Page 1 PC50MRx-2 5001 and up This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
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Page 3: Foreword
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 1 - 4...
Page 6: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
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 3-78)" for further details.
Page 9: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the left front of the frame. The design of the nameplate differs according to the territory.
Page 10: Emission Control Information Label And Its Location
FOREWORD PRODUCT INFORMATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION This is stuck on the inside right side of the counterweight. EPA: Environmental Protection Agency, U.S.A. SERVICE METER LOCATION On top of the machine monitor 1 - 9...
Page 11: Your Machine Serial Numbers And Distributor
FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 10...
Page 12: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NUMBER PLATE AND ITS LOCATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10 SAFETY SAFETY INFORMATION...
Page 13 FOREWORD CONTENTS BEFORE STARTING ENGINE 3- 40 STARTING ENGINE 3- 54 AFTER STARTING ENGINE 3- 58 STOPPING THE ENGINE 3- 61 MACHINE OPERATION 3- 62 STEERING THE MACHINE 3- 67 SWINGING 3- 69 WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 70 PROHIBITED OPERATIONS 3- 72 GENERAL OPERATION INFORMATION...
Page 14 FOREWORD CONTENTS SAFETY CRITICAL PARTS 4- 15 SAFETY CRITICAL PARTS LIST 4- 15 MAINTENANCE SCHEDULE 4- 16 MAINTENANCE SCHEDULE CHART 4- 16 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 17 MAINTENANCE PROCEDURE 4- 18 WHEN REQUIRED 4- 18 CHECK BEFORE STARTING 4- 46 EVERY 500 HOURS MAINTENANCE 4- 47...
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Page 17 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION Safety Rules 2- 11 If Abnormalities are Found 2- 11 Working Wear and Personal Protective Items 2- 11 Fire Extinguisher and First Aid Kit 2- 11 Safety Equipment 2- 12 Keep Machine Clean...
Page 18: Safety
SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION 2- 20 STARTING ENGINE 2- 20 Checks Before Starting Engine 2- 20 Safety Rules for Starting Engine 2- 21 Starting Engine in Cold Weather 2- 21 OPERATION 2- 22 Checks Before Operation 2- 22 Safety Rules for Changing Machine Directions 2- 22 Safety Rules for Traveling...
Page 19: 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 20: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and maintenance (09651-03001) (2) Precautions for before operation (22L-98-22160) (3) Warning for leaving operator's seat (09654-03001) 2 - 5...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Warnings for high voltage (09801-03001) (5) Precautions for operating pattern (09822-03000) Austraria and New Zealand specified 2 - 6...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS Machine with operating pattern selector valve installed (22J-98-1A630) (6) Precautions for high-temperature cooling water (20M-98-83250) (7) Precautions for high-temperature hydraulic oil (22L-98-22240) 2 - 7...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (8) Precautions for handling electric wires (09808-03000) (9) Precautions for check and adjust track tention (09657-03003) (10) Caution when opening while engine is running (09667-03001) (11) Prohibited to enter range of swing (20M-98-73130) 2 - 8...
Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Precautions for stowage (09803-03000) (Machines equipped with cab) (13) Caution when changing operating pattern (22L-98-22310) (14) Caution for lock pin when opening floor (22L-98-22390) (15) Caution when closing floor (22L-98-22410) 2 - 9...
Page 25 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (16) Precaution for handling battery (09664-30002) North America specified (17) Precaution for handling ROPS (22L-98-22321) 2 - 10...
Page 26: Safety Information
SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 27: Safety Equipment
SAFETY SAFETY INFORMATION SAFETY EQUIPMENT Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. 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.
Page 28: Handrails And Steps
SAFETY SAFETY INFORMATION HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. machine equipped with cab To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and...
Page 29: Burn Prevention
SAFETY SAFETY INFORMATION BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 30: Action If Fire Occurs
SAFETY SAFETY INFORMATION Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers. Fire coming from electric wiring Short circuits in the electrical system can cause fire.
Page 31: Falling Objects, Flying Objects And Intruding Objects Prevention
If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.
Page 32: 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 33: Distance To High Voltage Cables
SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.
Page 34: 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 - 19...
Page 35: 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 36: Safety Rules For Starting Engine
(A) (normal: 0 mm), lock bolt (1) may be broken or loose, so check lock bolts (1). If any abnormality is found, always carry out repairs or ask your Komatsu distributor to carry out repairs. SAFETY RULES FOR STARTING ENGINE Start and operate the machine only while seated.
Page 37: 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. Fit the seat belt (if equipped) securely. Check that the movement of the machine matches the display on the control pattern card.
