Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
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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 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 5 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 6 FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR (PAGE 3-70)" for further details.
Page 7 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 right front of the frame. The design of the nameplate differs according to the territory.
Page 8 FOREWORD PRODUCT INFORMATION EPA NAMEPLATE This is stuck on the counterweight. EPA: Environmental Protection Agency, U.S.A. SERVICE METER LOCATION On top of the machine monitor 1 - 7...
Page 9 FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 8...
Page 10: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE PROTECTIVE STRUCTURE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NUMBER PLATE AND ITS LOCATION EPA NAMEPLATE SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS...
Page 11: Foreword
FOREWORD CONTENTS STOPPING THE ENGINE 3- 51 MACHINE OPERATION 3- 52 STEERING THE MACHINE 3- 57 SWINGING 3- 59 WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 60 PROHIBITED OPERATIONS 3- 63 GENERAL OPERATION INFORMATION 3- 65 TRAVELING ON SLOPES 3- 67 ESCAPE FROM MUD 3- 69 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR...
Page 12 FOREWORD CONTENTS MAINTENANCE PROCEDURE 4- 16 WHEN REQUIRED 4- 16 CHECK BEFORE STARTING 4- 38 EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE 4- 38 EVERY 500 HOURS MAINTENANCE 4- 39 EVERY 1000 HOURS MAINTENANCE 4- 47 EVERY 1500 HOURS MAINTENANCE 4- 50 EVERY 2000 HOURS MAINTENANCE 4- 51...
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Page 15: Safety Information
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION 2- 10 Safety Rules 2- 10 If Problems are Found 2- 10 Working Wear and Personal Protective Items 2- 10 Fire Extinguisher and First Aid Kit 2- 10 Safety Equipment 2- 11 Keep Machine Clean...
Page 16 SAFETY SAFETY TRANSPORTATION 2- 27 Loading and Unloading 2- 27 Shipping the Machine 2- 27 BATTERY 2- 28 Battery Hazard Prevention 2- 28 Starting Engine with Booster Cables 2- 29 TOWING 2- 30 Safety Rules for Towing 2- 30 LIFTING OBJECTS WITH BUCKET 2- 31 Safety Rules for Lifting Objects 2- 31...
Page 17: 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. LOCATION OF SAFETY LABELS...
Page 18: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution for before operation (22L-98-22160) (3) Caution for leaving operator's seat (09654-03001) 2 - 5...
Page 19 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electric cables (09801-03001) (5) Caution for operating pattern (22J-98-1A631) (6) Caution for high-temperature coolant (20M-98-83250) 2 - 6...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (7) Caution for high-temperature hydraulic oil (22L-98-22240) (8) Caution for handling electric wires (09808-03000) (9) Caution for check and adjust track tention (09657-03003) (10) Caution when opening while engine is running (09667-03001) 2 - 7...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (11) Prohibited to enter range of swing (20M-98-73130) (12) Caution for handling ROPS (22L-98-31930) (13) Caution when changing operating pattern (22L-98-22311) (14) Caution for lock pin when opening floor (22L-98-22390) (15) Caution when closing floor (22L-98-22410) 2 - 8...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (16) Work prohibited when track guage is retracted (22J-98-25540) (17) Caution for handling accumulator and gas spring (09659-53000) (18) Caution blast site (09845-00480) 2 - 9...
Page 23: 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 24: Safety Equipment
SAFETY GENERAL PRECAUTIONS SAFETY EQUIPMENT Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features.
Page 25: 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 26: Burn Prevention
SAFETY GENERAL PRECAUTIONS BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 27: Action If Fire Occurs
If in any doubt contact your Komatsu distributor. With any combination of work tool (such as bucket, breaker) that Komatsu refer to in this manual, the overall weight of the machine does not exceed the certified value of the ROPS.
Page 28 If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfil its function properly. In such cases, always contact your Komatsu distributor for advice on the method of repair.
Page 29: Attachment Installation
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 30: 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 31: Signalman's Signal And Signs
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 18...
Page 32: 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 lens of the front lamps and working lamps, and check that they light up correctly.
Page 33: Safety Rules For Starting Engine
Open the engine rear cover and check that 2 floor tilt lock bolts (1) are securely tightened. If any problem is found, always repair it or contact your Komatsu distributor for repairs. SAFETY RULES FOR STARTING ENGINE Start and operate the machine only while seated.
Page 34: 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 35: Safety Rules For Traveling
SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply. When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.
Page 36: Traveling On Slopes
SAFETY SAFETY MACHINE OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine.
Page 37: Operations On Slopes
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION Always travel straight up or down a slope. Traveling at an angle or across the slope is extremely dangerous. Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again.
Page 38 SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations. Do not carry out demolition work under the machine.
Page 39: Operations On Snow
SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SNOW Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 40: Transportation
SAFETY SAFETY MACHINE OPERATION TRANSPORTATION LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.
Page 41: 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 42: 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 43: 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 3-96)". Always wear leather gloves when handling wire rope.
Page 44: 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 45: 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 46: 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 and blade completely to the ground. Check that the battery relay is off and main power is not conducted.
