SEAM01 6301

Operation
& Maintenance
Manual

PC200=
HYDRAULIC EXCAVATOR

SERIAL NUMBERS PC200-6 n Cl0001 mdup

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.

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 add improvements at any time without incurring any obligation to install such changes on products sold
previously.

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

February 1998 Copyright 1998 Komatsu Jmerica International Company

1. FOREWORD

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

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

Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.

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

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

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

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

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

O-l
2. SAFETY INFORMATION

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

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

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

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

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

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

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

O-2
3. INTRODUCTION

3.1 INTENDED USE

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

See the section “12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.

3.2 FEATURES

l Wrist control levers make operations smooth and easy.

l Air-conditioned operator’s cab assures comfortable operation.
l Low noise level and smart urban-style design and coloring.
l Superb operating performance provided by powerful engine and high-performance hydraulic
pumps.

3.3 BREAKING IN THE MACHINE

Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.

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

o-3
5. CONTENTS

1. Foreword ............................................................................................................................................ o- 1

2. Safety information ............................................................................................................................ o- 2

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

4. Location of plates, table to enter serial No. and distributor ...................................................... 0- 4

SAFETY

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

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

7.1 Before starting engine ............................................................................................................. I- 9
7.2 After starting engine.. .............................................................................................................. I-II
7.3 Transportation .......................................................................................................................... 1-18
7.4 Battery ....................................................................................................................................... 1-19
7.5 Towing ...................................................................................................................................... 1-21
7.6 Lifting operations ..................................................................................................................... 1-21

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

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

9. Position for attaching safety labels . ... . .. .. . ... . . . ... ... . . .. .. . ... . . ... .. . . ... ... ... . . . ... .. . .. ... .. .. . .. ... . . ... .. . . .. .. . .. .. . . .. 1-31

OPERATION

IO. General view ...................................................................................................................................... 2- 2

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

11. Explanation of components ............................................................................................................. 2- 4

11 .I Machine monitor ...................................................................................................................... 2- 4
11.2 Switches.. .................................................................................................................................. 2- 9
11.3 Control levers and pedals ....................................................................................................... 2-13
11 .4 Ceiling window ........................................................................................................................ 2-18
11.5 Front window ........................................................................................................................... 2-19
11.6 Door lock.. ................................................................................................................................. 2-21
11.7 Ashtray ...................................................................................................................................... 2-21
11.8 Cap, cover with lock.. .............................................................................................................. 2-22
11.9 Cooler ........................................................................................................................................ 2-23
11 .I0 Cassette/Radio .......................................................................................................................... 2-25
11.11 Fuse ........................................................................................................................................... 2-31
11.12 Fusible link ................................................................................................................................ 2-32
11.13 Tool box .................................................................................................................................... 2-32
11 .I4 Grease pump holder ............................................................................................................... 2-32
11.15 Handling accumulator ............................................................................................................. 2-33

o-5
5. CONTENTS

12. Operation ... .. .. . .. . .. .. . . ... . . .. . .. . .. . ... . . .. . . .. . .. . .. .. .. . .. ... . .. . .. .. .. .. .. . .. . . . ... . .. . .. . .. . .. .. .. .. . .... .. . .. .. . .. . .. . . ..................... 2-34
12.1 Check before starting engine ................................................................................................. 2-34
12.2 Starting engine.. ....................................................................................................................... 2-43
12.3 Operations and checks after starting engine.. ...................................................................... 2-45
12.4 Moving machine off ................................................................................................................ 2-47
12.5 Steering machine ..................................................................................................................... 2-50
12.6 Stopping machine.. .................................................................................................................. 2-52
12.7 Swinging ................................................................................................................................... 2-53
12.8 Operation of work equipment ................................................................................................ 2-54
12.9 Prohibitions for operation ....................................................................................................... 2-55
12.10 Precautions for operation ....................................................................................................... 2-57
12.11 Precautions when traveling up or down hills ...................................................................... 2-58
12.12 How to escape from mud ....................................................................................................... 2-60
12.13 Work possible using hydraulic excavator ............................................................................. 2-61
12.14 Replacement and inversion of bucket ................................................................................... 2-62
12.15 Parking machine ...................................................................................................................... 2-64
12.16 Check after finishing work ...................................................................................................... 2-65
12.17 Stopping engine ....................................................................................................................... 2-66
12.18 Check after stopping engine.. ................................................................................................. 2-67
12.19 Locking . .. . . .. .. . .. ... . .. . . .. . . . ... .. . .. . . . .. .. .. .. .. .. . .. . .. . .. . . .. .. . . . .. . . .. . .. . .. ... . . .. .. .. . .. .. . .... . .. .. . .. . .. . . . . ... . . ............... 2-67

13. Transportation ................................................................................................................................... 2-68

13.1 Loading, unloading work ........................................................................................................ 2-68
13.2 Precautions for loading ........................................................................................................... 2-70
13.3 Precautions for transportation.. .............................................................................................. 2-71

14. Cold weather operation .................................................................................................................... 2-72

14.1 Precautions for low temperature ........................................................................................... 2-72
14.2 Precautions after completion of work ................................................................................... 2-74
14.3 After cold weather ................................................................................................................... 2-74

75. Long-term storage ............................................................................................................................. 2-75

15.1 Before storage .......................................................................................................................... 2-75
15.2 During storage ......................................................................................................................... 2-76
15.3 After storage.. ........................................................................................................................... 2-76
15.4 Starting machine after long-term storage ............................................................................ 2-76

16. Troubleshooting ................................................................................................................................. 2-77

16.1 Phenomena that are not failures ........................................................................................... 2-77
16.2 Method of towing machine .................................................................................................... 2-77
16.3 Using method for light-weight towing hole ......................................................................... 2-77
16.4 Precautions on particular jobsites ......................................................................................... 2-78
16.5 If battery is discharged ........................................................................................................... 2-78
16.6 Other trouble ............................................................................................................................ 2-82

O-6
 5. CONTENTS

MAINTENANCE

17. Guides to maintenance . .. .. . .. . . . .. . . . .. . ... .. . .. . . . . .. . .. . .. . . .. . .. . . .. .. . . . ... . . .. .. . . .. . . ... . . .. ... . . .. .. .. .. . .. . .. .. .. . .. . . . .. .. .. ... .. 3- 2

18. Outlines of service . .. . .. .. . . .. . .. . . .. . .. . .. .. . . .. . . . .. . . .. .. . .. . . .. . .. . . .. . . .. .. . . . .. ... . .. . .. .. .. . . .. ... . .. .. .. .. . .. . . .. . .. .. . ... .. . ... . ..... 3- 5

18.1 Outline of oil, fuel, coolant.. ................................................................................................... 3- 5
18.2 Outline of electric system ....................................................................................................... 3- 8
18.3 Outline of hydraulic system ................................................................................................... 3- 9

19. Wear parts list . ... . . .. .. . .. .. . . ... .. . . . . . . .. .. .. . .. . .. .. . .. . . .. . .. . .. . .. . . . .. . .. . ... . .. ... .. .. .. .. . ... . .. .. . .. . ... .. . ... .. .. . .. .. . .. . . ........... 3-10

20. Use of fuel, coolant and lubricants according to ambient temperature ... . ... . .. . . .. .. . .. . .. . .. .. . ... .. . . 3-12

21. Standard tightening torques for bolts and nuts ........................................................................... 3-16
21.1 Introduction of necessary tools .............................................................................................. 3-16
21.2 Torque list ................................................................................................................................. 3-17

22. Periodic replacement of safety critical parts . .. . . ..*......................................................................... 3-18

23. Maintenance schedule chart ............................................................................................................ 3-22

23.1 Maintenance schedule chart ................................................................................................... 3-22
23.2 Maintenance interval when using hydraulic breaker.. ......................................................... 3-24

24. Service Procedure ............................................................................................................................. 3-25

24.1 Initial 250 hours service .......................................................................................................... 3-25
24.2 When required ......................................................................................................................... 3-26
24.3 Check before starting .............................................................................................................. 3-44
24.4 Every 100 hours service .......................................................................................................... 3-49
24.5 Every 250 hours service.. ........................................................................................................ 3-52
24.6 Every 500 hours service .......................................................................................................... 3-58
24.7 Every 1000 hours service ........................................................................................................ 3-63
24.8 Every 2000 hours service ........................................................................................................ 3-66
24.9 Every 4000 hours service ........................................................................................................ 3-69
24.10 Every 5000 hours service ........................................................................................................ 3-70

SPECIFICATIONS

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

o-7
OPTIONS, ATTACHMENTS

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

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

27. Handling bucket with hook .............................................................................................................. 5- 4

27.1 Checking for damage to bucket with hook ........................................................................... 5- 4
27.2 Prohibited operations .............................................................................................................. 5-4
27.3 Precautions during operations ............................................................................................... 5-4

28. Using seat belt .................................................................................................................................. 5-5

28.1 Seat belt .................................................................................................................................... 5- 5

29. Machines ready for attachments ..................................................................................................... 5- 7

29.1 Explanation of components .................................................................................................... 5- 7
29.2 hydraulic circuit ........................................................................................................................ 5- 9
29.3 Attachment mounting/dismounting procedure .................................................................... 5-11
29.4 Operation .................................................................................................................................. 5-13
29.5 Long-term storage ................................................................................................................... 5-14
29.6 Specifications ........................................................................................................................... 5-14

30. Introduction of attachments ............................................................................................................ 5-15

30.1 Specification, use ..................................................................................................................... 5-15
30.2 Attachment installation combination table ........................................................................... 5-16
30.3 Selection of track shoes .......................................................................................................... 5-17
30.4 Selection of bucket teeth ........................................................................................................ 5-18
30.5 Handling rubber pad shoe.. .................................................................................................... 5-19
30.6 Handling trapezoidal bucket ................................................................................................... 5-21
30.7 Handling extension arm .......................................................................................................... 5-22
30.8 Handling clamshell bucket ...................................................................................................... 5-23

31. Extending machine service life ........................................................................................................ 5-24

31 .I Hydraulic breaker ..................................................................................................................... 5-24
31.2 Power ripper ............................................................................................................................. 5-27
31.3 Fork grab ................................................................................................................................... 5-28
31.4 Grapple bucket ......................................................................................................................... 5-29
31.5 Scrap grapple ........................................................................................................................... 5-30
31.6 Crusher & cutter ...................................................................................................................... 5-31
31.7 Hydraulic pile driver ................................................................................................................ 5-32
31.8 Hydraulic excavator with multi-purpose crane .................................................................... 5-33

O-8
 SAFETY

result in serious injury or death.

This safety section also contains precautions for optional equip-

ment and attachments.

l-l
 a WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.

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

l Be sure that all guards and covers are in their proper position. Have guards and covers repaired
if damaged.
l Use safety features such as safety lock levers @ and the seat belt properly.
l Never remove any safety features. Always keep them in good operating condition.
Safety lock lever + See “12.15 PARKlNG MACHINE”.
Seat belt * See “28. USING SEAT BELT”.
l Improper use of safety features could result in serious bodily
injury or death.

AN317008

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

AE305770

UNAUTHORIZED MODIFICATION 1
Any modification made without authorization from Komatsu can create hazards. Before making a
modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or
damage caused by any unauthorized modification.

l-2
A ~$~bl;~~;~~C$rr;~ follow these safety precautions may lead
6. GENERAL PRECAUTIONS

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

l When standing up from the operator’s seat, always place the safety lock levers @ securely in the
LOCK position. If you accidentally touch the levers when they are not locked, the work equipment
may suddenly move and cause serious injury or damage.
l When leaving the machine, lower the blade and ripper completely to the ground, set the safety
lock levers @I to the LOCK position, then stop the engine. Use the key to lock all the equipment.
Always remove the key and take it with you.
Work equipment posture + See “12.15 PARKING MACHINE”.
Locking * See “12.19 LOCKING”

AN317008

-I MOUNTING AND DISMOUNTING 1

Never jump on or off the machine. Never get on or off a moving machine.
When getting on or off the machine, always face the machine and use the handrails and steps.
Never hold any control levers or lock levers when getting on or off the machine.
To ensure safety, always maintain three-point contact (both feet and one hand, or both hands and
one foot) with the handrails and steps to ensure that you support yourself.
If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose bolts.
When getting on or off the machine, or when moving along the top of the track, if you hold the
handrail inside the door when moving on top of the track shoe, and the door lock is not locked
securely, the door may move and cause you to fall.
Always lock the door securely.
Method of locking door + See “11.6 DOOR LOCK”.

AL187320

l-3
 a WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.

FIRE PREVENTION FOR FUEL AND OIL

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

M”5QlXl AOiX5030 Aoffi5040

1
PRECAUTIONS WHEN HANDUNG AT HIGH TEMPERATURE
Immediately after operations are stopped, the engine oil and hydraulic oil are at high temperature
and are stili under pressure. Attempting to remove the cap, drain the oil or water, or replace the
filters may lead to serious burns. Always wait for the temperature to go down, and follow the
specified procedures when carrying out these operations.

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

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

l-4
& ~~RJW&~~$I~~&I follow these safety precautions may lead
6. GENERAL PRECAUTIONS

ASBESTOS DUST HAZARD PREVENTlON

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

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

A0066090

1
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any injury or fire should occur.
Be’sure that fire.extinguishers have been .provided and read the labels to ensure that you know
how to use them.
Provide a first aid kit at the storage point. Carry out periodic checks and add to the contents if
necessary.
Know what to do in the event of a fire or injury.
Decide the phone numbers of persons (doctor, ambulance, fire station, etc.) to contact in case of
an emergency. Post these contact numbers in specified places and make sure that all personnel
know the numbers and correct contact procedures.

A0055070
J

l-5
 a WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.

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

l For work with breakers, install a front guard on the windshield. Also, place a laminate coating
sheet over the windshield.

l For demolition or shear work, install a front guard on the windshield and a top guard on the
cab. Also, place a laminate coating sheet over the windshield.

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

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

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

Be sure to close the front window before commencing work.

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

Front guard (half)

AB300508 A8300528

:ront guard (fu

Front guard

1-6
a gJ;bl;~(gFa;;a;;; follow these safety precautions may lead
6. GENERAL PRECAUTIONS

1 PRECAUTIONS FOR AlTACHMENTS 1

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

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

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

MACHINES WITH ACCUMULATOR

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

When releasing the pressure inside the work equipment circuit on machines equipped with an
accumulator, follow the procedure given in the inspection and maintenance section.
Method of releasing pressure + See “11.15 HANDLING ACCUMULATOR”.

The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is
handled in the wrong way. Always observe the following precautions.
l Never make any hole in the accumulator or expose it to flame or fire.
l Do not weld any boss to the accumulator.
l When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, it is necessary to release the gas from the accumulator. A special air bleed valve is
necessary for this operation, so please contact your Komatsu distributor.
Gas in accumulator + See “11.15’ HANDLING ACCUMULATOR”.

AN3 I7008

l-7
 g Ef;;;;;e Fc;sreasons cf safety, always
6. GENERAL PRECAUTIONS ty precautrons.

VENTILATION FOR ENCLOSED AREAS

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

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

-j PRECAUTIONS WITH CAB GLASS 1

If by mistake the cab glass on the work equipment side should crack, there is danger of direct contact
between the operator’s body and the work equipment. This is extremely dangerous.
If the glass is cracked, stop operations immediately and replace the glass.

EMERGENCY EXIT FROM OPERATORS CAB 1

l If it should become impossible to open the cab door, open the rear window and use it as an
emergency escape.

l Remove the rear window as follows.

1. Pull ring @ and completely remove seal @ from the window
frame rubber.
2. Push the corner of the rear window glass strongly to push it out
and make it possible to remove.

l Remove the rear window only when it is being used as an

emergency escape.

AE300540

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

7.1 BEFORE STARTING ENGINE

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

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

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

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

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

Check the ground condition and the depth and flow of water before operating in water or crossing
a river. NEVER be in water which is in excess of the permissible water depth.
Permissible water depth + See “12.10 PRECAUTIONS POR OPERATION”.

AN112960

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

l Check the coolant level, fuel level, and oil level in the hydraulic tank, check for clogging of the air
cleaner, and check the electric wiring.
Checks before starting + See “12.1.2 CHECK BEFORE STARTING”.
l Adjust the operator’s seat to a position where it is easy to carry out operations, and check for wear
or damage to the seat belt and seat belt mounting equipment.
Adjusting operator’s seat + See “12.1.3 ADJUSTING SEAT POSITION”.
Seat belt + See “28. USING SEAT BELT”.
l Check that the gauges work properly, and check that the control levers are all at the NEUTRAL
position.
Method of checking operation of gauges -
See “12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE”.
l Check that the mirrors and window glass provide a clear view.
If the above inspections show any abnormality, carry out repairs immediately.

1-9
 A WARNING: For reasons of safety, always
7. PRECAUTIONS DURING OPERATION follow these safety precautions.

WHEN STARTING ENGINE

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

DO NOT operate
whenthis plate is not being used
keep it in the storage compartment.
03663-03000 J AE305910

I-10
A ~~IWWA~; FaiJai;o follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION

7.2 AFTER STARTING ENGINE

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

PRECAUTIONS WHEN STARTING OFF

I Check the direction of the track frame before operating the travel
lever.
When the sprocket is at the front, the operation of the travel
Travel in reverse direction

lever is reversed, so operate the machine carefully.

Method of steering machine -) See “12.4 MOVING MACHINE
OFF”.
Before moving the machine off, check again that there are no
persons or obstacles in the surrounding area.
When moving the machine off, sound the horn to warn people Sprbcket
AN112970
in the surrounding area.
Always sit in the operator’s seat when driving the machine.
Fasten your seat belt securely.
The operator must not let any other person sit anywhere except
in the assistant’s seat.
Check that the travel alarm (option) works properly.
Always close the door of the operator’s cab and check that the
door is locked in position securely.
AE2.05800

CHECK WHEN CHANGING DIRECTION 1

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

A0067190
I A0067200

I-II
 a )WiM;;;?ije fbbereasons qf safety, always
7. PRECAUTIONS DURING OPERATION ty precautions.

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

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

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

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

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

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

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

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

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

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

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

Permissible water depth + See “12.10 PRECAUTIONS FOR OPERATION”.

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

Travel posture INCORRECT

t40-50cm AM089000
(16-20in) AM089010

1-12
A E;lV.l;E;l; Pa$~e&o follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION

Traveling on slopes could result in the machine tipping over or slipping to the side.
When traveling on slopes, keep the blade approximately 20 - 30 cm (8 - 12 in) above the ground.
In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these
operations.
Method of traveling on slopes -) See “12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN
HILLS”.
Do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes may cause the machine
to slip to the side, so travel at low speed and make sure that the machine is always traveling
directly up or down the slope.
If the engine stops on a slope, place the travel lever at the neutral position and lower the bucket
to the ground. Do not operate the steering. There is danger that the machine will turn under its
own weight.

CORRECT
INCORRECT

AN112980 AN113COO

1 PROHIBITED OPERATlONS 1
Do not dig the work face under an overhang. This may cause the overhang to collapse and fall
on top of the machine.
Do not carry out deep digging under the front of the machine. The ground under the machine may
collapse and cause the machine to fall. Take emergencies into consideration and set with the travel
motor at the rear and the track (undercarriage) at right angles to the road shoulder before digging
to enable the machine to move back quickly. If the ground under the machine collapses and there
is no time to drive in reverse, do not suddenly raise the arm and boom. In some cases, it may
in fact be safer to lower the arm and boom.
Do not swing the work equipment to the side when it is carrying a heavy load. The stability to
the side is less than the stability to the front, so there is danger that the machine may turn over.
Limits on use
To prevent accidents caused by breakage of the work equipment or tipping over of the machine
under excessive load, do not use the machine in excess of its capacity. Always be sure to keep
within the maximum specified load and safe angle determined for the structure.

INCORRECT I

I-13
 a LV~J$J;;~;e~;ereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautrons.

PRECAUTIONS WHEN OPERATING

l Be careful not to approach too close to the edge of cliffs.
l Carry out only work that is specified as the purpose of the machine.
Carrying out other operations will cause breakdowns.
Specified operations + See “12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR”.
l Do the following to ensure good visibility.
l When operating in dark places, turn on the working lamps and front lamps, and install lighting
at the jobsite if necessary.
l Do not carry out operations in fog, mist, snow, or heavy rain, or other conditions where the
visibility is poor. Wait for the weather to clear so that visibility is sufficient to carry out work.
l Always do as follows to prevent the work equipment from hitting other objects.
When operating in tunnels, under bridges, under electric wires, or other places where the height
is limited, be extremely careful not to let the bucket, boom, or arm hit anything.
To prevent accidents caused by hitting other objects, always operate the machine at a speed
which is safe for operation, particularly in confined spaces, indoors, and in places where there
are other machines.
Never pass the bucket over the head of any worker or over the operator’s cab on a dump truck.

AE305810

1-14
A ~~~FJ~~~;~~~e follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION

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

Voltage Min. safety distance

3% 100 l 200 v 2m
2% 2m
> 6,600 v
22,000 v 3m
8
z 66,000 v 4m
2 154,000 v 5m
t

OPERATE CAREFULLY ON SNOW }

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

I-15
 g LV;;F$-dge Fooereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautions.

WORKING ON LOOSE GROUND

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

PRECAUTIONS WHEN WORKING ON SLOPES 1

l When working on slopes, there is danger that the machine may lose its balance and turn over
when the swing or work equipment are operated. Always carry out these operations carefully.
l Do not swing the work equipment from the uphill side to the downhill side when the bucket is
loaded. This operation is dangerous.
l If the machine has to be used on a slope, pile the soil to make a platform that will keep the machine
as horizontal as possible.
Piled soil on slope + See “12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS”.

INCORRECT CORRECT

AN113040 iN113050

1-16
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS DURING OPERATION

PARKING MACHINE
Park the machine on level ground where there is no danger of falling rocks or landslides, or of
flooding if the land is low, and lower the work equipment to the ground.
If it is necessary to park the machine on a slope, set blocks under the tracks to prevent the machine
from moving, then dig the work equipment into the ground.
After stopping the engine, operate the right work equipment control lever several times to the
RAISE and LOWER positions to release the remaining pressure in the hydraulic circuit.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other
necessary signs to ensure that passing traffic can see the machine clearly, and park the machine
so that the machine, flags, and fences do not obstruct traffic.
Parking procedure -, See “12.15 PARKING MACHINE”.
When leaving the machine, set the safety lock lever @ to the LOCK position, stop the engine, and
use the key to lock all the equipment. Always remove the key and take it with you.
Work equipment posture -+ See “12.15 PARKING MACHINE”.
Locks -) See “12.19 LOCKING”.
Always close the door of the operator’s compartment.

CORRECT

Thrust the bucket

-I PRECAUTIONS IN COLD AREAS 1

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

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

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

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

AU05820

1-17
 e ~;.X;N.?sze Foiereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautions.

7.3 TRANSPORTATION
PRECAUTIONS FOR TRANSPORTATION
1
When transporting the machine, followthe relevant rules and regulations, and take steps to ensure
safety.

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

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

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

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

1-18
a kV;RsM~G; f%iJ%i;o follow these safety precautions may lead
7. PRECAUTIONSDURING OPERATION

7.4 BATTERY

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

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

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

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

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

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

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

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

When removing or installing, check which is the positive @ terminal and negative 0 terminal, and
tighten t.he nuts securely.
If the battery electrolyte is near the LOWER LEVEL, add distilled water. Do not add distilled water
above the UPPER LEVEL.

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

Tighten the battery caps securely.

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

Always remove the battery from the chassis before charging it.

@fJ &
AE305830 A00551 10

1-19
 a )V$;:@Jf;e Foiereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautrons.

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

When starting from another machine, do not allow the two machines to touch.

When connecting the booster cables, turn the starting switch OFF for both the normal machine
and problem machine.

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

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

When removing the booster cables, be careful not to let the booster cable clips touch each other
or to let the clips touch the machine.
INCORRECT

9 n

v A0067320

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

INCORRECT

A0055110

I-20
a r;;bl;W& z;$;o follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION

7.5 TOWING
1 WHEN TOWING 1
Injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in
the selection of the wire rope, so always do as follows.

Do not tow in a different way from the method given in the section “16.2 METHOD OF TOWING
MACHINE”.

Always wear leather gloves when handling wire rope.

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

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

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

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

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

7.6 LIFTING OPERATIONS

Do not use the work equipment to carry out lifting operations.

In particular, do not do the following.
l Do not weld a hook to the bucket to lift a load.

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

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

1-21
8. PRECAUTIONS FOR A )%$..;;FEe;;ereasons of safety, always
MAINTENANCE ty precautrons.

8.1 BEFORE CARRYING OUT MAINTENANCE

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

WARNING TAG
ALWAYS attach the “DO NOT OPERATE” warning tag to the work equipment control lever in the
operator’s cab to alert others that you are workingonthe machine. Attach additional warning tags
1
around the machine if necessary.

If others start the engine, or touch or operate the work equipment control lever while you are
performing service or maintenance, you could suffer serious injury or death.

Warning tag Part No. 09963-03000

DO NOT operate
When this plate is not being used
keep it in the storage compartment.
AE305910
c9s63-03000J

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

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

When washing the machine, always do as follows.

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

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

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

A0055150 AE305820

l-22
g ElfVJFJ;G; ;;$~o follow these safety precautions may lead
8. PRECAUTIONS FOR MAINTENANCE

KEEP WORK PLAC

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

APPOINT LEADER; WHE

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

RADIATOR WATER LEVEL 1

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

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND

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

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

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

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

AM089160
AD314048 AN31700B

l-23
 g )W;WeGs:, Fo;, reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE ty precautions.

