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Galeo PC78MR-6 Operation & Maintenance Manual

Hydraulic excavator
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Operation & Maintenance
Manual
PC78MR
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
April 2005
PC78MR-6
Copyright 2005 Komatsu
Printed in U.S.A.
Komatsu America Corp.
TEN00074-00
-6
1507
and up

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  • Page 1 TEN00074-00 Operation & Maintenance Manual PC78MR HYDRAULIC EXCAVATOR PC78MR-6 1507 SERIAL NUMBERS and up This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp.
  • Page 2 1 - 1...
  • Page 3 FOREWORD FOREWORD FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
  • Page 4 FOREWORD FOREWORD 1 - 3...
  • Page 5 FOREWORD FOREWORD 1 - 4...

  • Page 6: Foreword

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
  • Page 7 FOREWORD SAFETY INFORMATION Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. Example of safety label using words Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous...

  • Page 8: Introduction

    FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "RECOMMENDED APPLICATIONS (PAGE 3-98)" for further details. DIRECTIONS OF MACHINE In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine.

  • Page 9: Product Information

    FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is on the left side of the swing bracket mount. The design of the nameplate differs according to the territory. ENGINE SERIAL NUMBER PLATE AND ITS LOCATION On the upper side of the engine cylinder head cover.

  • Page 10: Emission Control Information Label And Its Location

    FOREWORD PRODUCT INFORMATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION This is on the side face of the intake air mount bracket. EPA: Environmental Protection Agency, U.S.A. SERVICE METER LOCATION On top of the machine monitor 1 - 9...

  • Page 11: Your Machine Serial Numbers And Distributor

    FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 10...

  • Page 12: Table Of Contents

    FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NUMBER PLATE AND ITS LOCATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10 SAFETY SAFETY INFORMATION...
  • Page 13 FOREWORD CONTENTS TOOL BOX 3- 54 GREASE PUMP HOLDER 3- 54 ASHTRAY 3- 54 FIRE EXTINGUISHER 3- 55 MACHINE OPERATIONS AND CONTROLS 3- 56 BEFORE STARTING ENGINE 3- 56 STARTING ENGINE 3- 72 AFTER STARTING ENGINE 3- 77 STOPPING THE ENGINE 3- 80 CHECK AFTER SHUT OFF ENGINE 3- 80...
  • Page 14 FOREWORD CONTENTS ELECTRIC SYSTEM MAINTENANCE WEAR PARTS WEAR PARTS LIST RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 TIGHTENING TORQUE SPECIFICATIONS 4- 12 TIGHTENING TORQUE LIST...
  • Page 16 2 - 1...
  • Page 17 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION Safety rules 2- 13 If problems are found 2- 13 Working wear and personal protective items 2- 13 Fire extinguisher and first aid kit 2- 13 Safety equipment 2- 13 Keep machine clean...

  • Page 18: Safety

    SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION 2- 21 STARTING ENGINE 2- 21 Checks before starting engine 2- 21 Safety rules for starting engine 2- 22 Starting engine in cold weather 2- 22 OPERATION 2- 23 Checks before operation 2- 23 Safety rules for changing machine directions 2- 23 Safety rules for traveling...

  • Page 19: Safety Labels

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

  • Page 20: Location Of Safety Labels

    SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2 - 5...

  • Page 21: Safety Labels

    SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution before operating (09802-03000) (3) Warning for leaving operator's seat (09654-03001) 2 - 6...
  • Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Warnings for high voltage (09801-03001) (5) Caution for operating pattern (09822-03000) Standard machine 2 - 7...
  • Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (6) Caution for operating pattern (if equipped) Machine equipped with operating pattern selector valve (09822-03010) (7) Caution when opening or closing front window (09839-03000) (8) Caution when stowing front window (09803-03000) 2 - 8...
  • Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (9) Caution when window comes out, breaks (20U-98-21910) (10) Caution when switching operating pattern (22M-98-11181) Machine equipped with operating pattern selector valve (if equipped) (11) Caution with high-temperature coolant (14X-98-11531) 2 - 9...
  • Page 25 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Caution with high-temperature hydraulic oil (09653-03001) (13) Caution with high-temperature parts (09817-A0753) (14) Caution when adjusting track tension (09657-03003) 2 - 10...
  • Page 26 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (15) Caution when handling cable (09808-03000) (16) Stop rotation during inspection and maintenance (09667-03001) (17) Prohibition to enter swing range (09133-23000) (18) Caution when handling battery (09664-30082) (19) Jump start prohibited (09842-A0481) 2 - 11...
  • Page 27 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (20) Do not remove an additional weight (21W-98-48170) The safety labels, (1) through (5) and (7), are a single seal. In replacement, place an order for it with Part No. 22U-00-21290. 2 - 12...

  • Page 28: 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 29: 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 30: 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 31: 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 32: Action If Fire Occurs

    SAFETY SAFETY INFORMATION Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always keep electric wiring connections clean and securely tightened. Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.

  • Page 33: Attachment Installation

    SAFETY SAFETY INFORMATION ATTACHMENT INSTALLATION When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact your Komatsu distributor for advice. Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.

  • Page 34: Working On Loose Ground

    SAFETY SAFETY INFORMATION WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.

  • Page 35: Ventilation For Enclosed Area

    SAFETY SAFETY INFORMATION VENTILATION FOR ENCLOSED AREA Exhaust fumes from the engine can kill. If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

  • Page 36: Safety Machine Operation

    SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers . CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.

  • Page 37: Safety Rules For Starting Engine

    SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR STARTING ENGINE Start and operate the machine only while seated. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. When starting the engine, sound the horn as a warning.

  • Page 38: Operation

    SAFETY SAFETY MACHINE OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check that the movement of the machine matches the display on the control pattern card.

  • Page 39: 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 level ground, keep the work equipment at a height of 40 to 50 cm (16 to 20 in) from the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.

  • Page 40: Traveling On Slopes

    SAFETY SAFETY MACHINE OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine.

  • Page 41: Operations On Slopes

    SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SLOPES When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.

  • Page 42: Operations On Snow

    SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION Do not carry out demolition work under the machine. There is a hazard that the machine may become unstable and tip over. When working on or from the top of buildings or other structures, check the strength and the structure before starting operations.

  • Page 43: 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 lock lever (1) to the LOCK position, then stop the engine.

  • Page 44: Transportation

    SAFETY SAFETY MACHINE OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.

  • Page 45: 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 46: 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 47: 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 3-128)". Always be sure to check carefully that the capacity of the wire rope used for towing is ample for the weight of the towed machine.

  • Page 48: 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 49: 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 50: Two Workers For Maintenance When Engine Is Running

    SAFETY SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION Set lock lever (1) to the LOCK position. Put blocks under the track to prevent the machine from moving. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running.

  • Page 51: Proper Tools

    SAFETY SAFETY MAINTENANCE INFORMATION PROPER TOOLS Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury. ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas.

  • Page 52: Work Under The Machine

    SAFETY SAFETY MAINTENANCE INFORMATION WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.

