Page 2 1 - 1...
Page 3 Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 1 - 4...
Page 6: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION Signal words Example of safety message using signal word When standing up from the operator's seat, always place the safety lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death. Other signal words 1 - 5...
Page 7 FOREWORD SAFETY INFORMATION Safety labels Example of safety label using words Safety labels using pictogram 1 - 6...
Page 8: Directions Of Machine
FOREWORD INTRODUCTION INTRODUCTION DIRECTIONS OF MACHINE 1 - 7...
Page 9: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1 - 8...
Page 10: Service Meter Location
FOREWORD PRODUCT INFORMATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION SERVICE METER LOCATION 1 - 9...
Page 11: Your Machine Serial Numbers And Distributor
FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Distributor name Address Service Personnel Phone/Fax 1 - 10...
Page 12 FOREWORD CONTENTS CONTENTS 1 - 11...
Page 13 FOREWORD CONTENTS 1 - 12...
Page 14 FOREWORD CONTENTS 1 - 13...
Page 15 2 - 1...
Page 16 SAFETY SAFETY INFORMATION SAFETY INFORMATION 2 - 2...
Page 17 SAFETY SAFETY INFORMATION 2 - 3...
Page 18: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS 2 - 4...
Page 19: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2 - 5...
Page 20 SAFETY SAFETY LABELS SAFETY LABELS 2 - 6...
Page 21 SAFETY SAFETY LABELS 2 - 7...
Page 22 SAFETY SAFETY LABELS 2 - 8...
Page 23 SAFETY SAFETY LABELS 2 - 9...
Page 24 SAFETY SAFETY LABELS 2 - 10...
Page 25 SAFETY SAFETY LABELS 2 - 11...
Page 26 SAFETY SAFETY INFORMATION SAFETY INFORMATION 2 - 12...
Page 27 SAFETY SAFETY INFORMATION 2 - 13...
Page 28 SAFETY SAFETY INFORMATION 2 - 14...
Page 29 SAFETY SAFETY INFORMATION Hot coolant Hot oil Fire caused by fuel or oil Fire caused by accumulation of flammable material. 2 - 15...
Page 30 SAFETY SAFETY INFORMATION Fire coming from electric wiring Fire coming from hydraulic line Explosion caused by lighting equipment 2 - 16...
Page 31 SAFETY SAFETY INFORMATION 2 - 17...
Page 32 SAFETY SAFETY INFORMATION Voltage of Cables Safety Distance 2 - 18...
Page 33 SAFETY SAFETY INFORMATION 2 - 19...
Page 34: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE 2 - 20...
Page 35 SAFETY SAFETY MACHINE OPERATION 2 - 21...
Page 36: Operation
SAFETY SAFETY MACHINE OPERATION OPERATION 2 - 22...
Page 37 SAFETY SAFETY MACHINE OPERATION 2 - 23...
Page 38 SAFETY SAFETY MACHINE OPERATION 2 - 24...
Page 39 SAFETY SAFETY MACHINE OPERATION 2 - 25...
Page 40 SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION 2 - 26...
Page 41 SAFETY SAFETY MACHINE OPERATION 2 - 27...
Page 42 SAFETY SAFETY MACHINE OPERATION TRANSPORTATION 2 - 28...
Page 43 SAFETY SAFETY MACHINE OPERATION BATTERY 2 - 29...
Page 44 SAFETY SAFETY MACHINE OPERATION 2 - 30...
Page 45 SAFETY SAFETY MACHINE OPERATION TOWING 2 - 31...
Page 46: Lifting Objects With Bucket
SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET 2 - 32...
Page 47: Safety Maintenance Information
SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION 2 - 33...
Page 48 SAFETY SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION 2 - 34...
Page 49 SAFETY SAFETY MAINTENANCE INFORMATION 2 - 35...
Page 50 SAFETY SAFETY MAINTENANCE INFORMATION 2 - 36...
Page 51 SAFETY SAFETY MAINTENANCE INFORMATION 2 - 37...
Page 52 SAFETY SAFETY MAINTENANCE INFORMATION 2 - 38...
Page 53 3 - 1...
Page 54: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW 3 - 2...
