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Galeo PC600-7 Operation & Maintenance Manual

Hydraulic excavator
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Operation & Maintenance
Manual
PC600
PC600LC
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp..
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
October 2006
-7
PC600-7
PC600LC-7 20001
Copyright 2006 Komatsu
Printed in U.S.A.
Komatsu America Corp.
SEAM053202T
-7
20001
and up
and up

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  • Page 1 SEAM053202T Operation & Maintenance Manual PC600 PC600LC HYDRAULIC EXCAVATOR PC600-7 20001 SERIAL NUMBERS and up PC600LC-7 20001 and up This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp..
  • Page 2 FOREWORD...
  • Page 3 FOREWORD FOREWORD FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre- cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci- dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
  • Page 4 FOREWORD FOREWORD...
  • Page 5 FOREWORD FOREWORD...

  • Page 6: Foreword

    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 situa- tions.
  • Page 7 FOREWORD SAFETY INFORMATION q Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. Example of safety label using words Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous...

  • Page 8: Introduction

    FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Digging work q Leveling work q Ditching work q Loading work q Demolition work See the section "RECOMMENDED APPLICATIONS (3-119)" for further details. DIRECTIONS OF MACHINE In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine.

  • Page 9: Breaking-In The New Machine

    FOREWORD INTRODUCTION BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How- ever, operating the machine under full load before breaking the machine in can adversely affect the perfor- mance and shorten the machine life. Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).

  • Page 10: Product Information

    FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the front bottom right of the operator's cab (side of upper frame) The design of the nameplate differs according to the territory.

  • Page 11: Service Meter Location

    FOREWORD PRODUCT INFORMATION SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1-10...

  • Page 12: Table Of Contents

    CONTENTS CONTENTS FOREWORD FOREWORD................................. 1-2 SAFETY INFORMATION............................1-5 INTRODUCTION..............................1-7 DIRECTIONS OF MACHINE ........................1-7 BREAKING-IN THE NEW MACHINE ......................1-8 PRODUCT INFORMATION ..........................1-9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........1-9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................. 1-9 SERVICE METER LOCATION .........................
  • Page 13 CONTENTS Basic Operation Of Machine Monitor ....................3-6 Basic Check Monitors ........................3-8 Caution Monitors..........................3-10 Emergency Monitors ........................3-12 Meter Display Portion ........................3-14 Monitor Switches Portion ......................... 3-18 SWITCHES ............................... 3-27 CONTROL LEVERS AND PEDALS ......................3-34 SUN ROOF ............................... 3-37 Opening ............................
  • Page 14 CONTENTS Operations Before Starting Engine ....................3-86 STARTING ENGINE ..........................3-89 Normal Starting..........................3-89 Starting Engine In Cold Weather ..................... 3-91 AFTER STARTING ENGINE ........................3-94 Warming-Up Operation........................3-94 In Cold Weather Areas ........................3-97 STOPPING THE ENGINE ........................3-101 MACHINE OPERATION .........................
  • Page 15 CONTENTS BEFORE STORAGE..........................3-137 DURING STORAGE ..........................3-137 AFTER STORAGE..........................3-138 STARTING MACHINE AFTER LONG-TERM STORAGE ..............3-138 TROUBLES AND ACTIONS ..........................3-139 RUNNING OUT OF FUEL ........................3-139 PHENOMENA THAT ARE NOT FAILURES ................... 3-141 TOWING THE MACHINE ........................3-142 SEVERE JOB CONDITION ........................
  • Page 16 CONTENTS MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..............4-18 MAINTENANCE PROCEDURE.......................... 4-19 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) ........4-19 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) ........4-19 WHEN REQUIRED ........................... 4-20 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............4-20 CLEAN INSIDE OF COOLING SYSTEM ..................
  • Page 17 CONTENTS CHANGE OIL IN P.T.O CASE ......................4-64 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER ............4-64 CHECK PLAY TURBOCHARGER ROTOR..................4-64 REPLACE CORROSION RESISTOR CARTRIDGE ............... 4-65 GREASE FAN PULLEY AND TENSION PULLEY ................4-65 CHECK WELDED STRUCTURE..................... 4-66 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker) ....4-68 EVERY 2000 HOURS MAINTENANCE....................

  • Page 18: Safety

    SAFETY...

  • Page 19: Safety Information

    SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS..............................2-42 LOCATION OF SAFETY LABELS ....................... 2-52 SAFETY LABELS............................2-62 SAFETY INFORMATION ..........................2-12 Safety Rules............................... 2-122 If Abnormalities are Found ......................... 2-122 Working Wear and Personal Protective Items ................... 2-122 Fire Extinguisher and First Aid Kit......................2-122 Safety Equipment............................
  • Page 20 SAFETY SAFETY INFORMATION TOWING ..............................2-332 Safety rules for towing ........................2-332 LIFTING OBJECTS WITH BUCKET......................2-342 Safety rules for lifting objects ......................2-342 SAFETY MAINTENANCE INFORMATION....................... 2-352 Warning Tag .............................. 2-352 Keep Work Place Clean and Tidy ......................2-352 Appoint Leader when Working with Others....................

  • Page 21: Safety Labels

    SAFETY SAFETY LABELS SAFETY LABELS The following warning signs and safety labels are used on this machine. q Be sure that you fully understand the correct position and content of labels. q To ensure that the content of labels can be read properly, be sure that they are in the correct place and always keep them clean.

  • Page 22: Location Of Safety Labels

    SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...

  • Page 23: Safety Labels

    SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and maintenance (09651-03001) (2) Warning before moving (09802-03000) (3) Warning when leaving operator's seat (09654-03001)
  • Page 24 SAFETY SAFETY LABELS (4) Warning for electric lines (09801-03001) (5) Warning when opening front window (09839-03000) (6) Warning when stowing front window (09803-03000)
  • Page 25 SAFETY SAFETY LABELS (7) Warning for hot oil (09653-03001) (8) Warning for hot cooling water (09668-03001) (9) Warning in handling accumulator (09659-53000) (10) Warning when adjusting track tension (09657-03003)
  • Page 26 SAFETY SAFETY LABELS (11) Warning for improper use of cables (09808-03000) (12) Stop engine when performing inspection or maintenance (09667-03001) (13) Emergency escape instruction (20Y-00-22880) (14) Warning against falling off the edge (09805-23000)
  • Page 27 SAFETY SAFETY LABELS (15) Warning against falling (09805-13000) (16) Keep off swing area (09133-23000) (17) Warning when handling battery (09664-30082) (18) Precautions for high voltage (7872-10-1600) 2-10...
  • Page 28 SAFETY SAFETY LABELS (19) Jump start prohibited (09842-A0481) 2-11...

  • Page 29: Safety Information

    SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

  • Page 30: Safety Equipment

    SAFETY SAFETY INFORMATION SAFETY EQUIPMENT q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. q Understand the method of use of safety features and use them properly. q Never remove any safety features.

  • Page 31: Handrails And Steps

    SAFETY SAFETY INFORMATION q When leaving the machine, always lower the work equipment completely to the ground, set lock lever (1) securely to the LOCK position (L), then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place.

  • Page 32: Mounting And Dismounting

    SAFETY SAFETY INFORMATION MOUNTING AND DISMOUNTING q Never jump on or off the machine. Never get on or off a moving machine. q If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.

  • Page 33: Fire Prevention And Explosion Prevention

    SAFETY SAFETY INFORMATION FIRE PREVENTION AND EXPLOSION PREVENTION q Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.

  • Page 34: Action If Fire Occurs

    SAFETY SAFETY INFORMATION ACTION IF FIRE OCCURS If a fire occurs, escape from the machine as follows. q Turn the start switch OFF to stop the engine. q Use the handrails and steps to get off the machine. WINDSHIELD WASHER FLUID Use an ethyl alcohol base washer liquid.

  • Page 35: Cab Widow Glasses

    SAFETY SAFETY INFORMATION CAB WINDOW GLASSES q If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact the operator's body directly. Stop operation immediately and replace the glass. q The ceiling window is made of organic glass (polycarbonate), and as such it is apt to break easily when receiv- ing damage on the surface, thereby deteriorating its protective characteristic.

  • Page 36: Distance To High Voltage Cables

    SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.

