Page 1 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. 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.
Page 2 FOREWORD...
Page 3 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
Page 4 FOREWORD FOREWORD...
Page 5 FOREWORD FOREWORD...
Page 6: Foreword
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following works: Digging work ● Leveling work ● Ditching work ● Loading work ● Demolition work ● See the section "RECOMMENDED APPLICATIONS (PAGE 3-83)" for further details.
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 On the bottom right of the operator's cab The design of the nameplate differs according to the territory.
Page 10: Service Meter Location
FOREWORD PRODUCT INFORMATION SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personal Phone/Fax...
Page 11: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD ................................. 1-2 SAFETY INFORMATION............................1-5 INTRODUCTION..............................1-7 DIRECTIONS OF MACHINE ........................1-7 BREAKING-IN THE NEW MACHINE ......................1-7 PRODUCT INFORMATION ..........................1-8 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........1-8 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ................. 1-8 SERVICE METER LOCATION ........................
Page 12 FOREWORD CONTENTS 4-SYSTEM ..............................3-9 SWITCHES ............................... 3-12 CONTROL LEVERS, PEDALS ......................... 3-17 FRONT WINDOW............................. 3-21 SLIDING DOOR............................3-24 REAR WINDOW ............................3-25 HAMMER FOR EMERGENCY ESCAPE....................3-25 STOW-AWAY TYPE STEP........................3-26 CAP, COVER WITH LOCK........................3-28 ENGINE HOOD ............................3-29 CAB REAR COVER..........................
Page 13 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................. 4-11 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..... 4-12 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ................4-13 TIGHTENING TORQUE SPECIFICATIONS ...................... 4-14 TIGHTENING TORQUE LIST........................4-14 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................
Page 14 FOREWORD CONTENTS MAINTENANCE PROCEDURE.......................... 4-18 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ........4-18 WHEN REQUIRED ........................... 4-19 CHECK BEFORE STARTING ........................4-41 EVERY 50 HOURS MAINTENANCE......................4-42 EVERY 100 HOURS MAINTENANCE...................... 4-43 EVERY 250 HOURS MAINTENANCE...................... 4-46 EVERY 500 HOURS MAINTENANCE......................
Page 15 FOREWORD CONTENTS MEMO 1-14...
Page 16: Safety
SAFETY WARNING Please be sure that you fully understand this manual and the precautions related to safety for the machine. When operat- ing or servicing the machine, always follow these precau- tions strictly.
Page 17: Safety Information
SAFETY SAFETY INFORMATION SAFETY INFORMATION POSITION FOR ATTACHING SAFETY LABELS ....................2-4 POSITION FOR ATTACHING SAFETY LABELS .................... 2-5 SAFETY LABELS............................. 2-6 SAFETY INFORMATION ............................ 2-12 SAFETY RULES ............................2-12 IF ABNORMALITIES ARE FOUND ......................2-12 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ..............2-12 FIRE EXTINGUISHER AND FIRST AID KIT ....................
Page 18 SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION ........................2-21 BEFORE STARTING ENGINE ........................2-21 CHECKS BEFORE STARTING ENGINE ....................2-21 SAFETY RULES FOR STARTING ENGINE .................... 2-22 STARTING ENGINE IN COLD WEATHER ....................2-22 AFTER STARTING ENGINE ......................... 2-23 CHECKS AFTER STARTING ENGINE ....................2-23 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS ..............
Page 19: Position For Attaching Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part ● numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
Page 20 SAFETY POSITION FOR ATTACHING SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS...
Page 21: Safety Labels
SAFETY POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and mainte- (2) Precautions for operation (09802-03000) nance (09651-03001) (3) Precautions for leaving the operator's seat (4) Precautions for going close to electric cables (09654-03001) (09801-03001)
Page 22 SAFETY POSITION FOR ATTACHING SAFETY LABELS (5) Precautions for operating pattern (09822-03000) (6) Precautions for opening the window (09839-03000) (7) Precautions for stowage (09803-03000) (8) Precautions for broken or becomes dislodged to the window (20U-98-21910)
Page 23 SAFETY POSITION FOR ATTACHING SAFETY LABELS (9) Cautions for emergency work equipment actua- (10) Cautions for handling interference prevention tion switch (21W-98-21521) device (21W-98-21420) (11) Precautions for high-temperature cooling water (12) Precautions for high-temperature hydraulic oil (09668-03001) (09653-03001)
Page 24 SAFETY POSITION FOR ATTACHING SAFETY LABELS (13) Precautions for handling accumulator (14) Precautions for check and adjust track tension (09659-53000) (09657-03003) (15) Precautions for handling electric wires (16) Precautions when handling battery (09808-03000) (09664-30082) (This plate is stick on the machine by the battery maker.)
Page 25 SAFETY POSITION FOR ATTACHING SAFETY LABELS (17) Precautions for opening engine hood (18) Precautions for avoiding falling down (09667-03001) (09805-03000) (19) Precautions for avoiding falling down (20) Prohibited to enter range of swing (09133-23000) (09805-13000) 2-10...
Page 26 SAFETY POSITION FOR ATTACHING SAFETY LABELS (21) Jump start prohibited (09842-A0481) This safety label is fixed to the engine starting motor. 2-11...
Page 27: 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 ●...
Page 28: Safety Equipment
SAFETY SAFETY INFORMATION SAFETY EQUIPMENT Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if ● they are damaged. Understand the method of use of safety features and use them properly. ●...
Page 29: Handrails And Steps
SAFETY SAFETY INFORMATION When leaving the machine, always lower the work equip- ● ment completely to the ground, set lock lever (1) securely to the LOCK position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place.
Page 30: Mounting And Dismounting
SAFETY SAFETY INFORMATION MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. ● If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try ●...
Page 31: Fire Prevention And Explosion Prevention
SAFETY SAFETY INFORMATION FIRE PREVENTION AND EXPLOSION PREVENTION Fire caused by fuel or oil ● Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. ●...
Page 32: Action If Fire Occurs
Always contact your Komatsu distributor for advice. ATTACHMENT INSTALLATION When installing optional parts or attachments, there may be problems with safety or legal restrictions, so ●...
Page 33: Attachment Combinations
UNAUTHORIZED MODIFICATIONS Any modification mode without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications ● made without authorization from Komatsu.
Page 34: Distance To High Voltage Cables
SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows. Before starting work near electric cables, inform the local ●...
Page 35: Ventilation For Enclosed Area
Do not allow other persons to approach during the operation. ● Always observe the rules and regulations for the work site and environmental standards. ● This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-20...
Page 36: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION BEFORE STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol 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 seri- ● ous bodily injury or fire. When starting the engine, sound the horn as a warning.
Page 38: After Starting Engine
SAFETY SAFETY MACHINE OPERATION AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE 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. ●...
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, pull in the work equipment ● and keep it at a height of 40 to 50cm (16 to 20 in) from the ground.
