Page 1 SAA6D107E-1 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
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Page 4: Before Reading This Manual
Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.
Page 6: Introduction
FOREWORD INTRODUCTION INTRODUCTION USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "RECOMMENDED APPLICATIONS (PAGE 3-119)" for further details. DIRECTIONS OF MACHINE...
Page 7: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the bottom right of the operator's cab The design of the nameplate differs according to the territory.
Page 8: Service Meter Location
FOREWORD PRODUCT INFORMATION SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 6...
Page 9: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL SAFETY INFORMATION INTRODUCTION USE OF MACHINE DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS...
Page 10 FOREWORD CONTENTS SLIDING DOOR 3- 49 REAR UNDERVIEW MIRROR 3- 49 CAP WITH LOCK 3- 50 EMERGENCY ESCAPE HAMMER 3- 51 HOT AND COOL BOX 3- 52 MAGAZINE BOX 3- 52 ASHTRAY 3- 52 AIR CONDITIONER CONTROLS 3- 53 RADIO 3- 60 AUXILIARY ELECTRIC POWER 3- 65...
Page 11 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ELECTRIC SYSTEM MAINTENANCE WEAR PARTS WEAR PARTS LIST RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 TIGHTENING TORQUE SPECIFICATIONS 4- 12 TIGHTENING TORQUE LIST 4- 12...
Page 12 FOREWORD CONTENTS ATTACHMENT REMOVAL AND INSTALLATION 6- 13 ATTACHMENT OPERATIONS 6- 16 LONG TERM STORAGE 6- 17 SPECIFICATIONS 6- 17 ATTACHMENT GUIDE 6- 18 TRACK SHOES SELECTION 6- 18 RECOMMENDED ATTACHMENT OPERATIONS 6- 19 HYDRAULIC BREAKER 6- 19 HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 23 BASIC PRECAUTIONS 6- 23...
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Page 14: Safety
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12 PRECAUTIONS BEFORE STARTING OPERATION 2- 12 ENSURING SAFE OPERATION 2- 12 UNDERSTANDING THE MACHINE 2- 12 PREPARATIONS FOR SAFE OPERATION 2- 12 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 12...
Page 15 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 20 PRECAUTIONS FOR JOBSITE 2- 20 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 20 WORKING ON LOOSE GROUND 2- 20 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 21 ENSURE GOOD VISIBILITY 2- 21 CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 21 BEWARE OF ASBESTOS DUST 2- 22...
Page 16 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE 2- 34 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 34 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 34 KEEP WORKPLACE CLEAN AND TIDY 2- 34 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 34 ONLY AUTHORIZED PERSONNEL 2- 34 APPOINT LEADER WHEN WORKING WITH OTHERS...
Page 17: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. LOCATION OF SAFETY LABELS...
Page 18: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution before operating (09802-03000) (3) Caution for leaving operator's seat (09654-03001) 2 - 6...
Page 19 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electric cables (09801-03001) (5) Caution for operating pattern (09822-03000) 2 - 7...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (6) Caution when opening or closing front window (09839-03000) (7) Caution when stowing front window (09803-03000) (8) Caution for high-temperature hydraulic oil (09653-03001) (9) Caution with high-temperature coolant (09668-03001) 2 - 8...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Caution for handling accumulator and gas spring (09659-53000) (11) Caution for adjusting track tension (09657-03003) (12) Caution for handling cable (09808-03000) (13) Stopping rotation for inspection and maintenance (09667-03001) (14) Warning against falling off the edge (09805-23000) 2 - 9...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (15) Warning against falling (09805-13000) (16) Keep off swing area (09133-23000) (17) Bware of work equipment (09134-A1681) (18) Caution when handling battery (09664-30082) 2 - 10...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (19) Jump start prohibited (09842-A0481) (20) Prevention of burns (22U-00-21940) (21) Caution blast site (09845-00480) (only when equipped with KOMTRAX) 2 - 11...
Page 24: General Precautions Common To Operation And Maintenance
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 25: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE KEEP MACHINE CLEAN If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 26: Fire Prevention
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION ACTION IF FIRE OCCURS Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine. Do not jump off the machine. There is the danger of falling and suffering serious injury. PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, COOLANT or window washer fluid Do not bring any flame or fire close to flammable substances...
Page 27: Precautions When Getting On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Fire coming from piping Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or death.
Page 28: No Jumping On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE NO JUMPING ON OR OFF MACHINE Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 29: 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 contact your Komatsu distributor for advice on the method of repair.
Page 30: Protection Against Falling, Flying, Intruding Objects
In such a case, do not operate the machine without an additional guard. Be sure to consult with your Komatsu distributor about necessary guards. 2 - 18...
Page 31: Unauthorized Modification
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE UNAUTHORIZED MODIFICATION Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu. Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor.
Page 32: 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 personal injury or death. Before starting operations, always check the following to confirm that there is no danger on the jobsite. When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
Page 33: Do Not Go Close To High-Voltage Cables
SAFETY PRECAUTIONS FOR OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 34: Starting Engine
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. STARTING ENGINE USE WARNING TAGS If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine.
Page 35: Inspection And Maintenance Before Starting Engine
SAFETY PRECAUTIONS FOR OPERATION INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly problems may occur with the operation of the machine, and there is danger that this may lead to serious personal injury or death.
Page 36: Operation
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. Always wear safety goggles and rubber gloves when starting the engine with booster cable.
Page 37: Precautions When Traveling In Forward Or Reverse And Swinging
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING When traveling, drive with sprocket (1) at the rear of the machine. If sprocket (1) is at the front, the operation of the travel levers will be the opposite of the actual direction of travel, so there is a hazard that the machine may travel in an unexpected direction, leading to serious injury or death.
Page 38: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING When traveling or carrying out operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them. When traveling on the level ground, keep the work equipment approximately 40 to 50 cm above the ground.
Page 39: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine.
Page 40: Operating On Slopes
SAFETY PRECAUTIONS FOR OPERATION OPERATING ON SLOPES When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.
Page 41 SAFETY SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION When carrying out demolition work, do not carry out demolition work under the front of the machine. This makes the ground unstable, and there is a hazard of the machine falling. When carrying out demolition work, do not carry out demolition work above your head.
Page 42: Traveling On Snow-Covered Or Frozen Surfaces
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SNOW-COVERED OR FROZEN SURFACES Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 43: Transportation
The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 44: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING PRECAUTIONS WHEN TOWING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or towing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For towing, see "TOWING THE MACHINE (PAGE 3-147)".
Page 45: Lifting Objects With Bucket
SAFETY PRECAUTIONS FOR OPERATION LIFTING OBJECTS WITH BUCKET PRECAUTIONS FOR LIFTING OPERATIONS Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable. Use wire rope that conforms to the specified standard. Determine the signals to be used and place a signalman in position.
Page 46: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine.