  • Page 37: Signalman's Signal And Signs

    SAFETY SAFETY INFORMATION SIGNALMAN'S SIGNAL AND SIGNS q Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman. q Only one signalman should give signals.

  • Page 38: 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.

  • Page 39: Safety Rules For Starting Engine

    SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR STARTING ENGINE q Start and operate the machine only while seated. q Do not short circuit the starting motor circuit to start the engine. Short circuit can cause serious injury or fire. q When starting the engine, sound the horn as a warning. q Do not allow anyone apart from the operator to ride on the machine.

  • Page 40: 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. q Check that the movement of the machine matches the display on the control pattern card. If it does not match, replace it immediately with the correct control pattern card.
  • Page 41 SAFETY SAFETY MACHINE OPERATION q Do not allow anyone apart from the operator to ride on the machine. q Check that the travel alarm works properly. q Always lock the door and windows of the operator's compart- ment in position (open or closed). On jobsites where there is a hazard of flying objects or of objects entering the operator's compartment, check that the door and windows are securely closed.

  • Page 42: Safety Rules For Traveling

    SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING q When traveling on flat ground, keep the work equipment 40 to 50 cm (15.8 to 19.7 in) high above the ground. q When traveling on rough ground, travel at low speed and do not operate the steering suddenly.

  • Page 43: Operations On Slopes

    SAFETY SAFETY MACHINE OPERATION q When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 40 to 50cm (15.8 to 19.7 in) above the ground, and travel at low speed. q When traveling downhill, lower the engine speed, keep the travel lever close to the neutral position, and travel at low speed.
  • Page 44 SAFETY SAFETY MACHINE OPERATION q Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall. q To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations.

  • Page 45: Operations On Snow

    SAFETY SAFETY MACHINE OPERATION q When using a breaker or other heavy work equipment, there is a hazard of the machine losing its balance and tipping over. When operating on flat ground as well as on slopes. q Do not suddenly lower, swing, or stop the work equipment. q Do not suddenly extend or retract the boom cylinder.

  • Page 46: Parking Machine

    SAFETY SAFETY MACHINE OPERATION PARKING MACHINE q Park the machine on firm, level ground. q Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. q Lower the work equipment completely to the ground. q When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine.

  • Page 47: Transportation

    SAFETY 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 particu- lar care is necessary.

  • Page 48: 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. q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.

  • Page 49: 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 fol- lows. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).

  • Page 50: 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 selec- tion or inspection of the wire rope. For towing, see "TOWING THE MACHINE (3-142)". q Always wear leather gloves when handling wire rope.

  • Page 51: Lifting Objects With Bucket

    SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS q Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable. q Use wire rope that conforms to the specified standard. q Always observe the specified lifting load strictly.

  • Page 52: Safety Maintenance Information

    SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG q 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.

  • Page 53: Stop Engine Before Carrying Out Maintenance

    SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE q Stop the machine on firm, level ground. q Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. q Lower the work equipment completely to the ground and stop the engine.

  • Page 54: Proper Tools

    SAFETY SAFETY MAINTENANCE INFORMATION q Set lock lever (1) to the LOCK position (L). q When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in the parts, so be careful not to come close. q Do not touch any control levers.

  • Page 55: Attachments

    SAFETY SAFETY MAINTENANCE INFORMATION ATTACHMENTS q Appoint a leader before starting removal or installation opera- tions for attachments. q Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.

  • Page 56: Removing Battery Terminals

    SAFETY SAFETY MAINTENANCE INFORMATION REMOVING BATTERY TERMINALS When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the battery to prevent the flow of current. SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION q Grease is pumped into the track tension adjustment system under high pressure.

  • Page 57: Precaution For High Fuel Pressure

    SAFETY SAFETY MAINTENANCE INFORMATION PRECAUTION FOR HIGH FUEL PRESSURE High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting inspection or maintenance.

  • Page 58: Compressed Air

    SAFETY SAFETY MAINTENANCE INFORMATION COMPRESSED AIR q When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. q When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves, and other protective equipment.

  • Page 59: Operation

    OPERATION...

  • Page 60: 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) OPG (Operator Protection Guard) (if equipped)

  • Page 61: Controls And Gauges

    OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Car radio (11) Machine monitor Lower wiper switch (12) Horn switch (machines with fixed front window cab) (13) R.H. work equipment control lever or Large capacity airflow air conditioner blower (14) Starting switch switch (If equipped) (15) Fuel control dial Revolving warning lamp switch (option)
  • Page 62 OPERATION MACHINE VIEW ILLUSTRATIONS Machine monitor No function (16) Fuel gauge Working mode selector switch (17) Fuel level monitor Wiper monitor (18) Auto-deceleration switch Engine pre-heating monitor (19) Display control switch Swing lock monitor (20) Input control switch Engine water temperature monitor (21) Window washer switch Engine oil pressure monitor (22) Wiper switch...

  • Page 63: Detailed Controls And Gauges

    OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays.

  • Page 64: Basic Operation Of Machine Monitor

    OPERATION DETAILED CONTROLS AND GAUGES Basic Operation Of Machine Monitor If There Is Abnormality When Starting Engine q If there is any abnormality when starting the engine, the check before starting screen (A) changes to the main- tenance interval warning screen (B), warning screen (D), or error screen (E). q After displaying the check before starting screen (A) for 2 seconds, the screen changes to the maintenance interval warning screen (B).
  • Page 65 OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation q If any abnormality occurs during operation, the normal operation screen (A) changes to warning screen (B) or the error screen (D). q After displaying warning screen (B) for 2 seconds, the screen automatically changes to warning screen (C).

  • Page 66: Basic Check Monitors

    OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not ensure that the machine is in good condition. When carrying out checks before starting (daily checks), do not simply rely on the monitors. Always get off the machine and check each item directly.
  • Page 67 OPERATION DETAILED CONTROLS AND GAUGES Engine Oil Level Monitor This monitor (2) warns the operator that there has been a drop in the oil level in the engine oil pan. If the oil level in the engine oil pan is low, the lamp lights up red, so check the oil level in the engine oil pan, and add oil.

  • Page 68: Caution Monitors

    OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor lights up red, stop operations as soon as possible and carry out 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 69 OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor This monitor (2) lights up to warn that the operator that the level in the fuel tank is low. If the remaining amount of fuel goes down to 101 liters (26.68 US gal), the light changes from green to red, so add fuel as soon as possible.

  • Page 70: Emergency Monitors

    OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run it at low idling, then check the applicable location and carry out the necessary action. These are items that should be observed while the engine is running. If there is an abnormality, the monitor for the abnormal location lights up red and the buzzer sounds, so carry out action immediately.
  • Page 71 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor This monitor (2) warns the operator that the hydraulic oil tempera- ture has risen. If it lights up red during operations, run the engine at low idling or stop the engine and wait until the oil temperature goes down and the monitor changes to green.

  • Page 72: Meter Display Portion

    OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion D(1) Engine pre-heating monitor D(7) One-touch power-up monitor D(2) Swing lock monitor D(8) Engine water temperature gauge D(3) Wiper monitor D(9) Fuel gauge D(4) Auto-deceleration monitor D(10) Hydraulic oil temperature gauge D(5) Working mode monitor D(11) Service meter D(6) Travel speed monitor Pilot Display...
  • Page 73 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Monitor This monitor (2) informs the operator that the swing lock is being actuated. Actuated: Lights up When the swing lock switch is turned ON (ACTUATED), the mon- itor lamp lights up. This monitor flashes when the swing holding brake release switch is turned on.
  • Page 74 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Monitor This monitor (6) displays the set mode for the travel speed. The monitor display when the travel speed selector switch is operated is as follows. Lo : Low speed Hi : High speed One touch power up monitor This monitor (7) shows if the power max function is being actu- ated.
  • Page 75 OPERATION DETAILED CONTROLS AND GAUGES Fuel Gauge This gauge (9) indicates the amount of fuel in the fuel tank. During operations, the indicator should be within the black range. If the indicator enters the red range (A) during operation, there is less than 101 liters (26.68 US gal) of fuel remaining in the tank;...

