Page 1 PC1250LC 30001 SERIAL NUMBERS and up NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages . If a foreign language manual is necessary , contact your local distributor for availability . WARNING Unsafe use of this machine may cause serious injury or Death.
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Page 3 In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 1 - 4...
Page 6 FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8 FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work See the section "RECOMMENDED APPLICATIONS (PAGE 3-132)" for further details. DIRECTIONS OF MACHINE Front Operator's seat...
Page 9 FOREWORD INTRODUCTION VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. PROXIMITY VISIBILITY The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below.
Page 10 BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 11 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 12 FOREWORD PRODUCT INFORMATION SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 11...
Page 13: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT BREAKING-IN THE NEW MACHINE PRODUCT INFORMATION 1- 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 10 EPA REGULATIONS, ENGINE NUMBER PLATE 1- 10 SERVICE METER LOCATION 1- 11 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 11...
Page 14: Foreword
FOREWORD CONTENTS GREASE PUMP 3- 71 MACHINE OPERATIONS AND CONTROLS 3- 75 BEFORE STARTING ENGINE 3- 75 STARTING ENGINE 3- 98 AFTER STARTING ENGINE 3-101 STOPPING THE ENGINE 3-111 MACHINE OPERATION 3-112 STEERING THE MACHINE 3-116 SWINGING 3-118 WORK EQUIPMENT CONTROLS AND OPERATIONS 3-119 WORKING MODE 3-121...
Page 15 FOREWORD CONTENTS RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 TIGHTENING TORQUE SPECIFICATIONS 4- 12 TIGHTENING TORQUE LIST 4- 12 SAFETY CRITICAL PARTS 4- 13 SAFETY CRITICAL PARTS LIST 4- 13 MAINTENANCE SCHEDULE 4- 14...
Page 16 FOREWORD CONTENTS RELEASING PRESSURE 7- 13 TRANSPORTATION 7- 14 MACHINE CONFIGURATION FOR TRANSPORT 7- 14 WEAR PARTS 7- 21 WEAR PARTS LIST 7- 21 MAINTENANCE 7- 22 CHECK BEFORE STARTING 7- 22 EVERY 10 HOURS MAINTENANCE 7- 24 EVERY 5000 HOURS MAINTENANCE 7- 25 SPECIFICATION 7- 27...
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Page 19: Safety Information
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION Safety rules 2- 12 If problems are found 2- 12 Working wear and personal protective items 2- 12 Fire extinguisher and first aid kit 2- 12 Safety equipment 2- 12 Keep machine clean 2- 13...
Page 20 SAFETY SAFETY SAFETY MACHINE OPERATION 2- 21 STARTING ENGINE 2- 21 Checks before starting engine 2- 21 Safety rules for starting engine 2- 21 Starting engine in cold weather 2- 22 OPERATION 2- 23 Checks before operation 2- 23 Safety rules for changing machine directions 2- 23 Safety rules for traveling 2- 24...
Page 21: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. 2 - 4...
Page 22: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2 - 5...
Page 23: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution before operating (09802-03000) (3) Caution for leaving operator's seat (09654-03001) 2 - 6...
Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electric cables (09801-03001) (5) Caution for operating pattern (09822-03000) 2 - 7...
Page 25 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (6) Caution when opening or closing front window (09839-03000) (7) Caution when stowing front window (09803-03000) (8) Caution for high-temperature hydraulic oil (09653-03001) (9) Caution with high-temperature coolant (09668-03001) 2 - 8...
Page 26 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Caution for handling accumulator and gas spring (09659-53000) (11) Caution for adjusting track tension (09657-03003) (12) Caution for handling cable (09808-03000) (13) Stopping rotation for inspection and maintenance (09667-03001) 2 - 9...
Page 27 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (14) Explanation of methods for emergency escape (20Y-00-31170) (15) Caution against falling (09805-23000) (16) Caution against falling (09805-13000) (17) Prohibited to enter within swing range (09133-23000) 2 - 10...
Page 28 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (18) Beware of work equipment (09134-A1681) (19) Caution when handling battery (14X-98-11370) (20) Caution for high-pressure fuel (6217-71-9331) (21) Prohibition of jump start (09842-A0481) 2 - 11...
Page 29: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 30: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS Never remove any safety features. Always keep them in good operating condition. KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors).
Page 31: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe)
Page 32: Do Not Get Caught In Articulated Portion
SAFETY GENERAL PRECAUTIONS DO NOT GET CAUGHT IN ARTICULATED PORTION The clearance around the work equipment will change according to the movement of the link. If you get caught, this may lead to serious personal injury. Do not allow anyone to approach any rotating or telescoping part. BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when...
Page 33: Fire Prevention And Explosion Prevention
SAFETY GENERAL PRECAUTIONS FIRE PREVENTION AND EXPLOSION PREVENTION Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling.
Page 34: Action If Fire Occurs
Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual.
Page 35: Unauthorized Modifications
GENERAL PRECAUTIONS UNAUTHORIZED MODIFICATIONS If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility.
Page 36: Distance To High Voltage Cables
SAFETY GENERAL PRECAUTIONS 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 personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 37: 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 38: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 39: Starting Engine In Cold Weather
SAFETY SAFETY MACHINE OPERATION Do not allow anyone apart from the operator to ride on the machine. STARTING ENGINE IN COLD WEATHER Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a way not expected by the operator.
Page 40: Operation
SAFETY SAFETY MACHINE OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check that the movement of the machine matches the display on the control pattern card.
Page 41: Safety Rules For Traveling
SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING When traveling on level ground, keep the work equipment at a height of 40 to 50 cm (16 to 20 in) from the ground. If the work equipment blocks the view and it is difficult to travel in safety, raise the work equipment to a greater height.
Page 42: Operations On Slopes
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.
Page 43: Prohibited Operations
SAFETY SAFETY MACHINE OPERATION PROHIBITED OPERATIONS Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine. Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
Page 44: Operations On Snow
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When carrying out demolition work, do not carry out demolition above your head. There is a hazard of broken parts falling or of the building collapsing and causing serious injury or property damage.
Page 45: Parking Machine
SAFETY SAFETY MACHINE OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment completely to the ground. When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine.
Page 46: Transportation
SAFETY MACHINE OPERATION TRANSPORTATION This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 47: Battery
SAFETY SAFETY MACHINE OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 48: Starting Engine With Booster Cables
SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 49: Towing
SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-156)". Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Page 50: Lifting Objects With Bucket
SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS Determine the signals to be used and place a signalman in position. To prevent the machine from tipping over or falling, carry out the operation on flat ground. To prevent the danger of contact with a raised load or the danger from a falling load, do not allow any worker inside the area.
Page 51: Safety Maintenance Information
SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 52: Stop Engine Before Carrying Out Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment completely to the ground and stop the engine.
Page 53: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal 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. One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 54: Accumulator, Gas Spring
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine.
Page 55: When Using Hammer
SAFETY SAFETY MAINTENANCE INFORMATION WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause serious personal injury.
Page 56: Do Not Disassemble Recoil Springs
If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. SAFETY RULES FOR HIGH-PRESSURE OIL The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.
Page 57: Precaution For High Voltage
If it is necessary to touch the injector terminal or the inside of the engine controller, please contact your Komatsu distributor. WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials.
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Page 59: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Boom cylinder Bucket link Sprocket Bucket cylinder Track frame (10) Track shoe Arm cylinder (11) Idler Boom (12) Overhead guard 3 - 2...
Page 60: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Radio (12) Horn switch Large capacity airflow air conditioner blower (13) R.H. work equipment control lever switch (if equipped) (14) Cigarette lighter Revolving warning lamp switch (if equipped) (15) Starting switch Lower wiper switch (machines equipped with (16) Step light switch fixed front window cab)
Page 61 OPERATION MACHINE VIEW ILLUSTRATIONS Machine monitor AA: Screen with all lamps lighted up BB: Screen for standard CC: Maintenance time warning screen User mode adjustment switch (16) Air cleaner clogging monitor Working mode selector switch (basic switch) (17) Fuel gauge Alarm buzzer stop switch (18) Fuel level monitor...
Page 62: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM AA: Screen with all lamps lighted up BB: Screen for standard...
Page 63 OPERATION DETAILED CONTROLS AND GAUGES Basic Operation of Machine Monitor Starting Engine When Situation is Normal When the starting switch is turned to the ON position, the opening screen GG is displayed. After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen After the check before starting screen DD is displayed for 2 seconds, the screen switches to the working mode/travel mode display screen HH.
Page 64 OPERATION DETAILED CONTROLS AND GAUGES If There Is Abnormality When Starting Engine If there is any abnormality when starting the engine, the check before starting screen DD changes to the maintenance interval warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance interval warning screen CC.
Page 65 OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation If any abnormality occurs during operation, the standard screen BB changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2). 3 - 8...
Page 66 OPERATION DETAILED CONTROLS AND GAUGES REMARK The colors lighting up the monitors related to the emergency stop items, caution items, and basic check items are as follows. Color when monitor lights up Type of monitor When When At low normal abnormal temperature Engine coolant temperature monitor...
