Page 1 WENAM00150 Operation & Maintenance Manual PC30MR- PC35MR- HYDRAULIC EXCAVATOR SERIAL NUMBERS PC30MR-5 F50001 and up PC35MR-5 F50001 and up WARNING ORIGINAL INSTRUCTIONS Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 Keep it in the pocket inside the cover of toolbox under the oper- ator's seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 6: Safety Labels
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 ques- tions regarding information in this manual.
Page 7: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, si- mulated working cycle). Canopy spec ISO 6396 Cab spec The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with...
Page 8: Vibration Levels
VIBRATION LEVELS FOREWORD VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 9: Introduction
FOREWORD INTRODUCTION INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Ditching work • Loading work • Leveling work For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 10: Visibility From Operator's Seat
INTRODUCTION FOREWORD In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine. VISIBILITY FROM OPERATOR'S SEAT The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below.
Page 11: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is located on the front left of revolving frame.
Page 12: Fluorinated Greenhouse Gases
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: Komatsu Italia Manufacturing S.p.A. Address: Via Atheste, 4 35042 Este (PD) Italy Distributor name Address...
Page 13: Serial Plate
FOREWORD SERIAL PLATE SERIAL PLATE SERIAL NUMBER MACHINE DESIGNATION/TYPE WEIGHT YEAR OF CONSTRUCTION PRODUCT IDENTIFICATION NUMBER ENGINE POWER MANUFACTURER 1-11 WENAM00150...
Page 14: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Italia Manufacturing S.p.A. Via Atheste, 4 35042 Este (PD) Italy Declares that this machines: PC30MR-5 PC35MR-5 Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive...
Page 15: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-3 SAFETY LABELS ............................. 1-4 NOISE............................... 1-5 VIBRATION LEVELS ..........................1-6 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-6 INTRODUCTION ............................1-7 MAIN USE OF MACHINE ........................
Page 16 PRECAUTIONS FOR DISCHARGED BATTERY ................3-183 OTHER TROUBLE......................... 3-187 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 1-14 WENAM00150...
Page 17 EVERY 2000 HOURS MAINTENANCE ................... 4-57 EVERY 4000 HOURS MAINTENANCE ................... 4-66 SPECIFICATIONS ............................5-1 SPECIFICATIONS ............................ 5-2 SPECIFICATIONS: PC30MR-5 ......................5-2 SPECIFICATIONS: PC35MR-5 ......................5-4 EXPLANATION OF LIFT CAPACITY CHART.................... 5-6 ATTACHMENTS AND OPTIONS ........................6-1 PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS..............6-2 PRECAUTIONS WHEN SELECTING ....................
Page 18 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-7 INDEX................................8-1 1-16 WENAM00150...
Page 19: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly. WENAM00150...
Page 20: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 21: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS LOCATION OF SAFETY LABELS: CANOPY SPEC RKA63740 (1) Caution for work equipment (8) Caution for high-temperature coolant and hydraulic (2) Caution for handling accumulator and gas spring (9) Warning for operation, inspection and maintenance (3) Notice for floor unit locking (10) Caution for handling cable (4) Caution when opening floor...
Page 22 SAFETY LABELS SAFETY (17) Warning against high-voltage cable (26) Control levers operational function diagram (19) Caution for blast jobsite (27) Switches operational function diagram (21) Warning always fasten safety belt (28) Lifting and fastening decals for transport (22) Warning when leaving operator's seat (29) Lifting capacities diagram (24) Warning for handling ROPS (30) Caution for overload machine...
Page 23 SAFETY SAFETY LABELS RKA63640 (1) Caution for work equipment (16) Warning when reversing (2) Caution for handling accumulator and gas spring (17) Warning against high-voltage cable (3) Notice for floor unit locking (18) Caution when standing in operator's cab (4) Caution when opening floor (19) Caution for blast jobsite (5) Caution for adjusting track tension (20) Warning for quick coupler system...
Page 24: Contents Of Safety Labels
SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS (1) Caution for work equipment (09134-A0881) Keeping out of working range area • Sign indicates a hazard of being hit by the working device of the machine. • Keep away from the machine during operation. (2) Caution for handling accumulator and gas spring (09659-A057B) •...
Page 25 SAFETY SAFETY LABELS (5) Caution for adjusting track tension (09657-A0881) • Sign indicates a hazard of flying plug from track adjuster that could cause injury. • Read manual regarding adjusting track for safe and proper handling. (6) Danger do not enter within swing range (22N-98-51740) •...
Page 26 SAFETY LABELS SAFETY (8) Caution for high temperature coolant and hydraulic oil (09653-A0361) • Never remove the cap when the engine is at operating (high) temperature. Steam or high temperature oil blowing up from the radiator or hydraulic tank will cause personal injury and/or burns.
Page 27 SAFETY SAFETY LABELS (11) Caution for handling battery (09664-60001) (a) Never smoke or use any naked flame near the batteries, no sparks. (b) Always wear safety glasses when working with batteries. (c) Keep children away from batteries. KS000327 (d) Caution battery acid. WENAM00150...
Page 28 SAFETY LABELS SAFETY (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases. (12) Caution when closing floor (09824-K0481) • There is danger of being caught between the frame or oth- er moving parts and suffering injury. •...
Page 29 SAFETY SAFETY LABELS (14) Quick release battery terminal (-) (22E-98-21140) (15) Caution when stowing front window (Cab spec) (09803-A0481) • Sign indicates a hazard from falling window. • After raising window, be sure to lock it in place with lock pins.
Page 30 SAFETY LABELS SAFETY (17) Warning against high-voltage cable (09801-A0481) • An electrocution hazard if the machine is brought too near to electric power lines. • Keep a safe distance from electric power lines. (18) Caution when standing in operator cab (Cab spec) (09839-A0481) •...
Page 31 SAFETY SAFETY LABELS (19) Caution for blast jobsite (09845-00480) Caution of an explosive hazard caused by active radio transmit- ter at a blast zone. • Keep machine at a safe distance from blast zone and a detonator. (20) Warning for quick coupler system (Cab spec) (22N-98-53830) •...
Page 32 SAFETY LABELS SAFETY (22) Warning when leaving the operator's seat (09654-A0841) • Before standing up from operator's seat. • Lower the work equipment to the ground and move safety lock lever (located near seat) to lock position to avoid hit- ting unlocked operation levers.
Page 33 SAFETY SAFETY LABELS Canopy spec: 22F-98-51430 (27) Switches operational function diagram 1 attachment • Canopy spec: 22F-98-32930 • Cab spec: 22F-98-32960 2 attachment (22F-98-32991) 2-15 WENAM00150...
Page 34 SAFETY LABELS SAFETY (28) Lifting and fastening decals for transport (22F-98-51150) (29) Lifting capacities diagrams PC30MR-5 • Canopy spec: • Standard arm: 22L-98-52540 • Long arm: 22L-98-52560 • Cab spec: • Standard arm: 22L-98-52550 • Long arm: 22L-98-52570 PC35MR-5 •...
Page 35: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 36: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 37: Precautions When Getting On Or Off Machine
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE When wearing cotton work gloves, wear rubber gloves under them. PREVENT FIRE Fire caused by fuel, oil, coolant, or window washer fluid Do not bring any open flame close to flammable substances such as fuel, oil, coolant, or window washer fluid.
Page 38 Be sure to securely tighten the loosen bolts of the handrail. If the handrail is broken or deformed, it should be repaired immediately. Ask your Komatsu distributor to perform this work. • Do not grip the control levers or lock lever when getting on or off the machine.
Page 39 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT Before standing up from the operator's seat in order to open or close the front window or to adjust the operator's seat, be sure to lower the work equipment to the ground, set the lock lever (1) to LOCK position (L), and stop the engine.
Page 40: Do Not Get Caught In Work Equipment
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor •...
Page 41: Protection Against Falling, Flying Or Intruding Objects
Be sure to consult with your Komatsu distributor about necessary guards. UNAUTHORIZED MODIFICATION • Komatsu will not be responsible for any personal injuries, product failures, physical loss or damage, or influ- ence on the environment resulting from modifications made without authorization from Komatsu. •...
Page 42: Precautions When Running Engine Inside Building
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or ma- chine must be operated inside a building or underground, where the ventilation is poor, take steps to ensure that the en- gine exhaust gas is removed and that ample fresh air is...
Page 43: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 44 PRECAUTIONS FOR OPERATION SAFETY Voltage of Cables Safety Distance 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 45: Start Engine
SAFETY PRECAUTIONS FOR OPERATION This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 46: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the following. • Start the engine only while sitting down in the operator's seat. •...
Page 47 SAFETY PRECAUTIONS FOR OPERATION • Fasten the seatbelt. When the brakes are applied sudden- ly, the operator may be thrown out of the operator's seat. It is dangerous and may cause personal injury. • Check that the movement of the machine matches the dis- play on the control pattern card.
Page 48 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN TRAVELING Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact. Always observe the following. • Do not drive the machine with excess speed, stop suddenly, and starts suddenly. It is quite dangerous. •...
Page 49 SAFETY PRECAUTIONS FOR OPERATION • Keep the work equipment at height (a) 20 to 30 cm above the ground. In case of emergency, lower the work equip- ment to the ground immediately to help stopping the ma- chine. • When driving the machine up slopes, set the operator's cab facing uphill, when driving downhill , set the operator's cab facing downhill.
Page 50 PRECAUTIONS FOR OPERATION SAFETY • Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that the machine may slip. • If the engine stops, move the control levers immediately to NEUTRAL position, set the lock lever to LOCK position, and then start the engine.
Page 51 SAFETY PRECAUTIONS FOR OPERATION • For a quick escape in an emergency, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when performing operations. • Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other hauling equipment.
Page 52: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 53: Towing And Being Towed
SAFETY PRECAUTIONS FOR OPERATION • Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. (1) Chocks (2) Ramp (3) Ramp width...
Page 54: Lifting Operation By Using Lifting Device (Optional Equipment)
PRECAUTIONS FOR OPERATION SAFETY • Use wire rope that conforms to the specified standard. • Do not perform any lifting operation with a load heavier than the specified lifting load. It may cause a seri- ous accident such as tipping over of the machine. •...
Page 55 SAFETY PRECAUTIONS FOR OPERATION • Do not swing or operate the work equipment suddenly. There is a danger that this may cause the load to swing and the machine to become unstable or tip over. • Do not leave the operator's seat while the load is being lifted. •...
Page 56 PRECAUTIONS FOR OPERATION SAFETY • If the load is to be lifted at a height where this is not possi- ble, the sling or chain must only be guided by the back wall of the bucket and not any other part of the machine. 2-38 WENAM00150...
Page 57: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the "DAN- GER! Do NOT operate!" warning tag. If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 58 PRECAUTIONS FOR MAINTENANCE SAFETY • Lower the work equipment to the ground and stop the en- gine before performing any inspection and maintenance. • Turn the starting switch to ON position. Operate the work equipment control lever back and forth, right and left a few times fully to release the remaining internal pressure in the hydraulic circuit.
Page 59 SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the maintenance with the engine running, always observe the following. • One worker must always sit on the operator's seat and be ready to stop the engine at any time.
Page 60: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY • Never jump down from the machine. When getting on and off the machine, always face the machine and maintain at least three-point contact (both feet and one hand, or both hands and one foot) with the hand- rails and steps to ensure that you support yourself.