  • Page 76: Monitor Switches Portion

    OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion E(1) Working mode selector switches (basic switches) E(7) No function E(2) Auto-deceleration switch (selection switch) E(8) Return 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 77 OPERATION DETAILED CONTROLS AND GAUGES REMARK When the mode selector switch is pressed, the mode is displayed in the center of the monitor display portion (A), and the screen returns to the normal screen after 2 seconds. (The diagram on the right is an example of the display for the E mode.) Auto-deceleration Switch (Selection Switch) When this switch (2) is depressed, the auto-deceleration is actu-...
  • Page 78 OPERATION DETAILED CONTROLS AND GAUGES REMARK When the auto-deceleration switch is pressed and the auto-decel- eration is actuated, the mode is displayed in the center of the monitor display portion (A), and the screen returns to the normal screen after 2 seconds. Travel Speed Selector Switch WARNING q When loading on or unloading from a trailer, always travel at low speed (with the travel speed selector...
  • Page 79 OPERATION DETAILED CONTROLS AND GAUGES REMARK Each time that the travel speed selector switch is operated, the mode is displayed in the center of the monitor display portion (A), and the screen returns to the normal screen after 2 seconds. Wiper Switch This switch (4) operates the wiper for the front glass.
  • Page 80 OPERATION DETAILED CONTROLS AND GAUGES Window Washer Switch This switch (5) is kept continuously pressed, window washer fluid is sprayed out on the front glass. When the switch is released, the spray stops. q If switch (5) is kept pressed when the wiper is stopped, the window washer fluid will spray out, and at the same time, the wiper will be actuated continuously.
  • Page 81 OPERATION DETAILED CONTROLS AND GAUGES q The maintenance display items are as follows. Monitor Initial setting Maintenance item display (H) Engine oil change Replace engine oil filter Replace fuel filter Replace hydraulic oil filter 1000 Replace hydraulic tank breather 1000 Replace corrosion resistor 1000 PTO case oil change...
  • Page 82 OPERATION DETAILED CONTROLS AND GAUGES 3. Check the time remaining to maintenance. (a) : Time remaining to maintenance (b) : Default setting for maintenance interval When only checking the time remaining to maintenance, press back switch (8) twice. The screen will return to the normal operation monitor screen. When canceling the time remaining to maintenance and returning to the default time setting, press input confirmation switch (11).
  • Page 83 OPERATION DETAILED CONTROLS AND GAUGES Input Confirmation Switch Press this switch (11) to confirm the selected mode when in the maintenance mode, brightness/contrast adjustment mode, or select mode. Adjusting Brightness And Contrast Press this switch (12) to adjust the brightness and contrast of the monitor display screen.
  • Page 84 OPERATION DETAILED CONTROLS AND GAUGES 3. When the screen changes to the brightness adjustment screen, press up switch (9) or down switch (10) to adjust the bright- ness. 4. After completing adjustment of the brightness, press input con- firmation switch (11). q Adjusting contrast 2.

  • Page 85: Switches

    OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch (10) Emergency pump drive switch Fuel control dial (11) Swing brake cancel switch Cigarette lighter (12) Revolving warning lamp switch Swing lock switch (13) Lower wiper switch Lamp switch (machines with fixed front window cab) Alarm buzzer stop switch or Large capacity airflow condition blower switch Machine push-up switch...
  • Page 86 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial This dial (2) adjusts the engine speed and output. (a) Low idling (MIN): Turned fully to the left (b) Full speed (MAX): Turned fully to the right REMARK When the fuel control dial is turned, the engine speed does not change for the first few notches from MIN and the last few notches before MAX, but this does not indicate any abnormality.
  • Page 87 OPERATION DETAILED CONTROLS AND GAUGES Lamp Switch This switch (5) is used to light up the front lamps, working lamp, additional lamp at the top front of the cab, rear lamp, and monitor lighting. (a) ON: Lamps light up (b) OFF: Lamps go off 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 an abnormality in a...
  • Page 88 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 room lamp even when the starting switch is at the OFF position, so be careful not to forget to turn it off.
  • Page 89 OPERATION DETAILED CONTROLS AND GAUGES Swing Holding Brake Release Switch NOTICE This switch makes it possible to carry out swing operations for a short time even when there is an abnormality in the swing brake system. Do not use this switch except in emer- gencies.
  • Page 90 OPERATION DETAILED CONTROLS AND GAUGES Lower Wiper Switch (If equipped) This switch (13) operates the lower wiper (A). (a) ON position: Lower wiper (A) is actuated (b) OFF position: Lower wiper (A) stops If this switch is turned to the ON position at the same time as the wiper switch, the wiper and lower wiper (A) will be actuated in turn.
  • Page 91 OPERATION DETAILED CONTROLS AND GAUGES Step Light Switch (If equipped) Use this switch (14) when getting off the machine at night. q When the switch is turned to the ON (a) position, the step light will light up for approx. 60 seconds. q Even if the starting switch key is at the OFF position, the step light will light up for approx.

  • Page 92: Control Levers And Pedals

    OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS (1) Lock lever (3) Left work equipment control lever (2) Travel lever (with Auto-deceleration System) (with a pedal and auto-deceleration system) (4) Right work equipment control lever (with Auto-deceleration System) Lock Lever WARNING q When standing up from the operator's seat, push lock lever (1) down securely to set it to LOCK position (L).
  • Page 93 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers WARNING q Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may sud- denly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations.
  • Page 94 OPERATION DETAILED CONTROLS AND GAUGES This Right work equipment control lever(4) is used to operate the boom and bucket. Boom operation (a) RAISE (b) LOWER Bucket operation (c) DUMP (d) CURL N (Neutral): The boom and bucket are held in position and do not move.

  • Page 95: Sun Roof

    OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF (PC600-7, PC600LC-7 full cab specification machine only) WARNING When leaving the operator's seat, set lock lever (1) securely to the LOCK position (L). If lock lever (1) is at the FREE position (F) and the control lever is touched by mistake, this may lead to a serious acci- dent.

  • Page 96: Windshield

    OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD (PC600-7, PC600LC-7 full cab specification machine only) WARNING q When opening or closing the front window, bottom win- dow, or door, always set lock lever (1) to the LOCK posi- tion (L). If the control levers are not locked and they are touched by accident, this may lead to a serious accident.
  • Page 97 OPERATION DETAILED CONTROLS AND GAUGES 4. Grip handles (A) at the top right and left of the front window, and pull lock lever (B) toward yourself to release the lock at the top of the front window. The top of the front window will come out.
  • Page 98 OPERATION DETAILED CONTROLS AND GAUGES 5. Hold lower knob (C) with your left hand from inside the opera- tor's cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
  • Page 99 OPERATION DETAILED CONTROLS AND GAUGES Closing WARNING When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2.
  • Page 100 OPERATION DETAILED CONTROLS AND GAUGES 5. When the bottom of the window reaches the top of the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock. 6.

  • Page 101: Emergency Exit From Operator's Cab

    OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY EXIT FROM OPERATOR'S CAB q If for some reason, the cab door does not open, remove the rear window and use it as an emergency escape. q Remove the rear window as follows. 1. Pull ring (1) and completely remove seal (2) from the rubber core.

  • Page 102: Cap With Lock

    OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Use the starting 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 (3-124)". Insert the key as far as it will go to the shoulder (A). If the key is turned before it is inserted all the way, it may break.

  • Page 103: Hot And Cool Box

    OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Cover with Lock Opening the Cover (Locked Cover) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. (A): Open (B): Lock Locking the Cover 1.

  • Page 104: Ashtray

    OPERATION DETAILED CONTROLS AND GAUGES ASHTRAY This is under the machine monitor at the front right of the opera- tor's compartment. Always make sure that you extinguish your cigarette, then put it in the ashtray and close the lid. 3-46...

  • Page 105: Air Conditioner Controls

    OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel OFF switch RECIRC/FRESH selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Defroster selector lever Auto switch When the function of the switch is actuated, the pilot lamp for the switch lights up. OFF Switch This switch (1) is used to stop the fan and air conditioner.
  • Page 106 OPERATION DETAILED CONTROLS AND GAUGES Fan Switch This switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. q Press the ∧ switch to increase the air flow; press the ∨ switch to reduce the air flow.
  • Page 107 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch This switch (4) is used to select the vents. q When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. q During automatic operation, the vents are automatically selected.
  • Page 108 OPERATION DETAILED CONTROLS AND GAUGES Auto Switch With this switch (5), the air flow, vents, and air source (RECIRC/ FRESH) are automatically selected according to the set tempera- ture. q When auto switch (5) is pressed, the lamp at the top of the auto switch lights up.
  • Page 109 OPERATION DETAILED CONTROLS AND GAUGES Display Monitor This display monitor displays the status of temperature setting (a), air flow (b), and vents (c). q When OFF switch (1) is pressed, the display of temperature setting (a) and air flow (b) goes out, and operation stops. Air Conditioner Switch This switch (8) is used to turn the air conditioner (cooling, dehu- midifying, heating) ON or OFF.