Page 47: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. Turn the starting switch to the ON position. Operate the work equipment control lever back and forth, left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then move lock lever (1) to the LOCK...
Page 48: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 49: Precautions When Working Under Machine Or Work Equipment
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight of the component. Never use jacks at places where the machine is damaged, bent, or twisted.
Page 50: Precautions For Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
Page 51: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE Danger of sparks There is hazard that sparks will be generated, so always observe the following. Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying around near the battery.
Page 52: Precautions With High-Pressure Oil
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, please consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 53: Operation
If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. It is necessary to disassemble the recoil spring assembly, always ask your Komatsu distributor to carry out the operation.
Page 54: Handling Accumulator And Gas Spring
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PRECAUTIONS WITH COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying dust or particles.
Page 55: Method Of Selecting Window Washer Fluid
SAFETY PRECAUTIONS FOR MAINTENANCE METHOD OF SELECTING WINDOW WASHER FLUID Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To enable this machine to be used safely for a long period, always carry out periodic replacement of safety critical parts that have a particularly close relation to safety, such as hoses and the seatbelt.
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Page 58: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Boom cylinder Bucket cylinder Sprocket Track frame Track shoe Arm cylinder Boom (10) Idler 3 - 2...
Page 59: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Car radio (11) Machine monitor Revolving warning lamp switch (if equipped) (12) Horn switch Air conditioner control switch (13) Right work equipment control lever Lock lever (14) Starting switch Lift work equipment control lever (15) Fuel control dial One-touch power max.
Page 60 OPERATION MACHINE VIEW ILLUSTRATIONS Machine monitor AA: Screen with all lamps lighted up BB: Screen for standard CC: Maintenance time warning screen Select switch (17) Fuel gauge Working mode selector switch (18) Water separator monitor Alarm buzzer stop switch (19) Fuel level monitor Wiper monitor (20)
Page 61: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM AA: Screen with all lamps lighted up BB: Screen for standard...
Page 62 OPERATION DETAILED CONTROLS AND GAUGES Basic Operation of Machine Monitor If There Is Abnormality When Starting Engine If there is any abnormality when starting the engine, the check before starting screen DD changes to the maintenance interval warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance interval warning screen CC.
Page 63 OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation If any abnormality occurs during operation, the standard screen BB changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2). 3 - 7...
Page 64 OPERATION DETAILED CONTROLS AND GAUGES REMARK The colors lighting up the monitors related to the emergency stop items, caution items, and basic check items are as follows. Color when monitor lights up Type of monitor When When At low normal abnormal temperature Engine coolant temperature monitor...
Page 65 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
Page 66 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor Monitor (2) warns operator that the hydraulic oil temperature has risen. If monitor lights up red during operations, run engine at low idle or stop the engine and wait until the oil temperature goes down and monitor (2) changes to green.
Page 67 OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running.
Page 68 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor If this monitor (2) lights up white in low temperatures, carry out the warming-up operation. For details, see "Hydraulic Equipment Warm Up (PAGE 3-93)". Continue the warming-up operation until monitor (2) changes to green.
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Water Separator Monitor This monitor (6) shows that the water separator is full of water. If the red lamp lights up, stop the engine and drain the water from the water separator. For details of the method of draining the water from the water separator, see "Check for Water and Sediment in Water Separator, Drain Water (PAGE 3-74)".
Page 70 OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly.
Page 71 For details of the method of checking the maintenance interval, see "Maintenance Switch (PAGE 3-26)" in the Detailed controls and gauges. If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 15...
Page 72 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Pilot display Gauges and Meter Engine pre-heating monitor Engine coolant temperature gauge Swing lock monitor Fuel gauge Wiper monitor (10) Hydraulic oil temperature gauge Auto-deceleration monitor (11) Service meter Working mode monitor Travel speed monitor One-touch power max.
Page 73 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Monitor This monitor (2) informs the operator that the swing lock is being actuated. Actuated: Lights up When the swing lock switch is turned ON (ACTUATED), the monitor lamp lights up. This lamp lights up when the swing parking brake release switch is set to the FREE position.
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Monitor This monitor (6) shows the setting for the travel speed. The monitor display is as follows according to the operation of the travel speed selector switch. Lo: Low-speed travel Mi: Mid-range speed travel Hi: High-speed travel One-Touch Power Max.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES Gauges and Meter Engine Coolant Temperature Gauge Gauge (8) indicates the engine coolant temperature. During normal operations, indicator should be in the black range (A) - (C). If indicator enters the red range (A) - (B) during operations, the overheat prevention system is actuated.
Page 76 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Gauge Meter (10) displays the hydraulic oil temperature. During operations, the indicator should be in the black range. If the indicator enters red range (A) during operations, the hydraulic oil temperature has gone above 102°C (215.6°F). Stop the engine or run it at low idle and wait for the hydraulic oil temperature to go down.
Page 77 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion Working mode selector switches (basic switches) Back switch Auto-deceleration switch (selection switch) Up switch Travel speed selector switch (selection switch) (10) Down switch Wiper switch (11) Input confirmation switch Window washer switch (12) Liquid crystal monitor adjustment switch Maintenance switch...
Page 78 If it is desired to have the working mode set to start automatically in E, L, or B mode (default options setting), please contact your Komatsu distributor to change the setting. REMARK When the mode selector switch is pressed, the mode is displayed in the center of monitor display portion (GG), and the screen returns to standard screen (BB) after 2 seconds.
Page 79 OPERATION DETAILED CONTROLS AND GAUGES Auto-deceleration Switch (Selection Switch) When switch (2) is pressed, the auto-deceleration is actuated, if the control levers are in neutral position, the engine speed is automatically lowered to reduce fuel consumption. Monitor display portion GG ON : Auto-deceleration actuated Monitor display portion GG OFF : Auto-deceleration canceled Each time the switch is pressed, auto-deceleration switches between actuated and canceled.
Page 80 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch (Selection Switch) WARNING When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (3) at the Lo position). Never operate travel speed selector switch (3) while loading or unloading. 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 81 OPERATION DETAILED CONTROLS AND GAUGES Wiper Switch This switch (4) actuates the front window wiper. Each time the switch is pressed, it changes ON → INT → stop (OFF). Monitor display portion GG INT lighted up: Wiper moves intermittently Monitor display portion GG ON lighted up: Wiper moves continuously Monitor display portion GG OFF: Wiper stops REMARK...
Page 82 Check damper case oil level, add oil 1000 Change final drive case oil 2000 Change swing machinery case oil 1000 Change hydraulic oil 5000 If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 26...
Page 83 OPERATION DETAILED CONTROLS AND GAUGES The method of checking time remaining until maintenance is as follows: 1. Look at the maintenance screen, press up switch (9) or down switch (10) on the monitor switch portion, and select the item. (Color of the monitor for selected item is inverted to black.) 2.