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. When traveling on slopes, keep the work equipment ● approximately 20 to 30cm (8 to 12 in) above the ground. In case of emergency, quickly 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 SAFETY 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: Operations On Snow
SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SNOW Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ● machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 44: Transportation
SAFETY SAFETY MACHINE OPERATION TRANSPORTATION 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. Always do as follows. Perform loading and unloading on firm, level ground only. ●...
Page 45: Shipping The Machine
SAFETY SAFETY MACHINE OPERATION SHIPPING THE MACHINE When shipping the machine on a trailer, do as follows. Investigate all state and local laws governing the weight, width, and length of a load. If necessary, disassemble ● the work equipment. The width, height and weight of the load differ according to the work equipment, so take this into account when determining the shipping route.
Page 46: 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 ●...
Page 47: 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 ●...
Page 48: Towing
SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec- tion or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-124)". Always check that the wire rope used for towing has ample strength for the weight of the machine being ●...
Page 49: 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. ●...
Page 50: 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 nec- essary.
Page 51: Stop Engine Before Carrying Out Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. ● Select a place where there is no danger of falling rocks, ● landslides, or flooding. Lower the work equipment completely to the ground and ●...
Page 52: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 53: Accumulator
● When disposing of the accumulator, the gas must be released. ● Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
Page 54: Noise
SAFETY SAFETY MAINTENANCE INFORMATION NOISE If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov- ers or ear plugs while working.
Page 55: 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 sys- ● tem 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 56: Safety Handling High-Pressure Hoses
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 57: Periodic Replacement Of Safety Critical Parts
SAFETY SAFETY MAINTENANCE INFORMATION PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service ● and maintenance at periodic intervals. In order to further increase safety, components with a strong relation- ship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Page 58: Operation
OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 59: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE (1) Bucket (10) Boom cylinder (2) Bucket cylinder (11) Additional lamp (3) Arm (12) Working lamp (4) Third bracket (13) Sprocket (5) Arm cylinder (14) Track frame (6) Second boom (15) Track shoe (7) Offset cylinder (16) Idler (8) Sub link...
Page 60: General View Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW CONTROLS AND GAUGES Additional light switch (19) Depth display Wiper switch (20) Mode indicator Car heater switch (21) Electrical system monitor Lamp switch (22) Charge monitor Travel speed switch (23) Engine oil pressure monitor Lock lever (24) Service meter Left work equipment control lever (25) Engine oil pre-heating monitor...
Page 61: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays. MACHINE MONITOR A: Caution Items C: Meter Display Portion...
Page 62 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the warning monitor flashes or lights up, carry out inspection and maintenance of the appropriate point as soon as possible. If the problem is not corrected, it may lead to failure of the machine. These are items which need to be observed when the engine is running.
Page 63 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEMS CAUTION If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point immediately and repair the problem. These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal location on the monitor will lights up and the buzzer will sound.
Page 64 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION Pilot Display Gauges And Meter (1) Engine Pre-heating Monitor (3) Engine Coolant Temperature Gauge (2) Swift Deceleration Display Lamp (4) Fuel Gauge (5) Service Meter PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. ENGINE PRE-HEATING MONITOR This monitor lamp(1) indicates the pre-heating time required when starting the engine at an ambient temperature below 0°C...
Page 65 OPERATION EXPLANATION OF COMPONENTS GAUGES AND METER ENGINE COOLANT TEMPERATURE GAUGE This meter(3) shows the engine cooling water temperature. During normal operation, the lamp should light up in the green range. If the lamp in the red range lights up during operation, run the engine at low idling and wait for the temperature to go down to the green range.
Page 66: 4-System
OPERATION EXPLANATION OF COMPONENTS 4-SYSTEM Electric System (5) Depth Mode Indicator Mode Selector Switch (6) Height Mode Indicator Setting Switch (7) Offset Mode Indicator Depth Display (8) Emergency Work Equipment Actuation Switch ELECTRIC SYSTEM If there is any abnormality in the 4-system line (interference prevention system and automatic work equipment control sys- tem), a warning signal is emitted, so stop the engine.
Page 67 OPERATION EXPLANATION OF COMPONENTS SETTING SWITCH This switch (3) is used to set or clear the mode selected by the mode selector switch. DEPTH DISPLAY This monitor (4) shows the depth of the bucket from the ground level. When the bucket is above the ground level, UP is always dis- played.
Page 68 OPERATION EXPLANATION OF COMPONENTS OFFSET MODE INDICATOR This indicator (7) lights up when the left offset amount is set. EMERGENCY WORK EQUIPMENT ACTUATION SWITCH WARNING Never carry out operations with the CANCEL switch ON. The 4-system is not actuated and the work equipment does not stop automatically, so there is danger that it will hit the chassis.
Page 69: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) Starting Switch Windshield Wiper Switch (2) Fuel Control Dial Additional light Switch (3) Swift Deceleration Switch Emergency pump drive Switch (4) Horn Switch (10) Swing Brake Cancel Switch (5) Travel Speed Selector Switch (11) Room Lamp Switch (6) Lamp Switch STARTING SWITCH This switch (1) is used to start or stop the engine.
Page 70 OPERATION EXPLANATION OF COMPONENTS FUEL CONTROL DIAL This dial(2) is used to control the engine speed and output. (a) Low idling position: The dial is turned to the left (counter- clockwise) (b) High idling position: The dial is turned to the right (clock- wise) REMARK When the swift deceleration display lamp is lighted up, the...
Page 71 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH When the button(4) at the tip of the right work equipment con- trol lever is pressed, the horn will sound. TRAVEL SPEED SELECTOR SWITCH WARNING When loading or unloading from a trailer, always ● travel at low speed.
Page 72 OPERATION EXPLANATION OF COMPONENTS WINDSHIELD WIPER SWITCH This switch (7) actuates the front window wiper. (a)OFF: The wiper stops. (b)ON: The wiper moves continuously. (c)Window washer fluid is sprayed out:When the switch is re- leased, it returns to (b). (d)Window washer fluid is sprayed out:When the switch is re- leased, it returns to (a).
Page 73 OPERATION EXPLANATION OF COMPONENTS SWING BRAKE CANCEL SWITCH NOTICE This switch is installed to make it possible to carry out operation temporarily if any abnormality should occur in the swing brake system. It is not intended for permanent use. Repair the cause of the abnormality immediately.
Page 74: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Lock Lever Travel Levers (Machines with travel pedal) Left Work Equipment Control Lever Offset Lock Cover Right Work Equipment Control Lever Boom Offset Control Pedal Blade Control Lever Traveling Accelerator Pedal 3-17...
Page 75 OPERATION EXPLANATION OF COMPONENTS LOCK LEVER WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position. If the lock ● lever is not at the LOCK position and the control levers are touched by mistake, it may lead to serious personal injury.
