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Page 3: Foreword
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
Page 4 FOREWORD FOREWORD...
Page 5 FOREWORD FOREWORD...
Page 6: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 9: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. MACHINE SERIAL NUMBER PLATE AND ITS LOCATION On the front bottom right of the operator's cab (side of upper frame) ENGINE SERIAL NUMBER PLATE AND ITS LOCATION On the right side of the engine cylinder block has seen from the fan.
Page 10: 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. Distributor name Address Service Personnel Phone/Fax 1 - 9...
Page 11: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE BREAKING-IN THE NEW MACHINE PRODUCT INFORMATION MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ENGINE SERIAL NUMBER PLATE AND ITS LOCATION SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS...
Page 12 FOREWORD CONTENTS ACCUMULATOR 3- 52 MACHINE OPERATIONS AND CONTROLS 3- 53 BEFORE STARTING ENGINE 3- 53 STARTING ENGINE 3- 67 AFTER STARTING ENGINE 3- 71 STOPPING THE ENGINE 3- 77 MACHINE OPERATION 3- 78 STEERING THE MACHINE 3- 82 SWINGING 3- 84 WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 85...
Page 13 FOREWORD CONTENTS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS PROPER SELECTION TIGHTENING TORQUE SPECIFICATIONS 4- 12 TIGHTENING TORQUE LIST 4- 12 SAFETY CRITICAL PARTS 4- 14 SAFETY CRITICAL PARTS LIST 4- 14 MAINTENANCE SCHEDULE 4- 15 MAINTENANCE SCHEDULE CHART 4- 15 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 17 MAINTENANCE PROCEDURE 4- 18...
Page 14 FOREWORD CONTENTS EVERY 10 HOURS MAINTENANCE 7- 16 EVERY 5000 HOURS MAINTENANCE 7- 17 SPECIFICATION 7- 19 COMBINATION OF WORK EQUIPMENT 7- 20 COMBINATION OF WORK EQUIPMENT 7- 20 INDEX 1 - 13...
Page 15 2 - 1...
Page 16 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION Safety Rules 2- 11 If Abnormalities are Found 2- 11 Working Wear and Personal Protective Items 2- 11 Fire Extinguisher and First Aid Kit 2- 11 Safety Equipment 2- 11 Keep Machine Clean...
Page 17: Safety
SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION 2- 19 STARTING ENGINE 2- 19 Checks Before Starting Engine 2- 19 Safety Rules for Starting Engine 2- 19 Starting Engine in Cold Weather 2- 19 OPERATION 2- 21 Checks Before Operation 2- 21 Safety Rules for Changing Machine Directions 2- 21...
Page 18: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. 2 - 4...
Page 19: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2 - 5...
Page 20: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and (2) Precautions for before operation (09802-03000) maintenance (09651-03001) (3) Warning for leaving operator's seat (4) Warnings for high voltage (09801-03001) (09654-03001) 2 - 6...
Page 21 SAFETY SAFETY LABELS (5) Warnings when opening front window (6) Warnings when stowing front window (09839-03000) (09803-03000) (7) Precautions for high-temperature oil (8) Precautions for high-temperature coolant (09653-03001) (09668-03001) 2 - 7...
Page 22 SAFETY SAFETY LABELS (9) Precautions when handling accumulator (10) Precautions when adjusting track tension (09659-53000) (09657-03003) (11) Precautions when handling cable (09808-03000) (12) Stop rotation when performing testing and adjusting (09667-03001) 2 - 8...
Page 23 SAFETY SAFETY LABELS (13) Explanation of methods for emergency escape (14) Roll-over precautions (09805-23000) (20Y-00-22880) (15) Roll-over precautions (09805-13000) (16) Prohibited to enter within swing range (09133-23000) 2 - 9...
Page 24 SAFETY SAFETY LABELS (17) Warning for battery (09664-30082) (18) Precautions for high voltage (6217-81-9260) (19) Precautions for high voltage (7872-10-1600) 2 - 10...
Page 25: Safety Information
SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. 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 26: Keep Machine Clean
SAFETY SAFETY INFORMATION KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.
Page 27: Handrails And Steps
SAFETY SAFETY INFORMATION HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe)
Page 28: Burn Prevention
SAFETY SAFETY INFORMATION BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 29: Action If Fire Occurs
The above recommendations assume that the conditions are for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice. 2 - 15...
Page 30: Attachment Installation
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 31: Distance To High Voltage Cables
SAFETY SAFETY INFORMATION When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.
Page 32: Ventilation For Enclosed Area
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 18...
Page 33: 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. Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails and steps.
Page 34 SAFETY SAFETY MACHINE OPERATION If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery. Before charging or starting the engine with a different power source, melt the battery electrolyte and check for frost and leakage of battery electrolyte before starting.
Page 35: 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. 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 36: Safety Rules For Traveling
SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply. When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.
Page 37: Operations On Slopes
SAFETY SAFETY MACHINE OPERATION When travel up slopes, set the operator's cab facing uphill, when travel down slopes, set the operator's cab facing downhill. Always check the firmness of the ground under the front of the machine when traveling. When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30cm (8 to 12 in) above the ground, and travel at low speed.
Page 38: Prohibited Operations
SAFETY SAFETY MACHINE OPERATION PROHIBITED OPERATIONS Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine. Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
Page 39: Operations On Snow
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When carrying out demolition work, do not carry out demolition above your head. There is a hazard of broken parts falling or of the building collapsing and causing serious injury or property damage.
Page 40: Parking Machine
SAFETY SAFETY MACHINE OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. When leaving the machine, set safety lock lever (1) to the LOCK position, then stop the engine.
Page 41: Transportation
SAFETY MACHINE OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 42: Battery
SAFETY SAFETY MACHINE OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 43: Starting Engine With Booster Cables
SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 44: Towing
SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-116)". Always wear leather gloves when handling wire rope.
Page 45: Lifting Objects With Bucket
SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable. Use wire rope that conforms to the specified standard. Do not exceed the specified lifting load.
Page 46: Safety Maintenance Information
SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 47: Stop Engine Before Carrying Out Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. Place the work equipment control lever to the neutral position, set safety lock lever (1) to the LOCK position, then stop the engine.