Page 55: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES 3 - 3...
Page 56: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES MONITORING SYSTEM 3 - 4...
Page 57 OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors If the warning monitor flashes, check the problem point as soon as possible and carry out maintenance. Failure to repair the problem will lead to failure of the machine. REMARK 3 - 5...
Page 58 OPERATION DETAILED CONTROLS AND GAUGES 3 - 6...
Page 59 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point immediately and repair the problem. 3 - 7...
Page 60 OPERATION DETAILED CONTROLS AND GAUGES REMARK 3 - 8...
Page 61 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Pilot Display ° ° 3 - 9...
Page 62 OPERATION DETAILED CONTROLS AND GAUGES REMARK Gauges and Meter REMARK REMARK 3 - 10...
Page 63 OPERATION DETAILED CONTROLS AND GAUGES REMARK 3 - 11...
Page 64 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion REMARK 3 - 12...
Page 65 OPERATION DETAILED CONTROLS AND GAUGES When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the loading or unloading operation. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 66 OPERATION DETAILED CONTROLS AND GAUGES 3 - 14...
Page 67 OPERATION DETAILED CONTROLS AND GAUGES SWITCHES 3 - 15...
Page 68 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES REMARK REMARK Always return the work equipment and travel levers to the neutral position before operating the swift deceleration switch. If the switch is operated when any lever is being operated, the engine torque will suddenly change. 3 - 16...
Page 69 OPERATION DETAILED CONTROLS AND GAUGES REMARK 3 - 17...
Page 70 OPERATION DETAILED CONTROLS AND GAUGES NOTICE This switch is installed to make it possible to carry out operation temporarily if any abnormality should occur in the pump control system. It is not intended for permanent use. Repair the cause of the abnormality immediately. If this switch is depressed and moved to the EMERGENCY position by mistake, thereby engaging the machine in the work, while the machine is in normal condition, an "E02"...
Page 71 OPERATION DETAILED CONTROLS AND GAUGES NOTICE Be sure to switch the lamp to the OFF position after use. If the switch is left at the ON position, the battery will run down. REMARK NOTICE This cigarette lighter is of a 24 V type. Hence do not use this as a power source for electric equipment of 12 V type, otherwise they will likely be damaged.
Page 72: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS When leaving the operator's cab, be sure to move the safety lock lever to the LOCK position. If the safety lock lever is not in the LOCK position and a control lever is touched accidentally, that may cause a serious bodily injury. If the safety lock lever is not secured in the LOCK position, it may cause a serious bodily injury.
Page 73 DETAILED CONTROLS AND GAUGES The operating pattern is set to the standard operating pattern (ISO pattern). When changing the operating pattern, please contact your Komatsu distributor. The method of using operating patterns other than the ISO pattern is given in the ATTACHMENT AND OPTIONS section. Always read and understand the contents before operating the machine.
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Do not put your foot on the pedal unless the machine is traveling. If you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident. Do not rest a foot on the pedal except when traveling or steering the machine, using the pedal.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES REMARK 3 - 23...
Page 76 OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF When leaving the operator's compartment, set the safety lock lever securely to the LOCK position. If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident. When opening or closing the roof hatch, carry out the operation on horizontal ground.
Page 77 OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD When opening or closing the front window, bottom window, or door, always set the safety lock lever to the LOCK position. If the control levers are not locked and they are touched by accident, this may lead to a serious accident.
Page 78 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3 - 26...
Page 79 OPERATION DETAILED CONTROLS AND GAUGES When closing the window, lower it slowly and be careful not to get your hand caught. 3 - 27...
Page 80 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3 - 28...
Page 81 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES NOTICE If the window rise up on lock base (C) or is not in contact with lock lever (B), and it is attempted to engage the lock by force, there is danger that the glass may break.
Page 82: Sliding Door
OPERATION DETAILED CONTROLS AND GAUGES SLIDING DOOR Be sure to check that the sliding door is locked in position both when it is open and when it is closed. Always stop the machine on level ground when opening or closing the door.
Page 83 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3 - 31...
Page 84: Cap With Lock
OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Opening the Cap Locking the Cap Opening the Cover Locking the Cover 3 - 32...