Page 76 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER This lever(4) is used to control the blade. (a): LOWER (b): RAISE TRAVEL LEVERS 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 EXPLANATION OF COMPONENTS OFFSET LOCK COVER WARNING When not operating the boom offset, always keep it locked with the offset lock cover. If the control pedal is not locked and it is touched by mis- take, it may lead to a serious accident. This offset lock cover (6) locks the boom offset control pedal.
Page 78: Front Window
OPERATION EXPLANATION OF COMPONENTS FRONT WINDOW WARNING When opening or closing the ceiling window, 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 acci- dent.
Page 79 OPERATION EXPLANATION OF COMPONENTS Pull lock pins (A) at the top left and right sides of the front window to the inside to release the lock. Hold the top grip with your right hand, pull it to the front to remove the top of the front window from the frame, then set it on the rail of the top roller.
Page 80 OPERATION EXPLANATION OF COMPONENTS When closing WARNING When closing the window, lower it slowly and be careful not to get your hand caught. Place the work equipment on flat ground and stop the engine. Securely lock the lock lever. Release the lock pin (A). Hold the grip at the bottom of the front window with your left hand and the grip at the top with your right hand, release the lock of catch (C) with your right thumb, then...
Page 81: Sliding Door
OPERATION EXPLANATION OF COMPONENTS Removing front window (bottom) With the front window open, remove lock pins (E), and the bot- tom part of the front window can be removed. Store the removed bottom part of the front window at the rear of the operator's cab and lock with lock pins (E).
Page 82: Rear Window
OPERATION EXPLANATION OF COMPONENTS REAR WINDOW It is possible to open the rear window. Lock the window securely in position with the lever lock. To open the rear window, open the left and right locks, then push the rear window up to the rear. HAMMER FOR EMERGENCY ESCAPE NOTICE To prevent injury from pieces of glass, remove all the broken glass from the window frame.
Page 83: Stow-Away Type Step
OPERATION EXPLANATION OF COMPONENTS STOW-AWAY TYPE STEP CAUTION Except when carrying out inspection and mainte- ● nance, keep step (1) at the stowed position and always check that it is locked before using the machine. If operations are carried out with the step extended, ●...
Page 84 OPERATION EXPLANATION OF COMPONENTS When setting it to position for getting on or off machine Use lock pin (A) under the step to release the lock. Set the step to the position for getting on or off the machine. 3-27...
Page 85: Cap, Cover With Lock
OPERATION EXPLANATION OF COMPONENTS CAP, COVER WITH LOCK There are locks fitted to the fuel tank filler port, operator’s cab, engine hood, door in front of the tool box, pump room door (right side of machine), inspection window at the front right of the machine, cover at the rear of the cab, and the battery room door (left side of machine).
Page 86: Engine Hood
OPERATION EXPLANATION OF COMPONENTS ENGINE HOOD CAUTION When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine hood open. NOTICE Always keep the hood locked except when opening it. Release lock (1) of the engine hood. For details, see "CAP, COVER WITH LOCK (PAGE 3- 28)".
Page 87: Cab Rear Cover
OPERATION EXPLANATION OF COMPONENTS CAB REAR COVER CAUTION When carrying out inspection and maintenance inside the cover, always use the cover support lever to hold the cover open. NOTICE Always keep the cover locked except when opening it. Release lock (1) of the cover. For details, see "CAP, COVER WITH LOCK (PAGE 3- 28)".
Page 88: Pump Room Door, Battery Room Door
OPERATION EXPLANATION OF COMPONENTS PUMP ROOM DOOR, BATTERY ROOM DOOR CAUTION When carrying out inspection and maintenance inside the door, always use the stopper to hold the door open. NOTICE Always keep the door locked except when opening it. Release lock (1) of the door. For details, see "CAP, COVER WITH LOCK (PAGE 3- 28)".
Page 89: Door At Front Of Tool Box
OPERATION EXPLANATION OF COMPONENTS DOOR AT FRONT OF TOOL BOX CAUTION When carrying out inspection and maintenance inside the door, always use the stopper to hold the door open. NOTICE Always keep the door locked except when opening it. Release lock (1) of the door. For details, see "CAP, COVER WITH LOCK (PAGE 3- 28)".
Page 90: Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 91: Power Source For Option
POWER SOURCE FOR OPTION NOTICE When installing electrical equipment not supplied by Komatsu, use 24 V specification with a maximum of 85 W (equivalent to 3.5 A). If equipment is to be installed with a capacity greater than this, please consult your Komatsu distributor.
Page 92: Handling Air Conditioner
OPERATION EXPLANATION OF COMPONENTS HANDLING AIR CONDITIONER GENERAL LOCATIONS OF CONTROL PANEL Air conditioner switch Temperature control switch Air flow selector switch Vent selector lever AIR CONDITIONER SWITCH This switch(1) is used to operate the air conditioner. A/C: Actuated OFF: Stopped AIR FLOW SELECTOR SWITCH The air flow can be set to three levels with this switch (2).
Page 93 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH This switch (3) is used to adjust the temperature. Turn the switch to adjust the temperature as follows. Turn to LEFT to LOWER temperature. Turn to RIGHT to RAISE temperature. VENT SELECTOR LEVER (FEET + UPPER BODY) This lever (4) can be used to select the vent to match the pur- pose of use.
Page 94 OPERATION EXPLANATION OF COMPONENTS (c): Send air to upper body PRECAUTIONS WHEN USING AIR CONDITIONER Ventilate the cab from time to time when using the cooler. If you smoke when the cooler is on, the smoke may start to hurt your eyes, so open the window and carry out ●...
Page 95: Radio
OPERATION EXPLANATION OF COMPONENTS RADIO CONTROL PANEL (1) Power switch, Volume control knob, Balance (5) AS/PS button control knob (6) Preset station buttons (1,2,3,4,5,6) (2) SEL button (7) Display (3) FM/AM selection button (8) Time reset button (4) Display selection button (9) Tuning button POWER SWITCH, VOLUME CONTROL KNOB, BALANCE CONTROL KNOB Press this knob (1) to turn the power for the radio on.
Page 96 OPERATION EXPLANATION OF COMPONENTS 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 97 OPERATION EXPLANATION OF COMPONENTS CONTROLS OF RADIO PRESET STATION BUTTONS Press power switch (1) and display the frequency on dis- play (7). Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and man- ual tuning.
Page 98 OPERATION EXPLANATION OF COMPONENTS 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. (TRE) Treble adjustment button: ●...
Page 99 OPERATION EXPLANATION OF COMPONENTS PRECAUTIONS WHEN USING To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera- ● tion. If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water ●...
Page 100: Operation And Maintenance Manual Holder
OPERATION EXPLANATION OF COMPONENTS OPERATION AND MAINTENANCE MANUAL HOLDER There is a pocket in the rear of the operator’s seat to hold the Operation and Maintenance Manual. Always keep the Operation and Maintenance Manual in this pocket so that it is possible to read it at any time. TOOL COMPARTMENT Open the door at the front of the tool box.
