Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
Page 2 1 - 1...
Page 3: Foreword
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
Page 4: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 5 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 6: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR (PAGE 3-82)" for further details.
Page 7: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the left front of the frame. The design of the nameplate differs according to the territory.
Page 8: Epa Nameplate
FOREWORD PRODUCT INFORMATION EPA NAMEPLATE This is stuck on the inside right side of the counterweight. EPA: Environmental Protection Agency, U.S.A. SERVICE METER LOCATION The service meter is displayed on the screen of the machine monitor. 1 - 7...
Page 9: Your Machine Serial Numbers And Distributor
FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 8...
Page 10: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE PROTECTIVE STRUCTURE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NUMBER PLATE AND ITS LOCATION EPA NAMEPLATE SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS...
Page 11 FOREWORD CONTENTS HANDLING MACHINES EQUIPPED WITH KOMTRAX 3- 38 MACHINE OPERATIONS AND CONTROLS 3- 39 BEFORE STARTING ENGINE 3- 39 STARTING ENGINE 3- 57 AFTER STARTING ENGINE 3- 61 STOPPING THE ENGINE 3- 64 MACHINE OPERATION 3- 65 STEERING THE MACHINE 3- 70 SWINGING 3- 72...
Page 12 FOREWORD CONTENTS TIGHTENING TORQUE LIST 4- 13 SAFETY CRITICAL PARTS 4- 14 SAFETY CRITICAL PARTS LIST 4- 14 MAINTENANCE SCHEDULE 4- 15 MAINTENANCE SCHEDULE CHART 4- 15 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 17 MAINTENANCE PROCEDURE 4- 18 WHEN REQUIRED 4- 18 CHECK BEFORE STARTING 4- 50...
Page 14 2 - 1...
Page 15: Safety
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS 2- 11 Safety Rules 2- 11 If Problems are Found 2- 11 Working Wear and Personal Protective Items 2- 11 Fire Extinguisher and First Aid Kit 2- 11 Safety Equipment 2- 12 Keep Machine Clean...
Page 16 SAFETY SAFETY Traveling on Slopes 2- 25 Operations on Slopes 2- 26 Prohibited Operations 2- 26 Operations on Snow 2- 28 Parking Machine 2- 28 TRANSPORTATION 2- 29 Loading and Unloading 2- 29 Shipping the Machine 2- 29 BATTERY 2- 30 Battery Hazard Prevention 2- 30 Starting Engine with Booster Cables...
Page 17: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. LOCATION OF SAFETY LABELS...
Page 18: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution for before operation (22L-98-22160) (3) Caution for leaving operator's seat (09654-03001) 2 - 5...
Page 19 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electric cables (09801-03001) (5) Caution for operating pattern (22J-98-1A631) (6) Caution for high-temperature coolant (20M-98-83250) 2 - 6...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (7) Caution for high-temperature hydraulic oil (22L-98-22240) (8) Caution for handling electric wires (09808-03000) (9) Caution for check and adjust track tention (09657-03003) (10) Caution when opening while engine is running (09667-03001) 2 - 7...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (11) Prohibited to enter range of swing (20M-98-73130) (12) Bware of work equipment (09134-A0881) (13) Caution for stowage (09803-03000) (Machines equipped with cab) (14) Caution when changing operating pattern (22L-98-22311) (15) Caution for lock pin when opening floor (22L-98-22390) 2 - 8...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (16) Caution when closing floor (22L-98-22410) (17) Caution for handling battery (09664-30011) (18) Caution for handling ROPS (22L-98-31930) (19) Caution for handling accumulator and gas spring (09659-53000) (20) Emergency escape (09844-00050) 2 - 9...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (21) Caution blast site (09845-00480) 2 - 10...
Page 24: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 25: Safety Equipment
SAFETY GENERAL PRECAUTIONS SAFETY EQUIPMENT Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features.
Page 26: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. machine equipped with canopy machine equipped with cab To ensure safety, always face the machine and maintain...
Page 27: Burn Prevention
SAFETY GENERAL PRECAUTIONS BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 28: Action If Fire Occurs
If in any doubt contact your Komatsu distributor. With any combination of work tool (such as bucket, breaker) that Komatsu refer to in this manual, the overall weight of the machine does not exceed the certified value of the ROPS.
