf there is still pressure remaining inside the case, the oil or

plug may fly out.
Loosen the plug slowly to release the pressure.

1. Stop the machine so that the plug @ on the outside of machine

is at the lowest position.

2. Remove plug @ and check that the oil level is near the bottom
of the plug hole.
If necessary, add engine oil through oil filler 0.

NOTICE
For detail of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3-54
24. -7.3 CHANGE DRAIN FILTER CARTRIDGE

1. Using a filter wrench, remove cartridge 0 by turning it

counterclockwise.

2. Fill the new cartridge with engine oil and refit it after applying
a dab of oil to the packing face.
To refit the cartridge, place the packing face in contact with the
AE17QQ70
seal face of the filter stand, then screw up the cartridge l/2 to
314 turn.

24.7.4 CHANGE OIL IN ENGINE OIL PAN, REPLACE

ENGINE OIL FILTER CARTRIDGE AND BYPASS
FILTER CARTRIDGE (FRONT AND REAR ENGINE)
I AWARNING ,-I
The oil is at high temperature after the engine has been oper-
ated, so never change the oil immediately after finishing opera-
tions. Wait for the oil to cool down before changing it.

Prepare the following

0 Container to catch drained oil: Min. 33.5 f? capacity
0 Refill capacity: 33.5 fi (8.9 US gal)
0 Filter wrench

1. Remove the filler cap, remove drain plug @I, install the hose
provided and loosen drain valve @2. After draining the oil,
remove the hose and tighten drain valve 81 and plug @.

2. Using a filter wrench, remove oil filter cartridges @ and bypass

filter cartridge @ by turning counterclockwise.
Clean the filter holder and check that the oil seal is not stuck to
the filter holder. If the old seal is still stuck to the filter holder,
it will cause oil leakage.
If filter cartridges @ are removed immediately after stopping the
engine, oil will spill. Wait at least 10 minutes after stopping the
engine before replacing the filter cartridge.

3. Fill the new cartridge with clean engine oil and refit it after
applying a dab of oil to the packing face.
To refit the cartridge, place the packing face in contact with the
seal face of the fitter holder, then screw up the cartridge 3/4 to
1 turn.

3-55
24. SERVICE PROCEDURE

4. After replacing the filter cartridge, add engine oil through oil
filler @ until the oil level is between the H and L marks on
dipstick 0.

NOTICE
For detail of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

5. Run the engine at idling for a short time, then stop the engine,
and check that the oil level is between the H and L marks on the I I
dipstick. For details, see “12.1 CHECK BEFORE STARTING”.

Even if the machine has not been operated for 250 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for
6 months, the oil and filter cartridge must be replaced when the
ADO52340
machine has been operated for 250 hours.
Change the oil and replace the filter cartridge for both the front
and rear engine.

24.7.5 CHECK ALTERNATOR DRIVE BELT TENSION,

ADJUST Alternator ~uilev

Checking
The standard deflection for the drive belt is 13 - 16 mm (0.51 -
13--16am
0.63 in) when pressed with a thumb [at approx. 98.1 N (approx. 10 (0.51-0.63 i n)
kgf)] at a point midway between the drive pulley and alternator
pulley. fl
Drive DuI leu
A8308578
Adjusting
1. Loosen bolts and nuts @ - @ in order, then turn nut @I to move
the alternator and adjust the belt tension.
Turn nut 0 as follows.
TIGHTEN to INCREASE belt tension
LOOSEN to DECREASE belt tension

2. After adjusting the belt tension, tighten the bolts and nuts in
order from @ to @ to secure the alternator in position. Finally,
tighten nut 0.
Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. Check in particular that the V-belt does not contact
the bottom of the V-groove.
If the V-belt is elongated and there is no more allowance for
adjustment, or if the belt is cracked or cut, replace the belt.

3-56
 24. SERVICE PROCEDURE

24.7.6 CHECK AIR CONDITIONER COMPRESSOR BELT

TENSION, ADJUST (ONLY FOR MACHINES
EQUIPPED WITH AIR CONDITIONER)
Checking
1. Remove bolts @ and 0, then remove cover 0.

