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Page 3: Foreword
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 1 - 4...
Page 6 FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8 BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 9 FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. MACHINE SERIAL NUMBER PLATE AND ITS LOCATION On the front bottom right of the operator's cab (side of upper frame)
Page 10 FOREWORD PRODUCT INFORMATION This is the exhaust manifold on the left side face of the engine (front of machine). SERVICE METER LOCATION On top of the machine monitor 1 - 9...
Page 11 FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Distributor name Address Service Personnel Phone/Fax 1 - 10...
Page 12: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE BREAKING-IN THE NEW MACHINE PRODUCT INFORMATION MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ENGINE SERIAL NUMBER PLATE AND ITS LOCATION SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10 CONTENTS 1- 11...
Page 13: Foreword
FOREWORD CONTENTS MACHINE OPERATIONS AND CONTROLS 3- 69 BEFORE STARTING ENGINE 3- 69 STARTING ENGINE 3- 87 AFTER STARTING ENGINE 3- 91 STOPPING THE ENGINE 3- 99 MACHINE OPERATION 3-100 STEERING THE MACHINE 3-104 SWINGING 3-106 WORK EQUIPMENT CONTROLS AND OPERATIONS 3-107 WORKING MODE 3-108...
Page 14 FOREWORD CONTENTS TIGHTENING TORQUE SPECIFICATIONS 4- 14 TIGHTENING TORQUE LIST 4- 14 SAFETY CRITICAL PARTS 4- 15 SAFETY CRITICAL PARTS LIST 4- 15 MAINTENANCE SCHEDULE 4- 16 MAINTENANCE SCHEDULE CHART 4- 16 MAINTENANCE PROCEDURE 4- 18 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) 4- 18 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) 4- 18...
Page 15 FOREWORD CONTENTS MAINTENANCE 7- 23 CHECK BEFORE STARTING 7- 23 EVERY 10 HOURS MAINTENANCE 7- 25 EVERY 5000 HOURS MAINTENANCE 7- 26 SPECIFICATION 7- 28 COMBINATION OF WORK EQUIPMENT 7- 29 COMBINATION OF WORK EQUIPMENT 7- 29 INDEX 1 - 14...
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Page 17: Safety Information
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION 2- 12 Safety Rules 2- 12 If Problems are Found 2- 12 Working Wear and Personal Protective Items 2- 12 Fire Extinguisher and First Aid Kit 2- 12 Safety Equipment 2- 12 Keep Machine Clean...
Page 18 SAFETY SAFETY SAFETY MACHINE OPERATION 2- 20 Starting Engine 2- 20 Checks Before Starting Engine 2- 20 Safety Rules for Starting Engine 2- 20 Starting Engine in Cold Weather 2- 21 Operation 2- 22 Checks Before Operation 2- 22 Safety Rules for Changing Machine Directions 2- 22 Safety Rules for Traveling 2- 23...
Page 19: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. 2 - 4...
Page 20: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2 - 5...
Page 21: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution for operation, inspection, and maintenance (09651-A0641) (2) Caution before operating (09802-03000) (3) Caution for leaving operator's seat (09654-A0641) 2 - 6...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electrical cables (09801-A0641) (5) Caution for operating pattern (09822-03000) 2 - 7...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (6) Caution for high-temperature coolant and hydraulic oil (09653-A0481) (7) Caution for handling accumulator and gas spring (09659-A057B) (8) Caution for adjusting track tension (09657-A0881) (9) Caution for handling cable (09808-A0881) 2 - 8...
Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Stopping rotation for inspection and maintenance (09667-A0481) (11) Explanation of methods for emergency escape (20Y-00-31170) (12) Caution against falling (09805-A0881) 2 - 9...
Page 25 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (13) Caution against falling (09805-C0881) (14) Prohibited to enter within swing range (09133-A3281) (15) Bware of work equipment (09134-A1681) 2 - 10...
Page 26 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (16) Prohibition of engine start by short-circuiting (09842-A0481) 2 - 11...
Page 27: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 28: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.
Page 29: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe)
Page 30: Burn Prevention
SAFETY GENERAL PRECAUTIONS BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 31: Action If Fire Occurs
The above recommendations assume that the conditions are for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice. 2 - 16...
Page 32: Attachment Installation
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 injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 33: Working On Loose Ground
SAFETY GENERAL PRECAUTIONS WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.
Page 34: Ventilation For Enclosed Area
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 19...
Page 35: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 36: Starting Engine In Cold Weather
SAFETY SAFETY MACHINE OPERATION STARTING ENGINE IN COLD WEATHER 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. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 37: Operation
SAFETY SAFETY MACHINE OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check that the movement of the machine matches the display on the control pattern card.
Page 38: Safety Rules For Traveling
SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.
Page 39: Operations On Slopes
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.
Page 40: Prohibited Operations
SAFETY SAFETY MACHINE OPERATION PROHIBITED OPERATIONS Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine. Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
Page 41: Operations On Snow
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When carrying out demolition work, do not carry out demolition above your head. There is a hazard of broken parts falling or of the building collapsing and causing serious injury or property damage.
Page 42: Parking Machine
SAFETY SAFETY MACHINE OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment completely to the ground. When leaving the machine, set safety lock lever (1) to the LOCK position (L), then stop the engine.
Page 43: Transportation
SAFETY MACHINE OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 44: Battery
SAFETY SAFETY MACHINE OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 45: Starting Engine With Booster Cables
SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 46: Towing
SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-137)". Always wear leather gloves when handling wire rope.
Page 47: Safety Maintenance Information
SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION 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 performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 48: Stop Engine Before Carrying Out Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment completely to the ground and stop the engine.
Page 49: Two Workers For Maintenance When Engine Is Running
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. 2 - 34...
Page 50: Personnel
SAFETY SAFETY MAINTENANCE INFORMATION PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall.
Page 51: Welding Works
If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. 2 - 36...
Page 52: Safety Rules For High-Pressure Oil
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 53: Air Conditioner Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION AIR CONDITIONER MAINTENANCE If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant. COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.
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Page 55: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Boom cylinder Bucket link Sprocket Bucket cylinder Track frame (10) Track shoe Arm cylinder (11) Idler Boom (12) Overhead guard 3 - 2...
Page 56: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Car radio (13) Right work equipment control lever Large capacity airflow air conditioner blower (14) Cigarette lighter switch (if equipped) (15) Starting switch Rotating lamp switch (if equipped) (16) Step light switch Lower wiper switch (machines equipped with (17) Fuel control dial fixed front window cab)
Page 57 OPERATION MACHINE VIEW ILLUSTRATIONS Machine monitor AA: Screen with all lamps lighted up BB: Screen for standard CC: Maintenance time warning screen Working mode selector switch (15) Fuel gauge Wiper monitor (16) Fuel level monitor Engine pre-heating monitor (17) Auto-deceleration monitor Swing lock monitor (18) Display control switch...
Page 58: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM A: Basic check Items D: Meter Display Portion...
Page 59 OPERATION DETAILED CONTROLS AND GAUGES Basic Operation of Machine Monitor If There Is Abnormality When Starting Engine If there is any abnormality when starting the engine, the check before starting screen changes to the maintenance warning screen, warning screen, or an error screen. After displaying the check before starting screen for 2 seconds, the screen changes to the maintenance warning screen.
Page 60 OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation If any abnormality occurs during operation, the normal operation screen changes to warning screen (1) or the error screen. After displaying warning screen (1) for 2 seconds, the screen automatically changes to warning screen (2). 3 - 7...
Page 61 OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly.
Page 62 For details of the method of checking the maintenance interval, see "Maintenance Switch (PAGE 3-24)" in the Detailed controls and gauges. If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 9...
Page 63: Caution Monitors
OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running.
Page 64 OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor Monitor (2) lights up to warn the operator the fuel level in the tank is low. If the remaining amount of fuel goes down to 300 liters (79.26 US gal), the light changes from green to red, so add fuel as soon as possible.
Page 65 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
Page 66 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor Monitor (2) warns operator that the hydraulic oil temperature has risen. If monitor lights up red during operations, run engine at low idle or stop the engine and wait until the oil temperature goes down and monitor (2) changes to green.
