Page 1 Operation & UEAM002401 Maintenance Manual PC160LC-7KA HYDRAULIC EXCAVATOR WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this FOR US MARKET ONLY machine. This manual should be kept inside the cab for reference and periodically reviewed by all personel who will come into contact with the machine.
Page 3 FOREWORD...
Page 4 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
Page 5 FOREWORD FOREWORD Storage location for the Operation and Maintenance Manual: magazine box on the left side of the operator's seat.
Page 6: Foreword
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section “RECOMMENDED APPLICATIONS ( 3-104 )“ for further details. DIRECTIONS OF MACHINE Front Operator’s seat...
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. MACHINE SERIAL NUMBER PLATE AND ITS LOCATION On the bottom right of the operator's cab PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER PLATE AND ITS LOCATION On top of the No.
Page 10: Service Meter Location
SERVICE METER LOCATION On top of the machine monitor TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product Identification Number Manufacturers name: KOMATSU UK Ltd. Address: Durham Road Birtley Chester-Le street County Durham DH32QX United Kingdom...
Page 11: Machine Serial Plate
FOREWORD PRODUCT INFORMATION MACHINE SERIAL PLATE Valid until 31 December 2003 MASS Komatsu UK Ltd, Birtley, Co. Durham, United Kingdom 205-00-K1290 Valid as of 1 January 2004 MODEL SERIAL No. MANUFACT. YEAR MASS ENGINE POWER Product Identification Number Manufactured by Komatsu UK Ltd.
Page 12: Table Of Contents
CONTENTS CONTENTS FOREWORD FOREWORD ................................. 1-2 SAFETY INFORMATION............................1-4 INTRODUCTION..............................1-6 DIRECTIONS OF MACHINE ........................1-6 PRODUCT INFORMATION ..........................1-7 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ..............1-7 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ................. 1-7 SERVICE METER LOCATION ........................1-8 TABLE TO ENTER SERIAL NO.
Page 13 CONTENTS OPERATION MACHINE VIEW ILLUSTRATIONS ........................3-2 OVERALL MACHINE VIEW........................3-2 CONTROLS AND GAUGES ........................3-3 DETAILED CONTROLS AND GAUGES......................3-4 MONITORING SYSTEM..........................3-4 Basic Operation Of Machine Monitor....................3-5 Basic Check Monitors ........................3-7 Caution Monitors..........................3-9 Emergency Monitors........................3-11 Meter Display Portion ........................
Page 14 CONTENTS Adjustment............................3-71 Seat Belt ............................3-73 Operations Before Starting Engine ....................3-74 STARTING ENGINE ..........................3-77 Normal Starting ..........................3-77 Starting Engine In Cold Weather ..................... 3-78 AFTER STARTING ENGINE ........................3-81 Breaking-In The New Machine ......................3-81 Warming-Up Operation ........................3-81 In Cold Weather Areas ........................
Page 15 Oil ..............................4-4 Fuel..............................4-4 Cooling System Coolant ........................4-4 Grease ............................... 4-5 Carrying out KOWA (Komatsu Oil Wear Analysis) ................4-5 Oil And Fuel Storage ......................... 4-6 Filters ..............................4-6 ELECTRIC SYSTEM MAINTENANCE ....................... 4-6 WEAR PARTS ..............................4-7 WEAR PARTS LIST............................
Page 16 CONTENTS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS................. 4-8 PROPER SELECTION ..........................4-8 TIGHTENING TORQUE SPECIFICATIONS ...................... 4-12 TIGHTENING TORQUE LIST ........................4-12 SAFETY CRITICAL PARTS ..........................4-14 SAFETY CRITICAL PARTS LIST ......................4-15 MAINTENANCE SCHEDULE ..........................4-16 MAINTENANCE SCHEDULE CHART ...................... 4-16 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..............
Page 17 CONTENTS EVERY 1000 HOURS MAINTENANCE....................4-51 REPLACE HYDRAULIC OIL FILTER ELEMENT ................4-51 CHANGE OIL IN SWING MACHINERY CASE ................4-52 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ................. 4-53 CHECK FAN BELT TENSION AND REPLACE FAN BELT ............4-53 EVERY 2000 HOURS MAINTENANCE....................
Page 18 CONTENTS HYDRAULIC CIRCUIT..........................6-12 SWITCHING HYDRAULIC CIRCUIT ....................6-13 ADJUSTING OIL FLOW ........................6-13 SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT ........... 6-14 HYDRAULIC CIRCUIT CONNECTION ................... 6-15 PATH OF OIL ..........................6-15 ATTACHMENT REMOVAL AND INSTALLATION .................... 6-16 Attachment Removal ........................6-16 Attachment Installation ........................
Page 19: Safety
SAFETY WARNING Please be sure that you fully understand this manual and the precautions described in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 20: Safety Information
SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS..............................2-4 LOCATION OF SAFETY LABELS ......................... 2-4 SAFETY LABELS............................2-5 SAFETY INFORMATION Safety Rules..............................2-10 If Abnormalities are Found ........................... 2-10 Working Wear and Personal Protective Items ..................... 2-10 Fire Extinguisher and First Aid Kit........................ 2-10 Safety Equipment............................
Page 21 SAFETY SAFETY INFORMATION SAFETY MAINTENANCE INFORMATION......................2-30 Warning Tag ..............................2-30 Keep Work Place Clean and Tidy ........................ 2-30 Appoint Leader when Working with Others....................2-30 Stop Engine Before Carrying Out Maintenance................... 2-31 Two Workers for Maintenance when Engine is Running ................2-31 Proper Tools ..............................
Page 22: 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 23: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and (2) Precautions for before operation (09802-03000) maintenance (09651-03001) (3) Warning for leaving operator's seat (4) Warnings for high voltage (09801-03001) (09654-03001)
Page 24 SAFETY SAFETY LABELS (5) Warnings when opening front window (6) Warnings when stowing front window (09839-03000) (09803-03000) (7) Precautions for high-temperature oil (8) Precautions for high-temperature coolant (09653-03001) (09668-03001)
Page 25 SAFETY SAFETY LABELS (9) Precautions when handling accumulator (10) Precautions when adjusting track tension (09659-53000) (09657-03003) (11) Precautions when handling cable (09808-03000) (12) Stop rotation when performing testing and adjusting (09667-03001)
Page 26 SAFETY SAFETY LABELS (13) Explanation of methods for emergency escape (14) Roll-over precautions (09805-23000) (20Y-00-31170) (15) Roll-over precautions (09805-13000) (16) Prohibited to enter within swing range (09133-23000)
Page 27 SAFETY SAFETY LABELS (17)Precautions for broken or becomes dislodged to the window (09664-30082)
Page 28: Safety Information
SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired putting yourself and everyone else on your jobsite in danger.
Page 29: Keep Machine Clean
SAFETY SAFETY INFORMATION KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.
Page 30: Handrails And Steps
SAFETY SAFETY INFORMATION HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the dia- gram 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...