Page 29 If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfil its function properly. In such cases, always contact your Komatsu distributor for advice on the method of repair.
Page 30: Attachment Installation
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 31: Distance To High Voltage Cables
SAFETY GENERAL PRECAUTIONS DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 32: Signalman's Signal And Signs
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 19...
Page 33: Safety Machine Operation
SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 34 Whenever you find an abnormal spot with the floor, be sure to fix it by yourself or call on your Komatsu distributor for repair. 2 - 21...
Page 35: Safety Rules For Starting Engine
SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR STARTING ENGINE Start and operate the machine only while seated. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. When starting the engine, sound the horn as a warning.
Page 36: 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 37: Safety Rules For Traveling
SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply. When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.
Page 38: Traveling On Slopes
SAFETY SAFETY MACHINE OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine.
Page 39: Operations On Slopes
SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION Always travel straight up or down a slope. Traveling at an angle or across the slope is extremely dangerous. Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again.
Page 40 SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations. Do not carry out demolition work under the machine.
Page 41: Operations On Snow
SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SNOW Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 42: Transportation
SAFETY SAFETY MACHINE OPERATION TRANSPORTATION LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.
Page 43: 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 44: Starting Engine With Booster Cables
SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 45: Towing
SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-109)". Always wear leather gloves when handling wire rope.
Page 46: Lifting Objects With Bucket
SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS Determine the signals to be used and place a signalman in position. To prevent the machine from tipping over or falling, carry out the operation on flat ground. To prevent the danger of contact with a raised load or the danger from a falling load, do not allow any worker inside the area.
Page 47: Safety Maintenance Information
SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 48: Stop Engine Before Carrying Out Maintenance
SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment and blade completely to the ground. Check that the main power is not conducted.
Page 49: Cautions For Opening (Tilting) Floor
SAFETY SAFETY MAINTENANCE INFORMATION CAUTIONS FOR OPENING (TILTING) FLOOR When opening (tilting) the cab or floor, see "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-29)" for details. Precautions when parking machine Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding.
Page 50: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 51: Accumulator, Gas Spring
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine.
Page 52: When Using Hammer
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. 2 - 39...
Page 53: Safety Rules For High-Pressure Oil
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: Compressed Air
SAFETY SAFETY MAINTENANCE INFORMATION COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.
Page 56 3 - 1...
Page 57: Machine View Illustrations
OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Track shoe Bucket cylinder Sprocket Track frame Arm cylinder (10) Idler Boom (11) Blade cylinder Boom cylinder (12) Blade 3 - 2...
Page 58: Controls And Gauges
OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Operator's seat (14) Fuel control lever Heater switch (cab specification machine) (15) Starting switch FRESH/RECIRC Selector Lever (16) Floor lock cancel lever (cab specification machine) (17) Service meter Lock lever (18) Engine coolant temperature gauge Left work equipment control lever (19) Fuel gauge...
Page 59: Detailed Controls And Gauges
OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM Emergency monitors (C) Pilot lamps...
Page 60 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor flashes or the buzzer sounds, stop the engine immediately or run it at low idle, then inspect the problem point immediately and repair the problem. These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal location on the monitor will flash and the buzzer will sound.
Page 61 OPERATION DETAILED CONTROLS AND GAUGES Charge Level Monitor If there is a problem in the charging when the engine is running, this monitor (2) flashes and the buzzer sounds. If the monitor flashes, stop the engine and check the V-belt tension.
Page 62 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Engine coolant temperature gauge Service meter Fuel gauge Engine Coolant Temperature Gauge This meter (1) shows the engine coolant temperature. During operation, the indicator should be in range (A). If the indicator enters red range (B) during operation, pilot lamp (C) flashes and the buzzer sounds at the same time.
Page 63 OPERATION DETAILED CONTROLS AND GAUGES Fuel Gauge This meter (2) shows the fuel level in the fuel tank. F indicates that the tank is full. E indicates that the fuel level is low. If the fuel level goes below 8.0 liters (2.11 US gal), the indicator enters red range (A), and at the same time, pilot lamp (B) flashes.