Page 48: Two Workers For Maintenance When Engine Is Running
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. 2 - 34...
Page 49: Personnel
SAFETY SAFETY MAINTENANCE INFORMATION PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall.
Page 50: Welding Works
If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. 2 - 36...
Page 51: Safety Rules For High-Pressure Oil
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 52: Waste Materials
SAFETY SAFETY MAINTENANCE INFORMATION WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials. Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes.
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Page 54: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW (1) Bucket (7) Boom cylinder (2) Bucket link (8) Sprocket (3) Bucket cylinder (9) Track frame (4) Arm (10) Track shoe (5) Arm cylinder (11) Idler (6) Boom (12) Overhead guard 3 - 2...
Page 55: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES (1) Left work equipment control lever (21) Heavy lift switch (2) Safety lock lever (22) Working mode selector switch (3) Travel lever (23) Hydraulic oil level monitor (4) Travel pedal (24) Engine oil pressure monitor (5) Machine monitor (25) Radiator water level monitor (6) Horn switch...
Page 56: 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 perform suitable operations correctly and safely, it is important to completely understand the methods of operating equipment and meanings of the displays. MONITORING SYSTEM A:Basic check Items D:Meter Display Portion...
Page 57 OPERATION DETAILED CONTROLS AND GAUGES B. Caution items (See Caution Monitors (PAGE 3-8)) CAUTION If these monitor items flash, check and repair the appropriate location as soon as possible. These are items which need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired as soon as possible are displayed.
Page 58 OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors DO NOT ensure that the machine is in good condition. When performing checks before starting (daily checks), do not simply rely on the monitors. Always dismount the machine and check each item directly. This displays the basic items that should be checked before starting the engine.
Page 59 OPERATION DETAILED CONTROLS AND GAUGES Engine Oil Level Monitor This warns monitor A(2) that the oil level in the engine oil pan is too low. If the monitor lamp flashes, check the oil level in the engine oil pan, and add oil. Hydraulic Oil Level Monitor This warns monitor A(3) that the hydraulic oil level is too low.
Page 60 OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor flashes, check the problem point as soon as possible and carry out maintenance. Failure to repair the problem will lead to failure of the machine. These are items which need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired as soon as possible are displayed.
Page 61 OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor This monitor B(2) warns the amount of fuel in the fuel tank. This lamp flashes if the level of the remaining fuel goes down to approximately 55 liters (14.5 US gal), so add fuel soon. Air Cleaner Clogging Monitor This monitor (3) warns that the air cleaner is clogged.
Page 62 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point immediately and repair the problem. These are items that should be watched when the engine is running. If any abnormality occurs, the monitor for the problem point lights up and the buzzer sounds.
Page 63 Stop the engine, then turn the starting switch to the ON position and check that the monitor lights up for 3 seconds. If it does not light up, please contact your Komatsu distributor to have the monitor inspected. 3 - 11...
Page 64 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion (1)Swing Lock Monitor (Pilot Display) (3)Fuel Gauge (Gauges and Meter) (2)Engine Coolant Temperature Gauge (Gauges and (4)Display (Gauges and Meter) Meter) (5)Service Meter (Gauges and Meter) Pilot Display When ignition switch is ON, the pilot display lights up when display items are functioning. Swing Lock Monitor This monitor (1) informs the operator that the swing lock is being actuated.
Page 65 OPERATION DETAILED CONTROLS AND GAUGES Gauges and Meter Engine Coolant Temperature Gauge This gauge (2) indicates the engine cooling water temperature. If the temperature is normal during operation, the green range will light up. If the red range lights up during operation, the overheat prevention system will be actuated.
Page 66 OPERATION DETAILED CONTROLS AND GAUGES Manual Setting 1. At the time display, keep time switch (B) pressed for at least 2.5 seconds. 2. Symbol (A) flashes. 3. If H switch (C) is pressed, the hour will advance, and if M switch (D) is pressed, the minute will advance.
Page 67 OPERATION DETAILED CONTROLS AND GAUGES REMARK If the machine has a fault, error information appears while the starting switch is ON. The monitor flashes and displays all error information sequentially. Monitor display Failure mode TVC system error Swing brake system error E1 0 E1 1 E1 2...
Page 68 OPERATION DETAILED CONTROLS AND GAUGES Switches (1)Working Mode Selection Switch (3)Travel Speed Switch (2)Auto-deceleration Switch (4)Heavy Lift Switch Working Mode Selection Switch This switch (1) is used to set the movement or power for the work equipment. By selecting the mode to match the working conditions, it is possible to carry out operations more easily. DH lights up:Powerful operation for short time during heavy-duty operations H lights up:Heavy-duty operations...
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Auto-deceleration Switch This switch (2) acts to activate the function that automatically lowers the engine speed and reduces fuel consumption when the control lever is at neutral. ON lights up:Auto-deceleration is actuated. OFF:Auto-deceleration is canceled. Each time the switch is pressed, the auto-deceleration is actuated or canceled.
Page 70: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES (1)Starting Switch (9)Machine Pushup Switch (2)Fuel Control Dial (with Auto-deceleration System) (10)Horn Switch (3)Cigarette Lighter (11)Knob Switch (4)Swing Lock Switch (12)Room Lamp Switch (5)Windshield Wiper Switch (13)Pump Drive Emergency Switch (6)Lamp Switch (14)Swing Holding Brake Release Switch (7)Alarm Buzzer Stop Switch (8)Cab Heater Switch 3 - 18...
Page 71 OPERATION DETAILED CONTROLS AND GAUGES Starting Switch This switch (1) is used to start or stop the engine. OFF position The key can be inserted or withdrawn. The switches for the electric system are all turned off and the engine is stopped. ON position Electric current flows in the charging and lamp circuits.
Page 72 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Switch WARNING When the machine is traveling under its own power, or when the swing is not being operated, always set the switch to the ON (ACTUATED) position. On a slope, the work equipment may swing to the down side even if the swing lock switch is located at the ON position. Be careful concerning this point.