  • Page 53: Safety First When Using High-Pressure Grease To Adjust Track Tension

    SAFETY SAFETY MAINTENANCE INFORMATION SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment system under high pressure. If the specified procedure for maintenance is not followed when making adjustment, grease drain plug (1) may fly out and cause serious injury or property damage.

  • Page 54: Waste Materials

    SAFETY SAFETY MAINTENANCE INFORMATION Replace the hose if any of the following problems are found. Damaged or leaking hydraulic fitting. Frayed or cut covering or exposed reinforcement wire layer. Covering swollen in places. Twisted or crushed movable portion. Foreign material embedded in covering. WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials.
  • Page 56 3 - 1...

  • Page 57: Machine View Illustrations

    OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Working lamp Bucket cylinder Sprocket (10) Track frame Arm cylinder (11) Track shoe Boom (12) Idler Boom cylinder (13) Blade cylinder Additional lamp (if equipped) (14) Blade 3 - 2...

  • Page 58: Controls And Gauges

    OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Car radio (20) Lamp switch Air conditioner control panel (21) Alarm buzzer stop switch Lock lever (22) Pump drive emergency switch Left work equipment control lever (23) Emergency boom swing operation/brake cancel Swift deceleration switch switch (24) Travel speed selector switch...

  • Page 59: Detailed Controls And Gauges

    OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM Caution monitors Meter display portion...
  • 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 when the engine is running. If any abnormality occurs, the item needing immediate repair is display.
  • Page 61 OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor This monitor (2) warns against the reduced fuel level in the fuel tank. When the remaining fuel reaches 30 liters (7.93 US gal) level, the fuel level monitor begins to flash. Then refill fuel without delay. 3 - 6...
  • Page 62 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor flashes, stop the engine immediately or run at low idle, then inspect the problem point immediately and repair the problem. These are items which need to be observed when the engine is running. If there is any problem, the abnormal location on the monitor will lights up and the buzzer will sound.
  • Page 63 OPERATION DETAILED CONTROLS AND GAUGES Engine Oil Pressure Monitor If the engine lubricating pressure is below the normal value, this monitor (2) flashes. If it flashes, stop the engine, and check the oil level in the oil pan and lubricating system. REMARK This lamp will light up if the starting switch is turned ON when the engine is stopped, but this does not indicate any problem.
  • Page 64 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Pilot display Gauges and meter Engine pre-heating monitor Engine coolant temperature gauge Swift deceleration monitor Fuel gauge Display Service meter Pilot Display When starting switch is ON, the pilot display lights up when display items are functioning. Engine Pre-heating Monitor This monitor (1) indicates the pre-heating time required when starting the engine at an ambient temperature below 0°C (32°F).
  • Page 65 OPERATION DETAILED CONTROLS AND GAUGES Swift Deceleration Monitor This monitor (2) informs the operator that the swift deceleration function is being actuated. Actuated: Lights up Canceled: Goes off When the swift deceleration switch is pressed, the swift deceleration display monitor lights up. When it is pressed again, the monitor goes off.
  • Page 66 OPERATION DETAILED CONTROLS AND GAUGES Display This monitor (5) serves to display failure contents, if any problem occurs on the machine. REMARK If the machine has a problem, error information appears while the starting switch is ON. The monitor flashes and displays all error information sequentially.
  • Page 67 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion Working mode selector switch Wiper switch Travel speed selector switch Window washer switch Working Mode Selector Switch This switch (1) is used to set the power and movement of the work equipment. Operations can be carried out more easily by selecting the mode to match the type of operation.
  • Page 68 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch WARNING When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the loading or unloading operation. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.

  • Page 69: Switches

    OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch Pump drive emergency switch Fuel control dial Emergency boom swing operation/brake cancel Swift deceleration switch switch Horn switch Room lamp switch Lamp switch (10) Cigarette lighter Alarm buzzer stop switch Starting Switch Starting switch (1) is used to start or stop the engine.
  • Page 70 OPERATION DETAILED CONTROLS AND GAUGES REMARK The engine does not start, if the lock lever is not in the LOCK position. Make sure first that the lock lever is in the LOCK position, and then turn the engine starting switch. Fuel Control Dial This dial (2) is used to control engine speed and output.
  • Page 71 OPERATION DETAILED CONTROLS AND GAUGES REMARK When fuel control dial is at the low idling position, the engine speed will not go down any lower even if this switch is pressed. If the engine speed does not rise, it is possible that this switch is ON. Lock at the swift deceleration monitor to check the condition of the switch.
  • Page 72 OPERATION DETAILED CONTROLS AND GAUGES Emergency Pump Drive Switch NOTICE This switch is installed to make it possible to carry out operation temporarily if any abnormality should occur in the pump control system. It is not intended for permanent use. Repair the cause of the abnormality immediately. If this switch is depressed and moved to the EMERGENCY position by mistake, thereby engaging the machine in the work, while the machine is in normal condition, an "E02"...
  • Page 73 OPERATION DETAILED CONTROLS AND GAUGES Room Lamp Switch NOTICE Be sure to switch the lamp to the OFF position after use. If the switch is left at the ON position, the battery will run down. This switch (9) is used to light up the room lamp. ON position: Lights up OFF position: Goes off REMARK...

  • Page 74: Control Levers And Pedals

    OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Swing lock cover Left work equipment control lever Boom swing control pedal Right work equipment control lever Attachment control pedal Blade control lever Traveling accelerator pedal Travel levers (with pedals) Lock Lever WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position.
  • Page 75 OPERATION DETAILED CONTROLS AND GAUGES Work Equipment Control Lever WARNING The operating pattern is set to the standard operating pattern (ISO pattern). When changing the operating pattern, please contact your Komatsu distributor. The method of using operating patterns other than the ISO pattern is given in the ATTACHMENT AND OPTIONS section.
  • Page 76 OPERATION DETAILED CONTROLS AND GAUGES Blade Control Lever This lever (4) is used to control the blade. (a): LOWER (b): RAISE Travel Levers (with Pedals) WARNING Do not put your foot on the pedal unless the machine is traveling. If you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident.
  • Page 77 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Cover WARNING When boom swing operation is not required, lock the boom with the swing lock cover. If the operation pedal is accidentally pressed while it is not lock, a serious accident or injury. This pedal (6) is used to lock the boom swing pedal.
  • Page 78 OPERATION DETAILED CONTROLS AND GAUGES Traveling Accelerator Pedal If the pedal (9) is depressed, the machine speed will increase. For details of the travel speed values, see "SPECIFICATIONS (PAGE 5-2)". REMARK The acceleration pedal works, when the travel speed shifting switch in the monitor panel is at low speed position (Lo lamp lights up).

  • Page 79: Sun Roof

    OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position. If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident. When opening or closing the roof hatch, carry out the operation on horizontal ground.

  • Page 80: Windshield

    OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD WARNING When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK position. If the 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 5. Hold lower knob (C) with your left hand from inside the operator's cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
  • Page 82 OPERATION DETAILED CONTROLS AND GAUGES Closing WARNING When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2.
  • Page 83 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. When the bottom of the window reaches the top of the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock. 6.
  • Page 84 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 1) Set the hollow in the glass at the front face, set the protruding part of grip (A) on the inside, and insert between the left switch lever box and magazine box on the inside left of the operator's cab.