Page 47: Cautions For Opening (Tilting) Floor
SAFETY SAFETY MAINTENANCE INFORMATION CAUTIONS FOR OPENING (TILTING) FLOOR When opening (tilting) the floor, see "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-23)" for details. Precautions when parking machine Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding.
Page 48: Two Workers For Maintenance When Engine Is Running
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. 2 - 35...
Page 49: Personnel
SAFETY SAFETY MAINTENANCE INFORMATION PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall.
Page 50: Welding Works
If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. SAFETY RULES FOR HIGH-PRESSURE OIL The hydraulic system is always under internal pressure.
Page 51 SAFETY SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.
Page 52: Safety Handling High-Pressure Hoses
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
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Page 55: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Track shoe Bucket cylinder Sprocket Track frame Arm cylinder (10) Idler Boom (11) Blade cylinder Boom cylinder (12) Blade 3 - 2...
Page 56: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Operator's seat (14) Blade/Variable gauge control lever Blade/Variable gauge selector switch (15) Machine monitor Lamp switch (16) Fuel control lever Armrest (17) Starting switch Lock lever (left) (18) Floor lock cancel lever Left work equipment control lever (19) Electrical System Warning Monitor(*) Travel Levers...
Page 57: 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 Emergency monitors (C) Pilot lamps...
Page 58 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor flashes or the buzzer sounds, stop the engine immediately or run it at low idle, then inspect the problem point immediately and repair the problem. These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal location on the monitor will flash and the buzzer will sound.
Page 59 OPERATION DETAILED CONTROLS AND GAUGES Charge Level Monitor If there is a problem in the charging when the engine is running, this monitor (2) flashes and the buzzer sounds. If the monitor flashes, stop the engine and check the V-belt tension.
Page 60 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Engine coolant temperature gauge Service meter Fuel gauge Engine Coolant Temperature Gauge This meter (1) shows the engine coolant temperature. During operation, the indicator should be in range (A). If the indicator enters red range (B) during operation, pilot lamp (C) flashes and the buzzer sounds at the same time.
Page 61 OPERATION DETAILED CONTROLS AND GAUGES Fuel Gauge This meter (2) shows the fuel level in the fuel tank. F indicates that the tank is full. E indicates that the fuel level is low. If the fuel level goes below 6.0 liters (1.59 US gal), the indicator enters red range (A), and at the same time, pilot lamp (B) flashes.
Page 62 OPERATION DETAILED CONTROLS AND GAUGES Pilot Lamps Engine pre-heating monitor Travel speed boost monitor Engine Pre-heating Monitor This monitor (1) flashes when the starting switch is set to the HEAT position. After approx. 18 seconds, the buzzer sounds and the monitor goes out.
Page 63: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch Travel speed selector switch Horn switch Blade/Variable gauge selector switch Lamp switch 3 - 10...
Page 64 OPERATION DETAILED CONTROLS AND GAUGES Starting Switch This switch (1) is used to start or stop the engine. (A): OFF position At this position, the starting switch key can be inserted and removed. When the starting switch key is turned to this position, the power to the electrical system is switched off and the engine stops.
Page 65 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch Use this switch (4) to switch the travel speed to low speed or high speed. Blade/Variable Gauge Selector Switch WARNING Use the narrow gauge only when traveling through confined places. For normal operation and for digging operations, always set the variable gauge to wide gauge.
Page 66: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Travel levers Left work equipment control lever Swing lock cover Right work equipment control lever Boom swing control pedal Fuel control lever Floor lock cancel lever Blade/Variable gauge control lever 3 - 13...
Page 67 OPERATION DETAILED CONTROLS AND GAUGES Lock Lever WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position (L). If the lock lever is not at the LOCK position (L) and the control levers are touched by mistake, it may lead to serious personal injury. If the lock lever is not set securely to LOCK position (L), it may cause serious personal injury.
Page 68 WARNING The operating pattern is set to the standard operating pattern (ISO pattern). When changing the operating pattern, please contact your Komatsu distributor. The method of using operating patterns other than the ISO pattern is given in the ATTACHMENT AND OPTIONS section. Always read and understand the contents before operating the machine.
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Lever This lever (4) is used to control the engine speed and output. (A) Low idle: Push the lever fully (B) High idle: Pull the lever fully Blade/Variable Gauge Control Lever WARNING This lever is not locked even when the lock lever is set to the LOCK position, so be careful not to touch the blade/variable gauge control lever if blade/variable gauge operations are not being carried out.
Page 70 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES Use this lever (6) to driver the machine. (a) FORWARD: The lever is pushed forward (b) REVERSE: The lever is pulled back N (Neutral): The machine stops Swing Lock Cover WARNING When the boom swing is not being used, lock the boom swing with the swing lock cover.
Page 71 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES When opening or closing the floor, pull this lever (9) to FREE (F) position to release the lock. Open or close the floor while pulling this lever (9). After opening or closing the floor, release lever (9). It will return automatically to LOCK position (L).
Page 72: Cover With Lock
OPERATION DETAILED CONTROLS AND GAUGES COVER WITH LOCK Use the starting switch key to open or close the cover with the lock. For details of the position of the cover with the lock, see "LOCKING (PAGE 3-75)". Insert the key as far as it will go to the shoulder (A). If the key is turned before it is inserted all the way, it may break.