Page 67 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
Page 68 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor Monitor (2) warns operator that the hydraulic oil temperature has risen. If monitor lights up red during operations, run engine at low idle or stop the engine and wait until the oil temperature goes down and monitor (2) changes to green.
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running.
Page 70 OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor Monitor (2) lights up to warn the operator the fuel level in the tank is low. If the remaining amount of fuel goes down to 210 liters (55.48 US gal), the light changes from green to red, so add fuel as soon as possible.
Page 71 OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly.
Page 72 REMARK For details of the method of confirming the maintenance interval, see "Maintenance Switch (PAGE 3-25)". If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 15...
Page 73 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Pilot display Gauges and Meter Engine pre-heating monitor Engine coolant temperature gauge Swing lock monitor Fuel gauge Wiper monitor Hydraulic oil temperature gauge Auto-deceleration monitor (10) Service meter Working mode monitor Travel speed monitor Pilot Display When the starting switch is ON, the pilot display lights up when the display items are functioning.
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Monitor This monitor (2) informs the operator that the swing lock is being actuated. Actuated: Lights up When the swing lock switch is turned ON (ACTUATED), the monitor lamp lights up. This lamp lights up when the swing parking brake release switch is set to the FREE position.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Monitor Monitor (6) displays set mode for the travel speed. The monitor display when the travel speed selector switch is operated, as follows. Lo : Low speed Hi : High speed Gauges and Meter Engine Coolant Temperature Gauge This meter (7) indicates the engine cooling water temperature.
Page 76 OPERATION DETAILED CONTROLS AND GAUGES If the indicator enters the red range (A) to (B), do not carry out operations on steep slopes. There is danger of the engine stalling. The correct fuel level may not be displayed for a short time when the starting switch is turned ON, but this is not an abnormality.
Page 77 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion Working mode selector switch (basic switch) Back switch Auto-deceleration switch (selection switch) Up switch Travel speed selector switch (selection switch) (10) Down switch Wiper switch (11) Input confirmation switch Window washer switch (12) Adjusting brightness and contrast Maintenance switch...
Page 78: Working Mode Selector Switch (Basic Switch)
If it is desired to have the working mode set to start automatically in E, L, or B mode (default option setting), have your Komatsu distributor change the setting. REMARK When the mode selector switch is pressed, the mode is displayed in the center of monitor display portion (GG), and the screen returns to standard screen (BB) after 2 seconds.
Page 79: Auto-Deceleration Switch (Selection Switch)
OPERATION DETAILED CONTROLS AND GAUGES Auto-deceleration Switch (Selection Switch) When switch (2) is pressed, the auto-deceleration is actuated, if the control levers are in neutral position, the engine speed is automatically lowered to reduce fuel consumption. Monitor display portion GG ON : Auto-deceleration actuated Monitor display portion GG OFF : Auto-deceleration canceled Each time the switch is pressed, auto-deceleration switches between actuated and canceled.
Page 80: Travel Speed Selector Switch (Selection Switch)
OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch (Selection Switch) WARNING When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (3) at the Lo position). Never operate travel speed selector switch (3) while loading or unloading. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 81: Wiper Switch
OPERATION DETAILED CONTROLS AND GAUGES Wiper Switch This switch (4) actuates the front window wiper. Each time the switch is pressed, it changes ON → INT → stop (OFF). Monitor display portion GG INT lighted up: Wiper moves intermittently Monitor display portion GG ON lighted up: Wiper moves continuously Monitor display portion GG OFF: Wiper stops REMARK...
Page 82: Maintenance Switch
Change PTO case oil 1000 Change final drive case oil 2000 Change swing machinery case oil 1000 Change hydraulic oil 5000 If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 25...
Page 83 OPERATION DETAILED CONTROLS AND GAUGES How to check a remaining time up to the next maintenance and reset after the maintenance is carried out is as explained below. 1. Look at the maintenance screen, press up switch (9) or down switch (10) on the monitor switch portion, and select the item.
Page 84 OPERATION DETAILED CONTROLS AND GAUGES User Mode Adjustment Switch Press this switch (7) to set to fan reverse rotation and to adjust the set value for the economy mode. Fan Reverse Rotation 1. Press switch (7) and the monitor display screen changes to the fan reverse rotation and economy mode adjustment screen show on the right.
Page 85 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. When the fan rotation is being changed, the screen changes to the waiting screen. The engine is automatically set to low idling, and after approx. 15 seconds, the fan rotates in reverse. After another approx.
Page 86 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 9. When changing the fan rotation direction from reverse direction to the normal direction, press input confirmation switch (11). (Press Back switch (8) to return to the previous screen.) 10. When the fan rotation is being changed, the screen changes to the waiting screen.
Page 87: Back Switch
OPERATION DETAILED CONTROLS AND GAUGES Adjusting Set Value of Economy Mode 1. Press switch (7) and the monitor display screen changes to the fan reverse rotation and economy mode adjustment screen show on the right. 01: Fan reverse rotation menu 02: Economy mode adjustment menu 2.
Page 88 OPERATION DETAILED CONTROLS AND GAUGES Up Switch, Down Switch Press up switch (9) or down switch (10) when in the maintenance mode, brightness/contrast adjustment mode, or select mode to move the cursor on the monitor display (colors of selected monitor are inverted) up, down, left, or right.
Page 89: Down Switch
OPERATION DETAILED CONTROLS AND GAUGES Liquid Crystal Monitor Adjustment Switch Press switch (12) to adjust the brightness or contrast of the display monitor. Adjusting Brightness 1.When monitor adjustment switch (12) is pressed, the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right.
Page 90: Alarm Buzzer Stop Switch
OPERATION DETAILED CONTROLS AND GAUGES Adjusting Contrast 1.When monitor adjustment switch (12) is pressed, the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right. 2.Use the brightness/contrast screen and press up switch (9) or down switch (10) to select the contrast monitor.
Page 91: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch Room lamp switch Fuel control dial (10) Emergency pump drive switch Cigarette lighter (11) Swing parking brake release switch Swing lock switch (12) Step light switch Lamp switch (13) Lower wiper switch (machines equipped with Machine push-up switch fixed front window cab) Boom shockless control switch...
Page 92 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial Dial (2) adjusts the engine speed and output. (a)Low idling (MIN): Turned fully to the left (b)Full speed (MAX): Turned fully to the right REMARK When the fuel control dial is turned, the engine speed does not change for the first few notches from MIN and the last few notches before MAX, but this does not indicate any abnormality.
Page 93 OPERATION DETAILED CONTROLS AND GAUGES Lamp Switch Switch (5) is used to turn on the front lamps, working lamps, additional lamps at top front of the cab, and monitor lighting. (a) ON: Lamps light up (b) OFF: Lamps go off Machine Push-up Switch WARNING When using the boom thrust force to push up the chassis when moving down from a bench, there is danger that the machine may...
Page 94 OPERATION DETAILED CONTROLS AND GAUGES Boom Shockless Control Switch Switch (7) controls the shaking of work equipment when the boom is stopped. Effect The shaking and spillage of load from the bucket is reduced. Operator fatigue is reduced when operating for long periods, so operations can be performed saftely.
Page 95 OPERATION DETAILED CONTROLS AND GAUGES Emergency Pump Drive Switch NOTICE Emergency pump drive switch is provided to make it possible to perform work for a short time when there is a failure in the pump control system. It is necessary to repair the abnormal location as soon as possible. This switch (10) is used to make it possible to carry out operations temporarily if any problem should occur in the pump control system (when the display shows "E02").
Page 96 OPERATION DETAILED CONTROLS AND GAUGES Lower Wiper Switch (machines equipped with fixed front window cab) This switch (13) operates the lower wiper (A). (a) ON position: Lower wiper (A) is actuated (b) OFF position: Lower wiper (A) stops If this switch is turned to the ON position at the same time as the wiper switch, the wiper and lower wiper (A) will be actuated in turn.
Page 97: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Left work equipment control lever Travel levers (with auto-deceleration system) (with pedal and auto-deceleration system) Right work equipment control lever (with auto-deceleration system) Lock Lever WARNING When standing up from the operator's seat, push lock lever (1) down securely to set it to LOCK position (L).
Page 98 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers WARNING Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may suddenly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations. When you are not using the pedal, do not rest your foot on it.
Page 99 OPERATION DETAILED CONTROLS AND GAUGES Work Equipment Control Lever Left work equipment control lever (3) is used to operate the arm and upper structure. Arm operation (a) Arm OUT (b) Arm IN Swing operation (c) Swing to right (d) Swing to left N (Neutral) : The upper structure and arm are held in position and do not move.
Page 100: Emergency Exit From Operator's Cab
OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY EXIT FROM OPERATOR'S CAB If it should become impossible to open the cab door, open the rear window and use it as an emergency escape. Remove the rear window as follows. 1. Pull ring (1) and completely remove seal (2) from the rubber core.
Page 101: Cap With Lock
OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Use the starting switch key to open and close the locks on the caps and covers. For details of the locations of the caps and covers with locks, see "LOCKING (PAGE 3-137)". Insert the key as far as it will go to the shoulder (A).