  • Page 85: Sliding Door

    OPERATION DETAILED CONTROLS AND GAUGES SLIDING DOOR CAUTION Be sure to check that the sliding door is locked in position both when it is open and when it is closed. Always stop the machine on level ground when opening or closing the door.
  • Page 86 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES To escape from the operator's cab, use hammer (A) to break the glass and escape through the window. 3 - 31...

  • Page 87: 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 3-109)". Insert the key as far as it will go, then turn it. If the key is turned before it is inserted fully, it may break.

  • Page 88: Engine Hood

    OPERATION DETAILED CONTROLS AND GAUGES ENGINE HOOD WARNING Never attempt to climb on the engine hood. There is the danger that you may slip off. When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine hood open.

  • Page 89: Mud Cover

    OPERATION DETAILED CONTROLS AND GAUGES MUD COVER WARNING Never attempt to climb on the cover. There is the danger that you may slip off. When carrying out inspection and maintenance inside the cover, always use the cover support lever to hold the cover open. NOTICE Always keep the hood locked except when opening it.

  • Page 90: Battery Inspection Cover

    OPERATION DETAILED CONTROLS AND GAUGES BATTERY INSPECTION COVER NOTICE Always keep the door locked except when opening it. 1. Release lock (1) of door. (For details see "Opening and Closing Covers with Lock (PAGE 3-32)".) 2. Put a finger in hook (2) and pull cover (3) open. 3.

  • Page 91: Fuse

    OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. Replace the fuse with another of the same capacity.

  • Page 92: Fusible Link

    OPERATION DETAILED CONTROLS AND GAUGES FUSIBLE LINK If power is not supplied even after turning the engine starting switch ON, fusible link (1) is suspected of disconnection. In that case, open up the dust cover on the right side of the machine, check and replace it if necessary.

  • Page 93: Air Conditioner Controls

    OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel Vent selector switch Air conditioner switch Air circulation selector switch (external/internal) Off switch Temperature control switch Defroster selector lever Air flow selector switch Vent Selector Switch (Air Flow to Upper Part of Body) If this switch (1) is pressed, the air from the air conditioner is all directed to the face.
  • Page 94 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch (Air Flow to Upper Part of Body and Foot) If this switch (1) is pressed, the air from the air conditioner is directed to the face and feet. Vent Selector Switch (Air Flow to Foot) If switch (1) is pressed, the air from the air conditioner is all directed to the feet.
  • Page 95 OPERATION DETAILED CONTROLS AND GAUGES Air Circulation Selector Switch (External Air Circulation) When switch (2) is pressed, fresh air is taken into the cab during heating or cooling. This position is used to bring in clean fresh air into the cab or to remove the mist from the cab windows.
  • Page 96 OPERATION DETAILED CONTROLS AND GAUGES Temperature Control Switch (Heating) Use switch (3) to increase the temperature. Press this switch to increase the temperature of the air sent from the air conditioner. The more times the switch is pressed, higher the temperature becomes, as the indicator light moves to the "H".
  • Page 97 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch Switch (5) is used to switch the air conditioner functions ON/OFF. Off Switch Switch (6) is used to stop operation of the fan. Defroster Selector Lever Switch (7) is used to remove the mist from the front glass during cold or rainy weather.
  • Page 98 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Maintenance When carrying out inspection and maintenance of a machine equipped with air conditioner, see "INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) (PAGE 4-16)". 3 - 43...

  • Page 99: Heater And Defroster Controls

    OPERATION DETAILED CONTROLS AND GAUGES HEATER AND DEFROSTER CONTROLS (If equipped) Heater and Defroster Control Panel Vent selector switch Air flow selector switch FRESH/RECIRC selector switch OFF switch Temperature control switch Defroster selector lever Vent Selector Switch (Sending Air to Face) If this switch (1) is pressed, the air from the heater is all directed to the face.
  • Page 100 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch (Sending Air to Face and Feet) If this switch (1) is pressed, the air from the heater is directed to the face and feet. Vent Selector Switch (Sending Air to Feet) If this switch (1) is pressed, the air from the heater is all directed to the feet.
  • Page 101 OPERATION DETAILED CONTROLS AND GAUGES FRESH/RECIRC Selector Switch (Fresh) When switch (2) is pressed, fresh air is taken into the cab during heating. This position is used to bring in clean fresh air into the cab or to remove the mist from the cab windows. FRESH/RECIRC Selector Switch (Recirc) When switch (2) is pressed, the air inside the cab is recalculated and no fresh air is taken in from outside.
  • Page 102 OPERATION DETAILED CONTROLS AND GAUGES Temperature Control Switch (Warm) Use switch (3) to increase the temperature. Press this switch to increase the temperature of the air sent from the heater. The more times the switch is pressed, the upper the blowing wind temperature becomes, as the indicator light moves to the right.
  • Page 103 OPERATION DETAILED CONTROLS AND GAUGES Off Switch Switch (5) is used to stop operation of heater function. Defroster Selector Lever Switch (6) is used to remove the mist from the front glass during cold or rainy weather. Selector lever to front: To defroster (open) Selector lever to rear: Closed The defroster can be used when the vent selector switch is set to send air to the face or to the face and the feet.

  • Page 104: Radio

    OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel Power switch, Volume control knob, Balance AS/PS button control knob Preset station buttons (1,2,3,4,5,6) SEL button Display FM/AM selection button Time reset button Display selection button Tuning button Power switch, Volume control knob, Balance control knob Press this knob (1) to turn the power for the radio on.
  • Page 105 OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4) and the display will show the present time for 5 seconds. After 5 seconds pass, the display returns automatically to the frequency display.
  • Page 106 OPERATION DETAILED CONTROLS AND GAUGES Controls of Radio Preset Station Buttons 1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. 3.
  • Page 107 OPERATION DETAILED CONTROLS AND GAUGES Method of Operating Mode (BAS) Bass adjustment button: When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned counterclockwise, the bass sound is reduced.
  • Page 108 OPERATION DETAILED CONTROLS AND GAUGES Antenna NOTICE When transporting the machine or parking it in a garage, always fully retract the antenna to avoid the possibility of breakage. If the receiving wave is weak or generates noise, extend the antenna. If the wave is too strong, adjust the sensitivity by retracting the antenna.

  • Page 109: Operation Manual Storage

    OPERATION DETAILED CONTROLS AND GAUGES OPERATION MANUAL STORAGE A magazine box is provided on the left side of the operator's seat for safekeeping the operation and maintenance manual and oil chart. Always keep the Operation and Maintenance Manual in this pocket so that it is possible to read it at any time.

  • Page 110: Fire Extinguisher

    OPERATION DETAILED CONTROLS AND GAUGES FIRE EXTINGUISHER (If equipped) A fire extinguisher is prepared at the rear part inside the operator's cab. The directions are described on the nameplate affixed to it. Just in case, carefully read and grasp them beforehand. 3 - 55...