Page 38: 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 39: 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 40: 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 41 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 42: 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 43: 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 44: 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 45: 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 46: 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 3-105)". Always wear leather gloves when handling wire rope.
Page 47: Lifting Objects With Bucket
SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable. Use wire rope that conforms to the specified standard. Do not exceed the specified lifting load.
Page 48: 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 49: Stop Engine Before Carrying Out Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment and blade completely to the ground. Place the work equipment control lever to the neutral position, set safety lock lever (1) to LOCK position (L), then stop the engine.
Page 50: Cautions For Opening (Tilting) Floor
SAFETY SAFETY MAINTENANCE INFORMATION CAUTIONS FOR OPENING (TILTING) FLOOR When opening (tilting) the cab or floor, see Section "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-31)" for details. Precautions when parking machine Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.
Page 51: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 52: Attachments
SAFETY SAFETY MAINTENANCE INFORMATION 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. And take steps to prevent unauthorized persons from entering the storage area. WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work...
Page 53: Removing Battery Terminals
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 54: 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 57: 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 58: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Operator's seat (13) Fuel control lever Heater switch (cab specification machine) (14) Starting switch Safety lock lever (left) (15) Floor lock cancel lever (16) Service meter Left work equipment control lever Travel lever (pedal is equipment) (17) Engine water temperature gauge Boom swing control pedal...
Page 59: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays.
Page 60 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 idling, then inspect the problem point immediately and repair the problem. These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal location on the monitor will lights up and the buzzer will second.
Page 61 OPERATION DETAILED CONTROLS AND GAUGES Charge Level Monitor If there is an abnormality 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 62 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Engine Water Temperature Gauge Service Meter Fuel Gauge Engine Water Temperature Gauge This meter (1) shows the engine water 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 63 OPERATION DETAILED CONTROLS AND GAUGES Service Meter This meter (3) shows the total time that the machine has been operated. Use this display to manage the specified service intervals. If the engine is running, the service meter advances even if the machine is not being operated.
Page 64 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 65 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion Lamp Switch Travel Speed Selector Switch Lamp Switch Use this switch (1) to turn on the headlamps and the lamp inside the machine monitor. Each time the switch is pressed, it is switched between ON and OFF.
Page 66 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch WARNING When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the loading or unloading operation. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Page 67: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting Switch Windshield Wiper Switch Horn Switch (Machines equipped with cab) Lamp Switch Room Lamp Switch Travel Speed Selector Switch (Machines equipped with cab) Cab Heater Switch Cigarette Lighter (Machines equipped with cab) (Machines equipped with cab) 3 - 12...
Page 68 OPERATION DETAILED CONTROLS AND GAUGES Starting Switch This switch (1) is used to start or stop the engine. OFF position The key can be inserted or withdrawn. The switches for the electric system are all turned off and the engine is stopped. ON position Electric current flows in the charging and lamp circuits.
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Cab Heater Switch (Machines equipped with cab) This switch (5) is used to heat the operator's compartment. The flow rate of the hot air can be set to two levels. Position 0: Off Position 1: Weak Position 2: Strong Hot water from the engine is used to carry out heating, so heating is possible when the engine cooling water is hot.
Page 70 OPERATION DETAILED CONTROLS AND GAUGES Room Lamp Switch (Machines equipped with cab) This switch (7) is used to turn on the room lamp. Position (A): Lights off Position (B): Lights up Cigarette Lighter (Machines equipped with cab) This lighter (8) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette.
Page 71: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Safety Lock Lever Blade Control Lever (Machine equipped with cab: left side only) Travel Lever (pedal is equipment) Left Work Equipment Control Lever Pedal Lock (for boom swing control pedal) Right Work Equipment Control Lever Boom Swing Control Pedal Fuel Control Lever Floor Lock Cancel Lever...
Page 72 OPERATION DETAILED CONTROLS AND GAUGES Safety Lock Lever WARNING When leaving the operator's compartment, set the safety lock lever securely to the LOCK position (L). If the safety 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 safety lock lever is not set securely to LOCK position (L), it may cause serious personal injury.
Page 73 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 74 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Lever This lever (4) is used to control the engine speed and output. (a) Low idling: Push the lever fully. (b) High idling: Pull the lever fully. Blade Control Lever NOTICE When digging operations using the blade are continued for more than one hour, pay careful attention to the rise in the water temperature.
Page 75 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers The travel pedal may be an option. WARNING Do not put your foot on the pedal unless the machine is traveling. If you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident.