Page 102 OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Cover with Lock Opening the Cover (Locked Cover) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. (A): Open (B): Lock Locking the Cover 1.
Page 103: Hot And Cool Box
Always make sure that you extinguish your cigarette, then put it in the ashtray and close the lid. FIRE EXTINGUISHER (If equipped) The fire extinguisher can be set at the rear left of the cab. When installing, please consult your Komatsu distributor. 3 - 46...
Page 104: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel OFF switch FRESH/RECIRC selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Defroster selector lever Auto switch OFF Switch Switch (1) is used to stop the fan and air conditioner. When OFF switch (1) is pressed, the set temperature and air flow display on display monitor (7), the lamps above auto switch (5), and air conditioner (8) go out, and operation stops.
Page 105 OPERATION DETAILED CONTROLS AND GAUGES Fan Switch Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the ∧ switch to increase the air flow; press the ∨ switch to reduce the air flow. During auto operation, the air flow is automatically adjusted.
Page 106 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch Switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. During automatic operation, the vents are automatically selected.
Page 107 OPERATION DETAILED CONTROLS AND GAUGES Auto Switch With switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. When auto switch (5) is pressed, the lamp above the auto switch lights up. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under automatic control.
Page 108 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch Switch (8) is used to turn the air conditioner (cooling, dehumidifying, heating) ON or OFF. When the fan is actuated (display (b) is shown) and air conditioner switch (8) is pressed, the air conditioner is switched ON, lamp above the air conditioner switch lights up, and the air conditioner starts.
Page 109 OPERATION DETAILED CONTROLS AND GAUGES Method of Operation The air conditioner can be operated automatically or manually. Select the method of operation as desired. Automatic Operation 1. Turn auto switch (5) ON. The lamp above switch (5) lights up. The set temperature (a) and air flow (b) are displayed on the monitor.
Page 110 OPERATION DETAILED CONTROLS AND GAUGES Stopping Automatic Operation Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on monitor (7), and lamps above auto switch (5) and air conditioner switch (8) go out, the operation stops. Manual Operation 1.
Page 111 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Press temperature setting switch (3) and adjust temperature inside the cab. 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
Page 112 OPERATION DETAILED CONTROLS AND GAUGES Stopping Manual Operation Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on monitor (7), and lamps above auto switch (5) and air conditioner switch (8) go out, the operation stops. Operation with Cold Air to Face and Warm Air to Feet To operate with cold air blowing to the face and warm air blowing to the feet, set as follows.
Page 113 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Turn air conditioner switch (8) ON. Check that the lamp above air conditioner switch lights up. 4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired positions. Defroster Operation 1.
Page 114 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the right. 3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air.
Page 115 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (8) ON. Use Air Conditioner with Care NOTICE When running the air conditioner, always start with the engine running at low speed.
Page 116 OPERATION DETAILED CONTROLS AND GAUGES Other Functions Self-diagnostic Function It is possible to perform troubleshooting of various sensors and equipment used on the air conditioner. 1. Turn the starting switch key to the ON (B) position. 2. Press OFF switch (1). The temperature setting and air flow display on the liquid crystal display portion go out and operation stops.
Page 117 After completing the troubleshooting, press OFF switch (1) again to return to the normal display. If any problem is detected by the self-diagnostic function, contact your Komatsu distributor perform inspection and repair. Function to Switch Set Temperature Display Between Fahrenheit and Celsius It is possible to switch the set temperature display between °F and...
Page 118: Radio
OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel Power switch, Volume control knob, Balance AS/PS button control knob Preset station buttons (1,2,3,4,5,6) SEL button Display FM/AM selection button Time reset button Display selection button Tuning button Power switch, Volume control knob, Balance control knob Press this knob (1) to turn the power for the radio on.
Page 119 OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4) and the display will show the present time for 5 seconds. After 5 seconds pass, the display returns automatically to the frequency display.
Page 120 OPERATION DETAILED CONTROLS AND GAUGES Controls of Radio Method of Setting with Preset Button 1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. 3.
Page 121 OPERATION DETAILED CONTROLS AND GAUGES Method of Operating Mode (BAS) Bass adjustment: When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned counterclockwise, the bass sound is reduced.
Page 122 OPERATION DETAILED CONTROLS AND GAUGES Antenna When transporting the machine or parking the machine inside the garage, stow away the antenna to prevent it from causing any obstruction. The procedure for stowing the antenna away is as follows. 1. Loosen antenna mounting bolt (1) and store the antenna at position (A).
Page 123: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 24V Power Source NOTICE Do not use this as the power supply for 12V equipment. It will cause failure of the equipment. Pull out the connector plug for taking out electric power from the rear side of the panel.
Page 124: Fuse
OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 125: Circuit Breaker
OPERATION DETAILED CONTROLS AND GAUGES CIRCUIT BREAKER NOTICE When resetting the circuit breaker, always turn the starting switch OFF first. If the starting switch does not work even when the starting switch is turned ON, open the circuit breaker box inside the grease pump box at the front right of the machine and carry out inspection.
Page 126 OPERATION DETAILED CONTROLS AND GAUGES Fuse Name of circuit capacity Monitor Working lamp, right front light of machine Pump controller Cab upper head lamp Starting switch Engine controller (direct from battery) (10) Monitor (direct from battery) (11) Fuse box (direct from battery) 3 - 69...
Page 127: Controller
The engine controller has been given moisture prevention treatment, so there is no problem if rain gets on it, but do not spray it with water when washing the machine. If any abnormality occurs in the controller, do not disassemble it yourself. Contact your Komatsu distributor for repairs. Engine controller This is under the fuel pre-filter inside the engine room.
Page 128: Grease Pump
OPERATION DETAILED CONTROLS AND GAUGES GREASE PUMP This is stored inside the grease pump box on the right side of the chassis. Method of Use 1. Open cover (1). 2. Rotate the lever of valve (2) upward 90° to set it to the (A) position.
Page 129 OPERATION DETAILED CONTROLS AND GAUGES Precautions when Using NOTICE When not using the grease pump, always rotate the lever of valve (2) down 90° to set it to the (B) position to prevent internal pressure from forming inside grease gun (3). Set so that the grease fitting and the nozzle at the tip of the grease gun are perpendicular.
Page 130 OPERATION DETAILED CONTROLS AND GAUGES Supplying Grease 1. Remove 3 wing bolts (2) from grease can (1), then remove cover (3) from the pump. 2. Remove follow plate (4) inside the grease can. REMARK If the hollow in the center of the follow plate is not fully filled with grease, air will be sucked in and it may not be possible to use all the grease.
Page 131 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES REMARK Put the spare grease can beside the grease pump in the grease pump box at the right side of the machine. 3 - 74...
Page 132: Machine Operations And Controls
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor.
Page 133 OPERATION MACHINE OPERATIONS AND CONTROLS 8. Check for problem in gauges, monitor. Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts. Clean off any dirt from the surface. 9. Clean, check rear view mirror Check that there is no damage to the rear view mirror.
Page 134 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 135 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK When adding water to the radiator, remove cover (3), then loosen radiator cap (4) slowly. After checking that the pressure has been released, push in the cap, keep it pushed in, then loosen it further and remove it.
Page 136 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 137 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 139 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS NOTICE Do not add oil above the correct level. This will damage the hydraulic circuit and cause oil to spurt out. If oil is added above the correct level, remove plug (1) under the chassis, then loosen drain valve (P) and drain the excess oil.
Page 140 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Swing Machinery Case, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. There are 2 swing machinery cases: one at the front of the swing circle and the other at the rear.
Page 141 OPERATION MACHINE OPERATIONS AND CONTROLS 5. If the oil level is above the (H) mark on dipstick (G), loosen drain valve (P) and drain the excess oil. When draining the oil, first pull hose (1) out from inspection hole (2), then loosen the drain valve (P). Swing machinery at front of machine Swing machinery at rear of machine 6.
Page 142 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in PTO Case, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.
Page 143 OPERATION MACHINE OPERATIONS AND CONTROLS Check Air Cleaner For Clogging 1. Confirm that the air cleaner clogging monitor does not light up. 2. If it lights up, immediately clean or replace the element. For details of method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-17)".
Page 144 Check that the working lamps and lamps inside the instruments light up properly. Check also that there is no dirt or damage. If any lamp does not light up, the bulb is probably blown up or there is a disconnection, so ask your Komatsu distributor to carry out repairs.
Page 145 OPERATION MACHINE OPERATIONS AND CONTROLS Drain Water And Sediment from Fuel Tank 1. Set a container under the drain hose to catch the drained fuel. 2. Pull out drain hose (1) from hole (2) in the cover. 3. Turn drain valve (3) to the OPEN position (O) and drain all the sediment and water accumulated at the bottom together with the fuel.
Page 146 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's back against the backrest.
Page 147 OPERATION MACHINE OPERATIONS AND CONTROLS (D) Adjusting armrest angle Armrest (5) can be made to spring up by hand approx. 90°. In addition, by turning the bottom (6) of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle.