Page 61 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR WELDING Welding operations must always be performed by a qualified welder and in a place equipped with proper equip- ment. There is a hazard of gas, fire, or electric shock when performing welding, so never allow any unqualified person to perform welding.
Page 62 PRECAUTIONS FOR MAINTENANCE SAFETY • Install the cover above the battery so that it envelops the battery and it is not flipped. If the cover is damaged, replace it Immediately. • If chloride is accumulated on the top surface of battery and around terminals, clean them with warm water of approximately 40 °C {104 °F} , dry them thoroughly, and connect the battery cable to them.
Page 63 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 64 If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. HANDLE ACCUMULATOR AND GAS SPRING This machine is equipped with an accumulator.
Page 65 • When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 66 WENAM00150...
Page 67: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section. WENAM00150...
Page 68: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Arm cylinder (8) Idler (2) Boom (9) Blade cylinder (3) Boom cylinder (10) Blade (4) Dirt cover (11) Bucket (5) Track (12) Bucket cylinder (6) Sprocket (13) Arm (7) Track frame WENAM00150...
Page 69 OPERATION GENERAL VIEW (14) Engine rear cover (16) Battery (15) Cooling cover WENAM00150...
Page 70: Controls And Gauges Names
GENERAL VIEW OPERATION CONTROLS AND GAUGES NAMES CONTROLS AND GAUGES NAMES: CANOPY SPEC RKA64310 (1) Lock lever (12) Travel speed selector switch (2) L.H. work equipment control lever (13) Blade control lever (3) Travel pedal (14) Fuel control dial (4) Travel lever (15) Lamp switch (5) Swing lock cover (16) Starting switch...
Page 71 OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES: CAB SPEC RKA64300 (1) Lock lever (11) Breaker operation switch (2) L.H. work equipment control lever (12) R.H. work equipment control lever (3) Wiper switch (13) Travel speed selector switch (4) Travel pedal (14) Blade control lever (5) Travel lever (15) Temperature control switch...
Page 72 GENERAL VIEW OPERATION (21) Revolving lamp switch (if equipped) (25) Floor lock release lever (22) Pump secondary drive switch (26) Room lamp switch (23) Lock lever automatic lock cancel switch (27) FRESH/RECIRC air selector lever (24) Engine shutdown secondary switch MACHINE MONITOR EQUIPMENT NAME (1) Message display (9) Auto-deceleration pilot lamp...
Page 73: Other Equipment Name
OPERATION GENERAL VIEW OTHER EQUIPMENT NAME OTHER EQUIPMENT NAME: CANOPY SPEC (1) Power supply outlet (6) Grease pump holder (2) Cup holder (7) Fusible link (3) Toolbox (8) Quick release battery terminal (-) (4) Fuse (9) System operating lamp (5) Operation and Maintenance Manual pocket WENAM00150...
Page 74 GENERAL VIEW OPERATION OTHER EQUIPMENT NAME: CAB SPEC (1) Front window (8) Power supply outlet (2) Ceiling window (9) Emergency escape hammer (3) Cab door (10) Small slide window (4) Door lock release lever (11) AUX (if equipped) (5) Toolbox (12) Cup holder (6) Fuse (13) Ashtray (if equipped)
Page 75 OPERATION GENERAL VIEW (14) Grease pump holder (16) Quick release battery terminal (-) (15) Fusible link (17) System operating lamp WENAM00150...
Page 76: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, BB: Warning or Error screen (1) Gauge display...
Page 77 OPERATION EXPLANATION OF COMPONENTS REMARK At starting of the engine, battery voltage may drop abruptly depending on the ambient temperature or battery condition, and the machine monitor may restart, but it is not a trouble. BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While the engine shutdown secondary switch is in ON (engine is stopped) position (a), when the starting switch is turned to...
Page 78 EXPLANATION OF COMPONENTS OPERATION End screen when any message has been received If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if the message is requesting a response, make a reply to it.
Page 79 OPERATION EXPLANATION OF COMPONENTS If there is an abnormality when starting the engine • If there is any abnormality when starting the engine, opening screen CC changes to warning screen BB. • After opening screen CC is displayed for 2 seconds, the screen changes to warning screen BB. •...
Page 80 EXPLANATION OF COMPONENTS OPERATION For checking the details of error, press the function switch “F3”, and then the Current Abnormality screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE • If any trouble occurs during machine operation, standard screen AA changes to warning screen BB. •...
Page 81 OPERATION EXPLANATION OF COMPONENTS If there is any error existing, “!” is displayed on top of the func- tion switch “F3”. For checking the details of error, press the function switch “F3”, and then the Current Abnormality screen is displayed. WARNING DISPLAY NOTICE Appearance of any of action levels “L01”...
Page 82 Stop the operation, and run the engine at medium speed with │ mittently no load or stop it. │ If the condition is not improved, ask your Komatsu distributor ↓ for the inspection and maintenance. Does not Lights up in...
Page 83 OPERATION EXPLANATION OF COMPONENTS Caution lamps and display colors Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue High temperature Engine coolant temperature Low temper- Normal caution lamp ature (L02) Fuel level caution lamp Low level Normal Abnormal Abnormal...
Page 84 EXPLANATION OF COMPONENTS OPERATION CURRENT ABNORMALITY LIST DISPLAY If any error occurs, “!” is displayed on top of function switch “F3”. While “!” is displayed, if you press the function switch “F3”, monitor display screen is changed to “Current Abnormality” screen.
Page 85 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 86 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 87 • The lighting time of maintenance time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on “Maintenance” menu screen, see “MAINTENANCE SCREEN SETTING”.
Page 88 EXPLANATION OF COMPONENTS OPERATION SEATBELT CAUTION LAMP The seat belt caution lamp lights up when the seat belt is not fastened. It goes out when the seat belt is fastened. Always fasten the seat belt while operating because there may be a possible danger.
Page 89 OPERATION EXPLANATION OF COMPONENTS PREHEATING PILOT LAMP The preheating pilot lamp is displayed while the engine is pre- heated before started. When the temperature is low (in cold weather) and the auto- matic preheating function operates, the preheating pilot lamp lights up.
Page 90 EXPLANATION OF COMPONENTS OPERATION “L” L mode (for lifting operations) RKA63180 “B” B mode (For breaker operations) (For machines ready for in- stallation of attachments) “ATT/P” ATT/P mode (For operations of 2-way attachments like crusher) (For machines ready for installation of attachment) “ATT/E”...
Page 91 Each time the travel mode is switched by the travel speed selector switch, it lights up in yellow at the center of the monitor display, and 2 seconds later, it lights up in blue again. MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “CHECK MESSAGE”. Lights up in green There is an unread message.
Page 92 EXPLANATION OF COMPONENTS OPERATION It goes out when the lock lever is set in FREE position. LOCK LEVER AUTOMATIC LOCK CANCEL PILOT LAMP The lock lever automatic lock cancel pilot lamp lights up when the lock lever automatic lock cancel switch is set to CANCEL position.
Page 93 OPERATION EXPLANATION OF COMPONENTS REMARK • The overheat prevention system is actuated when the graduation of gauge goes in red range (A). The engine runs at low idle. Engine coolant temperature caution lamp (D) lights up in red. The alarm buzzer sounds. It keeps sounding until the graduation of gauge goes in green range (B).
Page 94 EXPLANATION OF COMPONENTS OPERATION • Clock display (12-hour display) • Clock display (24-hour display) On the standard screen, if you press the function switch “F2”, you can switch between the clock display and the service me- ter display alternately. REMARK •...
Page 95 OPERATION EXPLANATION OF COMPONENTS FUNCTION SWITCHES AND GUIDANCE ICONS • There are 8 function switches (1) (“F1” to “F8”) at the bot- tom and right side of the monitor display. The function of each switch differs in accordance with the content of each screen.
Page 96 EXPLANATION OF COMPONENTS OPERATION Function switch “F4” Enters the selection and contents to change, and advances the display to the next screen. Function switch “F6” Moves to the left item. (When on the leftmost, it moves to the rightmost.) Function switch “F7” Moves to the right item.
Page 97 When the working mode is changed and screen returns to the standard screen, auto-deceleration function is automatically selected. Ask your Komatsu distributor to change the setting if you want to have the automatic setting of “P”, “E”, “L”, “B”, “ATT/P” or “ATT/E” modes (optional default setting) when starting the engine.
Page 98 EXPLANATION OF COMPONENTS OPERATION After the working mode is set, the working mode is dis- played in yellow in the center of the monitor display. 2 seconds later, yellow returns to blue. BUZZER CANCEL FUNCTION Operate the buzzer cancel function after starting the engine. When buzzer cancel icon is displayed, if you press the function switch “F8”, alarm buzzer for abnormality of warning items stops sounding.
Page 99 OPERATION EXPLANATION OF COMPONENTS The user menu consists of the following kinds. The right and left menu screens can be changed by pressing the function switches “F6” and “F7”. (a): “Working Record” (b): “Machine Setting” (c): “Maintenance” (d): “Monitor Setting” (e) Mail Check These menus (a) to (e) are for setting and confirming the fol- lowing items:...
Page 100 EXPLANATION OF COMPONENTS OPERATION (e) Mail Check • Check of mail contents and reply to mail On the user menu screen, you can perform the following opera- tions with the function switches “F1” to “F4”, “F6”, and “F7”. Function switch “F1” Moves to the next item (1 line below).
Page 101 OPERATION EXPLANATION OF COMPONENTS CHECK OPERATION RECORDS Select “Operation Records” on “Working Record” menu screen, and then press the function switch “F4”. If you select each item of “Operation Records” menu, each da- ta on daily basis or on a split measurement period basis are displayed at the bottom.
Page 102 EXPLANATION OF COMPONENTS OPERATION Operations on “Configurations” menu screen On “Configurations” menu screen, you can perform the follow- ing operations with function switches “F3” and “F4”. Function switch “F3” Returns the screen to “Working Record” menu screen. Function switch “F4” Displays the setting screen for the selected item.
Page 103 OPERATION EXPLANATION OF COMPONENTS REMARK If you select the Split Time measurement, “SPLIT” is displayed at the top right of “Operation Records” screen. If you want to stop the measurement, press the function switch “F8” on “Operation Records” screen, and move to “Split Time Information”...
Page 104 EXPLANATION OF COMPONENTS OPERATION “Breaker Setting” screen is displayed. Select the setting corresponding to the operation on “Breaker Setting” screen, and then press function switch “F4”. Setting of B mode is changed. On “Breaker Setting” screen, you can perform the following operations with function switches “F1”...
Page 105 OPERATION EXPLANATION OF COMPONENTS Function switch “F4” Enters the change and returns the screen to “Breaker Setting” screen. Function switch “F6” Moves to the left letter. When on the first letter, it moves to the last letter. Function switch “F7” Moves to the right letter.
Page 106 EXPLANATION OF COMPONENTS OPERATION Select “Attachment Setting” on “Machine Setting” menu screen, and then press function switch “F4”. “Attachment Setting” screen is displayed. Select proper setting matching to the installed attachment on “Attachment Setting” screen, and then press function switch “F4”. Setting of ATT/P and ATT/E mode is changed.