Page 73 OPERATION DETAILED CONTROLS AND GAUGES Alarm Buzzer Stop Switch This switch (7) is used to stop the alarm buzzer if it sounds to warn of an abnormality during operation. Cab Heater Switch (If equipped) This switch (8) is used to turn on the heater in the operator's cab. The heater uses the hot water from the engine, so it can be used when the engine cooling water is hot.
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Horn Switch When the button (10) at the tip of the right work equipment control lever is pressed, the horn will sound. At the same time, the flashing light (if equipped) at the low front of the cab will flash for approx.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES 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. This switch (12) is used to light up the room lamp. ON position: Lights up OFF position: Goes out It will also light up even when the engine is not running.
Page 76: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS (1)Safety Lock Lever (4)Right Work Equipment Control Lever (2)Travel Levers (with Pedals) (with Auto-deceleration System) (3)Left Work Equipment Control Lever (with Auto-deceleration System) Safety Lock Lever WARNING When leaving the operator's cab, be sure to move the safety lock lever to the LOCK position.
Page 77 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES This lever (1) locks the controls for the work equipment, swing, travel, and optional attachments. Pull the lever up to apply the lock. This lock lever is a hydraulic lock, so even if it is in the lock position, the work equipment control lever and travel lever will move, but the work equipment, travel motor, and swing motor will not work.
Page 78 OPERATION DETAILED CONTROLS AND GAUGES Work Equipment Control Lever This left lever (3) is used to operate the arm and upper structure. Arm operation (A): Arm OUT (B): Arm IN Swing operation (C): Swing to right (D): Swing to left N (Neutral): When the lever in this position, the upper structure and the arm will be retained in the position in which they stop.
Page 79: Sun Roof
OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF WARNING When leaving the operator's seat, set the safety lock lever securely to the LOCK position. If the safety lock lever is at the FREE position and the control lever is touched by mistake, this may lead to a serious accident. The ceiling window cannot be opened on the rock crushing specification machine.
Page 80: Windshield
OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD WARNING When opening or closing the ceiling window, front window, bottom window, or door, always set the safety lock lever to the LOCK position. If the control levers are not locked and they are touched by accident, this may lead to a serious accident.
Page 81 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 6. From the inside of the operator's cab, hold the bottom grip with your left hand and hold the top grip with your right hand, pull up, push securely against automatic lock catch (C), fix in position, and insert the left and right lock pins (A) securely in the holes to lock in position.
Page 82 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Hold the grip at the bottom of the front window with your left hand and the grip at the top with your right hand, release the lock of catch (C) with your right thumb, then pull the top grip to the front and lower the front window slowly.
Page 83: Emergency Exit From Operator's Cab
OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY EXIT FROM OPERATOR'S CAB If for some reason, the cab door does not open, remove the rear window and use it as an emergency escape. Remove the rear window as follows. 1. Pull ring (1) and completely remove seal (2) from the rubber core.
Page 84: 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 (PAGE 3-98)". Insert the key as far as it will go to the shoulder. If the key is turned before it is inserted all the way, it may break.
Page 85: Hot And Cool Box
OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Covers with Lock Opening the Cover 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. Locking the Cover 1. Close the cover and insert the key into the key slot. 2.
Page 86: Ashtray
OPERATION DETAILED CONTROLS AND GAUGES ASHTRAY This is on the left side of the operator's seat. Always make sure that you extinguish the cigarette before closing the lid. 3 - 34...
Page 87: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel (1)Vent Selector Switch (3)Temperature Control Switch (Heating) (Air Flow to Upper Part of Body) (4)Air Flow Selector Switch (Low) (1)Vent Selector Switch (Air Flow to Foot) (4)Air Flow Selector Switch (Medium) (2)Air Circulation Selector Switch (4)Air Flow Selector Switch (High) (Internal Air Circulation)
Page 88 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch (Air Flow to Upper Part of Body) When this switch (1) is pressed, the air from the air conditioner blows out to the upper part of the body. This position is suitable for blowing out cold air in summer.
Page 89 OPERATION DETAILED CONTROLS AND GAUGES Air Circulation Selector Switch (Internal Air Circulation) When switch (2) is pressed, the air inside the cab is recirculated and no fresh air is taken in from outside. This position is used when heating or cooling the cab quickly or when the outside air is dirty. Air Circulation Selector Switch (External Air Circulation) When switch (2) is pressed, fresh air is taken into the cab during heating or cooling.
Page 90 OPERATION DETAILED CONTROLS AND GAUGES Temperature Control Switch (Heating) Use switch (3) to increase the temperature. Press this switch to increase the temperature of the air sent from the air conditioner. The higher the temperature becomes, the further the indicator moves into the red range.
Page 91 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch This switch (5) is used to switch the air conditioner ON/OFF. Off Switch This switch (6) is use to stop the fan. Defroster Selector Lever This switch (7) is used to clear the mist that forms on the front glass in winter or in the rainy season.
Page 92 OPERATION DETAILED CONTROLS AND GAUGES Use Air Conditioner with Care Ventilation If you smoke when the cooler is on, the smoke may start to hurt your eyes, so turn the lever to FRESH to remove the smoke while continuing the cooling. When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry out ventilation and cooling.
Page 93: Radio
OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel (1)Power Switch/Volume Control (SW-VOLUME) and (6)Preset Station Buttons (1, 2, 3, 4, 5, 6) Balance (Pull BAL) Knob (7)Display (2)Tone Control Knob (TONE) (8)Time Reset Button (3)FM/AM Selection Button (AM/FM) (9)Stereo Indicator (ST) (4)Display Selection Button (TIME) (5)Tuning Button (TUNING) Manual Tuning (MANUAL)
Page 94 OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) This equipment gives priority to the frequency display. When the frequency is displayed, press button (4) and the display will change for five seconds to display the time. After five seconds pass, it will return automatically to the frequency display.
Page 95 OPERATION DETAILED CONTROLS AND GAUGES Controls Of Radio Preset Station Buttons 1. Press power switch (1) and display the frequency on display (7). 2. Turn the tuning button (5) (manual, auto) to adjust to the desired frequency. 3. Select a preset button to use for recording the frequency setting, and keep that button pressed for at least 1.5 seconds.