2. The standard deflection for the drive belt is approx. IO mm (0.4

in) when pressed with a thumb [at approx. 98.1 N (approx. 10
kgfll at a point midway between the drive pulley and air condi-
tioner compressor pulley.
Compressor pulley

Adjusting @
1. Loosen bolts and nuts @ - @I in order, then turn nut @I to move ‘I
10 mm
the compressor and adjust the belt tension. k (0.4 in)
Turn nut @ as follows.
TIGHTEN to INCREASE belt tension
LOOSEN to DECREASE belt tension Drive pulley
AEo83620

2. After adjusting the belt tension, tighten the bolts and nuts in
order from @ to @ to secure the compressor in position. Finally,
tighten nut 0.
Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. Check in particular that the V-belt does not contact
the bottom of the V-groove.
If the V-belt is elongated and there is no more allowance for
adjustment, or if the belt is cracked or cut, replace the belt.

3. Install cover 0.

I/
-A6306600

3-57
24. SERVICE PROCEDURE

24.7.7 CHECK LEVEL OF BATTERY ELECTROLYTE

A WARNING
l To avoid gas explosions, do not bring fire or sparks near the
battery.
l 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.

Carry out this check before operating the machine.

1. Open the battery box cover.

2. Remove cap @ and check that the battery electrolyte is up to the

UPPER LEVEL line. If the level is low, add distilled water to the
UPPER LEVEL line.
Do not add water above the UPPER LEVEL line. This may cause
leakage of the electrolyte, which may cause fire.

If the battery electrolyte is spilled, have dilute sulphuric acid added. 1 ’ ” -,” AEl80020

3. Clean the air hole in the battery cap, then tighten the cap
securely.

When adding distilled water in cold weather, add it before

starting operations in the morning to prevent the electrolyte from
freezing.

3-58
 24. SERVICE PROCEDURE

24.7.8 CHECK, CLEAN FUEL STRAINER

1. Tighten valve @ on the bottom of the fuel tank.

2. Open the cover on the rear body, remove cap @ under the air
cleaner, and take out the strainer. And clean the strainer and the
strainer case.

AE180030

24.7.9 CHECK AND TIGHTEN TRACK SHOE BOLTS

Shoe bolts @ which secure track shoes to links will break if used
in a loosened state, so loose bolts must always be retightened.

Tightening torque:
Tighten to an initial torque of 687 + 69 Nm (70 f 7 kgm, 507 2
51 Ibft), check that the mating surfaces are in contact, then tighten
a further 120” -c 10”.

Order for tightening:

Tighten the bolts in the order shown in the diagram. After
tightening, check that the nut and shoe are in close contact with the
link mating surface.

I ADo-
J
24.7.10 CHECK AND TIGHTEN TRACK FRAME AND AXLE
CONNECTING BOLTS

Bolts @ connecting the track frame and axle will break if they
remain loose. If any loose bolts are found, please contact your
Komatsu distributor to have them tightened.
Tightening torque: 4658 f 250 Nm
(475 2 25 kgm, 3436 + 180 Ibft)

3-59
24. SERVICE PROCEDURE

24.7.11 REPLACE FILTER ELEMENT OF HYDRAULIC

TANK BREATHER

A WARNING
When replacing the element, turn the cap of oil filler slowly to
release the internal pressure.

I WI I AE180070

1. Remove snap ring @ of breather 0, then replace filter element h

@ with a new part.

2. Install cover @ and snap ring 0.

3-60
 24. SERVICE PROCEDURE

24.8 EVERY 500 HOURS SERVICE

Maintenance for every 10,100 and 250 hours should be carried

out at the same time.

24.8.1 CLEAN AND INSPECT RADIATOR FINS, OIL

COOLER FINS, AFTER COOLER FINS, CONDENSER
FINS (ONLY FOR MACHINES EQUIPPED WITH AIR
CONDITIONER)

1. Open the engine hood and rear duct on the right side of the
machine.
iator
2. Blow off mud, dust or leaves clogging the radiator fins, oil cooler
fins and after cooler fins using compressed air.
At the same time, clean the net in front of the oil cooler. Clean
the condenser fins on machines equipped with air conditioner.
Steam or water may be used instead of compressed air.
When cleaning the radiator core, remove 4 covers @ at the top
of the hood and oil cooler recirculation cover 0, then use
compressed air or steam to carry out the cleaning through
clearance C.