1 SAFETY DEVICES FOR WORK EQUIPMENT ]

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

AN317008 A0055140

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

Hoses and other parts of the fuel, hydraulic, and brake system are critical parts for ensuring safety,
so they must be replaced periodically.
Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry
out replacement.
l Replace these components periodically with new ones, regardless of whether or not they appear
to be defective.
These components deteriorate over time, and can cause fire because of oil leakage or failure in
the work equipment system.
l Replace or repair any such components if any defect is found, even though they have not reached
the time specified.
Replacement of safety critical parts +
See “22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS”.

l-24
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE

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

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

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

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

A0055160

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

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

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

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

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

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

l-25
 g w$;F$J;;GszeFo;, reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE ty prscautrons.

8.2 DURING MAINTENANCE

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

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

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

l Place attachments that have been removed from the machine

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

a
A0055130

WORK UNDER THE MACHINE

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

Always block the track shoes securely.

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

shoes are off the ground and the machine is supported only by
the work equipment. Never work under the machine if the
machine is poorly supported.
A0055140

WORK ON TOP 0
When carrying out maintenance on top of the machine, make sure that the footholds are clean
and free of obstructions, and follow the precautions below to prevent yourself from falling.
l Do not spill oil or grease.
l Do not leave tools lying around.
l Mind your step when you are walking.

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

Use protective equipment if necessary.

1-26
a E$fX;;z:; FsiJsi;o follow these safety precautions may lead
8. PRECAUTIONS FOR MAINTENANCE

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

MAINTENANCE WITH ENGINE RUNNING

1
To prevent injury, do not carry out maintenance with the engine running. If maintenance must be
carried out with the engine running, carry out the operation with at least two workers and do as
follows.
One worker must always sit in the operator’s seat and be ready to stop the engine at any time.
All workers must maintain contact with the other workers.

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

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

Do not touch any control levers. If any control lever must be operated, always give a signal to the
other workers to warn them to move to a safe place.

Never touch the fan blade or fan belt with any tool or any part of your body. There is danger of
serious injury.

A0055210 AN317008

--/ DO NOT DROP TOOLS OR PARTS INSIDE MACHINE 1

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

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

PRECAUTIONS WHEN USING HAMMER 1

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

~ AE305880

1-27
 g ~P&N$a Fo;k reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE ty precautions.

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

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

AE305.390

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

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

IRULES1
If any flame is brought close to fuel or oil, there is danger that it will catch fire, so always follow the
precautions below.
l Stop the engine when adding fuel or oil.
l Do not smoke.
l Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
l Always tighten the cap of the fuel and oil fillers securely.
l Always add fuel and oil in a well-ventilated place.

A0055020 A0055030 A0055040

l-28
A ~$;M;.l; Fsi;sito follow these safety precautions may lead
8. PRECAUTIONS FOR MAINTENANCE

WHEN USING HIGH-PRESSURE GREASE TO

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

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

Never put your face, hands, feet, or any other part of your body directly in front of any grease
drain valve.
Adjusting track tension -) See “24.2 WHEN REQUIRED”.

A0055200

HANDLING HIGH-PRESSURE HOSES 1

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

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

PRECAUTIONS WlTH HIGH-PRESSURE OIL

When inspecting or replacing high-pressure piping or hoses, always check that the pressure in the
hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury
or damage, so always do as follows.
l For details of the method of releasing the pressure, see “8.1 BEFORE CARRYING OUT MAINTE-
NANCE, STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE”. Never carry
out inspection or replacement before releasing the pressure completely.

l Wear safety glasses and leather gloves.

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

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

lNCORREgp CORREC;_

A0055180 A0055190
 a ~~/~~~~e Fciereasons cf safety, always
8. PRECAUTIONS FOR MAINTENANCE ty precautrons.

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT

HIGH TEMPERATURE
Immediately after stopping operations, the engine coolant, oil at all parts, the exhaust manifold, and
the muffler are at high temperature.
In this condition, if the cap is removed, or the oil is drained, or the filters are replaced, this may result
in burns or other injury. Wait for the temperature to go down, then carry out the inspection and
maintenance in accordance with the procedures given in this manual.
Cleaning inside of cooling system + See “24.2 WHEN REQUIRED”.
Checking coolant level, oil level in hydraulic tank + see “24.3 CHECK BEFORE STARTING”.
Checking lubricating oil level, adding oil -) see “24.3-7 PERIODIC MAINTENANCE”.
Changing oil, replacing filters + see “24.5-10 PERIODIC MAINTENANCE”.

r failure to check the function of various

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

Checks when engine is running

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

Do the inspection and maintenance locations work normally?

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

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

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

Obey appropriate laws and regulations when disposing of

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

I-30
9. POSITION FOR ATTACHING SAFETY LABELS

Always keep these labels clean. If they are lost or damage, attach them again or replace them with
a new label.
There are other labels in addition to the safety labels listed as follows, so handle them in the same
way.
Safety labels may be available in languages other than English. To find out what labels are available,
contact your Komatsu distributor.

POSITION FOR ATTACHING SAFETY LABELS

AN325350

AN325360

1-31
9. POSITION FOR ATTACHING SAFETY LABELS

1. Warnings for leaving operator’s seat 3. Warnings for operation, inspection and
(203-00-61270) maintenance
(14X-98-l 1580)

g, WARNING
A WARNING
To avoid hitting unlocked operation levers,
lower equipment to ground and move
SAFETY LOCK LEVER (located near seat) to Improper operation and
LOCK position before standing up from
maintenance can cause
operator’s seat.
serious injury or death.
Sudden and unwanted machine movement
can cause serious injury or death.
Read manual and labels
203-00-61270 d before operation and
maintenance.
Follow instructions
and warnings in manual and
in labels on machine.

Keep manual in machine cab

near operator.
Contact Komatsu distributor
for a replacement manual.

14X-98-11580 -

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

(203-00-61291) (203-00-61310)

A WARNING g, DANGER

Hazardous voltage hazard.

To prevent SEVERE INJURY or DEATH. Serious injury or death can occur if
Do the following before moving machine machine or attachments are not kept
or its attachments: safe distance away from electric lines.
l Honk horn to alert people nearby.
l Be sure no one is on or near machine
or in swing area.
l Rotate cab for full view of travel path
if it can be done safely.
l Use spotter if view is obstructed. . 203-OO-613101

Follow above even if machine equipped

with travel alarm and mirrors.

- 203-00-61291 -

l-32
 9. POSITION FORATTACHING SAFETYLABELS

5. Warnings when adjusting track tension 7. Warnings for handling accumulator

(14x-9&11551) (14X-98-1 1390)

g, WARNING pp=.

High pressure hazard at track

adjuster.

When adjusting track tension,

never open plug more than one
turn.
Turning further could cause injury
from flying plug and grease.

See manual for adjustment

instructions.
14X-98-11551-

6. Warnings for hot oil 8. Keep off swing area

(203-00-61260) (2OY-00-21270)

HYDRAULIC
OIL
Keep off swing area
a WARNING
Hot oil hazard

To prevent hot oil from spurting out:

l Turn engine off.

l Allow oil to cool.
+ Slowly loosen cap to relieve pressure
before removing.

203-00-61260

l-33
9. POSITION FOR AlTACHlNG SAFETY LABELS

9. Warnings for hot water (14X-98-11531)

A WARNING
Hot water hazard.

To prevent hot water from

spurting out:
l Turn engine off.

l Allow water to cool.

l Slowly loosen cap to

relieve pressure
before removing.

14X-98-1 1531-

10. Warnings when opening front window

(203-00-61280)

g WARNING

l-34
OPERATION

2-l
 IO. GENERAL VIEW

10.1 GENERAL VIEW OF MACHINE

If directions are indicated in this section, they refer to the directions shown by the arrows in the
diagram below.

Boom
Arm CYI inder
\ I Boom cylinder

Rear
G;I

Bucket cylinder

Sprocket

\
\ Track shoe __..
Bucket
Fran;_‘ \
Idler

AE30059B

2-2
 10. GENERAL VIEW

10.2 GENERAL VIEW OF CONTROLS AND GAUGES

Travel lever

Horn switch
Left work equipment
Right work equipment
control lever
Safety lock lev\er

Monitor panel
Tra vel speed switch

SW ine lock switch,

Fuel control lever
Winer switch

Casset te/Radio

w ‘Starting switch

AE335156

Service Engine water Fuel Lam0

.I *
meter temperature gauge gauge swi rcn

Ens i ne oil Charge Swing lock

Pressur e monitor monitor monitor monitor

AD332038
1
2-3
11. EXPLANATION OF COMPONENTS

The following is an explanation of the devices needed for

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

11 .I MACHINE MONITOR

AN166950

NOTICE
When carrying out checks before starting, do not simply rely on
the monitor. Always refer to the periodic maintenance items or “12.
OPERATION” to carry out the checks.

2-4
 11. EXPLANATION OF COMPONENTS

A. CAUTION ITEMS (11.1.1)

I A CAUTlON -1
If these monitor items flash, check and repair the appropriate
location as soon as possible.

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

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

B. EMERGENCY STOP ITEMS (11.1.2)

A CAUTlON ,

lf these monitor items flash, stop operations immediately,

then check and repair the appropriate location.

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

running. If any abnormality occurs, items which need to be repaired
immediately are displayed.
If there is any abnormality, the appropriate monitor lamp will flash
to indicate the location of the abnormality and the buzzer will sound.

C. METER DISPLAY PORTlON (11.1.3)

This portion consists of pre-heating monitor, swing lock monitor,
service meter, engine water temperature gauge and fuel gauge.

2-5
 11. EXPLANATION OF COMPONENTS

I \\
AN166960

12.1.1 A: CAUTION ITEMS

If the caution monitor lamp flashes, repair the problem as soon

as possible.

1. CHARGE LEVEL
This monitor indicates an abnormality -in the charging system
while the engine is running.
If the monitor lamp flashes, check. the V-belt tension. If any
abnormality is found, see “16.6 OTHER TROUBLE”.

A0120660

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

2-6
 11. EXPLANATION OF COMPONENTS

11.1.2 B: EMERGENCY STOP ITEMS

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

/AcAumoNI
idling, and take the following action.

1. ENGINE OIL PRESSURE

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

REMARK
While the starting switch is ON, the lamp remains lit and goes
off once the engine is started. When the engine starts, the buzzer
A0120700
may sound for a short time, however, this does not indicate a fault.

11.1.3 C: METER DISPLAY PORTION

1. ENGINE PRE-HEATING MONITOR
This monitor lamp indicates the pre-heating time required when
starting the engine at an ambient temperature below 0°C.
The monitor lamp lights when the starting switch is turned to
HEAT position and flashes after about 30 seconds to show that the
pre-heating is completed. (The monitor lamp will go off after about
IO seconds.)
A0120710

2. SWING LOCK MONITOR

This 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.

REMARK 6”
A disc brake is installed in.the swing motor to mechanically stop
A0120720
motor rotation. i
The brake is always applied while the swing lock is actuated.

2-7
11. EXPLANATION OF COMPONENTS

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

While the engine is running, operation display @ at the top inside

of the meter will light to show that the meter is advancing.
AN106190

The meter will advance by 1 for each hour of operation regardless

of the engine speed.

4. ENGINE WATER TEMPERATURE GAUGE

This displays the engine cooling water temperature. During
normal operation, the lamp should light up in the green range. Red
If the lamp in the red range lights up during operation, run the H
engine at low idling and wait for the temperature to go down to the
green range.
After starting the engine, warm up it until the green range lights G r e&
up. AN106200

5. FUEL GAUGE
This shows the fuel level in the fuel tank. During normal opera-
tion, the lamp should light up in the green range.
If the lamp in the red range flashes during operation, there is less
than 45 liters (11.9 US gal, 9.9 UK gal) of fuel remaining, so check
and add fuel.
The correct level may not be displayed for a short time after the
starting switch is turned to the ON position, but this is not an
AN106210
abnormality.

2-8
 11. EXPLANATION OF COMPONENTS

11.2 SWITCHES

AE335160

1. STARTING SWITCH
This switch is used to start or stop the engine.

OFF position
The key can be inserted or withdrawn. Except for the cab lamp, the
switches for the electric system are all turned off.

ON position
Electric current flows in the charging and lamp circuits.
Keep the starting switch key at the ON position while the engine is
running.
AM089390

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

HEAT (preheat) position

When starting the engine in winter, set the key to this position. When
the key is set to the HEAT position, the pre-heating monitor lights
up. Keep the key at this position until the monitor lamp flashes.
Immediately after the pre-heating monitor flashes, release the key.
The key automatically returns to the OFF position. Then, start the
engine by turning the key to the START position.

2-9
 11. EXPLANATION OF COMPONENTS

2. TRAVEL SPEED SWlTCH

r------a WARNING p
HIGH
If the Hi-Lo switch is operated when the machine is traveling,
the machine may deviate even when traveling in a straight line.
To prevent this, always stop the machine before operating the
travel speed switch.

This is used to select the two travel speeds.

Lo: Low speed travel
Hi: High speed travel

3. SWING LOCK SWITCH

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

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

even if the swing lock switch is located at the ON position.
Be careful concerning this point.
1
This switch is used to lock the upper structure so that it cannot
swing.
ON position (actuated):
The swing lock is always applied, and the upper structure will not
swing even if the swing is operated. In this condition, the swing lock
lamp lights up. -
AM101430
OFF position (canceled):
The swing lock is canceled, and the upper structure will swing
when the swing lever is operated.

4. WIPER SWITCH
This switch actuates the front window wiper.
0 OFF: The wiper stops.
0 ON: The wiper moves continuously.
. 0 Window washer fluid is sprayed out: When the switch is re-
leased, it returns to 0.
0 Window washer fluid is sprayed out: When the switch is re-
leased, it returns to 0.
Ah4106230

2-10
 11. EXPLANATION OF COMPONENTS

5. LAMP SWITCH
This lights up the head lamps and the panel lamp.
Position 1: Panel lamp lights up.
Position 2: Head lamps and panel lamp light up.
Position OFF: Lamps go off. e
I

0
AM166970

2-11
 11. EXPLANATION OF COMPONENTS

AE335170 AE331070

6. HORN BUTTON I
When the button at the tip of the right work equipment control
lever is pressed, the horn will sound.

7. CAB LAMP SWITCH

This lights up the cab lamp.
ON position: Lights up
The cab lamp can be turned on even when the starting switch
is at the OFF position, so be careful not to leave it on by mistake. ON

I
OFF
AM101530

8. SHIFT DOWN FOOT SWITCH

If this switch is pressed, the travel speed is set low, even if travel
speed switch @ is at the Hi position (priority is given to the shift
down foot switch).
Use this switch when it is difficult to operate travel speed switch
@ by hand or when more power is needed to remove the machine
from soft ground.

2-12
 11. EXPLANATION OF COMPONENTS

11.3 CONTROL LEVERS AND PEDALS

AE335190

1. LOCK LEVER (FOR LEFT AND RIGHT WORK EQUIPMENT

LEVERS AND TRAVEL LEVERS)

ya WARNING
When leaving the operator’s compartment, set the safety
lever securely to the LOCK position. If the gear shift lever is
not locked, and it is touched by mistake, this may lead to a
serious accident.
lf the safety lever is not placed securely in the LOCK position,
the control lever may not be properly locked.
Check that the situation is as shown in the diagram.

a WARNING
l When pulling the lock lever up, be careful not to touch the
work equipment control lever. If the lock lever is not pulled
up fully, there is danger that the work equipment or swing
may move.

2-13
11. EXPLANATION OF COMPONENTS

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

This lever locks the work equipment control and swing systems. Free
When the lever is pulled up, the lever is locked.
,4iw70aa
This lock lever is a hydraulic lock, so even if it is in the lock
position, the work equipment control lever will move, but the work
equipment, travel motor, and swing motor will not work.

2. LEFT WORK EQUIPMENT CONTROL LEVER

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

3. RIGHT WORK EQUIPMENT CONTROL LEVER

This lever is used to operate the boom and bucket.
Boom operation Bucket operation
@ RAISE @ DUMP
@ LOWER @ CURL
N (Neutral)
When the lever in this position, the boom and the bucket will be
retained in the position in which they stop. AN106300

2-14
 71. EXPLANATION OF COMPONENTS

4. FUEL CONTROL LEVER

This lever is used to control the engine speed and output.
@ Engine stopping position: Push the lever in and forward
fully.
@ Low idling position: Pull the lever back from the
above position @I until the oper-
ating effort becomes light.
@ Full speed position: Pull the lever back fully from the
position of @ above.
Track frame facing front
5. TRAVEL LEVERS (WITH PEDAL)

A WARNING 1
Do not put your foot on the pedal unless the machine is
traveling. lf you leave your foot on the pedal and press it by
mistake, the machine will move suddenly, and this may lead
to a serious accident. Sprocket
AN112730

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

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

( 1: This indicates operation of the pedal.

REMARK
Machines equipped with travel alarm
If the lever is shifted to the advance or reverse position from the
neutral position, the alarm sounds to warn that the machine is
starting to advance.

2-15
11. EXPLANATION OF COMPONENTS

6. ATTACHMENT CONTROL PEDAL

a WARNING
l Be careful when operating the pedal in the deceleration
range. The engine speed will rise suddenly.
l Do not put your foot on the pedal except when operating the
pedal. tf resting your foot on the pedal during operations, and
it is depressed by accident, the attachment may move sud-
denly and cause serious damage or injury.

When breaker is installed

r
Never operate the breaker with the lock pin position @ (full
affect badly to the ma-
chine and breaker in durability.

l When the front part of the pedal is depressed, the breaker is

actuated.
l The lock pin actuates locking at 0. Position @ is the pedal half
stroke position and position @ is the pedal full stroke position.
l Use the lock pin at the position 0.
AN113340

When general attachment is installed

l When the pedal is depressed, the attachment is actuated.
l The lock pin actuates locking at 0. Position @ is the pedal half
stroke position and position @ is the pedal full stroke position.

2-16
 11. EXPLANATION OF COMPONENTS

HYDRAULIC OIL FLOW

When the front part of the pedal is depressed, the hydraulic oil
flows into the left-hand work equipment piping, and, when the rear
part of the pedal is depressed, the oil flows into the right-hand work
equipment piping. (When equipped with breaker, depress only the
front part of the pedal.)

” FY AN113360

7. SELECTOR VALVES FOR BREAKER AND GENERAL

AlTACHMENT (crusher etc.)

A WARNING
Do not touch the relief valve.

When using the breaker and general attachment (crusher etc.),

turn the rotors of 3-way valves 0 and @ to change them over
according to the following illustration.
(The arrow marks indicating the port direction are stamped on the
3-way valve heads.)

Attachments Left 3-way valve @ Right 3-way valve @

Forward direction Upper direction

of machine of machine
Breaker etc.

Q @

Forward direction Upper direction

of machine of machine
Crusher etc.

NOTICE
Perform work only after the engine is stopped and the work
equipment and machine body are in a stable posture on the ground.

REMARK
For details, see “30. MACHINES READY FOR ATTACHMENTS”.

2-17
11. EXPLANATION OF COMPONENTS

11.4 CEILING WINDOW

A WARNING
When leaving the operator’s compartment, set the safety lock
lever securely to the LOCK position.
If the control levers are not locked, and they are touched by
mistake, this may lead to a serious accident.

Free

AN31708B

When opening
1. Lock the safety lock lever securely.
2. Check for any ceiling window movement by pulling lock @
located on both sides, then push up and open the ceiling window
grasping grip 0.

When closing
Close the ceiling window grasping grip @ and lock it with lock 0.
If the lock cannot be applied, open and close the ceiling window
cB49 AN113390

again.

2-18
 11. EXPLANATION OF COMPONENTS

11.5 FRONT WINDOW

both hands and pull up. If you use only one hand, your hand may

It is possible to store (pull up) the front window (top) in the roof
AM101680
of the operator’s compartment.

When opening

A WARNING
When the front window is open, there is danger that it will fall,
so always lock it with left and right lock pins @.

Stop the machine on fiat ground, lower the work equipment to

the ground, and stop the engine.

Set the lock lever for the work equipment control levers securely
to the LOCK position.

Disconnect the wiring for the wiper motor from socket @I.

NOTICE ~
If it is attempted to open the front window without disconnect-
ing the wiring, the wiring will be torn off.

AL067750

4. Pull lock pins @ at the top left and right sides of the front window 1
to the inside to release the lock.

AM101710
,

2-19
11. EXPLANATION OF COMPONENTS

5. From the inside of the operator’s cab, hold the bottom grip with I
the left hand and the top grip with the right hand, pull up the
window, and push it in fully until it is locked by catch 0.

AM101720

I
6. Lock with lock pins @ on the left and right sides.

When closing

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

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

2. Securely lock the safety lock lever.

3. Release the lock pin @.

4. Hold the grip at the bottom of the front window with your left
hand and the grip at the top with your right hand, release the lock
of catch .@ with your right thumb, then pull the top grip slowly
and lower the front window. When releasing the lock of catch 0,
push release lever @I in the direction of the arrow to release the
lock.

AM101750

2-20
 11. EXPLANATION OF COMPONENTS

5. Lock securely with lock pins @ at the left and right sides.

6. Connect the wiper motor wiring to socket @I.

Removing front window (bottom)

With the front window open, remove lock pins 0, and the
bottom part of the front window can be removed.

Store the removed bottom part of the front window at the rear
of the opertor’s cab and lock with lock pins 0.

11.6 DOOR LOCK

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

1. The door will become fixed in place when it is pressed against

catch 0.

2. To release the lock, press knob @ down at the left side of the
operator’s seat to release the catch.
AN113460
When fixing the door, fix it firmly to the catch.

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

2-21
11. EXPLANATION OF COMPONENTS

11.8 CAP, COVER WITH LOCK

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

11.8.1 METHOD OF OPENING AND CLOSING CAP

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

A0131950

To lock the cap

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

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

AL067870

11.8.2 METHOD OF OPENING AND CLOSING COVER

WITH LOCK (cover with lock)
To open the cover (locked cover)
1. insert the key.
2. Turn it counterclockwise and open the cover by pulling the cover
grip.

To lock the cover

1. Close the cover and insert the key.
2. Turn the key clockwise and take the key out.

2-22
 11. EXPLANATION OF COMPONENTS

11.9 COOLER

11.9.1 HANDLING COOLER

A0332080 / AE331880
I.

1. Temperature control switch

This switch can be adjusted between low temperature and
normal temperature.

Purpose Setting to low temperature Setting to normal temperature

Switch @j $J
position

COOL COOL
AD332090 AD332100

The further the switch is moved to clockwise, the low

temperature; the further the switch is moved to counter-
clockwise, the normal temperature.

2. Air flow selector switch

The air flow can be adjusted to four levels.

Turning air Turning air Turning air

Turning air Turning air
Purpose flow to flow to flow to
flow OFF flow to LOW MEDlUM
HIGH MAX. HIGH

@ .@ .@ .@ .q

Switch

* + 9 *
AD3971
10 AD332120 AD332130 A0332140 AD332150

2-23
11. EXPLANATION OF COMPONENTS

11.9.2 PRECAUTIONS WHEN USING COOLER

When carrying out cooling, ventilate the cab from time to time.
l If you smoke when cooling the cab, your eyes may start to sting,
so in such cases, carry out ventilation and cooling together to
remove the smoke.
l If the cooler is used for a long period, carry out ventilation and
cooling together once every hour.

Be careful not to cool too much.

l For reasons of health, it is recommended that the cab should feel
pleasantly cool when you enter it from the outside (5 - 6°C lower
than the outside temperature). Pay attention to the temperature
when carrying out cooling.

11.9.3 CHECK, MAINTAIN MACHINE WITH EQUIPPED

COOLER
When carrying out inspection and maintenance of a machine
equipped with cooler, see “23.1 MAINTENANCE SCHEDULE CHART”.

2-24
 11. EXPLANATION OF COMPONENTS

11.10 CASSETTE/RADIO

11 .lO.l EXPLANATION OF COMPONENTS

1. FADER CONTROL
While the unit is being with a 4-speaker system, the control is used
to adjust the volume balance between the front two and rear two
speakers. To achieve the desired balance between the front and rear
speakers, rotate the control clockwise when the volume of the front
two speakers is low and, conversely, rotate it counterclockwise when
the volume of the rear two speakers is low.

AD332170

2. OFF/VOL (VOLUME) PUSH BALANCE CONTROL

Power ON/OFF: The Dower is turned OFF when the control is rotated
counterclockwise as far as it will go; it is turned ON when the
control is rotated clockwise.

Volume adjustment: When the control is rotated clockwise past the

point at which the power is turned on, the volume will be
cinreased. Conversely, when it is rotated counterclockwise, it will
AD332180
be reduced.

Balance adjustment: While the knob is pushed, if you rotate it, the
volume balance between the left and right channels can be
adjusted. Rotate it counterclockwise then the volume at the right
is low or rotate it clockwise when the volume at the left is low
and adjust the balance between the left and right channels.
Normally the control is kept at its center (clickstop) position.
After having performed the adjustment, release the control.

2-25
11. EXPLANATION OF COMPONENTS

3. EJECT SWITCH
During tape playback will cause the tape to be ejected from the
loading slot.

4. TAPE LOADING SLOT

Load the cassette tape with the side of the tape visible to the right.
Once you insert the tape it will automatically start playing.

A0332200

5. REWIND/FAST FORWARD/PROGRAM SWITCH

Pressing the switch indicates the same direction (4 4 or ) ) 1 as the
tape run direction, which is shown by the TAPE indicator, sets the
tape to the fast forward mode.
Conversely, pressing the switch corresponding to the other direction
sets tape to the rewind mode. To release either the fast forward or
rewind mode, press the switch which has not been depressed and
this will return the tape to normal playback, pushing this switch
AD332210
(both of them) during tape playback will reverse the direction of the
tape play and change the direction indicator on the display.