Page 107 OPERATION EXPLANATION OF COMPONENTS Select an attachment setting to change its name on “At- tachment Setting” screen, and then press function switch “F7”. “Attachment Name Setting” screen is displayed. On “Attachment Name Setting” screen, you can perform the following operations with function switches “F1” to “F4”, “F6”, “F7”, and “F8”.
Page 108 EXPLANATION OF COMPONENTS OPERATION The “2-Way Attachment Oil Flow Rate Setting” screen is displayed. On “2-Way Attachment Oil Flow Rate Setting” screen, you can perform the following operations with function switches “F3”, “F4”, “F6”, and “F7”. Function switch “F3” Returns to “Attachment Setting” screen without changing the flow rate.
Page 109 OPERATION EXPLANATION OF COMPONENTS Select the setting time on “Auto Idle Stop Timer Set” selec- tion screen, and then press the function switch “F4”. On “Auto Idle Stop Timer Set” selection screen, you can perform the following operations with function switches “F1”...
Page 110 EXPLANATION OF COMPONENTS OPERATION When the lock lever is set to FREE position according to the screen instructions, the countdown stops and the screen returns to the standard screen. When countdown continues and reaches 0, the engine stops and the guidance icon on the bottom right lights up in red.
Page 111 0 hours or less, the remaining time display (c) lights up in red. • If you want to change the setting for the maintenance time or maintenance notice time (default: 30 hours), consult your Komatsu distributor. Operations on Maintenance Due Time Reset screen Reset the maintenance time after starting the engine.
Page 112 EXPLANATION OF COMPONENTS OPERATION REMARK • When canceling the reset, press the function switch “F3”. The screen returns to “Maintenance” screen. • On “Maintenance Due Time Reset” screen, if no switch is operated for 30 seconds or more, the screen automatically changes to “Maintenance”...
Page 113 OPERATION EXPLANATION OF COMPONENTS CLOCK ADJUSTMENT “Clock Adjustment” menu screen is used to change the setting of the clock displayed on the standard screen. Select “Clock Adjustment” on “Monitor Setting” menu screen, and then press the function switch “F4”. “Clock Adjustment” menu screen is displayed. The items related to “Clock Adjustment”...
Page 114 EXPLANATION OF COMPONENTS OPERATION “Calendar” screen is displayed. Change the date of calendar according to the following op- eration. You can change the numeral displayed in yellow. Function switch “F1” Puts back the numeral by 1. Function switch “F2” Advances the numeral by 1. Function switch “F3”...
Page 115 OPERATION EXPLANATION OF COMPONENTS Function switch “F7” Moves to the blue display. SWITCH 12H/24H DISPLAY MODE Perform the setting of 12h/24h mode after starting the engine. On “12h/24h Mode” screen, you can set the display mode of clock. Select “12h/24h Mode” on “Clock Adjustment” menu screen, and then press function switch “F4”.
Page 116 EXPLANATION OF COMPONENTS OPERATION The “Daylight Saving Time” screen is displayed. “ON” The clock is displayed in daylight saving time (summer time). The clock display becomes 1 hour forward. “OFF” The clock is displayed in normal time. Change the display mode of clock with the following opera- tion.
Page 117 On machines equipped with KOMTRAX, when message pilot lamp is lit on the standard screen, you can see the messages from your Komatsu distributor on the mail check menu screen by pressing function switch “F4”. Message is distinguished as follows according to the lighting states of the message display.
Page 118 • When the message display lights up in blue, it means that no reply has been made yet to any read message to your Komatsu distributor. Reply to the message in accordance with the replying method mentioned below. • If the starting switch is turned to OFF position when there...
Page 119 OPERATION EXPLANATION OF COMPONENTS Function switch “F7” Moves to the leftmost menu. REPLY TO MESSAGE If a message requests reply, press function switch “F4”, and the screen moves to the screen for replying to the message. On the screen for replying to the message, input the num- ber of selected item as an input value.
Page 120: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES SWITCHES: CANOPY SPEC RKA64320 (1) Horn switch (6) Lamp switch (2) 1st line attachment proportional switch (7) Starting switch (3) Breaker operation switch (8) Pump secondary drive switch (4) Travel speed selector switch (9) Lock lever automatic lock cancel switch (5) Fuel control dial (10) Engine shutdown secondary switch 3-54...
Page 121 OPERATION EXPLANATION OF COMPONENTS SWITCHES: CAB SPEC RKA64330 (1) Wiper switch (9) Fuel control dial (2) Horn switch (10) Lamp switch (3) 1st line attachment proportional switch (11) Starting switch (4) Breaker operation switch (12) Revolving lamp switch (if equipped) (5) Travel speed selector switch (13) Room lamp switch (6) Temperature control switch...
Page 122 EXPLANATION OF COMPONENTS OPERATION STARTING SWITCH Starting switch is used to start or stop the engine. (A) OFF position The electrical current to the electrical system is cut, and the en- gine stops. The key can be inserted into or removed from the starting switch.
Page 123 OPERATION EXPLANATION OF COMPONENTS 1ST LINE ATTACHMENT PROPORTIONAL SWITCH The 1st line attachment proportional switch is used to operate the attachment. For handling of the 1st line attachment proportional switch, see section “ATTACHMENTS AND OPTIONS”. BREAKER OPERATION SWITCH The breaker control switch is used to operate the breaker. For handling of the breaker control switch, see section “AT- TACHMENTS AND OPTIONS”.
Page 124 EXPLANATION OF COMPONENTS OPERATION TRAVEL SPEED SELECTOR SWITCH WARNING • When loading to or unloading onto/from a trailer, always drive the machine at low speed (set it to Lo), and never operate the travel speed selector switch during travel. • If the travel speed is switched between high-speed and low-speed while the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 125 OPERATION EXPLANATION OF COMPONENTS If the wiper and washer position (b) is kept pressed while the wiper is in operation, the injection of the window washer fluid and the wiper operation are performed simultaneously. If the wiper switch is released, it returns to the wiper and wash- er position (b), the injection of the window washer fluid stops, and the state becomes that only the wiper is operated.
Page 126 (a), the lock lever automatic lock cancel pilot lamp lights up. After moving the machine or work equipment temporarily by canceling this switch, stop the engine, return the switch to the normal position (b), and then ask your Komatsu distributor for repair. 3-60 WENAM00150...
Page 127 OPERATION EXPLANATION OF COMPONENTS ENGINE SHUTDOWN SECONDARY SWITCH NOTICE The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Ask for repair of the problem part as soon as possible.
Page 128: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS RKA63450 (1) Lock lever (5) Boom swing control pedal (2) L.H. work equipment control lever (6) R.H. work equipment control lever (3) Travel lever (with pedal) (7) Blade control lever (4) Swing lock cover (8) Floor lock release lever LOCK LEVER WARNING...
Page 129 • When the hydraulic oil temperature is low • When the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends • When the system has a problem • Before setting the lock lever to FREE position, make sure that all control levers and control pedals are set to NEUTRAL position.
Page 130 EXPLANATION OF COMPONENTS OPERATION To cancel the lock lever automatic lock function, return the lock lever to LOCK position (L) according to “Lock Lever Auto Locked” screen, check that all control levers, control pedals, and attachment control pedals are in NEUTRAL position, and then set the lock lever to FREE position (F) again.
Page 131 OPERATION EXPLANATION OF COMPONENTS The travel lever is used to change the direction of travel be- tween forward and reverse. ( ) shows the pedal operation. (a) FORWARD The lever is pushed forward (The front side of pedal is depressed) (b) REVERSE The lever is pulled back (The rear side of pedal is depressed)
Page 132 EXPLANATION OF COMPONENTS OPERATION BOOM SWING CONTROL PEDAL Boom swing control pedal is used to swing the boom. (a) Swing RIGHT Depress right of the boom swing control pedal. (b) Swing LEFT Depress left of the boom swing control pedal. (N) NEUTRAL Boom is held at current position.
Page 133: Other Equipment
OPERATION EXPLANATION OF COMPONENTS The R.H. work equipment control lever is used to operate the boom and bucket. Boom operation (e): Boom RAISE (f): Boom LOWER Bucket operation (g): Bucket DUMP (h): Bucket CURL RKA63960 (N) NEUTRAL The boom and bucket are held in position and do not move. OTHER EQUIPMENT METHOD FOR OPENING AND CLOSING CAB FRONT WINDOW (Machine with cab specification)
Page 134 EXPLANATION OF COMPONENTS OPERATION Hold the right and left handles (1) at the center part of front window (inside). When holding the handle (1), put your thumb on the han- dle lock (2). While pushing down the handle locks (2) with your thumb, pull the right and left handles (1) backward to open the front window.
Page 135 OPERATION EXPLANATION OF COMPONENTS PROCEDURES FOR CLOSING UPPER CAB FRONT WINDOW CAUTION When closing the front window (upper side), lower it slowly and be careful not to get your hand caught. Stop the machine on a level ground, lower the work equipment to the ground, then stop the engine. Set the lock lever securely to LOCK position (L).
Page 136 EXPLANATION OF COMPONENTS OPERATION CAUTION Keep your hand or head inside the window when driving or operating the machine. The window at the right side of cab is sliding type small win- dow, and you can open or close it. EMERGENCY ESCAPE HAMMER (Machine with cab specification) CAUTION...
Page 137 OPERATION EXPLANATION OF COMPONENTS CAB DOOR CAUTION • Cab door must be checked to be locked either at the open position or closed position. • Always place the machine on a level ground when opening or closing the cab door. Avoid opening or closing the door on a slope, since there is a danger that the operating effort may sudden- ly change.
Page 138 EXPLANATION OF COMPONENTS OPERATION Push the cab door against the catch part (1) to lock it in position. Fix the cab door against the catch part (1) securely. When getting on or off the machine, hold the inside hand- rail. To close the cab door, push down the release knob (2).
Page 139 • If any damage or problem is found at the floor opening lock part, stop the work, close the floor, and then ask your Komatsu distributor for repair. • Do not remove the floor mounting bolts (1). The floor may jump up unexpectedly and it is danger- ous.
Page 140 EXPLANATION OF COMPONENTS OPERATION Set the lock lever to FREE position (F). Push the blade control lever forward to lower the blade to the ground. Operate the work equipment control levers to extend bucket cylinder and arm cylinder to their stroke end, and then lower the boom gently.
Page 141 OPERATION EXPLANATION OF COMPONENTS Remove the cover fixing bolts (3) (M8, 3 pieces), and re- move the cover (4). Pull the engine rear cover (5) backward to open it. Open the engine rear cover (5) fully and it is secured by rod (6).
Page 142 EXPLANATION OF COMPONENTS OPERATION While pulling the floor lock release lever (9) to FREE posi- tion (F) with your left hand, hold the handle (10) with your right hand and push it up to the direction of arrow (approxi- mately 45 °) to release the floor lock. Hold the handle (10) and push it up to the direction of ar- row (approximately 45 °) to raise the floor.
Page 143 OPERATION EXPLANATION OF COMPONENTS METHOD FOR OPENING FLOOR UNIT: CAB SPEC Open the dirt cover (1). Open the dirt cover (1) fully and it will be secured by the cover support lever (2). Remove the triangle cover fixing bolts (3) (M10, 2 pieces), and remove the triangle cover (4).