Page 148 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Mirror (A) Adjust the mirror mount so that it is possible to see people at the rear left of the machine.
Page 149 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Mirror (B) Adjust the mirror mount so that it is possible to see people at the rear right of the machine. Install the side view mirror in the location indicated in the figure at right.
Page 150 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Mirror (C) Adjust the mirror mount so that it is possible to see people at the rear right of the machine. Install the side view mirror in the location indicated in the figure at right.
Page 151 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt.
Page 152 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When starting the engine, check that the lock lever is securely at the LOCK position. If the lock lever is not locked securely and the control levers or control pedal are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
Page 153 If the monitors do not light up or the buzzer does not sound, there is probably a failure in the monitor, so contact your Komatsu distributor for repairs. 2) After approx. 3 seconds, the screen switches to the working mode/travel speed display monitor. Then it switches to the normal screen.
Page 154 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3) If the hydraulic oil temperature gauge goes out and caution lamp (15) stays lighted up red, perform inspection immediately for the item which is lighted up red. 4) If there are any items where the maintenance time has passed, maintenance interval monitor (16) lights up for 30 seconds.
Page 155: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 156 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to ON position (B). If the ambient temperature is low, the preheating monitor lights up and automatic preheating is carried out. Keep the key in starting switch (3) at the ON position until the preheating monitor goes out.
Page 157 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK Regardless of the ambient temperature, it is possible to start the engine preheating manually. 1. Turn the key in starting switch (3) to the left from OFF position (A). The preheating monitor lights up and engine preheating starts.
Page 158: After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 159 OPERATION MACHINE OPERATIONS AND CONTROLS 1. This machine is equipped with an automatic engine warm-up system, so if the engine water temperature is below 30 °C after the engine is started, the engine warm-up operation starts automatically. When the engine automatic warm-up operation starts, the engine speed is maintained at a speed higher than the normal low idling speed.
Page 160 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2] When fuel control dial (2) is returned to the low idle (MIN) position, the engine speed will drop. 3 - 103...
Page 161 OPERATION MACHINE OPERATIONS AND CONTROLS Hydraulic Equipment Warm Up WARNING Before carrying out the warm-up operation for the hydraulic equipment, turn the swing lock switch ON, check on the monitor that the swing lock is actuated, then start the warm-up operation. When warming up the hydraulic equipment, check that there is no person or obstacle in the surrounding area, then sound the horn and start the operation.
Page 162 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. To complete the warm-up operation of the hydraulic equipment more quickly, set the working mode to P mode (heavy-duty mode). For details of the procedure for setting the working mode, see "Working Mode Selector Switch (Basic Switch) (PAGE 3-21)".
Page 163 Hydraulic oil temperature monitor (7): Green display Fuel gauge (16): Indicator in black range Fuel level monitor (17): Green display 14. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 106...
Page 164 OPERATION MACHINE OPERATIONS AND CONTROLS In cold temperatures (ambient temperature below 0°C), even when the hydraulic oil temperature monitor displays green, carry out additional Step 15 to warm up all the hydraulic equipment. 15. Turn fuel control dial (4) to the full speed (MAX) position, repeat Steps 6 to 9 for 3 to 5 minutes, then check again that the hydraulic oil temperature monitor is displaying green.
Page 165 OPERATION MACHINE OPERATIONS AND CONTROLS 17. Before starting operations, repeat the following operations slowly 3 to 5 times to circulate warm oil through the control circuits. RAISE (E) ←→ LOWER (F) Boom operation IN (B) ←→ OUT (A) Arm operation CURL (D) ←→...
Page 166 OPERATION MACHINE OPERATIONS AND CONTROLS Operation After Completion Of Warm-Up Operation 1. Check that hydraulic oil temperature monitor (7) displays green. 2. Push working mode selector switch (19) of the machine monitor to select the working mode to be used. For details of the procedure for selecting the working mode, see "Working Mode Selector Switch (Basic Switch) (PAGE 3-21)".
Page 167 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3) Heavy-duty lift Boom lifting power increased when raising boom independently 4) Swing priority mode Priority given to swing when operating boom and swing simultaneously 3 - 110...
Page 168: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
Page 169: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the control lever, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction from the operation of the travel lever (front and rear travel is reversed, left and right steering is reversed).
Page 170 Slowly pull the levers (5) backward, or slowly depress the rear part of the pedals (6) to move the machine forward. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
Page 171 Slowly push the levers (5) forward, or slowly depress the front part of the pedals (6) to move the machine backward. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
Page 172 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3 - 115...
Page 173: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear, the machine moves in the reverse direction to the operation of the travel levers. Use the travel levers to change direction.
Page 174 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.
Page 175: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. 1. Before starting the swing operation, turn swing lock switch (1) OFF and check that swing lock monitor (2) has gone out.
Page 176: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, so operate the levers carefully. 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 177 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Bucket control Move the right work equipment control lever to the left or right to operate the bucket. 3 - 120...
Page 178: Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match operating conditions and purpose, thereby enabling work to be performed efficiently. Make effective use of each mode as follows. When the starting switch is turned to the ON position, the working mode is set to P mode (digging).
Page 179: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
Page 180 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as s pickaxe, breaker, or pile driver. This will drastically reduce the life of the machine. Operations Using Bucket as Lever Do not use the bucket to lever rocks out.
Page 181 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Digging at an Angle without Engaging Teeth Do not swing the upper structure when digging hard rock at a position higher than the machine if the bucket teeth will not penetrate the rock. The teeth will slip on the rock surface and generate excessive vibration of the machine, and this will lead to cracking of the work equipment or frame.
Page 182 OPERATION MACHINE OPERATIONS AND CONTROLS Swinging or Traveling When Rock Is on Top of Track Assembly Do not swing the upper structure or travel if there is in the rock on top of the track assembly. It will contact the undercover or frame and cause damage.
Page 183 OPERATION MACHINE OPERATIONS AND CONTROLS High-Speed Travel Operations on Rough Ground Do not travel at high speed on rough ground or rocks. Each time the machine travels over rough parts of the ground surface, the thrusting load on the machine will increase and reduce the service life of the machine.
Page 184: General Operation Information
OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid traveling over such obstacles as far as possible.
Page 185 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth NOTICE When driving the machine out of water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, and water will be thrown up by the cooling fan. This may cause the fan to break. Be extremely careful when driving the machine out of water.
Page 186: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be performed, pile soil to make a platform (A) on the slope so the machine is kept horizontal during operation.
Page 187 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.
Page 188: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out. Place the machine push-up switch at high-pressure set position (b).
Page 189: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine.
Page 190: Bucket Replacement
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 191 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. Remove the stopper at the end of the pin, then pull out pins (A) and (B) and remove the bucket. NOTICE After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both ends of the bushings, be careful not to damage them.
Page 192: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes.
Page 193: Machine Inspection After Daily Work
OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Set lock lever (3) in the LOCK position (L). 5. Check the engine cooling water temperature and engine oil pressure with the machine monitor.
Page 194: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Operator's cab door Always close the window. (2) Fuel tank filler port cap (3) Hydraulic tank filler port cap (4) Battery box cover (5) Engine room door (2 place) (6) Air creaner room door (7) Right side door of the machine (8) Tool box door...
Page 195: Transportation
This method of lifting applies to the standard specification machine. The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 196: Lifting Machine
OPERATION OPERATION TRANSPORTATION TRANSPORTATION 1. Lifting machine (lifting upper structure) Fit wires to boom foot pins (1) and lifting bracket (2) , and lift the machine. Lifting load is 26.7 tons (58,874 lb) (fuel: empty, hydraulic oil: M level). Diameter of boom foot pin (1): 160 mm (6.3 in) Diameter of hole at lifting position of lifting bracket (2): 70 mm (2.8 in) (G): center of gravity...
Page 197: Shipping Machine Information
OPERATION TRANSPORTATION SHIPPING MACHINE INFORMATION WARNING Load the machine on a level and hard place. Secure a sufficient distance between the road shoulder and the machine. NOTICE Stow the antenna away. After placing the machine on the specified position of the trailer, secure it according to the following procedure. 1.
Page 198: Transportation Posture
OPERATION TRANSPORTATION TRANSPORTATION POSTURE This machine can be divided into seven units for transportation. When transporting, contact your Komatsu distributor. Seven Units for Transportation Upper Structure Counterweight and bucket Undercarriage (right) Boom Undercarriage (left) Arm and Boom cylinder and Arm cylinder and...
Page 199 OPERATION TRANSPORTATION Posture for Each Unit (dimensions in diagram are in mm.) Upper Structure Unit PC1250-8, PC1250SP-8, PC1250LC-8 Overall widht mm (ft in) 3,490 (11' 5") 26,700 (58,874) Weight kg (lb) (fuel: enpty, Hydraulic oil: M level) Secure the upper structure to the platform with a chain and block. Undercarriage Unit PC1250-8, PC1250SP-8, PC1250LC-8...
Page 200 OPERATION TRANSPORTATION Center Frame Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 9,700 (21,389) Counterweight Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 18,000 (39,690) 3 - 143...