6. BAND SWITCH (FMI, FM2. FM3, AMl, AM21

Push this button to select desired radio band FMI, FM2, FM3, AMI,
AM2.

A0332220

7. TIME FREQ SWITCH

When you wish to knob the time during a radio broadcast reception,
depress this switch. The time will be indicated in hours and minute
for a period of 5 seconds. The display will then return to the
frequency of the radio station to which the unit is currently turned.

AD332230

8. MONO SWITCH
This is used to change the mode between Mono/Stereo during FM
reception.

AD332240

2-26
 11. EXPLANATION OF COMPONENTS

9. LOUDNESS SWITCH
Press this switch to ON when you hear to sound at a low listening
level. Our ears are such that the bass and treble seem to drop of
when sound is low but by setting this switch to ON, both the bass
and treble can be.boosted to create a more balanced sound.

AD332250

10. P/S SWITCH tPS/MA)

A. Preset scan: This switch to use auto store memory or preset
scan function. When the P.SCAN switch is pressed within 2
seconds during reception, the preset stations are tuned in for
about 5 seconds each. During this time, the numbers of the
preset station switches and the frequencies of the stations
appear on the display, and “CH” flashes on and off to indicate
that preset scanning is taking place. Once the desired station has
AD332260
been reached, press the switch again and this will release preset
scanning function. This makes it possible to continue listening to
the program of the station you have now tuned in.

B. Auto-store memory: Automatically searches a station and writes

to the preset memory. When this switch is pressed for more than
2 seconds, the Auto-Store memory starts, the station search is
done in the up direction from the frequency currently received.
This Operation completes if 6 key is stored. Auto-Store operation
differs in way of reception between Lot, DX modes. In Lot
modes, the frequency reception is stored in sequence by 3
cycling of frequency band-from the strongest reception, strong
reception, DX reception.

11. SCAN SWITCH

When this switch is pressed during broadcast reception, scan tuning
will start. Stations are tuned in automatically and held for 5 seconds,
after which scanning resumes until the next station is located.
Pressing this switch again will stop scan tuning.

AD332270

12. LOCAL SWITCH (LOCI

This is used to change the tuning stop level during tuning by search.
LOCAL mode is established when the switch is pressed to its ON
position. At this position, stations with weak transmission signals
are skipped and only the stations with relatively strong signals are
tuned in. This function makes it possible to search quickly all those
stations cable of providing reception. Press the switch again to its
OFF position to scan stations with weak signals.
AD332280

2-27
11. EXPLANATION OF COMPONENTS

13. CD JACK
CD mode is established while the CD plug is inserted in the radio
mode or the tape mode.

14. TUNE SWITCH (VA)

This is used to tune the broadcasting stations. When right (A) side
of the switch is pressed, the frequencies of the stations to be
received increase; when the left (V) side is pressed, they decrease.
4

AD332300
1
15. PRESET STATION SWITCH (l-6)
A total of 12 AM and 18 FM stations can be preset into the six preset
station switches. When any one of these switches is pressed within
5 seconds after the MEMO switch has been pressed, the station
received at that time will be preset into that switch.

AD332310

16. BASS AND TREBLE CONTROLS

The BASS control is used to adjust the bass (low-frequency) sound
quality; the TREBLE control is used to adjust the treble (high-
frequency) sound quality. The bass or treble is boosted when the
corresponding control is slided to the right from its center position
and it is attenuated when the control is slided to the left.

AD332320

17. DISPLAY
The display comes with the following functions.
l Frequency display: The reception frequency is indicated in
MHz units for the FM band and in KHz
units or. the AM band.
Preset channel display: The preset station number is indicated
while a program from a station preset
in one of the preset station switches is
AD332330
being received.
l TAPE indicator: The TAPE indicator operates as follow
in accordance with the tape travel.

11.10.2 TIME SE-KING

Only when the display more on LCD is in clock mode, you can adjust
time. So if the display is showing frequency, press the clock switch
once, in order to have time shown on display.
Then the press “T/F” switch you can adjust hour and minute by
tuning switch. Pressing the right side tuning switch (A) will increase
the minute and pressing the left side tuning switch (V) will increase
hour while you hold “T/F” switch pressed.

2-28
 11. EXPLANATION OF COMPONENTS

11.10.3 SETTING METHOD

Basic operation
1. Turn the unit on by means of the OFF/VOLUME control, and
adjust it to obtain the desired volume.
2. Press BAND selector to change the radio mode from, FM, to AM.
3. Press the TUNING button to tune in the desired station.
When this is to the right, the reception frequency is increased,
while pressing it to the left reduceds the reception frequency.
4. SCAN Tuning: When the SCAN button is pressed, tuning starts,
and station will be tuned in automatically and help for 5 seconds
each. When the desired station is tuned in, press this button
again to stop scan tuning.
5. Use the volume, BALANCE, FADER, BASS and TREBLE controls
to adjust the set to your liking.
l Your set is in the tape playmode if a cassette tape is in the
tape deck.

Preset scanning function

Simply by pressing a switch, this convenient function recalls all the
stations preset in preset station switches 1 through 6 in succession.
When the P. SCAN switch is pressed during reception, with in 2
seconds the preset stations are tuned in for about 5 seconds each.
During this time, the numbers of the preset station switches and the
frequencies of the stations appear on the display, and “CH” flashes
on and off to indicate that preset scanning is taking place.
Once the desired station has been reached, press the P. SCAN switch
again and this will release preset scanning function. This makes it
possible to continue listening to the program of the station you have
now tuned in.

Memory back-up power supply

This unit is provided with a memory back-up power supply which
functions to retain the contents of both the preset station memory,
which is used to store the preset stations, and the last station
memory, which is used to store the station, which was tuned in
before the power was switched off.

Antenna
If the receiving wave is weak or generates noise, extend the
antenna. If the wave is too strong, adjust the sensitivity by retracting
the antenna.

NOTICE
When transporting the machine or parking it in a garage, always !
fully retract the antenna to avoid the possibility of breakage.
r
11.10.4 REPLACING THE FUSE
Shut off ignition before opening the fuse holder. If fuse is brown,
replace with a new fuse of same amperage rating. If the new fuse
blows as soon as it is inserted, check all wiring connections.
7A Fuse (with red cord)
IA Fusetwith yellow cord)
AE33234B

2-29
11. EXPLANATION OF COMPONENTS

11.10.5 PRECAUTIONS FOR USE

l To assure safe operation, adjust the volume level so that external

noise is still audible.
l Ensure no water is splashed over the speaker case or car radio
(auto tuning) to prevent unexpected malfunction.
l Never use solutions such as benzine or thinners to clean the dial
or buttons. These should be wiped with a dry, soft cloth. (Use a
cloth dipped in alcohol for very dirty surfaces.)
l At battery replacement, all the memory preset with the preset
buttons will be cleared. Perform presetting again.

11.10.6 SPECIFICATIONS
Audio section
Rated output power .. . . .. ... . . .. .. . ... . 25 watts per channel into 4 ohms
Load impedance ... . .. .. . . ... . . . .. .. . . ..._ 4 ohms
Total harmonic distortion . . .. . . . .. .. less than 10% at 15 watts
Signal to noise ratio
(A network) . . .. . .. ... . . .. . . .. . .. . . . .. .. 80 dB
Frequency response .. .. .. .. .. .. .. . . .. .. 125 to 14 kHz 23 dB
Control
BASE/TREBLE .. . . .. .. . . .. . .. . . .. . .. .. +‘lO dB at 100 Hz/IO kHz

Tape section
Track format ... . .. . .. . ... ... .. . . .._....... 4-track/2-channel system
Tape speed ... .. ... .. . .. . .. . . ... . . . .. . . . .... . 3,000 (4.8 cm/set.)
Wow/flutter .. .. . ... . . ... . .. . . .. . . .. .._..... 0.15 max. (WRMS)
Frequency response
Normal (LH) tape . . .. . . .. . . .. . .. . .. 40 to 14 kHz

Tuner section
FM
Tuning range .. .. .. .. .. .. . .. . . .. . .. . . .. .. ... 87.5 to 108 MHz
Usable sensitivity
Mono IHF ... . .. . .. . . .. .. . .. .. . . . . .. . . .. . 12 dBu (4 uVf75 ohms)
50 dB quieting sensitivity
Stereo .. .. . .... . . ... . . .. .. . . .. . .. . . . .. . . ... 30 dBu (32 uV/75 ohms)
Signal to Noise ratio (at 65 dB)
Stereo/Mono . .. . .. .. . . . .. . .. . . .. . . .. .. 60 dBl60 dB

AM
Tuning range ... . . ... .. ... . . .. . . .. . .. .. .. . .. 522 to 1620 kHz
Usable sensitivity .. . . .. . ... . .. . .. . . .. . .. . 30 dB/uV (55 ohms at 999 kHz)

General
Power requirement .. . . .. . .. . . .. . .. ... . . DC 12.0V/Rated: 14.4 V
(Usable: 10.8 - 15.6 VI
negative ground
Current consumption . ... .. . . .. . . .. .. .. 5A Maximum
Dimension (WxHxD) . .. . . .. .. . . .. . .. . .. 188 x 58 x 186 mm
7-3j8” x 2-l/4” x 7-5fl6”
chassis size . ... . . .. .. ... . .. . .. . .. . . ... . 182 x 53 x 154 mm
7-3116” x 2-118” x 6”
Weight (net) ... . .. . ... . . .. .. . . . ... . .. . .. . . ... 1.8 kg

l Design and specifications subject to changes without notice for

improvements.

2-30
 11. EXPLANATION OF COMPONENTS

11.11FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.

The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded, or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.

Replace a fuse with another of the same capacity.

Fuse capacity and name of circuit

Fuse
No. capacity Name of circuit

0. IOA Room lamp, radio (back-up)

0 10 A Controller, monitor panel, solenoid valve

AN106630
0 15 A Wiper, radio, horn, window washer

@ 1 IO A 1 Head lamp

0 15 A Heater, head lamp, rear working lamp

0 20 A Spare fuse (Cooler), travel alarm

0 20 A Spare fuse

@ 15 A Spare fuse

@ 10 A Spare fuse

2-31
Il. EXPLANATION OF COMPONENTS

11.12 FUSIBLE LINK

If the starting motor will not rotate when the starting switch is
turned ON, a possible cause is disconnection of wire-type fusible link
0. Open the battery box cover on the right side of the machine body
to inspect the fusible link and, if necessary, replace it.

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

11.13 TOOL BOX

This is usecd for keeping the tools.

11.14 GREASE PUMP HOLDER

This is inside the left rear door of the machine.
Fit the grease pump to the holder when it is not being used.

2-32
 1 ‘I. EXPLANATION OF COMPONENTS

11.15 HANDLING ACCUMULATOR

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

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

it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions.
l Never make any hole in the accumulator or expose it to flame
or fire.
l Do not weld any boss to the accumulator.
l When disposing of the accumulator, it is necessary to release
the gas from the accumulator, so please contact your Komatsu
distributor.

This machine is equipped with the accumulator in the control circuit.

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

The accumulator is installed to the position shown in the diagram

on the right.

11.15.1 METHOD OF RELEASING PRESSURE IN

CONTROL CIRCUIT ON MACHINE
EQUIPPED WITH ACCUMULATOR
Place the work equipment on the ground. Close the crusher
attachment jaws, etc.

Stop the engine.

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

Move the safety lock lever to the lock position. Lock the control
lever and attachment control pedal. The pressure, however, will
not be completely released, so when the accumulator is re-
moved in the control circuit, gradually loosen the screws. Never
stand in the oil ejection direction.

2-33
12. OPERATION

12.1 CHECK BEFORE STARTING ENGINE

12.1.1 WALK-AROUND CHECK

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

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

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

10 5 6 7, 11 9 z3

AN113760

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

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

2-34
 12. OPERATION

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

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

3. Check for leakage of water or oil around engine

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

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

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

5. Check the undercarriage (track, sprocket, idler, guard) for dam-

age, wear, loose bolts, or leakage of oil from rollers

6 Check for damage to handrail, loose bolts

Repair any damage and tighten any loose.

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

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

8. Clean rear view mirror, check for damage

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

9. Seat belt and mounting clamps

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

10. Check bucket with hook for damage.

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

2-35
 12. OPERATION

12.1.2 CHECK BEFORE STARTING

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

CHECK COOLANT LEVEL, ADD WATER

A WARNING
Do not open the radiator cap unless necessary. When checking
the coolant, always check the radiator reserve tank when the
engine is cold.

Open the rear door on the left side of the machine and check that
the cooling water level is between the FULL and LOW marks on
radiator reserve tank @ (shown in the diagram on the right).
If the water level is low, add water through the water filler of
reserve tank @ to the FULL level.

After adding water, tighten the cap securely.

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

AN113780

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the engine hood.

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

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

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

0.
If the oil level is belowthe L mark, add engine oil through oil filler
o-
.
NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
AM)52340

2-36
5. If the oil is above the H mark, drain the excess engine oil from
drain plug 8, and check the oil level again.

6. If the oil level is correct, tighten the oil filler cap securely and
close the engine hood.

REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before check-
ing.
If the machine is at an angle, make it horizontal before checking.

CHECK FUEL LEVEL, ADD FUEL

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

1. Use sight gauge @I on the front face of the fuel tank to check that
the tank is full.

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

Fuel capacity: 340 e (89.8 US gal, 74.8 UK gal)

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

3. After adding fuel, tighten the cap securely.

REMARK
If breather hole 0 on the cap is clogged, the pressure in the tank
will drop and fuel will not flow.
Clean the hole from time to time.

AL067960

2-37
12. OPERATION

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

4I WARNING
l When removing the oil filler cap, oil may spurt out, so turn
the cap slowly to release the internal pressure before remov-

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

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

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

AN113810
2. Within 15 seconds after stopping the engine, move each control
lever (for work equipment and travel) to the full stroke in all
directions to release the internal pressure.

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

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

4. If the. level is below the L mark, add oil through oil filler 0.

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

REMARK
AE313580
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:
l Before operation: around L level
(Oil temperature 10 to 30°C (50 to 86°F))
l Normal operation: around H level
(Oil temperature 50 to 80°C (122 to 176°F))

2-38
CHECK DUST INDICATOR \
Open the engine hood and check that the red piston is not
showing in dust indicator a.,

If the red piston has appeared, clean or replace the element

immediately.
For details of the method of cleaning the element, see “24.2.1
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT”.

After checking, cleaning, and replacing, press the knob of dust

indicator @ to return the red piston to its original position.

I AN106650

CHECK ELECTRIC WlRlNGS

on the electrical wiring, locate the cause and carry out repair.

Check for damage of the fuse and any sign of disconnection or

short circuit in the electric wiring. Check also for loose terminals and
tighten any loose parts. Check the following points carefully.
o Battery
0 Starting motor
l Alternator
Please contact your Komats’u distributor for investigation and
correction of the cause.

A WARNING
Accumulation of flammable material (dead leaves, twigs, grass,
etc.) around the battery may cause fire, so always check and
remove such material.

When carrying out walk-arouind checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.

2-39
LUBRICATE CLAMSHELL BUCKET
0 Prepare a grease pump.
1. Place the work equipment in a stable posture on the ground,
then stop the engine.

2. Using a grease pump, pump in grease through the grease

fittings shown by arrows.

3. After greasing, wipe off any old grease that was pushed out.

1 AN113850

CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR,

DRAIN WATER
The water separator separates water mixed in the fuel. If float @
is at or above red line 0, drain the water according to the following
procedure:
1. Loosen drain plug @ and drain the accumulated water until the
float reaches the bottom.
1 = ’ AE032240
2. Tighten drain plug 0.

3. If the air is sucked into fuel line when draining and water, be sure
to bleed air in the same manner as for the fuel filter. See “24.6
EVERY 500 HOURS SERVICE”.

2-40
12.1.3 ADJUSTING BEFORE STARTING OPERATION I
ADJUSTING OPERATOR’S SEAT
@ Fore-and-aft adjustment of operator’s seat
The seat and the left and right console boxes slide to the front and
rear.
Move lever @ to the right, set the operator’s seat at the desired
position, then release the lever.

Fore-and-aft adjustment: 160 mm (6.3 in) (9 stages)

Adjust the position of the operator’s seat to match the operation. For
example, when carrying out deep digging operations, slide the seat
to the front to improve the view below the front of the machine.

@ Adjusting reclining angle of seat

Pull lever @ in the direction of the arrow, set the seat- back to the
desired position, then release the lever.

AE331890

2-41
 12. OPERATION

12.1.4 OPERATIONS AND CHECKS BEFORE STARTING

ENGINE
I- A WARNING I
If the control lever is touched by accident, the work equipment
or the machine may move suddenly. When leaving the opera-
tor’s compartment, always set the safety lock lever securely to
the LOCK position.

1. Check that safety lock lever @ is at the LOCK position.

2. Check the position of each lever.

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

position, then carry out the following checks.

(I) The buzzer will sound for approx. 1 set, and the following
monitors and gauges will light up for approx. 3 sec.
Charge level monitor @
Engine oil pressure monitor @
Swing lock monitor @
Engine water temperature gauge @
Fuel gauge @

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

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

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

(2) Turn lamp switch @?to turn on the head lamps.

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

AM167000

2-42
12.2 STARTING ENGINE

12.2.1 NORMAL STARTING

A WARNING
Check that there are no persons or obstacles in the surrounding
area, then sound the horn and start the engine.

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

1. Pull fuel control lever @ to the center position between LOW Low idlina
IDLING and HIGH IDLING.

AN106700

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

engine will start.

AM090350

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

:
5
AM090360

2-43
12. OPERATION

12.2.2 STARTING IN COLD WEATHER

4h WARNING
Check that there are no persons or obstacles in the surrounding
area, then sound the horn and start the engine.

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

When starting in low temperatures, do as follows.

Pull fuel control lever @ to the center position between LOW Low idling
IDLING and HIGH IDLING.

AN106700

Hold the key in starting switch @ at the HEAT position, and check
that preheating monitor @ lights up.
After approx. 30 seconds, preheating monitor @ goes out to
inform that the preheating is completed.

AM102070

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

3. When preheating monitor @I goes out, turn the key in starting

switch @ to the START position to start the engine.

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

2-44
12.3 OPERATIONS AND CHECKS AFTER
STARTING ENGINE
I A WARNING
If there has been any abnormal actuation or trouble, turn the
starting switch key to the OFF position and set the fuel
control lever to the STOP position. The electrical system and
engine will stop. Then, contact your Komatsu distributor for
inspection.
lf the work equipment is operated without warming the
machine up sufficiently, the response of the work equipment
to the movement of the control lever will be slow, and the
work equipment may not move as the operator desires, so
always carry out the warming-up operation. Particularly in
cold areas, be sure to carry out the warming-up operation
fully.

NOTlCE
The most suitable temperature for the hydraulic oil is 50 - 8O”C,
but in order to extend the life of the machine, the temperature must
be raised to at least 20°C before starting work.

NOTlCE
Do not suddenly operate the levers when the hydraulic oil
temperature is below 20°C.

NOTlCE
Do not suddenly accelerate the engine before the warming-up
operation is completed.
Do not run the engine at low idling or high idling continuously
for more than 20 minutes.
If it is necessary to run the engine at idling, apply a load from
time to time or run the engine at a mid-range speed.

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

1. Pull fuel control lever @ to the center position between LOW

IDLING and HIGH IDLING and run the engine at medium speed
for about 5 minutes with no load.

AN106730

2-45
2. Set lock lever @ to the FREE position, and raise the bucket from
the ground.

AN317500

3. Operate bucket control lever @ and arm control lever @ slowly Bucket operation
to move the bucket cylinder and arm cylinder to the end of the
stroke.

4. Carry out bucket and arm operation for 5 minutes at full stroke,
e Right swing
alternating between bucket operation and arm operation at 30
second intervals.
If the swing lock switch @ is set to the ON (actuated) position and
swing control lever @ is operated at full stroke, oil temperature-
rise can be increased earlier.

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

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

gauge and monitor lamp is in the following condition.
l Engine water temperature gauge 0. Inside green range
l Fuel gauge 0. Inside green range
l Engine oil pressure monitor 8. OUT
l Charge level monitor @. OUT

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

vibration. If any abnormality is found, repair it.

7. Set lock lever @ to the LOCK position and check that it is

impossible to operate the swing and work equipment with the
left and right work equipment control levers.

2-46
12.4 MOVING MACHINE OFF

12.4.1 MOVING MACHINE FORWARD

A WARNING
Before operating the travel levers, check the direction of the
track frame. If the sprocket is at the front, the operation of the
travel levers is reversed.

When moving off, check that the area around the machine is
safe, and sound the horn before moving.

Clear all personnel from the machine and the area.

Clear all obstacles from the path of the machine.

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

confirm that swing lock monitor lamp @ lights up.
ON
0

I AM167020 1

2. Pull fuel control lever @ towards the high idling position to

increase the engine speed.

I AN106600

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

Free

(16-20 in1
AM31 7346

l For machines equipped with the travel alarm (option), check that
the alarm works properly.

2-47
 4. Operate right and left travel levers @ or right and left travel >
pedals @ as follows.

l When the sprocket is at the rear of the machine

Push levers @ forward slowly to move the machine

0 When the sprocket is at the front of the machine

Pull levers @ backward slowly to move the machine off.

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

124.2 MOVING MACHINE BACKWARD

A WARNING
Before operating the travel levers, check the direction of the
track frame. If the sprocket is at the front, the operation of the
travel levers is reversed.

When moving off, check that the area around the machine is
safe, and sound the horn before moving.

Clear all personnel from the machine and the area.

Clear all obstacles from the path of the machine.

Use extreme care when reversing the machine. Note there is

an blind spot behind the machine.

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

confirm that swing lock monitor lamp @ lights up.

ON
6

AM167020

2. Pull fuel control lever @ towards the high idling position to

increase the engine speed. Low idling

. l For machines equipped with the travel alarm (option), check that
the alarm works properly.

AN106600

2-48
 Set lock lever @ in the FREE position, fold the work equipment, )
and raise it 40 - 50 cm (16 to 20 in) from the ground.

Free

(I 6-20 i 17)

Operate right and left travel levers @ or right and left travel
pedals @ as follows.
When the sprocket is at the rear of the machine
Pull levers @ backward slowly to move the machine off.

I I
When the sprocket is at the front of the machine
Push levers @ forward slowly to move the machine off.

sp'ocket AN114060 1

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

2-49
12.5 STEERING MACHINE

125.1 STEERING (CHANGING DIRECTION)

A WARNING
Before operating the travel levers, check the position of the
sprocket. If the sprocket is at the front, the operation of the
travel levers is reversed.

Use the travel levers to change direction.

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

E335260

Changing direction of machine when stopped

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

REMARK
When turning to the right, operate the left travel lever in the
same way.

Steering when traveling (left and right travel levers both operated
in same direction)
When turning to the left: Forward
If the left travel lever is returned to the neutral position, the
machine will turn to the left.

REMARK
When turning to the right, operate the right travel lever in the
same way.

2-50
When making counter-rotation turn (spin turn)
When turning lef? using counter-rotation, pull the left travel lever
back and push the right travel lever forward.

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

2-51
 12. OPERATION

12.6 STOPPING MACHINE

A WARNING 1
Avoid stopping suddenly. Give yourself ample room when
stopping.
When stopping the machine, select flat hard ground and avoid
dangerous places. lf it is unavoidably necessary to park the
machine on a slope, insert blocks underneath the track shoes.
As an additional safety measure, thrust the bucket into the
ground.
If the control lever is touched by accident, the work equipment hrust the bucket AN113060

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

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

Free

AN317498

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

ANI

2-52
 12. OPERATION

12.7 SWINGING

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

1. Before operating the swing, turn swing lock switch 0 OFF

(CANCELED).

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

AM167030

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

AN106630

3. When not operating the swing, turn swing lock switch @ ON

(ACTUATED).
ON

AM102280

2-53
12.8 OPERATION
The work equipment
OF WORK EQUIPMENT
is operated by the left and right work
equipment control levers. The left work equipment control lever
Arm operation
1
operates the arm and swing, and the right work equipment control
lever operates the boom and bucket.
The movements of the lever and work equipment are as shown
in the diagrams on the right. When the levers are released, they
automatically return to the neutral position and the work equipment AN31 7378
I I
is held in place.
I I
Swins oDeratio
REMARK
If the levers are operated within 15 seconds after stopping the
engine, it is possible to lower the work equipment to the ground.
In addition, the levers can also be operated to release any remaining
pressure inside the hydraulic cylinder circuit and to lower the boom
after loading the machine on a trailer.

I , , Boom operation

, Bucket operation

2-54
12.9 PROHIBITIONS FOR OPERATION

l If it is necessary to operate the work equipment control lever

the machine before
operating the work equipment control lever.
l Never operate the machine on a rock bed [hard or soft rock).

Prohibited operations using swing force

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

w - AN114190

Prohibited operations using travel force INCORRECT

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

Precautions when operating hydraulic cylinders to end of stroke

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

AN114210

Prohibited operations using dropping force of bucket

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

AN114220

2-55
 12. OPERATION

Prohibited operations using dropping force of machine

Do not use the dropping force of the machine for digging.