  • Page 110: Method Of Operation

    OPERATION DETAILED CONTROLS AND GAUGES Method Of Operation The air conditioner can be operated automatically or manually. Select the method of operation as desired. Automatic Operation 1. Turn auto switch (5) ON. q The lamp at the top of switch (5) lights up. q The set temperature (a) and air flow (b) are displayed on the monitor.
  • Page 111 OPERATION DETAILED CONTROLS AND GAUGES Stopping Automatic Operation Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on the display monitor, and the lamps above auto switch (5) and air conditioner switch (8) go out, and the operation stops.
  • Page 112 OPERATION DETAILED CONTROLS AND GAUGES 3. Press the temperature setting switch and adjust the tempera- ture 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 mon- itor changes according to the selection.
  • Page 113 OPERATION DETAILED CONTROLS AND GAUGES 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. 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are dis- played on the display monitor.
  • Page 114 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 dis- played on the display monitor. 2. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in (f) or (g) in the dia- gram on the right.
  • Page 115 OPERATION DETAILED CONTROLS AND GAUGES 4. Press temperature setting switch (3) and set the set tempera- ture display on the display monitor to the maximum heating temperature of 32.0. 5. Adjust vents (A), (B), and (D2) so that the air blows onto the window glass.

  • Page 116: Use Air Conditioner With Care

    OPERATION DETAILED CONTROLS AND GAUGES Use Air Conditioner With Care NOTICE q 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. q If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, so be careful not to let water get on these parts.

  • Page 117: Other Functions

    OPERATION DETAILED CONTROLS AND GAUGES Other Functions Self-diagnostic Function It is possible to carry out troubleshooting of the 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 118 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 ° ∨ ∧ If the " " and " " portions of temperature setting switch (3) are pressed at the same time for more than 5 seconds while the fan is °...

  • Page 119: Radio

    OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel Tuning button, manual tuning Power switch, Volume control knob, Balance control knob Preset station buttons (1, 2, 3, 4, 5, 6) Tone control knob Display FM/AM selection button Time reset button Display selection button Stereo indicator Power Switch/Volume Control (SW-VOLUME) and Balance (Pull BAL) Knob When this knob (1) is pressed, the power for the radio is turned on and the display shows the frequency.

  • Page 120: Controls Of Radio

    OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) This equipment gives priority to the frequency display. If the button (4) is pressed when the frequency is displayed, display will give the present time for 5 seconds. After 5 seconds pass, the display will automatically return to the frequency display.
  • Page 121 OPERATION DETAILED CONTROLS AND GAUGES Manual Tuning Press tuning button (5) and set to the desired frequency. Each time the button is pressed, the frequency will move up or down in steps of 9 kHz (AM) or 0.1 MHz (FM). ∨...

  • Page 122: Use Radio With Care

    OPERATION DETAILED CONTROLS AND GAUGES Antenna NOTICE Before transporting the machine or putting it inside a build- ing, stow the antenna at position (A) to prevent any interfer- ence. Use Radio With Care q To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera- tion.

  • Page 123: 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 burn- ing 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 124: Circuit Breaker

    OPERATION DETAILED CONTROLS AND GAUGES CIRCUIT BREAKER NOTICE When resetting the circuit breaker, always turn the starting switch OFF first. q 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 125: Controllers

    OPERATION DETAILED CONTROLS AND GAUGES CONTROLLERS NOTICE q Be careful not to get water, mud, or juice on the controller. This will cause failure. q If any abnormality occurs in the controller, do not disassemble it yourself. Contact your Komatsu dis- tributor for repairs.

  • Page 126: 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. When power switch (1) is turned on, pump (3) is actuated and grease is sent under pressure to grease gun (2). 2.

  • Page 127: Precautions When Using

    OPERATION DETAILED CONTROLS AND GAUGES Precautions when Using NOTICE When not using the grease pump, always turn off power switch (1) to prevent pressure from building up inside grease gun (2). q Set so that the nipple and the nozzle at the tip of the grease gun are perpendicular.
  • Page 128 OPERATION DETAILED CONTROLS AND GAUGES 5. Loosen check valve (5), and pump out all the grease which has air in it from hole (6) at the bottom of check valve (5). 6. After bleeding the air, close check valve (5) securely. 7.

  • Page 129: Accumulator

    OPERATION DETAILED CONTROLS AND GAUGES ACCUMULATOR WARNING The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo- sion which will lead to serious injury or damage. When handling the accumulator, always do as follows. The pressure in the control circuit cannot be completely removed. When removing the hydraulic equip- ment, do not stand in the direction that the oil spurts out when carrying out the operation.

  • Page 130: Releasing Hydraulic Pressure With Accumulator

    OPERATION DETAILED CONTROLS AND GAUGES Releasing Hydraulic Pressure With Accumulator 1. Place the work equipment on the ground. Close the crusher attachment jaws, etc. 2. Stop the engine. 3. Turn the key in starting switch to the ON position. 4. Set lock lever (1) to FREE position (F), then operate the work equipment control levers and the attachment control pedal (if equipped) fully to the front, rear, left, and right to release the pressure in the control circuit.

  • Page 131: Machine Operations And Controls

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS BEFORE STARTING ENGINE Walk-Around Checks Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for loose wiring, play, and accumulation of dust at places which reach high temperatures.
  • Page 132 OPERATION MACHINE OPERATIONS AND CONTROLS 8. Check for abnormality in gauges, monitor. Check that there is no abnormality in the gauges and monitor in the operator's cab. If any abnormality is found, replace the parts. Clean off any dirt on the surface. 9.

  • Page 133: 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 Water WARNING q 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 134 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level In Engine Oil Pan, 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. 1.
  • Page 135 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 com- pletely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
  • Page 136 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level In Hydraulic Tank, Add Oil WARNING When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. 1. If the work equipment is not in the condition shown in the dia- gram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinders, then lower the boom, set the bucket teeth in contact with the ground, and...
  • Page 137 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK The oil level will vary depending upon the oil temperature. Accordingly, use the following as a guide: Before operation: around L level ° ° (Oil temperature 10 to 30 C (50 to 86 Normal operation: around H level °...
  • Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level In P.T.O 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. NOTICE Park the machine on flat ground and stop the engine.
  • Page 139 OPERATION MACHINE OPERATIONS AND CONTROLS Check working Lamp switch Turn the lamp switch to the ON position and check that the work- ing lamp light up. If the lamps do not light up, there is probably a broken bulb or dis- connection in the wiring, so contact your Komatsu distributor for repairs.

  • Page 140: Adjustment

    OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set lock lever (1) to LOCK position (L) to pre- vent any accidental contact to the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q Adjust the seat so that the control levers and switches can be operated freely and easily with the operator's back against the backrest.
  • Page 141 OPERATION MACHINE OPERATIONS AND CONTROLS (C) Adjusting seat tilt q Forward tilt Push lever (3) up to adjust the angle of the front of the seat. (4 stages) q To raise the angle at the front of the seat, keep the lever pushed up and apply your weight to the rear of the seat.
  • Page 142 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors WARNING Adjust the position of the mirror to match the operator's physique and preference. When adjusting, set it to match the physique of the present operator or any other operator who will mount the machine so that the operators will be able to enter the cab or climb on or off the machine safely.

  • Page 143: Seat Belt

    OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING q Before fitting the seat belt, check that there is no abnormality in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. q Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manu- facture of the belt is shown on the back of the belt.

  • Page 144: Operations Before Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When starting the engine, check that lock lever (1) is securely at the LOCK position (L). If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious accident.
  • Page 145 OPERATION MACHINE OPERATIONS AND CONTROLS 4. The buzzer sounds for approx. 1 second, and the following monitors and meters light up for approx. 3 seconds. q Radiator water level monitor (4) q Engine oil level monitor (5) q Charge monitor (6) q Fuel level monitor (7) q Engine water temperature monitor (8) q Engine oil pressure monitor (9)
  • Page 146 OPERATION MACHINE OPERATIONS AND CONTROLS 7. If there are any items where the maintenance time has passed, maintenance interval monitor (16) lights up for 30 seconds. Press maintenance switch (17), check the item, then carry out maintenance immediately. For details of the method of checking the maintenance inter- val, see "Maintenance Switch (3-22)"...