Page 31: Burn Prevention
SAFETY SAFETY INFORMATION BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 32: Action If Fire Occurs
The above recommendations assume that the conditions are for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice. ATTACHMENT INSTALLATION When installing optional parts or attachments, there may be problems with safety or legal restrictions. There- fore contact your Komatsu distributor for advice.
Page 33: Cab Widow Glasses
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 34: Distance To High Voltage Cables
SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows. Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.
Page 35: Emergency Exit From Operator's Cab
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. 2-17...
Page 36: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers (1). DANGER - Do NOT operate When this tag is not being used, keep it in the storage com- partment.
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. Always fasten your seat belt. 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 When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to the work equipment, do not exceed the maximum permitted load or performance of the machine. When traveling on flat ground, keep the work equipment 40 to 50 cm (16-20 inches) high above the ground.
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 (8-12 inches) 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 MACHINE OPERATION OPERATIONS ON SLOPES When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.
Page 41: Operations On Snow
SAFETY SAFETY MACHINE OPERATION When carrying out demolition work, do not carry out demoli- tion above your head. There is a hazard of broken parts fall- ing or of the building collapsing and causing serious injury or property damage. Do not use the impact force of the work equipment for breaking work.
Page 42 SAFETY SAFETY MACHINE OPERATION When leaving the machine, set safety lock lever (1) to the LOCK position, then stop the engine. Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized Free person from moving the machine.
Page 43: Transportation
SAFETY MACHINE OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. SHIPPING THE MACHINE When shipping the machine on a trailer, do as follows.
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 opera- tor'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 selec- tion or inspection of the wire rope. For towing, see “TOWING THE MACHINE ( 3-123 )“. 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. Always observe the specified lifting load strictly.
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 neces- sary.
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 completely to the ground and stop the engine.
Page 50: Proper Tools
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine.
Page 51: Work Under The Machine
SAFETY SAFETY MAINTENANCE INFORMATION WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.
Page 52: Safety First When Using High-Pressure Grease To Adjust Track Tension
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 53: Safety Handling High-Pressure Hoses
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 54 SAFETY SAFETY MAINTENANCE INFORMATION 2-36...
Page 55 OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 56: Operation
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW (1) Bucket (6) Boom cylinder (2) Bucket cylinder (7) Sprocket (3) Arm (8) Track frame (4) Arm cylinder (9) Track shoe (5) Boom (10) Idler...
Page 57: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Maintenance interval Normal operation warning screen screen All lights up screen (1) Car radio (25) Engine coolant temperature monitor (2) Revolving warning lamp (if equipped) (26) Engine oil pressure monitor (3) Airconditioner control panel (27) Engine coolant temperature gauge (4) Safety lock levers (28) Charge monitor...
Page 58: 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 59: Basic Operation Of Machine Monitor
OPERATION DETAILED CONTROLS AND GAUGES Basic Operation Of Machine Monitor If There Is Abnormality When Starting engine Maintenance interval Normal operation screen Check before starting screen warning screen Error screen Warning screen If there is any abnormality when starting the engine, the check before starting screen changes to the mainte- nance interval warning screen, warning screen, or error screen.
Page 60 OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation Normal operation screen Warning screen (1) Warning screen (2) Error screen If any abnormality occurs during operation, the normal operation screen changes to warning screen (1) or the error screen. After displaying warning screen (1) for 2 seconds, the screen automatically changes to warning screen (2).
Page 61: Basic Check Monitors
OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not ensure that the machine is in good condition. When carrying out checks before starting (daily checks), do not simply rely on the monitors. Always get off the machine and check each item directly.
Page 62 This monitor screen goes out after 30 seconds and returns to the normal operation screen. For details of the method of checking the maintenance inter- val, see “Maintenance Switch ( 3-21 )“. If it is desired to change the setting of the maintenance interval, please consult your Komatsu distributor.
Page 63: Caution Monitors
OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor lights up red, stop operations as soon as possible and carry out inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running.
Page 64 OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor This monitor (2) lights up to warn that the operator that the level in the fuel tank is low. If the remaining amount of fuel goes down to 41 liters (106 US gallons), the light changes from green to red, so add fuel as soon as possible.
Page 65: Emergency Monitors
OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run it at low idling, then check the applicable location and carry out the necessary action. These are items that should be observed while the engine is running. If there is an abnormality, the monitor for the abnormal location lights up red and the buzzer sounds, so carry out action immediately.
Page 66 OPERATION DETAILED CONTROLS AND GAUGES Engine Oil Pressure Monitor This monitor (3) lights up red if the engine lubrication oil pres- sure goes below the normal level. If it lights up red, stop the engine, and check the lubrication system and the level of oil in the oil pan.
Page 67: Meter Display Portion
OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion (1) Engine Pre-heating Monitor (6) Travel speed monitor (2) Swing Lock Monitor (7) Engine water temperature gauge (3) Wiper monitor (8) Fuel Gauge (4) Auto-deceleration monitor (9) Hydraulic oil temperature gauge (5) Working mode monitor (10) Service Meter Pilot Display When the starting switch is ON, the pilot display lights up when the display items are functioning.
Page 68 OPERATION DETAILED CONTROLS AND GAUGES Wiper Monitor This monitor (3) indicates the operating status of the wiper. The monitor display when the wiper switch is operated is as fol- lows. When ON lights up: Wiper moves continuously When INT lights up: Wiper moves intermittently OFF: Wiper stops Auto-deceleration Monitor This monitor (4) shows if the auto-deceleration function is...
Page 69 OPERATION DETAILED CONTROLS AND GAUGES Gauges and Meter Engine Water Temperature Gauge This meter (7) indicates the engine cooling water temperature. During normal operations, the indicator should be in the black range. If the indicator enters the red range during operations, the overheat prevention system is actuated.
Page 70 OPERATION DETAILED CONTROLS AND GAUGES Service Meter This monitor (10) displays the total time that the machine has been operated. Use the time display to set the maintenance interval. When the starting switch is ON, the service meter advances even if the machine is not moving.
Page 71: Monitor Switches Portion
The monitor display on the monitor display portion changes for each mode. If it is desired to have the working mode set to start automatically in E, L, or B mode (default options setting), please ask your Komatsu distributor to change the setting. 3-17...
Page 72 OPERATION DETAILED CONTROLS AND GAUGES REMARK Monitor display portion When the mode selector switch is pressed, the mode is displayed in the center of the monitor display, and the screen returns to the normal screen after 2 seconds. (The diagram on the left is an example of the display for the E mode.) 2 sec.
Page 73 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch WARNING When loading on or unloading from a trailer, always travel at low speed (with the travel speed selector switch put at the Lo position). Never operate the travel speed selector switch during the loading or unloading operation.
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Wiper Switch This switch (4) operates the wiper for the front glass. Each time the switch is pressed, it changes ON → INT → stop Monitor display portion (OFF). Monitor display INT lighted up: Wiper moves intermittently Monitor display ON lighted up: Wiper moves continuously Monitor display OFF: Wiper stops REMARK...
Page 75 Check damper case oil level, add 1000 Change final drive case oil 2000 Change swing machinery case oil 1000 Change hydraulic oil 5000 If it is desired to change the setting for the maintenance interval, please contact your Komatsu distributor. 3-21...