Page 201 OPERATION TRANSPORTATION Boom PC1250-8 Unit PC1250SP-8 PC1250LC-8 mm (ft in) 9,475 (31' 1") 8,170 (26' 10") mm (ft in) 2,894 (9' 6") 3,095 (10' 2") Overall widht mm (ft in) 1,474 (4' 10") 1,474 (4' 10") Weight kg (lb) 11,200 (24,696) 11,100 (24,476) PC1250-8 Unit...
Page 202 OPERATION TRANSPORTATION Bucket (except side cutter, shroud) PC1250-8 Unit PC1250SP-8 PC1250LC-8 mm (ft in) 2,580 (8' 6") 2,527 (8' 3") mm (ft in) 2,276 (7' 6") 2,420 (7' 11") Overall widht mm (ft in) 2,250 (7' 5") 2,520 (8' 3") Weigh kg (lb) 5,500 (12,128)
Page 203 OPERATION TRANSPORTATION Outer Cover Radiator duct (same for all models) Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 100 (221) Radiator duct upper cover (same for all models) Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 17 (37) 3 - 146...
Page 204 OPERATION TRANSPORTATION Catwalk (right) : (same for all models) Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 17 (37) Catwalk (left, front) : (same for all models) Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 150 (331) 3 - 147...
Page 205 OPERATION TRANSPORTATION Catwalk (left, rear) : (same for all models) Unit PC1250-8, PC1250SP-8, PC1250LC-8 Weight kg (lb) 160 (353) 3 - 148...
Page 206: Cold Weather Operation
Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze. NOTICE Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant.
Page 207 OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 208 OPERATION COLD WEATHER OPERATION Monitor A feature of the liquid crystal monitor is that the screen becomes dark and is difficult to read in cold weather (particularly with the starting switch ON). In this case, adjust the brightness and contrast of the screen. For details, see "Liquid Crystal Monitor Adjustment Switch (PAGE 3-32)".
Page 209: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 210: Long Term Storage
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately. Lock each control lever and pedal with the lock lever and pedal lock. To prevent rust, fill with Komatsu genuine supercoolant (AF-NAC) to give a density of at least 30% for the engine coolant.
Page 211: Starting Machine After Long-Term Storage
OPERATION LONG TERM STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE When starting the engine after long-term storage, carry out the warming-up operation thoroughly. For details, see "Engine Warm Up (PAGE 3-101)". 3 - 154...
Page 212: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. For details of the method of bleeding the air, see "BLEEDING AIR FROM FUEL CIRCUIT (PAGE 4-40)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the...
Page 213: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Page 214: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 215 OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-157)" and the instruction manual accompanying the charger, and do as follows. Set the voltage of the charger to match the voltage of the battery to be charged.
Page 216 OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows. Connecting and Disconnecting Booster Cables WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
Page 217 OPERATION TROUBLES AND ACTIONS Booster Cable Connection Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect the clip of booster cable (A) to the positive (+) terminal of battery (C) on the problem machine.
Page 218: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 219 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
Page 220 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights...
Page 221 OPERATION TROUBLES AND ACTIONS Electronic Control System If an error code appears on the machine monitor display (normally displays TIME), follow the countermeasure table as shown below in the self-diagnosis. Machine Monitoring System Monitor Error mode Remedy display When emergency pump drive switch is up, normal Error in pump control system operations become normal, but carry out inspection immediately.
Page 222 Check the point of contact telephone number on screen B. REMARK If the point of contact telephone number has not been registered, screen B is not displayed. If it is necessary to register the point of contact telephone number, ask your Komatsu distributor to register it. 3 - 165...
Page 224 4 - 1...
Page 225: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 226 MAINTENANCE MAINTENANCE INFORMATION Dusty Jobsite When working at dusty worksites, do as follows: Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. Replace the fuel filter more frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 227: 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. 4 - 4...
Page 228 2 years or 4000 hours. As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant (AF-NAC). If you use another coolant, it may cause serious problems such as corrosion of the engine and parts of the cooling system that use light metals such as aluminum.
Page 229 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 230: Electric System Maintenance
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 231: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 232: Recommended Fuel, Coolant, And Lubricant
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 233 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT ASTM: American Society of Testing and Material Swing Final drive Engine machinery Hydraulic Cooling case Fuel tank Oil pan case case oil system system (Each) (Each) Liter 13.5 24.3 1180 1360 Specified capacity US gal 25.63 3.57 6.42...
Page 234: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%. RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. 4 - 11...
Page 235: Tightening Torque Specifications
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 236: Safety Critical Parts
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. SAFETY CRITICAL PARTS LIST Safety critical parts for periodic replacement...
Page 237: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) CLEAN STRAINER OF PTO LUBRICATING OIL FILTER 4- 59 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) CHANGE OIL IN SWING MACHINERY CASE 4- 66 CHANGE OIL IN PTO CASE 4- 68...
Page 238 MAINTENANCE MAINTENANCE SCHEDULE EVERY 500 HOURS MAINTENANCE REPLACE FUEL PRE-FILTER CARTRIDGE 4- 51 REPLACE FULE MAIN FILTER CARTRIDGE 4- 53 CHECK SWING PINION GREASE LEVEL, ADD GREASE 4- 55 CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS,FUEL COOLER FINS, AFTERCOOLER FINS, CONDENSER FINS (machines equipped with air conditioner), PTO OIL COOLER 4- 56 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER...
Page 239: Maintenance Procedure
Change oil in PTO case Change oil in final drive case Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. For details of the method of replacing or maintaining, see EVERY 1000 HOURS and EVERY 2000 HOURS SERVICE.
Page 240: When Required
MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
Page 241 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Outer Element 1. Open the right door of the machine, remove 6 hooks (2), then remove cover (3). NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out.
Page 242 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Direct dry compressed air (less than 0.69 MPa (7 kg/cm , 99.4 PSI)) to the outer element from inside along its folds, then direct it from outside along its folds and again from inside. 1) Replace the outer element once a year or when monitor (1) flashes.
Page 243 (AF-NAC) whichever comes first *1: When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. When no corrosion resistor is used, use the special cover (600-411-9000). Please consult your Komatsu distributor about the method of installing.
Page 244 When changing the coolant or draining the coolant from the radiator before carrying out repairs, ask a specialist company to handle any coolant containing antifreeze, or contact your Komatsu distributor. Antifreeze is toxic, so never pour it into drainage water ditches or drain it onto the ground surface.
Page 245 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 3. Remove cover (2). 4. Check that the cooling water temperature has gone down enough to make it possible to touch the radiator cap surface by hand, then turn radiator cap (3) slowly until it contacts the stopper to release the pressure.
Page 246 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 16. Open sub-tank inspection cover (8), drain the coolant from sub-tank (9), wash the inside of the sub-tank, then add water to between the FULL and LOW marks. If the sub-tank is extremely dirty and it is difficult to clean, replace it with a new part.
Page 247 MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening 1. First, tighten to a tightening torque of 1372 ± 137.2 Nm (140 ± 14 kgm, 1,012.6 ± 101.3 lbft), then check that the nut and shoe are in tight contact with the link mating surface.
Page 248 MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION WARNING For details of starting the engine and operating the work equipment, see "BEFORE STARTING ENGINE (PAGE 3-75)", "STARTING ENGINE (PAGE 3-98)", "AFTER STARTING ENGINE (PAGE 3-101)", and "WORK EQUIPMENT CONTROLS AND OPERATIONS (PAGE 3-119)"...
Page 249 There is danger of plug (1) flying out under the high internal pressure of the grease. Never loosen plug (1) more than 1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. Increasing Track Tension Prepare a grease pump.
Page 250 Never loosen any part other than valve (1). Never put your face in the mounting direction of valve (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 251 There is a hazard that fragments will fly during the replacement work, so always wear protective equipment like safety glasses and gloves. If the tooth pins cannot be removed in this procedure, for safety's sake, be sure to ask your Komatsu distributor for the replacement.
Page 252 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Push pin (1) out by hand or with a hammer in the direction of the arrow to remove the teeth (2). 6. Clean the mounting surface, fit new tooth (2) to the adapter, insert new pin (1), then tighten 90°...
Page 253 MAINTENANCE MAINTENANCE PROCEDURE How to Remove Slinging Loop WARNING In case a slinging loop is fitted to the bucket tooth, remove it. If digging work is started without the slinging loop being removed, there is the danger that the slinging loop is broken and broken pieces are sent flying around.
Page 254 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Preheat the slinging loop to be cut to 100-150 oC and use a gas cutter to cut the slinging. Tip of tooth (1) Top of tooth (2) NOTICE When cutting the slinging loop at each part of the bucket, cut at the following cutting positions (A) - (A) or (B) - (B), according to the shape of the loop.
Page 255 MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance. Set the work equipment in a stable condition, stop the engine, then set lock lever (1) securely to the LOCK position (L). If there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.