INCORRECT

AN114240

Digging rocky ground

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

2-56
12.10 PRECAUTIONS FOR OPERATION INCORRECT

PRECAUTIONS WHEN TRAVELING

When traveling over obstacles such as boulders or tree stumps,
the machine (in particular, the undercarriage) is subjected to a large
shock, so reduce the travel speed and travel over the obstacle at the
center of the tracks. As far as possible, remove such obstacles or
avoid traveling over them. AN114270

PERMISSIBLE WATER DEPTH

NOTlCE
When driving the machine out of water, if the angle of the
machine exceeds 15”, the rear of the upper structure will go under
water, and water will be thrown up by the radiator fan. This may
cause the fan to break.
Be extremely careful when driving the machine out of water.
AN114280
Do not immerse the machine in water by more than the permis-
sible depth (under center of carrier roller 0).
In addition, for parts that have been immersed in water for a long
time, pump in grease until the old grease comes out from the
bearings. (Around the bucket pins)

2-57
 DOWN HILLS

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

When traveling over ridges or other obstacles, keep the work

equipment close to the ground and travel slowly.

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

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

lf the machine starts to slide or loses stability, lower the AN114800

bucket immediately and brake the machine.

INCORRECT CORRECT
Turning or operating the work equipment when working on
slopes may cause the machine to lose its balance and turn
over, so avoid such operations. It is particularly dangerous to
swing downhill when the bucket is loaded.
If such operations have to be carried out, pile soil to make
platform on the slope so that the machine can be kept
horizontal when operating. AN114310

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

machine may overturn.

I) When traveling down steep hills, use the travel lever and fuel 2
control lever to keep the travel speed low.
When traveling down slopes of more than 15”, set the work
equipment in the posture shown in the figure on the right, and
lower the engine speed.

\iO-30cm(8-12in)
AN112980

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

2-58
 12. OPERATION

Braking when traveling downhill

To brake the machine during downhill runs, put the travel lever in
the neutral position. This will cause the brake to be automatically
applied.

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

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

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

2-59
‘12. OPERATION

12.12 HOW TO ESCAPE FROM MUD

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

12.12.1 WHEN ONE SIDE IS STUCK CORRECT

When only one side is stuck in mud, use the bucket to raise the
track, then lay boards or logs and drive the machine out. If neces-
sary, put a board under the bucket also.

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

12.12.2 WHEN BOTH SIDES ARE STUCK CORRECT -

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

I.,.,, *” AN114330

2-60
 12. OPERATION

12.13 WORK POSSIBLE USING HYDRAULIC

EXCAVATOR
In addition to the following, it is possible to further increase the
range of applications by using various attachments.

12.13.1 BACKHOE WORK

When condition of the machine is as shown in the diagram at
right, each cylinders maximum pushing excavation force is obtained
when the bucket cylinder and link, arm cylinder and arm are at 90”.
When excavating, use this angle effectively to optimize your
work efficiency.
The range for excavating with the arm is from a 45” angle away from
the machine to a 30” toward the machine. AN114340
There may be some differences depending on the excavation .. . r
depth, but try to use within the above range rather than going all the
way to the extreme end of the cylinder stroke.

12.13.2 SHOVEL WORK

A shovel is suitable for excavating at a position higher than the
machine. Shovel work is performed by attaching the bucket in the
reverse direction.

AN114360

12.13.3 DITCHING WORK

Ditching work can be performed efficiently by attaching a bucket
to match the width of the ditch and then setting the tracks parallel
to the line of the ditch to be excavated.
To excavate a wide ditch, first dig out both sides and then finally
remove the center portion.

12.13.4 LOADING WORK

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

AN114380

2-61
12. OPERATION

12.14 REPLACEMENT AND INVERSION

OF BUCKET

A WARNING
l When knocking the pin in with a hammer, metal particles
may fly and cause serious injury, particularly if they get into
your eyes. When carrying out this operation, always wear
goggles, helmet, gloves, and other protective equipment.

l When the bucket is removed, place it in a stable condition.

Stop the machine on a firm, flat surface. When performing joint

work, make clear signals to each other and work carefully for safety’s
sake.

12.14.1 REPLACEMENT
1. Place the bucket in contact with a flat surface.

REMARK
When removing the pins, place the bucket so that it is in light
contact with the ground.
If the bucket is lowered strongly to the ground, the resistance will
be increased and it will be difficult to remove the pins.

2. Remove the stopper bolts and nuts, then remove pins @ and @,
Bucket cylinder
and remove the bucket.

NOTICE Link
After removing the pins, make sure that they do not become
contaminated with sand or mud and that the seals of bushing on
both sides do not become damaged.
AM090950
3. Align the arm with holes @ and the link with holes 0, then coat
with grease and install pins @ and @,.

AMOS0960

REMARK
When installing the bucket, the O-rings are easily damaged, so
fit the O-rings on the boss of the arm end as shown in the diagram.
When knocking the pin, move the O-ring down to the regular groove.

4. Install the stopper bolts and nuts for each pin, then grease the
pin.
Buck& O-‘ring AN114390

2-62
12.142 INVERSION I
Bucket cylinder
1. Place the bucket in contact with a flat surface.

REMARK Link
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.

2. Remove the stopper bolts and nuts, then remove pins @ and @,
and remove the bucket.

NOTlCE
After removing the pins, make sure that they do not become
contaminated with sand or mud and that the seals of bushing on
both sides do not become damaged.

AM090990

7
Install the bucket inversely.
After the bucket is inversed, correct the inclination and direction
of the retaining pin holes @ and @ and stabilize the bucket
securely.

Align the arm with holes @ and the link with holes 0, then coat
with grease and install pins @ and @I.

AM090990
REMARK
Install the O-rings into retaining hole @ of the arm and bucket.

When installing the bucket, the O-rings are easily damaged, so

fit the O-rings on the boss of the arm end as shown in the diagram.
When knocking the pin, move the O-ring down to the regular groove.

5. Install the stopper bolts and nuts for each pin, then grease the
pin.

2-63
12. OPERATION

12.15 PARKING MACHINE

a WARNiNG
I
0 Avoid stopping suddenly. Give yourself ample room when
stopping.

0 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.
\ Block
As an additional safety measure, thrust the bucket into the
ground. Thrust the bucket AN113060

l If the control lever is touched by accident, the work equipment

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

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

The machine stops.

AN114110

2. Lower the engine speed to low idling by fuel control lever @.

2-64
 12. OPERATION

3. Lower the bucket horizontally until the bottom touches the <I
ground.

AN114410

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

Free

AN317499

12.16 CHECK AFTER FINISHING WORK Engine water temPerature

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

AD33236B

2-65
 12. OPERATION

12.17 STOPPING ENGINE

stop- Low idline
NOTlCE
If the engine is abruptly stopped before it has cooled down,
engine life may be greatly shortened. Consequently, do not abruptly
stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop
it but run it at medium speed to allow it to cool gradually, then stop
AN32543B
it.

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

2. Push the fuel control lever to the STOP position to stop the
engine.

3. Turn the key in starting switch 0 to the OFF position and stop
the engine.
@q OFF
4. Remove the key from starting switch 0.

AM063160

2-66
 12. OPERATION

12.18 CHECK AFTER STOPPING ENGINE

Walk around the machine and check the work equipment, paint-
work, and undercarriage, and check also for leakage of oil or
water. If any abnormalities are found, repair them.

Fill the fuel tank.

Check the engine compartment for paper and debris. Clean out
any paper and debris to avoid a fire hazard.

Remove any mud stuck to the undercarriage.

12.19 LOCKING
Always lock the following places.
@ Door of operator’s cab
Always remember to close the window.
@ Fuel tank filler port
@ Engine hood
@ Battery box cover
@ Left side door of the machine
@ Right side door of the machine

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

2-67
13. TRANSPORTATION

When transporting the machine, observe all related laws and

regulations, and be careful to assure safety.

13.1 LOADING, UNLOADING WORK

A WARNING
l Loading or unloading the machine can be a dangerous opera-
tion, so be particularly careful.
When loading or unloading the machine, run the engine at
low idling and travel at low speed.

l Make sure the ramp has sufficient width, length and thick-
ness to enable the machine to be safely loaded and unloaded.
If the ramp sags appreciably, reinforce it with blocks, etc.

l When loading and unloading the machine, park the trailer on

a flat firm roadbed. Keep a fairly long distance between the
road shoulder and the machine.

l Remove the mud from the undercarriage to prevent the

machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials.

l Never change the direction of travel when on the ramps. If it

is necessary to change direction, drive off the ramps and
correct the direction, then drive on to the ramps again.

l When turning the machine on the trailer, the machine’s

footing is unstable, so carry out the operation slowly.

l Always check that the door on the cab is locked, regardless

of whether it is open or closed.
Do not open or close the door on ramps or on a platform.
This may cause a sudden change in the operating force.

When loading or unloading, always use ramps or a platform and

carry out the operations as follows.

1. Properly apply the brakes on the trailer and insert blocks beneath
the tires to ensure that it does not move. Then fix the ramps in
line with the centers of the trailer and the machine. Be sure that
the two sides are at the same level as one another.

Make the angle of the ramps a maximum of 15’.

Set the distance between the ramps to match the center of the
tracks. Distance between ramps

2-68
 13. TRANSPORTATION

2. Lower the engine speed using the fuel control lever. Low idling

3. Turn the swing lock switch ON to apply the swing lock.

4. Set in the direction of the ramps, lower the work equipment as ON

far as possible without letting it hit the trailer, then travel slowly
to load or unload the machine.

When on the ramps, do not operate any lever other than the travel
lever. AM167020

5. Load the machine correctly in the specified position on the

trailer.

REMARK
When the work equipment is installed, load the machine from
the front; when the work equipment is not installed, load the
machine from the rear.

2-69
13. TRANSPORTATION

13.2 PRECAUTIONS FOR LOADING

A WARNING
When loading the machine, park the trailer on a fiat firm
roadbed. Keep a fairly long distance between the road shoulder
and the machine.

After loading to the specified position, secure the machine as

follows.

1. Fully extend the bucket and arm cylinders, then slowly lower the
boom.

2. Stop the engine and remove the key from the starting switch.

I AN114460

3. Lock all the control levers securely with the safety lock lever.

Free

AN317490

4. When transporting the machine, place rectangular timber under-

neath the front and rear track shoes to prevent the machine from
moving about. Also, hold it down with chains or rope. Be
particularly ,careful to ensure that the machine does not slip
sideways.

NOTlCE
When transporting the machine, place rectangular timber under AN114470
one end of the bucket cylinder to prevent it touching the ground,
thereby saving it from possible damage.

2-70
 13. TRANSPORTATION

13.3 PRECAUTIONS FOR TRANSPORTATION

l Determine the route for transporting the machine by taking

into account the width, height and weight of the machine.

l Always check that the door on the cab is closed and locked

NOTICE
Always retract the car radio antenna.

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

2-71
14. COLD WEATHER OPERATION

14.1 PRECAUTIONS FOR LOW TEMPERATURE

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

14.1.1 FUEL AND LUBRICANTS

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

14.1.2 COOLANT

Keep antifreeze fluid away from an open flame. Never smoke

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

For details of the antifreeze mixture when changing the coolant,

see “24.2 WHEN REQUIRED”.
Use a Permanent Antifreeze (ethylene glycol mixed with corro-
sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements, ask the supplier of that
antifreeze for information.
Standard requirements for permanent antifreeze
l SAE ................ ............................... ......................... ................. J1034
l FEDERAL STANDARD ................................................... O-A-548D

REMARK
Where no permanent antifreeze is available, an ethylene glycol
antifreeze without corrosion inhibitor may be used only for the cold
season. In this case, clean the cooling system twice a year (in spring
and autumn). When refilling the cooling system, add antifreeze in
autumn, but do not add any in spring.

2-72
 14. COLD WEATHER OPERATION

14.1.3 BATTERY

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

l Battery electrolyte is dangerous. If it gets in your eyes or on

your skin, wash it off with large amounts of water, and
consult a doctor.

When the ambient temperature drops, the capacity of the battery

will also drop. If the battery charge ratio is low, the battery electro-
lyte may freeze. Maintain the battery charge as close as possible to
lOO%, and insulate it against cold temperature so that the machine
can be started easily the next morning.

REMARK
Measure the specific gravity and calculate the rate of charge
from the following conversion table.

Temp. 1
20°C 0°C -10°C -20°C

2-73
14. COLD WEATHER OPERATION

14.2 ~~%iE;UTIONS AFTER COMPLETION OF

To prevent mud, water, or the undercarriage from freezing and

making it impossible for the machine to move on the following
morning, always observe the following precautions.
Mud and water on the machine body should be completely
removed. This is to prevent damage to the seal caused by mud
or dirt getting inside the seal with frozen drops of water.

Park the machine on hard, dry ground. If this is impossible, park

the machine on wooden boards. The boards help protect the
tracks from being freezed in soil and the machine can start next
morning.

Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing.

After operation in water or mud, remove water from undercarraige

as described below, to extend undercarriage service life.

a WARNING
Performing idle-running of tracks is potentially dangerous so
stay well away from tracks at this time.

1. Swing by 90” with engine at low idle and bring work equipment AN114480
beside track.

2. Slightly float track by slowly pushing the ground and cause track
to idle-run. Perform this for the opposite track, too.

0 As the battery capacity drops markedly in low temperatures,

cover the battery or remove it from the machine, keep it in a
warm place, and install it again the next morning.

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

ing before beginning work. Do not add the water after the day’s
work so as to prevent fluid in the battery from freezing in the
night.

14.3 AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as

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

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

ethyl glycol base antifreeze (winter, one season type) is used
instead, or if no antifreeze is used, drain the cooling system
completely, then clean out the inside of the cooling system
thoroughly, and fill with fresh water.

2-74
15. LONG-TERM STORAGE

15.1 BEFORE STORAGE

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

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

AM091090
follows.
Wash and clean each part, then store the machine indoors. If you
must keep the machine outdoors, place it on a level place where
it will not be subjects to floods and other natural disasters, and
keep it covered.

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

Apply a thin coat of grease to metal surface of the hydraulic

piston rods.

Disconnect the negative terminals of the battery and cover it, or

remove it from the machine and store it separately.

If the ambient temperature is expected to drop below OT,

always add antifreeze to the cooling water.

Lock each control lever and pedal with the lock lever and pedal
lock.

Set the stop valve to the “lock” position on machines ready for
attachments. Install the blind plugs to the elbows.

Set the selector valve to the “When not use” position on ma-
chines ready for attachments.

2-75
15. LONG-TERM STORAGE

15.2 DURING STORAGE

A WARNING
If it is unavoidably necessary to carry out the rustpreventive
operation while the machine is indoors, open the doors and
windows to improve ventilation and prevent gas poisoning.

Operate the engine and move the machine for a short distance
once a month so that a new film of oil will be coated over movable
parts and component surfaces. At the same time, also charge the
battery.
Also carry out cooler operation in the case of machines equipped
with an air conditioner.

15.3 AFTER STORAGE

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

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

l Wipe off the grease from the hydraulic cylinder rods.

l Add oil and grease to all places.

15.4 STARTING MACHINE AFTER LONG-TERM

STORAGE
When starting the machine after a long-term storage, first cancel
the automatic warming-up function as follows.
1. Turn the starting switch key to the ON position.

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

2-76
16. TROUBLESHOOTING

16.1 PHENOMENA THAT ARE NOT FAILURES

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

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

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

the brake valve.

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

emitted from the travel motor.
AM091110

16.2 METHOD OF TOWING MACHINE

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

If the machine sinks in mud and cannot get out under its own
power, or if the drawbar pull of the excavator is being used to tow
AN114490
a heavy object, use a wire rope as shown in the diagram on the right.
Place pieces of wood between wire ropes and body to prevent
damage to ropes and body.
At this time, never use the hole for light-weight towing.

16.3 USING METHOD FOR LIGHT-WEIGHT

TOWING HOLE

l The shackle must always be used.

The track frame has been opened with a hole to pass the shackle
for towing light objects.

2-77
16. TROUBLESHOOTING

16.4 PRECAUTIONS ON PARTICULAR JOBSITES

1. When carrying out digging operations in water, if the work

equipment mounting pin goes into the water, carry out greasing
every time the ‘operation is carried out.

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

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

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

16.5 IF BATTERY IS DISCHARGED

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

The battery generates hydrogen gas, so there is danger of

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

When handling battery, always wear protective goggles.

When installing, connect the cable
When removing the battery, first disconnect the cable from to the positive @terminal first

the ground (normally, from the negative @ terminal). When

installing, install the positive @terminal first. If a tool touches
the cable connecting the positive terminal and the chassis,
there is danger that it will cause sparks.

If the terminals are loose, there is danger that the defective \I/” AL068671
contact may generate sparks that will cause an explosion.
When installing the terminals, install them tightly.

When removing or installing, check which is the positive @

terminal and negative 0 terminal.

2-78
16.5.1 REMOVAL AND INSTALLATION OF BATTERY
l When removing the battery, remove the cable from the ground
side first (normally the negative 0 terminal).
If any tool contacts between the positive @ terminal and the
chassis, a spark will be caused. This is dangerous.
l When installing, connect the ground cable last.
l Tightening torque for battery holder: 9.8 - 14.7 Nm (1.0 -
1.5 kgfm, 7.2 - 10.9 Ibft)

16.52 STARTING ENGINE WITH BOOSTER CABLE

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

Precautions when connecting and disconnecting booster cable

A WARNING
INCORRECT 0 I
When connecting the cables, never contact the positive @
and negative 0 terminals.

When starting the engine with a booster cable, always wear

safety glasses.

Be careful not to let the normal machine and problem ma-

chine contact each other. This prevents sparks from generat-
ing near the battery which could ignite the hydrogen gas
given off by the battery. If hydrogen- gas explodes, it could
cause serious injury.

Make sure that there is no mistake in the booster cable

connections. The final connection is to the revolving frame,
but sparks will be generated when this is done, so connect
to a place as far as possible from the battery. (However, avoid
connecting the cable to the work equipment, as conduction
is poor.)

Use care when removing the cables from the machine that
has been started. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.

NOTICE
l The size of the booster cable and clip should be suitable for the
battery size.

l The battery of the normal machine must be the same capacity

as that of the engine to be started.

l Check the cables and clips for damage or corrosion.

l Make sure that the cables and clips are firmly connected.

2-79
16. TROUBLESHOOTING

Connecting the booster cables

Keep the starting switch at the OFF position.
Connect the booster cable as follows, in the order of the num-
bers marked in the diagram.
1. Make sure that the starting switches of the normal machine and
problem machine are both at the OFF position.

2. Connect one clip of booster cable @ to the positive 0 terminal

of the problem machine.

3. Connect the other clip of booster cable @ to the positive @

terminal of the normal machine.

4. Connect one clip of booster cable @I to the negative 0 terminal

of the normal machine.

5. Connect the other clip of booster cable @I to the engine block of

the problem machine.

Starting the engine

1. Make sure the clips are firmly connected to the battery terminals.

2. Start the engine of the normal machine and keep it to run at high
idling speed.

3. Turn the starting switch of the problem machine to the START

position and start the engine. If the engine doesn’t start at first,
try again after 2 minutes or so.

2-80
Disconnecting the booster cables
After the engine has started, disconnect the booster cables in the
reverse of the order in which they were connected.

I, Remove one clip of booster cable @I from the engine block of the
problem machine.

2. Remove the other clip of booster cable @ from the negative 0

terminal of the normal machine.

3. Remove one clip of booster cable @from the positive @terminal

of the normal machine.

4. Remove the other clip of booster cable @ from the positive @

terminal of the problem machine.

2-81
16. TROUBLESHOOTING

16.6 OTHER TROUBLE

16.6.1 ELECTRICAL SYSTEM
0 ( 1:Always contact your Komatsu distributor when dealing with these items.
l In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.

Problem Main causes Remedy

Lamp does not glow brightly even l Defective wiring (o Check, repair loose terminals,
when the engine runs at high disconnections)
speed l Defective adjustment of alternator
belt tension
Lamp flickers while engine is l Check, repair alternator belt
running tension
For details, see EVERY 1000
HOURS SERVICE

Charge level monitor does not go l Defective alternator 10 Replace)

out even when engine is running l Defective wiring (o Check, repair)

Abnormal noise is generated from l Defective alternator 10 Replace)

alternator

Starting motor does not turn when l Defective wiring (o Check, repair)
starting switch is turned to ON l Insufficient battery charge l Charge

Pinion of starting motor keeps goin!B l Insufficient battery charge l Charge

in and out

Starting motor turns engine l Insufficient battery charge l Charge

sluggishly l Defective starting motor (o Replace)

Starting motor disengages before l Defective wiring (8 Check, repair)

engine starts l Insufficient battery charge l Charge

Pre-heating monitor does not light l Defective wiring (o Check, repair)

l Defective heater relay (o Replace)
l Defective monitor (o Replace)

Oil pressure monitor does not l Defective monitor (o Replace)

light up when engine is stopped l Defective caution lamp switch (o Replace)
(starting switch at ON position)

Outside of electrical heater is not l Defective wiring (o Check, repair)

warm when touched by hand l Disconnection in electric (0 Replace)
heater
l Defective operation of (o Replace)
heater relay switch

2-82
 16. TROUBLESHOOTING

16.6.2 CHASSIS
0 ( ): Always contact your Komatsu distributor when dealing with these items.
l In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.

Problem Main causes Remedy

Speed of travel, swing, l Lack of hydraulic oil l Add oil to specified level,
boom, arm, bucket is slow see CHECK BEFORE
STARTING

Pump generates abnormal l Clogged element in hydraulic l Clean, see EVERY 2066
noise tank strainer HOURS SERVICE

Excessive rise in hydraulic l Loose fan belt l Adjust fan belt tension,
oil temperature see EVERY 250 HOURS
SERVICE
l Dirty oil cooler l Clean, see EVERY 500
HOURS SERVICE
l Lack of hydraulic oil l Add oil to specified level,
see CHECK BEFORE
STARTING

Track comes off l Track too loose l Adjust track tension, see
WHEN REQUlRED
Abnormal wear of sprocket

Bucket rises slowly, does l Lack of hydraulic oil a Add oil to specified level,
not rise see CHECK BEFORE
STARTING

Does not swing l Swing lock switch still applied l Turn swing lock switch OFF

2-83
16. TROUBLESHOOTING

16.6.3 ENGINE
l ( 1: Always contact your Komatsu distributor when dealing with these items.
l In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.

Problem Main causes Remedy

Engine oil pressure monitor Engine oil pan oil level is low l Add oil to specified level, see
lights up [sucking in air) CHECK BEFORE STARTING
Clogged oil filter cartridge l Replace cartridge, see EVERY

250 HOURS SERVICE

Defective tightening of oil pipe (o Check, repair)
joint, oil leakage from damaged
part
Defective engine oil pressure (o Replace sensor)
sensor

Steam is emitted from top part Cooling water level low, water Add cooling water, repair, see
of radiator (pressure valve) leakage CHECK BEFORE STARTING
Loosen fan belt Adjust fan belt tension, see
EVERY 250 HOURS SERVICE
Dirt or scale accumulated in Change cooling water, clean
cooling system inside of cooling system, see
WHEN REQUIRED
Clogged radiator fin or Clean or repair, see EVERY
Red range of engine water damaged fin 500 HOURS SERVICE
temperature gauge lights up Defective thermostat (o Replace thermostat)
Loose radiator filler cap (high l Tighten cap or replace packing

altitude operation)

Engine does not start when Lack of fuel l Add fuel, see CHECK
starting motor is turned BEFORE STARTING
Air in fuel system l Repair place where air is

sucked in, see EVERY 500

HOURS SERVICE
Defective fuel injection pump or (o Replace pump or nozzle)
nozzle
Starting motor cranks engine
sluggishly
Preheating monitor does not
light up
Defective compression
I See ELECTRICAL SYSTEM

o Defective valve clearance (o Adjust valve clearance)

2-84
 16. TROUBLESHOOTING

ENGINE (cont’d) (16.6.3)

Problem Main causes Remedy

Exhaust gas is white or blue l Too much oil in oil pan Add oil to specified level,
see CHECK BEFORE
STARTING
0 Improper fuel Change to specified fuel

Exhaust gas occasionally turns l Clogged air cleaner element l Clean or replace, see WHEN
black REQUIRED
l Defective nozzle (a Replace nozzle)
l Defective compression (o See defective compression
a hove)
l Defective turbocharger l Clean or replace turbocharger

Combustion noise occasionally l Defective nozzle (o Replace nozzle)

makes breathing sound

Abnormal noise generated l Low grade fuel being used l Change to specified fuel
(combustion or mechanical) l Overheating l Refer to “Radiator water level
monitor lights up” as above
l Damage inside muffler (o Replace muffler)
l Excessive valve clearance (o Adjust valve clearance)

2-85
MAINTENANCE
17. GUIDES TO MAINTENANCE

Do not carry out any inspection and maintenance operation that is not given in this manual.
Perform maintenance work on hard, flat ground.

Check service meter:

Check the service meter reading every day to see if the time has come for any necessary maintenance
to be carried out.

Komatsu genuine replacement parts:

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

Komatsu genuine oils:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for
ambient temperature.

Always use clean washer fluid:

Use automobile window washer fluid and be careful not -to let any dirt get into it.

Always use clean oil and grease:

Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away
from oil and grease.

Keeping the machine clean:

Always keep the machine clean. This makes is easier to find parts causing problems. Keep in particular
grease fittings, breathers and oil level gauges clean and avoid foreign matters from getting in them.

Be careful of hot water and oil:

Draining hot oils and coolants and removing their filters immediately after the engine stops are
hazardous. Allow the engine to cool.
If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 40°C)
before draining it.

Checking foreign materials in drained oil and on filter:

After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign
materials. If large quantities of metallic particles or foreign materials are found, consult your Komatsu
distributor.

Fuel strainer:
If your machine is equipped with a fuel strainer, do not remove it while fueling.

Oil change:
Check or change oils in the places where dust is scarce to keep foreign materials away from oils.

3-2
 17. GUIDES TO MAINTENANCE

Warning tag:
Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who
is not aware of the circumstances from starting the engine.

Obey precautions:
During the operation, always obey the precautions on the safety label attached to the machine.