Page 84 OPERATION DETAILED CONTROLS AND GAUGES Select Switch These switches (7) are used when adjusting the E mode set values or when adjusting the oil flow when an attachment is installed. Adjusting E Mode Set Values When the E mode set values are adjusted, the engine output is adjusted, making it possible to improve the fuel consumption in E mode.
Page 85 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. The monitor display screen switches to the selection screen shown on the right. Press return switch (8) The monitor display screen returns to the standard screen. Setting Oil Flow 1.
Page 86 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3) The monitor display screen switches to the selection screen shown on the right. Press return switch (8) The monitor display screen returns to the standard screen. REMARK Even when the starting switch is turned OFF, the oil flow set by the above operation remains as the set value when the engine is started next.
Page 87 OPERATION DETAILED CONTROLS AND GAUGES Back Switch Press this switch (8) when in the maintenance mode, brightness/contrast adjustment mode, or select mode. The screen will return to the previous screen on the monitor display. Up Switch, Down Switch Press up switch (9) or down switch (10) when in the maintenance mode, brightness/contrast adjustment mode, or select mode to move the cursor on the monitor display (colors of selected monitor are inverted) up, down, left, or right.
Page 88 OPERATION DETAILED CONTROLS AND GAUGES Liquid Crystal Monitor Adjustment Switch Press switch (12) to adjust the brightness or contrast of the display monitor. Adjusting Brightness 1.When monitor adjustment switch (12) is pressed, the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right.
Page 89 OPERATION DETAILED CONTROLS AND GAUGES Adjusting Contrast 1.When monitor adjustment switch (12) is pressed, the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right. 2.Use the brightness/contrast screen and press up switch (9) or down switch (10) to select the contrast monitor.
Page 90: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch One-touch power max. switch Fuel control dial Room lamp switch Cigarette lighter Emergency pump drive switch Swing lock switch (10) Swing brake cancel switch Lamp switch (11) Revolving warning lamp switch (if equipped) Horn switch Starting Switch Starting switch (1) is used to start or stop the engine.
Page 91 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial Dial (2) adjusts the engine speed and output. (a)Low idling (MIN): Turned fully to the left (b)Full speed (MAX): Turned fully to the right REMARK Even if the fuel control dial is turned several notches up from low idling position (a) or down from full speed position (b), there is a range where the engine speed does not change, but this is not an abnormality.
Page 92 OPERATION DETAILED CONTROLS AND GAUGES Lamp Switch This switch (5) is used to light up the working lamp and monitor lighting. (a) ON: Lamps light up (b) OFF: Lamps go off Horn Switch When the switch (6) at the tip of the right work equipment control lever is pressed, the horn will sound.
Page 93 OPERATION DETAILED CONTROLS AND GAUGES Emergency Pump Drive Switch NOTICE This switch is provided to enable you to carry out operation temporarily, when any problem occurs on the pump control system. Do not use it except in emergency. Furthermore, remove the cause of the problem 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 94 OPERATION DETAILED CONTROLS AND GAUGES Revolving Warning Lamp Switch (If equipped) Use this switch (11) to light up the yellow rotating lamp on top of the cab. (a) ON: Lamps light up (b) OFF: Lamps go off 3 - 38...
Page 95: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Left work equipment control lever Travel levers (with auto-deceleration system) (with pedal and auto-deceleration system) Right work equipment control lever (with auto-deceleration system) Lock Lever WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position. If the lock lever is not at the LOCK position and the control levers or control pedals are touched by mistake, it may lead to serious personal injury.
Page 96 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers WARNING Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may suddenly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations. When you are not using the pedal, do not rest your foot on it.
Page 97 OPERATION DETAILED CONTROLS AND GAUGES Work Equipment Control Lever Left work equipment control lever (3) is used to operate the arm and upper structure. Arm operation (a) Arm OUT (b) Arm IN Swing operation (c) Swing to right (d) Swing to left N (Neutral) : The upper structure and arm are held in position and do not move.
Page 98: Sun Roof
OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF WARNING When leaving the operator's seat, set the lock lever securely to the LOCK position. If the lock lever is at the FREE position and the control levers or control pedals is touched by mistake, this may lead to a serious accident.
Page 99: Windshield
OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD WARNING When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK position. If the lock lever is at the FREE position and the control levers or control pedals is touched by mistake, this may lead to a serious accident.
Page 100 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Hold 2 grips (A) on the left and right top sides of the front window, and pull the 2 levers (B) to release the locks at the top of the front window. The top of the front window will come out. 3 - 44...
Page 101 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. Hold lower knob (C) with your left hand from inside the operator's cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
Page 102 OPERATION DETAILED CONTROLS AND GAUGES Closing WARNING When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2.
Page 103 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. When the bottom of the window reaches the top of the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock. 6.
Page 104 OPERATION DETAILED CONTROLS AND GAUGES Removing Lower Windshield 1. Open the front window, then hold grip (1), pull up, and remove the bottom window. 2. Turn knob (1) of the lower windshield toward the operator (inward) as shown at right so that dimple (2) faces the machine's front end.
Page 105: Sliding Door
OPERATION DETAILED CONTROLS AND GAUGES SLIDING DOOR CAUTION When opening or closing the sliding door, select a suitable position for your left and right hands and be extremely careful not to get your fingers caught. Always check that the sliding door is locked at the open or closed position. Always stop the machine on level ground when opening or closing the door.
Page 106: Cap With Lock
OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Use the starting switch key to open and close the locks on the caps and covers. For details of the locations of the caps and covers with locks, see "LOCKING (PAGE 3-127)". Insert the key as far as it will go to the shoulder (A).
Page 107: Emergency Escape Hammer
OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Cover with Lock Opening the Cover (Locked Cover) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. (A): Open (B): Lock Locking the Cover 1.
Page 108: Hot And Cool Box
OPERATION DETAILED CONTROLS AND GAUGES HOT AND COOL BOX Located on the right side at rear of the operator's seat. It is interconnected with the air conditioner. Box stays warm when the heater is used, and box stays cool when the air conditioning is used.
Page 109: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel Vent selector swich OFF switch Air circulation selector swich Defroster selector lever Temperature control swich Auto air conditioner switch Air flow selector switch Sunlight sensor Air conditioner switch Vent Selector Switch (Air Flow to Upper Part of Body) If this switch (1) is pressed, the air from the air conditioner is all directed to the face.
Page 110 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch (Air Flow to Upper Part of Body and Foot) If this switch (1) is pressed, the air from the air conditioner is directed to the face and feet. Vent Selector Switch (Air Flow to Foot) If switch (1) is pressed, the air from the air conditioner is all directed to the feet.
Page 111 OPERATION DETAILED CONTROLS AND GAUGES Air Circulation Selector Switch (External Air Circulation) When switch (2) is pressed, fresh air is taken into the cab during heating or cooling. This position is used to bring in clean fresh air into the cab or to remove the mist from the cab windows.