Page 85: Engine Hood
OPERATION DETAILED CONTROLS AND GAUGES ENGINE HOOD Never attempt to climb on the engine hood. There is the danger that you may slip off. When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine hood open.
Page 86 OPERATION DETAILED CONTROLS AND GAUGES MUD COVER Never attempt to climb on the cover. There is the danger that you may slip off. When carrying out inspection and maintenance inside the cover, always use the cover support lever to hold the cover open. NOTICE Always keep the hood locked except when opening it.
Page 87 OPERATION DETAILED CONTROLS AND GAUGES BATTERY INSPECTION COVER When carrying out inspection and maintenance inside the cover, always use the cover support lever to hold the cover open. NOTICE Always keep the door locked except when opening it. 3 - 35...
Page 88 OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. Fuse Capacities and Circuit Names 3 - 36...
Page 89: Auxiliary Electric Power
AUXILIARY ELECTRIC POWER NOTICE When installing electrical not supplied by Komatsu, use 24 V specifications with a maximum of 600 W (equivalent to 25 A). If equipment is to be installed with a capacity greater than this, please contact your Komatsu distributor.
Page 90 OPERATION DETAILED CONTROLS AND GAUGES HEATER AND DEFROSTAR CONTROLS Heater and Defroster Control Panel 3 - 38...
Page 91 OPERATION DETAILED CONTROLS AND GAUGES 3 - 39...
Page 92 OPERATION DETAILED CONTROLS AND GAUGES 3 - 40...
Page 93 OPERATION DETAILED CONTROLS AND GAUGES 3 - 41...
Page 94 OPERATION DETAILED CONTROLS AND GAUGES Precautions When Using Air Conditioner Ventilate the Cab From Time to Time When Using the Heater 3 - 42...
Page 95: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel 3 - 43...
Page 96 OPERATION DETAILED CONTROLS AND GAUGES 3 - 44...
Page 97 OPERATION DETAILED CONTROLS AND GAUGES 3 - 45...
Page 98 OPERATION DETAILED CONTROLS AND GAUGES 3 - 46...
Page 99 OPERATION DETAILED CONTROLS AND GAUGES Use Air Conditioner With Care Ventilation Temperature Control ° ° 3 - 47...
Page 100 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Maintenance 3 - 48...
Page 101 OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel 3 - 49...
Page 102 OPERATION DETAILED CONTROLS AND GAUGES ∧ ∨ 3 - 50...
Page 103 OPERATION DETAILED CONTROLS AND GAUGES 3 - 51...
Page 104 OPERATION DETAILED CONTROLS AND GAUGES Controls Of Radio ∨ ∧ → → ∨ ∧ 3 - 52...
Page 105 OPERATION DETAILED CONTROLS AND GAUGES → → → NOTICE When transporting the machine or parking it in a garage, always fully retract the antenna to avoid the possibility of breakage. Use Radio With Care 3 - 53...
Page 106: Grease Pump Holder
OPERATION DETAILED CONTROLS AND GAUGES OPERATION MANUAL STORAGE TOOL BOX NOTICE Except when opening the cover for some reason, always keep the cover locked. GREASE PUMP HOLDER ASHTRAY 3 - 54...
Page 107: Fire Extinguisher
OPERATION DETAILED CONTROLS AND GAUGES FIRE EXTINGUISHER 3 - 55...
Page 108: Machine Operations And Controls
Remove any flammable materials from around the battery or engine muffler, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and sure to repair any abnormalities, or please contact your Komatsu distributor. 3 - 56...
Page 109 OPERATION MACHINE OPERATIONS AND CONTROLS 3 - 57...
Page 110 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns.
Page 111 OPERATION MACHINE OPERATIONS AND CONTROLS The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. REMARK 3 - 59...
Page 112 OPERATION MACHINE OPERATIONS AND CONTROLS When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
Page 113 OPERATION MACHINE OPERATIONS AND CONTROLS The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 3 - 61...
Page 114 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS NOTICE Do not add oil above the H line. This will damage the hydraulic circuit or cause the oil to spurt out. If oil has been added above the H level, stop the upper structure so that the drain plug (P) under the hydraulic tank will be between both tracks, and stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from drain plug (P).