Page 73: Engine Rear Cover
OPERATION DETAILED CONTROLS AND GAUGES ENGINE REAR COVER CAUTION When carrying out inspection and service inside the engine rear cover, always open the cover fully until it is secured in position by the rod. NOTICE Except when opening the cover, always keep it locked. When it is locked, opening knob (2) of the cover does not move.
Page 74: Cooling Cover
OPERATION DETAILED CONTROLS AND GAUGES COOLING COVER CAUTION Always open each cover fully until it is secured in position by the rod. 1. Release lock (1) of the cover. (For details of the method of opening and closing the cover with the lock, see "Opening and Closing Covers with Lock (PAGE 3-19)".) 2.
Page 75: Battery Cover
OPERATION DETAILED CONTROLS AND GAUGES BATTERY COVER CAUTION Always open each cover fully until it is secured in position by the rod. 1. Release lock (1) of the cover. (For details of the method of opening and closing the cover with the lock, see "Opening and Closing Covers with Lock (PAGE 3-19)".) 2.
Page 76: Method Of Opening (Tilting) Floor
If any problem or damage to the lock portion is found when opening the floor, stop the operation immediately and ask your Komatsu distributor to carry out repairs. Before starting the opening (tilting) operation of the floor, read the precautions related to safety and maintenance in "CAUTIONS FOR OPENING (TILTING) FLOOR (PAGE 2-34)".
Page 77 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. Open engine rear cover (2) fully and secure it in position. (For details, see "ENGINE REAR COVER (PAGE 3-20)".) 6. Loosen floor tilt lock bolts (3) (M14 x 2). 7.
Page 78 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 10. Turn until the stopper hook at the top of lock pin (10) catches securely on pin (12) in the insertion portion. NOTICE Check that lock pin (10) is hooked to pin (12) and does not come out. This completes the 2nd stage lock, and and the operation to open the floor is completed.
Page 79 Before closing the floor, check that there is no damage or problem in the wiring, piping, or seats inside the floor or revolving frame. If any damage or problem is found, please ask your Komatsu distributor to carry out repairs.
Page 80: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 12V Power Source NOTICE Be sure to close cap (1) after use of the external power source. If the cap is left open, rainwater seeps in, possibly causing short-circuiting. An external power source terminal is provided on the front of the machine.
Page 81: Block Fuse
OPERATION DETAILED CONTROLS AND GAUGES Fuse Capacities and Circuit Names Fuse box (A) Fuse Name of circuit capacity PPC solenoid, battery Work lamp, feed pump Engine stop solenoid Monitor panel, buzzer, travel solenoid, Gauge solenoid Horn, option power source (1) Option power source (2) Spare Spare...
Page 82: Tool Box
OPERATION DETAILED CONTROLS AND GAUGES TOOL BOX NOTICE Except when opening the cover for some reason, always keep the cover locked. Store the tools in this box. 3 - 29...
Page 83: Handling Machines Equipped With Komtrax
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. 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 KOMTRAX equipment or to carry out action to stop communications.
Page 84: Machine Operations And Controls
Leakage of oil and fuel will cause the machine to catch fire. Always check thoroughly and repair any problems or contact your Komatsu distributor. Check that the floor is fixed securely in position by bolts (1). If it is not fixed securely in position, it may cause serious personal injury.
Page 85 If any problem is found, always repair it or ask your Komatsu distributor to carry out repairs. 11. Check bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, contact your Komatsu distributor for repairs. 3 - 32...
Page 86 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 87 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. REMARK If the machine is at an angle, reposition it to level before checking.
Page 88 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
Page 89 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 90 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 4. Extend the boom, arm, and bucket cylinder fully as shown in the diagram on the right, remove the oil filler cap, then install the cap and pressurize the inside of the tank. NOTICE Be sure to pressurize the hydraulic tank.
Page 91 Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. Check Function of Horn 1. Turn the starting switch to the ON position.
Page 92 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment WARNING Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switches can be operated freely and easily with the operator back against the backrest.
Page 93 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),(B) Adjust the angle so that the machine's side is reflected on the mirror as shown in the figure at right.
Page 94 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 there are no signs of damage, replace belts in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Page 95 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end of the belt on either the buckle body or tongue side. Lengthening Pull the belt while holding it at a right angle to the buckle or tongue. Operations Before Starting Engine WARNING When standing up from the operator's seat, always set the lock lever to the...
Page 96 If a monitor or gauge does not light up or the buzzer does not sound, there is probably a blown fuse or disconnection in the monitor, so contact your Komatsu distributor for repairs. After approx. 3 seconds, only the following monitors stay lighted up.
Page 97: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire.
Page 98 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to START position (C). The engine will start. 4. When the engine starts, release the key in starting switch (3). The key will automatically return to ON position (B). Starting Engine in Cold Weather WARNING Start the engine only after sitting down in the operator's seat.
Page 99 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 1. Check to make sure that lock lever (1) is at the LOCK position (L). If lock lever (1) is in the FREE position (F), the engine will not start. 2.