Page 64 OPERATION DETAILED CONTROLS AND GAUGES Pilot Display Engine pre-heating monitor Travel speed boost monitor Engine Pre-heating Monitor This monitor (1) flashes when the starting switch is set to the HEAT position. After approx. 18 seconds, the buzzer sounds and the monitor goes out.
Page 65: Switches
OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch Windshield wiper switch Horn switch (Machines equipped with cab) Lamp switch Room lamp switch Travel speed selector switch (Machines equipped with cab) Cab heater switch Cigarette lighter (Machines equipped with cab) (Machines equipped with cab) FRESH/RECIRC Selector Lever (Machines equipped with cab) 3 - 10...
Page 66 OPERATION DETAILED CONTROLS AND GAUGES Starting Switch This switch (1) is used to start or stop the engine. (A): OFF position At this position, the starting switch key can be inserted and removed. When the starting switch key is turned to this position, the power to the electrical system is switched off and the engine stops.
Page 67 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch Use this switch (4) to switch the travel speed to low speed or high speed. Cab Heater Switch (Machine equipped with cab) This switch (5) is used to heat the operator's compartment. The flow rate of the hot air can be set to two levels.
Page 68 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES Wiper only When the switch is set to position (B), the wiper is actuated. Position (A): Wiper stopped Position (B): Wiper actuated Wiper and window washer When the wiper is working and the switch is kept pushed to position (B), washer fluid is sprayed out.
Page 69: Control Levers And Pedals
OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Travel levers (with pedals) Left work equipment control lever Swing lock cover Right work equipment control lever Boom swing control pedal Fuel control lever Floor lock cancel lever Blade control lever 3 - 14...
Page 70 OPERATION DETAILED CONTROLS AND GAUGES Lock Lever WARNING When standing up from the operator's seat, be sure to shift the lock lever to the LOCK position.A careless touch on a control lever or pedal while the lock lever is not in the LOCK position can cause a serious personal injury. So make sure that the lock lever is in the LOCK position before standing up.
Page 71 WARNING The operating pattern is set to the standard operating pattern (ISO pattern). When changing the operating pattern, please contact your Komatsu distributor. The method of using operating patterns other than the ISO pattern is given in the ATTACHMENT AND OPTIONS section. Always read and understand the contents before operating the machine.
Page 72 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Lever This lever (4) is used to control the engine speed and output. (A) Low idle: Push the lever fully (B) High idle: Pull the lever fully Blade Control Lever NOTICE When digging operations using the blade are continued for more than one hour, pay careful attention to the rise in the coolant temperature.
Page 73 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers (with Pedals) WARNING Do not put your foot on the pedal unless the machine is traveling. If you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident. Do not rest a foot on the pedal except when traveling or steering the machine, using the pedal.
Page 74 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Cover WARNING When the boom swing is not being used, lock the boom swing with the swing lock cover. If the control pedal is accidentally depressed when it is not locked, it may lead to a serious accident or injury. This cover (7) is used to lock the boom swing control pedal.
Page 75: Windshield
OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD (Machine equipped with cab) WARNING When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK position. If the control levers are not locked and they are touched by accident, this may lead to a serious accident. When opening or closing the window at the front of the cab, stop the machine on horizontal ground, lower the work equipment completely to the ground, stop the engine, then carry out the operation.
Page 76 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Hold left and right grips (A) and pull the front window up diagonally. 5. When it will move no further to the rear, push up grips (A) to lock securely. When pushing up, check that lock lever (B) moves in lock release direction (F), then returns in the lock direction (L).
Page 77 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 78: Sliding Door
OPERATION DETAILED CONTROLS AND GAUGES SLIDING DOOR (Machine equipped with cab) CAUTION Be sure to check that the sliding door is locked in position both when it is open and when it is closed. Always stop the machine on level ground when opening or closing the door. If the door is opened or closed on a slope, there is danger that the operating effort will suddenly change.
Page 79: Emergency Escape Hammer
OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY ESCAPE HAMMER (Machine equipped with cab) CAUTION If it is necessary to break the window glass with the hammer, be extremely careful not to injure yourself on the flying pieces of broken glass. To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through the window. Be careful also not to slip on the broken pieces of glass.