Page 256 MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
Page 257: Check And Maintenance Air Conditioner
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 258: Clean Line Filter, Remove Dirt
MAINTENANCE MAINTENANCE PROCEDURE CLEAN LINE FILTER, REMOVE DIRT If there is any abnormality in the pump or other hydraulic equipment, remove the dirt from inside the line filter as follows. Before removing the dirt from inside the line filter, release the internal pressure in the hydraulic circuit.
Page 259: Check Gas Spring
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 260: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details of the procedure when starting the engine, see "STARTING ENGINE (PAGE 3-98)". If necessary, refer to the OPERATION volume for the sections for starting the engine, moving the machine off, steering, and stopping. CAUTION When starting the engine to bleed the air, cancel the automatic warming-up operation before starting.
Page 261 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2) If no oil oozes out, remove the drain hose from the pump case, and add hydraulic oil through drain port (2) to fill the pump case. Oil will come out when the drain hose is removed, so secure the hose mouthpiece at a position higher than the level of the oil in the hydraulic tank.
Page 262 MAINTENANCE MAINTENANCE PROCEDURE 5. Bleeding air from attachment (when installed) If an attachment has been installed, run the engine at low idling and operate the attachment pedal repeatedly (approx. 10 times) until the air has been bled from the attachment and circuit. NOTICE If the method of bleeding the air from the attachment itself is specified by the manufacturer, bleed the air according to the specified procedure.
Page 263: Bleeding Air From Fule Circuit
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM FUEL CIRCUIT This machine is equipped with an electric priming pump to bleed the air from the fuel circuit. In the following cases, use the procedure below to bleed the air. When fuel filter has been replaced When engine has run out of fuel When starting the engine for the first time after replacing the supply pump or modifying the piping or any other parts...
Page 264 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Turn the air bleed valve (2) to the open position (O). 5. Turn electric priming pump switch (3) to the ON position (A). Lamp (4) flashes and the electric priming pump starts. Release electric priming pump switch (3). Switch (3) will return automatically to the original position (N).
Page 265 MAINTENANCE MAINTENANCE PROCEDURE 10. Start the engine. If the engine does not start, the probable reason is that the air has not been completely bled. Do as follows, then start the engine again. 1) Check that the air bleed valve is closed. 2) Turn electric priming pump switch (3) ON position (A).
Page 266: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-77)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Check for water and sediment in water separator, drain water Check oil level in hydraulic tank, add oil Check oil level in swing machinery case, add oil...
Page 267: Every 10 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 10 HOURS MAINTENANCE LUBRICATING 1. Set to the greasing posture below, lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 268 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (2) Boom foot pin (2 places) (3) Boom cylinder rod end pin (2 places) (4) Arm cylinder foot pin (1 place) (5) Boom - Arm coupling pin (1 place) (6)Bucket cylinder foot pin (2 point) (7) Arm cylinder rod pin (1 place) (8) Arm - Link coupling pin (1 place) (9)Arm-Bucket coupling pin (2 point)
Page 269: Every 100 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. LUBRICATING SWING CIRCLE (4 points) 1. Lower the work equipment to the ground. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
Page 270: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 271: Check Level Of Battery Electrolyte
MAINTENANCE MAINTENANCE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Page 272 Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. When it is Possible to Use Indicator to Check Electrolyte Level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 273: Check And Tighten Track Frame And Axle Connecting Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS Bolts (1) connecting the track frame and axle will break if they remain loose, so loose bolts must always be retightened. Tightening torque: 3260 ± 370 Nm (333 ± 38 kgm, 2410 ± 275 lbft) 4 - 50...
Page 274: Every 500 Hours Maintenance
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 275 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2. Set the container to catch the fuel under the filter cartridge (1). 3. Remove transparent cup (2) from the filter and inspect it. If it is broken or damaged, replace it with a new part. 4.
Page 276: Replace Fule Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 277 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Remove filter cartridge cap (A), check that there is no dirt or damage to the filter holder and filter cartridge, then install the filter cartridge to the filter holder. NOTICE Do not fill the filter cartridge with fuel. Cap (A) is installed to prevent dirt from entering the inside of the filter cartridge.
Page 278 MAINTENANCE MAINTENANCE PROCEDURE CHECK SWING PINION GREASE LEVEL, ADD GREASE Prepare a scale. 1. Before starting the inspection, swing 2 times to the right or left, then lower the work equipment to the ground and stop the engine. 2. Open the grease pump box on the right side of the machine, remove 3 bolts (1), then remove plate (2) at the spare grease can location point.
Page 279: Clean, Check Radiator Fins, Oil Cooler Fins,Fuel Cooler Fins, Aftercooler Fins, Condenser Fins (Machines Equipped With Air Conditioner), Pto Oil Cooler
MAINTENANCE MAINTENANCE PROCEDURE CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER FINS,AFTERCOOLER FINS,CONDENSER FINS (machines equipped with air conditioner),PTO OIL COOLER WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury.
Page 280 MAINTENANCE MAINTENANCE PROCEDURE CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. REMARK If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner unit.
Page 281: Replace Pilot Filter Element
MAINTENANCE MAINTENANCE PROCEDURE 3. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash it in a neutral agent. After rinsing it in water, dry it thoroughly before using it again. If the clogging of the filter cannot be removed by blowing with air or washing in water, replace the filter with a new part.
Page 282: Clean Strainer Of Pto Lubricating Oil Filter
MAINTENANCE MAINTENANCE PROCEDURE CLEAN STRAINER OF PTO LUBRICATING OIL FILTER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Page 283: Replace Drain Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE REPLACE DRAIN FILTER CARTRIDGE 1. Using a filter wrench, turn the filter cartridge (1) to the left to remove it. 2. Fill the new filter cartridge with hydraulic oil, coat the packing surface with oil, then install it. When installing it, bring the packing surface into contact with the seal surface of the filter holder, then tighten a further 1/2 - 3/4 turns.
Page 284: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity: 86 liters (22.7 US gal) (When filter is replaced) Prepare a filter wrench 1.
Page 285 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 7. Open the engine room door. 8. Use a filter wrench to turn 3 filter cartridge (4) to the left to remove it. 9. Clean the filter holder, fill the new filter cartridge with clean oil, coat the thread and packing surface of the new filter cartridge with clean oil (or coat it thinly with grease), then install it to the filter holder.
Page 286: Every 1000 Hours Maintenance
3. After removing spring (2), valve (3) and strainer (5), take out element (4). If there are metal particles or foreign material inside strainer (5), contact your Komatsu distributor. 4. Clean the removed parts in flushing oil. 5. Install the new element in the place where old element (4) was installed.
Page 287: Replace Breather Element In Hydraulic Tank
MAINTENANCE MAINTENANCE PROCEDURE REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank. 11. Check for oil leakage and wipe off any spilled oil. 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.
Page 288: Clean Hydraulic Tank Return Strainer
MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK RETURN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 289: Change Oil In Swing Machinery Case
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity: 48.6 liters (12.84 US gal) (24.3 liters X 2 (6.42 US gal X 2)) 1.
Page 290 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Replace breather (3). 5. Remove dipstick (G) and air bleed plug (4) (remove air bleed plug (4) only when supplying oil to the front machinery), then add the specified amount of oil through dipstick guide (F). 6.
Page 291: Change Oil In Pto Case
MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN PTO CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.
Page 292: Replace Corrosion Resistor Cartridge
MAINTENANCE MAINTENANCE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE (If equipped) WARNING The oil is at high temperature after the engine has been operated, so never replace the cartridge immediately after finishing operations. Wait for the oil to cool down before replacing cartridge. Container to catch drained coolant Prepare a filter wrench for fuel filter element.
Page 293: Grease, Check Tension Pulley Assembly Of Alternator, Air Conditioner Compressor Drive Belt
Using a grease gun, lubricate the grease fitting marked by the arrow. (1) Tension pulley assembly (1 place) Check the pulley for play or leakage of grease. If any problem is found, please ask your Komatsu distributor to carry out disassembly and repair or replacement. 4 - 70...
Page 294: Check Welded Structure
MAINTENANCE MAINTENANCE PROCEDURE CHECK WELDED STRUCTURE (Color check) Cracks in welded structures can be seen easily with a color check. Check the revolving frame, center frame, boom, and arm every 1000 hours. In particular, carry out a color check on the important check points (marked with a circle). The procedure for the color check is as follows.
Page 295 MAINTENANCE MAINTENANCE PROCEDURE Boom 4 - 72...
Page 296 MAINTENANCE MAINTENANCE PROCEDURE 4 - 73...
Page 297: Every 2000 Hours Maintenance
Ask your Komatsu distributor to carry out the inspection. CHECK ALTERNATOR There is a possibility that the bearing is short of grease. Call your Komatsu distributor for inspection and repair. CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor.
Page 298: Clean Hydraulic Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to go down before starting the operation. When the cap of the oil filler port is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
Page 299: Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 300 MAINTENANCE MAINTENANCE PROCEDURE CHECKING FUNCTION OF ACCUMULATOR CAUTION When carrying out the inspection, check first that there is no person or obstacle in the surrounding area. Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm, level ground. 2.