Page 96 OPERATION DETAILED CONTROLS AND GAUGES Setting Correct Time 1. Press display selector button (4) to display the time. After 5 seconds, the display will return to the frequency display and the time cannot be corrected. If this happens, press display selector button (4) again. 2.
Page 97 OPERATION DETAILED CONTROLS AND GAUGES Installing Antenna on Machines without OPG 1. Install antenna (1) to stay (2), then tighten it together with the handrail at the top of the cab. 2. Connect the wiring to the connector at clips (3) at the right side of the cabin (4 places) and the top of the cab (2 places).
Page 98: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER NOTICE Do not use as a power supply for 12V equipment. This will cause failure of the equipment. It is possible to remove the cigarette lighter and use the socket as a power supply. Capacity of cigarette lighter: 85W (24V x 3.5A) FUSE NOTICE...
Page 99: Circuit Breaker
OPERATION DETAILED CONTROLS AND GAUGES CIRCUIT BREAKER NOTICE When resetting the circuit breaker, always turn the starting switch OFF first. If the starting switch does not work even when the starting switch is turned on, open the circuit breaker box inside the grease pump box at the front right of the machine and carry out inspection.
Page 100: Controllers
Never splash or spill water, mud or drink over the controllers as this may cause a fault. If a fault occurs in the controller, do not attempt repair, but consult your Komatsu distributor. Engine controller (1) and pump controller (2) are installed.
Page 101: 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 (4) is actuated and grease is sent under pressure to grease gun (2). 2.
Page 102 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). Set so that the nipple and the nozzle at the tip of the grease gun are perpendicular.
Page 103 OPERATION OPERATION DETAILED CONTROLS AND GAUGES 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 104: Accumulator
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 105: Machine Operations And Controls
Leakage of fuel or oil will cause fire on the machine. Check carefully, and if any abnormality is found, repair it immediately or contact your Komatsu distributor. Carry out the following inspections and cleaning every day before starting the engine for the day's work.
Page 106 Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new parts. 10. Check bucket with hook (if equipped) for damage. Check that there is no damage to the hook, guide, or hook mount. If any abnormality is found, please contact your Komatsu distributor for repair. 3 - 54...
Page 107 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 108 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation. 1.
Page 109 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 110 OPERATION MACHINE OPERATIONS AND CONTROLS Drain Water And Sediment from Fuel Tank 1. Carry out this procedure before operating the machine. 2. Prepare a container to catch the fuel that is drained. 3. Connect drain hose. 4. Open valve (1) at the bottom of the tank and drain the sediment and water that has accumulated at the bottom together with fuel.
Page 111 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 diagram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinders, then lower the boom, set the bucket teeth in contact with the ground, and stop...
Page 112 Turn the lamp switch to the ON position and check that the working lamp light up. If the lamps do not light up, there is probably a broken bulb or disconnection in the wiring, so contact your Komatsu distributor for repairs. Check Air Cleaner For clogging 1.
Page 113 Check Electric Wirings CAUTION If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Page 114 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the backrest.
Page 115 OPERATION MACHINE OPERATIONS AND CONTROLS Adjusting seat height It is possible to raise or lower the seat by combining the front tilt and rear tilt. Use the front (rear) tilt operation to set the seat to the desired height, then use the rear (front) tilt to make the seat horizontal.
Page 116 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors Loosen nut (1) and bolt (2) of each mirror and adjust the mirror angle at which you can see the reflected view most easily from the operator's seat. In particular, adjust the mirrors so that you can see persons on both left and right sides of the rear end of the machine.
Page 117 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end of the belt on either the buckle body or tongue side. Lengthening Pull the belt while holding it at a right angle to the buckle or tongue. Check the seat belt mounting bolts and re-tighten if necessary.
Page 118 If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or disconnection in the monitor wiring, so contact your Komatsu distributor for repairs. After approx. 3 sec, the following gauges will remain on and the other monitors will go out.
Page 119: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
Page 120 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 4. After starting the engine, do not touch the work equipment control lever or travel pedal while the engine oil pressure monitor lamp is lighted up. 3 - 68...
Page 121 OPERATION MACHINE OPERATIONS AND CONTROLS Starting Engine in Cold Weather When starting in low temperatures, do as follows. WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explosions. Exhaust gas is toxic.
Page 122 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. When preheating monitor (3) flashes, turn the key in starting switch (2) to the START position to start the engine. 4. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position.
Page 123: After Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS AFTER STARTING ENGINE WARNING Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. 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 124 Air cleaner clogging monitor (16): OUT Hydraulic oil temperature monitor (17): OUT Engine oil change monitor (set machine only)(18): OUT 7. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your Komatsu distributor. 3 - 72...
Page 125 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 8. Press working mode switch (2) on the monitor panel until the lamp for the working mode to be used lights up. 3 - 73...
Page 126 OPERATION MACHINE OPERATIONS AND CONTROLS In Cold Weather Areas (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30°C), the warming-up operation is carried out automatically.
Page 127 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Set fuel control dial (1) to the medium speed position. 4. Set safety lock lever (3) to the FREE position and raise the bucket from the ground. 5. Operate bucket control lever (4) and arm control lever (5) slowly to move the bucket cylinder and arm cylinder to the end of the stroke.
Page 128 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK If the above operation is not carried out, then may be a delay in response when starting or stopping the actuation of the travel, swing, or work equipment. 9. Use working mode switch (2) on the monitor panel to select the working mode to be used.
Page 129: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
Page 130: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION Preparations for Moving the Machine Off WARNING Before operating the steering levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed.
Page 131 Pull lever (5) back slowly or depress the front of pedal (6) slowly to move the machine off. 3. For machines equipped with a travel alarm (if equipped), check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repair. 3 - 79...
Page 132 Push lever (5) forward slowly or depress the front of pedal (6) slowly to move the machine off. 3. For machines equipped with a travel alarm (if equipped), check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repair. 3 - 80...
Page 133 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3 - 81...
Page 134: 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. Use the travel levers to change direction.