Page 80: Cover With Lock
OPERATION DETAILED CONTROLS AND GAUGES COVER WITH LOCK Opening and Closing Covers with Lock Use the starting switch key to open or close the cover with the lock. For details of the position of the cover with the lock, see "LOCKING (PAGE 3-87)".
Page 81 OPERATION DETAILED CONTROLS AND GAUGES In Case of Dirt Cover When Opening 1. Insert the key in the slot. 2. Turn the key counterclockwise and open the cover. When Locking 1. Close the cover and insert the key in the slot. 2.
Page 82: Engine Rear Cover
OPERATION DETAILED CONTROLS AND GAUGES ENGINE REAR COVER CAUTION When carrying out inspection and service inside the engine rear cover, always open the cover fully until it is secured in position by the rod. NOTICE Except when opening the cover, always keep it locked. When it is locked, opening knob (2) of the cover does not move.
Page 83: Mud Cover
OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Pull cooling cover (3) to open it, then set rod (4) in the LOCK position (L) to hold cover (3) in position. 4. When closing cooling cover (3), set rod (4) to the FREE position (F), then close the cover.
Page 84: Method Of Opening (Tilting) Floor
Do not start the engine when the floor is open. If there is any breakage or problem in the lock when the floor is opened, stop the operation and ask your Komatsu distributor to carry out repairs. Do not remove the floor mounting bolts (1). There is danger that the floor may suddenly come up.
Page 85 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Fit blocks securely under the track to prevent the machine from moving. 9 J A 0 5 4 6 6 5. Remove bolts (2) (M10 x 3), then remove triangular cover (3). 6.
Page 86 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 8. Open engine rear cover (8) fully and secure it in position. (For details of the method of opening and closing the cover with the lock, see "ENGINE REAR COVER (PAGE 3-27)".) 9.
Page 87 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 12. After the floor rises, push knob (13) up until lock pin (14) fits in the lock groove (16) of lock plate (15). When lock pin (14) moves to lock groove (16), the 1st stage lock is completed.
Page 88 Before closing the floor, check that there is no damage or problem in the wiring, piping, or seats inside the floor or revolving frame. If any damage or problem is found, please ask your Komatsu distributor to carry out repairs.
Page 89 REMARK If damage is found on any of bolts (6) and (7), replace it with a new genuine Komatsu bolt of the same size. 7. Install cover (5) with securing bolts (4) (M8 x 4). 8. Install triangular cover (3) with bolts (2) (M10 x 3).
Page 90: Auxiliary Electric Power
OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 12V Power Source NOTICE Be sure to close cap (1) after use of the external power source. If the cap is left open, rainwater seeps in, possibly causing short-circuiting. An external power source terminal is installed under the operator seat.
Page 91: Block Fuse
OPERATION DETAILED CONTROLS AND GAUGES Fuse Capacities and Circuit Names Fuse box (1) Fuse capacity Name of circuit Canopy specification specification Working lamp Horn, fuel pump Monitor panel, buzzer, speed boost solenoid OPT power supply (1) Heater, travel alarm buzzer, air conditioner (Cab specification) External power supply...
Page 92: Operation Manual Storage
OPERATION DETAILED CONTROLS AND GAUGES OPERATION MANUAL STORAGE NOTICE Except when opening the cover for some reason, always keep the cover locked. This is under the operator's seat. There is a box for keeping the Operation and Maintenance Manual in the rear of the operator's seat backrest. Keep the Operation and Maintenance Manual in the box so that it can be seen at any time.
Page 93: Handling Machines Equipped With Komtrax
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
Page 94: Machine Operations And Controls
Leakage of oil and fuel will cause the machine to catch fire. Always check thoroughly and repair any problems or contact your Komatsu distributor. Check that the floor is firmly secured with securing bolts (1) and (3) (3 bolts in use for canopy specification) or with securing bolts (2) (4 bolts in use for cab specification).
Page 95 OPERATION MACHINE OPERATIONS AND CONTROLS If the machine is at an angle, reposition it level before checking. Perform the following inspections and cleaning every day before starting engine for the day's work. 1. Check for damage, wear, play in work equipment, cylinders, linkage, and hoses. Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses.