Page 144 EXPLANATION OF COMPONENTS OPERATION While pulling the floor lock release lever (9) to FREE posi- tion (F) with your left hand, hold the handle (10) with your right hand and push it up to the direction of arrow (approxi- mately 45 °) to release the floor lock. Hold the handle (10) and push it up to the direction of ar- row (approximately 45 °) to raise the floor.
Page 145 Before closing the floor, check the wiring harness, piping, and seat inside floor and in the revolving frame for damage or problem. If any damage or problem is found, ask your Komatsu distributor for repair. METHOD FOR CLOSING FLOOR UNIT: CANOPY SPEC Remove the lock pin (14) of second lock, and insert it into holder hole (17).
Page 146 REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. Close the engine rear cover (5). Install the cover (4) with the cover fixing bolts (3) (M8, 3 pieces).
Page 147 Tighten the floor tilt fixing bolts (7) (M14, 2 pieces). Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgm} REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. Close the engine rear cover (5). 3-81 WENAM00150...
Page 148 EXPLANATION OF COMPONENTS OPERATION Install the triangle cover (4) with the triangle cover fixing bolts (3) (M10, 2 pieces). Close the dirt cover (1). Floor closing work is completed. POWER SUPPLY OUTLET 12 V power supply NOTICE After using the receptacle for external electric equipment, always close the cap. If the cap is left open, rainwater, etc.
Page 149 OPERATION EXPLANATION OF COMPONENTS • The fuse holder is provided inside the cover under the op- erator's seat. • The fuse protects the electrical component and wiring from burning out due to abnormal current. • If the fuse becomes corroded, or looks white powdery, or the fuse is loose in the fuse holder, replace the fuse.
Page 150 EXPLANATION OF COMPONENTS OPERATION Machine with cab specification No. Capacity Name of circuit Working lamp relay, additional working lamp re- 5 A lay, and pump secondary drive switch 10 A Solenoid valve 5 A PPC oil pressure lock solenoid 10 A Room lamp, radio, and windshield wiper 10 A Travel alarm, fuel pump, and horn 10 A...
Page 151 OPERATION EXPLANATION OF COMPONENTS REMARK A fusible link is the large-sized fuse wiring installed in the high current flowing part of the circuit. It protects electrical parts and wiring from burning out due to abnormal current, in the same way as an ordinary fuse.
Page 152 The quick release battery terminal (-) is used to cut out the electricity from the battery. The quick release battery terminal (-) is one of the parts for periodic replacement for every 2000 hours. Ask your Komatsu distributor for replacement of the quick release battery terminal (-). METHOD FOR DISCONNECTING QUICK RELEASE BATTERY TERMINAL (-)
Page 153 OPERATION EXPLANATION OF COMPONENTS Remove the nylon cover (5) to the engine side. Push the handle of plastic cover of the quick release bat- tery terminal (-) (6) against your palm (A) under the thumb, and pull it up to the arrow direction. After disconnecting the quick release battery terminal (-) (6), move the battery cable backward.
Page 154 EXPLANATION OF COMPONENTS OPERATION METHOD FOR CONNECTING QUICK RELEASE BATTERY TERMINAL (-) WARNING • When connecting the quick release battery terminal (-), take care not to pinch your finger in the clearance between the battery top face and the tip of plastic cover of the quick release battery ter- minal (-).
Page 155 If the data are lost, when you try to start the engine next time, “L04” is displayed on the machine monitor and the engine may not start. If the engine cannot be started, ask your Komatsu distribu- tor for inspection and repair. REMARK •...
Page 156 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 157: Machine Operations And Controls
Accumulation of combustible material or leakage of fuel or oil around the high temperature parts such as the engine muffler or battery may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. •...
Page 158 11. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one.
Page 159 OPERATION MACHINE OPERATIONS AND CONTROLS Pull the engine rear cover (1) toward you to open it. Open the engine rear cover (1) fully and it is secured by rod (2). Pull the cooling cover (3) toward you to open it. Open the cooling cover (3) fully, and it is secured by rod (4).
Page 160 MACHINE OPERATIONS AND CONTROLS OPERATION Check if the red piston is protruded at the arrow part of dust indicator (5). If the red piston is protruding, clean or replace the element immediately. For the cleaning method of the element, see “METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER”.
Page 161 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the handle (6) of the water separator (3) to CLOSE position (S). Place a container under the drain hose of the water separator (3) to catch the fuel. Loosen the drain plug (7), and drain the water until red ring (4) touches the bottom of transparent cup (5).
Page 162 MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever to FREE position (F). Operate the blade control lever to lower the blade to the ground. Operate the work equipment control levers, and re- tract arm cylinder and bucket cylinder to their stroke end (maximum reach posture of arm and bucket).
Page 163 OPERATION MACHINE OPERATIONS AND CONTROLS It is appropriate if the oil level is between H and L. If the oil level is below level L, the hydraulic oil is insuffi- cient. If the hydraulic oil is insufficient, add oil according to the following procedure.
Page 164 MACHINE OPERATIONS AND CONTROLS OPERATION Set the lock lever to FREE position (F). Operate the work equipment control levers, and ex- tend the boom cylinder, bucket cylinder, and arm cylin- der to their stroke end. Set the work equipment in the posture shown in the figure.
Page 165 OPERATION MACHINE OPERATIONS AND CONTROLS 10. Set the lock lever securely to LOCK position (L). 11. Stop the engine. METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check it with the reservoir tank when the engine is cold. •...
Page 166 MACHINE OPERATIONS AND CONTROLS OPERATION Check the coolant level in reservoir tank (5). If the coolant level is within the range between FULL and LOW, the coolant amount is at a proper level. If the coolant level is below LOW, add coolant of the same density according to the coolant density table in “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS AC- CORDING TO AMBIENT TEMPERATURE”...
Page 167 • If fuses are frequently blown out or if there are traces of short-circuiting on the electric wiring, im- mediately ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 168 MACHINE OPERATIONS AND CONTROLS OPERATION Insert the key into starting switch (1) and turn it to ON posi- tion. The machine monitor lights up. RKA63480 Check the fuel level with fuel gauge (2). After checking, turn the starting switch (1) back to OFF po- sition.
Page 169 Turn the starting switch to ON position. Check that the horn sounds immediately when the horn switch is pressed. If the horn does not sound, ask your Komatsu distributor for repair. After checking, turn the starting switch back to OFF posi- tion.
Page 170 If the floor tilt fixing bolt (3) is loosened, tighten it. Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgm} REMARK If the floor tilt fixing bolt is damaged, replace it with same size of Komatsu genuine part. Close the engine rear cover (1). METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT...
Page 171 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Operate lever (1) upward, set the seat to the desired position, and then release the lever. Fore-aft adjustment: 180 mm REMARK Adjust the position of operator's seat according to the type of the work.
Page 172 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING MIRRORS: CANOPY SPEC Mirror (A) Front left mirror Mirror (B) Front right mirror METHOD FOR ADJUSTING MIRRORS: CAB SPEC Mirror (A) Front left mirror Mirror (B) Front right mirror Mirror (C) Rear right mirror PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur-...
Page 173 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the mirror so that the side of the machine is reflect- ed in the mirror as shown in the figure. Check that you can see a person at the rear left end of the machine.
Page 174 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 175 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the lock lever is se- curely at LOCK position. RKA63490 Check that the lock lever (1) is at LOCK position (L). If the lock lever (1) is in FREE position (F), the engine does not start.
Page 176: Method For Starting Engine
Press the lamp switch (3) and check if the working lamps light up. If the working lamps do not light up, broken bulb or wire breakage is suspected. Ask your Komatsu distributor for repair. Press the horn switch (4) and check that the horn sounds.
Page 177 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not turn the starting motor continuously for 20 seconds or longer. If the engine does not start, wait for approximately 2 mi- nutes, and then try to start the engine again. REMARK Do not turn the starting switch to ON position or START posi- tion soon after the engine is stopped.
Page 178 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK If the ambient temperature is low, the preheating pilot lamp lights up and automatic preheating is performed. Keep the starting switch (3) key at ON position (B) until the preheating pilot lamp goes out. The time that the preheating pilot lamp stays lit depends on the ambient temperature as shown in the table.
Page 179: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 180 MACHINE OPERATIONS AND CONTROLS OPERATION Do not operate the control levers or fuel control dial during this time. • Perform warm-up operation for 5 minutes after the engine is started. • Avoid operation with heavy loads or at high speeds. •...
Page 181 If any problem is found, perform maintenance or repair. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. Set the lock lever (2) to LOCK position (L). Operate the following levers and pedals, and check that the machine does not move.
Page 182 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR HYDRAULIC SYSTEM WARM-UP OPERATION WARNING • Before warming up the hydraulic component, check that there is no person or obstacle in the area around the machine, then sound the horn and start the opera- tion.
Page 183 If any problem is found, perform maintenance or repair. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. In cold weather (ambient temperature is less than 0 °C), perform the warm-up operation for hydraulic sys- tem in cold weather.
Page 184 MACHINE OPERATIONS AND CONTROLS OPERATION Before starting the operation, turn the fuel control dial (5) to the point (c) of 2/3 between Low idle (MIN) position (a) and High idle (MAX) position (b). Operate each control lever and control pedal to circulate the warm hydraulic oil to all control circuits. Repeat the following operation slowly 3 to 5 times before starting actual work.
Page 185: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Blade operation LOWER (s) ←→ RAISE (t) Attachment operation For attachment operations (if equipped), change the work- ing mode to the attachment mode to perform. Warm-up operation for hydraulic component is completed. METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stop- ping the engine.
Page 186: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION Turn the starting switch key (1) to OFF position (A), and stop the engine. Remove the key from the starting switch (1). REMARK When the key in starting switch (1) is turned to OFF posi- tion (A), the engine stops but the power supply to the ma- chine is not turned off immediately.
Page 187 OPERATION MACHINE OPERATIONS AND CONTROLS PREPARATIONS FOR MOVING MACHINE Turn fuel control dial (1) from Low idle (MIN) position (a) to High idle (MAX) position (b). The engine speed increases. RKA63482 METHOD FOR TRAVELING FORWARD Move the lock lever (1) slowly and securely to FREE posi- tion (F).
Page 188 (Lo), although high-speed travel (Hi) is lit in travel speed display. When traveling, check that the travel alarm sounds nor- mally. If the alarm does not sound, ask your Komatsu distributor for repair. 3-122 WENAM00150...
Page 189 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TRAVELING REVERSE Move the lock lever (1) slowly and securely to FREE posi- tion (F). RKA63590 RKA63210 Set the machine state in the posture shown in the figure. Operate the R.H. and L.H. work equipment control lev- ers (2) and (3), and raise the work equipment to the height (a) of 40 to 50 cm.
Page 190 (Hi) is lit in travel speed display. When traveling, check that the travel alarm sounds nor- mally. If the alarm does not sound, ask your Komatsu distributor for repair. METHOD FOR STOPPING MACHINE Avoid a sudden stop. Stop the machine gradually.
Page 191: Method For Steering Machine
OPERATION MACHINE OPERATIONS AND CONTROLS Set right and left travel levers (1) in NEUTRAL position (N). The machine stops. RKA63601 METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket).