  • Page 147: Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING q Start the engine only after sitting down in the operator's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire.
  • Page 148 OPERATION MACHINE OPERATIONS AND CONTROLS 2. Set fuel control dial (2) at the low idling (MIN) position. If it is at the high idling (MAX) position, always change it to the low idling (MIN) position. 3. Turn the key in starting switch (3) to the START position (C). The engine will start.

  • Page 149: Starting Engine In Cold Weather

    OPERATION MACHINE OPERATIONS AND CONTROLS Starting Engine In Cold Weather WARNING q Start the engine only after sitting down in the operator's seat. q 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 150 OPERATION MACHINE OPERATIONS AND CONTROLS 3. Hold the key in starting switch (3) at the HEAT position (D), and check that preheating monitor (4) lights up. After about 30 seconds, preheating monitor lamp (4) will flash to indicate that preheating is finished. REMARK The monitors and gauges will light up also when the key is turned to the HEAT position, but this is not an abnormality.
  • Page 151 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK The actuation time for the turbo protect function and the relationship with the engine coolant temperature are as shown below. If the fuel control dial is operated within the time shown below, the engine speed will not change. Cooling water temperature Turbo protect time (sec.) °...

  • Page 152: After Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS AFTER STARTING ENGINE WARNING q If there has been any Emergency stop, abnormal actuation or trouble, turn the starting switch key to the OFF position. q If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always carry out the warming-up operation.
  • Page 153 OPERATION MACHINE OPERATIONS AND CONTROLS 3. Operate bucket control lever (3) and arm control lever (4) slowly to move the bucket cylinder and arm cylinder to the end of the stroke. 4. Operate the bucket for 30 seconds and the arm for 30 sec- onds in turn fully for 5 minutes.
  • Page 154 OPERATION MACHINE OPERATIONS AND CONTROLS 8. If air cleaner clogging monitor (16) is lighted up, clean or replace the element immediately. For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELE- MENT (4-20)". 9.

  • Page 155: In Cold Weather Areas

    OPERATION MACHINE OPERATIONS AND CONTROLS Working mode monitor display 10. A mode For heavy-load operations 11. E mode For operations with emphasis on fuel economy 12. Heavy-duty lift Boom lifting power increased when raising boom indepen- dently 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.
  • Page 156 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE q Do not suddenly accelerate the engine before the warm- ing-up operation is completed. Do not run the engine at low idling or high idling continu- ously for more than 20 minutes.This will cause leakage of oil from the turbocharger oil supply piping.
  • Page 157 OPERATION MACHINE OPERATIONS AND CONTROLS 5. After carrying out the warming-up operation, check that each gauge and monitor lamp is in the following condition. q Radiator water level monitor (7): OFF q Engine oil level monitor (8): OFF q Charge monitor (9): OFF q Fuel level monitor (10): Green display q Engine water temperature monitor (11): Green display q Engine oil pressure monitor (12): OFF...
  • Page 158 OPERATION MACHINE OPERATIONS AND CONTROLS Working mode monitor display 11. A mode For heavy-load operations 12. E mode For operations with emphasis on fuel economy 13. Heavy-duty lift Boom lifting power increased when raising boom indepen- dently NOTICE Canceling automatic warming-up operation If it becomes necessary in an emergency to cancel the automatic warming-up operation or to lower the engine speed to low idling, do as follows.

  • Page 159: Stopping The Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS 15. When fuel control dial (2) is returned to the low idling (MIN) position, the engine speed will drop. STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency.

  • Page 160: Machine Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION Preparations For Moving The Machine WARNING q 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. q When moving off, check that the area around the machine is safe, and sound the horn before moving.

  • Page 161: Moving Machine Forward

    OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 1. Set lock lever (4) in the FREE position (F), fold the work equipment, and raise it 40 to 50 cm (16 to 20 in) from the ground. 2. Operate right and left travel levers (5) or right and left travel pedals (6) as follows. q When the sprocket (A) is at the rear of the machine Push levers (5) forward slowly or depress the front part of pedals (6) slowly to move the machine off.

  • Page 162: Moving Machine Backward

    OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Backward 1. Set lock lever (4) in the FREE position (F), fold the work equipment, and raise it 40 to 50 cm (16 to 20 in) from the ground. 2. Operate right and left travel levers (5) or right and left travel pedals (6) as follows. q When the sprocket (A) is at the rear of the machine Pull levers (5) backward slowly or depress the rear part of pedals (6) to move the machine off.

  • Page 163: Stopping Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room and return the lever slowly when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3-105...

  • Page 164: Steering The Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel control levers, check the direction of the track frame (i.e. position of the sprocket) first. If the sprocket is at the front, the machine moves in the reverse direction to the operation of the travel lever.
  • Page 165 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.

  • Page 166: 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 167: 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. The left work equipment con- trol lever operates the arm and swing, and the right work equipment control lever operates the boom and bucket.
  • Page 168 OPERATION MACHINE OPERATIONS AND CONTROLS Boom operation Bucket operation 3-110...

  • Page 169: Working Mode

    OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match the operating conditions and purpose, thereby enabling work to be carried out efficiently. Make effective use of each mode as follows. When the starting switch is turned ON, the working mode is set to A mode (digging).

  • Page 170: Prohibited Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING q If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. q If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
  • Page 171 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 a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging.

  • Page 172: 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 173 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth NOTICE When driving the machine out of water, if the angle of the ° machine exceeds 15 C, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan. This may cause the fan to break.

  • Page 174: Traveling On Slopes

    OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING q Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded.
  • Page 175 OPERATION MACHINE OPERATIONS AND CONTROLS q When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 40 to 50cm (15.8 to 19.7 in) above the ground, and travel at low speed. Traveling Downhill Put the travel lever in the neutral position.

  • Page 176: Escape From Mud

    OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD When operating, be careful not to get stuck in mud. If the machine gets stuck in mud, do as follows to get the machine out. q If machine push-up switch (1) is turned ON, the pushing force of the boom is increased and it becomes easier to escape.

  • Page 177: 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 178: Bucket Replacement

    OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING q 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 equip- ment.
  • Page 179 OPERATION MACHINE OPERATIONS AND CONTROLS 3. Align the arm with holes (1) of the replacement bucket and the link with holes (2), then insert grease-coated pins (A) and (B) into hole (1) and hole (2) respectively. REMARK Carry out installation in the reverse order to removal. When installing the bucket (6), it is easy to damage the O-ring (7), so fit the O-ring (7) to the arm (4) in the position shown in the dia- gram on the right.

  • Page 180: Parking Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING q Avoid stopping suddenly. Give yourself ample room when stopping. q When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes.

  • Page 181: Check After Shut Off Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Set lock lever (3) in the LOCK position (L). CHECK AFTER SHUT OFF ENGINE Check the engine water temperature, engine oil pressure, and fuel level on the machine monitor.

  • Page 182: Locking

    OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Door of operator's cab Always remember to close the window. (2) Fuel tank filler port (3) Engine hood (4) Battery box cover (5) Left side door of the machine (2 places) (6) Tool box side door (7) Hydraulic tank filler port (8) Spare pail cover...

  • Page 183: Transportation

    OPERATION 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 divided into several units for transportation. When transporting the machine, please consult your Komatsu distributor. LIFTING MACHINE WARNING q Never carry out the lifting operation with any person on the machine.

  • Page 184: Shipping Machine Information

    OPERATION TRANSPORTATION SHIPPING MACHINE INFORMATION WARNING q When loading the machine, choose firm level ground. Keep well away from the road shoulder. q Run the engine at low speed and operate slowly. After placing the machine on the specified position of the trailer, secure it according to the following procedure. 1.