  • Page 111: Machine Operations And Controls

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS BEFORE STARTING ENGINE Walk-around Checks Before starting the engine, look around and under the machine to check for loose nuts and bolts, or leakage of oil, fuel, or coolant, and check condition of the work equipment and hydraulic system. Also check for loose wiring, play, and accumulation of dust at places with high temperatures.
  • Page 112 OPERATION MACHINE OPERATIONS AND CONTROLS 7. Check for problems in gauges and monitor Check that there is no problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts. Clean off any dirt on the surface. 8.
  • Page 113 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. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
  • Page 114 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
  • Page 115 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
  • Page 116 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
  • Page 117 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. Open battery inspection cover (1) and check sight gauge (G) for the oil level. If it stays within the following range, it is regarded as appropriate. In Machine Condition A: Within the range a In Machine Condition B: Within the range b NOTICE Do not add oil above the H line.
  • Page 118 OPERATION MACHINE OPERATIONS AND CONTROLS Check Dust Indicator 1. Open the engine hood and check that the red piston is not showing in dust indicator (1). 2. If the red piston has appeared, clean or replace the element immediately. For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-17)".
  • Page 119 OPERATION MACHINE OPERATIONS AND CONTROLS Check Electric Wiring WARNING If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately perform repairs, or contact your Komatsu distributor for repairs. Keep the top surface of the battery clean and check the breather hole in the battery cap.
  • Page 120 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment WARNING Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the backrest.
  • Page 121 OPERATION MACHINE OPERATIONS AND CONTROLS Rigid Seat (If equipped) (A) Fore-and-aft adjustment Move lever (1) to the upper, set the operator's seat at the desired position, then release the lever. Fore-and-aft adjustment: 50 mm (2.0 in) (B) Adjusting reclining REMARK The seat can be reclined more when the seat is pushed to the front.
  • Page 122 OPERATION MACHINE OPERATIONS AND CONTROLS Wind-in Type Seat Belt WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt.
  • Page 123 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt (If equipped) WARNING Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
  • Page 124 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end on the tongue side. Lengthening Pull the seat belt with a tongue in the direction perpendicular to the tongue. 3 - 69...
  • Page 125 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When standing up from the operator's seat, always set the lock lever to the LOCK position, regardless of whether the engine is running or stopped. 1. Check the lock lever (1) is at the LOCK position. REMARK The engine does not start, if the lock lever is not in the LOCK position.
  • Page 126 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2) Press horn switch (11) to confirm that the horn will sound. 3) Press lamp switch (12) to turn on the working lamps. If it does not light up, there is probably a blown bulb or disconnection, so please contact your Komatsu distributor for repairs.

  • Page 127: Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire.
  • Page 128 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to the START position. The engine will start. 4. When the engine start, release the key in the starting switch (3). The key will return automatically to the ON position. 5.
  • Page 129 OPERATION MACHINE OPERATIONS AND CONTROLS Starting Engine in Cold Weather WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
  • Page 130 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn fuel control dial (2) to the center position between LOW IDLE and HIGH IDLE. 4. Hold the key in starting switch (3) at the HEAT position, and check that pre-heating monitor (4) lights up. After about 30 seconds, pre-heating monitor (4) will flash 10 seconds to indicate that pre-heating is finished.
  • Page 131 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 8. Check that charge level monitor (5) and engine oil pressure monitor (6) goes off. 3 - 76...

  • Page 132: After Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS AFTER STARTING ENGINE WARNING Emergency stop If there has been any abnormal action 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, Particularly in cold areas, be sure to carry out the warming-up operation fully.
  • Page 133 OPERATION MACHINE OPERATIONS AND CONTROLS Warming-up Operation NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the lever suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warming-up operation is completed.
  • Page 134 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. After carrying out the warming-up operation, check that machine monitor (5) is in the following condition. Engine coolant temperature gauge (6): Inside green range Fuel gauge (7): Inside green range Engine coolant temperature monitor (8): OUT Engine oil pressure monitor (9): OUT Charge level monitor (10): OUT...

  • Page 135: 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 136: Machine Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the steering levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. When moving off, check that the area around the machine is safe, and sound the horn before moving. Do not allow anyone in the area around the machine.
  • Page 137 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 1. Set lock lever (2) to the FREE position, then raise the work equipment 40 to 50 cm (16 to 20 in) from the ground. 2. Raise the blade. 3. Operate right and left travel control levers (3) or right and left travel pedals (4) in the following manner. When sprocket (A) is situated at the rear of the machine;...
  • Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Backward 1. Set lock lever (2) to the FREE position, then raise the work equipment 40 to 50 cm (16 to 20 in) from the ground. 2. Raise the blade. 3. Operate right and left travel control levers (3) or right and left travel pedals (4) in the following manner. When sprocket is situated at the rear of the machine;...
  • Page 139 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3 - 84...

  • Page 140: Steering The Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear, the machine moves in the reverse direction to the operation of the travel levers. Use the travel levers to change direction.
  • Page 141 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. REMARK When turning to the right, operate the right travel lever in the same way.

  • Page 142: Swinging

    OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING When operating the swing, check that the area around the machine is safe. 1. Operate left work equipment control lever (1) to swing the upper structure. 2. When not using the swing, set left work equipment control lever (1) to the N position.

  • Page 143: Work Equipment Controls And Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING For operation modes other than the standard one (ISO pattern), refer to the chapter of ATTACHMENTS AND OPTIONS in this manual. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
  • Page 144 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Bucket control Move the right work equipment control lever to the left or right to operate the bucket. Boom swing operation The boom swing operation can be carried out with the boom swing control pedal.

  • Page 145: Working Mode

    OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE By using the working mode selector switch to select a working mode that matches the operating condition, it is possible to carry out operations efficiently. Use the following procedure to make effective use of each working mode. Active Mode (for heavy-duty work) and E Mode (for work focusing on fuel consumption ratio) are alternated, every time the working mode switch is depressed.

  • Page 146: Prohibited Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING Do not attempt to operate the work equipment control lever, while the machine is traveling. Operations Using Swing Force Do not use the swing force to compact soil or break objects. This is not only dangerous, but will also drastically reduce the life of the machine.
  • Page 147 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging.

  • Page 148: General Operation Information

    OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid traveling over such obstacles as far as possible.
  • Page 149 OPERATION MACHINE OPERATIONS AND CONTROLS Blade During Backhoe Operations When carrying out deep digging operations with the blade at the front, be careful not to the boom cylinder hit the blade. Always position the blade at the back unless it is needed at the front. Permissible Water Depth CAUTION When driving the machine out of water, if the angle of the machine exceeds...

  • Page 150: Traveling On Slopes

    OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.
  • Page 151 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. When traveling up a steep hill of more than 15°, set the work equipment to the posture shown in the diagram on the right. 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, stop the machine, then start the engine again.

  • Page 152: Escape From Mud

    OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get the machine out. Track on One Side Stuck NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.