Page 101: Machine Operations And Controls
Always check the items in this section before starting the engine each day. Check sensors for damage Check the sensors for damage. If any abnormality is found, please contact your Komatsu distributor for ser- vice or repair. Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses.
Page 102 Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new parts. 12. Check bucket with hook (if equipped) for damage. Check that there is no damage to the hook, guide, or hook mount. If any abnormality is found, please contact your Komatsu distributor for repair. 3-45...
Page 103 OPERATION MACHINE OPERATIONS AND CONTROLS CHECKS BEFORE STARTING Always carry out the items of the checks in this section before starting the engine. CHECK COOLANT LEVEL, ADD WATER WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the ●...
Page 104 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 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. Open the engine hood on the machine.
Page 105 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK FUEL LEVEL, ADD FUEL WARNING Be careful not to let the fuel overflow when adding fuel. This may cause a fire. Wipe up all fuel that is spilled. If there is sand where the fuel is spilled, remove all the sand. Fuel is flam- mable and dangerous.
Page 106 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. If the work equipment is not in the condition shown in the diagram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinders, then lower the boom, set the bucket teeth in contact with the...
Page 107 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK The oil level will vary depending upon the oil temperature. Accordingly, use the following as a guide: Before operation: around L level ● (Oil temperature 10 to 30ºC (50 to 86ºF)) Normal operation: around H level ●...
Page 108 If the fuses frequently blower if there are traces of short circuits on the electrical wiring, locate the ● cause immediately and carry out repairs, or contact your Komatsu distributor for repairs. If flammable materials (dead leaves, twigs, dry grass, etc.) accumulate around the battery, they will ●...
Page 109 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUST BEFORE OPERATION WARNING Adjust the seat position before starting operations or after changing the operator. ● Adjust the seat so that the brake pedal can be depressed fully with the operator’s back against the ●...
Page 110 OPERATION MACHINE OPERATIONS AND CONTROLS SEAT BELT WARNING Before fitting the seat belt, check that there is no abnormality in the belt mount bracket or mounting ● belt. If it is worn or damaged, replace the seat belt. Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manu- ●...
Page 111 OPERATION MACHINE OPERATIONS AND CONTROLS SEAT BELT ADJUSTMENT Shortening Pull the free end of the belt on either the buckle body or tongue side. Lengthening Pull the belt while holding it at a right angle to the buckle or tongue. 3-54...
Page 112 Depth display (9) ● If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or discon- nection in the monitor wiring, so contact your Komatsu distributor for repairs. 3-55...
Page 113 Engine water temperature gauge (6) ● Fuel gauge (7) ● Press lamp switch(10) to turn on the head lamps. If it does not light up, there is probably a blown bulb or disconnection, so please contact your Komatsu dis- tributor for repairs. 3-56...
Page 114: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE NORMAL STARTING WARNING Start the engine only after sitting down in the opera- ● tor's seat. 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 115 OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE IN COLD WEATHER WARNING Start the engine only after sitting down in the opera- ● tor'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 116 OPERATION MACHINE OPERATIONS AND CONTROLS When preheating monitor (3) goes out, turn the key in starting switch (2) to the START position to start the engine. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position. 3-59...
Page 117: After Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS AFTER STARTING ENGINE WARNING Emergency stop ● If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. If the work equipment is operated without warming the machine up sufficiently, the response of the ●...
Page 118 OPERATION MACHINE OPERATIONS AND CONTROLS Operate bucket control lever (3) and arm control lever (4) slowly to move the bucket cylinder and arm cylinder to the end of the stroke. NOTICE When the work equipment is retracted, take care that it does not interfere with the machine body or ground.
Page 119 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the stow-away type step at the front right ● part on the outside of the machine is locked in the stowed position. Set the work equipment to the maximum left offset pos- ● ture shown in the diagram on the right, then raise the boom and check that it stops automatically when it comes close to the operator's compartment.
Page 120 If any abnormality is found during the inspection, use the procedure in Item 3 to warm up the hydraulic oil, then carry out the inspection again. If there is still an abnormality, move the machine to a safe place, stop the engine, and contact your Komatsu dis- tributor for inspection and repair.
Page 121: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Conse- quently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at mediumspeed to allow it to cool gradually, then stop it.
Page 122: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION PREPARATIONS FOR MOVING THE MACHINE OFF WARNING Before operating the steering levers, check the direc- ● tion 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 ●...
Page 123 When booster pedal (4) is depressed, the speed will increase. For details of the speed, see SPECIFICATIONS (PAGE 5-2). For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repairs. 3-66...
Page 124 When booster pedal (4) is depressed, the speed will increase. For details of the speed, see SPECIFICATIONS (PAGE 5-2). For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repairs. 3-67...
Page 125 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 posi- tion, then stop the machine. 3-68...
Page 126: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levers is reversed. Use the travel levers to change direction. Avoid sudden changes of direction as far as possible.
Page 127 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 128: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The rear of the machine extends outside the track ● width. Check that the surrounding area is safe before swinging be upper structure. Check that swing lock monitor is not lighted up. ● If the swing control lever is operated quickly, the ●...
Page 129: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the work equipment control lever is operated quickly, the work equipment will move quickly; and if it is operated slowly, the work equipment will move slowly. 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 130 OPERATION MACHINE OPERATIONS AND CONTROLS Bucket control ● Move the right work equipment control lever to the left or right to operate the bucket. Boom offset operation ● Boom offset operations can be carried out with the boom offset control pedal. Blade control ●...
Page 131: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, be extremely careful when operating. OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects. This is not only dangerous, but will also markedly reduce the life of the machine.
Page 132 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 133 OPERATION MACHINE OPERATIONS AND CONTROLS AVOID HITTING BLADE Be careful not to hit the blade against rocks or boulders. This will cause premature damage to the blade or cylinders. FOLDING IN WORK EQUIPMENT When folding in the work equipment to the travel or transporta- tion posture, be careful not to let the bucket hit the blade.
Page 134 OPERATION MACHINE OPERATIONS AND CONTROLS AVOID INTERFERENCE BETWEEN ARM CYLINDER AND OBSTACLES When the arm is operated, the position of the rear tip of the arm cylinder changes. Be careful not to get the wiring caught or hit anything in the surrounding area. 3-77...
Page 135: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION TRAVELING When traveling over obstacles such as boulders or tree stumps, the machine (in particular, the undercarriage) is sub- jected to a large shock, so reduce the travel speed and travel over the obstacle at the center of the tracks. As far as possible, remove such obstacles or avoid traveling over them.
Page 136 OPERATION MACHINE OPERATIONS AND CONTROLS PROTECTION OF SENSORS FROM OBSTACLES Be careful not to hit interference prevention sensors or sensor levers with other objects (logs, ditches, steel sheets, etc.). 3-79...