Page 96 Whenever you find an abnormal spot with the floor, be sure to fix it by yourself or call on your Komatsu distributor for repair. When tightening any loose bolts, tighten also the 2 bolts inside the triangular cover on the left side of the machine.
Page 97 OPERATION MACHINE OPERATIONS AND CONTROLS 11. Check bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, contact your Komatsu distributor for repairs. 3 - 42...
Page 98 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub-tank.
Page 99 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. REMARK If the machine is at an angle, reposition it to level before checking.
Page 100 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
Page 101 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 102 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. Extend each cylinder for the boom, arm and bucket fully as shown in the diagram on the right, remove the oil filler port cap and install the cap again. The inside of the hydraulic tank can be pressurized through this process.
Page 103 OPERATION MACHINE OPERATIONS AND CONTROLS Check Water Separator If red ring (1) of the water separator is at the bottom of case (2), there is no water. If the ring (1) is floating, there is water up to the bottom of the ring, so drain the water as follows.
Page 104 Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. Check Function of Horn 1. Turn the starting switch to the ON position.
Page 105 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment WARNING Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switches can be operated freely and easily with the operator back against the backrest.
Page 106 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Machine equipped with canopy Machine equipped with cab Mirror (A) Adjust the angle so that the machine's side is reflected on the...
Page 107 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Mirror (C) Adjust the angle so that an operator can see a person on the ground 1 m behind the machine from the operator's seat. (W):1 m (3.9 in) 3 - 52...
Page 108 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if there are no signs of damage, replace belts in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Page 109 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end of the belt on either the buckle body or tongue side. Lengthening Pull the belt while holding it at a right angle to the buckle or tongue. 3 - 54...
Page 110 If a monitor or gauge does not light up or the buzzer does not sound, there is probably a blown fuse or disconnection in the monitor, so contact your Komatsu distributor for repairs. After approx. 3 seconds, only the following monitors stay lighted up.
Page 111 2) Press lamp switch (10) and check that the headlight lights up. If it does not light up, there is probably a blown bulb or disconnection, so contact your Komatsu distributor for repairs. 3) Press horn switch (11) to confirm that the horn will sound.
Page 112: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire.
Page 113 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to START position (C). The engine will start. 4. When the engine starts, release the key in starting switch (3). The key will automatically return to ON position (B). Starting Engine in Cold Weather WARNING Start the engine only after sitting down in the operator's seat.
Page 114 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 1. Check to make sure that lock lever (1) is at the LOCK position (L). If lock lever (1) is in the FREE position (F), the engine will not start. 2.
Page 115 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. When the engine starts, release the key in starting switch (3). The key will automatically return to ON position (B). 3 - 60...
Page 116: After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 117 OPERATION MACHINE OPERATIONS AND CONTROLS Warming-up Operation NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the lever suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warming-up operation is completed.
Page 118 Engine oil pressure monitor (6): Monitor is off Charge level monitor (7): Monitor is off 5. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 6. Set lock lever (2) to the LOCK position (L), then check that the machine does not move even when the levers and pedals are operated.
Page 119: Stopping The Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
Page 120: Machine Operation
OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the travel lever or travel pedal, check the direction that the track frame is facing. When the track frame is facing the rear (when the sprocket is at the front), the direction of operation of the travel lever and travel pedal is the opposite to the direction of movement of the machine (forward/reverse, left/right).
Page 121 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 1. Set lock lever (2) to the FREE position (F), then raise the work equipment 40 to 50 cm (16 to 20 in) from the ground. 2. Raise the blade. 3. Operate right and left travel control levers (3) or right and left travel pedals (4) in the following manner. When sprocket (A) is situated at the rear of the machine;...
Page 122 When the load is reduced, the travel system returns to high speed travel. 5. Check that the travel alarm sounds. If the alarm does not sounds, please contact your Komatsu distributor for repairs. Moving Machine Backward 1. Set lock lever (2) to the FREE position (F), then raise the work equipment 40 to 50 cm (16 to 20 in) from the ground.