  • Page 153: 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 154 OPERATION MACHINE OPERATIONS AND CONTROLS Loading Work In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator. Loading dump trucks is easier and the loading capacity is greater if the hydraulic excavator loads from the rear of the dump truck rather than from the side.

  • Page 155: Machine Ready For Attachment

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE READY FOR ATTACHMENT Locations Stop valve Lock pin Selector valve Breaker circuit additional oil filter Attachment control pedal Stop Valve This valve (1) stops the flow of the hydraulic oil. 1. Loosen bolt (A) and then detach stopper (B). 2.
  • Page 156 OPERATION MACHINE OPERATIONS AND CONTROLS Selector Valve This valve (2) switches the flow of hydraulic oil. Position (a): When using breaker Position (b): When using general attachment (crusher, etc.) Attachment Control Pedal This pedal (3) is used to operate the attachment. Lock Pin This pin (4) locks the control pedal.
  • Page 157 OPERATION MACHINE OPERATIONS AND CONTROLS Hydraulic Circuit Hydraulic Circuit Connection When connecting the attachment, connect the hydraulic circuit as follows. 1. Check that the stop valve is at the LOCK position, then remove the plug. Be careful not to lose or damage any part that is removed. 2.
  • Page 158 OPERATION MACHINE OPERATIONS AND CONTROLS Attachment Operations WARNING Do not put your foot on the pedal except when operating the pedal. If rest your foot on the pedal during operations, and it is depressed by accident, the attachment may move sudden and cause serious damage or injury. Operate the attachment as follows.
  • Page 159 OPERATION MACHINE OPERATIONS AND CONTROLS When Using General Attachment Such As Crusher 1. If the pedal is depressed with lock pin (1) set at the full stroke position (c), the attachment begins to work. 2. After the work is finished, return the lock pin to the LOCK position (a) to lock the pedal.
  • Page 160 OPERATION MACHINE OPERATIONS AND CONTROLS Long Term Storage If the equipment is not to be used for a long time, do as follows. Set the stop valve in the LOCK condition. Install a plug to the valve. Install a plug to the stopvalve. Set the selector valve to the position for general attachments such as the crusher.

  • Page 161: Bucket Replacement And Inversion

    OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT AND INVERSION WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
  • Page 162 OPERATION MACHINE OPERATIONS AND CONTROLS Inversion WARNING When reversing a bucket, there is the danger that the bucket tooth tip overruns the normal trajectory and interferes with the cab, thus causing a serious trouble. Pay good attention to the work when reversing a bucket so that the bucket and the cab may not interfere with each other.

  • Page 163: Parking Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Park the machine on the firm, level ground. Avoid parking the machine on slopes. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the work equipment into the ground surface to stop the machine from moving.

  • Page 164: Machine Inspection After Daily Work

    OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. Set lock lever (2) in the LOCK position. MACHINE INSPECTION AFTER DAILY WORK Check the engine coolant temperature (1), engine oil pressure (2), and fuel level (3) on the machine monitor. LOCKING Always look the following places.

  • Page 165: Road Liners And Rubber Shoes

    OPERATION MACHINE OPERATIONS AND CONTROLS ROAD LINERS AND RUBBER SHOES (Machine equipped with road liner or rubber shoe) Road Liners and Rubber Shoes Information Road liners and rubber shoes have excellent properties that are not found in steel shoes. However, if they are used in the same way as steel shoes, full use cannot be made of their advantages.
  • Page 166 OPERATION MACHINE OPERATIONS AND CONTROLS Using Road Liners and Rubber Shoes Prohibited Works Do not carry out the following types of work. Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near the edges of steel plates will cause damage to the road liners and rubber shoes.
  • Page 167 OPERATION MACHINE OPERATIONS AND CONTROLS Always maintain the rubber shoes at the proper tension to prevent them from coming off. If the tension is low, the rubber shoes will come off under the following conditions. Even if the tension is correct, be extremely careful when carrying out operations. 1.
  • Page 168 OPERATION MACHINE OPERATIONS AND CONTROLS Mechanism of rubber shoe coming off track 1) When traveling over an obstacle, a gap is formed between the track roller and the rubber shoe. In this condition, the rubber shoe may come off. 2) Furthermore, if the machine travels in reverse, a gap is formed between the track roller, idler, and rubber shoe.
  • Page 169 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS If the machine is turned in this condition, the rubber shoe will come off. 3 - 114...

  • Page 170: Transportation

    OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a basic rule, transport the machine by trailer. Select the trailer to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)". Note that the value for the weight and transportation dimensions given in SPECIFICATIONS may differ according to the type of shoe or type of arm or other attachments.
  • Page 171 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Make the slope of the ramps a maximum of 15°.
  • Page 172 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 7. Do not operate the accelerator pedal. 8. Stop the machine at the specified place, then swing the upper structure slowly 180°. 9. Stop the machine at the specified position on the trailer. 3 - 117...
  • Page 173 OPERATION TRANSPORTATION Securing Machine After placing the machine on the specified position of the trailer, secure it according to the following procedure. NOTICE Stow the antenna and other parts away. Reassemble the mirrors (for machines equipped with mirrors) so that they are within the width of the machine.
  • Page 174 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer.
  • Page 175 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 9. Raise the work equipment, align the direction of travel with the ramp, and travel slowly. Lower the work equipment as far as possible without causing interference. When on the ramps, operate only the travel lever. Do not operate any other lever or pedal.

  • Page 176: Lifting Machine

    OPERATION TRANSPORTATION LIFTING MACHINE WARNING The person using the crane to carry out lifting operations must be a qualified crane operator. Never carry out lifting operations if any person is on the machine being lifted. Always use a wire rope that has ample strength for the weight of the machine being lifted. Keep the machine horizontal when lifting it.
  • Page 177 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 6. Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. 7. Put blocks between the wire rope and the machine to prevent damage to the rope or machine.

  • Page 178: Cold Weather Operation

    OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION INFORMATION If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. Fuel and Lubricants Change to fuel and oil with low viscosity for all components. For details of the specified visicosity, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-9)".
  • Page 179 OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.

  • Page 180: 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, observe the following precautions.

  • Page 181: Long Term Storage

    OPERATION LONG TERM STORAGE LONG TERM STORAGE BEFORE STORAGE NOTICE When storing the machine (1 month or more), set the machine in the posture shown in the diagram on the right to protect the cylinder rod. (To prevent rusting of the cylinder rod) When keeping in long-term storage (more than one month), store as follows.

  • Page 182: Troubles And Actions

    OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see "Air Bleeding (PAGE 4-61)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the...

  • Page 183: Towing The Machine

    OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.

  • Page 184: Discharged Battery

    OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge the battery as it is mounted on the machine. Do not attempt that. Before checking or handling the battery, turn the engine starting switch key OFF. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes or open flames near the battery, or do not do anything that will cause sparks.
  • Page 185 OPERATION TROUBLES AND ACTIONS Battery Removal and Installation Removal of Battery 1. Open up dust cover (1) and battery inspection cover (2). 2. Loosen bolts (3) to remove sheet (4) installed above the battery. 3. Disconnect cable (5) from the negative (-) terminal (grounding side) first.
  • Page 186 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 3-129)" and the instruction manual accompanying the charger, and do as follows. Set the voltage of the charger to match the voltage of the battery to be charged.
  • Page 187 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 188 OPERATION TROUBLES AND ACTIONS Starting the Engine WARNING When starting the engine, check that the lock lever is securely at the LOCK position. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious accident.