Page 67 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion D(1) Engine pre-heating monitor D(6) Travel speed monitor D(2) Swing lock monitor D(7) Engine water temperature gauge D(3) Wiper monitor D(8) Fuel gauge D(4) Auto-deceleration monitor D(9) Hydraulic oil temperature gauge D(5) Working mode monitor D(10) Service meter Pilot Display When the starting switch is ON, the pilot display lights up when the display items are functioning.
Page 68 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Monitor This monitor (2) informs the operator that the swing lock has been actuated. When actuated: Lights up The monitor lights up when the swing lock switch is turned to the ON (LOCK) position. The monitor flashes when the swing holding brake release switch is turned ON.
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Monitor Monitor (6) displays set mode for the travel speed. The monitor display when the travel speed selector switch is operated, as follows. Lo : Low speed Hi : High speed Gauges and Meter Engine Coolant Temperature Gauge This meter (7) indicates the engine cooling water temperature.
Page 70 OPERATION DETAILED CONTROLS AND GAUGES Fuel Gauge This meter (8) displays the level of the fuel in the fuel tank. During operations, the indicator should be in the black range. If the indicator enters red range (A) during operations, there is less than 300 liters (79.26 US gal) of fuel remaining in the tank, so check and add fuel.
Page 71 OPERATION DETAILED CONTROLS AND GAUGES Service Meter Monitor (10) displays the total time that the machine has been operated. Use the time display to set the maintenance interval. When the starting switch is ON, the service meter advances even if the machine is not moving.
Page 72: Monitor Switches Portion
OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion E(1) Working mode selector switch (Basic mode) E(7) Has no function E(2) Auto-deceleration switch (Selection switch) E(8) Back switch E(3) Travel speed selector switch E(9) Up switch E(4) Wiper switch E(10) Down switch E(5) Window washer switch E(11) Input confirmation switch E(6) Maintenance switch...
Page 73 The monitor display on the monitor display portion changes for each mode. If it is desired to have the working mode set to start automatically in E, L, or B mode (default option setting), have your Komatsu distributor change the setting. REMARK...
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Auto-deceleration Switch (Selection Switch) This switch (2) turns on the function to reduce fuel consumption and lowers the engine speed automatically when the work equipment control levers are at neutral. Monitor display ON: Auto-deceleration actuated Monitor display OFF: Auto-deceleration canceled Each time that the switch is pressed, the auto-deceleration switches between actuated and canceled.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch WARNING When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (3) at the Lo position). Never operate travel speed selector switch (3) while loading or unloading. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 76 OPERATION DETAILED CONTROLS AND GAUGES Wiper Switch This switch (4) actuates the front window wiper. Each time the switch is pressed, it changes ON → INT → stop (OFF). Monitor display ON lighted up : Wiper moves continuously Monitor display INT lighted up : Wiper moves intermittently Monitor display OFF : Wiper stops REMARK Each time that the wiper switch is operated, the mode is displayed...
Page 77 OPERATION DETAILED CONTROLS AND GAUGES Maintenance Switch Switch (6) is used to check the time remaining until maintenance. When switch (6) is pressed, screen on the monitor display changes to the maintenance screen, as shown in diagram on the right. The time remaining until maintenance is indicated by the color of each monitor display.
Page 78 Change hydraulic oil 5000 If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. The method of checking time remaining until maintenance is as follows: 1. Look at the maintenance screen, press up switch (9) or down switch (10) on the monitor switch portion, and select the item.
Page 79 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. After checking the time on the default setting screen, press input confirmation switch (11). The screen will return to the maintenance screen. (Press back switch (8) to return to the previous screen.) Back Switch Press switch...
Page 80 OPERATION DETAILED CONTROLS AND GAUGES Liquid Crystal Monitor Adjustment Switch Press switch (12) to adjust the brightness or contrast of the display monitor. Adjusting brightness and contrast 1.When monitor adjustment switch (12) is pressed, the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right.
Page 81 OPERATION DETAILED CONTROLS AND GAUGES Adjusting contrast 2.Use the brightness/contrast screen and press up switch (9) or down switch (10) to select the contrast monitor. (The selected monitor is inverted to black.) 3.When the screen changes to the contrast adjustment screen, press up switch (9) or down switch (10) to adjust the contrast.
Page 82: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES (1) Starting switch (10) Pump drive emergency switch (2) Fuel control dial (11) Swing holding brake release switch (3) Cigarette lighter (12) Rotating lamp switch (if equipped) (4) Swing lock switch (13) Lower wiper switch (machines equipped with (5) Lamp switch fixed front window cab) (6) Alarm buzzer stop switch...
Page 83 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial Dial (2) adjusts the engine speed and output. (a)Low idling (MIN): Turned fully to the left (b)Full speed (MAX): Turned fully to the right Cigarette Lighter Lighter (3) is used to light cigarettes. To use, push the lighter in.
Page 84 OPERATION DETAILED CONTROLS AND GAUGES Lamp Switch Switch (5) is used to turn on the front lamps, working lamps, additional lamps at top front of the cab, and monitor lighting. Alarm Buzzer Stop Switch This switch (6) is used (when the engine is running) to stop the alarm buzzer when it has sounded to warn of a problem in a warning item.
Page 85 OPERATION DETAILED CONTROLS AND GAUGES Horn Switch When the switch (8) at the tip of the right work equipment control lever is pressed, the horn will sound. Room Lamp Switch NOTICE It is possible to turn on the interior cab room lamp even when starting switch is in the OFF position, do not forget to turn it off.
Page 86 OPERATION DETAILED CONTROLS AND GAUGES Swing Parking Brake Release Switch NOTICE This switch makes it possible to perform swing operations for a short even when there is a problem in the swing parking brake electric system. DO NOT use this switch except in emergencies. Repair the problem as soon as possible.
Page 87 OPERATION DETAILED CONTROLS AND GAUGES Large Capacity Airflow Air Conditioner Blower Switch (if equipped) Switch (14) operates the large capacity airflow air conditioner blower. Boom Shockless Control Switch This switch (13) controls the shaking of the work equipment when the boom is stopped. Effect The shaking and spillage of load from the bucket is reduced.
Page 88: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS (1) Safety lock lever (3) Left work equipment control lever (2) Travel levers (Machines with pedal (with auto-deceleration device) auto-deceleration device) (4) Right work equipment control lever (with auto-deceleration device) Safety Lock Lever WARNING When leaving the operator's compartment, set the safety lock lever securely to the LOCK position (L).
Page 89 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers WARNING Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may suddenly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations.
Page 90: Emergency Exit From Operator's Cab
OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES This right lever (4) is used to operate the boom and bucket. Boom operation (a): RAISE (b): LOWER Bucket operation (c): DUMP (d): CURL N (Neutral): When the lever in this position, the boom and the bucket will be retained in the position in which they stop.
Page 91: Cap With Lock
OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Use the starting switch key to open and close the locks on the caps and covers. For details of the locations of the caps and covers with locks, see "LOCKING (PAGE 3-121)". Insert the key as far as it will go to the shoulder.
Page 92 OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Cover with Lock Opening the Cover (Locked Cover) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. Locking the Cover 1.
Page 93: Hot And Cool Box
OPERATION DETAILED CONTROLS AND GAUGES HOT AND COOL BOX Located on the right side at rear of the operator's seat. It is interconnected with the air conditioner. Box stays warm when the heater is used, and box stays cool when the air conditioning is used.
Page 94: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel (1) OFF switch (6) FRESH/RECIRC selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Defroster selector lever (5) Auto switch OFF Switch Switch (1) is used to stop the fan and air conditioner.
Page 95 OPERATION DETAILED CONTROLS AND GAUGES Fan Switch Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the ∧ switch to increase the air flow; press the ∨ switch to reduce the air flow. During auto operation, the air flow is automatically adjusted.
Page 96 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch Switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. During automatic operation, the vents are automatically selected.
Page 97 OPERATION DETAILED CONTROLS AND GAUGES Auto Switch With switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. When auto switch (5) is pressed, the lamp above the auto switch lights up. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under automatic control.
Page 98 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch Switch (8) is used to turn the air conditioner (cooling, dehumidifying, heating) ON or OFF. When the fan is actuated (display (b) is shown) and air conditioner switch (8) is pressed, the air conditioner is switched ON, lamp above the air conditioner switch lights up, and the air conditioner starts.