NOTICE
When using compressed air, if the nozzle is brought too near the
fins, the fins may be damaged. Especially for the aftercooler, blow
the air from a distance of at least 300 mm and at an angle of 45’.

3. Check the rubber hose. Replace with a new one if the hose is
found to have cracks or to be hardened by ageing.
Further, check hose clamps for looseness.
Cleani: nozzle

After cooler hose clamp tightening torque: 8.8 f 0.49 Nm

(0.9 2 0.05 kgm)
(6.5 + 0.36 Ibft)

NOTICE
When use the compressed air, keep a distance from air nozzle,
to prevents damage to the fins. Especially for after cooler, blow the
air from 300 mm or more, and across the 45”.
To prevent damage to the fins, apply compressed air from and Right side
appropriate distance. Damaged fins may cause water leakage or of machine

overheating. In a dusty site, check the fins daily, irrespective of the

maintenance interval.
Oil cooler

3-61
24. SERVICE PROCEDURE

24.8.2 CLEAN PILOT FILTER STRAINER

A WARNING
The oil is at high temperature after engine has been operated.
Wait for the oil to cool down before carrying out maintenance.

1. Remove filter case 0.

2. Take out the strainer and wash the strainer in the fuel. Replace
the strainer if finding some defects.

3. Install the strainer and filter case 0.

24.8.3 CLEAN STRAINER OF PTO LUBRICATING OIL

FILTER

A WARNING
The oil is at high temperature after engine has been operated.
Wait for the oil to cool down before carrying out maintenance.

1. Remove filter case 0.

2. Take out the strainer @ and wash the strainer in the fuel. Replace
the strainer if finding some defects.

3. Install the strainer @ and tube 0.

3-62
 24. SERVICE PROCEDURE

24.8.4 REPLACE FUEL FILTER CARTRIDGE

l Engine is at high temperature immediately after the machine

has been operated. Wait for engine to cool down before

l Do not bring fire or sparks near the fuel.

Prepare a filter wrench and a container to catch the fuel.

1. Close valve @ (fuel supply side) of the bottom of the fuel tank.

2. Set the container to catch the fuel under the filter cartridge.

3. Using a filter wrench, turn filter cartridge @ counterclockwise to

remove it.
AE180030

4. 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.

5. When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten a further Z/3 turn.

If the filter cartridge is tightened too far, the packing will be

damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.

6. After replacing the fuel filter cartridge, bleed the air from the
system.
Bleed the air as follows.

7. Fill the fuel tank with fuel (to the position where the fuel gauge
shows FULL).

8. After replacing filter cartridge 0, loosen air bleed plug @I.

9. Loosen the knob of feed pump 0, operate it up and down, and

continue until no more bubbles come out with the fuel from air
bleed plug 0.

9. Tighten air bleed plug 0.

Use a genuine Komatsu filter cartridge.
After replacing the filter cartridge, start the engine, and check
that there is no leakage of fuel from the filter seal surface.

3-63
24. SERVICE PROCEDURE

24.8.5 CLEAN FRESH/RECIRC AIR FILTERS OF AIR i

CONDITIONER- (ONLY FOR MACHINES EQUIPPED
WITH AIR CONDITIONER)

The FRESH filter is in box @ under the sub-seat.

Loosen screw 0, open cover 0, then pull filter @ out to the front
to remove it.

There are 2 air conditioners installed in the room under the cab.
Open cover @ of the air conditioner, then pull out FRESH filter
03.
Clean filters @ and @ with compressed air. If there is oil on the
filter or it is extremely dirty, wash it in a neutral washing agent.
After washing it, dry it completely before using it again.

If the dirt clogging the filter cannot be removed by blowing it

1W371660
with air or washing it in water, replace the filter with a new part. -

NOTICE
As a guideline, the filters should be cleaned every 500 hours, but
on dus$jobsites, clean the filters more frequently.