  • Page 185: Transportation Posture

    OPERATION TRANSPORTATION TRANSPORTATION POSTURE This machine can be divided into three units or four units for transportation. When transporting the machine please contact your Komatsu distributor. Three units for transportation (A) Upper structure + Undercarriage (B) Work equipment (C) Other Four units for transportation (A) Upper structure (B) Undercarriage...
  • Page 186 Weight kg (lb) 33,200 (73,206) 34,200 (75,411) Upper Structure Secure the upper structure to the platform with a chain and block. Unit PC600-7, PC600LC-7 Overall mm (ft in) 3,195 (10' 6") width mm (ft in) 2,500 (8' 2") mm (ft in) 4,970 (16' 4")
  • Page 187 OPERATION TRANSPORTATION Work Equipment q Boom Unit PC600-7, PC600LC-7 mm (ft in) 7,920 (25' 12") mm (ft in) 2,040 (6' 8") Overall mm (ft in) 1,190 (3' 11") width Weight kg (lb) 4,820 (10,628) q Arm Unit PC600-7, PC600LC-7 mm (ft in) 4,870 (15' 12")
  • Page 188 OPERATION TRANSPORTATION q Arm cylinder Unit PC600-7, PC600LC-7 mm (ft in) 3,108 (10' 2") Weight kg (lb) 770 (1,698) Others q Counterweight Unit PC600-7, PC600LC-7 mm (ft in) 1,320 (4' 4") mm (ft in) 3,195 (10' 6") mm (ft in) 680 (2' 3")
  • Page 189 OPERATION TRANSPORTATION q Catwalk (2) (same for all models) Unit PC600-7, PC600LC-7 mm (ft in) 2,310 (7' 7") mm (ft in) 500 (1' 8") Weight kg (lb) 37 (82) 3-131...

  • Page 190: Procedure For Increasing Or Reducing Track Frame Gauge

    OPERATION TRANSPORTATION PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE WARNING Never use the machine for operations with the track frame retracted. Reducing Track Gauge 1. Remove center frame mounting bolts (1). (one side, front + rear: 16 bolts) ° 2.
  • Page 191 OPERATION TRANSPORTATION Increasing Track Gauge 1. Remove center frame mounting bolts (2) (one side, front + rear: 8 bolts) from the front and rear of the track frame on the side to be extended. ° 2. Swing the upper structure so that it is at 90 on the opposite side to track frame (A) to be extended.

  • Page 192: Cold Weather Operation

    OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION INFORMATION If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol- lows. Fuel And Lubricants Change to fuel and oil with low viscosity for all components. For details of the specified visicosity, see "LUBRI- CANTS, FUEL AND COOLANT SPECIFICATIONS (4-9)".
  • Page 193 OPERATION COLD WEATHER OPERATION Battery WARNING q The battery generates flammable gas, so do not bring fire or sparks near the battery. q 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 194: After Daily Work Completion

    OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, so 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, always observe the following precautions.

  • Page 195: Long Term Storage

    OPERATION LONG TERM STORAGE LONG TERM STORAGE BEFORE STORAGE NOTICE When storing the machine, set the machine in the posture shown in the diagram on the right to protect the cylinder rod. (To prevent rusting of the cylinder rod) When putting the machine in storage for a long time, do as follows. q Clean and wash all parts, then store the machine indoors.

  • Page 196: After Storage

    OPERATION LONG TERM STORAGE AFTER STORAGE NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. q Wipe off the grease from the hydraulic cylinder rods.

  • Page 197: Troubles And Actions

    OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL WARNING When air bleed plug (2) at the top of the fuel filter head or supply pump air breather (4) are removed, the system is still under pressure, so fuel may spurt out. Loosen these parts slowly before opening them. When starting after running out of fuel, fill the filter cartridge with fuel and bleed the air from the fuel system before starting.
  • Page 198 OPERATION TROUBLES AND ACTIONS 2. Loosen air bleed plug (2) at the top of the fuel filter head and open fuel supply valve (1) at the bottom of the fuel tank. 3. Loosen the knob of priming pump (3), pump the knob, and check that fuel comes out from air bleed plug (2).

  • Page 199: Phenomena That Are Not Failures

    OPERATION TROUBLES AND ACTIONS PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: q When the arm control lever is operated to the IN position and the work equipment is lowered under no load from a high position, the arm speed will drop momentarily when the arm is more or less at the vertical position.

  • Page 200: Towing The Machine

    OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING q When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. q 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 201: Discharged Battery

    OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING q It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charg- ing. q When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. q The battery generates hydrogen gas, so there is a hazard of explosion.

  • Page 202: Battery Charges

    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 (3-143)" and the instruction manual accompanying the charger, and do as follows. q Set the voltage of the charger to match the voltage of the bat- tery to be charged.

  • Page 203: Starting Engine With Booster Cables

    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 q When connecting the cables, never contact the positive (+) and negative (-) terminals. q When starting the engine with a booster cable, always wear safety glasses.
  • Page 204 OPERATION TROUBLES AND ACTIONS Booster Cable Connection Keep the starting switch of the normal machine and problem machine at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect one clip of booster cable (A) to the positive (+) termi- nal of the problem machine.

  • Page 205: Other Trouble

    OPERATION TROUBLES AND ACTIONS OTHER TROUBLE Electrical System q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy...

  • Page 206: Chassis

    OPERATION TROUBLES AND ACTIONS Chassis q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm, •Lack of hydraulic oil...

  • Page 207: Engine

    OPERATION TROUBLES AND ACTIONS Engine q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy •Add oil to specified level, see •Engine oil pan oil level is low (suck-...
  • Page 208 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy •Oil leakage (•Check, repair) Excessive oil consumption •Excessive oil in il pan •Add oil to specified level. See CHECK BEFORE STARTING. •Worn piston, ring, cylinder liner (•Replace) •Improper fuel •Replace with specified fuel Exhaust gas is white or blue •Defective turbocharger (•Check, replace)

  • Page 209: Electronic Control System

    OPERATION TROUBLES AND ACTIONS Electronic Control System If an error code is displayed on the machine monitor display, follow the self-diagnostic remedy table below. Machine Monitoring System Monitor Failure mode Remedy display When emergency pump drive switch is up, normal operations TVC valve system error become normal, but carry out inspection immediately.

  • Page 210: Point Of Contact To Telephone When Error Occurs

    OPERATION TROUBLES AND ACTIONS Point Of Contact To Telephone When Error Occurs If an error screen is displayed on the monitor, the screen changes as follows each time input confirmation switch (1) is pressed. Error screen → screen A → screen B → screen C → error screen Check the point of contact telephone number on screen B.

  • Page 211: Maintenance

    MAINTENANCE...

  • Page 212: Maintenance Information

    MAINTENANCE MAINTENANCE INFORMATION MAINTENANCE INFORMATION Do not carry out any inspection and maintenance operation that is not found in this manual. Service Meter Reading Check the service meter reading every day to see if the time has come for any necessary maintenance to be car- ried out.
  • Page 213 MAINTENANCE MAINTENANCE INFORMATION Dusty Jobsite When working at dusty worksites, do as follows: q Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged. q Clean the radiator core frequently to avoid clogging. q Clean and replace the fuel filter frequently. q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

  • Page 214: Lubricants, Coolant And Filters

    MAINTENANCE LUBRICANTS, COOLANT AND FILTERS LUBRICANTS, COOLANT AND FILTERS HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC q Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres- sure), and deteriorates with use. Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Man- ual.

  • Page 215: Cooling System Coolant

    MAINTENANCE LUBRICANTS, COOLANT AND FILTERS Cooling System Coolant q River water contains large amount of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating. Do not use water that is not suitable for drinking.

  • Page 216: Oil And Fuel Storage

    MAINTENANCE LUBRICANTS, COOLANT AND FILTERS KOWA analysis items q Analysis of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of metal wear particles in the oil. q Measurement of particle quantity This uses a PQI (Particle Quantifier Index) measurer to mea- sure the quantity of large iron particles in the oil.

  • Page 217: Filters

    MAINTENANCE LUBRICANTS, COOLANT AND FILTERS Filters q Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems. Replace all filters periodically. For details, see the Operation and Maintenance Manual. However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used.

  • Page 218: Wear Parts

    MAINTENANCE WEAR PARTS WEAR PARTS Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the machine.