Page 123 When the load is reduced, the travel system returns to high speed travel. 5. Check that the travel alarm sounds. If the alarm does not sounds, please contact your Komatsu distributor for repairs. 3 - 68...
Page 124 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Shift the left and right travel levers to the neutral (N) position. 3 - 69...
Page 125: Steering The Machine
OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear, the machine moves in the reverse direction to the operation of the travel levers. REMARK When traveling at high speed, if the load increases, the automatic travel speed shifting function automatically shifts the transmission to low speed and the machine travels slowly.
Page 126 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the same way.
Page 127: Swinging
OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING When operating the swing, check that the area around the machine is safe. 1. Operate left work equipment control lever (1) to swing the upper structure. 2. When not using the swing, set left work equipment control lever (1) to the N position.
Page 128: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING For operation modes other than the standard one (ISO pattern), refer to the chapter of ATTACHMENTS AND OPTIONS in this manual. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
Page 129 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Bucket control Move the right work equipment control lever to the left or right to operate the bucket. Boom swing operation The boom swing operation can be carried out with the boom swing control pedal.
Page 130: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING Do not attempt to operate the work equipment control lever, while the machine is traveling. Operations Using Swing Force Do not use bucket swing force to compact soil or break an earth wall, or do not dig the bucket teeth into the ground while swinging the bucket.
Page 131 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. Operations Using Machine Dropping Force It is prohibited to carry out digging operations using the dropping force of the machine.
Page 132: 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 133 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth CAUTION When driving the machine out of water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan. This may cause the fan to break. Be extremely careful when driving the machine out of water.
Page 134: Traveling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be performed, pile soil to make a platform (A) on the slope so the machine is kept horizontal during operation.
Page 135 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. When traveling up a steep hill of more than 15°, set the work equipment to the posture shown in the diagram on the right. Traveling Downhill Put the travel lever in the neutral position. This will cause the brake to be automatically applied. Engine Stopped on Slope If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket to the ground, stop the machine, then start the engine again.
Page 136: Escape From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get the machine out. Track on One Side Stuck NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.
Page 137: Work Possible Using Compact Hydraulic Excavator
OPERATION MACHINE OPERATIONS AND CONTROLS WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work This is suitable for excavating places lower than the machine. When work equipment is in condition shown in diagram on right Bucket cylinder and link When the center line of arm cylinder and arm foot pin is at 90°, the...
Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS Smoothing Work When refilling after excavation and when smoothing the ground surface, use the blade. Side Ditching Work The machine can be used for side ditching in a confined worksite by combining the swing and boom swing operations. 3 - 83...
Page 139: Bucket Replacement
OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 140: Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Park the machine on the firm, level ground. Avoid parking the machine on slopes. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the work equipment into the ground surface to stop the machine from moving.
Page 141: Machine Inspection After Daily Work
OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Lower the blade to the ground. 5. Set lock lever (3) in the LOCK position. MACHINE INSPECTION AFTER DAILY WORK Before Stop Engine Use the machine monitor to check engine coolant temperature (1), engine oil pressure (2), and fuel level (3).
Page 142: Locking
OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Operator's cab door (machines equipped with cab) Always close the windows. (2) Engine rear cover (3) Dirt cover (4) Operation and Maintenance Manual, toolbox cover For details of locking, see "Opening and Closing Covers with Lock (PAGE 3-25)".
Page 143: Rubber Shoes (Machine With Rubber Shoes Only)
OPERATION MACHINE OPERATIONS AND CONTROLS RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY) (Machine equipped with rubber shoe) Rubber Shoes Information Rubber shoes have excellent properties that are not found in steel shoes. However, if they are used in the same way as steel shoes, full use cannot be made of their advantages.
Page 144 OPERATION MACHINE OPERATIONS AND CONTROLS Using Rubber Shoes Prohibited Works Do not carry out the following types of work. Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near the edges of steel plates will cause damage to the rubber shoes. In places such as river beds where there are large numbers of large and small boulders, the stones may get caught and damage the rubber shoes or make the shoes come off.
Page 145 OPERATION MACHINE OPERATIONS AND CONTROLS Always maintain the rubber shoes at the proper tension to prevent them from coming off. If the tension is low, the rubber shoes will come off under the following conditions. Even if the tension is correct, be extremely careful when carrying out operations. 1.