Page 192 MACHINE OPERATIONS AND CONTROLS OPERATION (A) Left turn in forward Push the right travel lever forward. The machine turns left in forward. (B) Left turn in reverse Pull the right travel lever backward. The machine turns left in reverse. REMARK When turning right, read the preceding procedure by replacing the word "left"...
Page 193: Method For Swinging Machine
OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION FOR COUNTER-ROTATION TURN • Counter-rotation turn to left Pull the left travel lever toward you. Push the right travel lever forward. The machine make a counter-rotation turn to the left. • Counter-rotation turn to right Pull the right travel lever toward you.
Page 194: Method For Operating Work Equipment
MACHINE OPERATIONS AND CONTROLS OPERATION Move L.H. work equipment control lever (1) to the right and left. The upper structure swings. (a) Swing RIGHT The upper structure swings to the right. (b) Swing LEFT The upper structure swings to the left. When you do not swing the upper structure, set L.H.
Page 195 OPERATION MACHINE OPERATIONS AND CONTROLS • Arm operation Move the L.H. work equipment control lever back and forth. Arm moves in or out. • Boom operation Move the R.H. work equipment control lever back and forth. Boom moves up or down. 3-129 WENAM00150...
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION • Bucket operation Move the R.H. work equipment control lever to the right and left. Bucket moves in or out. • Boom swing operation Depress either right or left of the Boom swing control ped- Boom swings either right or left.
Page 197: Handle Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS • Blade operation Move the blade control lever back and forth. Blade moves up or down. REMARK This machine is equipped with an accumulator in the control circuit. For some time after stopping the engine, even if the engine is stopped, if the starting switch key is turned to ON position, and the lock lever is set to FREE position, following work equipment operations are possible.
Page 198: Prohibited Operations
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATING WORKING MODE Press function switch “F5” on the standard screen of ma- chine monitor. The screen changes to “Working Mode” screen. On “Working Mode” screen, press function switches “F1”, “F2”, and “F5” to select the appropriate working mode. After selecting the working mode, press function switch “F4”.
Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF OPERATIONS USING TRAVEL FORCE Do not use the travel force to perform excavation by digging the bucket into the ground. This damages the machine or work equipment. PROHIBITION OF OPERATIONS USING HYDRAULIC CYLINDERS TO STROKE If the work equipment is used with the cylinder rod operated to its stroke end (fully extended or fully retracted), and given impact by some external force, the hydraulic cylinders may be damaged, causing personal injury.
Page 200 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING MACHINE DROPPING FORCE Do not use the dropping force of the machine for digging. PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces.
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS In this case, prepare an embankment, etc. in front of the track to stabilize the machine. PROHIBITION OF SWINGING OR TRAVELING WHEN ROCK IS ON TOP OF TRACK ASSEMBLY If the machine travels or swings with crushed stones, soil, or sand on the track, they hit and damage the undercover and frame.
Page 202 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF HIGH-SPEED TRAVEL OPERATIONS ON ROUGH GROUND If the machine travels on rough ground (rock-bed, etc.) at high speed, large push-up loads are applied to the chassis, thus the service life of the chassis is shortened. When driving on rough ground (rock-bed, etc.), direct the idler (1) having the cushion mechanism in the travel direction and drive the machine at low speed.
Page 203: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELING Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the under- carriage), and this will cause damage to the machine. For this reason, always remove any obstacles or drive the machine around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS FOR BLADE POSITION DURING BACKHOE OPERATION When performing the backhoe operation near the blade, take care that the boom cylinder does not touch the blade. Dig with the blade at the rear usually, and dig in front of the blade only when required.
Page 205: Precautions For Working On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR WORKING ON SLOPE WARNING • When performing the swing operation or operating the work equipment on slopes, machine may lose its bal- ance and tip over. Avoid such operations as much as possible. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 206: Method For Escaping From Mud
MACHINE OPERATIONS AND CONTROLS OPERATION REMARK Drive the machine down with sprocket (1) downward. If the machine travels down with sprocket (1) upward, the tracks may be loosened and may jump teeth. When driving the machine up steep hills of 15 ° or more, set the machine to the posture shown in the figure with bucket height (b) at 20 to 30 cm, and drive the machine.
Page 207: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ESCAPING WHEN TRACKS ON BOTH SIDES ARE STUCK When the tracks on both sides get stuck, pull out the machine according to the following procedure. Place logs, wooden blocks, etc. under the tracks according to the above procedure.
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION SIDE DITCHING WORK Ditching work can be performed in a narrow space by combin- ing swing and boom swing operations. LOADING WORK In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator.
Page 209: Method For Lifting Objects With Lifting Device
In the absence of such a device, the machine can only be used as an earth moving machine. If the machine is not equipped with the appropriate hook, contact the Komatsu distributor. Fitting a lifting hook must be monitored and certified by the competent Authorised Body.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION PC30MR-5 Standard arm PC30MR-5 Long arm PC35MR-5 Standard arm 3-144 WENAM00150...
Page 211: Method For Replacing Bucket
OPERATION MACHINE OPERATIONS AND CONTROLS PC35MR-5 Long arm PC35MR-5 Quick coupler and 3rd attachment line (cab specification) METHOD FOR REPLACING BUCKET WARNING • When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When performing this operation, always wear protective eyeglasses, helmet, gloves, and other pro- tective equipment.
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • After removing the pins, make sure that mud or sand does not get on them. • Dust seals are fitted at both ends of the bushings, be careful not to damage them. When replacing the bucket, replace the dust seal with a new one if it is damaged. If a damaged one is used without being replaced, sand and dirt may enter the part of pin and cause abnormal wear of the pin.
Page 213: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS Align arm (2) with hole (4) of the replacement bucket. Align link (3) with hole (5) of the replacement bucket. Apply grease to pins (A) and (B) and insert them into holes (4) and (5) of the bucket. REMARK •...
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION Set the R.H. and L.H. travel levers (1) in NEUTRAL posi- tion (N). The machine stops. Turn the fuel control dial (2) to Low idle (MIN) position (a) and lower the engine speed. Set the work equipment in the posture shown in the figure. Operate the R.H.
Page 215: Method For Checking After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING AFTER FINISHING WORK Perform it after stopping the engine. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant. If any problems are found, repair them. Fill the fuel tank.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION Lock positions for the machine with cab specification (1) Operator's cab door Always close the window. (2) Dirt cover (3) Engine rear cover COVER WITH LOCK Use the starting switch key to open and close the covers with locks. Insert the starting switch key as far as it will go to shoulder (A) and turn it.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING ENGINE REAR COVER Insert the starting switch key into the key slot (1). Turn the starting switch key to “OPEN” position (A), and then remove the starting switch key. Position (A) OPEN Position (B) LOCK Pull the engine rear cover opening knob (2).
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the starting switch key to “LOCK” position (B), and then remove the starting switch key. Position (A) OPEN Position (B) LOCK METHOD FOR OPENING AND CLOSING COOLING COVER CAUTION When performing check and maintenance for inside of the cooling cover, open the engine rear cover, and then open the cooling cover.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS While pulling up the cooling cover opening lever (1), close the cooling cover (2). Push down the cooling cover opening lever (1), and secure the cooling cover. METHOD FOR OPENING AND CLOSING DIRT COVER CAUTION •...
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION Hold the grip part (2) and open the dirt cover (3). Open the dirt cover (3) fully and it will be secured by the cover support lever (4). Check that dirt cover (3) is secured by the cover support lever (4).
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS WARNING • Before releasing the door lock, always place the machine on a level ground. • Do not release the door lock when the machine is on a slope. The cab door may suddenly close and pinch your hand, and it causes injury. •...
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR LOCKING OPERATOR CAB DOOR Lower the door lock cancel lever (4) to release the door lock (3). Hold the handle inside the cab door and pull the cab door, and hold the cab door handle (2) to close the cab door. Insert the starting switch key into the key slot (1).
Page 223: Handle Air Conditioner
OPERATION HANDLE AIR CONDITIONER HANDLE AIR CONDITIONER (Machine with cab specification) • When the air conditioner is not used every day, to prevent loss of the film of oil at various parts, run the air conditioner with the engine at low speed from time to time and perform cooling or dry heating for several minutes.
Page 224 HANDLE AIR CONDITIONER OPERATION TEMPERATURE CONTROL SWITCH Use the temperature control switch to adjust the inside temper- ature. Lower the inside temperature. Turn the temperature control switch counterclockwise. Raise the inside temperature. Turn the temperature control switch clockwise. AIRFLOW SELECTOR SWITCH Air flow selector switch can adjust air flow in 3 levels.
Page 225: Method For Operating Air Conditioner
OPERATION HANDLE AIR CONDITIONER AIR CONDITIONER SWITCH Each time the air conditioner switch is pressed, operation (ON) and stop (OFF) is switched. When the air conditioner switch is turned to operation (ON), the lamp inside the air conditioner switch lights up. METHOD FOR OPERATING AIR CONDITIONER METHOD FOR STARTING AIR CONDITIONER Turn the air flow selector switch, and adjust the air flow.
Page 226 HANDLE AIR CONDITIONER OPERATION Turn the louver of each vent to adjust to the desired vent direction. Change the FRESH/RECIRC air selector lever to select ei- ther FRESH (a) or RECIRC (b). METHOD FOR STOPPING AIR CONDITIONER Press the air conditioner switch, and turn it off. The lamp inside the switch goes out.
Page 227: Handle Rubber And Road Liners Shoes
OPERATION HANDLE RUBBER AND ROAD LINERS SHOES HANDLE RUBBER AND ROAD LINERS SHOES RECOMMENDED USE OF RUBBER AND ROAD LINERS SHOES The rubber shoes and road liners have good features which the steel shoes do not have. However, if it is used similarly to the steel shoes, its features are not used fully.
Page 228: Precautions For Using Rubber And Road Liners Shoes
HANDLE RUBBER AND ROAD LINERS SHOES OPERATION • If the rubber parts of the road liner are worn and damaged and the mounting bolt heads are damaged, re- place the shoes with new ones immediately. If the mounting bolt heads are crushed, they cannot be removed or installed anymore. •...
Page 229 OPERATION HANDLE RUBBER AND ROAD LINERS SHOES When traveling uphills in reverse do not steer on the line between the level ground and the slope. If it is obliged to steer while traveling uphills, steer slowly. Do not travel with either track raised on a face of slope or convex ground surface (with the machine leaning approximately 10 °...
Page 230 HANDLE RUBBER AND ROAD LINERS SHOES OPERATION When the machine travels further in reverse, clear- ance (b) is made between track roller (1), idler (3), and rubber shoe (2). Rubber shoe (2) comes off under this condition. • When the machine is steered while the rubber shoe cannot move sideway because of a material to ride over or anoth- er thing.
Page 231: Transportation
OPERATION TRANSPORTATION TRANSPORTATION PRECAUTIONS FOR TRANSPORTING MACHINE SELECT TRANSPORTATION METHOD When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS”. Note that the weight and dimension shown in “SPECIFICATIONS” may differ in accordance with the type of track shoe or arm, or other attachments.
Page 232: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER Precautions for loading and unloading operations WARNING Always observe the following when loading or unloading the machine onto/from a trailer. • Select the firm, level ground when loading or unload- ing the machine.