Page 135 OPERATION MACHINE OPERATIONS AND CONTROLS Steering when Traveling When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. REMARK When turning to the right,operate the right travel lever in the same way.
Page 136: 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 operating the swing, turn swing lock switch (1) OFF (CANCELED).
Page 137: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, so operate the levers carefully. The work equipment is operated by the left and right work equipment control levers.
Page 138: 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 the most commonly used general operation mode, so normal operations can be carried out without setting the mode.
Page 139: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
Page 140 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will bring excessive force to bear on the rear of the machine, and will not only damage the machine, but is also dangerous.
Page 141: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling When traveling over obstacles such as boulders or tree stumps, the machine (in particular, the undercarriage)is subjected to a large shock, so reduce the travel speed and travel over the obstacle at the center of the tracks.
Page 142: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.
Page 143 OPERATION MACHINE OPERATIONS AND CONTROLS Traveling Downhill Put the travel lever in the neutral position. This will cause the brake to be automatically applied. Engine Stopped on Slope If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket to the ground, stop the machine, then start the engine again.
Page 144: 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. If machine push-up switch (1) is turned ON, the pushing force of the boom is increased and it becomes easier to escape.
Page 145: 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 at a position lower than the machine.
Page 146: Bucket Replacement
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 147 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. Remove the stopper bolts and nuts, then remove pins (A) and (B), and remove the bucket. NOTICE After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, so be careful not to damage them.
Page 148: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid sudden stops. Leave as much room as possible when stopping. Park the machine on firm level ground. Avoid parking the machine on a slope. If the machine must be parked on a slope, put blocks under tracks and dig the work equipment into the ground to prevent the machine from moving.
Page 149: Check After Shut Off Engine
OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Set the work equipment in the posture shown in the diagram on the right. 4. Set safety lock lever (3) in the LOCK position. CHECK AFTER SHUT OFF ENGINE Check the engine water temperature, engine oil pressure, and fuel level on the machine monitor.
Page 150: 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 REMARK...
Page 151: 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 Never carry out the lifting operation with any person on the machine.
Page 152: Shipping Machine Information
OPERATION TRANSPORTATION SHIPPING MACHINE INFORMATION WARNING When loading the machine, choose firm level ground. Keep well away from the road shoulder. 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 153: 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 Four units for transportation 3 - 101...
Page 154 OPERATION TRANSPORTATION Posture for each unit Upper Structure + Undercarriage Unit PC600-6 PC600LC-6 Overall width mm (ft in) 3195 (10' 6'') 3195 (10' 6'') mm (ft in) 3345 (11') 3345 (11') mm (ft in) 6165 (20' 3'') 6340 (20' 10'')
Page 155 OPERATION TRANSPORTATION Work Equipment Boom Unit PC600-6 mm (ft in) 7920 (26') mm (ft in) 2040 (6' 8'') Overall width mm (ft in) 1190 (3' 11'') Weight kg (lb) 4820 (10630) Unit PC600-6 mm (ft in) 4870 (16') mm (ft in)
Page 156 OPERATION TRANSPORTATION Boom cylinder (same for all models) Unit PC600-6 mm (ft in) 2672 (8' 9'') 1040 (2290) Weight kg (lb) [520 x 2 (1145 x 2)] Arm cylinder Unit PC600-6 Number mm (ft in) 3108 (10' 2'') Weight kg (lb)
Page 157 OPERATION TRANSPORTATION Catwalk (1) (same for all models) Unit PC600-6 mm (ft in) 1430 (4' 8'') mm (ft in) 500 (1' 8'') 60 (132) Weight kg (lb) [30 X 2 pieces (66 X 2 pieces)] Catwalk (2) (same for all models)
Page 158: 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. Swing the upper structure so that it is at 90° on the side of track frame (A) to be retracted, then use the work equipment to jack up the track frame.
Page 159 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 160: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 161 OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 162: 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 163: Long Term Storage
If the ambient temperature is expected to drop below 0°C (32°F), always add antifreeze to the cooling water. Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water, so there is no need to change the density for temperatures down to -10°C (14°F).
Page 164: Starting Machine After Long-Term Storage
OPERATION LONG TERM STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE When starting the engine after the machine has been in storage for a long time, carry out the automatic warming-up operation. If the engine is started according to the starting procedure for cold weather, the warming-up operation is carried out automatically.
Page 165: 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 166 OPERATION OPERATION TROUBLES AND ACTIONS 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 167: Phenomena That Are Not Failures
OPERATION TROUBLES AND ACTIONS PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the 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 168: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope. If the machine sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram on the...
Page 169: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.
Page 170 OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-117)" and the instruction manual accompanying the charger, and do as follows. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line.
Page 171 OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows: Connecting and Disconnecting Booster Cables WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
Page 172 OPERATION TROUBLES AND ACTIONS Starting the Engine WARNING Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in the HOLD or neutral position. 1.
Page 173: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 174 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
Page 175 ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. If user codes [02] or [04] are displayed, stop the machine at a safe place, apply the safety lock lever, then check the service code and contact your Komatsu distributor.
Page 176 Air entering suction side of fuel line There is knocking Poor quality fuel being used (combustion or mechanical) Overheating Error code is displayed on monitor Alarm buzzer sounds Please contact your Komatsu distributor Engine suddenly loses power (entered delayed mode) 3 - 124...
Page 177 OPERATION TROUBLES AND ACTIONS Electronic Control System If an error code is displayed on the machine monitor display (normally this displays the time), follow the self-diagnostic remedy table below. Machine Monitoring System Monitor Failure mode Remedy display TVC valve system error If the emergency pump drive switch is moved up, it becomes possible to carry out normal operations, but have inspection carried out immediately.
Page 178 4 - 1...
Page 179: Maintenance
Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 180 MAINTENANCE MAINTENANCE INFORMATION Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil. Avoid Mixing Lubricants If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil.
Page 181: Lubricants, Coolant And Filters
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 182 Make sure that the oil is well mixed before sampling. Carry out sampling regularly at fixed intervals. Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. 4 - 5...
Page 183: Electric System Maintenance
Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor. When working at the seashore, carefully clean the electric system to prevent corrosion.