  • Page 189: How To Lower Work Equipment When Engine Stops Due To Abnormality

    OPERATION TROUBLES AND ACTIONS HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY WARNING Before loosening the plug, thoroughly check safety under the work equipment and the blade. Never allow anyone to go under the work equipment or the blade. While the work equipment is descending, keep holding the plug with a tool, so that the descent may be stopped any moment.

  • Page 190: Other Trouble

    OPERATION TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp dose not glow brightly even Defective wiring...
  • Page 191 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm Lack of hydraulic oil Adding oil to specified level, and bucket is slow...
  • Page 192 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights Oil level low in oil pan (sucking Add oil to specified level, see air in)
  • Page 193 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Abnormal noise generated Low grade fuel being used Change to specified fuel (combustion or mechanical) Overheating See "Red range of engine coolant temperature gauge lights up" Damage inside muffler Replace muffler Excessive valve clearance ( Adjust valve clearance) Engine stops while in work Clogging feed pump pre-filter...
  • Page 194 OPERATION TROUBLES AND ACTIONS Electronic Control System If an error code appears on machine monitor display (1) (normally displays TIME), follow the countermeasure table for the self-diagnosis as shown below. Machine Monitoring System Monitor Error mode Countermeasure display Pump control system error If emergency pump drive switch is set to the ON position, operation can be carried out.
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  • Page 197: Maintenance

    MAINTENANCE MAINTENANCE INFORMATION MAINTENANCE INFORMATION Do not perform any inspection and maintenance operation that is not found in this manual. Service Meter Reading Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed.
  • Page 198 MAINTENANCE MAINTENANCE INFORMATION Dusty Jobsite When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

  • Page 199: Outline Of Service

    MAINTENANCE OUTLINE OF SERVICE OUTLINE OF SERVICE Always use Komatsu genuine parts for replacement parts, grease or oil. When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil and fill completely with the new oil.
  • Page 200 MAINTENANCE OUTLINE OF SERVICE FUEL To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work. The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly. Be extremely careful not to let impurities get in when storing or adding fuel.
  • Page 201 MAINTENANCE OUTLINE OF SERVICE CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other problems.

  • Page 202: Electric System Maintenance

    MAINTENANCE OUTLINE OF SERVICE STORING OIL AND FUEL Keep indoors to prevent any water, dirt, or other impurities from getting in. When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the side to prevent moisture from being sucked in.

  • Page 203: Wear Parts List

    MAINTENANCE WEAR PARTS WEAR PARTS Replace filter elements, bucket teeth, and other wear parts at the specified interval or before they reach the wear limit. 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 204: Recommended Fuel, Coolant, And Lubricant

    MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.

  • Page 205: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature

    MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE SAE: Society of Automotive Engineers ASTM: American Society of Testing and Material API: American Petroleum Institute Swing Engine oil Final drive PTO gear Hydraulic Cooling machinery Fuel tank...

  • Page 206: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil

    MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT Note .1: Power train of oil has different properties from engine oil. Be sure to use the recommended oil. Note .2: Hyper white grease (G2-T) has a high performance. When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-T is recommended.

  • Page 207: Tightening Torque Specifications

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

  • Page 208: Safety Critical Parts

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

  • Page 209: 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 4-15)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Replace Fuel Filter Cartridge...

  • Page 210: Maintenance Interval For Hydraulic Breaker

    MAINTENANCE MAINTENANCE SCHEDULE EVERY 500 HOURS MAINTENANCE Replace Fuel Filter Cartridge 4- 61 Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge 4- 62 Clean Air Conditioner Fresh/Recirc Filters 4- 63 Clean, Check Radiator Fins, Oil Cooler Fins and Condenser Fins 4- 65 Lubricate Swing Circle 4- 67...

  • Page 211: Maintenance Procedure

    MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance only after the first 250 hours. Replace fuel filter cartridge Change oil in engine oil pan, replace engine oil filter cartridge For details of the method of maintaining, see EVERY 500 HOURS MAINTENANCE.

  • Page 212: When Required

    MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
  • Page 213 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the same time. 4. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm , 99.4 PSI)) from the inside of the outer element along its folds.
  • Page 214 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 7. Set the arrow mark on cover (3) at the top, install to the air cleaner body, then secure with clip (2). 8. Press the button of dust indicator (1) to return the red piston to its original position.
  • Page 215 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. Replace O-ring (7) for cover (3) with new one. 7. Set the arrow mark on cover (3) at the top, install to the air cleaner body, then secure with clip (2). 8. Replace the seal attached to cover (3) with new one. 9.

  • Page 216: 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 217 MAINTENANCE MAINTENANCE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100).
  • Page 218 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Remove the cover under the drain valve. 6. Set the container under drain valve (2) and drain plug (3) to catch the coolant mixture. 7. After draining the antifreeze solution, close drain valve (2) and tighten drain plug (3), then fill with clean water.

  • Page 219: Replace Water Separator Element

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE WATER SEPARATOR ELEMENT WARNING Do not bring any fire or flame close. Prepare the filter wrench for water separator. 1. Open inspection cover (1) on the left side of the machine and set handle (2) of the filter inside to the CLOSED position (a). 2.

  • Page 220: Clean Fuel Tank

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN FUEL TANK NOTICE Never use trichlene for washing the inside of the tank. Use diesel fuel only. 1. Drain fuel in the fuel tank, referring to the steps 1. through 3. of the section of "DRAIN WATER FROM FUEL TANK (PAGE 4-51)"...

  • Page 221: Check And Tighten Track Shoe Bolts

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS (Machine equipped with steel shoes, road liners) If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Method for further tightening of steel shoe 1.

  • Page 222: Check And Adjust Track Tension

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION (Machine equipped with steel shoes, road liners) The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil, so inspect the track tension frequently in order to maintain the standard tension. Stop the machine on firm, horizontal ground when carrying out the inspection and maintenance.
  • Page 223 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Continue to pump in grease until dimension S becomes zero (0). If the tension is still loose, the pin and bushing are excessively worn, so they must be either turned or replaced. Please contact your Komatsu distributor for repairs. Loosening Track Tension WARNING It is extremely dangerous to release the grease by any method except the procedure given below.

  • Page 224: Check Road Liners Or Rubber Shoes

    MAINTENANCE MAINTENANCE PROCEDURE CHECK ROAD LINERS OR RUBBER SHOES (Machine equipped with road liner or rubber shoe) If the road liners and rubber shoes are in the following condition, they must be repaired or replaced, so please contact your Komatsu distributor for repairs or replacement. Lug Height If lug height "a"...
  • Page 225 MAINTENANCE MAINTENANCE PROCEDURE Rubber Shoe Core Separations If the rubber core has separated at one place or more, replace with a new part. Rubber Shoe Tension If the rubber shoe is still slack even when grease is pumped in, replace with a new part or replace the seal inside the cylinder.