Page 76 OPERATION DETAILED CONTROLS AND GAUGES Pedal Lock (For boom swing contol pedal) WARNING When boom swing operation is not required, lock the boom with the pedal lock. If the operation pedal is accidentally pressed while it is not lock, a serious accident or injury.
Page 77: Windshield
OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD (Machines equipped with cab) WARNING When opening or closing the front window, bottom window, or door, always set the safety lock lever to the LOCK position. If the control levers are not locked and they are touched by accident, this may lead to a serious accident. When opening or closing the window at the front of the cab, stop the machine on horizontal ground, lower the work equipment completely to the ground, stop the engine, then carry out the operation.
Page 78 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Grip left and right knobs (A) and pull the front window up diagonally. 5. When it will move no further to the rear, push up knobs (A) to lock securely. When pushing up, check that lock lever (B) moves in lock release direction (F), then returns in the lock direction (L).
Page 79 OPERATION DETAILED CONTROLS AND GAUGES Closing WARNING When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2.
Page 80 OPERATION DETAILED CONTROLS AND GAUGES Removing Lower Windshield 1. Open the front window, then hold grip (A), pull up, and remove the bottom window. 2. After removing the lower window, stow it in left and right brackets (B) at the rear of the operator's cab. Installing Lower Windshield With the front window open, install the bottom part of the front window.
Page 81: Sliding Door
OPERATION DETAILED CONTROLS AND GAUGES SLIDING DOOR (Machines equipped with cab) CAUTION Be sure to check that the sliding door is locked in position both when it is open and when it is closed. Always stop the machine on level ground when opening or closing the door. If the door is opened or closed on a slope, there is danger that the operating effort will suddenly change.
Page 82: Emergency Escape Hammer
OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY ESCAPE HAMMER (Machines equipped with cab) CAUTION When you are obliged to break the window glass pane with a hammer, take good care not to get hurt with flying glass shards. Before getting out of the operator's cab, remove glass fragments remained in the windowsills not to get hurt with them. Moreover watch your step not to slip over the broken glasses scattered on the ground.
Page 83: Cover With Lock
OPERATION DETAILED CONTROLS AND GAUGES COVER WITH LOCK Opening and Closing Covers 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 Section "LOCKING (PAGE 3-83)".
Page 84: 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 (1) of the cover does not move.
Page 85: Mud Cover
OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Pull cooling cover (3) to open it, then set rod (4) in the LOCK position (L) to hold cover (3) in position. 4. When closing cooling cover (3), set rod (4) to the FREE position (F), then close the cover.
Page 86: Method Of Opening (Tilting) Floor
Do not start the engine when the floor is open. If there is any breakage or abnormality in the lock when the floor is opened, stop the operation and ask your Komatsu distributor to carry out repairs. Do not remove the canopy. There is danger that the floor may suddenly come up.
Page 87 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Fit blocks securely under the track to prevent the machine from moving. 9 J A 0 5 4 6 6 5. Remove bolts (2) (M10 x 3), then remove triangular cover (3). 6.
Page 88 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 10. Open inspection window (7), use your left hand to pull floor lock release lever (8) in the direction of the arrow (to the rear) while holding knob (9) with your right hand and pushing it up in the direction of the arrow (approx 45°).
Page 89 Number of floor tilt lock bolts (6): Canopy specification: 5 Cab specification: 4 Tightening torque: 156.8 to 196 N·m (16 to 20 kgf·m, 115.7 to 144.7 lbft) REMARK If any bolt (6) is damaged, replace it with a genuine Komatsu part of the same size. 3 - 34...
Page 90 Tightening torque: 156.8 to 196 N·m (16 to 20 kgf·m, 115.7 to 144.7 lbft) REMARK If bolt (4) is damaged, replace it with a genuine Komatsu part of the same size. 6. Close engine rear cover (5). 7. Install triangular cover (3) with bolts (2) (M10 x 3).
Page 91: Fuse
OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 92: Block Fuse
OPERATION DETAILED CONTROLS AND GAUGES BLOCK FUSE If the starting motor does not turn even when the starting switch is turned to the ON position, block fuse (1) is probably blown, so open the cover at the right side of the machine and check or replace the fuse.
Page 93: Auxiliary Electric Power
AUXILIARY ELECTRIC POWER NOTICE When installing electrical not supplied by Komatsu, use 12V specification with a maximum of 120W (equivalent to 10A). If equipment is to be installed with a capacity greater than this, please contact your Komatsu distributor. Connector (1) for electrical power supply for options is at the following place.