Page 76 OPERATION DETAILED CONTROLS AND GAUGES The method of checking the time remaining to maintenance is as follows. 1. Look at the maintenance screen, press up switch (9) or down switch (10) on the monitor switch portion, and select the item. (The color of the monitor for the selected item is inverted to black.) 2.
Page 77 OPERATION DETAILED CONTROLS AND GAUGES Select Switch This switch (7) is used to select the flow setting in each of working modes A, E, and B. When working mode is A or E (1) Press select switch (7) and the normal screen on the moni- tor display changes to the flow setting screen shown in the diagram on the right.
Page 78 OPERATION DETAILED CONTROLS AND GAUGES Back Switch Press this switch (8) when in the maintenance mode, bright- ness/contrast adjustment mode, or select mode. The screen will return to the previous screen on the monitor display. Up Switch, Down Switch Press up switch (9) or down switch (10) when in the mainte- nance mode, brightness/contrast adjustment mode, or select mode to move the cursor on the monitor display (colors of selected monitor are inverted) up, down, left, or right.
Page 79 OPERATION DETAILED CONTROLS AND GAUGES Adjusting Brightness And Contrast Press this switch (12) to adjust the brightness and contrast of the monitor display screen. Adjusting brightness and contrast 1. When monitor adjustment switch (12) is pressed, the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right.
Page 80 OPERATION DETAILED CONTROLS AND GAUGES Adjusting contrast 2.U se the brightness/contrast screen and press up switch (9) or down switch (10) to select the contrast monitor. (The selected monitor is inverted to black.) 3. When the screen changes to the contrast adjustment screen, press up switch (9) or down switch (10) to adjust the contrast.
Page 81: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES (1) Starting Switch (7) Horn Switch (2) Fuel Control Dial (8) Knob switch (3) Cigarette lighter (9) Room Lamp Switch (4) Swing Lock Switch (10) Emergency pump drive Switch (5) Lamp Switch (11) Swing Brake Cancel Switch (6) Alarm buzzer stop switch (12) Rotating Lamp Switch (if Equipped) Starting Switch...
Page 82 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial This dial(2) adjusts the engine speed and output. (a) Low idling (MIN):T turned fully to the left MAX. (b) Full speed (MAX): Turned fully to the right Cigarette Lighter This switch (3) is used to light cigarettes. To use, push the lighter in.
Page 83 OPERATION DETAILED CONTROLS AND GAUGES Lamp Switch This switch (5) is used to light up the front lamps, working lamp, additional lamp at the top front of the cab, rear lamp, and moni- tor lighting. Alarm Buzzer Stop Switch This switch (6) is used (when the engine is running) to stop the alarm buzzer when it has sounded to warn of an abnormality in STOP a warning item.
Page 84 OPERATION DETAILED CONTROLS AND GAUGES Room Lamp Switch NOTICE It is possible to turn on the room lamp even when the start- ing switch is at the OFF position, so be careful not to for- get to turn it off. This switch (9) is used to light up the room lamp.
Page 85: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS (3) Left work equipment control lever (with auto-decel- (1) Safety lock lever eration device) (4) Right work equipment control lever (with auto- (2) Travel levers (Machines with pedal) deceleration device) Safety Lock Lever WARNING Free When leaving the operator's compartment, set the...
Page 86 OPERATION DETAILED CONTROLS AND GAUGES This lever (1) is a device to lock the work equipment, swing, travel, and attachment (if equipped) control levers. Push the lever down to apply the lock. This lock lever is a hydraulic lock, so even if it is in the lock Free position, the work equipment control lever and travel lever will move, but the work equipment, travel motor, and swing motor...
Page 87 OPERATION DETAILED CONTROLS AND GAUGES Work Equipment Control Lever (With Auto-deceleration Device) WARNING If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers. This Left work equipment control lever (3) is used to operate the arm and upper structure.
Page 88: Sun Roof
OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF WARNING Free When leaving the operator's seat, set the safety lock lever securely to the LOCK position. If the safety lock lever is at the FREE position and the con- trol lever is touched by mistake, this may lead to a serious accident.
Page 89 OPERATION DETAILED CONTROLS AND GAUGES Opening 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2. Set the safety lock lever securely to the LOCK position. 3. Check that the wiper blade is stowed in the right stay. 4.
Page 90 OPERATION DETAILED CONTROLS AND GAUGES 5. Hold lower knob (C) with your left hand from inside the oper- ator's cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
Page 91 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 92 OPERATION DETAILED CONTROLS AND GAUGES 5. When the bottom of the window reaches the top of the bot- tom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock.
Page 93: Emergency Exit From Operator's Cab
OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY EXIT FROM OPERATOR'S CAB If for some reason, the cab door does not open, remove the rear window and use it as an emergency escape. Remove the rear window as follows. 1. Pull ring (1) and completely remove seal (2) from the rubber core.
Page 94: Cap With Lock
OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Locks are fitted to the fuel tank filler, hydraulic tank filler, operator's cab, engine hood, tool box cover, right side door of the machine, and left side door of the machine. Use the starting key to open and close the caps, doors and covers.
Page 95: Hot And Cool Box
OPERATION DETAILED CONTROLS AND GAUGES HOT AND COOL BOX This is on the right side at the rear of the operator's seat. It is interconnected with the air conditioner: it stays warm when the heating is used, and stays cool when the cooling is used. MAGAZINE BOX (with cup holder) This is on the left side of the operator's seat.
Page 96: Air Conditioner Controls
OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel Air conditioner control panel (1) OFF switch (6) FRESH/RECIRC selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Defroster selector lever (5) Auto switch (10) Sunlight sensor...
Page 97 OPERATION DETAILED CONTROLS AND GAUGES Fan Switch This switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the ∧ switch to increase the air flow; press the ∨ switch to reduce the air flow. During auto operation, the air flow is automatically adjusted.
Page 98 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch This switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. During automatic operation, the vents are automatically selected.
Page 99 OPERATION DETAILED CONTROLS AND GAUGES Auto Switch With this switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. When auto switch (5) is pressed, the lamp at the top of the auto switch lights up.
Page 100 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch This switch (8) is used to turn the air conditioner (cooling, dehumidifying, heating) ON or OFF. When the fan is actuated (the display monitor shows (b)) and air conditioner switch (8) is pressed, the air conditioner is switched ON, the lamp at the top of the air conditioner switch lights up, and the air conditioner starts.
Page 101: Method Of Operation
OPERATION DETAILED CONTROLS AND GAUGES Method Of Operation The air conditioner can be operated automatically or manually. Select the method of operation as desired. Automatic Operation 1. Turn auto switch (5) ON. The lamp at the top of switch (5) lights up. The set temperature (a) and air flow (b) are displayed on the monitor.
Page 102 OPERATION DETAILED CONTROLS AND GAUGES Stopping Automatic Operation Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on the display monitor, and the lamps above auto switch (5) and air conditioner switch (8) go out, and the operation stops.