24.8.6 CHECK FAN BELT

Check the V-belt and when the following conditions exist, re-
place the V-belt:
l When the V-belt makes contact with the bottom of the groove in
each pulley.
l When the V-belt is worn, and its surface is lower than the outer
diameter of the pulley.
l When cracking and peeling of the V-belt occurs.

An auto tensioner is installed, so it is unnecessary to adjust the

fan belt.

For details of the replacement procedure, refer to “24.3.11 RE-

PLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO
TENSIONER”.

3-64
 24. SERVICE PROCEDURE

24.8.7 CHANGE HYDRAULIC FILTER ELEMENT

When removing the oil filler cap, turn it slowly to release the
internal pressure before removrng It
When removing cover 0, undo the bolts (4 bolts) gradually to
prevent the cover flying off under the force of spring 0.
c

1. Remove the cover over the hydraulic tank.

2. Remove the cap from oil filler 0, and release the internal
pressure.

3. Loosen 4 bolts, then remove cover 0.

When doing this the cover may fly out under the force of spring
0, so hold the cover down when removing the bolts.

4. After removing spring @ and valve 0, take out element @I.

6. Clean the removed parts in diesel oil.

6. Install a new element in the place where old element @ was

installed.

7. Set valve @I and spring @ on top of the element.

8. Set cover @ in position, push it down by hand, and install the

cover with the mounting bolts.

9. Screw in the oil filler cap @ and install the cover.

10. To bleed the air, start the engine according to “12.2 STARTING
ENGINE” and run the engine at low idling for IO minutes.
j - - AEm
11. Stop the engine.

REMARK
Starting the engine after halting for more than 5 minutes to
eliminate bubbles in the oil inside the tank.

12. Check for oil leakage and wipe off any spilled oil.

3-65
24. SERVICE PROCEDURE

24.9 EVERY 1000 HOURS SERVICE

Maintenance for every 10,100,250 and 500 hours service should

be carried out at the same time.

24.9.1 CHANGE OIL IN SWING MACHINERY CASE

A WARNING
The oil is at high temperature immediately after the machine 1
has been operated. Wait for the oil to cool down before carrying
out maintenance.

Container to catch drained oil: Min. 30 e capacity

Refill capacity: 30 P (7.93 US gal)

Set a container under drain hose under the machine body to

catch the oil.

Loosen drain valve @ under the machine body, drain the oil,
then tighten the drain plug again.

Remove dipstick @ and air bleed plug 0, then add the specified
amount of engine oil through filler port @ of the,dipstick guide.

NOTlCE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

4. After adding oil, install air bleed plug 0.

5. Wipe off the oil on the dipstick with a cloth.

6. Insert dipstick @$Ifully into the dipstick guide, and then pull it out
again. Rear swing machinery

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

0. If the oil does not reach the L mark, add engine oil through
oil filler port 0.

8. If the oil is above the H mark, drain the excess engine oil from
drain valve 8, and check the oil level again.

9. Immediately after changing the oil, oil level is variable.

So operate for one hour, then check the oil level again.

24.9.2 CHECK TURBOCHARGER CLAMPfNG JOINT

Contact your Komatsu distributor for checking, or proceed as

follows:

3-56
 24. SERVICE PROCEDURE

24.9.3 CHANGE OIL IN PTO CASE

a WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carrying
out maintenance.

NOTICE
Park the machine on flat ground and stop the engine. After
waiting for more than 30 minutes after stopping the engine, check
the oil level.

Prepare the following.

l Contain to catch drain oil: Min. 40 l? capacity
l Refill capacity: 20 e each (10.6 US gal)

1. Drain oil from drain plug @ at the bottom of the PTO case. After
draining, tighten drain plug 8.

2. Pour in the specified amount of engine oil through oil filler 0.

NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

24.9.4 REPLACE CORROSION RESISTOR CARTRIDGE

1. Screw in valve @ (2 pieces) at the top of the corrosion resistor

2. Using a filter wrench, turn cartridge to the left to remove it.

3. Coat the seal surface of the new filter cartridge with engine oil,
then install it.
When installing, bring the packing surface into contact with the
seal surface of the filter holder, then tighten a further 2/3 turn.
Always use a genuine Komatsu cartridge.