Page 94: Operation Manual Storage
OPERATION DETAILED CONTROLS AND GAUGES OPERATION MANUAL STORAGE NOTICE Except when opening the cover for some reason, always keep the cover locked. This is under the operator's seat. There is a box for keeping the Operation and Maintenance Manual in the rear of the operator's seat backrest. Keep the Operation and Maintenance Manual in the box so that it can be seen at any time.
Page 95: Machine Operations And Controls
Leakage of fuel and oil will cause fire on the machine. Check thoroughly and repair any abnormalities or contact your Komatsu distributor. Check that the floor is securely held in position by bolts (1). If it is not held securely in position, this may cause serious personal injury.
Page 96 (1). If any abnormality is found, always carry out repairs or ask your Komatsu distributor to carry out repairs. When tightening any loose bolts, tighten also the 2 bolts inside the triangular cover on the left side of the machine.
Page 97 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always carry out the items of the checks in this section before starting the engine each day. Check Coolant Level, Add Water 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 98 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, 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. 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.
Page 99 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 100 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 101 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. 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 102 Be particularly careful to check the wiring for the battery, starting motor, and alternator. In addition, if any flammable material is accumulated around the battery, remove it. For repairs or investigation of the cause, please contact your Komatsu distributor. Check Function of Horn 1.
Page 103 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment WARNING Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the backrest.
Page 104 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors Adjust the angle so that the area behind the operator's compartment can be seen clearly. Machine equipped with canopy Machine equipped with cab 3 - 49...
Page 105 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fastening the seat belt, check that there is no abnormality in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no abnormality in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
Page 106 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end of the belt on either the buckle body or tongue side. Lengthening Pull the belt while holding it at a right angle to the buckle or tongue. 3 - 51...
Page 107 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When standing up from the operator's seat, always set the safety lock lever to the LOCK position, regardless of whether the engine is running or stopped. 1. Check that safety lock lever (1) is at the LOCK position (L). REMARK If the safety lock lever is not at LOCK position (L), the engine will not start.
Page 108 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 109: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting 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 serious bodily injury or fire.
Page 110 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to the START position. The engine will start. 4. When the engine start, release the key in the starting switch (3). The key will return automatically to the ON position. 3 - 55...
Page 111 OPERATION MACHINE OPERATIONS AND CONTROLS Starting Engine in Cold Weather WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 112 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Hold the key in starting switch (3) at the HEAT position and check that the buzzer sounds and preheating monitor (4) lights up, and that preheating monitor (4) flashes after that. After approx.
Page 113: After Starting Engine
Breaking-in the New Machine CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 114 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 115 Charge monitor (7): Monitor is off 5. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your Komatsu distributor. 6. Set safety lock lever (2) to the LOCK position, then check that the machine does not move even when the levers and pedals are operated.
Page 116: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
Page 117: 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 118 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 1. Set safety lock lever (2) to the FREE position, then raise the work equipment 40 to 50 cm (1.6 to 2.0 in) from the ground. 2. Raise the blade. 3. Opearate the both travel levers (3) as explained below. When the sprocket (A) is at the rear of the machine.
Page 119 When the load is reduced, the travel system returns to high speed travel. 5. Check that the travel alarm sounds. If the alarm dose not sounds, please contact your Komatsu distributor for repairs. Moving Machine Backward 1. Set safety lock lever (2) to the FREE position, then raise the work equipment 40 to 50 cm (1.6 to 2.0 in) from the ground.
Page 120 When the load is reduced, the travel system returns to high speed travel. 5. Check that the travel alarm sounds. If the alarm dose not sounds, please contact your Komatsu distributor for repairs. 3 - 65...
Page 121 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine WARNING 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 - 66...
Page 122: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel control levers, check the direction of the track frame (i.e. position of the sprocket) first. If the sprocket is at the front, the machine moves in the reverse direction to the operation of the travel lever. 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 123 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. REMARK When turning to the right, operate the right travel lever in the same way.
Page 124: 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 125: 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 126 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 127: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING Do not attempt to operate the work equipment control lever, while the machine is traveling. Operations Using Swing Force Do not use the swing force to compact soil or break earth mounds or walls.
Page 128 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 129: 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 130: Traveling On Slopes
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 131 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 1. When traveling down steep hills, use the travel lever and fuel control lever to keep the travel speed low. When traveling down a steep hill of more than 15°, set the work equipment to the posture shown in the diagram on the right, and lower the engine speed.
Page 132: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get the machine out. Stuck One Side of Track NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.
Page 133: 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 134 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 - 79...