Page 103 OPERATION DETAILED CONTROLS AND GAUGES 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection. 5. Press RECIRC/FRESH selector switch (6) and select recir- culation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
Page 104 OPERATION DETAILED CONTROLS AND GAUGES Operation with cold air to face and warm air to feet To operate with cold air blowing to the face and warm air blow- ing to the feet, set as follows. 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the display monitor.
Page 105 OPERATION DETAILED CONTROLS AND GAUGES Defroster Operation 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the display monitor. 2. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in (f) or (g) in the diagram on the right.
Page 106: Use Air Conditioner With Care
OPERATION DETAILED CONTROLS AND GAUGES 4. Press temperature setting switch (3) and set the set temper- ature display on the display monitor to the maximum heat- ing temperature of 32°. 5. Adjust vents (A), (B), and (D2) so that the air blows onto the window glass.
Page 107: Other Functions
When more than one failure is detected, press the “⁄“ or “Ÿ“ portion of temperature setting switch (3) to display the failures in turn. After completing the troubleshooting, press OFF switch (1) again to return to the normal display. If any abnormality is detected by the self-diagnostic function, ask your Komatsu distributor to carry out inspection and repair. 3-53...
Page 108 OPERATION DETAILED CONTROLS AND GAUGES Function To Switch Set Temperature Display Between Fahrenheit And Celsius It is possible to switch the set temperature display between °F and °C. If the “⁄“ and “Ÿ“ portions of temperature setting switch (3) are pressed at the same time for more than 5 seconds while the fan is running, the temperature display will switch between °F and °C.
Page 109: Radio
OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel (1) Power switch/Volume control knob/Balance knob (6) Preset buttons (2) Tone control knob (7) Display (3) FM/AM selector button (8) Time connection button (4) Display selector button (9) Stereo indicator (5) Manual tuning Power Switch/Volume Control (SW-VOLUME) and Balance (Pull BAL) Knob Press this knob (1) to turn the power for the radio on.
Page 110 OPERATION DETAILED CONTROLS AND GAUGES Tone Control Knob (TONE) Turn the knob (2) to adjust the tone as follows. Turn CLOCKWISE to emphasize the high sounds. Turn COUNTERCLOCKWISE to suppress the high sounds. FM/AM Selection Button (AM/FM) Press this button (3) and select the desired band. Each time the button is pressed, it switches AM …...
Page 111 OPERATION DETAILED CONTROLS AND GAUGES Preset Station Buttons (1, 2, 3, 4, 5, 6) If these buttons (6) are set to the frequency of the desired broadcasting station, the station can be selected at a touch. For details of the method of presetting, see “Preset Station But- tons ( 3-58 )“.
Page 112: Controls Of Radio
OPERATION DETAILED CONTROLS AND GAUGES Controls Of Radio Preset Station Buttons 1. Press power switch (1) and display the frequency on display (7). 2. Turn the tuning button (5) (manual, auto) to adjust to the desired frequency. 3. Select a preset button to use for recording the frequency setting, and keep that button pressed for at least 1.5 sec- onds.
Page 113: Use Radio With Care
OPERATION DETAILED CONTROLS AND GAUGES Setting Correct Time 1. Press display selector button (4) to display the time. After 5 seconds, the display will return to the frequency dis- play and the time cannot be corrected. If this happens, press display selector button (4) again. 2.
Page 114: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 12 V power source This power source can be used up to a capacity of 60 W (12 V x 5 A). 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.
Page 115: Fusiblelink
OPERATION DETAILED CONTROLS AND GAUGES Fuse Capacities and Circuit Names Fuse Name of circuit capacity Controller Electromagnetic valve PPC hydraulic lock solenoid Window washer, cigarette lighter Horn Spare Rotating lamp (arm crane solenoid) Light relay Radio, speaker, left knob switch (10) Spare (11)
Page 116: Controllers
Be careful not to get water, mud, or juice on the control- ler. This will cause failure. If any abnormality occurs in the controller, do not dis- assemble it yourself. Contact your Komatsu distributor for repairs. TOOL BOX This is used for keeping the tools.
Page 117: Accumulator
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 distribu- tor to have this work carried out.
Page 118: Machine Operations And Controls
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your Komatsu distributor. Carry out the following inspections and cleaning every day before starting the engine for the day's work.
Page 119: Checks Before Starting
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 120 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. 1.
Page 121 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up com- pletely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 122 OPERATION MACHINE OPERATIONS AND CONTROLS Check For Water and Sediment In Water Separator, Drain Water 1. Open the cover at the rear right of the machine. 2. Inspect the water separator, and check if the ring inside has risen to the marked line. 3.
Page 123 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level In Hydraulic Tank, Add Oil WARNING When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. 1. If the work equipment is not in the condition shown in the diagram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinder rods fully, then lower the boom, set the bucket teeth in contact with the...
Page 124 If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the cause immediately and carry out repairs, or contact your Komatsu distributor for repairs. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clean the breather hole.
Page 125: Adjustment
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. Seat Adjustment (A) Fore-and-aft adjustment Pull lever (1) up, set the seat to the desired position, then...
Page 126 OPERATION MACHINE OPERATIONS AND CONTROLS (E) Overall fore-and-aft adjustment of seat Move lever (7) to right, set to the desired position, then release the lever. In this case, the operator's seat, left and right control levers, and safety lock lever all slide together. Fore-and-aft adjustment:180 mm (9 stages) (F) Adjusting suspension (if equipped) Turn knob (8) to the right to make the suspension harder, or to the left to make the suspension softer.
Page 127: Seat Belt
OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fitting the seat belt, check that there is no abnormality in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manu- facture of the belt is shown on the back of the belt.
Page 128: Operations Before Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When starting the engine, check that the safety lock lever is securely at the LOCK position. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious accident.
Page 129 If the monitors do not light up or the buzzer does not sound, there is probably a failure in the monitor, so con- tact your Komatsu distributor for repairs. 2) After approx. 3 seconds, the screen switches to the working mode/travel speed display monitor. Then it switches to the normal screen.
Page 130 OPERATION MACHINE OPERATIONS AND CONTROLS 5) Press lamp switch (18) and check that the front lamp lights up. If it does not light up, there is probably a blown bulb or disconnection, so contact your Komatsu distributor for repairs. 3-76...
Page 131: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Start the engine only after sitting down in the opera- tor's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 132: Starting Engine In Cold Weather
OPERATION MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to the START position. The engine will start. 4. When the engine starts, release the key in starting switch (3). The key will return automatically to the ON position. 5.
Page 133 OPERATION MACHINE OPERATIONS AND CONTROLS When starting in low temperatures, do as follows. 1. Check the safety lock lever (1) is at the LOCK position. If the safety lock lever is in the FREE position, the engine does not start. Free Lock 2.
Page 134 OPERATION MACHINE OPERATIONS AND CONTROLS 5. When the engine starts, release the key in starting switch (3). The key will return automatically to the ON position. 6. After starting the engine, do not touch the work equipment control lever or travel pedal while the engine oil pressure monitor lamp is lighted up.
Page 135: 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.
Page 136 Air cleaner clogging monitor (16): OFF Hydraulic oil temperature gauge (17): Indicator in black range Hydraulic oil temperature monitor (18): Green display 6. Check that there is no abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 3-82...