Page 112 OPERATION DETAILED CONTROLS AND GAUGES Temperature Control Switch (Heating) Use switch (3) to increase the temperature. Press this switch to increase the temperature of the air sent from the air conditioner. The more times the switch is pressed, higher the temperature becomes, as the indicator light moves to the "H".
Page 113 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch Switch (5) is used to switch the air conditioner functions ON/OFF. Off Switch Switch (6) is used to stop operation of the fan. 3 - 57...
Page 114 OPERATION DETAILED CONTROLS AND GAUGES Defroster Selector Lever Switch (7) is used to remove the mist from the front glass during cold or rainy weather. (A): To defroster (open) (B): Closed The defroster can be used when the vent selector switch is set to send air to the face or to the face and the feet.
Page 115 OPERATION DETAILED CONTROLS AND GAUGES Use Air Conditioner with Care NOTICE When running the air conditioner, always start with the engine running at low speed. Never start the air conditioner when the engine is running at high speed. It will cause failure of the air conditioner. If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, be careful not to let water get on these parts.
Page 116: Radio
OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel Power switch, Volume control knob, Balance AS/PS button control knob Preset station buttons (1,2,3,4,5,6) SEL button Display FM/AM selection button Time reset button Display selection button Tuning button Power switch, Volume control knob, Balance control knob Press this knob (1) to turn the power for the radio on.
Page 117 OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4) and the display will show the present time for 5 seconds. After 5 seconds pass, the display returns automatically to the frequency display.
Page 118 OPERATION DETAILED CONTROLS AND GAUGES Controls of Radio Method of Setting with Preset Button 1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. 3.
Page 119 OPERATION DETAILED CONTROLS AND GAUGES Method of Operating Mode (BAS) Bass adjustment: When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned counterclockwise, the bass sound is reduced.
Page 120 OPERATION DETAILED CONTROLS AND GAUGES Antenna NOTICE Before transporting the machine or putting it inside a building, stored the antenna to prevent any interference. Use Radio with Care To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation. If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 121: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 24V Power Source NOTICE Do not use this as the power supply for 12V equipment. It will cause failure of the equipment. Pull out the connector plug for taking out electric power from the rear side of the panel.
Page 122: Fuse
OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 123: Fusible Link
Do not let water, mud, or juice spill on the controller. This will cause failures. If any problem occurs in the controller, do not repair it by yourself. Please contact your Komatsu distributor for repairs. TOOL BOX Store the tools in this box.
Page 124: Grease Pump Holder
OPERATION DETAILED CONTROLS AND GAUGES GREASE PUMP HOLDER The grease pump holder is installed on the inside of the rear left door of the body. Keep the grease pump hooked on this holder while it is not used. 3 - 68...
Page 125: Machine Operations And Controls
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor.
Page 126 Check for damage or wear to the seat belt and mounting clamps. If there is any damage, replace with new parts. 12. Check bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, contact your Komatsu distributor for repairs.
Page 127 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub-tank.
Page 128 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 129 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING 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 130 OPERATION MACHINE OPERATIONS AND CONTROLS Drain Water And Sediment from Fuel Tank 1. Open the rear door at the right of the machine. 2. Set a container under the drain valve (1) to catch the fuel when it is drained. 3.
Page 131 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment of Drain Valve If drain valve (4) is stiff, coat the O-ring portion of the drain valve with grease to make the movement smooth. 1. Turn the valve (6) at the bottom of the fuel tank to the CLOSE position (S).
Page 132 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature immediately 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 133 Check that the working lamps and lamps inside the instruments light up properly. Check also that there is no dirt or damage. If any lamp does not light up, the bulb is probably blown up or there is a disconnection, so ask your Komatsu distributor to carry out repairs.
Page 134 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's back against the backrest.
Page 135 OPERATION MACHINE OPERATIONS AND CONTROLS Adjusting seat height It is possible to move the seat up or down by combining adjustments forward tilt and rear tilt. After setting the forward tilt or rear tilt to the desired height, operate the opposite part to set the seat horizontal then secure in position.
Page 136 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Mirror (A) Adjust the mirror mount so that it is possible to see people at the rear left of the machine.
Page 137 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Mirror (B) Adjust the mirror mount so that it is possible to see people at the rear right of the machine. Install the side view mirror in the location indicated in the figure at right.
Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if there are no signs of damage, replace belts in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Page 139 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK For machines with a suspension seat,adjust the position of the seat, then adjust tether belt (6). Install the tether belt so that it is tensed when no one is sitting in the seat. (Only machines equipped with suspension seat) 3 - 83...
Page 140 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When starting the engine, check that the lock lever is securely at the LOCK position. If the lock lever is not locked securely and the control levers or control pedal are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
Page 141 After inputting the password, press input confirmation switch (3). REMARK Contact your Komatsu distributor for details of the method of setting, changing, or cancelling the password. 1) The buzzer sounds for approx. 1 second, and the following monitors and meters light up for approx.
Page 142 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3) If the hydraulic oil temperature gauge is out or caution lamp (16) stays lighted up red, immediately check the item that lights up red. 4) If there are any items where the maintenance time has passed, maintenance interval monitor (17) lights up for 30 seconds.
Page 143: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE WARNING 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 144 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to ON position (B). If the ambient temperature is low, the preheating monitor lights up and automatic preheating is carried out. Keep the key in starting switch (3) at the ON position (B) until the preheating monitor goes out.
Page 145 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK Regardless of the ambient temperature, it is possible to start the engine preheating manually. 1. Turn the key in starting switch (3) to the left from OFF position (A). The preheating monitor lights up and engine preheating starts.
Page 146: After Starting Engine
Breaking-in the New Machine NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 147 OPERATION MACHINE OPERATIONS AND CONTROLS Engine Warm Up NOTICE Do not accelerate the engine suddenly until the warm-up operation has been completed. Do not run the engine at low idling or high idling under no load for more than 20 minutes. This will have an adverse effect on the environment, and will also have an adverse effect on the internal structure of the engine.
Page 148 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Canceling automatic warm-up operation If it becomes necessary in an emergency to cancel the automatic warm-up operation or to lower the engine speed to low idle, do as follows. 1] Turn fuel control dial (2) to the full speed (MAX) position and hold it for 3 seconds.
Page 149 OPERATION MACHINE OPERATIONS AND CONTROLS Hydraulic Equipment Warm Up WARNING Before carrying out the warm-up operation for the hydraulic equipment, turn the swing lock switch ON, check on the monitor that the swing lock is actuated, then start the warm-up operation. When warming up the hydraulic equipment, check that there is no person or obstacle in the surrounding area, then sound the horn and start the operation.
Page 150 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. To complete the warm-up operation of the hydraulic equipment more quickly, set the working mode to P mode (heavy-duty mode). For details of the procedure for setting the working mode, see "Working Mode Selector Switch (Basic Switch) (PAGE 3-22)".