Page 100 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. When the engine starts, release the key in starting switch (3). The key will automatically return to ON position (B). 3 - 47...
Page 101: After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 102 OPERATION MACHINE OPERATIONS AND CONTROLS Warming-up Operation NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the lever suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warming-up operation is completed.
Page 103 Fuel gauge (5): Indicator is in correct range Engine oil pressure monitor (6): Monitor is off Charge level monitor (7): Monitor is off 5. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 50...
Page 104: 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 105: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the travel levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. When moving off, check that the area around the machine is safe, and sound the horn before moving. Clear all personnal from the machine and the area.
Page 106 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 1. Set lock lever (2) to the FREE position (F), then raise the work equipment 40 to 50 cm (16 to 20 in) from the ground. 2. Raise the blade. 3. Operate the both travel levers (3) as explained below. When the sprocket (A) is at the rear of the machine.
Page 107 When the load is reduced, the travel system returns to high speed travel. 5. For machines equipped with a travel alarm, check that the alarm sounds. If the alarm does not sound, contact your Komatsu distributor for repairs. Moving Machine Backward 1.
Page 108 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS When the sprocket (A) is at the front of the machine. Push the both travel levers (3) forward slowly to move the machine off. 4. Switch the travel speed as follows. When the travel speed selector switch (4) is pressed, the travel speed can be switched between high speed and low speed.
Page 109 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Shift the left and right travel levers to the neutral (N) position. 3 - 56...
Page 110: 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. REMARK When traveling at high speed, if the load increases, the automatic travel speed shifting function automatically shifts the transmission to low speed and the machine travels slowly.
Page 111 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 112: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING When operating the swing, check that the area around the machine is safe. 1. Operate left work equipment control lever (1) to swing the upper structure. 2. When not using the swing, set left work equipment control lever (1) to the N position.
Page 113: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING For operation modes other than the standard one (ISO pattern), refer to the chapter of ATTACHMENTS AND OPTIONS in this manual. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
Page 114 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Bucket control Move the right work equipment control lever to the left or right to operate the bucket. Boom swing operation The boom swing operation can be carried out with the boom swing control pedal.
Page 115 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Variable gauge operation WARNING Use the narrow gauge only when traveling through confined places. For normal operation and for digging operations, always set the variable gauge to wide gauge. When the machine is on a slope, the left-to-right stability is poor, so it is dangerous to change the track gauge.
Page 116: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING Do not attempt to operate the work equipment control lever, while the machine is traveling. Operations Using Swing Force Do not use bucket swing force to compact soil or break an earth wall, or do not dig the bucket teeth into the ground while swinging the bucket.
Page 117 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. Operations Using Machine Dropping Force It is prohibited to carry out digging operations using the dropping force of the machine.
Page 118: 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 119 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth CAUTION 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 radiator fan. This may cause the fan to break. Be extremely careful when driving the machine out of water.
Page 120: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.
Page 121 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. When traveling up a steep hill of more than 15°, set the work equipment to the posture shown in the diagram on the right. Traveling Downhill Put the travel lever in the neutral position. This will cause the brake to be automatically applied. Engine Stopped on Slope If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket to the ground, stop the machine, then start the engine again.
Page 122: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get the machine out. Track on One Side Stuck NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.
Page 123: Work Possible Using Compact Hydraulic Excavator
OPERATION MACHINE OPERATIONS AND CONTROLS WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work This is suitable for excavating places lower than the machine. When work equipment is in condition shown in diagram on right Bucket cylinder and link When the center line of arm cylinder and arm foot pin is at 90°, the...
Page 124 OPERATION MACHINE OPERATIONS AND CONTROLS Smoothing Work When refilling after excavation and when smoothing the ground surface, use the blade. Side Ditching Work The machine can be used for side ditching in a confined worksite by combining the swing and boom swing operations. 3 - 71...
Page 125: 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 126: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Park the machine on the firm, level ground. Avoid parking the machine on slopes. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the work equipment into the ground surface to stop the machine from moving.
Page 127: 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. Lower the blade to the ground. 5. Set lock lever (3) in the LOCK position (L). MACHINE INSPECTION AFTER DAILY WORK Before Stop Engine Use the machine monitor to check engine coolant temperature (1), engine oil pressure (2), and fuel level (3).
Page 128: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Engine rear cover (2) cooling cover (3) Battery cover (4) Operation and Maintenance Manual, toolbox cover For details of locking, see "Opening and Closing Covers with Lock (PAGE 3-19)". REMARK Use the starting switch key to lock and unlock all these places.
Page 129: Rubber Shoes (Machine With Rubber Shoes Only)
OPERATION MACHINE OPERATIONS AND CONTROLS RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY) (Machine equipped with rubber shoe) Rubber Shoes Information Rubber shoes have excellent properties that are not found in steel shoes. However, if they are used in the same way as steel shoes, full use cannot be made of their advantages.
Page 130 OPERATION MACHINE OPERATIONS AND CONTROLS Using Rubber Shoes Prohibited Works Do not carry out the following types of work. Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near the edges of steel plates will cause damage to the rubber shoes. In places such as river beds where there are large numbers of large and small boulders, the stones may get caught and damage the rubber shoes or make the shoes come off.