Page 137: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING When traveling, raise the bucket approx. 20 to 30cm (8 to 12 in) from the ground. Do not travel downhill in reverse. When traveling over ridges or other obstacles, keep ● the work equipment close to the ground and travel slowly.
Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK Travel down fills with the sprocket side down. If the machine travels down with the sprocket side up, the track tends to become loose, and that can cause skipping pitches. When traveling up a steep hill of more than 15º, set the work equipment to the posture shown in the diagram on the right.
Page 139: 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. STUCK ONE SIDE OF TRACK NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.
Page 140: 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. When the condition of the machine is as shown in the diagram at right, each cylinder's maximum pushing excavation force is obtained when the bucket cylinder and link, arm cylinder and...
Page 141 OPERATION MACHINE OPERATIONS AND CONTROLS SMOOTHING WORK When refilling after excavation and when smoothing the ground surface, use the blade. SIDE DITCHING WORK When the boom offset is used, it is possible to carry out side ditching work in confined spaces without swinging the upper works.
Page 142: Bucket Replacement
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING When the pin is knocked in with a hammer, pieces of metal may fly into your eyes and cause serious ● injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equip- ment.
Page 143 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket, the O-rings are easily damaged, so fit the O-rings on the boss of the arm end as shown in the dia- gram. When knocking in the pins, move the O-ring down to the regular groove.
Page 144: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room ● when stopping. When stopping the machine, select flat hard ground ● and avoid dangerous places. If it is unavoidably nec- essary to park the machine on a slope, insert blocks underneath the track shoes.
Page 145: Check After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS Lower the engine speed to low idling by fuel control dial (2). Lower the bucket horizontally until the bottom touches the ground. Lower the blade to the ground. (Only machines with blade specification) Set lock lever (3) in the LOCK position. CHECK AFTER FINISHING WORK Check the engine water temperature(1), engine oil pressure(2), and fuel level(3) on the machine monitor.
Page 146: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Door of operator’s cab Always remember to close the window. (2) Fuel tank filler port (3) Engine hood (4) Cover at rear of cab (5) Battery room door (6) Pump room door (7) Door at front of tool box (8) Inspection window at front right of machine...
Page 147: Handling 4-System
The auto-stop cancel switch must only be used for moving the machine to a safe place when there is ● an abnormality in the 4-system. It must not be used for any other reason. When changing to the telescopic arm or long arm specified by Komatsu, ask your Komatsu distribu- ● tor to change the attachment.
Page 148 If this happens, move the machine to a safe place, and contact your Komatsu distributor for inspection. Before using the 4-system, always carry out the ●...
Page 149 OPERATION MACHINE OPERATIONS AND CONTROLS INTERFERENCE PREVENTION DEVICE (BETWEEN BUCKET AND CAB) WARNING This device is a preventive device intended only for unexpected cases, so it is dangerous to relay on it completely during operations. Always be careful that the work equipment does not come close to the cab during operations.
Page 150 OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION WHEN THERE IS AUTOMATIC STOP WARNING After using the cancel switch to cancel the automatic stop, never try to raise the boom, pull in the arm, or operate the left offset. After automatic stop, it is impossible to raise the boom, pull in the arm, or operate the left offset. Move the work equipment to the front or to the right to move it away from the operator’s compartment, then carry out normal operations.
Page 151 OPERATION MACHINE OPERATIONS AND CONTROLS INTERFERENCE PREVENTION DEVICE (BETWEEN BUCKET AND FRONT RIGHT OUTSIDE, HANDRAIL) WARNING This device is a preventive device intended only for use in unexpected cases, so it is dangerous to rely on it completely during operations. Always be careful that the work equipment does not come close to the cab during operations.
Page 152 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping during arm IN If the arm is pulled in with the work equipment in the posture in the diagram on the right (maximum right offset), if the bucket enters area A (1000 - 1100 mm (39.4 - 43.3 in)) in the diagram on the right, the arm IN speed will be reduced.
Page 153 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping during right offset If the offset is operated to the right with the work equipment in the posture in the diagram on the right (offset at central posi- tion), if the bucket enters area B (50 - 100 mm (2.0 - 5.9 in)) in the diagram on the right, the right offset will automatically stop.
Page 154 OPERATION MACHINE OPERATIONS AND CONTROLS HANDLING AUTOMATIC CONTROL DEVICE Depth display: This displays the depth from the ground surface. Depth display 0 set mode: This displays the depth from the standard surface. Depth mode: This sets the amount the boom can be lowered. Height mode: This sets the amount the boom can be raised.
Page 155 OPERATION MACHINE OPERATIONS AND CONTROLS Offset mode: This determines the left offset position for opera- tions such as ditch digging. It is possible to set either the depth display or depth display 0 set mode together with the other three modes, so use these settings to match the operation.
Page 156 OPERATION MACHINE OPERATIONS AND CONTROLS Setting depth display 0 set mode (depth from standard surface) This displays the desired standard surface as 0.0 m (0.0 in), and displays the depth of the bucket from this surface. Turn mode selector switch (1) to the depth display 0 set mode position.
Page 157 OPERATION MACHINE OPERATIONS AND CONTROLS To return the setting so that it measures the depth from the ground surface, turn mode selector switch (1) to the depth display 0 set mode position, then turn setting switch (2) to the CLEAR position. The display will return to the depth display measured from the ground surface.
Page 158 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE As in the diagram on the right, if the arm is pulled in and the depth is set, the arm may become lower when it is pushed out, so be careful when setting. NOTICE As in the diagram on the right, if the arm is moved out and the depth is set, the bucket may become lower when it is pulled in, so be careful not to damage any buried object.
Page 159 OPERATION MACHINE OPERATIONS AND CONTROLS Turn mode selector switch (1) to the height mode posi- tion. Raise the boom to the position to be set. Turn setting switch (2) to the SET position. The buzzer will sound twice and indicator (3) will light up. If the boom is lowered, then raised again, it will stop at the set point.
Page 160 OPERATION MACHINE OPERATIONS AND CONTROLS Setting offset mode When the boom is offset to the left to the desired set position, it will automatically stop. Turn mode selector switch (1) to the offset mode position. Offset the boom to the position to be set. Turn setting switch (2) to the SET position.
Page 161: Handling Road Liner
OPERATION MACHINE OPERATIONS AND CONTROLS HANDLING ROAD LINER (Machine equipped with road liner) ROAD LINERS INFORMATION Road liner 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. Be sure to operate without straining the rubber shoes in a way that matches the condition of the jobsite and the nature of the work.
Page 162 OPERATION MACHINE OPERATIONS AND CONTROLS USING ROAD LINERS 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 rubber shoes and road liners. In places such as river beds where there are large numbers of large and small boulders, the stones may get ●...
Page 163: 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 164: Loading And Unloading With Trailer
OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING When loading or unloading on to a trailer, set to low ● speed, and do not operate the travel speed selector switch during the operation. Run the engine at low idling, set to low speed, and ●...