4. Open valve 0.

5. Run the engine and check that there is no leakage of water from
the seal surface.

24.9.5 CHECK INSPECTION OF WELDING STRUCTURE

(COLOR CHECK)
When the service meter over 4000 hours, check every 1000
hours.

3-67
24. SERVICE PROCEDURE

24.10 EVERY 2000 HOURS SERVICE

Maintenance for every 50,100,250,500 and 1000 hours should

be carried out at the same time.

24.10.1 CHANGE OIL IN FINAL DRIVE CASE

AWARNING
l The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
carrying out maintenance.
l lf there is still pressure remaining inside the case, the oil or
plug may fly out.
Loosen the plug slowly to release the pressure.

Prepare the following.

Container to catch drained oil: Min. 85 e capacity
Refill capacity: 85 e (22.5 US gal)
Handle

Set the drain plug on the outside of the machine is at the

bottom.

2. Set a container under plug @ to catch the oil.

3. Remove plug @ with the handle and drain the oil, then tighten
the olua.

4. Set a container under plug @ to catch the oil.

5. Remove plug @ with the handle and drain the oil, then tighten
the plug.

6. Add engine oil through the hole of plug 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

7. After adding oil, check oil level.

For details, see “24.7 EVERY 250 HOURS SERVICE”.

24.10.2 CLEAN, CHECK TURBOCHARGER

Excessive carbon or oil sludge adhering to turbocharger blower

impeller may deteriorate normal performance of turbocharger and
may sometimes damage it.
Ask your Komatsu distributor to clean the turbocharger and
check rotation of the rotor impeller, or perform the following.

3-68
 24. SERVICE PROCEDURE

24.10.3 CHECK TURBOCHARGER ROTOR PLAY

Contact your Komatsu distributor for checking.

24.10.4 CHECK SWING PINION GREASE LEVEL,

ADD GREASE
1. Remove 4 bolts @ on the inside of track frame, then remove
cover @_

2. Insert a scale into the grease and check that the depth of the
grease is approx. 156 mm (6.2 in). Add grease if necessary.

If the grease is particularly milky due to ingress of water, etc.,

then remove bolts @ and cover @from the bottom of the track frame
and remove the grease. Replace all of the grease with new grease.
The total amount of grease is 170 f? (45 US gal) (153 kg, (337 lb)).

24.10.5 CLEAN ENGINE BREATHER

1. Remove breather 0.
2. Rinse the breather in diesel oil or flushing oil, dry with com-
pressed air, then install again.

Before removing the breather, clean all the dirt from around it.
Replace the breather O-ring with a new part, and coat it with
engine oil before installing.

3-69
24. SERVICE PROCEDURE

24.10.6 CLEAN HYDRAULIC TANK STRAINER

l When removing the cap, turn it slowly to relieve inner pres-

l When removing cover 0, undo the bolts (4 bolts) gradually

to prevent the cover flying off under the force of spring 0.

1. Remove cap @ of the oil filler.

2. Remove cover @ and lift up the top of rod @I from above to take
out spring @ and strainer 0.

3. Wash the strainer with fuel oil. If strainer @ is damaged, replace

it with a new one.

4. When installing, check that the O-ring at the bottom of strainer

@ is not out of place or twisted, then coat the surface of the O-
ring with grease, insert it on to tank protrusion 0, and install.

AEl80090

24.10.7 CHECK ALTERNATOR, STARTING MOTOR

The brushes 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.

24.10.8 CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts,
request Komatsu distributor for service.

3-70
 24. SERVICE PROCEDURE

24.11 EVERY 4000 HOURS SERVICE

Maintenance for every 10, 100, 250, 500, 1000 and 2000 hours
should be carried out at the same time.

24.11.1 CHECK WATER PUMP

Check if there is oil leakage, water leakage, or clogging of the
drain hole. If any abnormality is found, contact your Komatsu
distributor for disassembly and repair or replacement.