Page 146 OPERATION MACHINE OPERATIONS AND CONTROLS Mechanism of rubber shoe coming off track 1) When traveling over an obstacle, a gap is formed between the track roller (1) and the rubber shoe (2). In this condition, the rubber shoe may come off. 2) Furthermore, if the machine travels in reverse, a gap is formed between the track roller (1), idler (3), and rubber shoe (2).
Page 147 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS If the machine is turned in this condition, the rubber shoe will come off. 3 - 92...
Page 148: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a basic rule, transport the machine by trailer. Select the trailer to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)". Note that the value for the weight and transportation dimensions given in SPECIFICATIONS may differ according to the type of shoe or type of arm or other attachments.
Page 149: Loading And Unloading With Trailer
OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING When loading or unloading, check that travel speed boost monitor (1) is off, and always travel at low speed. If the monitor is on, the speed is set to high-speed travel, so press travel speed selector switch (2).
Page 150 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks (1) under the tires to ensure that the trailer does not move. Make the slope (2) of the ramps (3) a maximum of 15°.
Page 151 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Set the lock lever to the FREE position (F). 6. When loading, set the work equipment at the front and the blade at the rear, with the undercarriage and upper structure set parallel. 7. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer.
Page 152 OPERATION TRANSPORTATION Securing Machine After placing the machine on the specified position of the trailer, secure it according to the following procedure. NOTICE To prevent damage to the bucket cylinder while in transportation, put a wooden block between the end of the bucket cylinder and the truck bed floor so that the bucket cylinder does not directly contact the floor.
Page 153 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks (1) under the tires to ensure that the trailer does not move. Make the slope (2) of the ramps (3) a maximum of 15°.
Page 154 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 7. Run the engine at low speed. (A): Low idling (B): High idling 8. Raise the blade. 9. Raise the work equipment, align the direction of travel with the ramp, and travel slowly. Lower the work equipment as far as possible without causing interference.
Page 155: 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. When lifting the machine, carry out the operation on flat ground as follows.
Page 156 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Operate the lock lever to the LOCK position (L). 6. Stop the engine, check that there is nothing around the operator's compartment, then get off the machine. For cab specification machines, close the cab door and front glass securely. 7.
Page 157 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 9. Set the lifting angle of the wire rope to 30° to 40°, then lift the machine slowly. 10. After the machine comes off the ground, check the hook condition and the lifting posture, and then lift slowly. 3 - 102...
Page 158: Cold Weather Operation
NOTICE Please use Komatsu genuine SUPERCOOLANT (AF-NAC) for the COOLANT. As a basic rule, we do not recommend the use of any COOLANT other than SUPERCOOLANT (AF-NAC).
Page 159: Cab Heater In Cold Weather
OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 160: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 161: Long Term Storage
AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 162 OPERATION LONG TERM STORAGE A plastic fuel tank is used, so never use trichloroethylene when washing it. Washing in trichloroethylene will reduce the strength of the fuel tank. 3 - 107...
Page 163: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. For details of bleeding the air, see "Air Bleeding (PAGE 4-56)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the...
Page 164: Towing The Machine
OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope. When the machine is stuck in soft ground and cannot escape under its own power, or when towing a heavy machine, pass the wire rope through the front of the track frame as shown in the...
Page 165: Discharged Battery
OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 166 OPERATION TROUBLES AND ACTIONS Battery Removal and Installation NOTICE After securing the battery, check that it does not move. If it moves, tighten it again securely. Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal). If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated.
Page 167 OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows. Connecting and Disconnecting Booster Cables WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
Page 168 OPERATION TROUBLES AND ACTIONS Starting the Engine CAUTION Always check that the lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are at the HOLD or neutral position. 1.
Page 169: Other Trouble
TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 170 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor flashes...
Page 171 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Exhaust gas occasionally turns Clogging air cleaner element Clean or replace, see WHEN black REQUIRED Defective nozzle ( Replace nozzles) Defective compression ( See defective compression above) Combustion noise occasionally Defective nozzle ( Replace nozzle) makes bresthing sound Abnornal noise generated...