Page 165 OPERATION TRANSPORTATION LOADING Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
Page 166 OPERATION TRANSPORTATION Align the direction of travel with the ramps 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. Do not operate the travel boost pedal.
Page 167 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. To prevent damage to the bucket cylinder during transportation, fit a wooden block at one end of the ●...
Page 168 OPERATION TRANSPORTATION UNLOADING Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
Page 169 OPERATION TRANSPORTATION Raise the work equipment, pull in the arm under the boom, then move the machine slowly. When the machine is horizontal on top of the rear wheels of the trailer, stop the machine. NOTICE If the machine is unloaded with the arm pulled in, the ●...
Page 170: Lifting Machine
The lifting procedure applies to machines with standard specifications. The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor. For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 171 OPERATION TRANSPORTATION Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. Put blocks between the wire rope and the machine to prevent damage to the rope or machine. Set the lifting angle (A) of the wire rope to 30o to 40o, then lift the machine slowly.
Page 172: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained ● when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 173 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 ●...
Page 174: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, so stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.
Page 175: After Cold Weather Season
OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER SEASON When season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. ● For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-11)". 3-118...
Page 176: 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 177: After Storage
NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. Wipe off all the grease coating the hydraulic cylinder rods.
Page 178: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting 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 "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-52)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm is pulled in, the speed of movement will drop...
Page 179 OPERATION TROUBLESHOOTING PHENOMENA THAT ARE NOT FAILURES ON THE 4-SYSTEM After automatic stop, even when the work equipment has ● been moved 5 - 10 cm (2 - 4 in) to the front or right, it is impossible to raise the boom, pull the arm in, or operate the left offset.
Page 180 OPERATION TROUBLESHOOTING When the work equipment angle sensor has been ● removed and installed again, the automatic stop position will change. When the cutting edge of the bucket is lowered to the ● ground surface, the depth display does not become 0.0 m (0.0 in).
Page 181: Towing The Machine
OPERATION TROUBLESHOOTING 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 ●...
Page 182: Lightweight Towing Hook
If the sensor should go under water, check the actuation of the automatic stop. If there is any abnormality, please contact your Komatsu distributor for repairs. When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry ●...
Page 183: Discharged Battery
OPERATION TROUBLESHOOTING DISCHARGED BATTERY WARNING It is dangerous to charge the battery while it is still ● mounted on the machine. Always remove the battery before charging it. When checking or handling the battery, stop the ● engine and turn the starting switch key to the OFF position.
Page 184 OPERATION TROUBLESHOOTING REMOVAL AND INSTALLATION OF BATTERY Removal of battery Open the battery room door, then remove rubber cover (1) installed to the top of the battery. Remove cable (2) from the negative (-) terminal (ground). Remove connection cable (4) and cable (3) from the pos- itive (+) terminal.
Page 185 OPERATION TROUBLESHOOTING BATTERY CHARGES When charging the battery, there is danger that the battery may explode if it is handled wrongly, so follow the instructions in "OTHER TROUBLE (PAGE 3-131)" and the instruction manual supplied with the charger, and be sure to observe the following precautions.
Page 186 OPERATION TROUBLESHOOTING 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 posi- ● tive (+) and negative (-) terminals. When starting the engine with a booster cable, always ●...
Page 187 OPERATION TROUBLESHOOTING BOOSTER CABLE CONNECTION Keep the starting switch of the normal machine and problem machine are both at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. Connect one clip of booster cable (A) to the positive (+) terminal of the problem machine.
Page 188: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. ● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for ● repairs. Problem Main causes...
Page 189 OPERATION TROUBLESHOOTING CHASSIS In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for ● repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm, Lack of hydraulic oil Add oil to specified level, see ●...
Page 190 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. ● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for ● repairs. Problem Main causes Remedy Engine oil pressure monitor lights...
Page 191 OPERATION TROUBLESHOOTING Problem Main causes Remedy Combustion noise occasionally Defective nozzle Replace nozzle) ● ● make breathing sound Abnormal noise generated (com- Low-grade fuel being used Change to specified fuel ● ● bustion or mechanical) Overheating See "Red range of engine ●...
Page 192 OPERATION TROUBLESHOOTING 4-SYSTEM RELATED PARTS If any error code is displayed on the depth display portion of the monitor panel, follow the procedure given in the table below for the action to take after self diagnosis. ACTION TO TAKE AFTER SELF DIAGNOSIS Error code Machine condition Probable cause...
Page 193 OPERATION TROUBLESHOOTING MEMO 3-136...
Page 194: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 195: Maintenance Information
KOMATSU GENUINE REPLACEMENT PARTS Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. WINDSHIELD WASHER FLUID Use automobile windshield washer fluid, and be sure not to let any dirt get into it.
Page 196 MAINTENANCE MAINTENANCE INFORMATION DO NOT DROP THINGS INSIDE MACHINE When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop ● nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead to failure.
Page 197 MAINTENANCE MAINTENANCE INFORMATION CHECKS AFTER INSPECTION AND MAINTENANCE WORKS If you forget to carry out the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injuly or property damage. Always do as follows. Checks after operation (with engine stopped) ●...
Page 198: Outline Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. ● We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil.
Page 199 Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 200 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. 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.
Page 201 Do not carry out sampling on rainy or windy days when water or dust can get into the oil. ● For further details of KOWA, please contact your Komatsu distributor. OIL AND FUEL STORAGE Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 202: Electric System Maintenance
External electro-magnetic interference may cause malfunction of the control system controller, so before ● installing a radio receiver or other wireless equipment, contact your Komatsu distributor. When working at the seashore, carefully clean the electric system to prevent corrosion. ●...
Page 203: Wear Parts List
The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.
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 4-12...
Page 206: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifica- tions, refer to the Komatsu web page or consult your Komatsu distributor. 4-13...
Page 207: Tightening Torque Specifications
The tightening torque is determined by the width across the flats of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 208: Periodic Replacement Of Safety Critical Parts
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty...
Page 209: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART Initial 250 Hours Maintenance (Only after the first 250 hours) REPLACE FUEL FILTER CARTRIDGE ......................4-52 CHECK ENGINE VALVE CLEARANCE, ADJUST....................4-61 When Required CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ................4-19 CLEAN INSIDE OF COOLING SYSTEM......................
Page 210 MAINTENANCE MAINTENANCE SCHEDULE CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT........... 4-50 Every 500 Hours Maintenance REPLACE FUEL FILTER CARTRIDGE ......................4-52 CHECK SWING PINION GREASE LEVEL, ADD GREASE ................4-53 LUBRICATE SWING CIRCLE (2 POINTS) ......................4-53 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)..............
Page 211: Maintenance Procedure
Check and adjust engine valve clearance ● Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS and 2000 HOURS SERVICE.
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 the engine will suffer damage. Always stop the engine before carrying out these opera- tions.