Page 135: 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 136: 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 137: Check After Shut Off Engine
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 safety lock lever (3) in the LOCK position. REMARK For machines equipped with a cab, there is only a safety lock lever on the left.
Page 138: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Operator's cab door (machines equipped with cab) Always close the windows. (2) Engine rear cover (3) Dirt cover (4) Operation and Maintenance Manual, toolbox cover For details of locking, see Section "Opening and Closing Covers with Lock (PAGE 3-28)".
Page 139: Rubber Shoes And Road Liners
OPERATION MACHINE OPERATIONS AND CONTROLS RUBBER SHOES AND ROAD LINERS (Machine equipped with rubber shoe or road liner) Rubber Shoes and Road Liners Information Rubber shoes and road liner have excellent properties that are not found in steel shoes. However, if they are used in the same way as steel shoes, full use cannot be made of their advantages.
Page 140 OPERATION MACHINE OPERATIONS AND CONTROLS Using Rubber Shoes and Road Liners Prohibited Works Do not carry out the following types of work. Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near the edges of steel plates will cause damage to the rubber shoes and road liners.
Page 141 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 142 OPERATION MACHINE OPERATIONS AND CONTROLS Mechanism of rubber shoe coming off track 1) When traveling over an obstacle, a gap is formed between the track roller and the rubber shoe. In this condition, the rubber shoe may come off. 2) Furthermore, if the machine travels in reverse, a gap is formed between the track roller, idler, and rubber shoe.
Page 143 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS If the machine is turned in this condition, the rubber shoe will come off. 3 - 88...
Page 144: 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 145: 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 travel speed selector switch (2).
Page 146 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Make the slope of the ramps a maximum of 15°.
Page 147 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. When loading, set the work equipment at the front and the blade at the rear, with the undercarriage and upper structure set parallel. 6. 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 148 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 149 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Make the slope of the ramps a maximum of 15°.
Page 150 OPERATION OPERATION TRANSPORTATION TRANSPORTATION Machine equipped with cab REMARK For machines equipped with a cab, there is only a safety lock lever on the left. 7. Run the engine at low speed. (A): Low idling 8. Raise the blade. 9. Raise the work equipment, align the direction of travel with the ramp, and travel slowly.
Page 151: 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 - 96...
Page 152 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 153 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 9. Set the lifting angle 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 - 98...
Page 154: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 155: Cab Heater In Cold Weather
OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 156: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, so stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.
Page 157: Long Term Storage
OPERATION LONG TERM STORAGE LONG TERM STORAGE BEFORE STORAGE NOTICE To protect the hydraulic cylinder piston rod while in storage, keep the work equipment in the posture shown at right. (This prevents rust from developing on the piston rod) When keeping in long-term storage (more than one month), store as follows. Clean and wash all parts, then store the machine indoors.
Page 158: During Storage
AFTER STORAGE NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it.
Page 159: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see "Air Bleeding (PAGE 4-52)". 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 160: 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. When the machine is stuck in soft ground and cannot escape under its own power, or when towing a heavy machine, pass the wire rope through the front of the track frame as shown in the...
Page 161: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.
Page 162 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 163 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 164 OPERATION TROUBLES AND ACTIONS Starting the Engine CAUTION Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are at the HOLD or neutral position. 1.
Page 165: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes...
Page 166 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
Page 167 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor...
Page 168 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Exhaust gas occasionally turns Clogging air cleaner element Clean or repalce, 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 170 4 - 1...
Page 171: Maintenance
Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 172 MAINTENANCE MAINTENANCE INFORMATION Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil.
Page 173: Lubricants, Coolant And Filters
Komatsu distributor. When using commercially available oil, it may be necessary to shorten the oil change interval. For this reason, we recommend making full use of the Komatsu oil clinic. Fuel After completing the day's operations, fill the fuel tank to force out any air containing moisture.
Page 174 When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 175 Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods.
Page 176: Electric System Maintenance
Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor. When working at the seashore, carefully clean the electric system to prevent corrosion.
Page 177: Handling Hydraulic System
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS 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 178: 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 the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 179: Lubricants, Fuel And Coolant Specifications
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS *1: ASTM D975 No.1 Final drive Hydraulic Engine oil pan Fuel tank Cooling system case (each) system Liters Specified capacity US gal 2.11 0.21 14.53 17.17 1.93 Liters Refill capacity US gal 1.96...
Page 180 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 181 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
Page 182 MAINTENANCE MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type...
Page 183: 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 184: Safety Critical Parts
To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, please contact your Komatsu distributor for periodic replacement of parts related to safety and fire prevention in the SAFETY CRITICAL PARTS list.
Page 185 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...