Page 301 Please contact your Komatsu distributor for inspection. 7. This completes the inspection. After completion of the inspection, set the lock lever to the LOCK position and turn the starting switch to the OFF position.
Page 302 MAINTENANCE MAINTENANCE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting. If the pressure is not released, high pressure oil may spurt out and cause serious personal injury.
Page 303: Every 4000 Hours Maintenance
Komatsu distributor for disassembly and repair or replacement. CHECK STARTING MOTOR Wear on the brush and the bearings short of grease are suspected, so ask the Komatsu distributor in your territory for the repairs. CHECK AIR COMPRESSOR, ADJUST As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.
Page 304: Check For Looseness Of High-Pressure Piping Clamp, Hardening Of Rubber
Check visually and touch by hand to check that there are no loose mounting bolts for high-pressure piping clamps (1) - (20) in the diagram and no hardening of any rubber parts. If any problem is found, the part must be replaced. In this case, please ask your Komatsu distributor to carry out the replacement. NOTICE If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure piping.
Page 305: Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
If there is any problem, the problem part must be replaced. Contact your Komatsu distributor for part replacement. 4 - 82...
Page 306: Every 5000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 10, 100, 250, 500, 1000, and 2000 hours of service should be performed at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 307 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Set the container to catch the oil under the drain plug at the bottom of the chassis. Remove plug (1), then loosen drain valve (P) and drain the oil. After draining the oil, tighten drain valve (P) and plug (1).
Page 308: Every 8000 Hours Maintenance
Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPRAY PREVENTION CAP Contact your Komatsu distributor to have the fuel spray prevention cap replaced. OVERHAUL STARTING MOTOR AND ALTERNATOR Ask your Komatsu distributor to carry out this work.
Page 310 5 - 1...
Page 311: Specifications
109,900 (242,330) 111,700 (246,299) 113,500 (250,268) Bucket capacity (cu.yd) 5.2 (6.8) 6.7 (8.8) 5.2 (6.8) Name of engine KOMATSU SAA6D170E-5 diesel engine Engine horsepower kW (HP) /rpm 502 (672)/1,800 A Overall length mm (ft in) 16,020 (52' 7") 14,790 (48' 6") 16,020 (52' 7")
Page 312 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC1250-8 PC1250SP-8 PC1250LC-8 A Max. digging reach mm (ft in) 15,350 (50' 4") 14,070 (46' 2") 15,350 (50' 4") B Max. digging depth mm (ft in) 9,350 (30' 8") 7,900 (25' 11") 9,350 (30' 8") C Max.
Page 314 6 - 1...
Page 315: Attachments And Options
There may also be problems of the attachment or option hitting the operator's cab. Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu. READ THE INSTRUCTION MANUAL THOROUGHLY Before installing or using any attachment or option, make sure that you thoroughly read and understand the instruction manuals for the machine and the attachment or option.
Page 316: Attachment Guide
WARNING Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.
Page 317 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE ATTACHMENT GUIDE Model PC1250LC Bucket width [mm (in)] Standard boom Boom 9.1 m Strong Excluding Including Standar Semilong Long Semilong side cutter side cutter d arm side shroud side shroud 1,500 1,670 3.4 <4.4>...
Page 318 ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE Working Range Diagram PC1250-8 PC1250-8 PC1250-8 PC1250SP PC1250-8 PC1250-8 Working ranges Unit Standard Semilong Strong Strong arm Long arm Semilong arm SE arm 15,350 15,350 16,340 16,340 17,450 14,070 A Max. digging reach (ft in) (50'4") (50'4") (53'7")
Page 319 ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE 6 - 6...
Page 320: Selection Of Track Shoes
ATTACHMENTS AND OPTIONS SELECTION OF TRACK SHOES SELECTION OF TRACK SHOES Select the most suitable track shoe to match the operating conditions. Check the use in the table below, and select the shoe from the table on the next page. Category Precautions when using Remarks...
Page 321: Auto-Greasing System
ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM EXPLANATION OF COMPONENTS Auto-greasing switch Grease pump Interval adjustment dial Regulator Warning lamp (red) Injector Auto-greasing/grease gun selector valve lever 6 - 8...
Page 322 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Auto-greasing Switch This switch (1) actuates the greasing system. When this switch is set to the AUTO position, the lamp (green) lights up and the auto-greasing system starts to operate. If the auto-greasing switch is at AUTO when the machine starting switch is turned ON, the greasing system is actuated immediately.
Page 323 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Auto-greasing/Grease Gun Selector Valve Lever This lever (4) is used to switch the flow of grease to the grease gun. When using the auto-greasing system, set it to the AUTO position (A); when using the grease gun, set it to the GREASE GUN position (B).
Page 324 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Injector This injector (7) supplies the grease sent from grease pump (5) to the greasing points. 6 - 11...
Page 325 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM Greasing Points for Auto-greasing System CAUTION If there is an abnormality and the auto-greasing system does not function, supply the grease manually to greasing points (1) - (8). For details, see the INSPECTION AND MAINTENANCE section. Greasing points (9) - (13) are not included in the auto-greasing system, so supply the grease manually to these greasing points.
Page 326: Operation
ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM OPERATION CHECK BEFORE STARTING OPERATIONS Check that there is ample grease in the grease pail in the grease pump inside the battery case. If the pump has run out of grease, replace the grease pail. Check that the grease pail is not dented or deformed.
Page 327 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM Set the auto-greasing switch to the OFF position when it is necessary to stop the auto-greasing system, such as when the grease piping is broken or damaged. 6 - 14...
Page 328 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM METHOD OF ADJUSTING INTERVAL TIMER CAUTION The setting of the interval timer differs according to the type of machine and the type of work. For this reason, it is necessary for the customer himself to set the interval timing to match the working condition of the machine. The interval timer is installed to control the greasing interval of the auto-greasing system.
Page 329 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM METHOD OF ADJUSTING INJECTOR DISCHARGE AMOUNT CAUTION The setting of the injector discharge amount differs according to the type of machine and the type of work. For this reason, it is necessary for the customer himself to set the injector discharge amount to match the working condition of the machine. The injector is operated by the pressure from the pump, and it feeds grease of the specified quantity to the bearing.
Page 330: Troubleshooting
Change to grease for cold is being used in cold area weather (NLGI No. 0 or equivalent) If any problem occurs where the cause is not listed in the above table, please contact your Komatsu distributor for repairs. 6 - 17...
Page 331: Maintenance
ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM MAINTENANCE REPLACE GREASE PAIL CAUTION Do not use a grease pail if it is dented or deformed. Follower plate (2) will not come down, or air pockets will form, so the grease will not be sucked in. After using the pail, remove all grease that leaked or sprayed out.
Page 332 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM PROCEDURE FOR BLEEDING AIR FROM GREASE LINE WARNING There is no check device to prevent reverse flow in the service grease nipple installed to the injector. If you forget to tighten the cap, there is danger that high-pressure grease may spurt out when the grease pump is actuated. Be sure not to forget to tighten the cap.
Page 333 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM AUTO-GREASING SYSTEM 5. Tighten plug (2) of the injector to prevent the grease from leaking. Tightening torque of plug (2): 19.6 - 24.9 Nm (2.0 - 3.0 kgm, 14.5 - 21.7 lbft) Carry out Steps 1 to 5 for every injector.
Page 334 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM INJECTOR POSITION IN AUTO-GREASING SYSTEM AND MANUAL GREASING WARNING There is no check device to prevent reverse flow in the service grease nipple installed to the injector. If you forget to tighten the cap, there is danger that high-pressure grease may spurt out when the grease pump is actuated. Be sure not to forget to tighten the cap.
Page 335 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM When greasing places on top of the arm: boom-arm connecting pin (8), bucket cylinder foot pins (9) and (10), and arm cylinder rod pin (11), the greasing can be carried out manually from the central block. 6 - 22...
Page 336 ATTACHMENTS AND OPTIONS AUTO-GREASING SYSTEM EVERY 10 HOURS MAINTENANCE Greasing Points not Including in Auto-greasing System 1. Set to the greasing posture below, lower the work equipment to the ground, then stop the engine. 2. Using a grease gun, supply grease to the grease fitting is marked by arrows. 3.
Page 337: Handling Machines Equipped With Vhms
Never disassemble, repair, modify, or move the VHMS, antenna, or cables. This may cause failure or fire on the VHMS equipment or the machine itself. (Your Komatsu distributor will carry out removal and installation of VHMS.) Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected wires may cause failure or fire on the VHMS equipment or the machine itself.
Page 338: Vhms And Communications Terminal Installed
Komatsu distributor before selling or exporting any machine equipped with VHMS. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the VHMS equipment or to carry out action to stop communications.
Page 340 7 - 1...
Page 341: Loading Shovel
LOADING SHOVEL EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS SWITCHES Starting switch (10) Emergency pump drive switch Fuel control dial (11) Swing parking brake release switch Cigarette lighter (12) Step light switch Swing lock switch (13) Lower wiper switch (machines equipped with Lamp switch fixed front window cab) Machine push-up switch...