24.11.2 CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface
of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor
to have the parts replaced.

24.11.3 CHECK FAN PULLEY AND TENSION PULLEY

Inspect the pulley for play and grease leakage.
If any fault is detected, ask Komatsu distributor to disassemble
and repair or replace.

24.11.4 CHECK AIR COMPRESSOR, ADJUST

As special tool is required for checking and adjusting the parts,
request Komatsu distributor for service.

3-71
24. SERVICE PROCEDURE

24.12 EVERY 5000 HOURS SERVICE

Maintenance for every 10,100,250,500 and 1000 hours should

be carried out at the same time.

24.12.1 CHANGE OIL IN HYDRAULIC TANK, CLEAN

STRAINER
AWARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before chang-
ing it. When removing the oil filter cap, turn it slowly to releasa
the internal pressure, then remove it carefully.

Prepare the following.

l Cantainer to catch drained oil: min. 1500 !J capcacity
l Refill, capacity: 1500 e (396 US gal)
AE171090
l Prepare a handle for the socket wrench set.
I

1. Retract the arm and bucket cylinder, lower the boom, put the tips
of the teeth in contact with the ground, then stop the engine.

2. Remove the cap of oil filler 0. I

- Y

3. Remove drain plug @ and loosen valve @ at the bottom of the

machine body to drain off the oil. After draining off the oil,
tighten up the drain valve and plug.

4. Pour in the specified amount of engine oil through oil filler 0.

NOTICE
For details of the oil to use, see “20. USE OF FUEL,
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

5. After changine the oil, fleed the air from the circuit, and check
the oil level.

For details of engine oil filling, see “12.1.2 CHECK OIL LEVERL
IN HYDRAULIC TANK, ADD OIL”.
For details of releasing the air inside the hydraulic tank and the
pressure inside the hydraulic circuit, see “18.5 BLEEDING AIR FROM
ClRCUlT”.

When loosening valve 0, be careful not to get oil on yourself.

NOTICE
This applies only when using the Komatsu specified oil + a
hybrid filter (07063-51210) and replacing the hybrid filter every 500
hours. When using other oil and the standard filter (07063-01210).
the replacement interval for the filter is 250 hours and the interval
for changing the hydraulic oil is 2000 hours.

3-72
25. SPECIFICATIONS

PC1 800-6

Item I Unit I PC1800-6

Operating weight
kg (lb) 180000 (396828)
(including 1 operator, 80 kg)
Bucket capacity SAE m3 (cu.yd) 12 (15.5)
(standard bucket) CECE m3 (cu.vd) 11 (14.2)
1 Name of engine 1 Komatsu SAA6Dl40 diesel engine x 2
1 Engine horsepower 1 kW (HPYrpm 1 338 (454)/1800
A 1 Overall lenath I mm (ft in) I 17185 (56’5”)
B 1 Overall height I mm (ft in) I 6745 (22’)
C Overall width mm Vt in) 6015 (19’9”)
D Track width mm (ft in) 810 (2’8”)
E Heiaht of cab mm (ft in) 6510 (21’4”)
F Tail swing radius mm (ft in) 6235 (20’5”)
G Length of track mm (ft in) 7436 (24’5”)
H Tumbler center distance mm (ft in) 5780 (18’12”)
Min. ground distance mm (ft in) 2080 (6’10”)
Travel speed km/h (MPH) 2.7 (1.7)
Swina sDeed ram 4.5

9JYO1459

4-2
PC1 800-6

Working ranges Unit PC1 800-6

A Max. digging reach mm (ft in) 15780 (51’7”)

B Max. digging depth mm (ft in) 9265 (30’5”)
C Max. digging height mm (ft in) 13380 (43’11”)
D Max. vertical wall depth mm (f-t in) 2740 (8’12”)
E Max. dumping height mm (ft in) 8620 (28’3”)
F Max. reach at ground level mm (ft in) 15305 (50’3”)

AW365000

4-3
OPTIONS, ATTACHMENTS
26. GENERAL PRECAUTIONS

26.1 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, please contact your
Komatsu distributor first.
If you do not contact Komatsu, we cannot accept any responsibility for any accident or failure.