Page 137 OPERATION MACHINE OPERATIONS AND CONTROLS 7. If air cleaner clogging monitor (16) is lighted up, clean or replace the element immediately. For details of the method of cleaning the element, see “CHECK, CLEAN AND REPLACE AIR CLEANER ELE- MENT ( 4-19 )“. 8.
Page 138: In Cold Weather Areas
OPERATION MACHINE OPERATIONS AND CONTROLS 4) B mode For breaker operations In Cold Weather Areas (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30°C (86°F)), the warming-up operation is carried out automatically.
Page 139 Hydraulic oil temperature monitor (18): Green display 6. Check that there is no abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 7. If air cleaner clogging monitor (16) is lighted up, clean or replace the element immediately.
Page 140 OPERATION MACHINE OPERATIONS AND CONTROLS 8. Turn fuel control dial (2) to the full speed (MAX) position and carry out the operation is Step 4. for 3 to 5 minutes. 9. Repeat the following operation 3 - 5 times and operate slowly.
Page 141 OPERATION MACHINE OPERATIONS AND CONTROLS 3) L mode For fine-control operations 4) B mode For breaker operations NOTICE Canceling automatic warming-up operation If it becomes necessary in an emergency to cancel the automatic warming-up operation or to lower the engine speed to low idling, do as follows. 1] Turn fuel control dial (2) to the full speed (MAX) posi- tion and hold it for 3 seconds.
Page 142: 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 gradu- ally, and then stop it.
Page 143: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION Preparations For Moving The Machine Off WARNING Before operating the steering levers, check the direc- tion of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. When moving off, check that the area around the machine is safe, and sound the horn before moving.
Page 144: Moving Machine Forward
Sprocket 3. For machines equipped with a travel alarm (if equipped), check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repair. REMARK In cold temperatures, if the machine travel speed is not normal, carry out the warming-up operation thor- oughly.
Page 145: Moving Machine Backward
Push levers (5) forward slowly or depress the front part of pedals (6) to move the machine off. Sprocket 3. For machines equipped with a travel alarm (if equipped), check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repair. 3-91...
Page 146: Stopping Machine
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. 3-92...
Page 147: 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.
Page 148 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. Reverse left turn REMARK Forward When turning to the right, operate the right travel lever in left turn the same way.
Page 149: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. 1. Before starting the swing operation, turn swing lock switch (1) OFF and check that swing lock monitor (2) has gone out. 2.
Page 150: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly rise, so be careful when operating the lever. If the work equipment control lever is operated quickly, the work equipment will move quickly; if the lever is operated slowly, the work equipment will move slowly.
Page 151: Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match the operating conditions and purpose, thereby enabling work to be carried out efficiently. Make effective use of each mode as follows. When the starting switch is turned ON, the working mode is set to A mode.
Page 152: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
Page 153 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging.
Page 154: 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 155: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when work- ing on slopes may cause the machine to lose it bal- ance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 156 OPERATION MACHINE OPERATIONS AND CONTROLS When traveling up a steep slope, extend the work equip- ment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 inches) above the ground, and travel at low speed. 20-30 cm (8-12 inches) Traveling Downhill Put the travel lever in the neutral position.
Page 157: 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 158: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine. When the condition of the machine is as shown in the diagram on the right (angle between [bucket cylinder and link] and [arm cylinder and arm] is 90°), the maximum excavation force is...
Page 159: Loading Work
OPERATION MACHINE OPERATIONS AND CONTROLS Loading Work In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator. Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.
Page 160: Inversion
OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket: For arm pin portion (A), fit an O-ring at the position on the bucket shown in the diagram on the right. After inserting the pin, fit it into the proper groove.
Page 161: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When reversing, do not install an O-ring. Keep the O-ring in a safe place until using it next. 5. Install the stopper bolts and nuts for each pin, then grease the pin. Bucket O-ring Link pin portion PARKING MACHINE WARNING...
Page 162 OPERATION MACHINE OPERATIONS AND CONTROLS 1. Put left and right travel levers (1) in the neutral position. The machine stops. 2. Turn fuel control dial (2) to lower the engine speed to low idling. Low idling 3. Lower the bucket horizontally until the bottom touches the ground.
Page 163: Machine Inspection After Daily Work
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE INSPECTION AFTER DAILY WORK Check the engine water temperature, engine oil pressure, and fuel level on the machine monitor. LOCKING Always lock the following places. (1) Door of operator's cab Always remember to close the window. (2) Fuel tank filler port (3) Engine hood (4) Tool box...
Page 164: 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 ( 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 165: Loading
OPERATION TRANSPORTATION When loading or unloading, always use ramps or a platform and carry out the operation as follows. Loading 1. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road. 2.
Page 166 OPERATION TRANSPORTATION 6. If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it; if it has no work equipment, travel in reverse to load it. Follow instructions and signals of a conductor particularly when traveling in reverse.
Page 167: Securing Machine
OPERATION TRANSPORTATION Securing Machine NOTICE Stow the car radio antenna. In addition, remove the mirrors. Tie the removed parts securely to the trailer. 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 168: Unloading
OPERATION TRANSPORTATION Removal 1. Loosen locknut (2) of mirror (1), then remove mirror (1) from support (3). 2. Loosen bolt (4) and remove support (3) and clamp (5) from the handrail. Installation 1. Install support (3) and clamp (5) to the handrail, then tighten with bolt (4).
Page 169 OPERATION TRANSPORTATION 6. Set the travel speed selector switch to the LOW position. To switch the travel speed, press travel speed selector Display portion switch (1). The travel speed is displayed as Lo, or Hi on the monitor display. 7. Turn auto-deceleration switch (1) OFF and operate the fuel control dial to set the engine speed to low idling.
Page 170 OPERATION TRANSPORTATION 12.When moving down the ramps, operate the boom and arm slowly to lower the machine carefully until it is completely off the ramps. 3-116...
Page 171: Lifting Machine
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. For details of the weight, see “SPECIFICATIONS ( 5-2 )“.
Page 172: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 173: Battery
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 large amount of water, and consult a doctor.
Page 174: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, so stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.
Page 175: Long Term Storage
NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods.
Page 176: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before stating. For details of bleeding the air, see “REPLACE FUEL FILTER CARTRIDGE ( 4-47 )“. PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position...
Page 177: 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 sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram...
Page 178: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING When removing, disconnect the cable from the ground terminal first. 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 haz- ard of explosion.
Page 179: Battery Charges
OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled cor- rectly, there is a hazard that the battery may explode. Always follow the instructions of “DISCHARGED BATTERY ( 3-124 )“ and the instruction manual accompanying the charger, and do as follows.
Page 180 OPERATION TROUBLES AND ACTIONS Booster Cable Connection Keep the starting switch of the normal machine and problem machine are both at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1.
Page 181: 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 182: Chassis
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, •Lack of hydraulic oil...
Page 183: Engine
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 pan oil level is low •Add oil to specified level, see...