Page 99 OPERATION DETAILED CONTROLS AND GAUGES Defroster Selector Lever This switch (9) is used in cold or rainy weather to remove the mist that forms on the front glass. Selector lever forward: To defroster (open) Selector lever back: Closed The defroster can be used when the vent selector switch is set to face or face and foot.
Page 100 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES REMARK When vent display monitor (c) displays (d) or (e), and engine coolant temperature is low, the air flow is automatically limited to prevent cold air from blowing out. Stopping Automatic Operation Press OFF switch (1).
Page 101 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2. Turn air conditioner switch (8) ON. Check that the lamp above air conditioner switch lights up. 3. Press temperature setting switch (3) and adjust temperature inside the cab. 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
Page 102 OPERATION DETAILED CONTROLS AND GAUGES Stopping Manual Operation Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on monitor (7), and lamps above auto switch (5) and air conditioner switch (8) go out, the operation stops. Operation with Cold Air to Face and Warm Air to Feet To operate with cold air blowing to the face and warm air blowing to the feet, set as follows.
Page 103 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Turn air conditioner switch (8) ON. Check that the lamp above air conditioner switch lights up. 4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired positions. 3 - 50...
Page 104 OPERATION DETAILED CONTROLS AND GAUGES Defroster Operation 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7). 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the right.
Page 105 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air. 4. Press temperature setting switch (3) and set temperature on the display (7) monitor to maximum heating. 5.
Page 106: Use Air Conditioner With Care
OPERATION DETAILED CONTROLS AND GAUGES Use Air Conditioner with Care NOTICE When running the air conditioner, always start with the engine running at low speed. Never start the air conditioner when the engine is running at high speed. It will cause failure of the air conditioner. If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, be careful not to let water get on these parts.
Page 107 OPERATION DETAILED CONTROLS AND GAUGES Other Functions Self-diagnostic Function It is possible to perform troubleshooting of various sensors and equipment used on the air conditioner. 1. Press OFF switch (1). The temperature setting and air flow display on the liquid crystal display portion go out and operation stops.
Page 108 OPERATION DETAILED CONTROLS AND GAUGES Function to Switch Set Temperature Display Between Fahrenheit and Celsius It is possible to switch the set temperature display between °F and °C. ∨ ∧ If the " " and " " portions of temperature setting switch (3) are pressed at the same time for more than 5 seconds while the fan is running, the temperature display will switch between °F and °C.
Page 109: Radio
OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel (1) Power switch/Volume control knob/Balance knob (6) Preset buttons (2) Tone control knob (7) Display (3) FM/AM selector button (8) Time connection button (4) Display selector button (9) Stereo indicator (5) Manual tuning Power Switch/Volume Control (SW-VOLUME) and Balance (Pull BAL) Knob Press this knob (1) to turn the power for the radio on.
Page 110 OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) The radio gives priority to the frequency display. If button (4) is pressed when the frequency is displayed, display will give the present time for 5 seconds. After 5 seconds pass, display will automatically return the frequency display. If any button other than TIME SET (H, M, SET) is pressed within the 5 seconds, display will return to the frequency display.
Page 111 OPERATION DETAILED CONTROLS AND GAUGES Controls of Radio Method of Setting with Preset Button 1. Press power switch (1) and display the frequency on display (7). 2. Turn the tuning button (5) (manual, auto) to adjust to the desired frequency. 3.
Page 112 OPERATION DETAILED CONTROLS AND GAUGES Setting Correct Time 1. Press display selector button (4) to display the time. After 5 seconds, the display will return to the frequency display and the time cannot be corrected. If this happens, press display selector button (4) again. 2.
Page 113: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 24V Power Source NOTICE Do not use this as the power supply for 12V equipment. It will cause failure of the equipment. Pull out the connector plug for taking out electric power from the rear side of the panel.
Page 114: Fuse
OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 115: Circuit Breaker
OPERATION DETAILED CONTROLS AND GAUGES CIRCUIT BREAKER NOTICE When resetting the circuit breaker, always turn the starting switch OFF first. If the starting switch does not work even when the starting switch is turned ON, open the circuit breaker box inside the grease pump box at the front right of the machine and carry out inspection.
Page 116 OPERATION DETAILED CONTROLS AND GAUGES Fuse Name of circuit capacity Monitor Working lamp, right front light of machine Pump controller Cab upper head lamp Starting switch Engine controller (direct from battery) (10) Monitor (direct from battery) (11) Fuse box (direct from battery) 3 - 63...
Page 117: Controller
Do not let water, mud, or juice spill on the controller. This will cause failures. If any problem occurs in the controller, do not repair it by yourself. Please contact your Komatsu distributor for repairs. TOOL BOX (Cloth bag) This is inside the storage box inside the cover (1) on the left side at the rear of the cab.
Page 118: Grease Pump
OPERATION DETAILED CONTROLS AND GAUGES GREASE PUMP This is stored inside the grease pump box on the right side of the chassis. Method of Use 1. Open cover (1). 2. Rotate the lever of valve (2) upward 90° to set it to the (A) position.
Page 119 OPERATION DETAILED CONTROLS AND GAUGES Precautions when Using NOTICE When not using the grease pump, always rotate the lever of valve (2) down 90° to set it to the (B) position to prevent internal pressure from forming inside grease gun (3). Set so that the grease fitting and the nozzle at the tip of the grease gun are perpendicular.
Page 120 OPERATION DETAILED CONTROLS AND GAUGES Supplying Grease 1. Remove 3 wing bolts (2) from grease can (1), then remove cover (3) from the pump. 2. Remove follow plate (4) inside the grease can. REMARK If the hollow in the center of the follow plate is not fully filled with grease, air will be sucked in and it may not be possible to use all the grease.
Page 121: Accumulator
Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Contact your Komatsu distributor for proper disposal. This machine is equipped with an accumulator in the control circuit. The accumulator is a device to store oil pressure for the control circuit.
Page 122: Machine Operations And Controls
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor.
Page 123 OPERATION MACHINE OPERATIONS AND CONTROLS 8. Clean, check rear view mirror Check for damage to the rear view mirror. If damaged, replace it with a new mirror. Clean surface of the mirror and adjust angle so area at the rear can be seen from the operator's seat. 9.
Page 124: Checks Before Starting
OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 125 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK When adding water to the radiator, remove cover (3), then loosen radiator cap (4) slowly. After checking that the pressure has been released, push in the cap, keep it pushed in, then loosen it further and remove it.
Page 126 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 127 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 128 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING If the oil filler cap is removed without releasing the internal pressure, oil will spurt out, so turn the oil filler cap slowly to release the internal pressure, then remove it carefully. 1.
Page 129 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS WARNING If the oil is above the H level, stop the engine, wait for the hydraulic oil to cool down, then drain the excess oil from drain plug (P1). When draining the oil, loosen bottom drain plug (P1), then loosen the side drain plug (P2) and drain the oil.
Page 130 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Swing Machinery Case, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 131 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in PTO Case, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.
Page 132 Turn the lamp switch to the ON position and check that the working lamp light up. If the lamps do not light up, there is probably a broken bulb or disconnection in the wiring, contact your Komatsu distributor for repairs. 3 - 79...
Page 133 Check Electric Wiring CAUTION If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Page 134 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's back against the backrest.
Page 135 OPERATION MACHINE OPERATIONS AND CONTROLS (C) Adjusting seat tilt Forward tilt Push lever (3) down to adjust angle of the front of seat. (4 stages) To raise the angle at front of the seat, keep the lever pushed down and apply your weight to the rear of seat. To lower the angle at front of the seat, keep the lever pushed down and apply your weight to the front of seat.
Page 136 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors Loosen nut (1) and bolt (2) mounting the mirror, and adjust to the position which gives the best view from the operator's seat of the blind spot to the left and right sides at the rear of the machine. Adjust the mirror mount so that it is possible to see people (or objects with a height of 1 m (3.3 ft) or a diameter of 30 cm (12 in)) at the rear left and right of the machine...
Page 137: Seat Belt
OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt.
Page 138 Engine coolant temperature gauge (10) Fuel gauge (11) Air cleaner clogging monitor (12) If the monitors do not light up or the buzzer does not sound, there is probably a failure in the monitor, so contact your Komatsu distributor for repairs. 3 - 85...