Welding instructions:
l Turn off the engine starting switch.
l Do not apply more than 200 V continuously.
l Connect grounding the cable within 1 m from the area to be welded.
l Avoid seals or bearings from being between the area to be welded and the position of grounding
point.
l Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding
point.

Fire prevention:
Use nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from light
oil.

Clamp faces:
When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with
new ones. Be sure to fit O-rings and gaskets when assembling.

Objects in your pockets:

Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when
you work on the machinery while bending over it.

Checking undercarriage:
When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and
damage in bolts and nuts. Loosen the track tension a little when working in such areas.

Precautions when washing machine:

l Never spray steam or water directly on the connectors and mechatronics parts.
l Do not allow water to get on the monitors inside the operator’s cab.
l Never spray steam or water directly at the radiator or oil cooler portions.

3-3
17. GUIDES TO MAINTENANCE

Pre-and post-work checks:

Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness.
Wash the machine immediately after the work to protect components from rusting.
Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they
are submerged in water.

Dusty worksites:
When working at dusty worksites, do as follows:
l Inspect the dust indicator to see whether the air cleaner is blocked up. Clean the air cleaner at shorter
intervals than specified.
l Clean the radiator core frequently to avoid clogging.
l Clean and replace the fuel filter frequently.
l Clean electrical components, especially the starting motor and alternator, to avoid accumulation of
dust.

Avoid mixing oils:

Never mix oils of different brands. If you have only oil which is a different brand from the one that is
used in the machine, do not add it but replace all the oil.

3-4
18. OUTLINES OF SERVICE

l Use Komatsu genuine parts for replacement.

l When changing or adding oil, do not use a different type of oil.

l Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as
shown in the table below.

Item Kind of fluid

Engine oil pan SAE 15W-40

API classification CD

Swing machinery case SAE 30

Final drive case API classification CD
Damper case

Hydraulic tank SAE IOW

API classification CD

ASTM D975 No. 2

Fuel tank (However, ASTM D975 No. 1 is
used for the winter season
(October to March)

Radiator Komatsu Super Coolant

(AF-ACL) 41% added to water

18.1 OUTLINE OF OIL, FUEL, COOLANT

18.1.1 OIL
Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and
Maintenenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.

Oil corresponds to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.

Never mix oils of different grades or brands.

Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.

If the oil in the work equipment is not clear, there is probably water or air getting into the circuit.
In such cases, please contact your Komatsu distributor.

When changing the oil, always replace the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to check the condition of the
machine. For those who wish to use this service, please contact your Komatsu distributor.

3-5
18.1.2 FUEL
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work
properly.

Be extremely careful not to let impurities get in when storing or adding fuel.

Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature
below-15X), so it is necessary to change to a fuel that matches the temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always
fill the fuel tank after completing the day’s work.

Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment
and water from the fuel tank.

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from
the circuit.

18.1.3 COOLANT
River water contains large amounts of calcium and other impurities, so if it is used, scale will stick
to the engine and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine
is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.

Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing proportions, see 24.2.2 CLEAN INSIDE OF COOLING SYSTEM.

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from
the air in the coolant.

3-6
 18. OUTLINES OF SERVICE

18.1.4 GREASE
l Grease is used to prevent twisting and noise at the joints.

l The nipples not included in the maintenance section are nipples for overhaul, so they do not need
grease.
If any part becomes stiff after being used for long time, add grease.

l Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places. Where sand or dirt sticking in the grease would cause wear of the rotating
parts.

18.1.5 STORING OIL AND FUEL

l Keep indoors to prevent any water, dirt, or other impurities from getting in.

l When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum
can is at the side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures
to protect them.

l To prevent any change in quality during long-term storage, be sure to use in the order of first in -
first out (use the oldest oil or fuel first).

18.1.6 FILTERS
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from
entering important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, it is necessary to consider replacing the filters at
shorter intervals according to the oil and fuel (sulfur content) being used.

Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles
are found, please contact your Komatsu distributor.

Do not open packs of spare filters until just before they are to be used.

Always use Komatsu genuine filters.

3-7
18.2 OUTLINE OF ELECTRIC SYSTEM

l If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result
in hazardous malfunction of the machine.

l Services relating to the electric system are (I) check of fan blet tension, (2) check of damage or wear
in the fan belt and (3) check of battery fluid level.

l Never remove or disassemble any electric components installed in the machine.

l Never install any electric components other than these specified by Komatsu.

l Be careful to keep the electric system free of water when washing the machine or when it rains.

l When working on the seashore, carefully clean the electric system to prevent corrosion.

l When installing a car cooler or any other electrical equipment, connect it to an independent power
source connector. The optional power source must never be connected to the fuse, starting switch,
or battery relay.

3-8
 18. OUTLINES OF SERVICE

18.3 OUTLINE OF HYDRAULIC SYSTEM

During operation and immediately after operation is ended, the temperature of the hydraulic system
still remains high.
In addition, high hydraulic pressure is applied to the system. Take care when inspecting and
maintaining the hydraulic system.
o Stop the machine on level ground, lower the bucket to the ground, then set so that there is no
pressure applied to the cylinder circuit.
o Always stop the engine.
o Immediately after operations, the hydraulic oil and lubricating oil are at high temperature and
high pressure, so wait for the oil temperature to go down before starting maintenance.
Even when the temperature goes down, the circuit may still be under internal pressure, so when
loosening the plug or screw, or the hose joint, do not stand in front of the part. Loosen it slowly
to release the internal pressure before removing it.
o When carrying out inspection or maintenance of the hydraulic circuit, always bleed the air form
the hydraulic tank to remove the internal pressure.

Periodic maintenance includes the inspection of the hydraulic oil level, replacement of the filter and
refilling of hydraulic oil.

When the high pressure hose, etc. is removed, check the O-ring for damage. If necessary, replace
it.

After the hydraulic filter element and strainer are cleaned or replaced, or after the hydraulic system
is repaired or replaced or the hydraulic piping is removed, bleed air from the hydraulic circuit.

The accumulator is charged with high-pressure nitrogen gas. Incorrect handling may be dangerous.
For the handling procedure, see “11.15 Handling accumulator”.

3-9
19. WEAR PARTS LIST

Wear parts such as the filter element, bucket tooth, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
When ordering parts, please check the part number in the parts book.

The parts in parentheses are to be replaced at the same time.

Replacement
Item Part No. Part Name wty
frequency

Engine oil filter 6735-51-5140 Cartridge 1 Every 250 hours service

I I
Hydraulic oil filter
2OY-60-21510
(07000-05180)
Element
(O-ring) I I
,
1
(1)
I
Every 500 hours service

Fuel filter 6732-71-6110 Cartridge 1 Every 500 hours service

Additional fuel
filter (option)
600-311-9121 Cartridge
I I 1 Every 500 hours service

Hydraulic tank
2OY-60-21410 Element 1 Every 500 hours service
breather I I

Air cleaner 600-181-6740

Additional 2OY-970- 1820

filter for breaker (07000-12115)

Electrical intake
6732-11-4810 Gasket
air heater

Corrosion resistor 600-41 l-l 151 Cartridge (400 g) 1 When change the coolant

Corrosion resistor 600-41 l-l 191 Cartridge (200 g) 1 Every 1000 hours service

3-10
 19. WEAR PARTS LIST

Replacement
Item Part No. Part Name Qw frequency

Bucket Vartical pin type

(PC200) 205-70-74272 Tooth 5
(205-70-74281) (Pin) (5)
(205-70-74291) (Lock) (5)

Horizontal pin type

205-70-19570 Tooth
(09244-02496) (Pin)

205-70-74180 Cutter (left) 1

205-70-74190 Cutter (right)
(176-32-11210) (Bolt) A
(01803-02430) (Nut) 03)

3-11
20. USE OF F JEL, COOLANT AND LUBRICANTS ACCORDING
TO AMBI :NT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY

KIND OF
RESERVOIR
FLUID -40 -22 -4 14 32 50 68 86 104 122°F
Specified Refill
-20 -10 0 10 20 30 40 5(

26.3 e 24.0 !?,

Engine oil pan 5.95 US gal 5.34 US gal
5.79 UK gal 5.28 UK gal

5.5 e 5.5 e
Swing machinery cast 1.45 US gal 1.45 US gal
1.21 UK gal 1.21 UK gal

4.4 e 4.2 I?
Final drive case (each 1.16 US gal 1.11 US gal
Engine oil 3.97 UK gal 1.92 UK gal

0.75 e
Damper case 0.20 US ga
0.17 UK ga

239 Q 166 a
Hydraulic system 63.1 US gal 43.8 US gal
52.6 UK gal 36.5 UK gal

340 a
Fuel tank IDiesel fuel 99.8 US gal -
74.8 UK gal

22.2 e
Cooling system Water Add antifreeze 5.87 US gal -
4.88 UK gal

% ASTM D975 No.1

3-12
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.

Change interval of oil in

Fuel sulphur content
ennin oil pan

0.5 to 1.0% l/2 of regular interval

Above 1.0% l/4 of regular interval

When starting the engine in an atmospheric temperature of lower than O’C, be sure to use engine
oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to
10°C more or less in the day time.

Use API classification CD, CE or CF-4 as engine oil and if API classification CC, reduce the engine
oil change interval to half.

There is no problem if single grade oil is mixed with multigrade oil (SAElOW-30, 15W-401, but be
sure to add single grade oil that matches the temperature in the table.

We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute

3-13
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil
Anti-freeze
[CD, CE or CF-41
Coolant
SAEIOW, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
1ow30, 15w40 [GL-4 or GL-51 [Lithium-Base]
Base1
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)

EO 1O-CD AF-ACL
EOSO-CD GO90 G2-LI AF-PTL
1 KOMATSU
EOIO-30CD GO140 GP-LI-S AF-PT (Winter, one
E015-40CD season typr

Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP
grade
*Sigma turbo

Multi-purpose gear RYKON prenium

3 AMOCO *Amoco 300
oil grease

Litholine HEP 2 -
4 ARC0 *Arcofleet S3 plus Arco HD gear oil
Arco EP moly D

Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP

*RPM delo 400 Universal thuban Marfak all purpose 2

6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2

EP
*Turbomax EPX
MS3
7 CASTROL *RX super HYP~Y Anti-freeze
Spheerol EPL2
CRD HYP~Y B
HYP~Y C

8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -

Universal gear -
9 CONOCO *Fleet motor oil Super-sta grease
lubricant

Multiperformance 3C Tranself EP
IO ELF Glacelf
Performance 3C Tranself EP type. 2

Essolube D3
*Essolube XD-3
EXXON Gear oil GP
*Essolube XD-3 Extra Beacon EP2 All season coolant
I1 (ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
-

Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolan t

Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77
Mobilube HD
1ow-30, 15w-40 Mobilgrease special

3-14
 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil Anti-freeze

[CD, CE or CF-41 Coolant
SAEIOW, 30, 40 Gear Oil Grease
JO. Supplier [Ethylene Glycol
1ow30, 1RN40 [GL-4 or GL-51 [Lithium-Base]
Base1
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)

Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL Multi-purpose 4140 707L White - bearing summer coolant
fleet motor oil
grease

FINA potonic N FINA tamidor

15 PETROFINA FINA kappa TD FINA marson EPLP
FINA potonic NE

Spirax EP
16 SHELL Rimula X Alvania EP grease
Spirax heavy duty

Sunoco ultra prestige Sunoco antifreeze

Sunoco GL5 and summer
17 SUN 2EP
gear oil coolant
Sun prestige 742

*Ursa super plus Multifak EP2 Code 2055 startex

18 TEXACO Multigear antifreeze coolant
Ursa premium Starplex 2

Total EP
Rubia S Multis EP2 Antigel/antifreeze
19 TOTAL Total transmission
*Rubia X
TM

20 UNION *Guard01 MP gear lube LS Unoba EP

*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B Antifreeze
MDC Multigear C

3-15
21. ;T&llDARD TIGHTENING TORQUES FOR BOLTS AND

21.1 INTRODUCTION OF NECESSARY TOOLS

The following tools are needed when carrying out maintenance.

No. Name of tool Part No. I Remarks

1 Wrench Applicable width across flats IS,-S,)

09002-01417 14mm - 17mm
09002-03032 30mm - 32mm

s2
AK63370

Screwdriver 09033-00190 Interchangeable fiat-head and cross-head type

Socket wrench 2OY-98-21130 Applicable width across flats

set 12 mm, 14 mm, 17 mm, 19 mm, 22 mm, 24 mm,
30 mm
Extension, Handle (large), Handle (small)

Hexagon wrench 09007-00836 Aoolicable width across flats 8 mm

5 Filter wrench 09019-08035

6 Grease pump 07950-I 0450 For greasing work

7 Nozzle 07951-I 1400

8 Grease cartridge 07950-90403 I (Lithium base grease, 400 g)

9 Hammer 0903940150

10 Pinch bar 09055-I 0390

If any of the above tools are broken, please order them from your Komatsu distributor.

3-16
 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

21.2 TORQUE LIST

Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.
The tightening torque is determined by the width across the flats
b
@ of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced.
Nm (newton meter): INm 6 0.1 kgm Am53380
* 0.74 Ibft

Thread diameter Width across

of bolt (mm) flat(mm)
(a) (b) @ @ AM54300
Nm kgm Ibft

6 10 13.2 + 1.4 1.35 2 0.15 9.13 f 1.03

8 13 31.4 + 2.9 3.2 + 0.3 23.2 + 2.1
10 17 65.7 + 6.8 6.7 2 0.7 48.5 2 5.0
12 19 112 t 9.8 11.5 2 1.0 82.6 + 7.2
14 22 177 + 19 18.0 * 2.0 131 f 14

16 24 279 + 29 28.5 + 3 206 zz21

18 27 383 + 39 39 2 3 282 + 29
20 30 549 + 58 56 f 6 405 + 43
22 32 745 + 78 76 2 8 549 + 58
24 36 927 + 98 94.5 f 10 684 f 72

27 41 1320 -c140 1352 15 973 f 100

30 46 1720 + 190 175520 1270~140
33 50 2210 + 240 225 + 25 1630 2 180
36 55 2750 + 290 280 + 30 2030 2 210
39 60 3280 + 340 335 + 35 2420 k 250

NOTICE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tightening
torque: doing so will damage the plastic parts.

3-17
 To ensure safety at all times when operating or driving the machine, the user of the machine must
always carry out periodic maintenance. In addition, to further improve safety, the user should also carry
out periodic replacement of the parts given in the table. These parts are particularly closely connected
to safety and fire prevention.

With these parts, the material changes as time passed, or they easily wear or deteriorate. However,
it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always
be replaced after a fixed time has passed, regardless of their condition, This is necessary to ensure that
they always maintain their function completely.
However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the
same as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same
time.
Ask your Komatsu distributor to replace the safety critical parts.

3-18
 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

SAFETY CRITICAL PARTS

No. Safety critical parts for periodic replacement Q’ty Replacement interval

1 Fuel hose (Fuel tank - Connector) 1

2 Fuel hose (Connector - Fuel injection pump) I

3 Fuel return hose (Fuel injection pump - Fuel tank) 1

4 Fuel return hose (Fuel filter - Connector) 1

5 Fuel return hose (Connector - Fuel tank) 1

6 Turbocharger lubricating oil hose 1

7 1 Pump outlet hose (Pump - Control valve) I 2 I

8 Work equipment hose (Boom cylinder inlet) 4
Work equipment hose Every 2 years or 4000 hours,
9 2
(Bucket cylinder line - Boom foot section) whichever comes sooner

10 Work equipment hose (Bucket cylinder inlet) 2

,, Work equipment hose 2
(Arm cylinder line - Boom foot section)
12 Work equipment hose (Arm cylinder inlet) 2

13 ( Additional attachment line hose (Boom foot section) I 2 I

14 Additional attachment line hose (Boom top section) 2

15 Swing line hose (Swing motor inlet) 2

16 Main suction hose 1

17 Water separator case, O-ring, Plug 1

18 rseat belt I 1 I Replace every 3 years

3-19
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

Additional fuel filter Water separator

AN330373

AE332370

3-20
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

AE313710

AE331940

3-21
23. MAINTENANCE SCHEDULE CHART

23.1 MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

INlTlAL 250 HOURS SERVICE (only after the first 250 hours)

Replace fuel filter cartridge and additional fuel filter cartridge 3-58

Check engine valve clearance, adjust 3-67

WHEN REQUIRED

Check, clean and replace air cleaner element 3-26

Clean inside of cooling system 3-28

Check and tighten track shoe bolts 3-32

Check and adjust track tension 3-33

Check electrical intake air heater 3-35

Replace bucket teeth (vertical pin type) 3-36

Replace bucket teeth (horizontal pin type) 3-39

Adjust bucket clearance 3-40

Check window washer fluid level, add fluid 3-41

Check and adjust cooler 3-42

Replace additional breaker filter element 3-43

CHECK BEFORE STARTING

Check coolant level, add water 3-44

Check oil level in engine oil pan, add oil 3-44

Check fuel level, add fuel 3-45

Check oil level in hydraulic tank, add oil 3-46

Check dust indicator 3-47

Check electric wirings 3-47

Lubricate clamshell bucket (12 points) 3-48

Check for water and sediment in water separator, drain water 3-48

EVERY 100 HOURS SERVICE

Lubricating 3-49

l Boom cvlinder foot oin (2 ooints) 3-49

3-22
 23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

Lubricating 3-49

l Boom foot pin (2 points) 3-49

l Boom cylinder rod end (2 points) 3-49

l Arm cylinder foot pin (I point) 3-49

l Boom-arm coupling pin (‘I point) 3-50

l Arm cylinder rod end (1 point) 3-50

l Bucket cylinder foot pin (I point) 3-50

l Arm-link coupling pin (I point) 3-50

l Arm-bucket coupling pin (I point) 3-50

l Link coupling pin (2 points) 3-50

l Bucket cylinder rod end (I point) 3-50

l Bucket-link coupling pin (1 point) 3-50

Check oil level in swing machinery case, add oil 3-50

Drain water and sediment from fuel tank 3-51

EVERY 250 HOURS SERVICE

Check oil level in final drive case, add oil 3-52

Check level of battery electrolyte 3-53

Change oil in engine oil pan, replace engine oil filter cartridge 3-54

Lubricate swing circle (2 points) 3-55

Check fan belt tension, adjust 3-56

Check cooler compressor belt tension, adjust 3-57

EVERY 500 HOURS SERVICE

Replace fuel filter cartridge and additional fuel filter cartridge 3-58

Check swing pinion grease level, add grease 3-59

Clean and inspect radiator fins, oil cooler fins and condenser fins 3-60
(only for machines equipped with cooler)

Clean internal air strainer of cooler system 3-61

Replace hydraulic tank breather element 3-61

Replace hydraulic filter element 3-62

3-23
 23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

EVERY 1000 HOURS SERVICE

Chanae oil in swina machinaw case 3-63

Check oil level in damper case, add oil 3-64

Check all tightening parts of turbocharger 3-64

Check play of turbocharger rotor 3-64

Check alternator belt tension and replace alternator belt 3-65

Replace corrosion re&tor cartridge 3-65

EVERY 2000 HOURS SERVICE

Change oil in final drive case 3-66

Clean hydraulic tank strainer 3-67

Clean, check turbocharger 3-67

Check alternator, starting motor 3-67

Check engine valve clearance, adjust 3-67

Check vibration damper 3-68

EVERY 4000 HOURS SERVICE

Check water pump 3-69

EVERY 5000 HOURS SERVICE

Change oil in hydraulic tank 3-70

23.2 MAINTENANCE INTERVAL WliEN USING

HYDRAULIC BREAKER

For machines equipped with a hydraulic breaker, the hydraulic

oil deteriorates faster than for normal bucket digging operations, so
set the maintenance intervals as follows.
Re0lacenent interval
0 Replacing hydraulic element for hvdraul ic oi I

On new machines, replace the element after the first 100 to 150
hours, then carry out further replacement of the element accord-
ing to the table on the right.
l Changing oil in hydraulic tank
Change the oil according to the table on the right.
. 0 Replacing additional filter element for breaker
20 40 60 80 100
Use a guideline of 250 hours for use of the breaker (operating
ratio for the breaker: 50 % or more), and replace the element
according to the table on the right. Hydraulic filter breaker only)
eleaent AD313738

3-24
24. SERVICE PROCEDURE

24.1 INITIAL 250 HOURS SERVICE

Carry out the following maintenance only after the first 250
hours.

l REPLACE FUEL FILTER CARTRIDGE AND ADDlTlONAL FUEL

FILTER CARTRIDGE
l CHECK ENGINE VALVE CLEARANCE, ADJUST

For details of the method of replacing or maintaining, see the

section on EVERY 500 HOURS and 2000 HOURS SERVICE.

3-25
24. SERVICE PROCEDURE

24.2 WHEN REQUIRED

24.2.1 CHECK, CLEAN AND REPLACE AIR

CLEANER ELEMENT

Never clean or replace the air cleaner element with the engine

l When using pressure air to clean the element wear safety

glasses or goggles to protect the eyes.

Checking
Whenever the red piston in dust indicator @ appears, clean the air
cleaner element.

Cleaning or replacing outer element

1. Open the front door on the left side of the machine, remove wing
nut @ and take out element 0.
To prevent entry of dirt and dust, cover the air connector side of
the rear end of the air cleaner with a clean cloth and adhesive
tape.

2. Clean the air cleaner body interior and the cover.

3. Direct dry compressed air (less than 700 kPa (7 kg/cm*, 100 psi))
to element @ from inside along its folds, then direct it from
outside along its folds and again from inside.
I) Remove one seal from the outer element whenever the outer
element has been cleaned.
2) Replace the outer element which has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace both inner and outer elements when the dust indi-
cator red piston appears soon after installing the cleaned
outer element even though it has not been cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if
necessary, retighten.

3-26
 24. SERVICE PROCEDURE

4. If small holes or thinner parts are found on the element when it

is checked with an electric bulb after cleaning replace the ele-
ment.

NOTICE
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against
something.

Remove the cloth and tape used for cover in Step 1.

Install the cleaned element and fix it with the wing nut.

Replace seal washer @ or wing nut @with new parts if they are
broken.

Remove evacuator valve @ and clean with compressed air.

After cleaning, install it.

Replacing inner element

1. First remove the cover and the outer element, and then remove
the inner element.

2. To prevent dust from getting in, use a clean cloth or tape to cover
the air connector (outlet side).

3. Clean the air cleaner body interior, then remove the cover
installed in Step 2.

4. Fit a new inner element to the connector and tighten it with nuts.
Do not clean and reinstall a inner element.

5. Install the outer element and fix it with the wing nut.

3-27
24. SERVICE PROCEDURE

24.2.2 CLEAN INSIDE OF COOLING SYSTEM

db WARNING
Soon after the engine has been stopped, the coolant is hot
and can cause personal injury. Allow the engine to cool
before draining water.

Since cleaning is performed while the engine is running, it is

very dangerous to enter the rear side of the machine as the
machine may suddenly start moving. If the under cover is left
removed, it may interfere with the fan. While the engine is
running, never enter the rear side of the machine.

Never remove the radiator cap when the engine is at operat-

ing temperature. At operating temperature, the coolant is
under pressure. Steam blowing up from the radiator could
cause personal injury. Allow the engine to cool until the
radiator filler cap is cool enough to touch with your hand.
Remove the filler cap slowly to allow pressure to be relieved.

l Clean the inside of the cooling system change the coolant and
replace the corrosion resistor (option) according to the table
below.

Cleaning inside of
Replacing corrosion
Kind of coolant cooling system and
resistor (option)
changing coolant
Every year (autumn) or
Permanent type antifreeze every go00 hours
(All season type)
whichever comes first
Every 1000 hours and
Non permanent type Ev;uvm;jmonths (spring,
when cleaning the in-
antifreeze containing side of the cooling
ethylene glycol (Winter, (Drain antifreeze in spring,
system and when
one season type) add antifreeze in autumn)
changing coolant
Every 6 months or every
When not using antifreeze 1000 hours whichever
comes first

l Stop the machine on level ground when cleaning or changing

the coolant.
0 Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type
antifreeze, use an antifreeze containing ethylene glycol.

3-28
 24. SERVICE PROCEDURE

l When deciding the ratio of antifreeze to water, check the lowest

temperature in the past, and decide from the mixing rate table
given below.
It is actually better to estimate a temperature about 10°C lower
when deciding the mixing rate.

Mixing rate of water and antifreeze

Min. “C -5 -10 -15 -20 -25 -30

atmospheric
temperature “F 23 14 5 -4 -13 -22

e 5.1 6.7 8.0 9.1 10.2 11.1

Amount of
antifreeze US gal 1.35 1.77 2.11 2.40 2.69 2.93

UK gal 1.12 1.47 1.76 2.00 2.24 2.44

e 17.1 15.5 14.2 13.1 12.0 11.1

Am~aut~~ Of US gal 4.52 4.10 3.75 3.96 3.17 2.93

UK aal 3.76 3.41 3.12 2.86 2.64 2.44

A WARNING
Antifreeze is flammable, so keep it away from any flame.

l Use city water for the cooling water.

If river water, well water or other such water supply must be
used, contact your Komatsu distributor.
l We recommend use of an antifreeze density gauge to control the
mixing proportions.

&L WARNING
When removing drain plug, avoid pouring coolant on yourself.

3-29
24. SERVICE PROCEDURE

0 Prepare a container to catch drained coolant: Min 23.3 fi (6.16 US

gal, 5.13 UK gal) capacity.

1. If a corrosion resistor cartridge is installed, close valves 0.

2. Turn radiator cap @ slowly to release the internal pressure.

3. Pushing radiator cap 0, turn it slowly to remove it.

4. Remove the undercover, then set a container to catch the coolant

under drain valve @ and drain plug 0. Open drain valve @I at
the bottom of the radiator to drain the water. Remove drain plug
@ in the cylinder block when draining the water.