Page 184 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Combustion noise occasionally •Defective nozzle (•Replace nozzle) make breathing sound •Low-grade fuel being used •Change to specified fuel •Overheating •Refer to “Radiator water level Abnormal noise generated (com- monitor lights up“ as above bustion or mechanical) •Damage inside muffler •Replace muffler...
Page 185: Electronic Control System
Komatsu distributor. In the case where the monitor will not dis- play error codes and work equipment Have the machine inspected immediately by your Komatsu distrib- operation and swing operation can not be utor. carried out.
Page 186: Point Of Contact To Telephone When Error Occurs
Check the point of contact telephone number on screen B. REMARK If the point of contact telephone number has not been reg- istered, screen B is not displayed. If it is necessary to register the point of contact telephone number, ask your Komatsu distributor to register it. 3-132...
Page 187: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 188: Maintenance Information
Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 189 MAINTENANCE MAINTENANCE INFORMATION Locking the Inspection Covers If inspection or maintenance has to be carried out with the inspection cover open, lock it securely in position with the lock bar. If inspection or maintenance is carried out with the inspection cover not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause injury to the worker.
Page 190: Lubricants, Coolant And Filters
(whole amount). The hydraulic oil that is not recommended by Komatsu can cause clogging of oil filter, so do not use it. The portion of the oil that remains in the piping or cylinders will not be a problem even though it will be mixed into new oil.
Page 191: Grease
Make sure that the oil is well mixed before sampling. Carry out sampling regularly at fixed intervals. Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor.
Page 192: Oil And Fuel Storage
External electro-magnetic interference may cause malfunction of the control system controller, so before install- ing 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 193: 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 194: Lubricants, Fuel And Coolant Specifications
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS PROPER SELECTION AMBIENT CAPACITY TEMPERATURE Kind of Reservoir Type fluid Min °C Max °C Specified Refill (°F) (°F) 0 (32) 40 (104) SAE 30 14.3 liter 14 liter -20 (-4) 10 (50) SAE 10W Engine oil pan...
Page 195 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 hydrauric work equipment applications.
Page 196 MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) AF-ACL EO10-CD AF-PTL...
Page 197 MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) Multi-purpose white PEN- *Supreme duty...
Page 198: 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 199 MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS Thread Width Tightening torque diameter across Target value Service limit a(mm/ flat N•m/lbf-ft kgf•m/lbf-ft N•m/lbf-ft kgf•m/lbf-ft inches) b(mm) 14/0.6 19/0.75 29.4/21.7 3.0/21.7 27.5-39.2/20.3-28.9 2.8-4.0/20.3-28.9 18/0.7 24/0.9 78.5/57.9 8.0/57.9 58.8-98.1/43.4-72.4 6.0-10.0/43.4-72.4 22/0.9 27/1.1 117.7/86.8 12.0/86.8 88.3-137.3/65.1-101.3 9.0-14.0/65.1-101.3 24/0.9 32/1.25 147.1/108.5...
Page 200: Safety Critical Parts
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the critical parts. Check the hydraulic hoses and the fuel hose, too, when carrying out the following periodic inspections.
Page 201: Safety Critical Parts List
MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (Fuel tank - Water separator) Fuel hose (Water separator - Fuel pump) Fuel return hose (Fuel injection pump - Fuel tank) Spill hose (Engine output connector - Fuel tank) Pump outlet hose (Pump - Control valve) Work equipment hose (Boom cylinder inlet)
Page 202: 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 ( 4-17 )“ to confirm the correct mainte- nance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) REPLACE FUEL FILTER CARTRIDGE......................
Page 203: Maintenance Interval For Hydraulic Breaker
When the machine is supplied from the factory with bio-degradable oil, the following change intervals should be used. The oil supplied from the factory is classed as BO46-G3. (If the machine has been filled with any other type of bio-degradable oil, then contact your Komatsu distributor for advice on change intervals). Filter changes 1) The first filter change should be made 50 hours after first use.
Page 204: Maintenance Procedure
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) Carry out the following maintenance only after the first 1000 hours of operation on new machines. CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. 4-18...
Page 205: When Required
MAINTENANCE .MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working at high places or where the foothold is poor, be careful not to fall because of the reac- tion when pulling out the outer element.
Page 206 MAINTENANCE .MAINTENANCE PROCEDURE 4. Wipe off or brush off the dirt stuck to cover (3) and the inside of the air cleaner body. Air cleaner body Cover 5. Remove any dirt or dust that is accumulated to evacuator valve (4) installed to cover (3). Evacuator valve 6.
Page 207 MAINTENANCE .MAINTENANCE PROCEDURE 8. If small holes or thinner parts are found on the element when it is checked by shining a light through it after clean- ing, replace the element. NOTICE When cleaning the element, do not hit or beat it against anything.
Page 208 MAINTENANCE .MAINTENANCE PROCEDURE Replacing inner element 1. First remove the outer element, and then remove the inner element. 2. Cover the air connector side (outlet side) with a clean cloth or tape. 3. Clean the air cleaner body interior, then remove the cover from the air intake port in Step 2. 4.
Page 209: Clean Inside Of Cooling System
MAINTENANCE .MAINTENANCE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns.
Page 210 If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. 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 211: Check And Tighten Track Shoe Bolts
MAINTENANCE .MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening Track shoe 1. First tighten to a tightening torque of 490 ± 49 N·m (361.4 ± 36.1 lbf-ft) then check that the nut and shoe are in close contact with the link contact surface.
Page 212 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 213: Check Electrical Intake Air Heater
MAINTENANCE .MAINTENANCE PROCEDURE CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater checked for dirt or disconnections. REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the bucket teeth before the adapter starts to wear.
Page 214 MAINTENANCE .MAINTENANCE PROCEDURE The steel balls are buried when they are pressed by hand. The steel balls can be buried when pressed with finger 4. Clean the surface of adapter (4) and remove the soil with a knife. 5. Use your hand or a hammer to push rubber pin lock (3) into the hole of the adapter.
Page 215: Replace Bucket Teeth (Horizontal Pin Type)
(2). REMARK If it cannot be removed by this method, for safety rea- sons, always contact your Komatsu distributor to have the replacement carried out. 3. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket.
Page 216: Adjust Bucket Clearance
MAINTENANCE .MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING Free It is dangerous if the work equipment moves by mistake while the bucket clearance is being adjusted. Set the work equipment on the ground in a stable condi- tion, then stop the engine and lock the safety lock lever Lock without fail.
Page 217: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE .MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture ratio of pure washer fluid and water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
Page 218: Check And Adjust Air Conditioner
MAINTENANCE .MAINTENANCE PROCEDURE CHECK AND ADJUST AIR CONDITIONER Check level of refrigerant (gas) WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.
Page 219: Wash Washable Floor
MAINTENANCE .MAINTENANCE PROCEDURE WASH WASHABLE FLOOR WARNING When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation. If the control levers are touched by mistake, the work equipment or machine may suddenly move, and this may lead to a serious accident.
Page 220 MAINTENANCE .MAINTENANCE PROCEDURE 3. Lower the work equipment to the ground and set the machine in a stable condition. Block 4. Set the safety lock lever to the LOCK position, then stop the engine. Free Lock 5. Remove the floor mat holder plate (4). 6.