Page 186: Maintenance Schedule
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 187: 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 188 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm , 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.
Page 189 MAINTENANCE MAINTENANCE PROCEDURE Machines Equipped with Double Element Checking 1. Open the engine rear cover. 2. If the dust indicator (1) shows red, clean the air cleaner element. NOTICE Do not clean the air cleaner element before the dust indicator becomes red. If the element is cleaned frequently before the dust indicator becomes red, the performance of the air cleaner is diminished and the cleaning effect is lowered.
Page 190 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit it or beat it against something . Do not use an element whose folds or gasket or seal are damaged.
Page 191 MAINTENANCE MAINTENANCE PROCEDURE Replacing element 1. Open the engine rear cover. 2. Remove clips (2), then remove dust cup (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4. Clean dust cup (3) and vacuator valve (6) inside the air cleaner body.
Page 192: Clean Inside Of Cooling System
30%. In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corrosion resistor agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liter (0.065 oz/US gal).
Page 193 Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 194 MAINTENANCE MAINTENANCE PROCEDURE 9. After the engine warming up, check that each gauge and caution lamp are in normal condition. If any abnormality is found, carry out adjustment or repairs. Operate the machine under a light load until the engine water temperature gauge (2) points to the white range (monitor panel spec.) or the green range(gauge panel spec.).
Page 195: 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 - 26...
Page 196 If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When It is Possible to Use Indicator to Check Electrolyte Level If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 197: 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 engine rear cover and cooling cover. For details, see Section "COOLING COVER (PAGE 3-29)".
Page 198: Check And Tighten Track Shoe Bolts (Machine Equipped With Road Liner, Steel Shoe)
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS (Machine equipped with road liner, steel shoe) If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately Road Liner Mounting Bolt - Check/Tighten After tightening to a tightening torque of 137 ±...
Page 199: Check And Adjust Track Tension (Machine Equipped With Road Liner, 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 - 30...
Page 200 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. 1. Loosen plug (1) gradually to release the grease.
Page 201: Check, Rubber Shoes Or Road Liners (Mechine Equipped With Rubber Shoes, Road Liner)
(Mechine equipped with rubber shoes, road liner) If the rubber shoes or road liner are in the following condition, they must be repaired or replaced, so please contact your Komatsu distributor for repairs or replacement. Lug Height If lug height "a" is reduced by wear, the drawbar pull will drop.
Page 202 If the length is less than 30mm (1.18 in) or the depth of the crack is less than 10mm (0.39 in), there is no particular need to carry out repairs. When making judgement whether to replace, repair, or continue using rubber shoe and load liner, please contact your Komatsu distributor. 4 - 33...
Page 203: 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 - 34...
Page 204 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 205: 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 206 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2. Loosen plug (1) gradually to release the grease. 3. When loosening plug (1), turn it a maximum of one turn. 4. Fit the steel pipes inside the rubber shoe, rotate the sprocket in reverse, so that the steel pipes make the rubber shoe come up from the idler, then to the side to remove.
Page 207: Replace Road Liners (Machine Equipped With Road Liner)
REPLACE ROAD LINERS (Machine equipped with road liner) When replacing all the road liner for the machine, please contact your Komatsu distributor to have the replacement carried out. When replacing only part of the road liner, use the special road liner removal tool. Please order the tool from your Komatsu distributor.
Page 208: 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 safety lock levers securely to the LOCK position (L). The pin is knocked out by force, so there is danger of the pin flying out.
Page 209 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE The rubber of the rubber pin lock is torn, and the steel balls may come out. The steel balls are buried when they are pressed by hand. 4. Clean the surface of adapter (4) and remove the soil with a knife. 5.
Page 210 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 8. Insert lock pin (2) in the hole of the teeth and hit it until its top is the same level as the surface of teeth (1). 9. After replacing a bucket tooth, always check the following. 1) After the lock pin has been knocked in completely, check that it is secured by the point and surface.
Page 211: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) If there is air in the window washer fluid, check the level of the fluid in window washer tank. Add automobile window washer fluid if necessary. REMARK Open the engine rear cover and cooling cover.
Page 212: Check, Clean And Lubricate Cab Slide Door Rail And Roller
1. Spray rail (1) and roller (2) thoroughly with lubricant. 2. After spraying with lubricant, slide the door and check that the door opens and closes smoothly. If the movement is not smooth, contact your Komatsu distributor for repair. LUBRICATING...
Page 213: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM NOTICE If the pump is operated without filling the pump case with hydraulic oil, there is danger that the pump may be prematurely damaged. Be sure to bleed the air completely. 1. Bleeding air from piston pump 1) Remove 3 M10 bolts (1), then remove triangular cover (2).