A WARNING
Precautions for removal and installation operations
When removing or installing attachments, obey the following precautions and take care to ensure
safety during the operation.
Carry out-the removal and installation operations on a flat, firm ground surface.

When the operation is carried out by two or more workers, determine signals and follow these
during the operation.

When carrying heavy objects (more than 25 kg (55 lb)), use a crane.

When removing heavy parts, always support the part before removing it.
When liiing such heavy parts with a crane, always pay careful attention to the position of the
center of gravity.

lt is dangerous to carry out operations with the load kept suspended. Always set the load on a
stand, and check that it is safe.

When removing or installing attachments, make sure that they are in a stable condition and will
not fall over.

Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load should fall.

NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an
unqualified person.
For details of the removal and installation operations, please contact your Komatsu distributor.

5-2
 26. GENERAL PRECAUTIONS

26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS

a WARNING
Long work equipment reduces the stability of the chassis, 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.

l Going downhill with l Traveling across slopes l Swinging the upper

the work equipment raised structure on slopes
CORRECT CORRECT
INCORRECT
INCORRECT

AD34129A AE341310
AD341MA

lf 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 structure stops completely), so there is danger of mistaking 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. lf the correct procedure
is not followed, this may lead to serious damage or injury, so please consult your Komatsu
distributor before carrying out installation.

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.

5-3
27. INTRODUCTION OF A-ITACHMENTS

27.1 GUARD

Name Specifications/Use

Used to protect operator. Must be installed

when machine is operated in a place where
FOPS Weight: 130 kg (287 lb)
rocks and other heavy materials may fall

54
28. AUTO-GREASING SYSTEM

The following is an explanation of the operation and equipment

needed for the optional auto-greasing system.

c”11710
I
1. AUTO-GREASING SWITCH I I
This switch is inside the base under the cab and is used to switch
between automatic and manual greasing.
Normally, keep this switch at the AUTO position.
When using a grease gun, set the switch to MANUAL.

2. AUTO GREASE/GREASE GUN selector lever

This lever is used to select automatic or manual greasing in the
same way as the auto-greasing switch.
Normally, keep this lever at the AUTO GREASE position.
When using a grease gun, check first that the grease pump is not
carrying out auto-greasing [if it is carrying out auto-greasing,
wait until the grease pump stops (within approx. 1 minute)], then
set the lever to the GREASE GUN position.

5-5
28. AUTO-GREASING SYSTEM

3. AUTO-GREASING LAMP
When the auto-greasing switch is operated, the auto-greasing
lamp (green) on the panel at the right side of the operator’s seat
will light up at the AUTO or MANUAL position.

b. AUTO-GREASING CAUTION LAMP

This lamp lights up if an abnormality occurs in the auto-greasing
system. Check the engine from the content of the display on the
auto-greasing controller inside the cab base, then carry out
repair work.

Set the auto-greasing controller to the OFF position when carry-

ing out repair work. If the starting switch is turned OFF, the
controller is also turned OFF.

Lamp Controller display Nature of abnormality Cause

Controller rest Pressure inside grease piping l Failure of pump
failure does not rise when pump is 0 Pump running empty
working l Cracked grease piping,
Lights up 1 leakage
Vent pressure SW Vent valve does not return, l Failure of vent valve
alarm injector cannot be recharged l Crushed, clogged grease
piping upstream from
injector

REMARK
If the engine is not running but the starting switch is left at the
ON position, the controller display will show CONTROLLER REST
FAILURE and the caution lamp will light up, but this does not
indicate any abnormality.
When the starting switch is turned OFF, the condition will return to
normal.

5-6
 28. AUTO-GREASING SYSTEM

5. GREASE NIPPLE FOR GREASE SUPPLEMENT

The grease nipple @ for supplement is located inside the cab
base room. It is possible to refill with grease without replacing
the grease pail. Use a grease gun to refill. The refilling operation
is completed when the oil level rod @ reaches the FULL position.

5-7
PC18OO-s HYDRAULIC EXCAVATOR

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