5. After draining the water, close drain valve @ and drain plug @,
and fill with city water.

6. Open drain valve @ and drain plug 0, run the engine at low
idling, and flush water through the system for 10 minutes.

When doing this, adjust the speed of filling and draining the
water so that the radiator is always full.
While flushing water through the system, watch carefully that
the water inlet hose does not come out of the radiator water
filler.

7. After flushing, stop the engine, open drain valve @ and drain
plug 0, then close it again after all the water has drained out.

8. After draining the water, clean with a flushing agent.

We recommend use of a Komatsu genuine cleaning agent. For
details of the cleaning method, see the instructions given with
the cleaning agent.

9. After cleaning, open drain valve @ and drain plug @to drain all
the cooling water, then close them and fill slowly with clean
water.

IO. When the water comes up to near the water filler port, open
drain valve @ and drain plug 0, run the engine at low idling, and
continue to run water through the system until clean colorless
water comes out.

When doing this, adjust the speed of filling and draining the water
so that the radiator is always full.

3-30
 24. SERVICE PROCEDURE

11. When the water is completely clean, stop the engine, close drain
valve 0, wrap the drain plug with seal tape, then close drain plug
0.

12. Replace the corrosion resistor cartridge and open valves 0.

For details of replacement of the corrosion resistor, see “24.7
EVERY 1000 HOURS SERVICE”.

13. Install the undercover.

14. Add cooling water until it overflows from the water filler.

15. To remove the air in the cooling water, run for five minutes at
low idling, then for another five minutes at high idling.
When doing this, leave radiator cap @ off.

16. After draining off the cooling water of reserve tank 0, clean the
inside of the reserve tank and refill the water between FULL and
LOW level.

17, Stop the engine, wait for about three minutes, add cooling water
up to near the radiator water filler port, then tighten cap 0.

3-31
24. SERVICE PROCEDURE

24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts @ loose, they will
break, so tighten any loose bolts immediately.

AN114580

Method for tightening

1 First tighten to a tightening torque of 490 2 50 Nm (50 2 5 kgm,
360 -c 36 Ibft) then check that the nut and shoe are in close
contact with the link contact surface.

2 After checking, tighten a further 120” f IO”.

Order for tightening

Tighten the bolts in the order shown in the diagram on the right.
After tightening, check that the nut and shoe are in close contact with
the link mating surface.

3-32
 24. SERVICE PROCEDURE

24.2.4 CHECK AND ADJUST TRACK TENSION

A WARNING
Carry out this operation with two workers. The operator must
move the machine in accordance with the signals from the other
worker. The track tension is checked with the chassis raised, so
it is extremely dangerous if the machine is lowered by mistake
during the inspection. Never move the machine while anyone is
carrying out measurements.

The wear of pins and bushings on the undercarriage will vary

with the working conditions and soil properties. It is thus necessary
to continually inspect the track tension so as to maintain the stand-
ard tension.
Carry out the check and adjustment under the same conditions
as when operating (on jobsites where the track becomes clogged
with mud, measure with the track clogged with mud).

Inspection
1. Raise the chassis with the boom and arm.
When doing this, operate the levers slowly.
2. Measure the clearance between the bottom of the track frame
and the top of the track shoe at a position that is safe even if the
chassis should come down.

Standard clearance: 303 -c 20 mm (11.9 +. 0.8 in)

Places to measure
Track frame
PC200-6 : 4th track roller from sprocket J

Track shoe
AN114590

3-33
 24. SERVICE PROCEDURE

If the track tension is not at the standard value, adjust it in the

following manner.
Adjustment

a WARNING
Grease inside the adjusting mechanism is under high pressure.
Grease coming from plug @ under pressure can penetrate the
body causing injury or death. For this reason, do not loosen plug
@ more than one turn. Do not loosen any part other than plug 0.
Furthermore, do not bring your face in front of the plug 0.
If the track tension is not relieved by this procedure, please
contact your Komatsu distributor.
AN114600

When increasing tension

Prepare a grease gun.

Pump in grease through grease fitting @ with a grease gun.

To .check that the correct tension has been achieved, move the
machine backwards and forwards.

v AN114610
Check the track tension again, and if the tension is not correct, 1
adjust it again.

Continue to pump in grease until S becomes 0 mm. If the tension

is still loose, the pin and bushing are excessively worn, so they
must be either turned or replaced. Please contact your Komatsu
distributor.

3-34
 24. SERVICE PROCEDURE

When loosening tension

I AWARNING Pl
It is extremely dangerous to release the grease by any method
except the procedure given below. If the track tension is not
relieved by this procedure, please contact your Komatsu dis-
tributor.
AN114600
1. Loosen plug @ gradually to release the grease.

2. Turn plug @ a maximum of one turn.

3. If the grease does not come out smoothly, move the machine
backwards and forwards a short distance.

4. Tighten plug 0.

5. To check that the correct tension has been achieved, move the
machine backwards and forwards.

6. Check the track tension again, and if the tension is not correct,
adjust it again.

24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your
Komatsu distributor to have the electrical intake air heater repaired
or checked for dirt or disconnections.

3-35
24. SERVICE RPOCEDURE

24.2.6 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)

Replace the point before the adapter starts to wear.

A WARNING
It is dangerous if the work equipment moves by mistake when
the teeth are being replaced. Set the work equipment in a stable
condition, then stop the engine and apply the locks securely to
the levers.

Free

Place a block under the bucket bottom to allow the pin of tooth 1
@ to be knocked out with a hammer. Carry out full stroke
operation of the control levers within 15 seconds after stopping
the engine. After confirming that the work equipment is in a
stable condition, lock the safety lock lever.
Set so that the bottom face of the bucket is horizontal.

Use a hammer and drift to knock out lock pin @ (If the drift is
set against rubber pin lock @ when it is hit, the rubber pin lock
may break. Set it against the back of the pin.)

After removing lock pin @ and rubber pin lock 0, check them.

AM091280

If lock pins and rubber pin locks with the following defects are used, The lock pin is too short
the point may come off the bucket. Replace them with new ones. Max. 113 of A

A
o The lock pin is too short.

@
Align with bottom face AM091290

3-36
 24. SERVICE PROCEDURE

o The rubber of the rubber pin lock is torn, and the steel balls may C
come out. The rubber is broken and the
steel balls come out easily
\

o The steel balls are buried when they are pressed by hand.

The steel bails can

be buried when
pressed with finger
AM091310

4. Clean the surface of adapter @I and remove the soil from it with
a knife.

5. Use your hand or a hammer to push rubber pin lock @ into the
hole of the adapter.
When doing this, be careful that the rubber pin lock does not fly
out from the adapter surface.

AM091320

6. Clean the inside of point 0, then install it to adapter 0. If there

is mud stuck to it or if there are protrusions, the point will not
enter the adapter properly, and there will not be proper contact
at the mating portion.

7. Fit point @ to adapter 0, and confirm that when the pointer is

pressed strongly, the rear face of the hole for the pin of the point
Sticky material
is at the same level as the rear face of the hole for the pin of the
adapter.

AM091330

3-37
24. SERVICE PROCEDURE

If the rear face of the hole for the pin of point @ is protruding to the
front from the rear face of the pin hole for adapter 0, do not try to
knock the pin in. There is something preventing point @) from
entering adapter @ fully, so remove the obstruction. When point @
enters adapter @ fully, knock in lock pin 0.

8. Insert lock pin @ in the hole of the point and hit it until its top
is the same level as the surface of point 0.

9. After replacing a bucket tooth, always check the following.

1) After the lock pin has been knocked in completely, check that
it is being secured by the point and surface.
21 Lightly hi lock pin 0 in the reverse direction from which it
was hit in.
3) Lightly hit the tip of the point from above and below, and hit
itssides from right and’ left.

4) Confirm that rubber pin lock @ and lock pin @ are set as
shown in the figure.

The life of the point can be lengthened and the frequency of its
replacement can be reduced by turning it upside down so that it will
wear evenly.

Replace the rubber pin and locking pin with new pins at the same
time as replacing the point to prevent the point from falling.

3-38
24.2.7 REPLACE BUCKET TEETH
(HORIZONTAL PIN TYPE)
Replace the teeth before the wear reaches the adapter.

A WARNING
It is dangerous if the work equipment moves by mistake when
the teeth are being replaced. Set the work equipment in a stable
condition, then stop the engine and apply the locks securely to
the levers.

Free

1. Place a block under the bucket bottom so that the pin @I of tooth
can be knocked out with a hammer. Carry out full stroke opera-
tion of the control levers within 15 seconds after the engine has
stopped. After confirming that the work equipment is in a stable
condition, lock the safety lock lever.
Set so that the bottom face of the bucket is horizontal.

2 Place a bar on the pin head and strike the bar with a hammer to
knock out pin 0. Remove tooth 0.

REMARK
Use a round bar with a smaller diameter than that of the pin.

AM0913SO

3. Clean the mounting face. Fit a new tooth @ in the adapter, push
in pin @ partially by hand, then lock it with a hammer to install
the tooth to the bucket.

AM091370

3-39
24. SERVICE PROCEDURE

24.2.8 ADJUST BUCKET CLEARANCE

a WARNING
It is dangerous if the work equipment moves by mistake when
the clearance is being adjusted.
Set the work equipment in a stable condition, then stop the
engine and lock the lever securely.

Free

AN317496

1. Set the work equipment to the position shown in the diagram at

right, stop the engine and set the lock lever to the locked
position.

2. Shift O-ring @ of the linkage and measure the amount of play

(a).
Measurement is easier of you move the bucket to one side or the
other so all the play can be measured in one place.
(In the diagram this is on the left-hand side)
Use a gap (clearance) gauge for easy and accurate measure-
ment.

3. Loosen the four plate fixing bolts of @ and loosen plate 0.

Because it uses split shims, you can carry out the operation
without removing the bolts entirely.

4. Remove shim @ corresponding to the amount of play (a) meas-

ured above.

[Example1
In the case of play of 3 mm, remove two 1.0 mm shims and one 0.5
mm shim. Play becomes 0.5 mm. For shim (4), two types of 1.0 mm
and 0.5 mm are used.
When play a is smaller than one shim, do not carry out any
maintenance.

5. Tighten the four bolts 0.

If the bolts @ are too stiff to tighten, pull out pin stopper bolt @I
for easier tightening.

3-40
 24. SERVICE PROCEDURE

24.2.9 CHECK WINDOW WASHER FLUID LEVEL, ADD

FLUID
If air is ejected with the window washer fluid, check the fluid
level in window washer tank (iJ If showing under the level, fill with
automobile window washer fluid.

When adding fluid, be careful not to let dirt or dust get in.

l Mixture ratio of pure washer fluid and water

Since the ratio should be varied depending on atmospheric tempera-
ture, replenish washer fluid at the following mixture ratio, taking
temperature into account.

Operation area Freezing

Mixture ratio
and season temperature

Pure washer fluid

Normal - 10°C (14°F)
l/3: water 2/3

Pure washer fluid

Winter in cold region - 20°C (- 4°F)
I/2: water l/2

Winter in extremely
Pure washer fluid - 30°C (- 22°F)
cold region

Pure washer fluid comes in two types: for -10°C (14°F) (for general
use) and for -30°C (-22°F) (cold regions).
Use pure washer fluid according to operation area and season.

3-41
24. SERVICE PROCEDURE

24.2.10 CHECK AND ADJUST COOLER

CHECK LEVEL OF REFRIGERANT (GAS)

v AWARNING -I
If the liquid gets into your eyes or on your hands, it may cause
loss of sight or frostbite, so never loosen any part of the
refrigerant circuit.

If there is a lack of refrigerant (Freon 134a), the cooling perform-

ante will be poor.
When operating the cooler at high speed, there should be no
bubbles in the sight glass (inspection window) mounted on the
condenser unit receiver.
l No bubbles in refrigerant flow: Correct
l Bubbles in refrigerant flow (bubbles continuously pass through):
Refrigerant level low
l Colorless, transparent: No refrigerant

0041:
REMARK
When there are bubbles, the refrigerant gas level is low, so Refrigerant
%: level low
contact your refrigerant dealer to have refrigerant added. If the air
No refrigerant
conditioner is run with the refrigerant gas level low, it will cause n (Colorless,
damage to the compressor. - transparent)
Receiver
ADO53280
Check in off-season
When not being used for a long period, operate the cooler for 3 to
5 minutes once a month to supply lubricant to each component of
the compressor.

Inspection and maintenance items list for cooler

Inspection and Maintenance

Contents
maintenance items interval

Twice a year;
Refrigerant (gas) Filling quantity
spring and autumn
I I

Condenser Clogging of fin Every 500 hours

Compressor Function Every 4000 hours

V belt Damage and tension Every 250 hours

Blower motor Function (Check for

When required
and fan abnormal sound)

Function (Check for

Control mechanism normal functionj When required

Piping for Installation condition

connection looseness of tightening When required
connection portions
gas leakage, damage

3-42
 24. SERVICE PROCEDURE

24.2.11 REPLACE ADDITIONAL BREAKER FILTER

ELEMENT

a
&WARNING
Immediately after operating the engine, all parts still retain high
temperature. Never replace the filter in sucn condition. Replace
it only after each part has sufficiently cooled.
[ I AN114650

l Prepare a container for draining off oil.

1. Place the container under the filter element. 0

@
2. Turn filter case @ counterclockwise to remove it. Remove ele-
ment @ from the case.

3. Unscrew plug @ from filter case @I.

4. Clean the removed parts. Mount a new element @ and O-ring 0.

a
5. After the case reaches the filter holder, additionally tighten the
case by more than a l/2 turn.

NOTICE
When the breaker is used, replace the element every approx 250
hours (when operating ratio is more than 50%). referring to the
chart at the right.

Hydraulic filter breaker only)

element AD31 3738

3-43
24. SERVICE PROCEDURE

24.3 CHECK BEFORE STARTING

24.3.1 CHECK COOLANT LEVEL, ADD WATER

Do not open the radiator cap unless necessary. When checking

the coolant, always check the radiator reserve tank when the
engine is cold.

Open the rear door on the left side of the machine and check that
the cooling water level is between the FULL and LOW marks on
radiator reserve tank @I (shown in the diagram on the right). FULL
If the water level is low, add water through the water filler of
reserve tank @ to the FULL level. LOW

After adding water, tighten the cap securely. AN113730

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

24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the engine hood.

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

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

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

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

NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
AD052340
5. If the oil is above the t-l mark, drain the excess engine oil from
drain valve @, and check the oil level again.

6. If the oil level is correct, tighten the oil filler cap securely and
close the engine hood.

REMARK
When checking the oil level after the engine has been operated,
for at least 15 minutes after stopping the engine before checking.
If the machine is at an angle, make it horizontal before checking.

3-44
 24. SERVICE PROCEDURE

24.3.3 CHECK FUEL LEVEL, ADD FUEL

When addmg fuel, never let the fuel overflow. This may cause
a fire. If spilling fuel, thoroughly
rewaRNING1 clean up any spillage.

1. Use sight gauge @I on the front face of the fuel tank to check that
the tank is full.

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

Fuel capacity: 340 e (89.8 US gal, 74.8 UK gal)

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

3. After adding fuel, tighten the cap securely.

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

AL067960

3-45
24. SERVICE PROCEDURE

24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

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

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

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

diagram on the right, start the engine run the engine at low
speed, retract the arm and bucket cylinders, then lower the
boom, set the bucket teeth in contact with the ground, and stop
the engine.
AN113810
Within 15 seconds after stopping the engine, move each control
lever (work equipment and travel) to full stroke in all directions
to release the internal pressure.

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

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

4. If the level is below the L mark, add oil through oil filler 0.

NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
1 ::
U
Ul
REMARK II ff AE313580
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:
l Before operation: around L level
(Oil temperature 10 to 30°C (50 to 86°F))
l Normal operation: around H level
(Oil temperature 50 to 80°C (122 to 176°F))

3-46
 24. SERVICE PROCEDURE

24.3.5CHECK DUST INDICATOR I /\!I \ /.

Open the engine hood, check that the red piston is not showing
in dust indicator 0.

If the red piston has appeared, clean or replace the element

immediately.
For details of the method of cleaning the element, see “24.2.1
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT”.

After checking, cleaning, and replacing, press the knob of dust

indicator @) to return the red piston to its original position.

I AN106660

24.3.6 CHECK ELECTRIC WIRINGS

I_ AWARNING -l
If the fuse blows frequently, or there are traces of shortcircuiting
in the electric wiring, always locate and repair the cause.

Check for damage of the fuse and any sign of disconnection or short
circuit in the electric wiring. Check also for loose terminals and
tighten any loose parts. Check the following points carefully.
l Battery
0 Starting motor
l Alternator

Please contact your Komatsu distributor for investigation and cor-

rection of the cause.

etc.) around the battery may cause fire, so always check and

When carrying out walk-around checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.

3-47
24.3.7 LUBRICATE CLAM/SHELL BUCKET (12 POINTS) fl
Prepare a grease pump.
Place the work equipment on the ground in a stable posture and
stop the engine.

Using a grease gun, pump in grease through the grease fittings

(12 points) shown by arrows.

After greasing, wipe off any old grease that was pushed out.

AN113850

24.3.8 CHECK FOR WATER AND SEDIMENT IN WATER

SEPARATOR, DRAIN WATER
The water separator separates water mixed in the fuel. If float @I
is at or above red line 0, drain the water according to the following
procedure:
1. Loosen drain plug @ and drain the accumulated water until the
float reaches the bottom.
( AEo822*
2. Tighten drain plug 0.

3. If the air is sucked into fuel line when draining and water, be sure
to bleed air in the same manner as for the fuel filter. See “24.6
EVERY 500 HOURS SERVICE”.

3-46
 24. SERVICE PROCEDURE

24.4 EVERY 100 HOURS SERVICE

24.4.1 LUBRICATING
l If any abnormal noise is generated from any greasing point,
carry out greasing regardless of the greasing interval.
0 Carry out greasing of greasing points 1 - 7 every 10 hours for
the first 100 hours on a new machine.

1. Set the work equipment in the greasing posture below, then

lower the work equipment to the ground and stop the engine.

2. Using a grease pump, pump in grease through the grease

fittings shown by arrows.

3. After greasing, wipe off any old grease that was pushed out.

6 8' 9' 10:11 i2

AN114670

1. Boom cylinder foot pin (2 points)

2. Boom foot pin (2 points)

3. Boom cylinder rod end (2 points)
4. Arm cylinder foot pin (1 point)
24. SERVICE PROCEDURE

5. Boom-Arm coupling pin (Ipoint)

6. Arm cylinder rod end (I point)
7. Bucket cylinder foot pin (I point)

8. Arm-Link coupling pin (1 point)

9. Arm-Bucket coupling pin (1 point)

AN114710

10. Link coupling pin (2 points)

11. Bucket cylinder rod end (I point)
12. Bucket-Link coupling pin (I point)

AN114720

24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE,

ADD OIL

A WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carrying
out this check.

1. Remove dipstick @ and wipe the oil from the dipstick with a
cloth.

2. Insert dipstick @ fully in the guide.

3. When dipstick @ is pulled out, if the oil level is between the H

and L marks of the gauge, oil level is proper.

3-50
 24. SERVICE PROCEDURE

4. If the oil does not reach the L mark on dipstick 0, add engine
oil through dipstick insertion hole 0.
When refilling, remove bleeding plug 0.

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

5. If the oil level exceeds the H mark on the dipstick, loosen drain
valve @ to drain the excess oil.

6. After checking oil level or adding oil, insert the dipstick into the
hole and install air bleeding plug 0.

24.4.3 MM&l WATER AND SEDIMENT FROM FUEL

1. Carry out this procedure before operating the machine.

2. Prepare a container to catch the fuel that is drained.

3. Open valve @ at the bottom of the tank and drain the sediment
and water that has accumulated at the bottom together with fuel.
When doing this, be careful not to get fuel on yourself.

4. When only clean fuel comes out, close drain valve 0.

NOTICE
Never use trichlene for washing the inside of the tank.

3-51
24. SERVICE PROCEDURE

24.5 EVERY 250 HOURS SERVICE

24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD

OIL
I-~ AWARNING

The oil is at high temperature immediately after the machine

has been operated. Wait for the oil to cool down before
starting the operation.

If there is still pressure remaining inside the case, the oil or

plug may fly out.
Loosen the plug slowly to release the pressure.

l Prepare a handle.

1. Set the TOP mark at the top, with the TOP mark and plug @
perpendicular to the ground surface.

2. Remove plug @ using the handle. When the oil level reaches a
point 10 mm below the bottom of the plug hole, the correct
amount of oil has been added.

3. If the oil level is too low, install plug 0, operate the travel levers,
and drive forward or in reverse to rotate the sprocket one turn.
Then repeat Step 2 to check again.

4. If the oil level is still too low, add engine oil through the hole in
plug @ until the oil overflows.

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

5. After checking, install plug 0.

3-52
 24. SERVICE PROCEDURE

24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE

dh WARNING
l To avoid gas explosions, do not bring fire or sparks near the

l Battery electrolyte is dangerous. If it gets in your eyes or on

your skin, wash it off with large amounts of water, and
consult a doctor.

Carry out this check before operating the machine.

1. Open the battery box cover on the right side of the machine.

2. Remove cap 0, and check that the battery electrolyte is up to the

UPPER LEVEL line. If the level is low, add distilled water to the
UPPER LEVEL line.
Do not add water above the UPPER LEVEL line. This may cuase
leakage of the electrolyte, which may cause fire.

If the battery electrolyte is spilled, have dilute sulphuric acid added.

3. Clean the air hole in the battery cap, then tighten the cap
securely.

When adding distilled water in cold weather, add it before

starting operations in the morning to prevent the electrolyte from
freezing.

3-53
24. SERVICE PROCEDURE

24.5.3 CHANGE OIL IN ENGINE OIL PAN, REPLACE

ENGINE OIL FILTER CARTRIDGE
Perform this maintenance every 500 hours on machines equipped
with bypass filter.

A WARNING
The oil is at high temperature after the engine has been oper-
ated, so never change the oil immediately after finishing opera-
tions. Wait for the oil to cool down before changing it.

Prepare the following

l Container to catch drained oil: Min 24 !J capacity
0 Refill capacity: 24 e (6.34 US gal, 5.28 UK gal)
l Filter wrench

1. Place a drain container under drain plug @ located on the

bottom of the machine.

2. Loosen drain plug @ slowly to avoid getting oil on yourself, and

drain the oil.

3. Check the drained oil, and if there are excessive metal particles
or foreign material, please contact your Komatsu distributor.

4. Install drain plug 8.

5. Open the engine hood. Using the filter wrench from the upper II I
side of the engine, turn filter cartridge @ counterclockwise to
remove it.
In particular, if this operation is carried out immediately after
I-;:I
stopping the engine, a large amount of oil will come out, so wait Plus
for 10 minutes before starting the operation. Portion P
AM325398

6. Clean the filter holder, coat the packing surface of a new filter
cartridge with engine oil (or coat it thinly with grease), then
install it to the filter holder.

REMARK
Confirm that no remnants of old packing still adhere to the filter
holder as this may result in oil leakage.

7. When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up 3/4 of a turn.

8. After replacing the filter cartridge, add engine oil through oil
filler @ until the oil level is between the H and L marks on
dipstick 0.

NOTICE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AD313780
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3-54
 24. SERVICE PROCEDURE

9. Run the engine at idling for a short time, then stop the engine,
and check that the oil level is between the H and L marks on the
dipstick. For details, see “24.3 CHECK BEFORE STARTING”.

NOTICE
Even if the machine has not been operated for 250 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for 6
months, the oil and filter cartridge must be replaced when the
machine has been operated for 250 hours.

24 ‘.5.4 LUBRICATE SWING CIRCLE (2 POINTS)

Lower the work equipment to the ground.

Using a grease gun, pump in grease through the grease fittings

shown by arrows.

After greasing, wipe off all the old grease that was pushed out. ,
// AN114800

3-55
24. SERVICE PROCEDURE

24.5.5 CHECK FAN BELT TENSION, ADJUST

Checking
The belt should normally deflect by about 5 - 6 mm (0.20 -
0.24 in) when pressed with the finger (with a force of approx. 6 kg
(13 lb) at a point midway between the fan pulley and tension pulley.

Adjusting
Fan PU
1. Loosen bolts and nuts @ and 0.

2. Loosen the lock nut and move tension pulley @ with adjustment
bolt @ so that the belt deflects about 5 - 6 mm (0.20 - 0.24 in)
(with a force of approx. 6 kg (13 lb)).

3. Tighten the bolts and nuts @ and @ to fix tension pulley @I in

Crank Pulley AE31379B
position.

4. 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.

5. Replace 2 belts if it has stretched, leaving no allowance for

adjustment, or if there is a cut or crack on belt.

6. When the new belt is set, readjust it after operation for an hour.

3-56
 24. SERVICE PROCEDURE

24.5.6 CHECK COOLER COMPRESSOR BELT TENTION,

ADJUST

Checking
The belt should normally deflect by about 5 - 8 mm (0.20 -
0.31 in) when pressed with the finger (with a force of approx. 6kg
(13 lb)) at a point midway between the drive pulley and compressor
pulley.

Adjusting Tension adj

1. Insert a tension adjusting bar wrapped with cloth or another
cushioning material between brackets @ and 0.

2. Loosen bolts @ and 0.

3. Move bracket @ with the tension adjusting bar so that the

deflection of the belt will be 5 - 8 mm (0.20 - 0.31 in).

4. Tighten bolts @ and @ to secure bracket 0. Then, take out the

tension adjusting bar.