Page 214 MAINTENANCE MAINTENANCE PROCEDURE 4. Bleeding air from attachment (when installed) 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. After completing the air bleeding operation, stop the engine, and leave the machine for 5 minutes before starting operations. This will remove the air bubbles in the oil inside the hydraulic cylinders.
Page 215: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-42)" in the OPERATION section. Check coolant level, add water 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 216: 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. Prepare a grease gun 1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2.
Page 217 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 218 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (13) Boom cylinder rod end (1 place) (14) Arm cylinder foot pin (1 place) (15) Arm cylinder rod end (1 place) (16) Boom - Arm connecting pins (1 place) (17) Bucket cylinder foot pin (1 place) 4 - 49...
Page 219: 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 220: Replace Fuel Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL FILTER CARTRIDGE WARNING Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. Prepare a filter wrench Prepare for cloth.
Page 221 MAINTENANCE MAINTENANCE PROCEDURE Air Bleeding 1. Fill the fuel tank with fuel. 2. Open the engine rear cover and cooling cover. For details, see Section "COOLING COVER (PAGE 3-29)". 3. Set handle (1) of the water separator to OPEN position (B). 4.
Page 222: 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 still pressure remaining inside the case, the oil or plug may fly out.
Page 223: Clean And Inspect Radiator Fins And Oil Cooler Fins
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS WARNING If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment. NOTICE When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins.
Page 224: Check And Adjust Cooling Fan Belt Tension
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 225: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Carry out the maintenance for EVERY 500 HOURS SERVICE at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 226: Change Oil In Final Drive Case
6. When oil comes out from the hole of plug (G), install plug (G). CHECK ENGINE VALVE CLEARANCE, ADJUST As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for service. 4 - 57...
Page 227: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Carry out the maintenance for EVERY 500 HOURS, and EVERY 1000 HOURS SERVICE at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 228 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Open dust cover (1) fully until it is secured in position. (For details of the method of opening and closing the cover with the lock, see Section "In Case of Engine Rear Cover and Dirt Cover (PAGE 3-28)") 6.
Page 229: Check Alternator, Starting Motor
MAINTENANCE PROCEDURE 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 230 5 - 1...
Page 231: Specifications
(lb) Cab specified 4,940 (10,893) 5,190 (11,444) Bucket capacity (cu/yd) 0.14 (0.18) 0.16 (0.21) Name of engine Komatsu 4D88E-5X diesel engine Engine horsepower KW (HP)/rpm 29.4 (39)/2,350 A Overall length mm (ft in) 5,390 (17'8") 5,550 (18'3") Canopy specified 2,625 (8'7")
Page 232 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC40MR-2 PC50MR-2 A Max. digging reach mm (ft in) 5,870 (19'3") 6,220 (20'5") B Max. digging depth mm (ft in) 3,500 (11'6") 3,800 (12'6") Canopy specified mm (ft in) 5,570 (18'3") 5,945 (19'6") C Max.
Page 234 6 - 1...
Page 235: 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 236: 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 237: Bucket With Hook
It is prohibited to swing or offset the boom when carrying out lifting operations. Set the boom facing the center. If a hook is to be installed, please consult your Komatsu distributor. 6 - 4...
Page 238: Air Conditioner
ATTACHMENTS AND OPTIONS AIR CONDITIONER AIR CONDITIONER CONTROL PANEL AND COMPONENTS Temperature control switch FRESH/RECIRC selector lever Air flow selector switch Vent Air conditioner switch Temperature Control Switch This switch (1) continuously adjusts the temperature between high and low. The more the switch is turned to the left, the lower the temperature becomes;...
Page 239: Air Conditioner Controls
ATTACHMENTS AND OPTIONS AIR CONDITIONER Air Conditioner Switch This switch (3) is used as the ON/OFF switch for the air conditioner. Each time this switch is pressed, it switches between ON and OFF. When the switch is ON, the lamp inside the switch lights up. FRESH/RECIRC Selector Lever Use this lever (4) to switch between recirculation of the air inside the cab and intake of fresh air from outside.
Page 240: Air Conditioner Maintenance
ATTACHMENTS AND OPTIONS AIR CONDITIONER AIR CONDITIONER MAINTENANCE When Required Check Refrigerant (Gas) Level WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant.
Page 241 ATTACHMENTS AND OPTIONS AIR CONDITIONER Every 250 Hours Maintenance CHECK AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION Checking The belt should deflect 5 to 6 mm (0.197 to 0.236 in) when pressed with a finger force of approx. 58.8 N (6 kgf, 13 lb) at a point midway between the idle pulley and compressor pulley.