  • Page 219: Lubricants, Fuel And Coolant Specifications

    MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS *1 :ASTM D975 No.1 *2 : Use only diesel fuel. NOTICE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics.
  • Page 220 MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Swing Final drive Engine P.T.O machinery case case Hydraulic Cooling Fuel tank Oil pan case (Each of right (Each of right oil system system and left) and left) Liter 10.5 Specified oil amount US gal 11.10 1.59 3.43...
  • Page 221 MAINTENANCE 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 marked * is CE.) EO10-CD AF-ACL...
  • Page 222 MAINTENANCE 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 marked * is CE.) Multi-purpose white *Superme duty...

  • Page 223: Tightening Torque Specifications

    MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE LIST CAUTION If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation. Always pay careful attention when tightening parts.

  • Page 224: Safety Critical Parts

    MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS For using the machine safely for an extended period of time, you are requested to periodically replace the safety - critical and fire prevention- related parts listed in the table of important parts on the following page. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate.

  • Page 225: Safety Critical Parts List

    MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST Periodical exchange parts Q’ty Change interval Fuel hose (fuel tank to strainer) Fuel hose (strainer to priming pump) Fuel hose (priming pump to supply pump) Fuel return hose (injection pump to fuel cooler) Every 2 years or 4,000 hours, whichever come first Fuel return hose (fuel cooler to fuel tank)

  • Page 226: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (4-18)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER ................
  • Page 227 MAINTENANCE MAINTENANCE SCHEDULE EVERY 500 HOURS MAINTENANCE REPLACE FUEL FILTER CARTRIDGE......................4-534 CHECK SWING PINION GREASE LEVEL, ADD GREASE ................4-554 CLEAN, CHECK RADIATOR FIN, OIL COOLER FIN, FUEL COOLER FIN, CONDENSER FIN (machines equipped with air conditioner)......................4-564 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)..........................

  • Page 228: Maintenance Interval For Hydraulic Breaker

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging operations, so set the maintenance intervals as follows. REPLACE HYDRAULIC OIL FILTER ELEMENT q On new machines, replace the element after the first 100 to 150 hours, then carry out further replacement of the element according to the table on the right.

  • Page 229: Maintenance Procedure

    MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)4 Carry out the following maintenance only after the first 100 hours. q Clean strainer of P.T.O lubricating oil filter For details of the method of maintaining, see EVERY 500 HOURS MAINTENANCE. INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)4 Carry out the following maintenance only after the first 500 hours.

  • Page 230: When Required

    MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING q When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. q When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working at high places or where the foothold is poor, be careful not to fall because of the reac- tion when pulling out the outer element.
  • Page 231 MAINTENANCE MAINTENANCE PROCEDURE NOTICE q Never remove the inner element (5). It will allow dirt to enter and cause failure of the engine. q Do not use a screwdriver or other tool. 3. After removing the outer element (6), cover the air connector inside the air cleaner body with a clean cloth or tape to pre- vent dirt or dust from entering.
  • Page 232 MAINTENANCE MAINTENANCE PROCEDURE 6. Direct dry compressed air (less than 0.69MPa (7kgf/cm 99.4PSI)) to the outer element (4) from inside along its folds, then direct it from outside along its folds and again from inside. 7. Remove one seal from the element whenever the element has been cleaned.
  • Page 233 MAINTENANCE MAINTENANCE PROCEDURE Install Air Cleaner Element NOTICE q Do not use any damaged gasket or seal or element with damaged pleats. q Cleaning the element or O-ring after one year has passed and using them again will cause problems. Always replace them with new parts.
  • Page 234 MAINTENANCE MAINTENANCE PROCEDURE Replacing inner element 1. First remove the outer element, and then remove the inner element. 2. Cover the air connector side (outlet side) with a clean cloth or tape. 3. Clean the air cleaner body interior, then remove the cover from the air intake port in Step 2. 4.

  • Page 235: Clean Inside Of Cooling System

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING q 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.
  • Page 236 MAINTENANCE MAINTENANCE PROCEDURE WARNING Antifreeze is flammable, so keep it away from flame. Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. Use city water for the cooling water.

  • Page 237: 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 784 ± 78 N m (80 ±...

  • Page 238: 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 (3- 73)", "STARTING ENGINE (3-89)", "AFTER STARTING ENGINE (3-94)", and "WORK EQUIPMENT CON- TROLS AND OPERATIONS (3-109)" in the OPERATION section. The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil, so inspect the track tension frequently in order to maintain the standard tension.

  • Page 239: Check Electrical Intake Air Heater

    MAINTENANCE MAINTENANCE PROCEDURE 4. Continue to pump in grease until (S) becomes 48 mm (1.9 in). If the tension is still loose, the pin and bushing are exces- sively worn, so they must be either turned or replaced. Please contact your Komatsu distributor. Loosening Track Tension WARNING It is extremely dangerous to release the grease by any method except the procedure given below.

  • Page 240: Replace Bucket Teeth (Horizontal Pin Type)

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the teeth before the wear reaches the adapter. WARNING q It is dangerous if the work equipment is mistakenly moved when replacing the teeth. Set the work equipment in a stable condition, stop the engine, then set the lock lever securely to the LOCK posi- tion (L).

  • Page 241: Adjust Bucket Clearance

    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 the lock lever securely to the LOCK position (L).

  • Page 242: Replace Of Fan Belt And Adjustment Of Auto Tensioner

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER An auto-tensioner is installed, so there is no need to adjust until the belt is replaced. 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), and if it is low, add automobile window washer fluid.

  • Page 243: Check And Adjust Air Conditioner

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST AIR CONDITIONER (Only for machines equipped with air conditioner) Check level of refrigerant (gas) WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite.

  • Page 244: 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 (4-40)".

  • Page 245: Replace Breaker Circuit Additional Oil Filter Element

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT (If equipped) 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. q Prepare a container to catch the oil.

  • Page 246: Clean Pilot Line Filter, Remove Dirt

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN PILOT LINE FILTER, REMOVE DIRT Prepare a container to catch drained fuel. 1. Place a container under the pilot line filter to catch the oil. 2. Remove plug (1). 3. Remove strainer (2) and wash it. 4.

  • Page 247: Bleeding Air From Hydraulic System

    MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (3-89)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. WARNING When starting the engine to bleed the air, follow the procedure given in "In Cold Weather Areas (3-97)". NOTICE q Bleed the air as follows.
  • Page 248 MAINTENANCE MAINTENANCE PROCEDURE 7. Bleeding air from cylinders 8. Run the engine at low idling, and extend and retract each cylinder 4 to 5 times, taking care so that a cylinder may not be brought up to its stroke end. (Stop the cylinder approx. 100 mm (3.9 in) short of its stroke end) 9.
  • Page 249 MAINTENANCE MAINTENANCE PROCEDURE 17. 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. 18.

  • Page 250: 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 q 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. If the pressure is not released, high pressure oil may spurt out and cause serious personal injury.

  • Page 251: Check Nitrogen Gas Charge Pressure In Accumulator (Control Circuit)

    MAINTENANCE MAINTENANCE PROCEDURE CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit) NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release the remaining pressure inside the hydraulic circuit in a failure occurs on the machine.

  • Page 252: Check Before Starting

    MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (3-75)" in the OPERATION section. q Check coolant level, add water q Check oil level in engine oil pan, add oil q Check fuel level, add fuel q Drain water and sediment from fuel tank q Check oil level in hydraulic tank, add oil q Check oil level in swing machinery case, add oil...

  • Page 253: 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 254 MAINTENANCE 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 (1 place) (7) Arm cylinder rod pin (1 place) (8) Arm-Link coupling pin (1 place) (9) Arm-Bucket coupling pin (1 place) 4-44...
  • Page 255 MAINTENANCE MAINTENANCE PROCEDURE (10) Link coupling pin (2 places) (11) Bucket cylinder rod pin (1 place) (12) Bucket-Link coupling pin (1 place) 4-45...

  • Page 256: 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 fit- tings shown by arrows.

  • Page 257: 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 q The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri- ous burns.

  • Page 258: Check Level Of Battery Electrolyte

    MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this check before operating the machine. WARNING q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler- ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion.
  • Page 259 MAINTENANCE MAINTENANCE PROCEDURE 2. If the electrolyte level is below the midway point between the U.L. and L.L. lines, remove cap (1) and add distilled water to the U.L. line. 3. After adding distilled water, tighten cap (1) securely. REMARK If distilled water is added to above the U.L.