Page 213 MAINTENANCE MAINTENANCE PROCEDURE NOTICE When cleaning the dust cup, do not remove evacuator valve (6). Clean the inside of the air cleaner body and the dust cap. NOTICE Do not clean the inner element and use it again. When replacing the outer element, replace the inner ele- ment with a new part at the same time.
Page 214 MAINTENANCE MAINTENANCE PROCEDURE Replacing inner element Open the battery room door on the left side of the machine, remove clips (2) at 3 places, then take out the dust cup. Remove outer element (4). Do not remove inner element (5) at this point. NOTICE When cleaning the dust cup, do not remove evacuator valve (6).
Page 215: Clean Inside Of Cooling System
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 216 MAINTENANCE MAINTENANCE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix- ing 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 (anti- freeze/total amount of coolant ×...
Page 217 MAINTENANCE MAINTENANCE PROCEDURE Stop the engine. Check that the coolant temperature has gone down enough to make it possible to touch the radiator cap sur- face by hand, then turn radiator cap (1) slowly until it con- tacts the stopper to release the pressure. Following this, push radiator cap (1), turn it until it con- tacts the stopper, then remove it.
Page 218: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Method for tightening First tighten to a tightening torque of 196 ± 19.6 N•m (20 ± 2 kgf•m, 144.7 ± 14.5 lbft) then check that the nut and shoe are in close contact with the link contact surface.
Page 219: Check And Adjust Track Tension
Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the proce- dure given here, please contact your Komatsu distributor. increasing track tension Prepare a grease gun.
Page 220 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Loosen plug (1) gradually to release the grease.
Page 221: Check Road Liner (Machines Equipped With Road Liner)
MAINTENANCE MAINTENANCE PROCEDURE CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER) If the road liner are in the following condition, they must be repaired or replaced, so please contact your Komatsu distributor for repair or replacement. Height of lug If lug height "a" is reduced by wear, the drawbar pull will ●...
Page 222: Replace Bucket Teeth (Vertical Pin Type)
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the point before the adapter starts to wear. WARNING It is dangerous if the work equipment moves by mis- ● take when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the levers.
Page 223 MAINTENANCE 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. ● Clean the surface of adapter (4) and remove the soil with a knife.
Page 224 MAINTENANCE MAINTENANCE PROCEDURE 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). After replacing a bucket tooth, always check the follow- ing. After the lock pin has been knocked in completely, check that it is secured by the point and surface.
Page 225: Replace Bucket Teeth (Horizontal Pin Type)
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the teeth before the wear reaches the adapter. WARNING It is dangerous if the work equipment moves by mis- ● take when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the levers.
Page 226: Adjust Bucket Clearance
MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when the clearance is being adjusted. Set the work equipment in a stable condition, then stop the engine and lock the lock lever securely. Set the work equipment to the position shown in the dia- gram at right, stop the engine and set the lock lever to the locked position.
Page 227: 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 Since the ratio should be varied depending on atmospheric temperature, replenish washer fluid at the following mixture ratio, taking temperature into account.
Page 228 MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER) CHECK LEVEL OF REFRIGERANT (GAS) WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant.
Page 229: Washing Washable Floor
MAINTENANCE MAINTENANCE PROCEDURE WASHING WASHABLE FLOOR With the washable floor, the dirt on the cab floor can be washed off directly with water. WARNING When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely ●...
Page 230 MAINTENANCE MAINTENANCE PROCEDURE Set the lock lever to the LOCK position, then stop the engine. Remove the floor mat. Flush out the dirt on the floor directly with water through water drain hole (1). After completing the washing operation, install the floor mat. 4-37...
Page 231 MAINTENANCE MAINTENANCE PROCEDURE METHOD OF SETTING MACHINE ANGLE Method Using Slope WARNING Select a firm flat place. Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground. Stop the machine so that the work equipment is on the downhill side.
Page 232: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-57)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. Bleeding air from pump Loosen air bleed plug (1) installed to the drain port and check that oil oozes out (air bleeding is com- pleted).
Page 233 MAINTENANCE MAINTENANCE PROCEDURE Bleeding air from travel motor (only when oil inside travel motor case has been drained) Run the engine at low idling, remove hose (1) from port C, then when the oil has flowed out, tighten it again. Run the engine at low idling and swing the work equipment 90º...
Page 234: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECKS BEFORE STARTING (PAGE 3-46)" in the OPERATION section. Check coolant level, add water ● Check oil level in engine oil pan, add oil ● Check fuel level, add fuel ●...
Page 235: Every 50 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 50 HOURS MAINTENANCE DRAIN WATER AND SEDIMENT FROM FUEL TANK NOTICE Never use trichloroethylene for washing the inside of the tank. Carry out this operation before starting to operate the machine. Open the pump room door on the right side of the machine.
Page 236: 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.
Page 237 MAINTENANCE MAINTENANCE PROCEDURE (7) Boom cylinder foot pin (1 point) (8) Offset cylinder foot pin (1 point) (9) Offset cylinder rod end pin (1 point) (10) Sub-link coupling pin (2 points) (11) Second boom-Third bracket coupling pin (2 points) (12) Arm cylinder foot pin (2 points) (13) Arm cylinder rod end pin (1 point) (14) Third bracket-Arm coupling pin (1 point) (15) Bucket cylinder foot pin (1 point)
Page 238: Check Oil Level In Swing Machinery Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL 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. Remove dipstick (G) and wipe the oil from the dipstick with a cloth.
Page 239: 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. CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. ●...
Page 240: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L line, use a pipette to lower the level to the U.L line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4-47...
Page 241 If distilled water is added to above the bottom of the sleeve, use a pipette to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When It is Possible to Use Indicator to Check Electrolyte Level If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 242: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. Prepare the following: Container to catch drained oil: Min.
Page 243: Check, Adjust Tension Of Air Conditioner Compressor Belt
MAINTENANCE MAINTENANCE PROCEDURE CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT WARNING If the fan guard has been removed, always be sure to install it again. If it is left removed, you may touch the belt and fan by accident and suffer serious injury. Checking Open the engine hood and remove fan guard (1).
Page 244 MAINTENANCE MAINTENANCE PROCEDURE Adjusting Remove fan guard (1). Insert a bar between compressor (2) and the bracket (3) to fix compressor (2) in position. When fixing in position, put a piece of wood between the bar and compressor (2) to prevent damage to compressor (2). NOTICE When loosening bolt (4), be careful not to damage piping (6) of the air conditioner.
Page 245: Every 500 Hours Maintenance
Tighten joint bolt (2). Always use a genuine Komatsu filter cartridge. After replacing the filter cartridge, start the engine and check for any leakage of oil from the filter seal sur- face.
Page 246: Check Swing Pinion Grease Level, Add Grease
Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Please contact your Komatsu distributor. The total amount of grease is 10 liters (9.1 kg) (2.64 US gal, [20 lb]). Install cover (2) with bolts (1).