Page 131 OPERATION MACHINE OPERATIONS AND CONTROLS Always maintain the rubber shoes at the proper tension to prevent them from coming off. If the tension is low, the rubber shoes will come off under the following conditions. Even if the tension is correct, be extremely careful when carrying out operations. 1.
Page 132 OPERATION MACHINE OPERATIONS AND CONTROLS Mechanism of rubber shoe coming off track 1) When traveling over an obstacle, a gap is formed between the track roller (1) and the rubber shoe (2). In this condition, the rubber shoe may come off. 2) Furthermore, if the machine travels in reverse, a gap is formed between the track roller (1), idler (3), and rubber shoe (2).
Page 133 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS If the machine travels in reverse in this condition, the rubber shoe will come off. If the machine is turned in this condition, the rubber shoe will come off. 3 - 80...
Page 134: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a basic rule, transport the machine by trailer. Select the trailer to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)". Note that the value for the weight and transportation dimensions given in SPECIFICATIONS may differ according to the type of shoe or type of arm or other attachments.
Page 135: Loading And Unloading With Trailer
OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING When loading or unloading, check that travel speed boost monitor (1) is off, and always travel at low speed. If the monitor is on, the speed is set to high-speed travel, so press the low-speed side of travel speed selector switch (2).
Page 136 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks (1) under the tires to ensure that the trailer does not move. Make the slope (2) of the ramps (3) a maximum of 15°.
Page 137 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Set the lock lever to the FREE position (F). 6. When loading, set the work equipment at the front and the blade at the rear, with the undercarriage and upper structure set parallel. 7. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer.
Page 138 OPERATION TRANSPORTATION Securing Machine After placing the machine on the specified position of the trailer, secure it according to the following procedure. NOTICE To prevent damage to the bucket cylinder during transportation, fit a wooden block at one end of the bucket cylinder to prevent it from touching the floor.
Page 139 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks (1) under the tires to ensure that the trailer does not move. Make the slope (2) of the ramps (3) a maximum of 15°.
Page 140 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 7. Run the engine at low speed. 8. Raise the blade. 9. Raise the work equipment, align the direction of travel with the ramp, and travel slowly. Lower the work equipment as far as possible without causing interference.
Page 141: Lifting Machine
For the details on the machine weight, see the section of "SPECIFICATIONS (PAGE 5-2)". The lifting procedure applies to machines with standard specifications. The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your Komatsu distributor for information. 3 - 88...
Page 142 OPERATION TRANSPORTATION When lifting the machine, carry out the operation on flat ground as follows. 1. Start the engine, then swing the upper structure so that the work equipment is at sprocket (1) end with the track frame and upper structure set parallel. 2.
Page 143 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 9. Set the lifting angle (A) of the wire rope to 30° to 40°, then lift the machine slowly. 10. After the machine comes off the ground, check the hook condition and the lifting posture, and then lift slowly. 3 - 90...
Page 144: Cold Weather Operation
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 SUPERCOOLANT (AF-NAC).
Page 145 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 146: 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 147: Long Term Storage
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods. AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 148: 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 bleeding the air, see "Air Bleeding (PAGE 4-43)". 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 149: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope. If the machine is stuck in soft ground and cannot escape under its own power, or when towing a heavy machine, fit the wire rope to the center of the track frame as shown in the diagram on the right,...
Page 150: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge a battery when installed on a machine. Make sure that it is removed 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 151 OPERATION TROUBLES AND ACTIONS Battery Removal and Installation NOTICE After securing the battery, check that it does not move. If it moves, tighten it again securely. Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal). If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated.
Page 152 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 153 OPERATION TROUBLES AND ACTIONS Starting the Engine CAUTION Always check that the lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are at the HOLD or neutral position. 1.
Page 154: 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 155 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 flashes...
Page 156 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Exhaust gas occasionally turns Clogging air cleaner element Clean or replace, see WHEN black REQUIRED Defective nozzle ( Replace nozzles) Defective compression ( See defective compression above) Combustion noise occasionally Defective nozzle ( Replace nozzle) makes bresthing sound Abnornal noise generated...
Page 158 4 - 1...
Page 159: 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. Fresh and Clean Lubricants Use clean oil and grease.
Page 160 MAINTENANCE MAINTENANCE INFORMATION When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil. Avoid Mixing Lubricants If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil.
Page 161: 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 162 COOLANT AND WATER FOR DILUTION Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Page 163 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 164: 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 165: Handling Hydraulic System
MAINTENANCE OUTLINE OF SERVICE HANDLING HYDRAULIC SYSTEM Hydraulic equipment is at a high temperature during operations and immediately after operations. During operations, it is also under high pressure, so be careful of the following points when carrying out inspection and maintenance of hydraulic-related equipment.
Page 166: 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 167: 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 168 G2-T or G2-TE is recommended. Note 3: COOLANT 1) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Page 169: 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 170: 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 171: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-15)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...
Page 172: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging operations, so set the maintenance intervals as follows. Replace hydraulic filter element On a new machine, replace the element after the first 100 to 150 hours, then carry out further replacement of the element according to the table on the right.