Page 221 MAINTENANCE .MAINTENANCE PROCEDURE Method of Setting Machine At Angle Method Using Slope WARNING Select a solid and smooth slope. Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground. 1. Stop the machine so that the work equipment is on the downhill side.
Page 222: Bleeding Air From Hydraulic System
NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. When replacing the travel motor safety valve, please contact your Komatsu distributor to have it replaced and to have the air bled. 4-36...
Page 223 MAINTENANCE .MAINTENANCE PROCEDURE 5. Bleeding air from travel motor (Bleed the air only when the oil inside the travel motor case has been drained.) 1) Run the engine at low idling, loosen air bleeder (1), and check that oil flows out. 2) Run the engine at low idling and swing the work equip- ment 90°...
Page 224: Method For Releasing Internal Pressure In Hydraulic Circuit
MAINTENANCE .MAINTENANCE PROCEDURE METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT WARNING The hydraulic circuit is always under pressure, so release the pressure inside the circuit before inspecting or replacing the piping or hoses. If the pressure is not released, high-pressure oil will spurt out and may cause serious personal injury. The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Page 225: Check Before Starting
MAINTENANCE .MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see “Checks Before Starting ( 3-65 )“ in the OPERATION section. Check Coolant Level, Add Water Check Oil Level In Engine Oil Pan, Add Oil Check fuel level, add fuel Drain Water and Sediment From Fuel Tank Check for Water and Sediment in Water Separator, Drain Water Check Oil Level In Hydraulic Tank, Add Oil...
Page 226: Every 250 Hours Maintenance
MAINTENANCE .MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE CHECK OIL LEVEL IN SWING MACHINERY 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. 1.
Page 227: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L line, use a pipette to lower the level to the U.L line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4-41...
Page 228: Check Air Conditioner Compressor Belt Tension, Adjust
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 229 MAINTENANCE .MAINTENANCE PROCEDURE 2. Press the belt at a point midway between the drive pulley and compressor pulley with a finger force of approx. 58.8 N Compressor pulley (43.4 lbf) and check that the deflection is 5 - 8 mm (0.2 - 0.3 inches).
Page 230: Every 500 Hours Maintenance
MAINTENANCE .MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 250 hours service should be carried out at the same time. LUBRICATING NOTICE For the first 50 hours on a new machine, carry out greasing for greasing points 1 to 12 every ten hours. Carry out the greasing for these points also at 250 hours and 500 hours on a new machine.
Page 231: Lubricate Swing Circle
MAINTENANCE .MAINTENANCE PROCEDURE (5) Boom - Arm coupling pin (1 point) (6) Arm cylinder rod end (1 point) (7) Bucket cylinder foot pin (1 point) (8) Arm-Link coupling pin (1 point) (9) Arm-Bucket coupling pin (1 point) (10) Link coupling pin (2 points) (11) Bucket cylinder rod end (1 point) (12) Bucket-Link coupling pin (1 point) LUBRICATE SWING CIRCLE...
Page 232: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE .MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. Refill capacity of oil pan: 14 liters (3.7 US gallons) Filter wrench 1.
Page 233: Replace Fuel Filter Cartridge
(3). Then tighten the knob of feed pump. 9. Tighten air bleed pug (3). Always use a genuine Komatsu filter cartridge. After replacing the filter cartridge, start the engine and check for any leakage of oil from the filter seal surface. REMARK Use the feed pump to bleed air from the fuel system, when the machine has run out of fuel, too.
Page 234: Check Swing Pinion Grease Level, Add Grease
3. Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Please contact your Komatsu distributor. The total amount of grease: 10.5 liters (2.8 US gallons) 4. Install cover (2) with bolts (1).
Page 235: Clean Internal And External Air Filters Of Air Conditioner
MAINTENANCE .MAINTENANCE PROCEDURE 7. Remove cover (10) of the under cover and dispose of the dirt, dust, dry leaves, etc. fallen on it. 8. Push in cleaned net (2) back to the original place and secure it with screw (3). CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER WARNING If compressed air is used, there is danger that dirt may fly and cause personal injury.
Page 236: Replace Breather Element In Hydraulic Tank
MAINTENANCE .MAINTENANCE PROCEDURE 2. Open cover (2) at the bottom left of the operator's cab by hand, pull out filter case (3) from the inside, then remove the filter. 3. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash it in a neu- tral agent.
Page 237: Every 1000 Hours Maintenance
MAINTENANCE .MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 250 and 500 hours service should be carried out at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 238: Change Oil In Swing Machinery Case
MAINTENANCE .MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY 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. Refill capacity: 6.6 liters (1.7 US gallons) 1.
Page 239: Check Oil Level In Damper Case, Add Oil
3. Install plugs (G) and (F). 4. Close the door. CHECK FAN BELT TENSION AND REPLACE FAN BELT Special tools are required for inspection and replacement of the fan belt. Contact your Komatsu distributors for inspection and replacement. REMARK An installed auto fan belt tension adjuster, “Auto Tensional Fan Belt“, dispenses with the belt deflection adjustment.
Page 240: Every 2000 Hours Maintenance
MAINTENANCE .MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 250, 500 and 1000 hours service should be carried out 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 seri- ous burns.
Page 241: Check Alternator, Starting Motor
.MAINTENANCE PROCEDURE CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or the bearing may have run out of grease, so contact your Komatsu distributor for inspec- tion or repair. If the engine is started frequently, have this inspection carried out every 1000 hours.
Page 242: Every 5000 Hours Maintenance
MAINTENANCE .MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK 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 243: Specifications
SPECIFICATIONS...
Page 244 SPECIFICATIONS Item Unit PC160LC-7 Operating weight kg (lb) 16,400 (36,155.8) Bucket capacity 0.65 (23) Name of engine KOMATSU SAA4D102E diesel engine Engine horsepower kW{HP}/rpm 82.40 {111}/2,200 A Overall length mm (ft) 8,565 (28.1) B Overall height mm (ft) 3,027 (9.9)
Page 245 SPECIFICATIONS SPECIFICATIONS Working ranges mm (ft) PC160LC-7 A Max. digging reach 8,960 (29.4) B Max. digging depth 5,960 (20.0) C Max. digging height 9,180 (30.1) D Max. vertical wall depth 5,690 (19.0) E Max. dumping height 6,370 (21.0) F Min. dumping height 2,400 (8.0) G Max.
Page 246 SPECIFICATIONS SPECIFICATIONS...
Page 247: Attachments And Options
ATTACHMENTS AND OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 248: Attachments And Options - General Information
INFORMATION0. 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 distribu- tor first.
Page 249: Attachment Installation
Always follow the correct procedure when installing the boom and arm. If the correct procedure is not followed, this may lead to serious damage or injury, so consult your Komatsu distributor before carrying out installation. If long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting something.
Page 250: 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 abnormality, contact your Komatsu distributor. PROHIBITED OPERATIONS Operations with Care During lifting operations, reduce the engine speed and carry out the operation in L mode.