Page 184: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 185: Lubricants, Fuel And Coolant Specifications
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS PROPER SELECTION *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 186 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 187 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
Page 188 MAINTENANCE MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type...
Page 189: Tightening Torque Specifications
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 190 MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS Apply the following table for Hydraulic Hose. Thread Width Tightening torque diameter across Target value Permissible range flats N · m kgf · m N · m kgf · m lbft lbft a (mm) b (mm) 14.7 10.8 12.7 - 16.7...
Page 191: Safety Critical Parts
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. Check the hydraulic hoses and the fuel hose, too, when carrying out the following periodic inspections.
Page 192: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...
Page 193 MAINTENANCE MAINTENANCE SCHEDULE CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) 4- 58 CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER 4- 59 CHECK FAN BELT 4- 59 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 60 EVERY 1000 HOURS MAINTENANCE CHANGE OIL IN SWING MACHINERY CASE...
Page 194: 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 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 195: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working at high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
Page 196 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE Never remove the inner element. It will allow dirt to enter and cause failure of the engine. Do not use a screwdriver or other tool. 3. After removing the outer element, cover the air connector inside the air cleaner body with a clean cloth or tape to prevent dirt or dust from entering.
Page 197 MAINTENANCE MAINTENANCE PROCEDURE 3) Replace both inner and outer elements when the monitor (1) flashed soon after installing the cleaned outer element even though it has not been cleaned 6 times. 4) Check that the inner element is fitted securely. If there is any play, insert it properly. 7.
Page 198 MAINTENANCE MAINTENANCE PROCEDURE Install Air Cleaner Element NOTICE Do not use any damaged gasket or seal or element with damaged pleats. 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 199 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 200: Clean Inside Of Cooling System
MAINTENANCE MAINTENANCE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.
Page 201 Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 202: 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 784.5 ± 78.4 N·m (80 ± 8 kgf·m, 578.6 ± 57.9 lbft), then check that the nut and shoe are in tight contact with the link mating surface.
Page 203: Check And Adjust Track Tension
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION WARNING For details of starting the engine and operating the work equipment, see "BEFORE STARTING ENGINE (PAGE 3-53)", "STARTING ENGINE (PAGE 3-67)", "AFTER STARTING ENGINE (PAGE 3-71)", and "WORK EQUIPMENT CONTROLS AND OPERATIONS (PAGE 3-85)"...
Page 204 Do not loosen any part other than plug (1). Furthermore, do not bring your face in front of the plug (1). If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Increasing Track Tension Prepare a grease gun.
Page 205: Replace Bucket Teeth (Horizontal Pin Type)
(2). REMARK If it cannot be removed by this method, for safety reasons, always contact your Komatsu distributor to have the replacement carried out. 3. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket.
Page 206: 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 safety lock lever (1) securely to the LOCK position. If there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.
Page 207: 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 208: 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. Do not touch the refrigerant.
Page 209: Clean Line Filter, Remove Dirt
MAINTENANCE MAINTENANCE PROCEDURE CLEAN LINE FILTER, REMOVE DIRT If there is any abnormality in the pump or other hydraulic equipment, remove the dirt from inside the line filter as follows. Before removing the line filter, release the pressure inside the hydraulic circuit. For details, see "METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT (PAGE 4-37)".
Page 210: Replace Breaker Circuit Additional Oil Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT (If equipped) WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation. Prepare a container to catch the oil.
Page 211: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-67)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. NOTICE Bleed the air as follows.
Page 212 MAINTENANCE MAINTENANCE PROCEDURE 2. Starting engine Start the engine. For details, see "STARTING ENGINE (PAGE 3-67)". Run the engine for 10 minutes at low idling, then go on to the next operation. 3. Bleeding air from cylinders 1) 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.
Page 213 MAINTENANCE MAINTENANCE PROCEDURE 6. Bleeding air from travel motor circuit If the piping has been removed from the travel motor circuit, bleed the air after reassembling. To bleed the air, run the engine at low idling and do as follows. 1) Start the engine and run at low idling.
Page 214: Method For Releasing Internal Pressure In Hydraulic Circuit
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting.
Page 215: Check Nitrogen Gas Charge Pressure In Accumulator (Control Circuit)
2. Stop the engine and carry out the LOWER operation for the boom. 3. Check that the tip of the bucket drops at least 1m. If the tip of the bucket drops less than 1m, the charge pressure inside the accumulator is low, so please contact your Komatsu distributor. 4 - 38...
Page 216: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-55)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check Fuel Level, Add Fuel Drain Water and Sediment From Fuel Tank Check oil level in hydraulic tank, add oil Check working lamp switch...
Page 217: 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 218 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (2)Boom foot pin (2 places) (3)Boom cylinder rod end pin (2 places) (4)Arm cylinder foot pin (1 place) (5)Boom-Arm coupling pin (1 place) (6)Bucket cylinder foot pin (1 place) (7)Arm cylinder rod pin (1 place) (8)Arm-Link coupling pin (1 place) (9)Arm-Bucket coupling pin (1 place) 4 - 41...
Page 219 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (10)Link coupling pin (2 places) (11)Bucket cylinder rod pin (1 place) (12)Bucket-Link coupling pin (1 place) 4 - 42...
Page 220: 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. Swing Machinery Case Oil - Check/Add WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation.
Page 221: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 222: Check Level Of Battery Electrolyte
MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this check before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion. The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks near the battery.
Page 223 U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When it is Impossible to Check Electrolyte Level from Side of Battery If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows.
Page 224: Lubricate Swing Circle
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. When it is Possible to Use Indicator to Check Electrolyte Level If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 225: Check Oil Level In P.t.o Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN P.T.O CASE, ADD OIL WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. NOTICE When checking the oil level, stop the machine on level ground, stop the engine, then wait for at least 30 minutes before checking.
Page 226: Check Alternator Drive Belt Tension, Adjust
MAINTENANCE MAINTENANCE PROCEDURE CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST Checking The standard deflection for the drive belt is 13 - 16 mm (0.51 - 0.63 in) when pressed with a thumb [at approx. 98.1 N (approx. 10 kgf)] at a point midway between the drive pulley and alternator pulley. Adjustment 1.