Page 115 OPERATION MACHINE OPERATIONS AND CONTROLS 3 - 63...
Page 116 If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the cause immediately and carry out repairs, or contact your Komatsu distributor for repairs. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clean the breather hole.
Page 117 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the backrest.
Page 118 OPERATION MACHINE OPERATIONS AND CONTROLS 3 - 66...
Page 119 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Before fastening the seat belt, check that there is no abnormality in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no abnormality in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
Page 120 OPERATION MACHINE OPERATIONS AND CONTROLS Shortening Lengthening 3 - 68...
Page 121 OPERATION MACHINE OPERATIONS AND CONTROLS Wind-in Type Seat Belt Before fitting the seat belt, check that there is no abnormality in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt.
Page 122 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine When standing up from the operator's seat, always set the safety lock lever to the LOCK position, regardless of whether the engine is running or stopped. REMARK 3 - 70...
Page 123 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3 - 71...
Page 124: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 125 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3 - 73...
Page 126 OPERATION MACHINE OPERATIONS AND CONTROLS Starting Engine In Cold Weather Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 127 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK 3 - 75...
Page 128 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3 - 76...
Page 129: After Starting Engine
Breaking-In The New Machine Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to breaking-in the machine for the initial 100 hours (as indicated by the service meter).
Page 130 OPERATION MACHINE OPERATIONS AND CONTROLS Warming-Up Operation NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the lever suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warming-up operation is completed.
Page 131 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3 - 79...
Page 132: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
Page 133: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION Before operating the steering levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. When moving off, check that the area around the machine is safe, and sound the horn before moving. Do not allow anyone in the area around the machine.
Page 134 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 3 - 82...
Page 135 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Backward 3 - 83...
Page 136 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 3 - 84...
Page 137: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering Before operating the travel control levers, check the direction of the track frame (i.e. position of the sprocket) first. If the sprocket is at the front, the machine moves in the reverse direction to the operation of the travel lever. REMARK 3 - 85...
Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK REMARK 3 - 86...
Page 139 OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING When operating the swing, check that the area around the machine is safe. 3 - 87...
Page 140: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS For operation modes other than the standard one (ISO pattern), refer to the chapter of ATTACHMENTS AND OPTIONS in this manual. 3 - 88...
Page 141: Working Mode
OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS WORKING MODE REMARK ± ± REMARK 3 - 89...
Page 142: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS Do not attempt to operate the work equipment control lever, while the machine is traveling. 3 - 90...
Page 143 OPERATION MACHINE OPERATIONS AND CONTROLS 3 - 91...
Page 144: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION 3 - 92...
Page 145 OPERATION MACHINE OPERATIONS AND CONTROLS When driving the machine out of water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan. This may cause the fan to break. Be extremely careful when driving the machine out of water.
Page 146: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.
Page 147 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS ° 3 - 95...
Page 148: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Stuck One Side Of Track NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground. (Never push with the teeth). The angle between the boom and arm should be 90°...
Page 149: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS Backhoe Work ° ° ° Shovel Work Ditching Work 3 - 97...
Page 150 OPERATION MACHINE OPERATIONS AND CONTROLS Loading Work Refill And Finishing Work 3 - 98...
Page 151: Bucket Replacement And Inversion
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT AND INVERSION When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 152 OPERATION MACHINE OPERATIONS AND CONTROLS Inversion When reversing a bucket, there is the danger that the bucket tooth tip overruns the normal trajectory and interferes with the cab, thus causing a serious trouble. Pay good attention to the work when reversing a bucket so that the bucket and the cab may not interfere with each other.
Page 153: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE Park the machine on the firm, level ground. Avoid parking the machine on slopes. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the work equipment into the ground surface to stop the machine from moving.
Page 154: Machine Inspection After Daily Work
OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS MACHINE INSPECTION AFTER DAILY WORK LOCKING REMARK 3 - 102...
Page 155 OPERATION MACHINE OPERATIONS AND CONTROLS ROAD LINERS AND RUBBER SHOES Road Liners And Rubber Shoes Information Warranty For Road Liners And Rubber Shoes 3 - 103...