Page 251: Machine Ready For Attachment (Deluxe Hcu System)
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM) MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM) LOCATIONS (1) Stop valve (5) Additional filter for breaker (2) Selector valve (6) Accumulator(low-pressure) (3) Attachment control pedal (7) Accumulator(high-pressure) (if equipped) (4) Lock pin Stop Valve This valve (1) stops the flow of the hydraulic oil.
Page 252 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM) Selector Valve This valve (2) switches the flow of hydraulic oil. It is automatically switched according to the selected working mode. It is necessary to switch the working mode to match the attachment that is installed.
Page 253 The need to install an accumulator depends on the breaker manufacturer. When installing a breaker made by another manufacturer, please consult your Komatsu distributor. Depending on the breaker manufacturer, it may be necessary to install the accumulator at the inlet or out-...
Page 254: Hydraulic Circuit
If A or E mode is selected: 27.4 MPa (3974 PSI) Adjustment may be needed depending on the attachment, so in such a case, please contact your Komatsu distributor. Switching Hydraulic Circuit Depending on the type of attachment, set the working mode on the monitor as follows.
Page 255: Hydraulic Circuit Connection
For the mouthpiece size and accumulator add-on, the action to take differs according to the attachment manufac- turer, so please consult your Komatsu distributor. Oil Flow Path The direction of operation of the pedal and the path of the oil flow is as shown in the diagram below.
Page 256: Replace Additional Breaker Filter Element
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM) Replace Additional Breaker Filter Element WARNING Immediately after operating the engine, all parts still retain high temperature. Never replace the filter in such condi- tion. Replace it only after each part has sufficiently cooled. Prepare a container to catch the oil.
Page 257: Machine Ready For Attachments
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM) MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM) EXPLANATION OF COMPONENTS (1) Stop valve (3) Attachment control pedal (2) Selector valve (4) Lock pin (1) STOP VALVE This valve stops the flow of the hydraulic oil. (1)FLOW:Hydraulic oil flows (2)STOP:Hydraulic oil stops Set this valve to the STOP position when removing or installing...
Page 258: Selector Valve
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM) (2) SELECTOR VALVE This switches the flow of the hydraulic oil. For details of the attachment to install and direction of right 3- way valve position, see "HYDRAULIC CIRCUIT (PAGE 6-12)". (3) ATTACHMENT CONTROL PEDAL This pedal (3) is used to control the attachment.
Page 259: Switching Hydraulic Circuit
If selector valve is in position for general attachments such as crusher : 27.4 MPa (3974 PSI) Adjustment may be needed depending on the attach- ment, so in such a case, please contact your Komatsu distributor. SWITCHING HYDRAULIC CIRCUIT Contact dealer to set left hand boom piping releif pressure.
Page 260: Switching Between Breaker And General Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM) SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT When a possible attachment (if equipped) is installed, the selector valve is set to the postition for using breaker and mode B is selected : 1.
Page 261: Hydraulic Circuit Connection
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM) HYDRAULIC CIRCUIT CONNECTION When connecting the attachment, connect the circuit as fol- lows. 4. Remove blind plugs (1) at the end of the stop valve piping. (Two places on the left and right) Be careful not to lose or damage any part that has been removed.
Page 262: Attachment Removal And Installation
ATTACHMENTS AND OPTIONS ATTACHMENT REMOVAL AND INSTALLATION ATTACHMENT REMOVAL AND INSTALLATION Attachment Removal 1. Lower the attachment to the ground and stop the engine. 2. Turn the starting switch to ON position and push down the safety lock lever to FREE position. 3.
Page 263: Attachment Installation
ATTACHMENTS AND OPTIONS ATTACHMENT REMOVAL AND INSTALLATION 7. Pull out the mounting pins (2 places), remove the attach- ment, then install the bucket. For details of the procedure for installing the bucket, see “BUCKET REPLACEMENT AND INVERSION ( 3-105 )“. 8.
Page 264: Attachment Operations
ATTACHMENTS AND OPTIONS ATTACHMENT REMOVAL AND INSTALLATION ATTACHMENT OPERATIONS WARNING Do not rest the foot on the pedal and depress it, when the auto deceleration switch is in ON position. The engine speed rises all of sudden and the attachment will move suddenly and cause serious dam- age or injury.
Page 265: When Using General Attachment Such As Crusher
ATTACHMENTS AND OPTIONS ATTACHMENT REMOVAL AND INSTALLATION When Using General Attachment Such As Crusher When the A mode or E mode control switch is ON and the lock pin position makes both the front and the rear of the pedal free, if the front or rear of the pedal is depressed, the attachment is actuated.
Page 266: Attachment Guide
Komatsu distributor before installing. Installing attachments or options without consulting your Komatsu distributor may not only cause prob- lems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment.
Page 267 ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE Content of work Quarries, mines, or other places Types of protective guard Breaker Demolition, cut- where there is danger of falling rocks operations ting operations Light load Heavy load Head guard Top guard Level II Front guard Level II Top guard (II)
Page 268: Attachment Combinations
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE ATTACHMENT COMBINATIONS WARNING Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine body. When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate with caution.
Page 269: Track Shoes Selection
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE TRACK SHOES SELECTION Select the most suitable track shoe to match the operating conditions. Selection Confirm the category from the list of uses in Table 1, then use Table 2 to select the shoe. Categories B and C are wide shoes, so there are limitations on their use. When using these shoes, check the pre-cautions, then investigate and study fully the conditions of use to confirm that these shoes are suitable.
Page 270: Bucket Teeth Selection
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE BUCKET TEETH SELECTION Depending on the working conditions, there is danger that an adapter and teeth may break, so select from the ver- tical pin and horizontal pin teeth to give teeth that are suitable for the purpose. While the standard teeth of both vertical and horizontal pin types may be used widely, the following kinds of teeth are recommended depending on the working conditions.
Page 271: 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.
Page 272 ATTACHMENTS AND OPTIONS 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. The direction of penetration of the chisel and the direction of the breaker body will gradually move out of line with each other, so always adjust the bucket cylinder to keep them...
Page 273 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations 6-27...
Page 274 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Extending the bucket cylinder fully and thrusting to raise the machine off the ground Greasing Supply grease in the correct position. Chisel NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary.
Page 275 INDEX INDEX <A> <G> Accumulator ............3-63 General Operation Information ......3-100 Air Conditioner Controls ........3-42 Grease Gun Holder ..........3-62 Ashtray ..............3-41 Attachment Guide ..........6-20 <H> Attachment Combinations ......6-22 Handling Oil, Fuel, Coolant, And Performing Oil Clinic Bucket Teeth Selection ........
Page 276 INDEX <W> Monitoring System ..........3-4 Wear Parts ............4-7 Wear Parts List ..........4-7 <O> Windshield ............3-34 Overall Machine View ...........3-2 Work Equipment Controls And Operations ..3-96 Working Mode ............. 3-97 <P> Parking Machine ..........3-107 <Y> Product Information ..........1-7 Your Machine Serial Numbers And Distributor ..

Komatsu PC160LC-7KA Operation & Maintenance Manual

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