  • Page 226: Check And Adjust Rubber Shoe Tension

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST RUBBER SHOE TENSION (Machine equipped with rubber shoes) The wear of the rubber shoe will vary with the work conditions and type of soil, so inspect the wear and track tension whenever necessary. Stop the machine on firm, horizontal ground when carrying out the inspection and maintenance.

  • Page 227: Replace Road Liners

    MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE Prepare a grease gun. 1. Pump in grease through grease fitting (5) with a grease pump. 2. To check that the track tension is correct, run the engine at low idle, move the machine forward a distance equal to the length of track on ground, then stop the machine.

  • Page 228: Replace Rubber Shoes

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE RUBBER SHOES (Machine equipped with rubber shoes) WARNING Carry out this operation with two workers. The operator must move the machine in accordance with the signals from the other worker. The rubber shoes are replaced with the machine raised, so it is extremely dangerous if the machine is lowered by mistake during the replacement operation.
  • Page 229 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2. Loosen plug (1) gradually to release the grease. 3. When loosening plug (1), turn it a maximum of one turn. 4. Fit the steel pipes inside the rubber shoe, rotate the sprocket in reverse, so that the steel pipes make the rubber shoe come up from the idler, then to the side to remove.

  • Page 230: Change Steel Shoes Or Road Liner To Rubber Shoes

    MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Fit a steel pipe in the rubber shoe, then rotate the sprocket again and fit the rubber shoe securely on the idler. 5. Stop the rotation, and check that the rubber shoe is securely fitted to the sprocket and idler.

  • Page 231: Replace Bucket Teeth (Vertical Pin Type)

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.
  • Page 232 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE The rubber of the rubber pin lock is torn, and the steel balls may come out. The steel balls are buried when they are pressed by hand. 4. Clean the surface of adapter (4) and remove the soil with a knife. 5.
  • Page 233 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 8. Insert lock pin (2) in the hole of the teeth and hit it until its top is the same level as the surface of teeth (1). 9. After replacing a bucket tooth, always check the following. 1) After the lock pin has been knocked in completely, check that it is secured by the point and surface.

  • Page 234: Replace Bucket Teeth (Horizontal Pin Type)

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.

  • Page 235: Adjust Bucket Clearance

    MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake while the bucket clearance is being adjusted. Set the work equipment on the ground in a stable condition, then stop the engine and lock the lock lever without fail. 1.

  • Page 236: Check Window Washer Fluid Level, Add Fluid

    MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.

  • Page 237: Check And Adjust Air Conditioner

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST AIR CONDITIONER Check Level of Refrigerant (gas) WARNING If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant.

  • Page 238: Check, Clean And Lubricate Cab Slide Door Rail And Roller

    MAINTENANCE MAINTENANCE PROCEDURE CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER Checking When opening or closing the slide door, it may sometimes not slide smoothly due to mud stuck to the rail. In that case clean and lubricate slide door rail (1) and roller (2) at three points. Cleaning 1.

  • Page 239: Replace Breaker Circuit Additional Oil Filter Element

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. When removing the cap from oil filler port (F), turn it slowly to release the internal pressure, then remove it carefully.

  • Page 240: Wash Washable Floor

    MAINTENANCE MAINTENANCE PROCEDURE WASH WASHABLE FLOOR With the washable floor, it is possible to flush out the dirt on the cab floor directly with water. WARNING When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation.
  • Page 241 MAINTENANCE MAINTENANCE PROCEDURE Method of Setting Machine at Angle Method Using Slope WARNING Select a solid and smooth slope. Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground. 1. Stop the machine so that the work equipment is on the downhill side.

  • Page 242: Bleeding Air From Hydraulic System

    MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-72)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. 1. Bleeding air from pump NOTICE If the pump is operated without filling the pump case with hydraulic oil, there is danger that the pump may be prematurely damaged.
  • Page 243 MAINTENANCE MAINTENANCE PROCEDURE 4. Bleeding air from cylinders NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing. 1) Run the engine at a mid-range speed (1650 rpm) and extend and retract the cylinders 4 to 5 times to a point 100 mm (3.9 in) from the end of the stroke.
  • Page 244 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2) Run the engine at low idle and swing the work equipment 90° to bring it to the side of the track. 3) Jack up the machine until the track is raised slightly from the ground.

  • Page 245: Check Before Starting

    MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-58)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Check oil level in hydraulic tank, add oil Check dust indicator Check water separator...

  • Page 246: Every 50 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 50 HOURS MAINTENANCE DRAIN WATER FROM FUEL TANK Carry out this procedure before operating the machine. Prepare a container to catch the fuel that is drained. 1. Swing the upper structure so that inspection cover (1) is between the tracks. 2.

  • Page 247: Every 100 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval. Carry out greasing every 10 hours for the first 50 hours on a new machine.

  • Page 248: Every 250 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval. Carry out greasing every 10 hours for the first 50 hours on a new machine.
  • Page 249 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (6) Boom cylinder rod end pin (1 place) (7) Arm cylinder foot pin (2 places) (8) Arm cylinder rod end pin (1 place) (9) Boom-Arm coupling pin (1 place) (10) Bucket cylinder foot pin (1 place) (11) Arm link pin (1 place) (12) Link coupling pin (2 places) (13) Bucket cylinder rod end pin (1 place)

  • Page 250: Check Oil Level In Final Drive Case, Add Oil

    MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.

  • Page 251: Check Level Of Battery Electrolyte

    MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Perform 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 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 252 MAINTENANCE MAINTENANCE PROCEDURE 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. 1.

  • Page 253: Check And Adjust Cooling Fan Belt Tension

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST COOLING FAN BELT TENSION Checking If deflection amount "a" shows approx. 8 mm (0.3 in) when the belt is pressed with a thumb of approx. 58.8 N (6 kgf) force at the midpoint between the alternator pulley and the fan pulley, then it is the standard deflection amount.
  • Page 254 MAINTENANCE MAINTENANCE PROCEDURE Adjustment Prepare a bar. Prepare a wooden block. 1. Detach fan guard (1). 2. Insert a bar in between alternator (2) and the cylinder block to secure alternator (2). At that time put a wooden block between the bar and alternator (2) to avoid damage to alternator (2).

  • Page 255: Check Air Conditioner Compressor Belt Tension, Adjust

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (If equipped) Checking If deflection amount "a" shows 10 to 12 mm (0.4 to 0.5 in) when the belt is pressed with a finger of approx. 58.8 N (6 kgf) force at the midpoint between the fan pulley and compressor pulley, then it is the standard deflection amount.

  • Page 256: Every 500 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 50, 100 and 250 hours service should be carried out at the same time. REPLACE FUEL FILTER CARTRIDGE WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter.

  • Page 257: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge

    MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity: 7.0 liters (1.85 US gal) Filter wrench 1.