Page 173: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 174 MAINTENANCE MAINTENANCE PROCEDURE Air Cleaner Element - Clean/Replace 1. Open the engine rear cover. (For details, see "ENGINE REAR COVER (PAGE 3-20)".) 2. Remove clips (2), then remove dust cup (3). 3. Take out element (4) and cover the air connector at the end of the air cleaner body with a clean cloth or tape.
Page 175 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 7. Remove the cloth or adhesive tape used to cover the air connector inside the air cleaner body. 8. Install cleaned element (4) or a new element. 9. Set dust cup (3) with the arrow pointing up, then set it to the air cleaner body and secure it with clip (2).
Page 176: Clean Inside Of Cooling System
(AF-NAC) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing.Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
Page 177 When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 178 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Place a container to catch the coolant under the drain hose installed to drain valve (3) and under coolant drain plug (4) on the engine cylinder block. 6. Open drain valve (3) and drain the water. Remove drain plug (4) from the engine cylinder block and drain the water.
Page 179: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 22...
Page 180 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 181: Clean Water Separator Element
MAINTENANCE MAINTENANCE PROCEDURE CLEAN WATER SEPARATOR ELEMENT WARNING Do not bring any fire or flame close. Prepare a filter wrench Prepare a container to catch the fuel that is drained. 1. Open the cooling cover. (For details, see "COOLING COVER (PAGE 3-21)".) 2.
Page 182: Check And Adjust Track Tension (Machine Equipped With Steel Shoe)
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. 4 - 25...
Page 183 It is extremely dangerous to release the grease by any method except the procedure given below. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. 1. Loosen plug (1) gradually to release the grease.
Page 184: Check Rubber Shoes (Machine Equipped With Rubber Shoes)
MAINTENANCE MAINTENANCE PROCEDURE CHECK RUBBER SHOES If the rubber shoes are in the following condition, they must be repaired or replaced, so please contact your Komatsu distributor for repair or replacement. Lug Height If lug height "a" is reduced by wear, the drawbar pull will drop.
Page 185 If the length is less than 30 mm (1.18 in) (B) or the depth of the crack is less than 10 mm (0.39 in), there is no particular need to carry out repairs. When making judgement whether to replace, repair, or continue using rubber shoes, please contact your Komatsu distributor. 4 - 28...
Page 186: Check And Adjust Rubber Shoe Tension (Machine Equipped With Rubber Shoes)
When loosening plug (1), never loosen it more than one turn. Never loosen any part other than plug (1). Never put your face in line with the mount of plug (1). If the Rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor. 4 - 29...
Page 187 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 188: Replace Rubber Shoes (Machine Equipped With Rubber Shoes)
It is extremely dangerous to release the grease by any method except the procedure given below. If the rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.
Page 189 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2. Loosen plug (1) gradually to release the grease. 3. When loosening plug (1), turn it a maximum of one turn. 4. Insert steel pipes (2) in between the rubber shoe and track frame, rotate the sprocket in the reverse direction (A) so that steel pipes (2) make the rubber shoe come up the from the idler and then slide it in the side direction (B) to remove.
Page 190 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Insert steel pipes (2) in between the rubber shoe and track frame, rotate the sprocket in the reverse direction (A) again and set the rubber shoe to the idler securely. 5. Stop the rotation, and check that the rubber shoe is securely fitted to the sprocket and idler.
Page 191: Replace Bucket Teeth
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, stop the engine, then set the lock lever securely to the LOCK position (L). The pin is knocked out by force, so there is danger of the pin flying out.
Page 192 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE Rubber (6) of the rubber pin lock is cut and the steel ball is about to come out. Steel ball (7) sinks in when it is pushed by hand. 4. Clean the surface of adapter (4) and remove the soil with a knife. 5.
Page 193 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 8. Insert lock pin (2) in the hole of the teeth (1) and hit it until its top is the same level as the surface of teeth (1). 9. After replacing a bucket tooth, always check the following. 1) After the lock pin (2) has been knocked in completely, check that it is secured by the teeth (1) and surface.
Page 194: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM 1. Start the engine. For details, see "STARTING ENGINE (PAGE 3-44)". Run the engine at low idle for 10 minutes, then do as follows. 2. Bleeding air from cylinders NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.
Page 195: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-33)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Check oil level in hydraulic tank, add oil Check dust indicator Check water separator...
Page 196: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE LUBRICATING Lubricating Swing Components WARNING When lubricating the swing circle and the swing pinion, do not swing the upper structure while carrying out the lubricating. NOTICE For the first 100 hours on new machines where the parts are settling in, carry out greasing every 10 hours. Prepare a grease pump 1.
Page 197 MAINTENANCE MAINTENANCE PROCEDURE Lubricating Work Equipment NOTICE When breaking in a new machine, carry out lubrication every 10 hours for the first 100 hours of operation. If any abnormal sound comes from the greasing point, carry out greasing regardless of the inspection and maintenance interval.
Page 198 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (11) Arm cylinder rod end (1 place) (12) Boom - Arm connecting pins (1 place) (13) Bucket cylinder foot pin (1 place) 4 - 41...
Page 199: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
2. Remove drain plug (P) slowly to avoid getting oil on yourself, and drain the oil. 3. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 4. Install drain plug (P).