  • Page 260: Check, Clean Fuel Tank Strainer

    MAINTENANCE MAINTENANCE PROCEDURE REMARK If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. 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.

  • Page 261: Check Alternator Drive Belt Tension, Adjust

    MAINTENANCE MAINTENANCE PROCEDURE CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST Checking If you push the belt at the center between the alternator (1) and the drive pulley (2) with your thumb [approximately 98.1N (10 kgf)] and you get deflection of (A), it is normal.

  • Page 262: Check Air Conditioner Compressor Belt Tension, Adjust

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST Checking 1. Remove 4 bolts (2), then remove cover (1). 2. The standard deflection for the drive belt is of (A) when pressed with a thumb [at approx.98.1 N (approximately 10 kgf)] at a point midway between the drive pulley (3) and the air conditioner compressor pulley (4).

  • Page 263: Every 500 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 10, 100 and 250 hours service should be carried out at the same time. REPLACE FUEL FILTER CARTRIDGE WARNING q After the engine has been operated, all parts are at high temperature, so do not replace the filter imme- diately.
  • Page 264 MAINTENANCE MAINTENANCE PROCEDURE 4. 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 265: Check Swing Pinion Grease Level, Add Grease

    MAINTENANCE MAINTENANCE PROCEDURE CHECK SWING PINION GREASE LEVEL, ADD GREASE q Prepare a scale. 1. Remove bolts (1) (2 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 266: Clean, Check Radiator Fin, Oil Cooler Fin, Fuel Cooler Fin, Condenser Fin (Machines Equipped With Air Conditioner)

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN, CHECK RADIATOR FIN, OIL COOLER FIN, FUEL COOLER FIN, CONDENSER FIN (machines equipped with air conditioner) WARNING If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury.

  • Page 267: Clean Fresh/Recirc Air Filters Of Air Conditioner (Only For Machines Equipped With Air Conditioner)

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) WARNING If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear safety glasses, dust mask, and other protective equipment. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently.

  • Page 268: Replace Breather Element In Hydraulic Tank

    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 neu- tral 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 269: Clean Strainer Of P.t.o Lubricating Oil Filter

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER WARNING q 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. q When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.

  • Page 270: 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 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. q Oil pan refill capacity: 40 liters (10.6 US gal) q Filter wrench 1.
  • Page 271 MAINTENANCE MAINTENANCE PROCEDURE 5. When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten a further 3/4 - 1 turn. q When using a filter wrench for tightening, be extremely careful not to damage the filter or cause dents. 6.

  • Page 272: Every 1000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 10, 100, 250 and 500 hours service should be carried out at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

  • Page 273: Change Oil In Swing Machinery Case

    MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY 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. q Refill capacity: Each 13 liters (3.4 US gal) 1.

  • Page 274: Change Oil In P.t.o Case

    MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN P.T.O 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. NOTICE Park the machine on flat ground and stop the engine.

  • Page 275: Replace Corrosion Resistor Cartridge

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE WARNING The oil is at high temperature after the engine has been operated, so never replace the cartridge immedi- ately after finishing operations. Wait for the oil to cool down before replacing cartridge. q Container to catch coolant q Filter wrench 1.

  • 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 q Center frame (A): Important check points q Boom 4-67...

  • Page 278: Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)

    MAINTENANCE MAINTENANCE PROCEDURE q Arm CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker) (If equipped) A special tool is needed for inspecting and charging with nitrogen gas. Please ask your Komatsu distributor. 4-68...

  • Page 279: Every 2000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri- ous burns.

  • Page 280: Clean Hydraulic Tank Strainer

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING q 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. q 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 281: Clean Engine Breather

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN ENGINE BREATHER WARNING q 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. q When using compressed air, there is a hazard that dirt may be blown up and cause serious injury. Always use safety glasses, dust mask, or other protective equipment.

  • Page 282: Every 4000 Hours Maintenence

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 4000 HOURS MAINTENENCE Maintenance for every 10, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time. CHECK WATER PUMP Check if there is oil leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.

  • Page 283: Check For Looseness Of High-Pressure Clamp, Hardening Of Rubber

    MAINTENANCE MAINTENANCE PROCEDURE CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER Check that there is no looseness in the high-pressure clamp mounting bolts (1) - (15) in the drawing on the next page. Check visually and feel with your finger to check that the rubber has not hardened. If there is any problem, the problem part must be replaced.

  • Page 284: Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber

    MAINTENANCE MAINTENANCE PROCEDURE CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER Fuel spray prevention caps (1) - (16) and fuel spray prevention cover (17) are protective parts installed to prevent fire caused by fuel leaking and spraying out on to high temperature parts of the engine. Check visually that there are no missing caps or loose bolts, and feel with your finger to check that the rubber has not hardened.

  • Page 285: Every 5000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
  • Page 286 MAINTENANCE MAINTENANCE PROCEDURE 6. Remove the 10 mounting bolts of cover (2), take off the cover, then remove drain plug (3) at the bottom of the pump suction tube. 7. After draining the oil, tighten drain plug (3) and install cover (2).

  • Page 287: Every 8000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 8000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Please contact your Komatsu distributor to have the engine high-pressure clamp replaced. REPLACE FUEL SPRAY PREVENTION CAP Please contact your Komatsu distributor to have the fuel spray prevention cap replaced.

  • Page 288: Specifications

    SPECIFICATIONS...
  • Page 289 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS PC600-7 GALEO PC600LC-7 GALEO Item Unit PC600-7 PC600LC-7 Operating weight kg (lb) 56,600 (124,803) 57,600 (127,008) (including one person) Bucket capacity 2.7 (3.5) 2.7 (3.5) (cu.yd) Name of engine KOMATSU SA6D140E deisel engine Rated horsepower of engine...
  • Page 290 SPECIFICATIONS SPECIFICATIONS PC600-7 GALEO PC600LC-7 GALEO Working ranges Unit PC600-7 PC600LC-7 A Max. digging reach mm (ft in) 13,020 (42' 9") 13,020 (42' 9") B Max. digging depth mm (ft in) 8,490 (27' 10") 8,490 (27' 10") C Max. digging height mm (ft in) 11,880 (38' 12")

  • Page 291: Attachments And Options

    ATTACHMENTS AND OPTIONS...

  • Page 292: General Precautions For Safety

    ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY GENERAL PRECAUTIONS FOR SAFETY When installing attachments or options to the machine, it is necessary to pay attention to safety. Please obey the following precautions strictly when selecting, installing, or using attachments or options. PRECAUTIONS WHEN SELECTING q Please consult your Komatsu distributor before installing attachments or options to the machine.

  • Page 293: Precautions When Using

    ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY PRECAUTIONS WHEN USING When long or heavy work equipment is installed, remember the following precautions. Before starting operations, move the machine to a safe place and carry out a test operation to make sure that you fully understand the move- ment, center of gravity, and working range of the machine.

  • Page 294: Attachment Guide

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE ATTACHMENT GUIDE WARNING q Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. q When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.

  • Page 295: Working Range Diagram

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE Working Range Diagram PC600-7 PC600-7 PC600-7 PC600-7 Working ranges Unit Standard arm semi-long arm Long arm SE arm 3.5 m (11’ 6") 4.3 m (14' 1") 5.2 m (17' 1") 2.9 m (9' 6") A Max. digging reach mm (ft in) 13,020 (42' 9")

  • Page 296: Track Shoes Selection

    • Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid going over obstacles, shift down and travel at half speed in Lo. PC600-7 PC600LC-7 Specifications Classification Standard 600 mm (1’...
  • Page 297 INDEX Index <A> <G> Accumulator ............3-71 General Operation Information ......3-114 Air Conditioner Controls ........3-47 General Precautions For Safety ......6-2 Ashtray ..............3-46 Precautions When Removing Or Installing ..6-2 Attachment Guide ..........6-4 Precautions When Selecting ......6-2 Combinations of Work Equipment .....
  • Page 298 INDEX <O> <W> Overall Machine View ..........3-2 Wear Parts ............. 4-8 Wear Parts List..........4-8 Windshield ............3-38 <P> Work Equipment Controls And Operations ..3-109 Parking Machine ..........3-122 Working Mode............ 3-111 Product Identification Number (Pin)/ machine Serial No. Plate ........1-9 <Y>...

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Pc600lc-7

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