Page 233 OPERATION TRANSPORTATION Precautions for ramps and platform WARNING Always observe the following regarding the ramps and platform. • Use ramps with ample width, length, thickness, and strength and install them with a slope of 15 ° or less. When using piled soil for the platform, compact the piled soil fully to prevent the slope face from collaps- ing.
Page 234 TRANSPORTATION OPERATION If Hi is displayed, press the travel speed selector switch to change the travel speed to Lo. Set the lock lever to FREE position (F). Operate the work equipment control lever to swing the up- per structure so that the work equipment is on the sprocket side.
Page 235 OPERATION TRANSPORTATION 11. Place the machine at the specified position on the trailer. METHOD FOR SECURING MACHINE NOTICE • Prevent the machine from moving during transportation, by putting wooden blocks on the front and rear sides of the tracks. • Do not use the fixing hole at the rear of the track frame for towing or lifting the machine.
Page 236 TRANSPORTATION OPERATION • Method for securing machine with tie-down point Tie one end of each chain or wire rope of appropriate strength to the tie-down holes on the track frame. X: 50 to 100 mm (Keep the chains off the track frame.) Cover the blade with cloth so that the chain or wire does not hit the blade directly.
Page 237 OPERATION TRANSPORTATION Set the chocks (1) to the tires to secure the trailer. Set the right and left ramps (2) parallel to each other and equally spaced to the right and left of the center (3) of the trailer. Make the installation angle (A) at 15 ° or less. If the ramps bend largely under the weight of the machine, put blocks under the ramps to prevent them from bending.
Page 238: Method For Lifting Machine
TRANSPORTATION OPERATION 10. Set the machine in the posture shown in the figure. Pull the blade control lever backward to raise the blade. Operate the work equipment control levers, and raise the work equipment. 11. Push the travel levers forward and drive the machine slow- ly toward the ramps.
Page 239 The method of lifting differs depending on the attachments and options installed. For the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS”. When lifting the machine, perform the operation on a flat ground according to the following procedure.
Page 240 TRANSPORTATION OPERATION Set the lock lever to LOCK position (L). Stop the engine. Check that there is nothing around the operator's seat, and then get off the machine. When the machine is equipped with cab, close the cab door and front window, etc. securely. Install shackles to the holes (2 places) for lifting at both ends of blade, and set the wire ropes.
Page 241 OPERATION TRANSPORTATION Set the lifting angle (a) between the front and rear wire ropes at 30 to 40 °, and then sling the machine slowly up- ward. After the machine comes off the ground, check the hook condition and the lifting posture, and then sling the ma- chine slowly upward.
Page 242: Cold Weather Operation
• When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 243: Precautions After Daily Work Completion
OPERATION COLD WEATHER OPERATION 1.24 1.25 1.26 1.27 1.23 1.24 1.25 1.26 • When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it from the machine to place it in the warm place. Restore it again before the operation. •...
Page 244: Precautions For Long-Term Storage
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION PRECAUTIONS FOR LONG-TERM STORAGE PREPARATION FOR LONG-TERM STORAGE NOTICE When storing the machine (more than 1 month), set the machine in the posture shown in the figure to protect the piston rod of hydraulic cylinder. (To prevent the cylinder piston rods from rusting) When putting the machine in storage for a long time (more than 1 month), do as follows.
Page 245: Starting Machine After Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. Perform the following items when using the machine after long-term storage. • Wipe off the grease from the piston rods of the hydraulic cylinder.
Page 246: Troubles And Actions
TROUBLES AND ACTIONS OPERATION TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system before starting the engine. Always check the fuel level to prevent running out of fuel. If the engine has stopped due to run out of fuel, all air must be sufficiently bled from the fuel circuit.
Page 247: Phenomena That Are Not Failures
OPERATION TROUBLES AND ACTIONS Turn the starting switch key to ON position (B). After 10 to 15 seconds, return it to OFF position (A). The air is bled automatically with automatic air bleeding device. Close the engine rear cover (3). PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: •...
Page 248: Precautions For Towing Machine
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR TOWING MACHINE WARNING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death. •...
Page 249: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch key to OFF position, and disconnect the quick release battery terminal (-).
Page 250 TROUBLES AND ACTIONS OPERATION Pull the engine rear cover (1) backward to open it. Open the engine rear cover (1) fully and it is secured by rod (2). Pull the cooling cover (3) backward to open it. Open the cooling cover (3) fully, and it is secured by rod (4).
Page 251 OPERATION TROUBLES AND ACTIONS Place the battery in the specified position. If chloride is accumulated on the top surface of battery and around terminals, clean them with approximately 40 °C of warm water and dry them thoroughly. Fix the battery securely with the mounting nut (5) and bat- tery mounting hardware (6).
Page 252 TROUBLES AND ACTIONS OPERATION START ENGINE WITH JUMPER CABLES WARNING • Never connect the positive (+) terminal with negative (-) terminal when connecting the cables. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 253: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 254 Replace. (*) (starting switch is in ON position). PHENOMENA AND ACTIONS FOR CHASSIS • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm, Lack of hydraulic oil Set oil to specified level.
Page 255 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Steam spurts out from top of radiator. Lowered coolant level, leakage of Check, add coolant, repair by refer- (pressure valve) coolant ring to CHECKS BEFORE START- ING. Loose fan belt Adjust fan belt tension by referring to EVERY 500 HOURS MAINTE- NANCE.
Page 256 (emergency) position enables operations temporarily. For details of the pump secondary drive switch, see “PUMP SECONDARY DRIVE SWITCH”. Immediately ask your Komatsu distributor for an inspection and repair after the operation. Telephone number for the point of contact if an error occurs When an error screen is displayed on the machine monitor, press the function switch “F3”...
Page 257: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section. WENAM00150...
Page 258: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 259: Avoid Mixing Oil
MAINTENANCE PRECAUTIONS FOR MAINTENANCE • When checking and replacing the oil or filters, move the machine to a place where there is no dust and take care to prevent dust from entering the system. AVOID MIXING OIL Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil.
Page 260: Fuel And Lubricants To Match The Ambient Temperature
PRECAUTIONS FOR MAINTENANCE MAINTENANCE FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE It is necessary to select fuel or lubricant according to the ambient temperature. WENAM00150...
Page 261: Outline Of Maintenance
Komatsu distributor. • When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. FUEL •...
Page 262 The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible.
Page 263 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 264: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 265: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 266 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Taper seal Width Tightening torque Outside di- acros ameter of Target value Allowable range s flats hose “a” “b” (mm) (mm) 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132 8.5 to 13.5...
Page 267: Maintenance Schedule
Check the maintenance interval and perform maintenance by referring to “MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER”. • Ask your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ..........4-13 WHEN REQUIRED ............................
Page 268: Maintenance Interval For Hydraulic Breaker
MAINTENANCE SCHEDULE MAINTENANCE METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR ........... 4-66 METHOD FOR REPLACING QUICK RELEASE BATTERY TERMINAL (-)..........4-66 EVERY 4000 HOURS MAINTENANCE ......................4-66 REPLACE DEFINED LIFE PARTS......................4-67 METHOD FOR REPLACING ACCUMULATOR (FOR CONTROL CIRCUIT) .......... 4-67 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket dig- ging operations, so set the maintenance intervals as follows.
Page 269: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) Until first 100 hours operation, perform the following maintenance every 10 hours. • Lubrication of swing equipment • Lubrication of work equipment For details of the method of replacement or maintenance, see “EVERY 100 HOURS MAINTENANCE”. WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING...
Page 270 MAINTENANCE PROCEDURE MAINTENANCE NOTICE Do not clean the outer element before the red piston is projected into the transparent part of dust indicator (5). If the outer element is cleaned frequently before the red piston protrudes, the air cleaner cannot display its normal performance and the cleaning effect decreases.
Page 271 MAINTENANCE MAINTENANCE PROCEDURE Blow dry compressed air (0.2 MPa or less {2.1 kg/cm less}) from the inside of the outer element (8) along the pleats. Blow along the pleats from the outside, then blow again from the inside. 10. After the cleaning, illuminate the inside of the element with an electric bulb to check.
Page 272 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING AIR CLEANER ELEMENT Release the hooks (6) and remove the cover (7). Hold the outer element (8), rock it lightly up and down and to the right and left, and pull out the outer element (8) while turning it to the right or left.
Page 273: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 274 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, request a qualified company to perform the operation or contact your Komatsu distributor. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 275 MAINTENANCE MAINTENANCE PROCEDURE Place containers to catch the coolant under the drain hose installed to the drain valve (6) and under the coolant drain plug (7) of the engine block. Open the drain valve (6) and remove the drain plug (7) to drain the coolant.
Page 276: Method For Checking Battery Electrolyte Level
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL WARNING • Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it will reduce the service life of the battery. In addition, it may cause an explosion. •...
Page 277 UPPER LEVEL line. Neutralize the removed replenishment water for a battery with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu dis- tributor or battery manufacturer. After adding, tighten the cap (5) securely.
Page 278: Method For Cleaning Water Separator Element
(UPPER LEVEL line). Neutralize the removed replenishment water for a battery with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery manufacturer. After adding, tighten the cap (5) securely.
Page 279 MAINTENANCE MAINTENANCE PROCEDURE Pull the engine rear cover (1) backward to open it. Open the engine rear cover (1) fully and it is secured by rod (2). Turn the handle (4) of the water separator (3) to CLOSE position (S). Place a container under the drain hose of the water sepa- rator (3) to catch the fuel.
Page 280: Method For Checking Looseness And Tightening Road Liner Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE 13. Turn the handle (4) of the water separator (3) to OPEN po- sition (O). 14. After the cleaning of element is completed, bleed air from the fuel circuit. For bleeding air, see “PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT”. 15.
Page 281 0 mm. If the track ten- sion is still loose, the pins and bushings are excessively worn. Ask your Komatsu distributor to turn the bushing 180° or replace it. To check if the tension is correct, run the engine at low idle, and move the machine slowly forward by an amount equal to the length of track on ground.
Page 282: Method For Checking Road Liner
If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. METHOD FOR CHECKING ROAD LINER If the road liners are in the following condition, they must be replaced. Ask your Komatsu distributor to replace it. Lug height •...
Page 283 MAINTENANCE MAINTENANCE PROCEDURE Lug height • When lug height (a) is reduced to 5 mm and below, re- place it with a new one. If lug height (a) is reduced by wear, the drawbar pull will drop. (1) Track roller (2) Rubber shoe •...
Page 284: Method For Checking And Adjusting Rubber Shoes Track Tension
A crack max. 30 mm in length and max. 10 mm in depth does not need to be repaired. For judgment of replacement, repair, and continuation of use of the rubber shoe, consult your Komatsu distribu- tor. METHOD FOR CHECKING AND ADJUSTING RUBBER SHOES TRACK TENSION •...
Page 285: Method For Replacing Rubber Shoes
Check the track tension again, and if the tension is not correct, adjust it again. If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. METHOD FOR REPLACING RUBBER SHOES WARNING •...
Page 286 MAINTENANCE PROCEDURE MAINTENANCE Set the machine in the posture shown in the figure. Start the engine and run it at low idle. Set the lock lever to FREE position (F). Operate the work equipment control lever to swing the up- per structure to make it right angle with the undercarriage.