Page 139 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2) After approx. 3 seconds, the screen switches to the working mode/travel speed display monitor. Then it switches to the normal screen. Fuel level monitor (7) Engine coolant temperature monitor (8) Engine coolant temperature gauge (10) Fuel gauge (11) Hydraulic oil temperature gauge (13)
Page 140: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 141 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to the START position. The engine will start. 4. When the engine starts, release the key in starting switch (3). The key will return automatically to the ON position. 5.
Page 142 OPERATION MACHINE OPERATIONS AND CONTROLS Starting Engine in Cold Weather WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 143 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Hold the key in starting switch (3) at the HEAT position, and check that preheating monitor (4) lights up. After about 30 seconds, preheating monitor lamp (4) will flash to indicate that preheating is finished.
Page 144: After Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS AFTER STARTING ENGINE WARNING If there has been any Emergency stop, abnormal actuation or trouble, turn the starting switch key to the OFF position. If the work equipment is operated without sufficiently warming the machine up, response of the work equipment to movement of the control lever will be slow, and the work equipment may not respond as the operator desires, so always perform the warming-up operation.
Page 145 OPERATION MACHINE OPERATIONS AND CONTROLS After the engine starts, do not start operating the machine immediately. First, carry out the following operations and checks. 1. Set fuel control dial (2) to a point midway between low idling (MIN) and full throttle (MAX), and run the engine at a mid-range speed under no load until the engine water temperature monitor enters the green display.
Page 146 Hydraulic oil temperature monitor (18): Green display 6. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 7. If air cleaner clogging monitor (16) lights up, clean or replace the element immediately.
Page 147 OPERATION MACHINE OPERATIONS AND CONTROLS Working mode monitor display 1) A mode For heavy-load operations 2) E mode For operations with emphasis on fuel economy 3) Heavy-duty lift Boom lifting power increased when raising boom independently 4) Swing priority mode Priority given to swing when operating boom and swing simultaneously 3 - 94...
Page 148 OPERATION MACHINE OPERATIONS AND CONTROLS In Cold Weather Areas (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30°C (86°F), the warming-up operation is performed automatically.
Page 149 Hydraulic oil temperature monitor (18): Green display 6. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 7. If air cleaner clogging monitor (16) lights up, clean or replace the element immediately.
Page 150 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 8. Turn fuel control dial (2) to the full speed (MAX) position and carry out the operation is Step 6. for 3 to 5 minutes. 9. Repeat the following operation 3 - 5 times and operate slowly. RAISE ←→...
Page 151 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3) Heavy-duty lift Boom lifting power increased when raising boom independently 4) Swing priority mode Priority given to swing when operating boom and swing simultaneously NOTICE Canceling automatic warm-up operation If it becomes necessary in an emergency to cancel the automatic warm-up operation or to lower the engine speed to low idle, do as follows.
Page 152: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
Page 153: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION Preparations for Moving the Machine WARNING Before operating the steering levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. When moving the machine, check that the area around the machine is safe, and always sound the horn before moving.
Page 154 (6) to move the machine forward. 3. For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, contact your Komatsu distributor for repairs. REMARK In cold temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation.
Page 155 Slowly push the levers (5) forward, or slowly depress the front part of the pedals (6) to move the machine backward. 3. For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, contact your Komatsu distributor for repairs. 3 - 102...
Page 156: Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3 - 103...
Page 157: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear, the machine moves in the reverse direction to the operation of the travel levers. Use the travel levers to change direction.
Page 158 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. REMARK When turning to the right, operate the right travel lever in the same way.
Page 159: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. 1. Before starting the swing operation, turn swing lock switch (1) OFF and check that swing lock monitor (2) has gone out.
Page 160: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, so operate the levers carefully. The work equipment is operated by the left and right work equipment control levers.
Page 161: Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match operating conditions and purpose, thereby enabling work to be performed efficiently. Make effective use of each mode as follows. When the starting switch is turned to the ON position, the working mode is set to A mode (digging).
Page 162: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, so operate the levers carefully. Operations Using Swing Force Do not use the swing force to compact soil or break objects. This is not only dangerous, but will also drastically reduce the life of the machine.
Page 163 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as s pickaxe, breaker, or pile driver. This will drastically reduce the life of the machine. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging.
Page 164: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 165 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth NOTICE 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 cooling fan. This may cause the fan to break. Be extremely careful when driving the machine out of water.
Page 166: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose 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 a platform on the slope so that the machine can be kept horizontal when operating.
Page 167 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.
Page 168: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out. Place the machine push-up switch at position (1). This will increase the pushing power of the boom and make it easier to escape.
Page 169: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine.
Page 170: Bucket Replacement
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 171 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. Remove the stopper bolts and nuts, then remove pins (A) and (B), and remove the bucket. NOTICE After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, be careful not to damage them.
Page 172: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure, thrust the bucket into the ground.
Page 173 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Set lock lever (3) in the LOCK position. 3 - 120...
Page 174: Check After Shut Off Engine
OPERATION MACHINE OPERATIONS AND CONTROLS CHECK AFTER SHUT OFF ENGINE Check the engine coolant temperature, engine oil pressure, and fuel level on the machine monitor. REMARK After stopping the engine, if the starting switch is turned within approx. 10 seconds to the ON or START position to start the engine again, the monitor display is not reset, and the screen before the starting switch was turned OFF is displayed.
Page 175: Transportation
TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. PRECAUTIONS FOR TRANSPORTATION WARNING This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. LIFTING MACHINE WARNING Never perform lifting operations with any person on the machine.
Page 176: Shipping Machine Information
OPERATION TRANSPORTATION 2. Combination of wire length The length of the wire is the length from the pin and center of the hole. When using the following wire, use wire of more than the length given below. In addition, select a wire length that will bring the lifting position directly above the center of gravity of the machine.
Page 177: Transportation Posture
OPERATION TRANSPORTATION TRANSPORTATION POSTURE This machine can be divided into four units for transportation. Four Units for Transportation (A) Upper structure (C) Work equipment (B) Undercarriage (D) Others Posture for Each Unit (dimensions in diagram are in mm.) Upper Structure Secure the upper structure to the platform with a chain and block.
Page 178 OPERATION TRANSPORTATION Undercarriage If there is a warning tag hanging on the work equipment control lever, do not start the engine. Unit same for all models Q'ty 30,500 (67,253 lb) Weight kg (lb) (15,250 X 2) (33,626 lb X 2) 3 - 125...
Page 179 OPERATION TRANSPORTATION Work Equipment Boom Unit PC1250-7 PC1250SP-7 mm (ft in) 9475 (31'1") 8170 (26'10") mm (ft in) 2894 (9'6") 3095 (10'2") Overall mm (ft in) 1474 (4'10") 1474 (4'10") width Weight kg (lb) 12700 (28,004) 12600 (27,783) Unit PC1250-7...
Page 180 OPERATION TRANSPORTATION Bucket (except side cutter, shroud) Unit PC1250-7 PC1250SP-7 mm (ft in) 2580 (8'6") 2527 (8'3") mm (ft in) 2276 (7'6") 2420 (7'11") Overall mm (ft in) 2250 (7'5") 2520 (8'3") width Weight kg (lb) 5100 (11,246) 6000 (13,230)
Page 181 OPERATION TRANSPORTATION Others Center frame Unit same for all models Weight kg (lb) 9700 (21,389) Counterweight Unit same for all models Weight kg (lb) 18000 (39,690) 3 - 128...
Page 182 OPERATION TRANSPORTATION Radiator duct (same for all models) Unit same for all models Weight kg (lb) 80 (176) Catwalk (right) : (same for all models) Unit same for all models Weight kg (lb) 17 (37.49) 3 - 129...
Page 183 OPERATION TRANSPORTATION Catwalk (left, front) : (same for all models) Unit same for all models Weight kg (lb) 150 (331) Catwalk (left, rear) : (same for all models) Unit same for all models Weight kg (lb) 160 (353) 3 - 130...
Page 184: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 185 OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 186: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 187: Long Term Storage
For machines equipped with an air conditioner, run the air conditioner. AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 188: Starting Machine After Long-Term Storage
OPERATION LONG TERM STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE When starting the engine after the machine has been in storage for a long time, perform the automatic warming-up operation. If the engine is started according to the starting procedure for cold weather, the warming-up operation is performed automatically.