  • Page 258: Clean Air Conditioner Fresh/Recirc Filters

    MAINTENANCE MAINTENANCE PROCEDURE 8. After replacing the filter cartridge, add engine oil through oil filler port (F) so that the oil level is between the H and L marks on dipstick (G). 9. Run the engine idle for a while, then stop the engine and confirm that the oil level is between the H and L lines according to "Check Oil Level in Engine Oil Pan, Add Oil (PAGE 3-59)".
  • Page 259 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Fresh Air Filter 1. Pull up pop-up rivet (4) of the air intake duct at the left rear of the operator's seat. Cover (5) will be released automatically. 2. Pull up external filter (6). 3. Clean external filter (6) by blowing it with compressed air. If there is oil stuck to the filter or it is extremely dirty, wash it in a neutral agent.

  • Page 260: Clean, Check Radiator Fins, Oil Cooler Fins And Condenser Fins

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS 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. Always use safety glasses, dust mask, or other protective equipment. NOTICE When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins.
  • Page 261 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Remove two oil cooler securing bolts (5) on the upper side and bracket (6). 6. Loosen two oil cooler securing bolts (7) on the lower side. 7. Tilt oil cooler (8) to create some space between oil cooler (8) and radiator (9).

  • Page 262: Lubricate Swing Circle

    MAINTENANCE MAINTENANCE PROCEDURE LUBRICATE SWING CIRCLE 1. Lower the work equipment to the ground. 2. Using a grease gun, pump in grease through the grease fittings shown by arrows. (2 places) 3. After greasing, wipe off any old grease that was pushed out. CHECK SWING PINION GREASE LEVEL, ADD GREASE Prepare a scale.

  • Page 263: Every 1000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
  • Page 264 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. Loosen 3 bolts, then remove cover (2). When doing this , may fly out under, the force of spring (3), so hold the cover down when removing the bolts. 7. After removing spring (3) and vlve (4),take out element (5). 8.

  • Page 265: Change Oil In Swing Machinery Case

    MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY CASE 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 starting the operation. Refill capacity: 2.0 liters (0.53 US gal) 1.

  • Page 266: Change Oil In Final Drive Case

    MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.

  • Page 267: Every 2000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHECK PTO GEAR 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 268: Every 4000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 4000 HOURS MAINTENANCE Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time. CHECK WATER PUMP Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any problem is found, please contact your Komatsu distributor for repairs or replacement.

  • Page 269: Every 5000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
  • Page 270 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Open mud cover (1), then remove the cap of oil filler (F) to release the internal pressure. 6. Place a container under the drain plug which is located on the machine underside. Then remove drain plug (P), using a handle, and drain oil.
  • Page 272 5 - 1...

  • Page 273: Specifications

    SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Item Unit Steel shoe specified Road linre speicified Operating weight (blade specified) kg (lb) 8,270 (18,235) 8,300 (18,301) Bucket capacity (cu/yd) 0.28 (0.37) Name of engine Komatsu 4D95LE-3-A diesel engine Engine horsepower kW (HP)/rpm 40.5 (54.0)/1,850 A Overall length mm (ft in) 6,200 (20' 4") 6,230 (20' 5")
  • Page 274 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit Steel shoe specified Max. digging reach mm (ft in) 6,960 (22' 10") Max. digging depth mm (ft in) 4,160 (13' 8") Max. digging height mm (ft in) 6,570 (21' 7") Max. vertical wall depth mm (ft in) 2,900 (9' 6") Max.
  • Page 276 6 - 1...

  • Page 277: Attachments And Options

    ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS - GENERAL INFORMATION ATTACHMENTS AND OPTIONS - GENERAL INFORMATION SAFETY FIRST If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor first.

  • Page 278: Attachment Installation

    ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS - GENERAL INFORMATION ATTACHMENT INSTALLATION WARNING Long work equipment or heavy work equipment cause the machine to have poor stability, so there is danger of the machine losing its balance and tipping over when traveling down steep hills or when swinging on slopes. Never do any of the following.

  • Page 279: Bucket With Hook

    ATTACHMENTS AND OPTIONS BUCKET WITH HOOK BUCKET WITH HOOK HOOK CONDITION Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu distributor. PROHIBITED OPERATIONS Operations with Care When carrying out lifting operations, reduce the engine speed and operate slowly.

  • Page 280: Method For Removing And Installing Extra Counterweight

    ATTACHMENTS AND OPTIONS METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT Installing Extra Counterweight WARNING For lifting up this machine, use a wire rope with sufficient strength to withstand the machine weight. Do not attempt to lift up the machine in a posture other than explained below. Otherwise there is the danger that the lifted machine may lose a balance in the air.
  • Page 281 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT 6. Install plastic cap (7). 7. Fix nameplate (2) with 4 screws (1). 6 - 6...

  • Page 282: Changing Machine Control Pattern (If Pattern Change Valve Equipped)

    ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) WARNING When changing the operating pattern of the machine, set the machine in the parking posture, stop the engine, check that the lock lever is at the LOCK position, then change the operating pattern.

  • Page 283: Machine Control Patterns

    ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) MACHINE CONTROL PATTERNS WARNING After changing the operating pattern, always change the operating pattern card in the operator's compartment. ISO pattern Backhoe pattern 6 - 8...

  • Page 284: Attachment Guide

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE 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 285: Attachment Combinations

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE ATTACHMENT COMBINATIONS 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 286: Selection Of Track Shoes

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE SELECTION OF TRACK SHOES Select the most suitable track shoe to match the operating conditions. METHOD OF SELECTING SHOES Check the category from the uses in the table below, then select the shoes from the table below that. Category of use B is the wide shoe, so there are limits on the use.

  • Page 287: Recommended Attachment Operations

    ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Below described are instructions which must be followed without fail when doing the work using a hydraulic excavator equipped with an attachment. NOTICE Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can be mounted will vary.
  • Page 288 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge.
  • Page 289 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Prohibited Works To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. Do not operate all cylinders to the end of their strokes. Always leave approx. 5 cm (2 in) to spare. Using the mount to gather in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations...
  • Page 290 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 6 - 15...
  • Page 291 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Greasing Supply grease in the correct position. NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic components, while the breaker is in use.

  • Page 292: Index

    INDEX INDEX <A> Engine, Check After Shut Off 3- 80 Air Conditioner Controls 3- 38 Engine, Starting 3- 72 Ashtray 3- 54 Engine, Stopping the 3- 80 Attachment Guide Escape from Mud 3- 97 Attachment Combinations 6- 10 Other Attachments <F>...
  • Page 293 INDEX Initial 250 Hours (First 250 Hours Only) 4- 16 Starting Engine 2- 21 When Required 4- 17 Towing 2- 32 Maintenance Schedule 4- 14 Transportation 2- 29 Maintenance Interval for Hydraulic Safety Maintenance Information 2- 34 Breaker 4- 15 Service Meter Location Maintenance Schedule Chart 4- 14...
  • Page 295 PC78MR-6 GALEO HYDRAULIC EXCAVATOR Form No. TEN00074-00 © 2005 KOMATSU All Right Reserved Printed in Japan 04-05...

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