Page 287 MAINTENANCE MAINTENANCE PROCEDURE Insert the steel pipes (2) between the rubber shoe track and track frame. Turn the sprocket in reverse direction (A). The rubber shoe track is lifted off the idler by steel pipe (2). Slide the rubber shoe track sideway (B) and remove it. METHOD FOR INSTALLING RUBBER SHOES Engage the rubber shoe track with the sprocket and place it over the idler.
Page 288: Method For Changing Shoes
WARNING The idler cushion must be removed and adjusted when the steel shoes or road liner are replaced with the rubber shoes, or reversely. Accordingly, be sure to ask your Komatsu distributor for the replace- ment. METHOD FOR REPLACING BUCKET TEETH WARNING •...
Page 289: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE With two 22 mm hexagonal wrenches, loosen and remove the nuts (2) and the screws (3) and remove the tooth (1). After removing the tooth (1), check that the screws and nuts are not damaged. Replace the screws and nuts that have their threads damaged.
Page 290: Method For Checking And Maintenance Air Conditioner
MAINTENANCE PROCEDURE MAINTENANCE Area, season Mixing proportion Freezing temperature Winter in extremely cold district Pure washer fluid -30 °C There are 2 types depending on the freezing temperature: -10 °C (general use) and -30 °C (cold district use), select according to the area and season. Close the dirt cover (1).
Page 291: Method For Lubricating Boom Swing Cylinder Foot Pin
Transparent with no color REMARK When there are bubbles, the refrigerant (gas) level is low, so ask your Komatsu distributor to add the refrigerant. If the air conditioner continues to run with low refrigerant (gas) level, it will cause damage to the compressor.
Page 292 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING CAB FLOOR NOTICE Do not let the machine monitor, connector, air conditioner and its filter inside the operator's cab get wet during the operation Start the engine. Set the lock lever to FREE position (F). Place the machine on a firm, level ground.
Page 293: Method For Checking Gas Spring
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to perform this work. Gas springs are installed inside the left console (1 place), at the cab front window (1 place each on right and left), and under the floor (1 place).
Page 294 MAINTENANCE PROCEDURE MAINTENANCE Open the dirt cover (1). Open the dirt cover (1) fully and it will be secured by the cover support lever (2). Loosen the cap of oil filler port (F) of the hydraulic tank slowly to release the internal pressure. Remove the bolts (3) (M10, 2 pieces), and remove the tri- angle cover (4).
Page 295 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR BLEEDING AIR FROM CYLINDER NOTICE If the engine runs at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause the piston packing to be damaged. If air is bled while the cap of the oil filler port (F) of the hydraulic tank is kept closed, negative pressure is generated inside the hydraulic tank, and it may adversely affect the piping.
Page 296 MAINTENANCE PROCEDURE MAINTENANCE Turn the fuel control dial to Low idle (MIN) position (a). Operate each cylinder to the end of its stroke, and relieve it to remove the air completely. 10. Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end.
Page 297: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR BLEEDING AIR FROM ATTACHMENT (When the machine is equipped with attachment) NOTICE • If the method of air bleeding from the attachment is specified by the manufacturer, bleed the air ac- cording to the specified procedure. •...
Page 298: Method For Lubricating Work Equipment
MAINTENANCE PROCEDURE MAINTENANCE By using a grease pump, pump in grease through the grease fittings shown by arrows. (1) Swing pinion (1 place) (2) Swing circle (1 place) Check visually that the greasing has been performed prop- erly. When greasing swing circle and swing pinion, swing the upper structure little by little to change the position so that the whole circumference will be greased.
Page 299 MAINTENANCE MAINTENANCE PROCEDURE (1) Bucket and link connection pin (1 place) (2) Arm and bucket connection pin (1 place) (3) Arm and link connection pin (1 place) (4) Bucket cylinder rod end (1 place) (5) Links connection pin (1 place) (6) Blade cylinder foot pin (1 place) (7) Blade cylinder rod end (1 place) (8) Blade foot pin (2 places)
Page 300: Every 250 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE REMARK For the greasing to boom swing cylinder foot pin, it is the item to be performed in “WHEN REQUIRED”. Check visually that the greasing has been performed properly. After greasing, wipe off any old grease that is pushed out. EVERY 250 HOURS MAINTENANCE METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...
Page 301: Every 500 Hours Maintenance
If the V-belt is stretched and has no allowance for ad- justment, or has slipping sound or squeak because of cuts or cracks of the belt, ask your Komatsu distributor to replace it. When the new V-belt is installed, readjust it after oper- ating for 1 hour.
Page 302: Method For Replacing Fuel Main Filter Cartridge
When replacing the parts, Komatsu recommends using Komatsu genuine parts. • If any cartridge other than a Komatsu genuine filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Never use a substitute.
Page 303 MAINTENANCE MAINTENANCE PROCEDURE Items to be prepared • Filter wrench • Container to receive drained fuel • Cloth Pull the engine rear cover (1) toward you to open it. Open the engine rear cover (1) fully and it is secured by rod (2).
Page 304: Method For Checking And Cleaning Radiator Fins, Oil Cooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE PROCEDURE MAINTENANCE For bleeding air, see “PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT”. 11. After air bleeding is completed, start the engine and run it at low idle for approximately 10 minutes. 12. Check the filter seal surface for fuel leakage. If the fuel leaks, check according to the following procedure.
Page 305: Method For Cleaning Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE Check the front and rear sides of radiator fins (5), oil cooler fins (6), fuel cooler fins (7), and condenser fins (8) (ma- chine equipped with air conditioner). If there is any mud, dirt, leaves, etc. stuck to the fins, blow it off with com- pressed air.
Page 306: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE Remove the fresh air filter (4). Clean the recirculation air filter (1) and fresh air filter (4) with compressed air. • If the recirculation air filter (1) and fresh air filter (4) are contaminated by oil or they are extremely dirty, wash it in a neutral detergent.
Page 307 MAINTENANCE MAINTENANCE PROCEDURE Remove the nut (4) of breather (3), and then remove the cover (5). Use a tool when nut (4) is too tight to remove. Replace the element (6) with a new element. Install the cover (5) and nut (4). In order not to damage the threaded portion of nut, tighten the nut (4) by hand until it is seated, then retighten it 15 to 30 °...
Page 308: Method For Checking Oil Level In Final Drive Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE 15. Operate the work equipment control levers, and set the work equipment to the state shown in the figure. By doing so, the hydraulic tank is pressurized. NOTICE If the hydraulic tank is not pressurized, air is sucked in the pump and it affects the components badly.
Page 309: Method For Checking Fan Belt Tension And Replacing Fan Belt
Before opening and closing of the floor, thoroughly read , and then start the operation, or ask your Komatsu distributor to perform the work. • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 310: Every 1000 Hours Maintenance
Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks. When replacing the belt to a new one, ask your Komatsu distributor to perform the work. After the adjustment is completed, close the floor.
Page 311 MAINTENANCE MAINTENANCE PROCEDURE Open the dirt cover (1). Open the dirt cover (1) fully and it will be secured by the cover support lever (2). Turn the cap of oil filler port (F) slowly and release the in- ternal pressure. Remove the cover mounting bolt (3), and remove the cov- er (4).
Page 312: Method For Changing Oil In Final Drive Case
MAINTENANCE PROCEDURE MAINTENANCE 13. Set the lock lever securely to LOCK position (L). 14. Stop the engine. 15. Tighten the cap of oil filler port (F) on the hydraulic tank se- curely. 16. Close the dirt cover (1). 17. Start the engine. 18.
Page 313: Every 1500 Hours Maintenance
(G) and (F). METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. EVERY 1500 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours should be performed at the same time.
Page 314: Method For Changing Oil In Hydraulic Tank, Cleaning Hydraulic Tank Strainer
Before opening and closing the floor, thoroughly read “METHOD FOR OPENING AND CLOSING FLOOR UNIT”, and then start the operation, or ask your Komatsu distributor to perform the work. •...
Page 315 MAINTENANCE MAINTENANCE PROCEDURE Set the lock lever to LOCK position (L). Stop the engine. Open the dirt cover (1). Open the dirt cover (1) fully and it will be secured by the cover support lever (2). Loosen the bolt (3) of the hydraulic tank, move the plate (4) on oil filler port (F), and turn the cap of oil filler port (F) slowly to remove it.
Page 316 MAINTENANCE PROCEDURE MAINTENANCE Remove the bolt (5) of hose clamp. 10. Loosen the hose clamp (6) and remove the hose (7). 11. Loosen the bolts (8) and remove the strainer (9). 12. Remove all the dirt from strainer (9), then wash it in clean diesel fuel or flushing oil.
Page 317 MAINTENANCE MAINTENANCE PROCEDURE 21. Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end. Set the work equipment in the posture shown in the figure. 22. Set the lock lever securely to LOCK position (L). 23.
Page 318: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to perform this work. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 319 MAINTENANCE MAINTENANCE PROCEDURE Set the lock lever to FREE position (F). Place the machine on a firm, level ground. Set the work equipment to the posture shown in the figure according to the following procedure. Operate the work equipment control levers, and re- tract arm cylinder and bucket cylinder to their stroke end (maximum reach posture of arm and bucket).
Page 320 • If the work equipment does not go down or stops at halfway, ask your Komatsu distributor for inspection. Nitrogen gas charge pressure in accumulator for con- trol circuit may be decreased. After checking the nitrogen gas charge pressure in accu- mulator, set the lock lever to LOCK position (L).
Page 321 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT Start the engine. Set the lock lever to FREE position (F). Place the machine on a firm, level ground. Set the work equipment to the posture shown in the figure according to the following procedure.
Page 322: Every 4000 Hours Maintenance
Turn the starting switch to OFF position (A). METHOD FOR CHECKING ALTERNATOR AND STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for in- spection and repairs. If the engine is started frequently, have this inspection performed every 1000 hours.
Page 323 Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to perform this work. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 324 MAINTENANCE PROCEDURE MAINTENANCE The accumulator is installed to the position shown in the figure. 4-68 WENAM00150...
Page 325: Specifications
SPECIFICATIONS WENAM00150...
Page 326: Specifications: Pc30Mr-5
Machine weight (including blade) kg 3000 3150 Bucket capacity 0.09 m Engine model Komatsu 3D88E-7 diesel engine Rated horsepower SAE J1995 (Gross) kW/ rpm • 18.2 / 2200 18.2 / 2200 ISO 9249/ SAE J1349 (Net) • 17.4 / 2200 17.0 / 2200...
Page 327 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC30MR-5 A Max. digging reach mm 5050 B Max. digging depth mm 2760 C Max. digging height mm 4840 D Max. vertical wall digging depth mm 2400 E Max. dumping height mm 3350 Min. swing radius of work equipment 2055 mm...
Page 328: Specifications: Pc35Mr-5
Machine weight (including blade) kg 3635 3785 Bucket capacity m 0.11 Engine model Komatsu 3D88E-7 diesel engine Rated horsepower SAE J1995 (Gross) kW/ rpm 18.2 / 2200 18.2 / 2200 • ISO 9249/ SAE J1349 (Net) • 17.4 /2200 17.0 / 2200...