Page 200: Replace Fuel Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL FILTER ELEMENT WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. Prepare a filter wrench Prepare a container to catch the oil.
Page 201: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE 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. If there is internal pressure inside the case, the oil or plug may fly out.
Page 202: Check And Adjust Cooling Fan Belt Tension
Before starting the operation to open the floor, read the precautions in "CAUTIONS FOR OPENING (TILTING) FLOOR (PAGE 2-34)" in the safety and maintenance sections thoroughly, and refer to the explanation for each part in "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-23)" when carrying out the operation. Or ask your Komatsu distributor to carry out the maintenance.
Page 203 6. Check for damage to the pulleys, and wear of the V-groove and V-belt. Be particularly careful to check that the V-belt is not in contact with the bottom of the V-groove. 7. If the belt is stretched, leaving no allowance for adjustment, or if it is cut or cracked, contact your Komatsu distributor for replacement.
Page 204: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Carry out the maintenance for EVERY 500 HOURS SERVICE at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 205: Replace Hydraulic Oil Filter Element
Before starting the operation to open the floor, read the precautions in "CAUTIONS FOR OPENING (TILTING) FLOOR (PAGE 2-34)" in the safety and maintenance sections thoroughly, and refer to the explanation for each part in "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-23)" when carrying out the operation. Or ask your Komatsu distributor to carry out the maintenance.
Page 206: Check Engine Valve Clearance, Adjust
11. After completing the replacement, close the floor. For details, see "When Closing (tilt close) (PAGE 3-26)". CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. 4 - 49...
Page 207: Every 1500 Hours Maintenance
The fuel injection valves need to work normally so that the engine can fully demonstrate its performance. Carry out an inspection an cleaning of the fuel injection valves. But a set of special tools are required for this work, so it is recommended to ask your Komatsu distributor for the inspection and cleaning service. 4 - 50...
Page 208: Every 2000 Hours Maintenance
Before starting the operation to open the floor, read the precautions in "CAUTIONS FOR OPENING (TILTING) FLOOR (PAGE 2-34)" in the safety and maintenance sections thoroughly, and refer to the explanation for each part in "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-23)" when carrying out the operation. Or ask your Komatsu distributor to carry out the maintenance.
Page 209: Check Alternator, Starting Motor
CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or the bearing may have run out of grease. Contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 210: 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 211 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 212 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 (L) and turn the starting switch to the OFF position.
Page 214 5 - 1...
Page 215: Specifications
Unit PC18MR-3 Operating Weight kg (lb) 1,855 (4,090) Bucket capacity (cu.yd) 0.044 (0.06) Name of engine Komatsu 3D67E-2 diesel engine Engine horsepower kW(HP)/rpm 11.2(15)/2,600 A Overall length mm (ft in) 3,650 (11'12") B Overall height mm (ft in) 2,410 (7'11")
Page 216 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC18MR-3 A Max. digging reach mm (ft in) 4,025 (13'2") B Max. digging depth mm (ft in) 2,160 (7'1") C Max. digging height mm (ft in) 3,615 (11'10") D Max. vertical wall depth mm (ft in) 1,785 (5'10")
Page 218 6 - 1...
Page 219: Attachments And Options
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION SAFETY FIRST If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor first.
Page 220: Attachment Installation
If the correct procedure is not used when installing the boom and arm, it may lead to serious damage. Please consult your Komatsu distributor. When long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting other objects.
Page 221: Bucket With Hook
ATTACHMENTS AND OPTIONS BUCKET WITH HOOK BUCKET WITH HOOK HOOK CONDITION Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu distributor. PROHIBITED OPERATIONS Operations with Care When lifting loads, do not exceed the following weights.
Page 222: Machine Ready For Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT LOCATIONS Selector valve Attachment lock cover Attachment control pedal 6 - 5...
Page 223 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Selector Valve This valve (1) switches the flow of hydraulic oil. WARNING When the selector valve stopper is not installed, if a general attachment is being used, the movement of the attachment may not match the intention of the operator.
Page 224 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Attachment Lock Cover WARNING When attachment operation is not required, lock the attachment control pedal with the attachment lock cover. If the attachment control pedal is accidentally pressed while it is not locked, a serious accident may occur. This cover (3) is a device to lock the attachment control pedal.
Page 225: Hydraulic Circuit
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT HYDRAULIC CIRCUIT Hydraulic Circuit Connection Bleeding Air After connecting the piping, bleed the air from the circuit. 1. Starting engine Start the engine according to "STARTING ENGINE (PAGE 3-44)" keep running the engine at low idle for 10 minutes, and carry out the following procedure.
Page 226: Attachment Operations
When Using Breaker Depress the bottom of the pedal to operate the breaker. REMARK If it is necessary to adjust the oil flow, please ask your Komatsu distributor to carry out the adjustment. Precautions when Using Check that selector valve (1) is at the 1 WAY (breaker) position (a).
Page 227: Long Term Storage
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Precautions when Using Check that selector valve (1) is at the 2 WAY (crusher or other attachment) position (b). For details of pther precautions when handling the attachment, read and use correctly the instruction manual provided by the attachment manufacturer.