Page 151 Hydraulic oil temperature monitor (7): Green display Fuel gauge (17): Indicator in black range Fuel level monitor (18): Green display 14. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 95...
Page 152 OPERATION MACHINE OPERATIONS AND CONTROLS In cold temperatures (ambient temperature below 0°C), even when the hydraulic oil temperature monitor displays green, carry out additional Step 15 to warm up all the hydraulic equipment. 15. Turn fuel control dial (4) to the full speed (MAX) position, repeat Steps 6 to 9 for 3 to 5 minutes, then check again that the hydraulic oil temperature monitor is displaying green.
Page 153 OPERATION MACHINE OPERATIONS AND CONTROLS 17. Before starting operations, repeat the following operations slowly 3 to 5 times to circulate warm oil through the control circuits. RAISE (E) ←→ LOWER (F) Boom operation IN (B) ←→ OUT (A) Arm operation CURL (D) ←→...
Page 154 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 18. Check that hydraulic oil temperature monitor (7) is displaying green. If the hydraulic oil temperature monitor is not displaying green (it is displaying white), repeat Steps 6 to 10 until the display is green.
Page 155 OPERATION MACHINE OPERATIONS AND CONTROLS Operation After Completion Of Warm-Up Operation 1. Check that hydraulic oil temperature monitor (7) displays green. 2. Push working mode selector switch (20) of the machine monitor to select the working mode to be used. For details of the procedure for selecting the working mode, see "Working Mode Selector Switch (Basic Switch) (PAGE 3-22)".
Page 156 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3) L mode For operations requiring fine control 4) B mode For breaker operations 3 - 100...
Page 157: 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. 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 158: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the control lever, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction from the operation of the travel lever (front and rear travel is reversed, left and right steering is reversed).
Page 159 Start the machine either by pulling lever (5) back slowly or by stepping on the rear part of pedal (6) slowly. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
Page 160 Slowly push the levers (5) forward, or slowly depress the front part of the pedals (6) to move the machine backward. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
Page 161 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3 - 105...
Page 162: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear, the machine moves in the reverse direction to the operation of the travel levers. Use the travel levers to change direction.
Page 163 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.
Page 164: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. 1. Before starting the swing operation, turn swing lock switch (1) OFF and check that swing lock monitor (2) has gone out.
Page 165: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
Page 166 OPERATION MACHINE OPERATIONS AND CONTROLS If the work equipment control levers are returned to the neutral position when the machine is stopped, even if the fuel control dial is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a mid-range speed.
Page 167: Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match operating conditions and purpose, thereby enabling work to be performed efficiently. Make effective use of each mode as follows. When the starting switch is turned to the ON position, the working mode is set to P mode (digging).
Page 168: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
Page 169 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as s pickaxe, breaker, or pile driver. This will drastically reduce the life of the machine. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging.
Page 170 OPERATION MACHINE OPERATIONS AND CONTROLS Long-Time Continuous Travel Operations Do not travel continuously at high speed for 1.5 hours or more. The lubricating oil inside the track rollers and final drive will rise to a high temperature, and there is danger that this will cause damage to the oil seal or leakage of oil.
Page 171: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 172: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING 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 performed, pile soil to make a platform (A) on the slope so the machine is kept horizontal during operation.
Page 173 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.
Page 174: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out. Track on One Side Stuck NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.
Page 175: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine.
Page 176 OPERATION MACHINE OPERATIONS AND CONTROLS Loading Work In places where the swing angle is narrow, work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator. Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.
Page 177: Bucket Replacement And Inversion
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT AND INVERSION WARNING 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 178 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket, for arm pin portion (A), fit O-ring (3) to bucket (4) in the position shown in the diagram on the right. After inserting the pin, fit it in the standard groove. For link pin portion (B), install the bucket with O-ring (3) fitted in the standard groove.
Page 179 OPERATION MACHINE OPERATIONS AND CONTROLS Inversion 1. Place the bucket in contact with a flat surface. REMARK When removing the pins, place the bucket so that it is in light contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.
Page 180 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK When reversing, do not install an O-ring. Keep the O-ring in a safe place until using it next. 5. Install the stopper bolts and nuts for each pin, then grease the pin.
Page 181: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes.
Page 182: Machine Inspection After Daily Work
OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 4. Set lock lever (3) in the LOCK position (L). MACHINE INSPECTION AFTER DAILY WORK Before Stop Engine Check the engine coolant temperature, engine oil pressure, and fuel level on the machine monitor. REMARK After stopping the engine, if the starting switch is turned within approx.
Page 183: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Door of operator fs cab Always remember to close the window. (2) Fuel tank filler port (3) Engine hood (4) Front door at the right of the machine (5) Rear door at the left of the machine (6) Rear door at the right of the machine (7) Hydraulic tank filler port...
Page 184: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE Select the method of transportation to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)". Note that the weight and dimensions given in SPECIFICATIONS may differ according to the type of shoe or arm, or other attachments.
Page 185: Loading And Unloading With Trailer
OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING Always obey the following when loading or unloading the machine from a trailer. Select firm, level ground when loading or unloading the machine. Maintain a safe distance from the edge of the road. Always turn the auto-deceleration switch OFF (cancel).
Page 186 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer.
Page 187 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 6. If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it; if it has no work equipment, travel in reverse to load it. Follow instructions and signals of a conductor particularly when traveling in reverse.
Page 188 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 10. When the machine travels over the rear wheels of the trailer, it becomes unstable, drive slowly and carefully. (Never operate the steering.) 11. At the moment the machine passes the rear wheels, it tilts forward, be careful not to let the work equipment hit the trailer body.
Page 189 OPERATION TRANSPORTATION Securing Machine NOTICE Stow the antenna and reassemble the mirrors so that they are within the width of the machine. 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.
Page 190 OPERATION TRANSPORTATION Rearview Mirrors The mirrors are at the positions shown in the diagram on the right. If they are damaged, or are to be removed for shipment, or are to be installed again, use the following procedure. After installing the mirrors, be sure to adjust them, referring to "Rearview Mirrors (PAGE 3-80)".
Page 191 OPERATION TRANSPORTATION Installation Mirror (A) 1. Fasten support (3) and clamp (5) with bolts (4) and (6). 2. Install mirror (1) to bracket (3),then tighten lock bolt (2). Mirror (B) 3. Install bracket (3) to the machine with bolt (4). 4.
Page 192 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer.
Page 193 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 8. Raise the work equipment, pull in the arm under the boom, then move the machine slowly. 9. When the machine is horizontal on top of the rear wheels of the trailer, stop the machine. NOTICE When unloading the machine, always keep the arm and boom at an angle of 90°...
Page 194: Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 195 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. However, for machines equipped with a full roller guard for the track roller, pass the wire rope under the track.