Page 227: 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 approx. 10 mm (0.4 in) when pressed with a thumb [at approx.98.1 N (approx. 10 kgf)] at a point midway between the drive pulley and air conditioner compressor pulley.
Page 228: Check, Clean Fuel Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE CHECK, CLEAN FUEL TANK STRAINER Remove cap (1) from the strainer case at the bottom of the fuel tank, take out the strainer, then wash the strainer and strainer case. 4 - 51...
Page 229: Every 500 Hours Maintenance
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 230: Check Swing Pinion Grease Level, Add Grease
MAINTENANCE MAINTENANCE PROCEDURE CHECK SWING PINION GREASE LEVEL, ADD GREASE 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.33 mm (1.3 in).
Page 231: Replace Breather Filter Element In Hydraulic Tank
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREATHER FILTER ELEMENT IN HYDRAULIC TANK WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. When removing the cap from oil filler port (F), turn it slowly to release the internal pressure, then remove it carefully.
Page 232: Clean Hydraulic Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. When the cap of the oil filler port is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
Page 233: Replace Hydraulic Oil Filter Element
(4). If there are metal particles or foreign material inside strainer (5), please contact your Komatsu distributor. 4. Clean the removed parts in diesel oil. 5. Install the new element in the place where old element (4) was installed.
Page 234: (Machines Equipped With Air Conditioner)
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS 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 235: Clean Fresh/Recirc Air Filters Of 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 236: Clean Strainer Of P.t.o Lubricating Oil Filter
MAINTENANCE MAINTENANCE PROCEDURE CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Page 237: 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 Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation. Oil pan refill capacity: 37 liters (9.8 US gal) Filter wrench 1.
Page 238 MAINTENANCE MAINTENANCE PROCEDURE 4. Clean the filter holder, fill the new filter cartridge with clean engine oil, coat the thread and packing surface of the new filter cartridge with clean engine oil (or coat it thinly with grease), then install it to the filter holder. REMARK Check that there is no old packing affixed to the filter holder.
Page 239: 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. CHANGE OIL IN SWING MACHINERY CASE WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation.
Page 240: Change Oil In P.t.o Case
If excess oil is supplied, drain it to the specified amount to avoid overheating. CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions of the turbocharger checked. CHECK PLAY TURBOCHARGER ROTOR Contact your Komatsu distributor to have the rotor play checked.
Page 241: Replace Corrosion Resistor Cartridge
4. Clean the filter holder, coat the seal surface of the new cartridge thinly with engine oil, then install the cartridge. Always use a genuine Komatsu part for the cartridge. 5. When installing the cartridge, bring the packing surface into contact with the seal surface of the filter holder, then tighten a further 2/3 times.
Page 242 MAINTENANCE MAINTENANCE PROCEDURE Revolving frame Center frame 4 - 65...
Page 243: Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)
MAINTENANCE MAINTENANCE PROCEDURE Boom 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 - 66...
Page 244: Every 2000 Hours Maintenance
CHECK INJECTOR Check the color of the exhaust gas visually. If there is any abnormality in the exhaust gas color, contact your Komatsu distributor for inspection. For details, see "TROUBLES AND ACTIONS (PAGE 3-113)" "Exhaust color is black". 4 - 67...
Page 245: Clean Engine Breather
Contact your Komatsu distributor for cleaning and inspection. CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn,or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. When the engine is frequently started, ask for inspection every 1000 hours or every 6 months, whichever comes sooner.
Page 246: Every 4000 Hours Maintenence
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. CHECK VIBRATION DAMPER There may be leakage from the damper, dents, or face runout, so please contact your Komatsu distributor for replacement. CHECK FAN PULLEY AND TENSION PULLEY Inspect the pulley for play and grease leakage.
Page 247: 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. In such a case, please contact your Komatsu distributor. NOTICE If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure piping.
Page 248: Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
If there is any problem, the problem part must be replaced. In such a case, please contact your Komatsu distributor.
Page 249: 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, CLEAN STRAINER WARNING 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 250 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Set the container to catch the oil under the drain plug at the bottom of the chassis. Remove drain plug (P1), then loosen plug (P2) and drain the oil. After draining the oil, tighten drain plugs (P1) and (P2).
Page 251: 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. 4 - 74...
Page 252 5 - 1...
Page 253: Specifications
(lb) 56,680 (124,980) 57,680 (127,185) (with operator) Bucket capacity (cu.yd) 2.7 (3.5) 2.7 (3.5) – Engine model Komatsu SA6D140E diesel engine Flywheel horsepower kW(HP)/rpm 287 (385)/1,800 390/1,800 Overall length mm (ft in) 12,810 (42') 12,810 (42') Overall height mm (ft in)
Page 254 SPECIFICATIONS SPECIFICATIONS PC600-6 PC600LC-6 Working range Unit PC600-6 PC600LC-6 Maximum digging radius mm (ft in) 13,020 (42' 9'') 13,020 (42' 9'') Maximum digging depth mm (ft in) 8,490 (27' 10'') 8,490 (27' 10'') Maximum digging height mm (ft in) 11,880 (39')
Page 255 6 - 1...
Page 256: Attachments And Options
There may also be problems of the attachment or option hitting the operator's cab. Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu. READ THE INSTRUCTION MANUAL THOROUGHLY Before installing or using any attachment or option, make sure that you thoroughly read and understand the instruction manuals for the machine and the attachment or option.
Page 257: Bucket With Hook
Loads suspended must not exceed the limit indicated in the "LIFTING CAPACITY TABLE" stuck on the right-side lower portion of the operator's seat. If you are planning to newly install a hook, contact your Komatsu distributor. 6 - 3...
Page 258: Attachment Guide
WARNING Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.
Page 259: 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. PC600-6, PC600LC-6 Unit Specifications Category...
Page 260 7 - 1...
Page 261: Loading Shovel
LOADING SHOVEL EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS SWITCHES (1)Starting Switch (7)Alarm Buzzer Stop Switch (2)Fuel Control Dial (with Auto-deceleration System) (8)Cab Heater Switch (3)Cigarette Lighter (9)Machine Pushup Switch (4)Swing Lock Switch (10)Bottom Dump Switch (5)Windshield Wiper Switch (11)Horn Switch (6)Lamp Switch Starting switch Fuel control dial...