Page 156 OPERATION MACHINE OPERATIONS AND CONTROLS Using Road Liners And Rubber Shoes Long Life Operations ° ° ° ° 3 - 104...
Page 157 OPERATION MACHINE OPERATIONS AND CONTROLS ° 3 - 105...
Page 158 OPERATION MACHINE OPERATIONS AND CONTROLS 3 - 106...
Page 159 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3 - 107...
Page 160: Transportation Procedure
OPERATION TRANSPORTATION TRANSPORTATION TRANSPORTATION PROCEDURE LOADING AND UNLOADING WITH TRAILER When loading a machine to a trailer or unloading from it, be sure to travel the machine at low speed. Never attempt to change the speed or depress the accelerator. Run the engine at low idling, set to low speed, and operate the machine slowly when loading or unloading.
Page 161 OPERATION TRANSPORTATION Loading ° ° 3 - 109...
Page 162 OPERATION OPERATION TRANSPORTATION TRANSPORTATION ° 3 - 110...
Page 163 OPERATION TRANSPORTATION Securing Machine NOTICE To prevent damage to the bucket cylinder during transportation, fit a wooden block at one end of the bucket cylinder to prevent it from touching the floor. 3 - 111...
Page 164 OPERATION TRANSPORTATION Unloading ° 3 - 112...
Page 165 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 3 - 113...
Page 166: Lifting Machine
For the details on the machine weight, see the section of "SPECIFICATIONS (PAGE 5-2)". The lifting procedure applies to machines with standard specifications. The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your Komatsu distributor for information. 3 - 114...
Page 167 OPERATION OPERATION TRANSPORTATION TRANSPORTATION NOTICE Do not attempt to lift up the machine by hanging a wire rope to the bracket that is provided for fastening the machine in transportation. Such a practice will damage the machine. ° ° 3 - 115...
Page 168: Cold Weather Operation Information
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 169 OPERATION COLD WEATHER OPERATION Battery The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amount of water, and consult a doctor.
Page 170: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION Performing idle-running of the tracks is dangerous, so stay well away from the tracks. ° AFTER COLD WEATHER SEASON 3 - 118...
Page 171: Long Term Storage
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors, open the doors and windows to improve ventilation and prevent gas poisoning. AFTER STORAGE NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. 3 - 119...
Page 172: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL PHENOMENA THAT ARE NOT FAILURES TOWING THE MACHINE When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope.
Page 173: Severe Job Condition
OPERATION TROUBLES AND ACTIONS SEVERE JOB CONDITION 3 - 121...
Page 174: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY It is dangerous to charge the battery as it is mounted on the machine. Do not attempt that. Before checking or handling the battery, turn the engine starting switch key OFF. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes or open flames near the battery, or do not do anything that will cause sparks.
Page 175 OPERATION TROUBLES AND ACTIONS Battery Removal And Installation NOTICE After securing the battery, check that it does not move. If it moves, tighten it again securely. · · · · 3 - 123...
Page 176 OPERATION TROUBLES AND ACTIONS Battery Charges 3 - 124...
Page 177 OPERATION TROUBLES AND ACTIONS Starting Engine With Booster Cables When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses. Be careful not to let the normal machine and problem machine contact each other.
Page 178 OPERATION TROUBLES AND ACTIONS Before starting the engine, check that the safety lock lever is securely at the LOCK position. If the work equipment control lever is touched by mistake when starting the engine, the work equipment may move unexpectedly and cause serious damage or personal injury.
Page 179 OPERATION TROUBLES AND ACTIONS HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY Before loosening the plug, thoroughly check safety under the work equipment and the blade. Never allow anyone to go under the work equipment or the blade. While the work equipment is descending, keep holding the plug with a tool, so that the descent may be stopped any moment.
Page 180: Other Trouble
OPERATION TROUBLES AND ACTIONS OTHER TROUBLE Electrical System 3 - 128...
Page 181 OPERATION TROUBLES AND ACTIONS Chassis 3 - 129...
Page 182 OPERATION TROUBLES AND ACTIONS Engine 3 - 130...
Page 183 OPERATION TROUBLES AND ACTIONS 3 - 131...