Page 189: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before stating. For details on bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-54)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the...
Page 190: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope. If the machine sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram on the...
Page 191: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 192 OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-138)" and the instruction manual accompanying the charger, and do as follows. Set the voltage of the charger to match the voltage of the battery to be charged.
Page 193 OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows. Connecting and Disconnecting Booster Cables WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
Page 194 OPERATION TROUBLES AND ACTIONS Starting the Engine WARNING Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in the HOLD or neutral position. 1.
Page 195: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 196 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
Page 197 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights...
Page 198 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Abnormal noise generated Low-grade fuel being used Change to specified fuel (combustion or mechanical) Overheating Refer to "Radiator coolant level monitor lights up" as above Damage inside muffler ( Replace muffler) Excessive valve clearance ( Adjust valve clearance) 3 - 145...
Page 199: Electronic Control System
OPERATION TROUBLES AND ACTIONS Electronic Control System If an error code appears on the machine monitor display (normally displays TIME), follow the countermeasure table as shown below in the self-diagnosis. Machine Monitoring System Monitor Error mode Remedy display When emergency pump drive switch is up, normal Error in pump control system operations become normal, but carry out inspection immediately.
Page 200 Check the point of contact telephone number on screen B. REMARK If the point of contact telephone number has not been registered, screen B is not displayed. If it is necessary to register the point of contact telephone number, ask your Komatsu distributor to register it. 3 - 147...
Page 202 4 - 1...
Page 203: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 204 MAINTENANCE MAINTENANCE INFORMATION Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil.
Page 205: Outline Of Service
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. We recommend periodic performance of the oil clinic to ensure that you always know the condition of the machine. Please contact your Komatsu distributor for details of the oil clinic. 4 - 4...
Page 206 When using antifreeze, 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.
Page 207 Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods.
Page 208: Index
MAINTENANCE OUTLINE OF SERVICE KOWA Analysis Items Measurement of density of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of iron, copper, and other metal wear particles in the oil. Measurement of quantity of particles This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of iron particles of 5µm or more, enabling early detection of failures.
Page 209: Electric System Maintenance
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 210: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 211: Lubricants, Fuel And Coolant Specifications
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Reservoir Swing machinery Final drive Engine oil Hydraulic Cooling P.T.O case case (Front & case Fuel tank system system rear) (each) Capacity Liters 13.5 24.3 1360 Specified US gal 17.97 3.57 6.42...
Page 212 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 213 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
Page 214 MAINTENANCE MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type...
Page 215: Tightening Torque Specifications
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 216: Safety Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 217: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) CLEAN STRAINER OF PTO LUBRICATING OIL FILTER 4- 64 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) CHANGE OIL IN SWING MACHINERY CASE 4- 69 CHANGE OIL IN PTO CASE 4- 70...
Page 218 MAINTENANCE MAINTENANCE SCHEDULE EVERY 500 HOURS MAINTENANCE REPLACE FUEL FILTER CARTRIDGE 4- 54 CHECK SWING PINION GREASE LEVEL, ADD GREASE 4- 56 CLEAN HYDRAULIC TANK STRAINER AND RETURN STRAINER 4- 57 REPLACE HYDRAULIC OIL FILTER ELEMENT 4- 59 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER) 4- 60 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER...
Page 219: Maintenance Procedure
Change oil in PTO case Change oil in final drive case Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. For details of the method of replacing or maintaining, see EVERY 1000 HOURS and EVERY 2000 HOURS SERVICE.
Page 220: When Required
MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
Page 221 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Outer Element 1. Open the right door of the machine, remove 6 hooks (2), then remove cover (3). NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 2. Hold the outer element, rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out.
Page 222 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Direct dry compressed air (less than 0.69 MPa (7 kg/cm , 99.4 PSI)) to the outer element from inside along its folds, then direct it from outside along its folds and again from inside. 1) Remove one seal from the element whenever the element has been cleaned.
Page 223: Clean Inside Of Cooling System
MAINTENANCE MAINTENANCE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.
Page 224 Use city water for the coolant. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 225 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 3. Remove the under cover (4), then set a container to catch the coolant under drain valves (5) and (6). Open drain valve (5) at the bottom of the radiator to drain the water. Open drain valve (6) at the cylinder block to drain the water.
Page 226: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening 1. First, tighten to a tightening torque of 1372 ± 137.2 Nm (140 ± 14 kgm, 1,012.6 ± 101.3 lbft), then check that the nut and shoe are in tight contact with the link mating surface.
Page 227: Check And Adjust Track Tension
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION WARNING For details of starting the engine and operating the work equipment, see "BEFORE STARTING ENGINE (PAGE 3-69)", "STARTING ENGINE (PAGE 3-87)", "AFTER STARTING ENGINE (PAGE 3-91)", and "WORK EQUIPMENT CONTROLS AND OPERATIONS (PAGE 3-107)"...
Page 228 There is danger of plug (1) flying out under the high internal pressure of the grease. Never loosen plug (1) more than 1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. Increasing Track Tension Prepare a grease pump.
Page 229: Check Electrical Intake Air Heater
CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. Remove the electrical intake air heater from the engine intake manifold, and check it for possible disconnections and dirt.
Page 230: Replace Bucket Teeth (Vertical Pin Type)
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the bucket tooth before it wears down to the adapter. When replacing the bucket teeth, do not replace only both sides with new parts. If both sides only are replaced with new parts, the bucket will easily deform.
Page 231 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. When the short part of pin removal jig (4) enters fully, put the long part in contact with pin (2) and remove the pin. 5. Turn tooth (2) counterclockwise and remove it from adapter (5).
Page 232 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 9. Hit pin (1) with the hammer and knock it in until it is level with the end of the ears of tooth (2). 4 - 31...
Page 233: Replace Bucket Teeth (Horizontal Pin Type)
REMARK If the bucket teeth cannot be safely removed by this mothod, have your Komatsu distributor replace the bucket teeth. 3. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket.
Page 234: Adjust Bucket Crearance
MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance. Set the work equipment in a stable condition, stop the engine, then set safety lock lever (1) securely to the LOCK position. If there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.
Page 235: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
Page 236: Check And Maintenance Air Conditioner
Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 237: Clean Line Filter, Remove Dirt
MAINTENANCE MAINTENANCE PROCEDURE CLEAN LINE FILTER, REMOVE DIRT If there is any abnormality in the pump or other hydraulic equipment, remove the dirt from inside the line filter as follows. Before removing the line filter, release the pressure inside the hydraulic circuit. For details, see "METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT (PAGE 4-40)".
Page 238: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-87)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. NOTICE Bleed the air as follows.
Page 239 MAINTENANCE MAINTENANCE PROCEDURE 2. Starting engine Start the engine according to "STARTING ENGINE (PAGE 3-87)" keep running the engine at low idle for 10 minutes, and carry out the following procedure. 3. Bleeding air from cylinders 1) Run the engine at low idle, and extend and retract each cylinder 4 to 5 times, taking care that a cylinder is not moved to the end of its stroke.
Page 240 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. Bleeding air from travel motor circuit If the piping has been removed from the travel motor circuit, bleed the air after reassembling. To bleed the air, run the engine at low idling and do as follows. 1) Start the engine and run at low idling.
Page 241: Method For Releasing Internal Pressure In Hydraulic Circuit
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting.
Page 242: Check Nitrogen Gas Charge Pressure In Accumulator (Control Circuit)
3. Check that the tip of the bucket drops at least 1 m (3 ft). If the tip of the bucket drops less than 1 m (3 ft), the charge pressure inside the accumulator is low, so contact your Komatsu distributor. 4 - 41...
Page 243: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-71)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check Fuel Level, Add Fuel Check oil level in hydraulic tank, add oil Check oil level in swing machinery case, add oil Check oil level in PTO case, add oil...