Page 329 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC35MR-5 (with long arm) A Max. digging reach mm 5640 B Max. digging depth mm 3455 C Max. digging height mm 5270 D Max. vertical wall digging depth mm 3120 E Max. dumping height mm 3790 Min.
Page 330: Explanation Of Lift Capacity Chart
With fully extended bucket cylinder. • On a compact horizontal level ground. • If object handling is performed with other tool installed, the weight difference of the tool shall be deducted from value of this table. PC30MR-5 - Standard arm (Canopy specification) WENAM00150...
Page 331 SPECIFICATIONS EXPLANATION OF LIFT CAPACITY CHART PC30MR-5 - Standard arm (Cab specification) PC35MR-5 - Standard arm (Canopy specification) PC35MR-5 - Standard arm (Cab specification) WENAM00150...
Page 332 EXPLANATION OF LIFT CAPACITY CHART SPECIFICATIONS PC35MR-5 - Long arm (Canopy specification) PC35MR-5 - Long arm (Cab specification) PC35MR-5 - Quick coupler and 3rd line attachment (Cab specification) WENAM00150...
Page 333: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section. WENAM00150...
Page 334: Precautions For Using Attachment And Options
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any not authorized by Komatsu. Any personal injury, failure, or property damage caused by the use of unauthorized attachments or options will not be the responsibility of Komatsu.
Page 335 ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS • The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight when it is stopped in a raised position) also becomes greater. Do not stop the work equip- ment in air.
Page 336: Quick Coupler System
Check that the valve is correctly set. • Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu dealer. Standard calibration: 20 MPa (204 kg/cm²) Maximum pressure of the circuit: 27 MPa (276 kg/cm²)
Page 337 • At the start, the machine performs a self-check and verifies the operation of the buzzer. In case the buzzer is not functioning properly, contact the Komatsu distributor. • The European Norm requires that the LOCK position must be seen from the operator's position.
Page 338 QUICK COUPLER SYSTEM ATTACHMENTS AND OPTIONS TO RELEASE A BUCKET OR ATTACHMENT If the bucket or attachment has any hydraulic connections to the machine these must be disconnected before proceeding. Position the attachment on the ground safely where it is to be left.
Page 339 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM Operate switch (1), and with switch (1) in position “a” press and hold button (2) on the left hand lever, to activate quick coupler. NOTICE The switch has a safety lock mechanism to prevent ac- cidental operation.
Page 340: Handle Bucket With Hook
ATTACHMENTS AND OPTIONS HANDLE BUCKET WITH HOOK When using the bucket with hook, check that there is no damage to the hook, stopper, or hook mount. If there is any problem, ask your Komatsu distributor. PRECAUTIONS FOR OPERATION PRECAUTIONS FOR LIFTING OPERATION •...
Page 341: Handle Machine Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT RKA64080 (1) Selector valve (3) Breaker operation switch (2) 1st line attachment proportional switch (4) Horn switch SELECTOR VALVE The selector valve switches the flow of the hydraulic oil.
Page 342: Method For Changing Over And Connecting Hydraulic Circuit Of Machines Ready For Installation Of Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS ATTACHMENT 1 PROPORTIONAL SWITCH Use the 1st-line attachment proportional switch when operating general attachments such as crusher, etc. Flow rate can be adjusted according to the operating amount of 1st-line attachment proportional switch. This switch does not operate unless the working mode selector switch is set to attachment mode.
Page 343 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT When arranging the piping, take care that the bucket does not interfere with link (a) even if it is moved to the dump side fully. Connect the hydraulic circuit according the following procedures when installing the attachment. Remove the plug.
Page 344: Method For Operating Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS • When changing it to the position for breaker (1 way), turn the spool (1) counterclockwise until it stops, and set it to the position (b) for breaker (1 way). •...
Page 345 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Press function switch “F5” on the standard screen. “Working Mode” screen is displayed. Select breaker mode “B” with function switches “F1” or “F2” or “F5”. While breaker mode “B” is selected, press function switch “F4”...
Page 346 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Turn the fuel control dial to High idle (MAX) position, and return it a little bit. Set the engine output at 80 % position. Press the breaker operation switch. The breaker operates. CHECK POINTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER •...
Page 347: Long-Term Storage
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Select attachment mode “ATT/P” or “ATT/E” with function switches “F1” or “F2” or “F5”. While attachment mode “ATT/P” or “ATT/E” is selected, press function switch “F4” or leave it as it is for 5 seconds. Attachment mode is set to “ATT/P”...
Page 348: Specifications
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS If the equipment is not to be used for a long time set the selector valve to the position for general attachment such as crusher. SPECIFICATIONS Hydraulic specifications Max. flow rate (engine speed: at 2200 rpm) 50 ℓ/min Safety valve set pressure 20.5 MPa(210 kg/cm...
Page 349: Handle Machine Ready For Installation Of Attachment (2Nd/3Rd Line)
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS (2nd/3rd LINE) HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT (2nd/3rd LINE) EXPLANATION OF COMPONENTS (2nd/3rd LINE) RKA64170 (1) Selector valve (4) Quick coupler activation switch (2) 2nd/3rd line attachment proportional switch (5) 3rd line (3) 2nd line activation switch SELECTOR VALVE...
Page 350 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (2nd/3rd LINE) ATTACHMENTS AND OPTIONS 2nd LINE ACTIVATION SWITCH When the switch is pressed, activates the 2nd line. Pressing the switch again, the 2nd line is deactivated. RKA46120 The activation of the 2nd line is marked by a light positioned at the left side of operator's seat.
Page 351: Method For Connecting Hydraulic Circuit Of Machine Ready For Installation Attachment (2Nd/3Rd Line)
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS (2nd/3rd LINE) 3rd LINE The 3rd line uses for its operation the same control hydraulic element of the 2nd line. When starting the machine the 3rd line is active. RKA45960 To activate the 2nd line you need to press the switch on the left control lever.
Page 352 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT (2nd/3rd LINE) ATTACHMENTS AND OPTIONS Piping on left side of arm (shaft end) FASTER NV 12 GAS M Connect the hydraulic circuit according the following procedures when installing the attachment. Release the pressure in hydraulic circuit. For detail see MAINTENANCE “METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT”.
Page 353: Method For Operating Attachment (2Nd/3Rd Line)
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS (2nd/3rd LINE) • When handling the breaker, follow the instruction manual from the manufacturer and use the breaker cor- rectly. Check that the working mode is set to attachment mode ATT/P or ATT/E on the machine monitor.
Page 354: Handle Heater
HANDLE HEATER ATTACHMENTS AND OPTIONS HANDLE HEATER EXPLANATION OF HEATER COMPONENTS (1) Heater switch HEATER SWITCH Heater switch is used to warm up inside of operator's compart- ment. Warm air flow can be adjusted in 2 levels with heater switch. Use this switch after the engine coolant is warmed up.
Page 355 ATTACHMENTS AND OPTIONS HANDLE HEATER Turn the valve attached to the water manifold counter- clockwise to open. Close the engine rear cover (1). Turn the heater switch to adjust the air flow rate. If the heater is not used for a long time, turn the valve clockwise to close it.
Page 356: Attachments And Options
• Installing attachments or optional equipment without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the ma- chine and the life of the equipment.
Page 357 General digging ○ × Bucket 0.123 General digging ○ × Bucket 0.097 1300 Ditch-cleaning ○ × Attachment for hydraulic quick coupler PC30MR-5 Opening width Capacity (Body) Name Standard arm Long arm ( m ( mm) Bucket 0.043 Narrow digging ○ ○ Bucket 0.063...
Page 358: Recommended Attachment Operations
Select the optimum attachment model for the hydraulic excavator body. The attachments and models ready for installation differ according to the machine body. For details of the selection of the attachments or the models, consult your Komatsu distributor. HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows.
Page 359 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm off the ground. Do not raise it off the ground unnecessarily. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 360 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not use the mount to gather in pieces of rock. Do not work by using the swing force. Do not move the chisel while performing breaking operation. Do not perform breaker operation in horizontal or upward direc- tion.
Page 361 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Do not perform the operation with bucket cylinder rod extended fully to raise the machine off the ground. Do not perform the breaker work with any cylinder at the stroke end.
Page 362 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Grease the breaker while holding it in the right posture shown below. • Lower the chisel perpendicularly to the ground. • Insert the grease gun perpendicularly to the greasing point. Wrong posture 6-30 WENAM00150...
Page 363: Replacement Parts
REPLACEMENT PARTS WENAM00150...
Page 364: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 365: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 366: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 367 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication chart are explained in the following table. Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level...
Page 368: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 369: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
In this case, fill up the tank with pre-diluted fluid. (Never dilute the Non-Amine Engine Coolant with ordinary water.) RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. WENAM00150...
Page 370 WENAM00150...
Page 371: Index
INDEX INDEX Symbols Basic operation of machine monitor......3-10 Battery..............3-176 12H24H display mode - Switch......3-49 Battery - Check electrolyte level from side....4-20 1st line attachment proportional switch....3-57 Battery - Check electrolyte level impossible from side. 2nd line activation switch........6-18 ...............4-21 2nd/3rd line attachment proportional switch..
Page 372 INDEX Cooling cover - Open / Close......3-152 Engine rear cover - Lock........3-151 Cooling system - Clean inside......4-17 Engine rear cover - Open........3-151 Counter-rotation turn - Operate......3-127 Engine rear cover - Opening / Closing....3-150 Cover with lock............3-150 Engine shutdown secondary switch......3-61 Crankcase breather - Check.........
Page 373 General attachment such as crusher, etc. - Check Keep machine clean..........2-17 points when using.......... 6-14 Komatsu genuine lubricants........4-2 General precautions common to operation and main- Komatsu genuine replacement parts...... 4-2 tenance............2-17 KOMTRAX............3-90 General view............3-2 Grease..............4-6 Grease pump holder..........
Page 374 ............... 3-11 Machine monitor - Operate when stopping engine in normal situation..........3-11 Machine monitor - Operate when trouble occurs while Perform KOWA (Komatsu Oil Wear Analysis)..4-6 operating machine......... 3-14 Periodic replacement of defined life parts.....2-47 Machine monitor equipment name......3-6 Permissible depth of water, soil and dirt.....
Page 375 INDEX Precautions for high-pressure fuel......2-45 Precautions when using hammer......2-44 Precautions for high-pressure grease when adjusting Precautions when using rubber and road liners shoes track tension..........2-46 ..............3-162 Precautions for high-pressure oil......2-44 Precautions when working on loose ground..2-25 Precautions for high-speed travel.......
Page 376 Vacuator valve - Check / Replace......4-17 Slide window............3-69 Vent..............3-158 Specifications..........5-2,6-16 Vibration levels............1-6 Specifications: PC30MR-5........5-2 Visibility from operator's seat........1-8 Specifications: PC35MR-5........5-4 Standard tightening torque for bolts and nuts..4-9 Start engine............2-27 Start the machine after long-term storage..3-179 Warning display.............3-15...
Page 377 INDEX Wear well-fitting clothes and protective equipment................2-17 When handling accumulator and gas spring..2-46 When operating on slopes........2-32 When required............4-13 Window washer fluid - Check level / Add....4-33 Window washer fluid - select........ 2-47 Wiper switch............3-58 Work equipment - Lubricate........4-42 Work equipment - Operate........3-128 Work equipment control lever.......

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