Page 196: Cold Weather Operation
NOTICE Please use Komatsu genuine SUPERCOOLANT (AF-NAC) for the COOLANT. As a basic rule, we do not recommend the use of any COOLANT other than SUPERCOOLANT (AF-NAC).
Page 197 OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas. 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 a large amount of water and consult a doctor.
Page 198 OPERATION COLD WEATHER OPERATION Monitor A feature of the liquid crystal monitor is that the screen becomes dark and is difficult to read in cold weather (particularly with the starting switch ON). In this case, adjust the brightness and contrast of the screen. For details, see "Liquid Crystal Monitor Adjustment Switch (PAGE 3-32)".
Page 199: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 200: Long Term Storage
AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 201: Starting Machine After Long-Term Storage
OPERATION LONG TERM STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE When starting the engine after long-term storage, carry out the warming-up operation thoroughly. For details, see "Engine Warm Up (PAGE 3-91)". 3 - 145...
Page 202: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. Procedure for Bleeding Air 1.
Page 203: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Page 204: Lightweight Towing Hole
OPERATION TROUBLES AND ACTIONS LIGHTWEIGHT TOWING HOLE WARNING The shackle must always be used. Hold the wire rope level and direct it straight to the track frame. Move the machine slowly and be careful not to apply any sudden load to the wire rope. There is a hole in the track frame to fit the shackle when towing light objects.
Page 205: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 206 OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-149)" and the instruction manual accompanying the charger, and do as follows. Set the voltage of the charger to match the voltage of the battery to be charged.
Page 207 OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows. Connecting and Disconnecting Booster Cables WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
Page 208 OPERATION TROUBLES AND ACTIONS Booster Cable Connection Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect the clip of booster cable (A) to the positive (+) terminal of battery (C) on the problem machine.
Page 209: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 210 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
Page 211 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights...
Page 212 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Abnormal noise generated Low-grade fuel being used Change to specified fuel (combustion or mechanical) Overheating Refer to "Radiator coolant level monitor lights up" as above Damage inside muffler ( Replace muffler) Excessive valve clearance ( Adjust valve clearance) 3 - 156...
Page 213 OPERATION TROUBLES AND ACTIONS Electronic Control System When the user code is shown on the display portion of the machine monitor, take the respective measures shown in the self-diagnosis chart below. Machine Monitoring System Monitor Failure mode Action display When emergency pump drive switch is at the up Pump control system error (emergency) position, normal operations become possible, but have inspection carried out immediately.
Page 214 Check the point of contact telephone number on screen B. REMARK If the point of contact telephone number has not been registered, screen B is not displayed. If it is necessary to register the point of contact telephone number, ask your Komatsu distributor to register it. 3 - 158...
Page 215 4 - 1...
Page 216: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 217 MAINTENANCE MAINTENANCE INFORMATION Dusty Jobsite When working at dusty worksites, do as follows: Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. Replace the fuel filter more frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 218: Outline Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. 4 - 4...
Page 219 COOLANT AND WATER FOR DILUTION Komatsu genuine SUPERCOOLANT (AF-NAC) 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 antifreeze COOLANT is essential.
Page 220 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.
Page 221: Electric System Maintenance
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 222: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 223: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 224 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT ASTM: American Society of Testing and Material Swing Final drive Engine oil Damper Hydraulic Cooling machinery case Fuel tank case system system case (each) liter 25.4 0.75 Specified capacity US gal 6.71 2.17 2.38 0.20 58.12 5.55...
Page 225: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
G2-T or G2-TE is recommended. Note 4: COOLANT 1) Komatsu genuine SUPERCOOLANT (AF-NAC) 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 antifreeze COOLANT is essential.
Page 226: Tightening Torque Specifications
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, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 227: Safety Critical Parts
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps 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 critical parts. 4 - 13...
Page 228: Safety Critical Parts List
MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST Safety critical parts for periodic replacement Q'ty Replacement interval Fuel hose (fuel tank - fuel pre-fillter) Fuel hose (fuel pre-fillter - supply pump) Fuel return hose, cooler (engine - fuel cooler) Fuel return hose (fuel cooler - fuel tank) Fuel hose (supply pump - fuel main fillter) Fuel return tube (injector, supply pump, fuel return merge tube from common rail)
Page 229: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) REPLACE FUEL PRE-FILTER CARTRIDGE...
Page 230 MAINTENANCE MAINTENANCE SCHEDULE EVERY 1000 HOURS MAINTENANCE REPLACE HYDRAULIC OIL FILTER ELEMENT 4- 58 CHANGE OIL IN SWING MACHINERY CASE 4- 59 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4- 60 REPLACE FUEL MAIN FILTER CARTRIDGE 4- 61 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS 4- 63 CHECK FAN BELT TENSION AND REPLACE FAN BELT 4- 63...
Page 231: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging operations, so set the maintenance intervals as follows. Replace hydraulic filter element On a new machine, replace the element after the first 100 to 150 hours, then carry out further replacement of the element according to the table on the right.
Page 232: Maintenance Procedure
Carry out the following maintenance only after the first 1000 hours of operation on new machines. Check engine valve clearance, adjust Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.
Page 233: When Required
MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
Page 234 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Outer Element NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 1. Open the rear door at the left side of the machine, remove 4 hooks (2), then remove cover (3). NOTICE Never remove the inner element (6).
Page 235 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 3) Remove one seal from the element whenever the element has been cleaned. 8. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element.
Page 236 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling.
Page 237 MAINTENANCE MAINTENANCE PROCEDURE Replacing Element 1. Open the rear door at the left side of the machine, remove 4 hooks (2), then remove cover (3). 2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out.
Page 238 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element cylinder (face where no hole is drilled) (B), (C) is at cover (3) end. If the direction of installation is mistaken, there is danger that it will cause breakage of the air cleaner element or serious damage to the engine.
Page 239 MAINTENANCE MAINTENANCE PROCEDURE Check and Clean of Air Cleaner Inlet 1. Open the door on the left side at the rear of the machine. 2. Remove dry leaves and dust stuck to the inlet of air cleaner suction (1) with a hand. 3.
Page 240: Clean Inside Of Cooling System
(AF-NAC) Komatsu genuine SUPERCOOLANT (AF-NAC) 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 antifreeze COOLANT is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
Page 241 When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 242 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 12. Drain the coolant from sub-tank (4), clean the inside of the sub-tank, then add coolant until the coolant level is between the FULL and LOW marks. If the sub-tank is extremely dirty and it is difficult to clean, replace it with a new part.
Page 243: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening 1. First tighten to a tightening torque of 392 ± 39.2 Nm (40 ± 4 kgm , 290 ± 30 lbft) then check that the nut and shoe are in close contact with the link contact surface.
Page 244: Check And Adjust Track Tension
Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. Increasing Track Tension Prepare a grease pump.