Page 184 OPERATION TROUBLES AND ACTIONS Electronic Control System 3 - 132...
Page 185 4 - 1...
Page 186: Maintenance Information
MAINTENANCE MAINTENANCE INFORMATION MAINTENANCE INFORMATION 4 - 2...
Page 187 MAINTENANCE MAINTENANCE INFORMATION 4 - 3...
Page 188: Handling Oil, Fuel, Coolant, And Performing Oil Clinic
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS LUBRICANTS, COOLANT AND FILTERS HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC Fuel ° ° Cooling System Coolant 4 - 4...
Page 189 MAINTENANCE LUBRICANTS, COOLANT AND FILTERS Grease Carrying out KOWA (Komatsu Oil Wear Analysis) 4 - 5...
Page 190: Electric System Maintenance
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS Oil And Fuel Storage Filters ELECTRIC SYSTEM MAINTENANCE 4 - 6...
Page 191: Wear Parts List
MAINTENANCE WEAR PARTS WEAR PARTS WEAR PARTS LIST 4 - 7...
Page 192 MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS PROPER SELECTION 4 - 8...
Page 193 MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS REMARK ° ° ° ° 4 - 9...
Page 194 MAINTENANCE MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 4 - 10...
Page 195 MAINTENANCE MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 4 - 11...
Page 196: Tightening Torque Specifications
MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE LIST If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation. Always pay careful attention when tightening parts.
Page 197: Safety Critical Parts List
MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST 4 - 13...
Page 198: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) WHEN REQUIRED CHECKS BEFORE STARTING EVERY 50 HOURS MAINTENANCE EVERY 100 HOURS MAINTENANCE EVERY 250 HOURS MAINTENANCE 4 - 14...
Page 199: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE EVERY 500 HOURS MAINTENANCE EVERY 1000 HOURS MAINTENANCE EVERY 2000 HOURS MAINTENANCE EVERY 4000 HOURS MAINTENANCE EVERY 5000 HOURS MAINTENANCE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER Replacing additional filter element for breaker (if equipped) 4 - 15...
Page 200: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4 - 16...
Page 201 MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and the engine will suffer damage. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 202 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE The inner element must not be used again even after its cleaning. When replacing the outer element, replace the outer element at the same time. NOTICE When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds, gasket or seal are damaged.
Page 203 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE Replacing element 4 - 19...
Page 204 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4 - 20...
Page 205: Clean Inside Of Cooling System
MAINTENANCE MAINTENANCE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.
Page 206 MAINTENANCE MAINTENANCE PROCEDURE Antifreeze is flammable, so keep it away from flame. Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. °...
Page 207 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE REPLACE WATER SEPARATOR ELEMENT Do not bring any fire or flame close. 4 - 23...
Page 208 MAINTENANCE MAINTENANCE PROCEDURE CLEAN FUEL TANK NOTICE Never use trichlene for washing the inside of the tank. Use diesel fuel only. Carry out this procedure before operating the machine as a daily maintenance. 4 - 24...
Page 209: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS ± · ± · ± ± · ± · ± ° ± ° 4 - 25...
Page 210: Check And Adjust Track Tension
Never loosen any part other than plug (4). Never put your face in the mounting direction of plug (4). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. Increasing Track Tension 4 - 26...
Page 211 MAINTENANCE PROCEDURE Loosening Track Tension It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. 4 - 27...
Page 212 MAINTENANCE MAINTENANCE PROCEDURE CHECK ROAD LINERS OR RUBBER SHOES 4 - 28...
Page 213 MAINTENANCE MAINTENANCE PROCEDURE 4 - 29...
Page 214 Never loosen any part other than plug (4). Never put your face in line with the mount of plug (4). If the Rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor. Increasing Track Tension NOTICE The standard value is low, so be careful not to tighten the rubber shoe too much.
Page 215: Replace Road Liners
Loosening Track Tension It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. REPLACE ROAD LINERS 4 - 31...
Page 216 It is extremely dangerous to release the grease by any method except the procedure given below. If the rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.
Page 217 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4 - 33...