Page 228: Changing Machine Control Pattern (If Pattern Change Valve Equipped)
ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) WARNING When changing the operating pattern of the machine, set the machine in the parking posture, stop the engine, check that the lock lever is at the LOCK position, then change the operating pattern.
Page 229: Machine Control Patterns
ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) MACHINE CONTROL PATTERNS WARNING After changing the operating pattern, always change the operating pattern card in the operator's compartment. ISO pattern Backhoe pattern 6 - 12...
Page 230: 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 231: Handling Arm With Built-In Breaker
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER HANDLING ARM WITH BUILT-IN BREAKER (A) When a chisel is installed (B) When a bucket is installed Breaker Breaker Chisel Lock Pin Chisel Lock Pin Chisel Dummy Chisel Arm Link Arm Link Bucket Coupler Bucket The breaker arm is used for breaker operations after the bucket is removed.
Page 232 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER HANDLING ARM WITH BUILT-IN BREAKER CAUTION When pin (3) is being pulled out, the bucket tends to turn with pin (4) serving as a pivot, depending on an angle of the bucket. Be careful when pulling out pin (3).
Page 233 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER HANDLING ARM WITH BUILT-IN BREAKER 6. Pull out chisel lock pin (2) to remove dummy chisel (10). 7. Face chisel notch (A) in the direction of the pin and insert the chisel into the breaker.
Page 234: Procedure For Breaker Operations
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER PROCEDURE FOR BREAKER OPERATIONS WARNING When the breaker is not in use, keep it in a locked condition with the attachment lock cover. It is locked when the control pedal is covered with the plate.
Page 235: Precautions When Carrying Out Breaker Operations
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS Set the chisel in position so that it is at a right angle to the surface to be broken. When the chisel is applied obliquely, the breaker's breaking force is not fully transmitted to the impact surface.
Page 236: Installation Of Bucket
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER INSTALLATION OF BUCKET WARNING Install stopper pin (1) without fail. If it is not installed, chisel lock pin (2) could slip off because of vibrations from the breaker, causing the chisel to come off during the operation. If stopper pin (1) is not installed securely, there is a possibility that the chisel drops off of its own weight.
Page 237 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER HANDLING ARM WITH BUILT-IN BREAKER 5. Install chisel lock pin (2) and stopper pin (1) and push down the ring of stopper pin (1) to lock the pin securely. 6.
Page 238: Precautions When Carrying Out Bucket Operations
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS Install dummy chisel (1) to prevent sand and dust from entering the chisel installation portion. For the installation of the dummy chisel, see "INSTALLATION OF BUCKET (PAGE 6-19)". STOWING CHISEL, DUMMY CHISEL CAUTION Use a cloth to wipe off all mud from the chisel and dummy chisel before installing.
Page 239: Check Before Starting
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER CHECK BEFORE STARTING CHECK FOR LOOSE MOUNTING BOLTS ON BREAKER ARM BRACKET Check bracket bolt (1) (3 pc) for loosening. If there is any loosened one, tighten it again. Bolt Size: 24 x 1.5 Specified Tightening Torque: 686 to 735 Nm (70 to 75 kgm , 506 to 543 lbft) Target 706 Nm (72 kgm , 521 lbft)
Page 240: Specifications
ATTACHMENTS AND OPTIONS HANDLING ARM WITH BUILT-IN BREAKER SPECIFICATIONS Working range diagram Working ranges Unit Breaker arm A Max. digging reach mm (ft in) 4,075 (13'4") B Max. digging depth mm (ft in) 2,210 (7'3") C Max. digging height mm (ft in) 3,760 (12'4") D Max.
Page 241: Recommended Attachment Operations
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selection of optimum attachments. HYDRAULIC BREAKER...
Page 242 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge.
Page 243 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Prohibited Works To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. Do not operate all cylinders to the end of their strokes. Always leave approx. 5 cm (2 in) to spare. Using the mount to gather in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations...
Page 244 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 6 - 27...
Page 245 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Greasing Supply grease in the correct position. NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit can damage the hydraulic components, while the breaker is in use.
Page 246: Index
INDEX INDEX <A> AFTER STARTING ENGINE 3- 48 <F> ATTACHMENT GUIDE 6- 13 FOREWORD ATTACHMENT COMBINATIONS 6- 13 FUSE 3- 27 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION <G> ATTACHMENT INSTALLATION GENERAL OPERATION INFORMATION 3- 65 SAFETY FIRST GENERAL PRECAUTIONS 2- 10 AUXILIARY ELECTRIC POWER 3- 27 <H>...
Page 247 INDEX MACHINE OPERATIONS AND SAFETY INFORMATION CONTROLS 3- 31 SAFETY LABELS MACHINE READY FOR ATTACHMENT LOCATION OF SAFETY LABELS ATTACHMENT OPERATIONS SAFETY LABELS HYDRAULIC CIRCUIT SAFETY MACHINE OPERATION 2- 19 LOCATIONS BATTERY 2- 28 LONG TERM STORAGE 6- 10 LIFTING OBJECTS WITH BUCKET 2- 31 SPECIFICATIONS 6- 10...

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