Page 245 It is extremely dangerous to release the grease by any method except the procedure given below. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. 1. Loosen plug (1) gradually to release the grease.
Page 246: Adjust Bucket Crearance
MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance. Set the work equipment in a stable condition, stop the engine, then set lock lever securely to the LOCK position (L). 1.
Page 247: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
Page 248: Check And Maintenance Air Conditioner
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 249 MAINTENANCE MAINTENANCE PROCEDURE WASH WASHABLE FLOOR WARNING When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation. If the control levers are touched by mistake, the machine may suddenly move, and this may lead to a serious accident. Always set the lock lever securely to the LOCK position before standing up from the operator's seat.
Page 250 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Set lock lever (2) to LOCK position (L) and stop the engine. 5. Remove the floor mat. 6. Flush out the dirt on the floor directly with water through water drain hole (1). 7.
Page 251 MAINTENANCE MAINTENANCE PROCEDURE Method of Setting Machine at Angle Method Using Slope WARNING Select a solid and smooth slope. Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground. 1. Stop the machine so that the work equipment is on the downhill side.
Page 252: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-87)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. 1. Bleeding air from pump 1) Loosen air bleeder (1) and check that oil oozes out from the air bleeder.
Page 253 NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. When replacing the travel motor safety valve, please contact your Komatsu distributor to have it replaced and to have the air bled. 5. Bleeding air from travel motor (Bleed the air only when the oil inside the travel motor case has been drained.)
Page 254: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-71)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Drain water and sediment from fuel tank Check for water and sediment in water separator, drain water Check oil level in hydraulic tank, add oil...
Page 255: 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 256: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING 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.
Page 257 Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. When it is Possible to Use Indicator to Check Electrolyte Level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 258: 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 259: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 100 and 250 hours should be carried out at the same time. LUBRICATING NOTICE During the initial 50 hours breaking-in period for a new machine, carry out lubrication every 10 hours. If digging operations have been carried out in water (such as digging holes), always carry out greasing for the pins that were under water.
Page 260 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (5) Boom - Arm coupling pin (1 place) (6) Arm cylinder rod end (1 place) (7) Bucket cylinder foot pin (1 place) 4 - 46...
Page 261: 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 WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity of oil pan: 23.1 liters (6.10 US gal) Prepare a filter wrench 1.
Page 262 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. After replacing the filter cartridge, open the engine hood and add engine oil through oil filler (F) to between the (H) and (L) marks on dipstick (G). 7. Run the engine at idling for a short time, then stop the engine and check again that the oil level is between the (H) and (L) marks on dipstick (G).
Page 263: Replace Fuel Pre-Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 264 MAINTENANCE MAINTENANCE PROCEDURE 9. When installing, apply oil to the packing surface and bring the packing surface into contact with the seal surface of filter cartridge (4) and then tighten it further by 1/4 - 1/2 turns. If the transparent cap is tightened too much, the O-ring will be damaged and this will cause leakage of fuel; if it is not tightened enough, fuel will leak through the gap at the O-ring.
Page 265: Check Swing Pinion Grease Level, Add Grease
3. Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Please contact your Komatsu distributor. The total amount of grease is 33 liters (29.7 kg) [8.7 US gal (65 lb)].
Page 266: Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS,FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury.
Page 267: Clean Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. 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 268 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Fresh Air Filter 1. Pull up pop-up rivet (4) of the air intake duct at the left rear of the operator's seat. Cover (5) will be released automatically. 2. Pull up external filter (6). 3. Clean external filter (6) by blowing it with compressed air. If there is oil stuck to the filter or it is extremely dirty, wash it in a neutral agent.
Page 269: Replace Breather Element In Hydraulic Tank
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREATHER ELEMENT IN HYDRAULIC TANK WARNING The parts and oil are at high temperature immediately 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. 1.
Page 270: Lubricate Swing Circle
MAINTENANCE MAINTENANCE PROCEDURE LUBRICATE SWING CIRCLE (2 places) 1. Lower the work equipment to the ground. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.
Page 271: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING 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 272: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours service should be carried out at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 273: Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank. 12. Check for oil leakage and wipe off any spilled oil. CHANGE OIL IN SWING MACHINERY CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.
Page 274: Check Oil Level In Damper Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.
Page 275: Replace Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 276 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE Replace inner seal (3) with a new part. NOTICE Do not fill the new filter cartridge with fuel. Remove cap (B) and install the filter cartridge. 6. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn.
Page 277: Check All Tightening Points Of Engine Exhaust Pipe Clamps
MAINTENANCE PROCEDURE CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS Please ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. CHECK FAN BELT TENSION AND REPLACE FAN BELT Special tools are required for inspection and replacement of the fan belt.
Page 278: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING 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.
Page 279: Clean Hydraulic Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING The parts and oil are at high temperature immediately 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. 1.
Page 280: Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 281 MAINTENANCE MAINTENANCE PROCEDURE CHECKING FUNCTION OF ACCUMULATOR CAUTION When carrying out the inspection, check first that there is no person or obstacle in the surrounding area. Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm, level ground. 2.
Page 282 Please contact your Komatsu distributor for inspection. 7. This completes the inspection. After completion of the inspection, set the lock lever to the LOCK position and turn the starting switch to the OFF position.
Page 283 MAINTENANCE MAINTENANCE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT 1. Place the work equipment on the ground. Close the crusher attachment jaws, etc. 2. Operate the work equipment lock lever to the LOCK position. 3. Insert the lock pin for the attachment control pedal in position (c) where it is possible to operate the pedal.
Page 284: Check Alternator
Contact your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection carried out every 1000 hours. CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. 4 - 70...
Page 285: Every 4000 Hours Maintenance
Maintenance for every 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time. CHECK WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, please ask your Komatsu distributor to carry out disassembly, repair, or replacement. CHECK VIBRATION DAMPER For the check and replacement of the vibration damper, special tools are required.
Page 286: Replace Accumulator (For Control Circuit)
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 287: Check For Looseness Of High-Pressure Piping Clamp, Hardening Of Rubber
Check visually and touch by hand to check that there is no hardening of the rubber and no loose bolts of the mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail. If there are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out replacement.
Page 288: Check Operating Condition Of Compressor
1. When the air conditioner switch is turned ON-OFF, do the compressor and magnet clutch also turn ON-OFF? 2. Is any abnormal noise generated by the clutch or compressor body? If any problem is found, contact your Komatsu distributor to have the parts disassembled, repaired, or replaced. 4 - 74...
Page 289: Every 5000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time. CHANGE OIL IN HYDRAULIC TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 290 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Remove undercover (1). 6. Set a container direct under the drain plug located on the machine's underside to catch oil that is drained. Remove drain plug (P) and drain the oil. Check an O-ring installed to Plug (P), and if it has a scratch or damage, replace it with new one.