Page 244: Every 10 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 10 HOURS MAINTENANCE LUBRICATING 1. Set to the greasing posture below, lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 245 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (2) Boom foot pin (2 places) (3) Boom cylinder rod end pin (2 places) (4) Arm cylinder foot pin (1 place) (5) Boom - Arm coupling pin (1 place) (6)Bucket cylinder foot pin (2 point) (7) Arm cylinder rod pin (1 place) (8) Arm - Link coupling pin (1 place) (9)Arm-Bucket coupling pin (2 point)
Page 246: Every 100 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. LUBRICATING SWING CIRCLE (4 points) 1. Lower the work equipment to the ground. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
Page 247: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 248: Check Level Of Battery Electrolyte
MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Page 249 If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 48...
Page 250 If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. When it is Possible to Use Indicator to Check Electrolyte Level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 251: Lubricating Aftercooler Fan Mount
MAINTENANCE MAINTENANCE PROCEDURE LUBRICATING AFTERCOOLER FAN MOUNT (1 place) 1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out. CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS Bolts (1) connecting the track frame and axle will break if they remain loose, so loose bolts must always be retightened.
Page 252: Check Alternator Drive Belt Tension, Adjust
MAINTENANCE MAINTENANCE PROCEDURE CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST Checking The standard deflection for the drive belt is 15 mm (0.59 in) when pressed with a thumb [at approx. 58.8 N (approx. 6 kg)] at a point midway between the drive pulley and alternator pulley. Adjustment 1.
Page 253: Check Air Conditioner Compressor Belt Tension, Adjust (Only For Machines Equipped With Air Conditioner)
MAINTENANCE MAINTENANCE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST Checking 1. Remove bolts (2), (3) and (4), then remove cover (1). 2. The standard deflection for the drive belt is approx. 16 mm (59 in) when pressed with a thumb [at approx. 58.8 N (approx. 6 kg)] at a point midway between the drive pulley and air conditioner compressor pulley.
Page 254 MAINTENANCE MAINTENANCE PROCEDURE Adjustment 1. Loosen the bolts and nuts in the order (5) to (9), and move compressor. Adjust the belt tension with nut (9) as follows: TIGHTEN to INCREASE tension LOOSEN to DECREASE tension 2. After adjusting the belt, tighten the bolts and nuts in the order (5) to (8) (the opposite order from loosening).
Page 255: Every 500 Hours Maintenance
The HPI fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 256 MAINTENANCE MAINTENANCE PROCEDURE 5. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 1/2 to 3/4 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.
Page 257: Check Swing Pinion Grease Level, Add Grease
MAINTENANCE MAINTENANCE PROCEDURE CHECK SWING PINION GREASE LEVEL, ADD GREASE Prepare a scale. 1. Remove bolts (1) (4 bolts) on the top of the revolving frame and remove cover (2). 2. Insert a scale into the grease and check that the depth of the grease is approx.
Page 258: Clean Hydraulic Tank Strainer And Return Strainer
MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK STRAINER AND RETURN STRAINER WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. When the cap of the oil filler port is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
Page 259 MAINTENANCE MAINTENANCE PROCEDURE Clean Return Strainer 1. Remove (4) mounting bolts (1) of the return strainer holder cover at the top of the hydraulic tank, then remove return filter holder cover (2). 2. Remove strainer (3). 3. Remove any dirt stuck to strainer (3), then wash it with flushing oil.
Page 260: Replace Hydraulic Oil Filter Element
3. After removing spring (2), valve (3) and strainer (5), take out element (4). If there are metal particles or foreign material inside strainer (5), contact your Komatsu distributor. 4. Clean the removed parts in flushing oil. 5. Install the new element in the place where old element (4) was installed.
Page 261 MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner) WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury.
Page 262 MAINTENANCE MAINTENANCE PROCEDURE CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. REMARK If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner unit.
Page 263 MAINTENANCE MAINTENANCE PROCEDURE 3. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash it in a neutral agent. After rinsing it in water, dry it thoroughly before using it again. If the clogging of the filter cannot be removed by blowing with air or washing in water, replace the filter with a new part.
Page 264: Replace Pilot Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE PILOT FILTER ELEMENT WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. 1. Set a container under drain plug (1) to catch the oil. 2.
Page 265: Clean Strainer Of Pto Lubricating Oil Filter
MAINTENANCE MAINTENANCE PROCEDURE CLEAN STRAINER OF PTO LUBRICATING OIL FILTER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Page 266: Check Wear Of Fan Belt, Replace, Adjust
MAINTENANCE MAINTENANCE PROCEDURE CHECK WEAR OF FAN BELT, REPLACE, ADJUST Checking Check the V-belt and when the following conditions exist, replace the V-belt: When the V-belt makes contact with the bottom of the groove in each pulley. When the V-belt is worn, and its surface is lower than the outer diameter of the pulley. When cracking and peeling of the V-belt occurs.
Page 267: Replace Drain Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE Adjustment 1. Tighten adjustment screw (2) to bring the tip of the adjustment screw into contact with tension pulley lever (5), then tighten the adjustment screw a further 180° and secure with locknut (1). 2. If wear is a gap between the tip of adjustment screw (2) and tension pulley lever (5) during operations, repeat Step 1 to adjust again.
Page 268: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity: 51 liters (13.5 US gal) Prepare a filter wrench 1.
Page 269 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Open the front cover of the engine hood, use a filter wrench from the top of the engine, turn filter cartridge (4) to the left, and remove it. A large amount of oil will come out immediately after the engine is stopped, so wait for 10 minutes after the engine is stopped before draining the oil.
Page 270: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, and 500 hours of service should be performed at the same time. CHANGE OIL IN SWING MACHINERY CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
Page 271: Change Oil In Pto Case
2. Refill the specified quantity of oil through oil filler (F). NOTICE If excess oil is supplied, drain it to the specified amount to avoid overheating. CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions checked. 4 - 70...
Page 272: Replace Corrosion Resistor Cartridge
MAINTENANCE MAINTENANCE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE WARNING If the engine has been operated, all parts will be at a high temperature, so never try to replace the cartridge immediately after stopping the engine. Always wait for the engine and other parts to cool down. Container to catch drained coolant Prepare a filter wrench for fuel filter element.
Page 273: Lubricating Fan Pulley Assembly, Tension Pulley Assembly
MAINTENANCE MAINTENANCE PROCEDURE LUBRICATING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY Add grease through the fittings marked by arrows. (1) Fan pulley assembly (1 point) (2) Tension pulley assembly (1 point) 4 - 72...
Page 274: Replace Hydraulic Tank Breather Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 275: Check Fuel Strainer, Clean
MAINTENANCE MAINTENANCE PROCEDURE CHECK FUEL STRAINER, CLEAN 1. Close fuel supply valve (1) at the bottom of the fuel tank. 2. Remove undercover (2) on the inside rear of the fuel tank. 3. Remove filter case (3). 4. Take out the strainer, clean off dirt clung to it, and wash it in clean light oil or diesel oil.
Page 276: Check Welded Structure
MAINTENANCE MAINTENANCE PROCEDURE CHECK WELDED STRUCTURE (Color check) Cracks in welded structures can be seen easily with a color check. Check the revolving frame, center frame, boom, and arm every 1000 hours. In particular, carry out a color check on the important check points (marked with a circle). The procedure for the color check is as follows.
Page 277 MAINTENANCE MAINTENANCE PROCEDURE Boom 4 - 76...
Page 278 MAINTENANCE MAINTENANCE PROCEDURE 4 - 77...
Page 279: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500, and 1000 hours of service should be performed at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 280: Clean Engine Breather
Please contact your Komatsu distributor to have the rotor play checked. CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn,or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. When the engine is frequently started, ask for inspection every 1000 hours or every 6 months, whichever comes sooner.
Page 281: Every 4000 Hours Maintenance
Check the pulley for play and leakage of grease. If there is any abnormality, please contact your Komatsu distributor for disassembly and repair or replacement. CHECK AIR COMPRESSOR, ADJUST As special tool is required for checking and adjusting the parts, request Komatsu distributor for service. 4 - 80...
Page 282: Every 5000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500, 1000, and 2000 hours of service should be performed at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 283 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Set the container to catch the oil under the drain plug at the bottom of the chassis. Remove drain plug (P1), then loosen plug (P2) and drain the oil. After draining the oil, tighten drain plugs (P1) and (P2).
Page 284 5 - 1...