Page 342 LOADING SHOVEL EXPLANATION OF COMPONENTS Machine Push-up Switch Shackles Boom Control Switch Horn Switch When the switch (8) at the tip of the right work equipment control lever is pressed, the horn will sound. Room Lamp Switch Emergency Pump Drive Switch Swing Parking Brake Release Switch Step Light Switch Lower Wiper Switch...
Page 343 LOADING SHOVEL EXPLANATION OF COMPONENTS Bottom Dump Switch Use this switch (16) to open and close the front bucket. If the button at the tip of the left work equipment control lever is depressed, the bucket will close. If the button at the tip of the right work equipment control lever is depressed, the front bucket will open.
Page 344: Fuse
LOADING SHOVEL EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. Fuse Capacities and Circuit Name Fuse Name of circuit capacity Redundancy Solenoid valve PPC lock solenoid Window washer, cigar lighter Horn, flash lamp light (if equipped), L/S (if equipped) Auto greasing system (if equipped) Rotating lamp (if equipped)
Page 345: Operations
LOADING SHOVEL OPERATIONS OPERATIONS OPERATION OF WORK EQUIPMENT WARNING If the lever is operated in the deceleration range, the engine speed will suddenly rise. Operate the levers carefully. If the work equipment control levers are operated quickly, the engine speed will suddenly rise. Operate the levers carefully. The work equipment is operated with the left work equipment control lever and right work equipment control lever.
Page 346 LOADING SHOVEL LOADING SHOVEL OPERATIONS OPERATIONS Boom operation (A): Boom RIASE (B): Boom LOWER Bucket operation (A): Bucket DUMP (B): Bucket CURL Bottom dump operation (A): OPEN (B): CLOSE 7 - 7...
Page 347: Precautions During Operation
LOADING SHOVEL OPERATIONS PRECAUTIONS DURING OPERATION WARNING When the arm is pushed out to the front, the speed momentarily becomes slow around the vertical position of the arm. Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations.
Page 348 LOADING SHOVEL OPERATIONS Do not Carry Out Operations with the Hydraulic Cylinder at the End of its Stroke. If the cylinder is operated to the end of its stroke during operations, a large force will be brought to bear on the stopper inside the cylinder, and this will reduce the service life of the machine, so leave room (distance a) at the end of the stroke as far as possible.
Page 349 LOADING SHOVEL OPERATIONS It is Prohibited to Grip Rocks. Do not use the bottom dump bucket to grip rocks. It is Prohibited to Use the Bucket for Leaving Operations. Using the rear bucket to carry out leveling operations will bring an excessive force to bear on the work equipment, so do not use the rear bucket in this way.
Page 350 LOADING SHOVEL OPERATIONS Scraping-down Operations are Prohibited. Never use the front bucket of a bottom-dump bucket to scrap down rocks or soil. Digging Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment. It is better to excavate it after breaking up by some other means.
Page 351: Excavator Work
LOADING SHOVEL OPERATIONS EXCAVATOR WORK In addition to the following, it is possible to further increase the range of applications by using various attachments. Shovel Work This is suitable for digging a place which is higher than the machine's position. It is most efficient if the arm s digging angle is from vertical to 60i forward, and the arm cylinder is used effectively.
Page 352: Precautions When Disassembling Machine
LOADING SHOVEL PRECAUTIONS WHEN DISASSEMBLING MACHINE PRECAUTIONS WHEN DISASSEMBLING MACHINE RELEASING PRESSURE When disassembling the machine or removing the piping during inspection or maintenance, always release the pressure as follows. Releasing Pressure from Work Equipment Circuit, Swing Circuit, Travel Circuit WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting.
Page 353 LOADING SHOVEL TRANSPORTATION TRANSPORTATION MACHINE CONFIGURATION FOR TRANSPORT This machine can be divided into eight units for transportation. When transporting, contact your Komatsu distributor. Eight Units for Transportation Upper Structure Counterweight Undercarriage (right) Bucket Undercarriage (left) Work equipment Center frame...
Page 354 LOADING SHOVEL TRANSPORTATION Posture for Each unit (dimensions in diagram are in mm.) Upper Structure Unit PC1250-8 Overall width mm (ft in) 3,490 (11' 5") 26,700 (58,874) Weight kg (lb) (fuel: enpty, Hydraulic oil: M level) Secure the upper structure to the platform with a chain and block. Undercarriage Unit PC1250-8...
Page 355 LOADING SHOVEL TRANSPORTATION Center Frame Unit PC1250-8 Weight kg (lb) 9,700 (21,389) Counterweight Unit PC1250-8 Weight kg (lb) 18,000 (39,690) 7 - 16...
Page 356 LOADING SHOVEL TRANSPORTATION Bucket Unit PC1250-8 mm (ft in) 3,000 (9' 10") mm (ft in) 2,700 (8' 10") Overall width mm (ft in) 2,700 (8' 10") Weight kg (lb) 9,300 (20,507) Work Equipment Unit PC1250-8 mm (ft in) 8,730 (28' 8") mm (ft in) 2,750 (9') Overall width mm (ft in)
Page 357 LOADING SHOVEL TRANSPORTATION Outer Cover Radiator duct (same for all models) Unit PC1250-8 Weight kg (lb) 100 (221) Radiator duct upper cover (same for all models) Unit PC1250-8 Weight kg (lb) 17 (37) 7 - 18...
Page 358 LOADING SHOVEL TRANSPORTATION Catwalk (right) : (same for all models) Unit PC1250-8 Weight kg (lb) 17 (37) Catwalk (left, front) : (same for all models) Unit PC1250-8 Weight kg (lb) 7 - 19...
Page 359 LOADING SHOVEL TRANSPORTATION Catwalk (left, rear) : (same for all models) Unit PC1250-8 Weight kg (lb) 150 (331) 7 - 20...
Page 360 When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 361 LOADING SHOVEL MAINTENANCE MAINTENANCE CHECK BEFORE STARTING Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 362 LOADING SHOVEL LOADING SHOVEL MAINTENANCE MAINTENANCE The proper way to check the hydraulic oil level is as follows. When the hydraulic oil is at normal temperature (15°C to 30° C), the oil level should be within the blue range of gauge label (a) in the diagram on the right.
Page 363 LOADING SHOVEL MAINTENANCE EVERY 10 HOURS MAINTENANCE LUBRICATTING 1. Set to the greasing posture below, lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 364 LOADING SHOVEL MAINTENANCE EVERY 5000 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 365 LOADING SHOVEL LOADING SHOVEL MAINTENANCE MAINTENANCE 5. Set the container to catch the oil under the drain plug at the bottom of the chassis. Remove plug (1), then loosen drain valve (P) and drain the oil. After draining the oil, tighten drain valve (P) and plug (1).
Page 366 Unit PC1250-8 Operating weight kg (lb) 110,900 (244,535) Bucket capacity (cu.yd) 6.5 (8.5) Name of engine KOMATSU SAA6D170E-5 diesel engine Engine horsepower kW(HP)/rpm 502(672)/1,800 A Overall length mm (ft in) 10,940 (35' 11") B Overall height mm (ft in) 6,200 (20' 4")
Page 367 LOADING SHOVEL COMBINATION OF WORK EQUIPMENT COMBINATION OF WORK EQUIPMENT WARNING Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
Page 368 LOADING SHOVEL COMBINATION OF WORK EQUIPMENT Working Range Diagram PC1250-8 Loading shovel Working ranges Without bucket link A Max. digging reach 11,400 (37' 5") B Max. digging depth 10,900 (35' 9") C Max. digging height 12,330 (40' 5") D Max. vertical wall depth 3,650 (11' 12") E Max.
Page 370 INDEX INDEX <A> FOREWORD AFTER STARTING ENGINE 3-101 FUSE 3- 67 AIR CONDITIONER CONTROLS 3- 47 FUSE ASHTRAY 3- 46 ATTACHMENT GUIDE <G> COMBINATIONS OF WORK GENERAL OPERATION INFORMATION 3-127 EQUIPMENT GENERAL PRECAUTIONS 2- 12 AUTO-GREASING SYSTEM GENERAL PRECAUTIONS FOR AUXILIARY ELECTRIC POWER 3- 66 SAFETY...
Page 371 CHECK BEFORE STARTING 7- 22 RECOMMENDED QUALITY FOR EVERY 10 HOURS MAINTENANCE 7- 24 PRODUCTS OTHER THAN EVERY 5000 HOURS MAINTENANCE 7- 25 KOMATSU GENUINE OIL 4- 11 MAINTENANCE INFORMATION MAINTENANCE PROCEDURE 4- 16 <S> CHECK BEFORE STARTING 4- 43...
Page 372 INDEX OTHER TROUBLE 3-161 PHENOMENA THAT ARE NOT FAILURES 3-155 RUNNING OUT OF FUEL 3-155 SEVERE JOB CONDITION 3-156 TOWING THE MACHINE 3-156 <V> VISIBILITY FROM OPERATOR'S SEAT <W> WEAR PARTS WEAR PARTS 7- 21 WEAR PARTS LIST WEAR PARTS LIST 7- 21 WORK EQUIPMENT CONTROLS AND OPERATIONS...

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