Page 291: Every 8000 Hours Maintenance
Maintenance for every 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPRAY PREVENTION CAP Contact your Komatsu distributor to have the fuel spray prevention cap replaced. 4 - 77...
Page 293 5 - 1...
Page 294: Specifications
PC308USLC-3E0 Operating weight kg (lb) 32,550 (71,773) Bucket capacity (cu.yd) 1.2 (1.6) Name of engine Komatsu SAA6D107E-1 diesel engine Rated horsepower of engine kW (HP)/rpm 140 (187) /2,050 Overall length mm (ft in) 9,545 (31' 4") Overall height mm (ft in) 3,230 (10' 7")
Page 295 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC308USLC-3E0 Max. digging reach mm (ft in) 10,210 (33' 6") Max. digging depth mm (ft in) 6,460 (21' 2") Max. digging height mm (ft in) 10,000 (32' 10") Max. vertical wall digging depth mm (ft in) 5,650 (18' 6")
Page 297 6 - 1...
Page 298: Attachments And Options
There may also be problems of the attachment or option hitting the operator's cab. Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu. READ THE INSTRUCTION MANUAL THOROUGHLY Before installing or using any attachment or option, make sure that you thoroughly read and understand the instruction manuals for the machine and the attachment or option.
Page 299: Bucket With Hook
ATTACHMENTS AND OPTIONS BUCKET WITH HOOK BUCKET WITH HOOK HOOK CONDITION Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu distributor. PROHIBITED OPERATIONS Operations with Care When carrying out lifting operations, reduce the engine speed and use the L mode (for fine-control operations).
Page 300: Machine Ready For Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT LOCATIONS Stop valve Lock pin Selector valve Breaker circuit additional oil filter Attachment control pedal Accumulator Stop Valve This valve (1) stops the flow of the hydraulic oil. (a) FREE: Hydraulic oil flows. (b) LOCK: Hydraulic oil stops.
Page 301 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Selector Valve This valve (2) switches the flow of hydraulic oil. It is automatically switched according to the selected working mode. It is necessary to switch the working mode to match the attachment that is installed. For details of switching the working mode, see "HYDRAULIC CIRCUIT (PAGE 6-8)".
Page 302 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Lock Pin This pin (4) locks the control pedal. Position (a): Locked Position (b): Only front of pedal can be operated to full position (rear is locked) Position (c): Both front and rear of pedal can be operated to full position When not using the attachment, set the lock pin to position (a).
Page 303 If the breaker is operated without an accumulator being installed, the life of the machine will be reduced. Please contact your Komatsu distributor if you have questions about the applicable breaker. For details, see "CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker) (PAGE 4-63)".
Page 304: Hydraulic Circuit
When P or E mode is selected: 27.5 MPa (280 kg/cm , 3976 PSI) Depending on the attachment, it may be necessary to adjust the pressure. In this case, please ask your Komatsu distributor to carry out the adjustment. Switching Hydraulic Circuit Depending on the type of attachment, set the working mode on the monitor as follows.
Page 305 3. After removing plug (3), connect the attachment piping (4) is provided by the attachment manufacturer. For the mouthpiece size and accumulator add-on, the action to take differs according to the attachment manufacturer, so please consult your Komatsu distributor. 6 - 9...
Page 306 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Oil Flow Path The direction of operation of the pedal and the path of the oil flow is as shown in the diagram below. When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the rear of the pedal is depressed, oil flows to the piping on the right side of the work equipment.
Page 307 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Replace Additional Breaker Filter Element WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the operation. If compressed air is used, there is danger of dirt flying and causing personal injury.
Page 308 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 4. Set the lock lever to LOCK position (L). 5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit. 6.
Page 309: Attachment Removal And Installation
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT ATTACHMENT REMOVAL AND INSTALLATION Attachment Removal 1. Lower the attachment to the ground and stop the engine. 2. Turn the starting switch to the ON position (B), then set the lock lever to the FREE position (F). 3.
Page 310 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 6. After checking that the hydraulic oil temperature has gone down, set the rotor of the stop valve (installed to the piping for the outlet port and inlet port on the side face of the arm) to LOCK position (b).
Page 311 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Attachment Installation 1. Remove the bucket. For bucket dismounting procedure, see "BUCKET REPLACEMENT AND INVERSION (PAGE 3-121)". 2. Place the attachment in a horizontal position, then install to the arm with pin (A) and then pin (B). 3.
Page 312: Attachment Operations
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT ATTACHMENT OPERATIONS WARNING If the pedal is operated when the auto-deceleration is being actuated and the engine speed has dropped, the engine speed will suddenly rise, so be careful when operating. If you leave your foot resting on the pedal and depress the pedal by mistake, there is danger that the attachment may suddenly move and cause serious personal injury.
Page 313: Long Term Storage
In addition, valves with a safety valve relief set pressure of 24.53 MPa (250 kg/cm , 3550 PSI) and relief valve cracking pressure of 20.11MPa (205 kg/cm , 2911 PSI) are also avilable so please contact your Komatsu distributor. 6 - 17...
Page 314: Attachment Guide
WARNING Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.
Page 315: 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 316 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge.
Page 317 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations 6 - 21...
Page 318 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Extending the bucket cylinder fully and thrusting to raise the machine off the ground Greasing Supply grease in the correct position. NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary.
Page 319: Handling Machines Equipped With Komtrax
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
Page 321: Index
INDEX INDEX <A> DO NOT GET CAUGHT IN WORK AFTER STARTING ENGINE 3- 90 EQUIPMENT 2- 17 AIR CONDITIONER CONTROLS 3- 53 FIRE PREVENTION 2- 14 ASHTRAY 3- 52 PRECAUTIONS BEFORE STARTING ATTACHMENT GUIDE 6- 18 OPERATION 2- 12 AUXILIARY ELECTRIC POWER 3- 65 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...
Page 322 4- 75 RECOMMENDED BRANDS, EVERY 8000 HOURS RECOMMENDED QUALITY FOR MAINTENANCE 4- 77 PRODUCTS OTHER THAN INITIAL 1000 HOURS KOMATSU GENUINE OIL 4- 11 MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) 4- 18 <S> INITIAL 250 HOURS SAFETY MAINTENANCE (ONLY AFTER...
Page 323 INDEX STARTING ENGINE 3- 87 STEERING THE MACHINE 3-106 STOPPING THE ENGINE 3-101 SUN ROOF 3- 42 SWINGING 3-108 SWITCHES 3- 34 <T> TIGHTENING TORQUE LIST 4- 12 TIGHTENING TORQUE SPECIFICATIONS 4- 12 TOOL BOX 3- 67 TRANSPORTATION 3-128 TRANSPORTATION PROCEDURE 3-128 TRAVELING ON SLOPES 3-116...
Page 324 PC308USLC-3E0 HYDRAULIC EXCAVATOR Form No. TEN00501-00...

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