Page 285: Specifications
Operating weight kg (lb) 108,700 (239,684) 109,500 (241,448) Bucket capacity (cu.yd) 5.2 (6.8) 6.7 (8.8) Name of engine KOMATSU SA6D170E diesel engine Engine horsepower KW(HP)/rpm 485(651)/1,800 485(651)/1,800 A Overall length mm (ft in) 16,020 (52'7") 14,790 (48'6") B Overall height mm (ft in) 6,040 (19'10")
Page 286 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC1250-7 PC1250SP-7 A Max. digging reach mm (ft in) 15,350 (50'4") 14,070 (46'2") B Max. digging depth mm (ft in) 9,350 (30'8") 7,900 (25'11") C Max. digging height mm (ft in) 13,400 (43'12") 13,000 (42'8")
Page 288 6 - 1...
Page 289: Attachments And Options
There may also be problems of the attachment or option hitting the operator's cab. Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu. READ THE INSTRUCTION MANUAL THOROUGHLY Before installing or using any attachment or option, make sure that you thoroughly read and understand the instruction manuals for the machine and the attachment or option.
Page 290: Attachment Guide
WARNING Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.
Page 291 ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE Working Range Diagram PC1250-7 PC1250-7 PC1250-7 PC1250-7 PC1250-7 PC1250SP-7 Working ranges Unit Standard Strong arm Semilong Strong Long arm SE arm Semilong arm 15,350 15,350 16,340 16,340 17,450 14,070 A Max. digging reach (ft in) (50'4")
Page 292: Selection Of Track Shoes
Lo speed. the pins, loosening of the shoe bolts, or other problems. Shoe Double grouser shoe Model PC1250-7 PC1250SP-7 Shoe width mm (in) 700 (27.6 in) 1000 (39.4 in) 700 (27.6 in)
Page 293: Auto-Greasing System
ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM EXPLANATION OF COMPONENTS (1) Auto-greasing switch (5) Grease pump (2) Interval adjustment dial (6) Regulator (3) Warning lamp (red) (7) Injector (4) Auto-greasing/grease gun selector valve lever 6 - 6...
Page 294 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Auto-greasing Switch This switch (1) actuates the greasing system. When this switch is set to the AUTO position, the lamp (green) lights up and the auto-greasing system starts to operate. If the auto-greasing switch is at AUTO when the machine starting switch is turned ON, the greasing system is actuated immediately.
Page 295 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Auto-greasing/Grease Gun Selector Valve Lever This lever (4) is used to switch the flow of grease to the grease gun. When using the auto-greasing system, set it to the AUTO position (A); when using the grease gun, set it to the GREASE GUN position (B).
Page 296 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Regulator WARNING Do not raise the pressure in the regulator above a maximum of 0.49 MPa (5 kg/cm ). The pump pressure ratio is 50:1, so the grease pressure rises to 24.5 MPa (250 kg/cm ).
Page 297 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Greasing Points for Auto-greasing System CAUTION If there is an abnormality and the auto-greasing system does not function, supply the grease manually to greasing points (1) - (8). For details, see the INSPECTION AND MAINTENANCE section. Greasing points (9) - (13) are not included in the auto-greasing system, so supply the grease manually to these greasing points.
Page 298 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM (1) Boom cylinder foot pin (2 places) (2) Boom foot pin (2 places) (3) Boom cylinder rod pin (2 places) (4) Arm cylinder foot pin (1 place) (5) Boom-Arm coupling pin (1 place) (6) Bucket cylinder foot pin (2 places) (7) Arm cylinder rod pin (1 place) (8) Swing circle (4 places)
Page 299: Operation
ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM OPERATION CHECK BEFORE STARTING OPERATIONS Check that there is ample grease in the grease pail in the grease pump inside the battery case. If the pump has run out of grease, replace the grease pail. Check that the grease pail is not dented or deformed.
Page 300 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM Set the auto-greasing switch to the OFF position when it is necessary to stop the auto-greasing system, such as when the grease piping is broken or damaged. 6 - 13...
Page 301 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM METHOD OF ADJUSTING INTERVAL TIMER CAUTION The setting of the interval timer differs according to the type of machine and the type of work. For this reason, it is necessary for the customer himself to set the interval timing to match the working condition of the machine. The interval timer is installed to control the greasing interval of the auto-greasing system.
Page 302 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM METHOD OF ADJUSTING INJECTOR DISCHARGE AMOUNT CAUTION The setting of the injector discharge amount differs according to the type of machine and the type of work. For this reason, it is necessary for the customer himself to set the injector discharge amount to match the working condition of the machine. The injector is operated by the pressure from the pump, and it feeds grease of the specified quantity to the bearing.
Page 303: Troubleshooting
Change to grease for cold is being used in cold area weather (NLGI No. 0 or equivalent) If any problem occurs where the cause is not listed in the above table, please contact your Komatsu distributor for repairs. 6 - 16...
Page 304: Maintenance
ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM MAINTENANCE REPLACE GREASE PAIL CAUTION Do not use a grease pail if it is dented or deformed. Follower plate (2) will not come down, or air pockets will form, so the grease will not be sucked in. After using the pail, remove all grease that leaked or sprayed out.
Page 305 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM PROCEDURE FOR BLEEDING AIR FROM GREASE LINE WARNING There is no check device to prevent reverse flow in the service grease nipple installed to the injector. If you forget to tighten the cap, there is danger that high-pressure grease may spurt out when the grease pump is actuated. Be sure not to forget to tighten the cap.
Page 306 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM 5. Tighten plug (2) of the injector to prevent the grease from leaking. Tightening torque of plug (2): 19.6 - 24.9 Nm (2.0 - 3.0 kgm, 14.5 - 21.7 lbft) Carry out Steps 1 to 5 for every injector.
Page 307 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM INJECTOR POSITION IN AUTO-GREASING SYSTEM AND MANUAL GREASING WARNING There is no check device to prevent reverse flow in the service grease nipple installed to the injector. If you forget to tighten the cap, there is danger that high-pressure grease may spurt out when the grease pump is actuated. Be sure not to forget to tighten the cap.
Page 308 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM When greasing places on top of the arm: boom-arm connecting pin (8), bucket cylinder foot pins (9) and (10), and arm cylinder rod pin (11), the greasing can be carried out manually from the central block. 6 - 21...
Page 309 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM EVERY 10 HOURS MAINTENANCE Greasing Points not Including in Auto-greasing System 1. Set to the greasing posture below, lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 310 7 - 1...
Page 311: Loading Shovel
LOADING SHOVEL EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS SWITCHES (1) Starting switch (11) Swing holding brake release switch (2) Fuel control dial (12) Rotating lamp switch (if equipped) (3) Cigarette lighter (13) Lower wiper switch (machines equipped with (4) Swing lock switch fixed window cab) (5) Lamp switch (14) Large capacity airflow air conditioner blower...
Page 312 LOADING SHOVEL EXPLANATION OF COMPONENTS Cigarette Lighter Swing Lock Switch Lamp Switch Alarm Buzzer Stop Switch Machine Push-up Switch Horn Switch When the switch (8) at the tip of the right work equipment control lever is pressed, the horn will sound. Room Lamp Switch Emergency Pump Drive Switch Swing Parking Brake Release Switch...
Page 313 LOADING SHOVEL EXPLANATION OF COMPONENTS Bottom Dump Switch Use this switch (17) to open and close the front bucket. If the button at the tip of the left work equipment control lever is depressed, the bucket will close. If the button at the tip of the right work equipment control lever is depressed, the front bucket will open.
Page 314: Fuse
LOADING SHOVEL EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. Fuse Capacities and Circuit Name Fuse Name of circuit capacity Prolix circuit Solenoid valve PPC hydraulic lock solenoid Window washer, cigarette lighter Horn, flash lamp light (if equipped), L/S (if equipped) Auto-greasing system (if equipped)
Page 315: Operations
LOADING SHOVEL OPERATIONS OPERATIONS OPERATION OF WORK EQUIPMENT WARNING If the lever is operated in the deceleration range, the engine speed will suddenly rise. Operate the levers carefully. If the work equipment control levers are operated quickly, the engine speed will suddenly rise. Operate the levers carefully. The work equipment is operated with the left work equipment control lever and right work equipment control lever.
Page 316 LOADING SHOVEL LOADING SHOVEL OPERATIONS OPERATIONS Boom operation (A): Boom RIASE (B): Boom LOWER Bucket operation (A): Bucket DUMP (B): Bucket CURL Bottom dump operation (A): OPEN (B): CLOSE 7 - 7...