5. Check each pulley for damage, and check the V-groove and V-
belt for wear. In particular, check that the V-belt is not contacting
the bottom of the V-groove.

6. If the V-belt is elongated and cannot be adjusted any further, or

if there are any cuts or cracks, replace the V-belt.

7. After replacing the V-belt, carry out the adjustment again after
one hour of operation.

3-57
24. SERVICE PROCEDURE

24.6 EVERY 500 HOURS SERVICE

Maintenance for every 100 and 250 hours should be carried out
at the same time.

24.6.1 REPLACE FUEL FILTER CARTRIDGE AND

ADDITIONAL FUEL FILTER CARTRIDGE

g WARNING
l Engine is at high temperature immediately after the machine
has been operated. Wait for engine to cool down before
replacing the filter.

l Do not bring fire or sparks near the fuel.

Prepare a filter wrench and a container to catch the fuel.

1. Set the container to catch the fuel under the filter cartridge.

2. Using a filter wrench, turn filter cartridge @ and @I

counterclockwise to remove it.

3. Clean the filter holder, fill a new filter cartridge Q with clean fuel,
coat the packing surface with engine oil, then install it to the filter
holder.

4. When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up l/2 of a turn.

5. Clean the additional filter holder, fill a new additional cartridge

@ with clean fuel, coat the packing surface with engine oil, then
install it to the filter holder.
AH328420
6. When installing, tighten until the packing surface contacts the
seal surface of the additional filter holder then tighten it up 2/3
of a turn.

If the filter cartridge is tightened too far, the packing will be

damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.

7. After replacing the fuel filter cartridge, bleed the air.

Bleed the air according to the following procedures.

3-58
 24. SERVICE PROCEDURE

l Normal air bleeding procedure

(1) Add fuel to the fuel tank until full (to FULL mark on the fuel
gauge).
(2) After replacing filter cartridge 0,
loosen joint bolt 0.
(3) Loosen the knob of feed pump 0, and move it up and down
about 50 - 60 times to cause fuel to overflow until bubbles do
not come out from the joint bolt any more.
(4) Tighten joint bolt 0.

NOTICE
Do not rotate the starting motor continuously for more than 20
seconds. Wait for 1 - 2 minutes before rotating again.

REMARK
When the engine stops because of running out of fuel, also
operate the feed pump according to the above procedure to bleed
air.

24.6.2 CHECK SWING PINION GREASE LEVEL, ADD

GREASE
Prepare a scale.

Remove bolts @ (2 bolts) on the top of the revolving frame and

remove cover 0.

Insert a scale into the grease and check that the height of the
grease in the portion where the pinion passes is at least 28 mm
(1.1 in). Add more grease if necessary.

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 21 e (18.9 kg) (5.5 US gal, 4.6 UK gal
f41.7 lb]).

4. Install cover @ with bolts 0.

3-59
24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL
COOLER FINS AND CONDENSER FINS (ONLY FOR
MACHINES EQUIPPED WITH COOLER)
:
A WARNING
If compressed air, steam, or water hit your body directly, there
is danger of injury. Always wear protective glasses, mask, and
safety shoes.

1. Open the engine hood and rear door on the left side of the
machine. Loosen 4 bolts @ and remove the radiator front cover.

2. Blow off mud, dust or leaves clogging the radiator fins and oil
cooler fins using compressed air.
At the same time, clean the net in front of the oil cooler.
Clean the condenser fins on machines equipped with the cooler.
Steam or water may be used instead of compressed air.
After cleaning, install the cover with bolts 0.

3. Check the rubber hose. Replace with a new one if the hose is
found to have cracks or to be hardened by ageing.
Further, check hose clamps for looseness.

NOTRE
To prevent damage to the fins, apply compressed air from and
appropriate distance. Damaged fins may cause water leakage or
overheating. In a dusty site, check the fins daily, irrespective of the
maintenance interval.

3-60
 24. SERVICE PROCEDURE

24.6.4 CLEAN INTERNAL AND EXTERNAL AIR FILTERS

OF COOLER SYSTEM

1. Internal air strainer @ covered cooler unit are at the inside

portion of seat rear cover 0.
Remove the seat rear cover 0.

2. Clean strainer @ with compressed air.

NOTICE
The normal cleaning interval is 500 hours. However, if the filters
are used at a dusty site, shorten this interval.

24.6.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT

A WARNING
Wait for the oil to cool down before replacing the breather
element. When removing the oil filler cap, turn it slowly to
release the internal pressure, then remove it carefully.

1. Remove the cap of oil filler 0.

2. Replace element (iJ inside the cap with a new one.

3-61
24. SERVICE PROCEDURE

24.6.6 REPLACE HYDRAULIC FILTER ELEMENT

internal pressure before removing it.

1. Remove the cap from oil filler 0, and release the internal
pressure.

2. Loosen 4 bolts, then remove cover 0.

When doing this, the cover may fly out under the force of spring
0, so hold the cover down when removing the bolts.

3. After removing spring @ and valve 0, take out element 0.

4. Clean the removed parts in diesel oil.

5. Install a new element in the place where old element @I was

installed.

6. Set valve @ and spring @ on top of the element.

7. Set cover @ in position, push it down by hand, and install the

cover with the mouning bolts.

6. Screw in the oil filler cap and install the cover.

9. To bleed the air, start the engine according to “12.2 STARTING

ENGINE” and run the engine at low idling for 10 minutes.

IO. Stop the engine.

REMARK
Operate the machine after halting for more than 5 minutes to
eliminate bubbles in the oil inside the tank.

11. Check for oil leakage and wipe off any spilled oil.

When the hydraulic breaker is installed, the hydraulic oil deteriorates

earlier than in normal bucket digging work.
The first element replacement should be at 100 to 150 hours for new
machines. Thereafter, replace the element according to the table on
the right. Reolacement interval
for hydraulic oil
Replace the additional filter element for the breaker every approx.
250 hours (when breaker operating ratio is more than 50%) accord-
ing to the table on the right. (See “24.2.11 REPLACE ADDITIONAL
BREAKER FILTER ELEMENT”.)

20 40 60 a0 100

Hrdraulic filler breaker onlvl

efenent AD31373B

3-62
 24. SERVICE PROCEDURE

24.7 EVERY 1000 HOURS SERVICE

Maintenance for every 100,250 and 500 hours should be carried

out at the same time.

24.7.1 CHANGE OIL IN SWING MACHINERY CASE

A WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carrying
out maintenance.

l Container to catch drained oil: Min. 5.5 e capacity

l Refill capacity: 5.5 1 (1.45 US gal, 1.21 UK gal)

1. Set an oil container under drain valve @ under the machine

body.

2. Loosen drain valve @ under the body, drain the oil, then tighten
the drain valve again.

3. Remove dipstick @ and bleeding plug 0.

Add the specified amout of engine oil through gauge hole 0.

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

4. After refilling, install bleeding plug 0.

5. Wipe off oil on the dipstick with a cloth.

6. Insert dipstick @ into the gauge pipe thoroughly and then pull
out it again.

7. When the oil level is between the H and L marks, on dipstick 0,

it is normal. If the oil does not reach the L mark, add more oil
through oil filler 0.

8. If the oil level exceeds the H mark, drain the excess engine oil
from drain valve @, and check the oil level again.

3-63
24. SERVICE PROCEDURE

24.72 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

A WARNING
The oil is at high temperature immediately afater the machine
has been operated. Wait for the oil to cool down before carrying
out maintenance.

NOTlCE
Park the machine on flat ground and stop the engine. After
waiting for more than 30 minutes after stopping the engine, check
the oil level.

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

2. Remove plug @ and check the oil level. If the oil is up to near
the bottom of the olug hole, it is normal.
If insufficient, remove-plug @ and add oil through the hole of
plug @ up to the bottom of the plug @ hole.

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

NOTlCE
If excess oil is supplied, drain it to the specified amount to avoid
overheating.

3. Install plugs @ and 0.

4. Close the door.

24.7.3 CHECK ALL TIGHTENING PARTS OF

TURBOCHARGER
Contact your Komatsu distributor to have the tightening portions
checked.

24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR

Ask Komatsu distributor to check the play of the turbocharger rotor.

3-64
 24. SERVICE PROCEDURE

24.7.5 CHECK ALTERNATOR BELT TENSION AND

REPLACE ALTERNATOR BELT

Special tools are required for inspection and replacement of the

alternator belt. Contact your Komatsu distributors for inspection and
replacement.

REMARK
Since the auto-tensioner alternator belt is installed, its tension
does not need to be adjusted.

24.7.6 REPLACE CORROSION RESISTOR CARTRIDGE

If the engine has been operated, all parts will be at a high

cartridge immediately

Always wait for the engine and other parts to cool down.

Prepare the following.

0 Container to catch drained coolant
0 Filter wrench

1. Close valves 0.

2. Set a container to catch the coolant under the cartridge.

3. Using a filter wrench, remove cartridge 0.

4. Clean the filter holder, coat the packing surface and thread of the
new cartridge with engine oil, then install it to the filter holder.
AN167100
5. When installing, tighten until the packing surface contacts the 1
seal surface of the filter holder, then tighten it up Z/3 of a turn.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of coolant. If the filter
cartridge is too loose, coolant will also leak from the packing, so
always tighten to the correct amount.

6. Open valves 0.

7. After replacing the cartridge, start the engine and check for any
leakage of water from the filter seal surface. If there is any water
leakage, check if the cartridge is tightened properly.

3-65
24. SERVICE PROCEDURE

24.8 EVERY 2000 HOURS SERVICE

Maintenance for every 100,250,500 and 1000 hours should be

carried out at the same time.

24.8.1 CHANGE OIL IN FINAL DRIVE CASE

7 AWARNING
0 The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
carrying out maintenance.
l If there is still pressure remaining inside the case, the oil or
plug may fly out.
Loosen the plug slowly to release the pressure.

Prepare the followina.

‘Container to catch drained oil: Min. 4.2 !J capacity
Refill capacity: 4.2 a (1.11 US gal, 0.92 UK gal)
Handle

Set the machine with plug @ and plug @ perpendicular to the

ground surface.

Drain the oil from drain plugs @ on both sides of the machine.
After draining, tighten the drain plugs.

Then, supply new engine oil through oil filler @ respectively to

the specified level. (Refer to EVERY 250 HOURS SERVICE.)

REMARK
Check the O-rings in the plugs for damage. If necessary, replace
with new ones.

4. Screw in plug 8.
AN1147750
5. Add engine oil through the hole of plug 0.

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

6. When the oil overflows from the hole of plug 0, install plug 0.
Tightening torque of plugs @ and 0: 70 +. 10 Nm (7 k 1 kgm, 50
2 7 Ibft)

3-66
 24. SERVICE PROCEDURE

24.8.2 CLEAN HYDRAULIC TANK STRAINER

The oil is at high temperature immediately after the machine

has been operated Wait for the 011to cool down before cleanmg
the strainer. When removing the oil filler cap, turn it slowly to
release the internal pressure, then remove it carefully.
9

1. Loosen 4 bolts, then remove cover 0.

When doing this, the cover may fly out under the force of spring
0, so push the cover down when removing the bolts.

2. Pull up the top of rod 0, and remove spring @ and strainer 0.

3. Remove the dirt stuck to strainer 0, then wash it in clean diesel

oil or flushing oil.
E313900
If strainer @ is damaged, replace it with a new one.

4. Refit strainer @ by inserting it into tank projecting part 0.

5. Install cover @ with bolts.

24.8.3 CLEAN, CHECK TURBOCHARGER

Contact your Komatsu distributor for cleaning or inspection.

24.8.4 CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn, or the bearing may have run out of
grease, so contact your Komatsu distributor for inspection or repair.
If the engine is started frequently, carry out inspection every 1000
hours.

24.8.5 CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts,
you shall request Komatsu distributor for service.

3-67
24. SERVICE PROCEDURE

24.8.6 CHECK VIBRATION DAMPER

Since special tools are required for inspection and replacement

of the vibration damper, contact your Komatsu distributor in the
following case.
Match marks 0 are stamped on the damp hub and inertia
member so that deviation from each other can be checked. If they
are deviated from each other by 1.6 mm (0.06 in) or more, or if there
is a dent @ below the bearing metal of the damper 3.2 mm (0.13 in)
or more, ask for replacement of the parts.

3-68
 24. SERVICE PROCEDURE

24.9 EVERY 4000 HOURS SERVICE

Maintenance for every 100, 250, 500, IWO and 2000 hours
should be carried out at the same time.

24.9.1 CHECK WATER PUMP

Since the pulley may have play, oil may leak, water may leak and
the drain hole may be clogged, contact your Komatsu distributor for
inspection, overhaul or replacement.

3-69
24.10 EVERY 5000 HOURS SERVICE

Maintenance for every 100,250,500 and 1000 hours should be

carried out at the same time.

24.10.1 CHANGE OIL IN HYDRAULIC TANK

The oil is at high temperature immediately after the machine

has been operated Wait for the oil to cool down before chang
ing the oil. When removing the oil filler cap, turn it slowly to
release the internal pressure, then remove it carefully.
i
Prepare the following.
0 Container to catch drained oil: min. 166 !2 capacity
0 Refill, capacity: 166 .r2(43.8 US gal, 36.5 UK gal)
0 Prepare a handle for the socket wrench set.

1. Swing the upper structure so that the drain plug under the
hydraulic tank comes at the middle of the left or right track.

2. Retract the arm and bucket cylinders to the stroke end, then
lower the boom and put the bucket teeth in contact with the
ground.

3. Lock the safety lock lever and stop the engine.

4. Remove the cap of oil filler @ over the hydraulic tank.

5. Set the oil container under the drain plug under the machine.
Using the handle, remove drain plug @ and drain the oil.
Check the O-ring installed to plug @, and if it is damaged, replace
the O-ring. After draining the oil, tighten drain plug @.
Tightening torque: 69 f 10 Nm (7 f 1 kgm, 51 2 7 Ibft).

When removing drain plug 8, be careful not to get oil on yourself.

3-70
 24. SERVICE PROCEDURE

6. Add the specified amount of engine oil through oil filler port 0.
Check that the oil level is between H and L on the sight gauge.

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

NOTlCE
When the hydraulic breaker is installed, the hydraulic oil dete-
riorates earlier than in normal bucket digging work. Therefore,
replace the hydraulic oil according to the chart at the right.

7. After replacing hydraulic oil and cleaning or replacing filter

element and strainer, bleed air from the circuit according to the RePlacement interval
following procedure. for hydraulic oil

20 40 60 80 100

ft~drrulic filter breaker oald

element AD31373B

. -,..
J-I I
24. SERVICE PROCEDURE

Air bleeding procedure

Follow Steps 1 to 7 to bleed the air.
1. Bleeding air from pump
1. Loosen air bleeding plug 0, and check that oil oozes out
from the air bleed plug.

2. If oil does not ooze out from the plug, remove the drain hose
from the pump case, and add oil through drain port @ to fill
the pump case with hydraulic oil.

Oil will come out from the drain hose when it is removed, so
secure the mouth of the hose at a place higher than the oil
level inside the hydraulic tank.

3. After completion of the air bleed operation, tighten air bleed-

ing plug 0, then install the drain hose.

NOTICE
If the drain hose is installed first, oil will spurt out from the hole
of plug 0.
lf the pump is operated without filling the pump case with
hydraulic oil, abnormal heat will be generated and this may lead to
premature damage of the pump.

2. Starting engine
Start the engine according to “12.2 STRAT ENGINE”. Keep running
the engine at low idling for 10 minutes, and carry out the following
procedure.

3. Bleeding air from cylinders

1. Run the engine at low idling, and extend and retract each
cylinder 4-5 times without operating it to the end of its stroke.
(Stop approx. 100 mm (4 in) before the end of the stroke)

2. Next, operate each cylinder to the end of its stroke 3-4 times.

3. After this, operate each cylinder 4-5 times to the end of its
stroke to completely bleed the air.

NOTICE
If, at first, the engine is run at high speed or the cylinder is
operated to the end of its stroke, the air inside the cylinder may
cause damage to the piston packing or other parts.

3-72
 24. SERVICE PROCEDURE

4. Bleeding air from swing motor

1. Run the engine idle at a low speed for about five minutes,
then loosen drain port plug @ and confirm that oil flows out.

NOTfCE
When doing this, do not operate the swing.

2. If oil does not flow out, stop the engine and fill the motor
case with hydraulic oil through drain port plug 0.

3. After completion of the air bleed operation, tighten drain port

4. Run the engine at low idling, and swing 2 or more times

slowly and uniformly to the left and right.

NOTlCE
If the air is not bled from the swing motor, the bearings of the
motor may be damaged.

5. Bleeding air from travel motor

(only after draining oil from travel motor case)

Run the engine at low idling, loosen air bleeding plug 0, and
if oil flows out, tighten the air bleed plug.

Keep the engine running at low idling, and swing the work
equipment 90” to bring it to the side of the track.

Jack up the machine until the track is raised slightly from the
ground. Rotate the track under no load for 2 minutes. Repeat
this procedure on both the left and right sides, and rotate the
track equally both forward and in reverse.

AN 114480
24. SERVICE PROCEDURE

6. Bleeding air from attachment (if installed)

For machines equipped with attachments such as the breaker,
actuate the attachment pedal about 10 times to bleed the air com-
pletely from the attachment circuit while running the engine at low
idling.

NOTICE
If the attachment bleeding procedure is specified by the manu-
facturer, bleed the attachment according to such procedure.

7. Operation
1. After completion of bleeding the air, stop the engine, and
wait for at least 5 minutes before starting operations. In this
way, the air bubbles are removed from the oil inside the
hydraulic tank.

2. Check for any leakage of oil, and wipe off any oil that has
been spilled.

3-74
SPECIFICATIONS
25. SPECIFICATIONS

PC2666 AVANCE SERIES

PC200-6 AVANCE SERIES

WEIGHT

l Operating weight (without operator) 19800 kg (43660 lb)

PERFORMANCE

l Bucket capacity (standard bucket) SAE/CECE 1 0.8 m3 (1.05 cu.ydYO.7 m3

(Standard bucket) 1045 mm (41 in)

l Width of opening
(With side cutter) 1150 mm (45 in)

High speed 5.5 km/h (3.4 MPH)

l Travel speed
Low speed 3.8 km/h (2.4 MPH)

l Swing speed 12.4 rpm

TRACK SHOE

l Triple grouser shoe (standard) 800 mm (31.5 in) width

ENGINE

l Model Komatsu S6D102E-1-A diesel engine

l Flywheel horsepower 95.6 kW (128 HP)/2000 rpm

0 Starting motor 24 V 4.5 kW

l Alternator 24V 35A

l Battery 12 V 100 Ah x 2 pieces (NIOO)

4-2
 25. SPECIFICATIONS

PC206-6 AVANCE SERIES

(,6 ,6) OL6Z

iqe!aq 11elaA0
25. SPECIFICATIONS

PC200-6
1. The mark % indicates the dimensions for shovel operation.
2. Never allow other person than the operator to enter the swing
range (Max. swing range, Max. digging radius).

-f

,
I
,
,

r
L6,OZ) 9669 i%
I-
LE,lZ) 5x*9 LL.61) 0869

(,.9.0&) SO&6 L6.1Z) OZ99

(.9,1&) 0696 % LZ,ZZ) 09L9 3%

AN115050

4-4
OPTIONS, ATTACHMENTS l
26. GENERAL PRECAUTIONS

26.1 PRECAUTIONS RELATED TO SAFETY

If attachments or options other than those authorized by Komatsu are installed, this will not only
affect the life of the machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, please contact your
Komatsu distributor first.
If you do not contact Komatsu, we cannot accept any responsibility for any accident or failure.

A WARNING
Precautions for removal and installation operations
When removing or installing attachments, obey the following precautions and take care to ensure
safety during the operation.
Carry outthe removal and installation operations on a flat, firm ground surface.

When the operation is carried out by two or more workers, determine signals and follow these
during the operation.

When carrying heavy objects (more than 25 kg (55 lb)), use a crane.

When removing heavy parts, always support the part before removing it.
When lifting such heavy parts with a crane, always pay careful attention to the position of the
center of gravity.

It is dangerous to carry out operations with the load kept suspended. Always set the load on a
stand, and check that it is safe.

When removing or installing attachments, make sure that they are in a stable condition and will
not fall over.

Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load should fall.

NOTlCE
Qualifications are required to operate a crane. Never allow the crane to be operated by an
unqualified person.
For details of the removal and installation operations, please contact your Komatsu distributor.

5-2
 26. GENERAL PRECAUTIONS

26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS

A WARNING
Long work equipment reduces the stability of the chassis, so if the swing is operated on a slope,
or when going down a steep hill, the machine may lose its balance and overturn.
The following operations are particularly dangerous, so never operate the machine in these ways.

l Going downhill with l Traveling across slopes l Swinging the upper structure
the work equipment raised on slopes

INCORRECT CORRECT

AN112980 AN114300 AN114310

If heavy work equipment is installed, the overrun of the swing becomes greater (the distance from
the point where the operator operates the control levers to stop the swing to the point where
the upper structure stops completely), so there is danger of mistaking the distance and hitting
something.
Always operate so that there is an ample margin to the stopping point.
Furthermore, the hydraulic drift also becomes larger (when the work equipment is stopped in
mid-air, it will gradually move down under its own weight).

Always follow the correct procedure when installing the boom and arm. lf the correct procedure
is not followed, this may lead to serious damage or injury, so please consult your Komatsu
distributor before carrying out installation.

long work equipment is installed, the working range will suddenly become larger, so there is
danger of mistaking the distance and hitting something.
Always operate the work equipment so that there is ample space from any obstacles in the area.

5-3
27. HANDLING BUCKET WITH HOOK

27.1 ;;klFING FOR DAMAGE TO BUCKET WITH

Check that there is no damage to the hook, stopper, or hook

mount. If any abnormality is found, please contact your Komatsu
distributor.

27.2 PROHIBITED OPERATIONS INCORRECT I

The standard work equipment must not be used for lifting loads.
If this machine is to be used for lifting loads, it is necessary to install
the specified bucket with hook.

27.3 PRECAUTIONS DURING OPERATIONS CORRECT

When carrying out lifting operations, reduce the engine speed
and use the lifting operation mode.
Depending on the posture of the work equipment, there is
danger that the wire or load may slip off the hook.
Always be careful to maintain the correct hook angle to prevent
this from happening.
Never steer the machine while lifting a load. AL069260
If the bucket with hook is turned and used for operations, it will
hit the arm during dumping operations, so be careful when INCORRECT
using it.
Loads suspended must not exceed the limit indicated in the
“LIFTING CAPACITY TABLE” stuck on the right-side lower por-
tion of the driver’s seat.
If you wish to install a hook in the future, please contact your
Komatsu distributor.
AL069270

5-4
28. USING SEAT BELT

28.1 SEAT BELT

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

l Adjust and fasten the seat belt before operating the machine.

l Always use seat belt when operating the machine.

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

28.1.1 FASTEN THE BELT AND REMOVE IT

0Ci\

1. Adjust the seat so that the operator is easy to operate, with the
operator’s back against the backrest.

2. After adjusting the seat position, sit in the seat. Grip buckle @
and tongue @ in each hand and insert tongue @ into buckle 0.
Confirm by pulling the belt that the tongue is securely locked to
the buckle.

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

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

5-5
 28. USING SEAT BELT

28.1.2 ADJUST THE BELT LENGTH

To shorten the blet

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

To lengthen the belt

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

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

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

or deformed from long service, replace the seat belt immediately.

5-6
29. MACHINES READY FOR ATTACHMENTS

29.1 EXPLANATION OF COMPONENTS

1. STOP VALVE
This valve stops the flow of the hydraulic oil.
@ FREE: Hydraulic oil flows
@ LOCK: Hydraulic oil stops
Set this valve to the LOCK position when removing or installing
attachments.

AN 115230

2. SELECTOR VALVE
This switches the flow of the hydraulic oil.
For attachment to be mounted and the direction of left and right 3-
way valves @ and 0, see “29.2 HYDRAULIC CIRCUIT”.

5-7
29. MACHINES READY FOR A-ITACHMENTS

3. AlTACHMENT CONTROL PANEL

This is used to operate the attachment.
When the operator depresses the pedal at the front, neutral or rear
portions, the attachment moves as follows.
Hydraulic breaker
Pedal front @ : actuated
Pedal neutral @ : stopped
Pedal rear @ : stopped AN115240

For other attachments, confirm with the manufacturer regarding the

relation between pedal operation and attachment movement when
the attachment is mounted. Use the attachment only after confirm-
ing the above.

4. LOCK PIN
This is used to lock the control pedal.
Position 0: lock
Position 0: pedal half stroke position (flow: about flow of one pump)
Position 0: pedal full stroke position (flow: about flow of two pumps)
l Use position @ for ordinary work with the breaker, etc.
l Use position @ for work with the crusher, etc. which needs a
large flow
Set the lock pin at the lock position when attachment is not used.

5. ADDITIONAL FILTER FOR BREAKER

This filter prevents degradation. of the hydraulic oil when the
breaker is used.
Oil flows only when the selector valve is turned to the breaker
position.

6. ACCUMULATOR

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

it is extremely dangerous if it is handled in the wrong way
For handling procedure, see “11.19 HANDUNG ACCUMULA-

The accumulator is provided to release the pressure remaining

in the attachment circuit after stopping the engine. Normally, never
touch it.

5-8
 29. MACHINES READY FOR ATTACHMENTS

29.2 HYDRAULIC CIRCUIT

Change-over hydraulic circuit
When the machine is equipped with an attachment or a bucket,
set left and right Sway valves @ and @ as follows.

Referring to the following chart, turn the rotors of left and right
3-way valves @ and @ using a wrench to select the attachment to
be mounted and the direction of both 3-way valves. (The arrows
indicating the port direction are stamped on the 3-way valve heads.)