Page 262 LOADING SHOVEL EXPLANATION OF COMPONENTS Bottom dump switch This switch serves to open and close the front bucket. If the button at the tip of the left work equipment control lever is depressed, the bucket will close. If the button at the tip of the right work equipment control lever is depressed, the front bucket will open.
Page 263: Operations
LOADING SHOVEL OPERATIONS OPERATIONS OPERATION OF WORK EQUIPMENT WARNING If the lever is operated in the deceleration range, the engine speed will suddenly rise. Operate the levers carefully. If the work equipment control levers are operated quickly, the engine speed will suddenly rise. Operate the levers carefully. The work equipment is operated with the left work equipment control lever and right work equipment control lever.
Page 264 LOADING SHOVEL LOADING SHOVEL OPERATIONS OPERATIONS Boom operation Bucket operation Bottom dump operation 7 - 5...
Page 265: Precautions During Operation
LOADING SHOVEL OPERATIONS PRECAUTIONS DURING OPERATION WARNING When the arm is pushed out to the front, the speed may suddenly become slower when the arm is close to the perpendicular position. It is prohibited to use the swing force for operations. Do not use the swing force to compact soil or break earth mounds or walls.
Page 266 LOADING SHOVEL OPERATIONS Do not carry out operations with the hydraulic cylinder at the end of its stroke. Precautions when operating hydraulic cylinders to end of stroke If the cylinder is operated to the end of its stroke during operations, force will be brought to bear on the stopper inside the cylinder, and this will reduce the life of the machine.
Page 267 LOADING SHOVEL OPERATIONS It is prohibited to grip rocks. Do not use the bottom dump bucket to grip rocks. It is prohibited to use the bucket for leaving operations. Using the rear bucket to carry out leveling operations will bring an excessive force to bear on the work equipment, so do not use the rear bucket in this way.
Page 268 LOADING SHOVEL OPERATIONS Scraping-down operations are prohibited. Never use the front bucket of a bottom-dump bucket to scrap down rocks or soil. Digging rocky ground It is better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce damage to the machine but make for better economy.
Page 269: Excavator Work
LOADING SHOVEL OPERATIONS EXCAVATOR WORK In addition to the following, it is possible to further increase the range of applications by using various attachments. Shovel work This is suitable for digging a place which is higher than the machine's position. It is most efficient if the arm s digging angle is from vertical to 60i forward, and the arm cylinder is used effectively.
Page 270: Precautions When Disassembling Machine
LOADING SHOVEL PRECAUTIONS WHEN DISASSEMBLING MACHINE PRECAUTIONS WHEN DISASSEMBLING MACHINE RELEASING PRESSURE When disassembling the machine or removing the piping during inspection or maintenance, always release the pressure as follows. Releasing pressure from work equipment circuit, swing circuit, travel circuit WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting.
Page 271: Transportation
LOADING SHOVEL TRANSPORTATION TRANSPORTATION The machine can be disassembled into the machinery, operator's cab, platform, attachment, and counterweight, and transported in pieces. Please contact your Komatsu distributor when transporting the machine. MACHINE CONFIGURATION FOR TRANSPORT PC600-6 LOADING SHOVEL Undercarriage Item Unit...
Page 272: Wear Parts
Replacing wear parts correctly ensures more economical use of the machine. When replacing parts, always use high-quality Komatsu genuine parts. When ordering parts, the parts differ according to the serial number of the machine, so please inform your Komatsu distributor of the machine serial number.
Page 273: Maintenance
LOADING SHOVEL MAINTENANCE MAINTENANCE CHECK BEFORE STARTING 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.
Page 274 LOADING SHOVEL MAINTENANCE 4. If the level is below the L mark, add oil through oil filler (F). 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°F)) Normal operation: around H level (Oil temperature 50 to 80°C (122 to 176°F))
Page 275 LOADING SHOVEL MAINTENANCE EVERY 10 HOURS MAINTENANCE LUBRICATTING 1. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 276 LOADING SHOVEL MAINTENANCE 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, CLEAN STRAINER WARNING 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 277 LOADING SHOVEL LOADING SHOVEL MAINTENANCE MAINTENANCE 5. 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. 6. After draining the oil, tighten drain plug (3) and install cover (2). When loosening drain plugs (P2) and (3), be careful not to get oil on yourself.
Page 278 LOADING SHOVEL SPECIFICATION SPECIFICATION PC600-6 LOADING SHOVEL PC600-6 LOADING SHOVEL Item Unit Without bucket link Operating weight (including 1 operator, 80 kg) kg (lb) 59,180 (130,492) Bucket capacity (cu.yd) 4.0 (5.2) Name of engine Komatsu SA6D140 diesel engine Engine horsepower...
Page 279 LOADING SHOVEL COMBINATION OF WORK EQUIPMENT COMBINATION OF WORK EQUIPMENT WARNING Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
Page 280 LOADING SHOVEL COMBINATION OF WORK EQUIPMENT Working Range Diagram PC600-6 LOADING SHOVEL PC600-6 LOADING SHOVEL Working ranges Unit Without bucket link A Max. digging radius mm (ft in) 9,190 (30' 2") B Max. digging reach at ground level mm (ft in) 8,850 (29' 0")
Page 281 INDEX INDEX <A> <F> Accumulator 3- 52 Forword Air Conditioner Controls 3- 35 Fuse 3- 46 Ashtray 3- 34 Attachment Guide <G> Combinations of Work Equipment General Operation Information 3- 89 Track Shoes Selection General Precautions For Safety Auxiliary Electric Power 3- 46 Precautions When Removing Or Installing...
Page 282 INDEX Every 5000 hours 7- 17 Lifting Objects with Bucket 2- 31 Maintenance Information Operation 2- 21 Maintenance Procedure 4- 18 Starting Engine 2- 19 Check Before Starting 4- 39 Towing 2- 30 Every 10 hours 4- 40 Transportation 2- 27 Every 100 hours 4- 43 Safety Maintenance Information...

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