Page 317: Precautions During Operation
LOADING SHOVEL OPERATIONS PRECAUTIONS DURING OPERATION WARNING When the arm is pushed out to the front, the speed momentarily becomes slow around the vertical position of the arm. (A): Platform It is Prohibited to Use the Swing Force for Operations. Do not use bucket swing force to compact soil or break an earth wall, or do not dig the bucket teeth into the ground while swinging the bucket.
Page 318 LOADING SHOVEL OPERATIONS Do not Carry Out Operations with the Hydraulic Cylinder at the End of its Stroke. If the cylinder is operated to the end of its stroke during operations, a large force will be brought to bear on the stopper inside the cylinder, and this will reduce the service life of the machine, so leave room (distance a) at the end of the stroke as far as possible.
Page 319 LOADING SHOVEL OPERATIONS It is Prohibited to Grip Rocks. Do not use the bottom dump bucket to grip rocks. It is Prohibited to Use the Bucket for Leaving Operations. Using the rear bucket to carry out leveling operations will bring an excessive force to bear on the work equipment, so do not use the rear bucket in this way.
Page 320 LOADING SHOVEL OPERATIONS Scraping-down Operations are Prohibited. Never use the front bucket of a bottom-dump bucket to scrap down rocks or soil. Digging Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment. It is better to excavate it after breaking up by some other means.
Page 321: Excavator Work
LOADING SHOVEL OPERATIONS EXCAVATOR WORK In addition to the following, it is possible to further increase the range of applications by using various attachments. Shovel Work This is suitable for digging a place which is higher than the machine's position. It is most efficient if the arm s digging angle is from vertical to 60i forward, and the arm cylinder is used effectively.
Page 322: Precautions When Disassembling Machine
LOADING SHOVEL PRECAUTIONS WHEN DISASSEMBLING MACHINE PRECAUTIONS WHEN DISASSEMBLING MACHINE RELEASING PRESSURE When disassembling the machine or removing the piping during inspection or maintenance, always release the pressure as follows. Releasing Pressure from Work Equipment Circuit, Swing Circuit, Travel Circuit WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting.
Page 323: Transportation
LOADING SHOVEL TRANSPORTATION TRANSPORTATION MACHINE CONFIGURATION FOR TRANSPORT This machine can be divided into four units for transportation. Four Units for Transportation (A) Upper structure (C) Work equipment (B) Undercarriage (D) Others 7 - 14...
Page 324 LOADING SHOVEL TRANSPORTATION Posture for Each unit (dimensions in diagram are in mm.) Upper Structure Secure the upper structure to the platform with a chain and block. Unit PC1250-7 Overall 3490 (11'5") width (ft in) Weight 24,300 (53,582) (lb) Undercarriage...
Page 325 LOADING SHOVEL TRANSPORTATION Work Equipment Boom cylinder Unit PC1250-7 3520 (11'7") (ft in) 2160 (4762) Weight kg (lb) 1080 X 2 (2381 X 2) Bucket cylinder Unit PC1250-7 3300 (10'10") (ft in) 1700 (3748) Weight kg (lb) 850 X 2...
Page 326 LOADING SHOVEL TRANSPORTATION Boom + Arm Unit PC1250-7 8730 (28'8") (ft in) 2750 (9'7") (ft in) Overall 2000 (6'7") width (ft in) Weight kg (lb) 16000 (35275) Bucket Unit PC1250-7 3000 (9'11") (ft in) 2700 (8'10") (ft in) Overall 2700 (8'10")
Page 327 LOADING SHOVEL TRANSPORTATION Others Center frame Unit PC1250-7 Weight kg (lb) 9700 (21,389) Counterweight Unit PC1250-7 Weight kg (lb) 18000 (39,690) 7 - 18...
Page 328 LOADING SHOVEL TRANSPORTATION Radiator duct (same for all models) Unit PC1250-7 Weight kg (lb) 80 (176) 7 - 19...
Page 329 LOADING SHOVEL TRANSPORTATION Catwalk (right) : (same for all models) Unit PC1250-7 Weight kg (lb) 17 (37.49) Catwalk (left, front) : (same for all models) Unit PC1250-7 Weight kg (lb) 150 (331) 7 - 20...
Page 330 LOADING SHOVEL TRANSPORTATION Catwalk (left, rear) : (same for all models) Unit PC1250-7 Weight kg (lb) 160 (353) 7 - 21...
Page 331: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 332 LOADING SHOVEL MAINTENANCE MAINTENANCE CHECK BEFORE STARTING Check Oil Level in Hydraulic Tank, Add Oil WARNING If the oil filler cap is removed without releasing the internal pressure, oil will spurt out, so turn the oil filler cap slowly to release the internal pressure, then remove it carefully.
Page 333 LOADING SHOVEL LOADING SHOVEL MAINTENANCE MAINTENANCE WARNING If the oil is above the H level, stop the engine, wait for the hydraulic oil to cool down, then drain the excess oil from drain plug (P1). When draining the oil, loosen bottom drain plug (P1), then loosen the side drain plug (P2) and drain the oil.
Page 334: Every 10 Hours Maintenance
LOADING SHOVEL MAINTENANCE EVERY 10 HOURS MAINTENANCE LUBRICATTING 1. Set to the greasing posture below, lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 335: Every 5000 Hours Maintenance
LOADING SHOVEL MAINTENANCE EVERY 5000 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 336 LOADING SHOVEL LOADING SHOVEL MAINTENANCE MAINTENANCE 5. Set the container to catch the oil under the drain plug at the bottom of the chassis. Remove drain plug (P1), then loosen plug (P2) and drain the oil. After draining the oil, tighten drain plugs (P1) and (P2).
Page 337: Specification
Unit PC1250-7 Operating weight kg (lb) 110,000 (242,550) Bucket capacity (cu.yd) 6.5 (8.5) Name of engine KOMATSU SAA6D170E diesel engine Engine horsepower KW(HP)/rpm 485 (651)/1,800 A Overall length mm (ft in) 10,940 (35'11") B Overall height mm (ft in) 6,200 (20'4")
Page 338: Combination Of Work Equipment
LOADING SHOVEL COMBINATION OF WORK EQUIPMENT COMBINATION OF WORK EQUIPMENT WARNING Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
Page 339 LOADING SHOVEL COMBINATION OF WORK EQUIPMENT Working Range Diagram PC1250-7 Loading shovel Working ranges Unit Without bucket link A Max. digging radius mm (ft in) 11,400 (37'5") B Max. digging reach at ground level mm (ft in) 10,900 (35'9") C Max. digging height mm (ft in) 12,330 (40'5")
Page 340 INDEX INDEX <A> <F> ACCUMULATOR 3- 68 FOREWORD AFTER STARTING ENGINE 3- 91 FUSE 3- 61 AIR CONDITIONER CONTROLS 3- 41 FUSE ASHTRAY 3- 40 ATTACHMENT GUIDE <G> AUTO-GREASING SYSTEM GENERAL OPERATION AUXILIARY ELECTRIC POWER 3- 60 INFORMATION 3-111 GENERAL PRECAUTIONS 2- 12 <B>...
Page 341 INDEX MACHINE VIEW ILLUSTRATIONS DISASSEMBLING MACHINE 7- 13 OVERALL MACHINE VIEW RELEASING PRESSURE 7- 13 MAGAZINE BOX 3- 40 PRODUCT INFORMATION MAINTENANCE 7- 23 PROHIBITED OPERATIONS 3-109 CHECK BEFORE STARTING 7- 23 EVERY 10 HOURS <R> MAINTENANCE 7- 25 RADIO 3- 56 EVERY 5000 HOURS RECOMMENDED APPLICATIONS...
Page 342 INDEX TOWING THE MACHINE 3-137 <W> WEAR PARTS WEAR PARTS 7- 22 WEAR PARTS LIST WEAR PARTS LIST 7- 22 WORK EQUIPMENT CONTROLS AND OPERATIONS 3-107 WORKING MODE 3-108 <Y> YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10 8 - 3...

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Pc1250sp-7

Komatsu PC1250-7 Operation & Maintenance Manual

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Foreword

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Maintenance Schedule

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