Attachment Left 3-way valve @ Right 3-way valve @

Forward direction of machine Upper direction of machine

Breaker etc.

Forward direction of machine Upper direction of machine

Crusher etc.

Forward direction of machine Upper direction of machine

When not used

NOTICE
l When the machine is equipped with the breaker, connect the
return circuit directly to the return filter.
l The set pressure of the low pressure safety valve is set to 20600
kPa (210 kg/cm*, 2980 psi) as standard when delivered from the
factory.
lf a breaker by another manufacturer is installed, adjustment is
required. Consult your Komatsu distributor.

5-9
29. MACHINES READY FOR ATTACHMENTS

29.2.1 CONNECTING HYDRAULIC CIRCUIT

When connecting the attachment, connect the circuit as follows.
1. Remove blind plugs @I located on the end of the stop valve
piping (2 places, left and right).
Take care not to lose or damage the removed parts.

2. Connect attachment tubes @ supplied by the attachment manu-

facturer to the end from which the plug was removed in step 1. AN115270

When the machine is shipped from the factory, a 1” taper seal

hose is installed to tube @_ The procedure used by the attachment
manufacturer if an accumulator is added is different, so please
consult your Komatsu distributor.

PATH OF OIL
The direction of operation of the pedal and the path of the oil are
as shown in the diagram below.

AN115290

5-10
 29. MACHINES READY FOR ATTACHMENTS

29.3 ATTACHMENT MOUNTING/DISMOUNTING

PROCEDURE

DISMOUNTING PROCEDURE
1. Place the attachment on the ground and stop the engine.

2. After stopping the engine, operate each work equipment control

lever and the attachment control pedal back and forth, left and
right at full stroke 2 to 3 times to eliminate the internal pressure
in the hydraulic circuit.

3. After confirming low oil temperature, turn the rotor of the stop
valve connected to the inlet and outlet piping on the arm side
face toward the lock side.

4. Remove the hoses on the attachment side. Install the blind plugs
to the two outlets.

The blind plugs are used to prevent the attachment from incor-
rect operation caused by mixing in of foreign matter. After the plugs
are correctly installed, store the attachment.

5. Dismount the attachment by removing the retaining pins (2

pins). Then, mount the bucket.

For the bucket mounting procedure, see “12.14 REPLACEMENT

AND INVERSION OF BUCKET”.

6. After the bucket is mounted, check the hydraulic oil level.

5-11
29. MACHINES READY FOR AlTACHMENTS

MOUNTING PROCEDURE
1. Remove the bucket.

For bucket dismounting procedure, see “12.14 REPLACEMENT

AND INVERSION OF BUCKET”.

Place the attachment on a fiat place, install pins @ and @to the
arm in that order.

After mounting the attachment, stop the engine. Operate each

work equipment control lever and the attachment control pedal
to full stroke back and forth, right and left to eliminate the
internal pressure in the hydraulic circuit. Pin0B

After confirming low oil temperature, remove the blind plug

from the outlet and inlet port respectively.

Take care that no dust, mud etc. adheres to the hose mousepiece
portions.
If O-ring is damaged, replace it with a new one.

5. Turn the rotor of the stop valve connected to the inlet and outlet
piping on the arm side face toward the free side.

6. Confirm that oil level in the hydraulic oil tank is correct, after
mounting the attachment.

5-12
 29. MACHINES READY FOR ATTACHMENTS

29.4 OPERATION
A WARNING
l Be careful when operating the pedal in the deceleration
range. The engine speed will rise suddenly.
l lf the operator rests his foot on the attachment pedal while
operating the machine, if he carelessly depresses the pedal,
the attachment may move suddenly and result in serious
trouble. Never place your foot on the pedal except when
actually performing pedal operation.

The operation of the attachment is as follows.

WHEN USING BREAKER

A WARNING
Never operate the breaker with the lock pin position @ (full
stroke). Otherwise such operation will affect badly to the ma-
chine and breaker in durability.

When the front portion of the pedal is depressed after the lock
pin is set at position 0, the breaker is actuated.

Note:
Position 0: For general attachments such as breaker
Position 0: For large capacity attachments such as crushers

Precautions when using

l Check that the stop valve is at the FREE position.
l Check that the selector valve is at the position for using the
breaker.
For details of the oil path, see “29.2 HYDRAULIC CIRCUIT”.
l Consult with the attachment manufacturer as to whether the
accumulator is required for the attachment circuit or not.
l For other precautions when using the breaker, see the instruc-
tion manual provided by the breaker manufacturer.
l When the breaker is used, the hydraulic oil degrades faster than
in normal operation. Shorten the maintenance interval of the
hydraulic oil and filter element.
See “23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC
BREAKER”.

5-13
29. MACHINES READY FOR ATTACHMENTS

WHEN USING LARGE CAPACITY AlTACHMENT SUCH AS CRUSHER

When the lock pin is set to the free position (0 or @and the
pedal is depressed at the front or rear portions, the attachment is
actuated.

Note:
Position 0: For general attachments such as breaker
Position 0: For large capacity attachments such as crushers AN113350

Precautions when using

l Check that the stop valve is at the FREE position.
l Confirm that the selector valve is set to the position for large
capacity attachments such as the crusher.
For details of the oil path, see “29.2 HYDRAULIC CIRCUIT”.
l For other precautions when using the attachment, see the in-
struction manual provided by the attachment manufacturer.

29.5 LONG-TERM STORAGE

If the equipment is not to be used for a long period, do as
follows.
l Set the stop valve to the LOCK position.
l Install the blind plugs and O-rings to the valves.
l Set the selector valve to the “when not use” position.
l Lock the lock pin to the lock position.

If the pedal is operated when there is no breaker or large capacity

attachment installed, it will cause overheating and other problems.

29.6SPECIFICATIONS
Hydraulic specifications
l Max. flow when flow is joined:
191 x 2 liter/min (50 x 2 US gal/min. 42 x 2 UK gal/min)
0 Safety valve relief set pressure of service valve:
27500 kPa (280 kg/cm*, 3980 psi)
l Safety valve cracking pressure of service valve:
24500 kPa (250 kg/cm*, 3550 psi)
0 Low pressure safety valve relief set pressure:
20500 kPa (210 kg/cm*, 2980 psi)
l Low pressure safety valve cracking pressure:
15200 kPa (155 kg/cm*, 2200 psi)
Other than these specifications, low pressure safety valve relief
set pressure of 24500 kPa (250 kg/cm*, 3550 psi) and low pressure
safety valve cracking pressure of 20100 kPa (205 kg/cm*, 2910 psi) are
provided. Consult your Komatsu distributor.

5-14
30. INTRODUCTION OF ATTACHMENTS

30.1 SPECIFICATION, USE

l PC206-6 AVANCE SERIES
Name I Specifications, use Name Specifications, use

Narrow bucket Capacity SAEKECE 0.5 n? (0.65 cu.ydYO.45mJ Three teeth ripper Shank width 90 mm (3.5”)
Outside width 750 mm (30”) bucket Crushing depth 640 mm (25”)

SAUCECE0.6 n-+(0.78 cu.yd110.55mr Track shoes Triple grouser shoe width 600 mm (23.6”)
Triple grouser shoe width 700 mm (28”)
Flate shoe width 610 mm (24”)
Swamp shoe width 860 mm (34”)
Rubber shoe width 800 mm (23.6”)

Light duty bucket Capacity SAEKECE 1.0 m3 (1.31 cu.ydVO.9I-I+

Outside width 1330 mm (52”)

Light duty bucket Capacity SAEKECE 1.17 mJ (1.53 cu.ydVl.0 n?

Outside width 1450 mm KJ”)

Slope finishing Capacity SAEKECE 0.40 n+ (0.52 cu.ydl/O.35mJ Extension arm Arm length 1130 mm (3’8”)
bucket Compacting width 2000 mm (79”) Max. digging depth 7750 mm (25’5”)
Compacting area 2.00 m2

Trapezoidal bucket Capacity SAEKECE 0.55 m3 (0.72 cu.ydVO.5m3

Outside width 3165 mm (10’5”) (45”)
3280 mm (10’9”) (45”)
3310 mm WlO”) (45”)

Ripper bucket Capacity SAE/CECE0.61 m3 (0.8 cu.ydV0.56m’

Outside width 950 mm (37”)

Clamshell bucket Capacity SAEKECE 0.66 m3 (0.86 cu.ydY0.6 m3

(Loading) Outside width 866 mm (34”)
Opening width 1782 mm (70”)

SAEKECE 0.80 mJ Il.05 cu.ydM0.7m3

AM092150

5-15
30. INTRODUCTION OF ATTACHMENTS

30.2 ATTACHMENT INSTALLATION COMBINATION TABLE

PCZOO-6 AVANCE SERIES
This table lists the combination of attachments which can be installed to the long arm (standard),
short arm and extension arm.
o : Can be used
A : Can be used only for light-duty work
x : Cannot be used

NOTlCE
l When the extension arm is equipped, if the bucket is drawn to the machine body, the arm interferes
with the body. Operate the extension arm carefully.
l When the boom is fully lowered during oblique digging, the boom interferes with the undercarriage.
Operate the boom carefully.

Categories of use
For general digging: digging or loading sand, gravel, clay etc.
For light duty digging: digging or loading dry, uincaked earth and sand, mud etc.
For loading work: loading dry, loose earth and sand
l For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with
high durability and high wear resistance be employed.

*: Equipped with side cutter

capm;itv 0;;;;; Standard Short Extension Short
Name of bucket Use arm arm arm arm
SAE (CECE) (mm) (2.9 m) (2.4 m) (1.1 m) (1.8 m)

* Narrow bucket 0.50 (0.45) 750 (30”) Narrow digging 0 0 0 0

* Narrow bucket 0.60 (0.55) 970 (38”) Narrow digging 0 0 x 0

* Standard bucket 0.8 (0.7) 1150 (45”) General dligging 0 0 x 0

* Light duty bucket 0.9 (0.8) 1200 (47”) Loading A A X A

Light duty bucket 1.0 (0.9) 1330 (52”) Loading X A x A

Light duty bucket 1.17 (1.0) 1450 (57”) Loading X A X A

Slope finishing bucket 0.40 (0.35) - Slope finishing 0 0 X 0

Trape zoidal bucket Trapezoidlal

(Variable slope type) 0.55 (0.5) - shaped diching 0 0 X 0

Sipper bucket 0.61 (0.56) 950 (37”) Digging rocks X 0 X 0

Clamshell bucket 0.66 (0.6) 866 (34”) Ditching, loading 0 0 x 0

Ditch cleaning bucket 0.8 (0.7) 1800 (71”) Ditching, cleaning 0 0 X 0

One tooth ripper Digging, removing rocks 0 0 X 0

I I I I I I I
Three teeth ripper Digging, removing rocks 0 0
x I O

5-16
 30. INTRODUCTION OF ATTACHMENTS

30.3 SELECTION OF TRACK SHOES

Select suitable track shoes to match the operating conditions.

METHOD OF SELECTING SHOES

Confirm the category from the list of uses in Table 1, then use Table 2 to select the shoe.
Categories B and C are wide shoes, so there are limitations on their use. When using these shoes, check
the precautions, then investigate and study fully the conditions of use to confirm that these shoes are
suitable.
When selecting the shoe width, select the narrowest shoe possible that will give the required flotation
and ground pressure. If a wider shoe than necessary is used, the load on the track will increase, and
this will cause the shoes to bend, links to crack, pins to break, shoe bolts to come loose, and various
other problems.

Table 1

Category Use Precautions when using

Rocky ground, riverbeds, l When traveling on rough ground where there are large obstacles such as
A
normal soil boulders and fallen trees, reduce speed and travel slowly.

l These shoes cannot be used on rough ground where there are large
obstacles such as boulders or fallen trees.
B Normal soil, soft ground
l If it is impossible to avoid traveling over obstacles, reduce speed to
about l/Z speed and travel slowly.

l Use the shoes only in places where the machine sinks and it is impossible
to use A or B shoes.
C Extremely soft ground l These shoes cannot be used on rough ground where there are large
(swampy ground) obstacles such as boulders or fallen trees.
l If it is impossible to avoid traveling over obstacles, reduce speed to
about l/2 speed and travel slowly.

D Paved road surfaces l The shoes are flat, and the gradeability is low, so use care on slopes.

l To protect the rubber shoes, always follow the instructions given in

E Paved road surfaces
30.5 HANDLING RUBBER PAD SHOE.

Table 2

PC200-6 AVANCE SERIES

Specifications Category

Option 500 triple grouser A

Option 600 triple grouser B

Option 700 triple grouser C

Standard 800 triple grouser C

Option 860 swamp shoe C

Option 610 flat shoe D

Option 600 rubber pad shoe E

Option

5-17
30. INTRODUCTION OF ATTACHMENTS

30.4 SELECTION OF BUCKET TEETH

Depending on the working conditions, there is danger that the adapter and teeth may break, so select
from the vertical pin teeth and horizontal pin teeth to give teeth that are suitable for the purpose.

METHOD OF SELECTING TEETH

Use of vertical pin tooth
General digging: Digging, loading normal soil, such as sand, gravel, clay
Light-duty digging: Digging, loading loose dry sandy soil or muddy soil.
Loading: Loading dry loosened soil

Use of horizontal pin tooth

Heavy-duty digging: Compacting, digging hard soil, soil mixed with rocks, heavy-duty work such as
scraping
l The heavy-duty bucket is a horizontal pin tooth type, so use it for heavy-duty digging.

The standard vertical pin and horizontal pin teeth can be used over a wide range, but we recommend
the following teeth to match the operating conditions.

Long-life teeth
l Jobsites where wear life is demanded, such as when loading hard rocks.
l Jobsites where no penetration is needed, such as when working with crushed rock after blasting or
ripping.
l Jobsites where heavy-duty operations are carried out, such as hitting or pulling up rocks with the
tips of the teeth.

Self-sharpening teeth (horizontal pin type, vertical pin type)

l Jobsites demanding penetration such as digging and loading sandy or clayey soil.

Standards for selecting horizontal pin type and vertical pin type teeth

Appropriate work site

Rock Crushed stone Clay, spread earth Sand

Heavy Ground breaking Lateral pin-type teeth

Lateral pin-type teeth
excavation Vertical pin-type teeth
I?
g Lateral pin-type teeth
z Scraping down Lateral pin-type teeth
Vertical pin-type teeth
8
General Lateral pin-type teeth
%z
excavation Vertical pin-type teeth
9 I Lateral pin-type teeth
Loading
Light Vertical pin-type teeth

5-18
 30. INTRODUCTION OF ATTACHMENTS

30.5 HANDLING RUBBER PAD SHOE

When using rubber shoes, always obey the following precau-
tions for handling.

WORKING ENVIRONMENT
l Use the rubber pad shoes mainly for work on paved road
surfaces.
If they are used on surfaces which are not paved, the rubber will
be cut or damaged, so its durability will drop markedly.
In particular, avoid the following operations.
o Operations on broken pieces on concrete or gravel.
o Operations on sharp protruding objects such as reinforcing
iron or glass (and in particular when traveling over steel
sheets driven into the ground).
o Operations traveling over the shoulder of concrete roads,
and operations on rockbed or stony river beds.

l Be careful not to let the machine slip when operating on road

surfaces covered with water, ice, snow, or gravel.
Be particularly careful when unloading the machine.

l Because of the physical properties of rubber, use the rubber pad

shoe in a temperature range of -25°C to 65°C (-13°F to 149°F).

OPERATING CONDITIONS
l Operations such as those shown in the diagram where the
machine is braced when working, side ditching operations, or
operations on slopes, or operations where the machine is fre-
quently steered from side to side, there will be an excessive load
on the rubber pad shoe and this will cause damage.
INCORRECT
l If special work equipment is installed, the durability of the rubber
pad shoe cannot be guaranteed.

INCORRECT

AM103900
J

5-19
30. INTRODUCTION OF AlTACHMENTS

STORAGE, MAINTENANCE
l Be careful not to get oil or grease on the rubber. If there is any
oil or grease on the rubber, wipe it off immediately.

l install the rubber pad shoe continuously to all links.

If it is not installed, it will cause excessive deformation of
damage to the rubber.
Rubber Dad shoe
AM103910
l When storing the rubber pad shoe for a long time, keep it 1
indoors out of direct sunlight or rain.

CONDITION OF DAMAGE TO RUBBER

l When traveling on concrete road surfaces, the rubber is trans-
ferred to the road surface, and leaves a black track.

l When the shoes contact each other, dents may be formed, but 3
the shoes can still be used.

Dents formed

AM103930

l Even if there are cuts or pieces of the rubber missing, and the
shoes look in extremely bad condition, this damage does not
extend immediately to the whole shoe, and it does not damage
the road surface, so the shoe can be used.

5-20
 30. INTRODUCTION OF ATTACHMENTS

30.6 HANDLING TRAPEZOIDAL BUCKET

This bucket is used to dig trapezoidal ditches in paddy fields,
farmland etc. and it can dig 3 types of ditch gradients (45”, 40” and
38”) when a movable plate is attached.

l The mounting position of the movable plate varies depending on

whether the ditch gradient is 45”, 40” or 38”.

ANllE3W

AN115370

HOW TO PERFORM EXCAVATION 45”,40”,38” ditch

Operate the boom, the arm and the bucket to make the line @ common hole 45’ditch hole
of the side-plate of the bucket vertical.
The guide elate 0 to check this position is installed beside the
bucket pins. A&ordiigly, hold this plate horizontal when digging.

38”,40” ditch common h&,538o

a
Ditch gradient of 45”
Attach the bucket only or the movable plate by selecting the 3165
related ditch holes. Perform digging by the above method.

45” 1385

400
AN115390

Ditch gradient of 40” and 38”

Attach the movable plate by selecting the related ditch holes.
Perform digging according to the above method.

Even if the trapezoidal bucket is provided with the movable plate,

always perform digging with the bucket side face perpendicular to
the ground.

AN115400

1 = AN115410

5-21
30. INTRODUCTION OF AlTACHMENTS

30.7 HANDLING EXTENSION ARM

When the extension arm is equipped, if the arm is retracted, the
bucket interferes with the boom cylinder foot and the revolution
frame. Be careful at operation and transportation.

l When the extension arm is equipped, use the narrow bucket

(bucket width: 750 mm (30”) and 560 mm (22”)) without the side
cutter.
Since the standard bucket causes body instability and the bucket
interferes with the operator’s cab when retracting the arm, do
not mount the standard bucket.

l Work in hard soil or rocky terrain will shorten the life of the
extension arm, the boom and the arm.
It is better not to use the extension arm in such conditions.

to be operated

AN115420

5-22
 30. INTRODUCTION OF ATTACHMENTS

30.8 HANDLING CLAMSHELL BUCKET

This bucket is used for digging and loading in side-ditches or the
confined spaces.

How to perform excavation

This clamshell digs by pushing the boom against the ground.
However, when perform bucket operation, perform digging while
gradually raising the boom.
If the clamshell bucket rotates, relieve the bucket cylinder pressure
then set the lever to the neutral position. This can temporarily stop
the rotation.

PRECAUTIONS WHEN USING

l For safety, always avoid abrupt traveling, swing and stopping.
l Make the teeth of the bucket vertical in digging.
l Do not swing the bucket to crush the rock or to cut through soil.
l Do not use the bucket for hammering or pulling out piles etc.
l Before leaving the machine, open the bucket and lower it to the
ground.

REMARK
Remove the bucket from the arm when transporting the ma-
chine.

5-23
31. EXTENDING MACHINE SERVICE LIFE

This section describes the necessary precautions to be observed when operating a hydraulic excavator
equipped with an attachment.

NOTlCE
Select the attachment most suited to the machine body.
l The machine models to which attachments can be mounted vary. For selection of attachment
and machine model, consult your Komatsu distributor.

31 .I HYDRAULIC BREAKER
MAIN FIELDS OF APPLICATION
o Crushed rock
o Demolition work
o Road construction
This attachment can be used for a wide range of work including
demolition of buildings, breaking up of road surfaces, tunnel work,
breaking up slag, rock crushing, and breaking operations in quarries.

AL069750

Keep the chisel pushed perpendicularly against the impact sur-

2
face when carrying out breaking operations.

90'
ro
0

/I
AL069760

When applying impact, push the chisel against the impact sur-
face and operate so that the chassis rises approx. 5 cm off the
ground. Do not let the machine come further off the ground than is
necessary.

5-24
 31. EXTENDING MACHINE SERVICE LIFE

When applying continuous impact to the same impact surface, if the

chisel does not penetrate or break the surface within 1 minute,
change the point of impact and carry out breaking operations closer
to the edge.

The direction of penetration of the chisel and the direction of the

breaker body will gradually move out of line with each other, so
always adjust the bucket cylinder to keep them aligned.

AL069790

Always keep the chisel pressed against the impact surface properly
to prevent using the impact force when there is no resistance.

AL069800
I

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

Using the mount to gather in pieces of rock

LO69810

Operations using the swing force

5-25
31. EXTENDING MACHINE SERVICE LIFE

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

AL069860

Extending the bucket cylinder fully and thrusting to raise the ma-
chine off the ground

I AL069870

5-26
 31. EXTENDING MACHINE SERVICE LIFE

31.2 POWER RIPPER

MAIN FIELDS OF APPLICATION
o Road repair work
o Demolition work
This attachment can be used for a wide range of work including
peeling off and crushing pavement roads, demolishing wooden
houses and buildings, and crushing foundation and roadbeds.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

AM092190

Impact operations using attachment

AM092200

Impact operations using swing force

AM092210

Overloading work equipment during lifting and loading operations II

AM092220

Operations using attachment to grip at an angle

I AM092230

5-27
31. EXTENDING MACHINE SERVICE LIFE

31.3 FORK GRAB

MAIN FIELDS OF APPLICATION
o Disposing of industrial waste
o Disposing of demolition waste
This can be used for a wide range of work including collecting
or loading demolition waste materials and debris, timber, grass etc.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

AM092240

Operations using the swing force

AM092250

Operations using one side of work equipment

Pushing fork into ground surface to jack up and change direction of z

machine

AM092270

Impact operation with no load

AM092280

5-28
 31. EXTENDING MACHINE SERVICE LIFE

31.4 GRAPPLE BUCKET

MAIN FIELDS OF APPLICATION
o Demolition
o Disposing of industrial waste
o Forestry
This bucket is widely used for demolition including breaking-up
work, grading and digging, clean-up work after natural disasters,
dumping industrial waste, and forestry work, etc.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

1 AM092290

Operations using the swing force

I AM092300

Grabbing a object using buckets on only one side

AM092310

Closing the sub-bucket with the boom and arm fully extended.

I AM092320

Impact operation with no load

AM092330

5-29
31. EXTENDING MACHINE SERVICE LIFE

31.5 SCRAP GRAPPLE

MAIN FIELDS OF APPLICATION
o Disposal of rock or debris
This attachment is mounted to the arm end and used to grasp
rock, debris etc. by opening and closing the claws (3 to 5) corre-
sponding to the extension and retraction of the hydraulic cylinder.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

AMOS2340

Operations using the swing force

AM032350

Operations using one side of work equipment

AM092360

Catching and dragging with claw end

AM092370

Gouging

AM092380

5-30
 31. EXTENDING MACHINE SERVICE LIFE

31.6 CRUSHER & CUTTER

MAIN FIELDS OF APPLICATION
o Demolition
o Road repair work
This is the optimum attachment for demolition of steel frame
reinforced structures, and for crushing of concrete blocks and rock,
etc. The unique blade shape provides heavy crushing power.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

Operations using cutting tip on one side only 1

Impact operation with no load

AM092400
1

AM092410

Twisting operations at end of cylinder stroke

AM092420

Sudden gripping and breaking operations

AM092490

5-31
31. EXTENDING MACHINE SERVICE LIFE

31.7 HYDRAULIC PILE DRIVER

MAIN FIELDS OF APPLICATION
o Foundation work
o River work
o Water supply and sewerage
This is a piling machine employing the hydraulic power source
of the excavator. The machine features a long arm and a chuck unit
movable by 360”. This facilitates operations such as driving and
removing long piles, driving in piles at corners, vertical driving etc.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
Always leave approx. 5 cm (2 in) to spare.

Forward or swing motion while grasping a pile

AM092450

Lifting more than two piles at the same time I I

AM092460

Work other than standard works

AM092470

Loading or unloading a machine equipped with hydraulic pile driver

I AM092480

5-32
 31. EXTENDING MACHINE SERVICE LIFE

31.8 HYDRAULIC EXCAVATOR WITH MULTI-

PURPOSE CRANE
MAIN FIELDS OF APPLICATION
0 Site preparation
o Water supply and sewerage
o River work
o Agricultural, civil engineering work
Crane operation can be carried out without removing the bucket.
This machine is used for laying U section gutters and hume pipes
for water supply and sewerage as well as river and canal work,
agricultural, civil engineering work and site preparation.

MISTAKEN METHODS OF USE

To ensure that the machine has a long life, and to ensure that
operations are carried out in safety, do not operate the machine in
any of the following ways.
l Do not operate the cylinder to the end of its stroke.
AM092490
Always leave approx. 5 cm (2 in) to spare.

Abrupt lever operation

AM092500

Traveling with a suspended load

Operating other work equipment during crane operation

AM092520

Excessive lengthening of wire rope

AM092530

5-33
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186

FOR INTERNAL USE ONLY -- No. PMR

2 NAME OF COMPANY: LOCATION:

: PHONE NO:

:
S DEPARTMENT: DATE:
E
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MANUAL NAME:

MANUAL NO:

MACHINE MODEL:
S/N IF APPLICABLE:

PAGE NO:

PROBLEM:

Attach photo or sketch.

If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:

PFMRl 081696