Page 247: Clean And Inspect Radiator Fins, Oil Cooler Fins And Condenser Fins (Only For Machines Equipped With Air Conditioner)
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) WARNING If compressed air, high-pressure water, or steamhit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury.
Page 248: Clean Internal And External Air Filters Of Air Conditioner System (Only For Machines Equipped With Air Conditioner)
MAINTENANCE MAINTENANCE PROCEDURE CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) WARNING If compressed air, high-pressure water, or steamhit 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.
Page 249: Replace Hydraulic Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE HYDRAULIC FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. ● Wait for the temperature to go down before cleaning the hydraulic tank strainer. When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal ●...
Page 250: Replace Breather Element In Hydraulic Tank
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREATHER ELEMENT IN HYDRAULIC TANK 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 251: 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. 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.
Page 252: Change Oil In Final Drive Case
Ask Komatsu distributor to check the play of the turbocharger rotor. CHECK FAN BELT TENSION AND REPLACE FAN BELT Special tools are required for inspection and replacement of the fan belt. Contact your Komatsu distributors for inspection and replacement. 4-59...
Page 253: 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 OIL LEVEL IN PTO GEAR CASE, ADD OIL 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.
Page 254: Clean Hydraulic Tank Strainer
Contact your Komatsu distributor for cleaning or inspection. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 255: Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)
● Do not hit it, roll it, or subject it to any impact. ● When disposing of the accumulator, the gas must be released. Please contact your Komatsu distribu- ● tor to have this work carried out. FUNCTION OF ACCUMULATOR The accumulator stores the pressure in the control circuit.
Page 256 In the following cases, the charge pressure of the accumulator has gone down. Please contact your Komatsu dis- tributor. Work equipment does not go down ●...
Page 257 MAINTENANCE MAINTENANCE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT NOTICE Carry out the following procedure to operate the work equipment control lever fully to the front, rear, left, and right within 15 seconds of stopping the engine. When the engine stops, the pressure in the accumulator gradually goes down, so the pressure can only be released immediately after the engine is stopped.
Page 258 MAINTENANCE MAINTENANCE PROCEDURE Turn the starting switch to the OFF position. Remove cover (1) at the top surface of the hydraulic tank, then slowly loosen oil filler cap (F) to release the internal pressure. 4-65...
Page 259: Every 4000 Hours Maintenence
● Do not hit it, roll it, or subject it to any impact. ● When disposing of the accumulator, the gas must be released. Please contact your Komatsu distribu- ● tor to have this work carried out. If operations are continued after the performance of the accu-...
Page 260: 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 WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before changing the oil.
Page 261 MAINTENANCE MAINTENANCE PROCEDURE Set the oil container under the drain plug under the machine. Using the handle, remove drain plug (P) and drain the oil. Check the O-ring installed to plug (P), and if it is dam- aged, replace the O-ring. After draining the oil, tighten drain plug (P).
Page 262: Specifications
SPECIFICATIONS...
Page 263 Unit PC128UU-2 Operating weight kg (lb) 13,500 (29,768) Bucket capacity 0.45 (0.58) (cu.yd) Name of engine KOMATSU S4D102E diesel engine Engine horsepower kW (HP)/rpm 64 (87) / 2,200 Overall length mm (ft in) 7,400 (24’3") Overall height mm (ft in) 2,755 (9’)
Page 264 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC128UU-2 Max. digging reach mm (ft in) 7,285 (23’11") Max. digging depth mm (ft in) 4,865 (15’12") Max. digging height mm (ft in) 8,150 (26’9") Max. vertical wall depth mm (ft in) 3,305 (10’10") Max. dumping height mm (ft in) 5,850 (19’2")
Page 265 SPECIFICATIONS SPECIFICATIONS MEMO...
Page 266: Attachments And Options
ATTACHMENTS OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 267: General Precautions
GENERAL PRECAUTIONS PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu- tor first.
Page 268 Stay in a safe place where there is no danger if the load should fall. NOTICE Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per- son. For details of removal and installation operations, contact your Komatsu distributor.
Page 269: Precautions When Installing Attachments
Always follow the correct procedure when installing ● the boom and arm. If the correct procedure is not followed, this may lead to serious damage or injury, so consult your Komatsu distributor before carrying out installation. If long work equipment is installed, the working range ●...
Page 270: Handling Bucket With Hook
● If the bucket with hook is turned and used for operations, it ● will hit the arm during dumping operations, so be careful when using it. If you are planning to install a hook, contact your Komatsu distributor. ●...
Page 271: Handling Car Heater
ATTACHMENTS AND OPTIONS HANDLING CAR HEATER HANDLING CAR HEATER EXPLANATION OF COMPONENTS The car heater utilizes the water heated by the engine. Use the car heater when the engine coolant is warmed. CAR HEATER FAN SWITCH This switch(1) adjusts air-flow in 2 steps. : Strong : Weak OFF : Car heater turned off.
Page 272: Location Of Fire Extinguisher
HANDLING CAR HEATER LOCATION OF FIRE EXTINGUISHER When fire extinguisher (1) is installed, it can be installed to the position inside the cab shown in the diagram. For details of the parts needed for installation, please contact your Komatsu distributor.
Page 273: Introduction Of Attachments
When installing optional parts or attachments, there may be problems with safety, so contact your ● Komatsu distributor for advice. Do not use optional parts or attachments that are not authorized by Komatsu or your Komatsu distrib- ● utor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
Page 274: Attachment Installation Combination Table
ATTACHMENTS AND OPTIONS ATTACHMENT INSTALLATION COMBINATION TABLE ATTACHMENT INSTALLATION COMBINATION TABLE ATTACHMENT COMBINATIONS This table lists the combination of attachments which can be installed to the standard arm, short arm and long arm. NOTICE When the long armis equipped, if the bucket is pulled in to the machine body, the arminterferes with ●...
Page 275: Selection Of Track Shoes
ATTACHMENTS AND OPTIONS ATTACHMENT INSTALLATION COMBINATION TABLE 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 and C are the wide shoe, so there are limits on the use.
Page 276: Index
CAP, COVER WITH LOCK ......... 3-28 GENERAL PRECAUTIONS ........6-2 CARRYING OUT KOWA GENERAL VIEW ..........3-2 (Komatsu Oil Wear Analysis) ......4-7 GENERAL VIEW CONTROLS AND GAUGES ..3-3 CHECK AFTER FINISHING WORK ....3-88 GENERAL VIEW OF MACHINE ......3-2 CHECK AFTER SHUT OFF ENGINE ....
Page 277 PRODUCT IINFORMATION .........1-8 PROHIBITED OPERATIONS .......3-74, 6-5 PUMP ROOM DOOR, BATTERY ROOM DOOR .............3-31 RADIO ..............3-38 REAR WINDOW ..........3-25 RECOMMENDED APPLICATIONS ....3-83 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ......4-13 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ...........4-11...
Page 278 MEMO...

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