Page 242 ATTACHMENTS AND OPTIONS AIR CONDITIONER Every 500 Hours Maintenance Clean Air Conditioner Condenser WARNING If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment. NOTICE When using compressed air, keep the air nozzle at a distance to prevent damage to the fins.
Page 243 ATTACHMENTS AND OPTIONS AIR CONDITIONER Clean Air Conditioner FRESH Filter WARNING If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear safety glasses, dust mask, and other protective equipment. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. If the air conditioner has been used, the air filter should be cleaned.
Page 244: Windshield Washer
ATTACHMENTS AND OPTIONS WINDSHIELD WASHER WINDSHIELD WASHER (Machine equipped with operator's cab) If the windshield washer is installed, operate it according to the following procedure. WINDSHIELD WASHER OPERATION Wiper and window washer When the wiper is working and the switch is kept pushed to position (B), washer fluid is sprayed out.
Page 245: Machine Ready For Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT There are two types for the hydraulic pressure takeoff: quick coupler and stop valve. LOCATIONS Quick Coupler Selector Valve (North America specified) Attachment Control Pedal Stop Valve Pedal Lock (for attachment control pedal) (Austraria and New Zealand specified) Quick Coupler North America specified...
Page 246 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Stop Valve Austraria and New Zealand specified This valve (2) stop the flow of the hydrauric oil. irection of slit at hexagonal portion Position (a): Hydraulic oil stops. Position (b): Hydraulic oil flows. When removing or installing attachments, set this valve to the position (a).
Page 247 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Pedal Lock (for attachment control pedal) WARNING When attachment operation is not required, lock the attachment control pedal with the pedal lock. If the attachment control pedal is accidentally pressed while it is not locked, a serious accident may occur.
Page 248: Hydraulic Circuit
Arm left side (hole end): 1/2" G Arm right side (shaft end): 3/4" G REMARK If the quick coupler size does not match, please contact your Komatsu distributor. NOTICE When connecting the piping, operate the bucket fully to the dump position and be careful not to interfere with link (a).
Page 249 The thread size of the elbow installed to the stop valve is PF1/2. REMARK If the elbow thread size does not match, please contact your Komatsu distributor. NOTICE When connecting the piping, operate the bucket fully to the dump position and be careful not to interfere with link (a).
Page 250 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Bleeding Air After connecting the piping, bleed the air from the circuit. 1. Starting engine Start the engine according to "STARTING ENGINE (PAGE 3-54)" keep running the engine at low idling for 10 minutes, and carry out the following procedure.
Page 251: 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 When equipped with stop valve Check that the stop valve is at the FREE position.
Page 252: Long Term Storage
Bottom of pedal depressed: Oil flows to left side of arm (operator's seat side). REMARK If it is necessary to adjust the oil flow, please ask your Komatsu distributor to carry out the adjustment. Precautions when Using When equipped with stop valve Check that the stop valve is at the FREE position.
Page 253: Specifications
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT SPECIFICATIONS Hydraulic Specifications Hydraulic pressure takeoff Quick coupler Stop valve Max. flow (engine speed) 70 liter/min (2,350 rpm) 70 liter/min (2,350 rpm) Safety valve setting pressure 17.2 MPa (175 kgf/cm , 2,490 PSI) 21.6 MPa (210 kgf/cm , 2,980 PSI) 6 - 20...
Page 254: 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 safety lock lever is at the LOCK position, then change the operating pattern.
Page 255: 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 - 22...
Page 256: 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 257: 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 258 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 259 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 260 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 261 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Greasing Supply grease in the correct position. NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic components, while the breaker is in use.
Page 262: Index
INDEX INDEX <A> Engine, Starting 3- 54 Air Conditioner Engine, Stopping The 3- 61 Air Conditioner Controls Escape From Mud 3- 77 Air Conditioner Maintenance Control Panel And Components <F> Attachment Guide 6- 23 Forword Attachment Combinations 6- 23 Fuse 3- 36 Attachments And Options - General Information...
Page 263 INDEX Every 2000 hours 4- 58 Tool Box 3- 39 When required 4- 18 Transportation 3- 89 Maintenance Schedule 4- 16 Lifting Machine 3- 96 Maintenance Interval For Hydraulic Transportation Procedure 3- 89 Breaker 4- 17 Traveling On Slopes 3- 75 Maintenance Schedule Chart 4- 16 Troubles And Actions...

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