Page 218 When charging from the steel shoe or road liner to the rubber shoe, when changing from the rubber shoe to the steel shoe or road liner, it is necessary to remove and adjust the idler cushion, so contact your Komatsu distributor to have the change carried out.
Page 219: Replace Bucket Teeth (Vertical Pin Type)
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the safety lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.
Page 220 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4 - 36...
Page 221 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4 - 37...
Page 222: Replace Bucket Teeth (Horizontal Pin Type)
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the safety lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.
Page 223: Adjust Bucket Clearance
MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE It is dangerous if the work equipment moves by mistake while the bucket clearance is being adjusted. Set the work equipment on the ground in a stable condition, then stop the engine and lock the safety lock lever without fail. 4 - 39...
Page 224: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID Mixture ratio of pure washer fluid and water ° ° ° ° ° ° ° ° ° ° 4 - 40...
Page 225: Check And Adjust Air Conditioner
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST AIR CONDITIONER If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.
Page 226: Check, Clean And Lubricate Cab Slide Door Rail And Roller
MAINTENANCE MAINTENANCE PROCEDURE CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER NOTICE Do not use high-viscosity oil for the lubricant. Use grease only. 4 - 42...
Page 227 MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. When removing the cap from oil filler port (F), turn it slowly to release the internal pressure, then remove it carefully.
Page 228: Wash Washable Floor
MAINTENANCE MAINTENANCE PROCEDURE WASH WASHABLE FLOOR When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation. If the control levers are touched by mistake, the work equipment or machine may suddenly move, and this may lead to a serious accident.
Page 229: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM NOTICE If the pump is operated without filling the pump case with hydraulic oil, there is danger that the pump may be prematurely damaged. Be sure to bleed the air completely. NOTICE If the engine is run at high speed without bleeding the air between the pump and hydraulic tank, there will be abnormal generation of heat, and this will lead to premature failure of the pump.
Page 230 MAINTENANCE MAINTENANCE PROCEDURE NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing. NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. 4 - 46...
Page 231 MAINTENANCE MAINTENANCE PROCEDURE ° NOTICE If the attachment maker specifies an air bleeding procedure for the attachment itself, follow the specified procedure to bleed the air. NOTICE After completing the air bleeding operation, stop the engine, and leave the machine for 5 minutes before starting operations. This will remove the air bubbles in the oil inside the hydraulic cylinders.
Page 232: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING 4 - 48...
Page 233: Every 50 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 50 HOURS MAINTENANCE DRAIN WATER FROM FUEL TANK 4 - 49...
Page 234: Every 100 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE LUBRICATING NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval. Carry out greasing every 10 hours for the first 50 hours on a new machine. After the machine was subjected to jobs in the water, be sure to grease the wet pins.
Page 235: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE LUBRICATING NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval. Carry out greasing every 10 hours for the first 50 hours on a new machine. After the machine was subjected to jobs in the water, be sure to grease the wet pins.
Page 236 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4 - 52...
Page 237: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 238: Check Level Of Battery Electrolyte
MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion. The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks near the battery.
Page 239 MAINTENANCE MAINTENANCE PROCEDURE REMARK 4 - 55...
Page 240: Check And Adjust Cooling Fan Belt Tension
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST COOLING FAN BELT TENSION 4 - 56...
Page 241 V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. If the belt is stretched and there is no allowance for adjustment, or if it is cut or cracked, please contact your Komatsu distributor for replacement. 4 - 57...
Page 242: Check Air Conditioner Compressor Belt Tension, Adjust
Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones. • The fan belt has elongated, leaving little allowance for adjustment.
Page 243: Replace Fuel Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE REPLACE FUEL FILTER CARTRIDGE Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. NOTICE If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel.
Page 244: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. REMARK REMARK 4 - 60...
Page 245 MAINTENANCE MAINTENANCE PROCEDURE CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear safety glasses, dust mask, and other protective equipment. NOTICE The guide for cleaning the filter is 500 hours, but if the machine is used on an extremely dusty jobsite, reduce the maintenance interval and clean the filter more frequently.
Page 246 MAINTENANCE MAINTENANCE PROCEDURE REMARK NOTICE Insert filter (6), paying attention to the top and bottom sides. 4 - 62...
Page 247 MAINTENANCE MAINTENANCE PROCEDURE CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment. NOTICE When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins.
Page 248 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4 - 64...
Page 249: Lubricate Swing Circle
MAINTENANCE MAINTENANCE PROCEDURE LUBRICATE SWING CIRCLE CHECK SWING PINION GREASE LEVEL, ADD GREASE 4 - 65...
Page 250: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE REPLACE HYDRAULIC OIL FILTER ELEMENT The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 251 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE REMARK 4 - 67...
Page 252: Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY CASE The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. · · 4 - 68...
Page 253: Change Oil In Final Drive Case
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 254: Clean, Check Turbocharger
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE CHECK PTO GEAR CASE, ADD OIL The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out.
Page 255: Check Water Pump
MAINTENANCE MAINTENANCE PROCEDURE EVERY 4000 HOURS MAINTENENCE CHECK WATER PUMP 4 - 71...
Page 256: Every 5000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 257 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE ± · ± · ± NOTICE Be sure to pressurize the hydraulic tank. If it is not pressurized, the pump will suck in air, and this will adversely affect the equipment. 4 - 73...
Page 258 5 - 1...
Page 259: Specifications
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS 5 - 2...
Page 260 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS 5 - 3...
Page 261 6 - 1...
Page 262: Safety First
Read the instruction manual for the attachment thoroughly, and do not use this attachment unless you are sure that you have understood the guides completely. If you lose the instruction manual, always ask the manufacturer or your Komatsu distributors for a new copy. Depending on the attachment, install the necessary front guard to the machine.
Page 263: Attachment Installation
If the correct procedure is not used when installing the boom and arm, it may lead to serious damage. Please consult your Komatsu distributor. When long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting other objects.
Page 264: Bucket With Hook
ATTACHMENTS AND OPTIONS BUCKET WITH HOOK BUCKET WITH HOOK HOOK CONDITION PROHIBITED OPERATIONS 6 - 4...
Page 265: Machine Ready For Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT LOCATIONS 6 - 5...
Page 266 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT 6 - 6...
Page 267: Hydraulic Circuit
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT HYDRAULIC CIRCUIT Hydraulic Circuit Connection NOTICE If the attachment maker specifies an air bleeding procedure for the attachment itself, follow the specified procedure to bleed the air. 6 - 7...
Page 268: Attachment Operations
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT ATTACHMENT OPERATIONS Do not put your foot on the pedal except when operating the pedal. If rest your foot on the pedal during operations, and it is depressed by accident, the attachment may move sudden and cause serious damage or injury. When Using Breaker NOTICE Never attempt to use the breaker with lock pin (1) set at the full stroke...
Page 269 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT When Using General Attachment Such As Crusher 6 - 9...
Page 270 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT LONG TERM STORAGE SPECIFICATIONS 6 - 10...
Page 271 ATTACHMENTS AND OPTIONS METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT For lifting up this machine, use a wire rope with sufficient strength to withstand the machine weight. Do not attempt to lift up the machine in a posture other than explained below. Otherwise there is the danger that the lifted machine may lose a balance in the air.
Page 272 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT 6 - 12...
Page 273 ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) When changing the operating pattern of the machine, set the machine in the parking posture, stop the engine, check that the safety lock lever is at the LOCK position, then change the operating pattern.
Page 274 ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) MACHINE CONTROL PATTERNS After changing the operating pattern, always change the operating pattern card in the operator's compartment. 6 - 14...
Page 275: Attachment Guide
ATTACHMENT GUIDE Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.
Page 276: Attachment Combinations
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE ATTACHMENT COMBINATIONS Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
Page 277: Recommended Attachment Operations
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selection of optimum attachments. HYDRAULIC BREAKER...
Page 278 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS 6 - 18...
Page 279 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS 6 - 19...
Page 280 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS 6 - 20...
Page 281 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic components, while the breaker is in use. Therefore, be sure to grease the breaker, holding it in the right posture.
Page 282 INDEX INDEX 7 - 1...
Page 283 INDEX 7 - 2...
Page 284 ©...

Komatsu PC78US-6 Operation & Maintenance Manual

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