Page 172 4 - 1...
Page 173: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 174 MAINTENANCE MAINTENANCE INFORMATION Dusty Jobsite When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently.
Page 175: Outline Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. 4 - 4...
Page 176 COOLANT AND WATER FOR DILUTION Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Page 177 MAINTENANCE OUTLINE OF SERVICE Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. 4 - 6...
Page 178 Perform sampling at regular fixed intervals. Do not perform 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. STORING OIL AND FUEL Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 179: Electric System Maintenance
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 180: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 181: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 182 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT ASTM: American Society of Testing and Material Final drive Hydraulic Engine oil pan case Fuel tank Cooling system system (each) liter Specified capacity US gal 2.14 0.21 14.5 17.2 2.25 liter Refill capacity US gal 1.98 0.21 5.28...
Page 183 G2-T or G2-TE is recommended. Note 3: COOLANT 1) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Page 184: 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 185: Safety Critical Parts List
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. SAFETY CRITICAL PARTS LIST Safety critical parts for periodic replacement...
Page 186: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...
Page 187 MAINTENANCE MAINTENANCE SCHEDULE CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) 4- 67 4 - 16...
Page 188: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging operations, so set the maintenance intervals as follows. Replace hydraulic filter element On a new machine, replace the element after the first 100 to 150 hours, then carry out further replacement of the element according to the table on the right.
Page 189: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 190 MAINTENANCE MAINTENANCE PROCEDURE Air Cleaner Element - Clean/Replace 1. Open the engine rear cover. 2. Remove clips (2), then remove dust cup (3). 3. Take out element (4) and cover the air connector at the end of the air cleaner body with a clean cloth or tape. 4.
Page 191 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 7. Remove the cloth or adhesive tape used to cover the air connector inside the air cleaner body. 8. Install cleaned element (4) or a new element. 9. Set dust cup (3) with the arrow pointing up, then set it to the air cleaner body and secure it with clip (2).
Page 192 MAINTENANCE MAINTENANCE PROCEDURE Machines Equipped with Double Element Checking Whenever the red piston in dust indicator (1) appears, clean the air cleaner element. NOTICE Do not clean the air cleaner element before the dust indicator becomes red. If the element is cleaned frequently before the dust indicator becomes red, the performance of the air cleaner is diminished and the cleaning effect is lowered.
Page 193 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds, gasket or seal are damaged.
Page 194 MAINTENANCE MAINTENANCE PROCEDURE Replacing Element 1. Open up the engine hood cover, then release clips (2) at 3 places and detach cover (3). 2. Remove outer element (4). Do not remove inner element (5) at this time, however. 3. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6).
Page 195: Clean Inside Of Cooling System
(AF-NAC) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing.Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
Page 196 When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 197 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Set the container under the drain hose installed to drain valve (2) to catch the coolant. REMARK For a machine equipped with an air conditioner, the coolant drain valve is arranged as shown in the diagram on the right. 5.
Page 198: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 27...
Page 199 Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. When It is Possible to Use Indicator to Check Electrolyte Level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 200: Clean Water Separator Element
MAINTENANCE MAINTENANCE PROCEDURE CLEAN WATER SEPARATOR ELEMENT WARNING Do not bring any fire or flame close. Prepare a filter wrench Prepare a container to catch the fuel that is drained. 1. Open the engine rear cover and cooling cover. For details, see "COOLING COVER (PAGE 3-27)".
Page 201: Drain Water And Sediment From Fuel Tank
MAINTENANCE MAINTENANCE PROCEDURE DRAIN WATER AND SEDIMENT FROM FUEL TANK NOTICE Never use trichlene for washing the inside of the tank. Use diesel fuel only. Carry out this procedure before operating the machine. Prepare a container to catch the fuel that is drained. 1.
Page 202: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS (Machine equipped with steel shoe) If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Steel Track Shoe Bolts - Check/Tighten 1.
Page 203: Check And Adjust Track Tension
Never loosen plug (1) more than 1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. 4 - 32...
Page 204 It is extremely dangerous to release the grease by any method except the procedure given below. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. 1. Loosen plug (1) gradually to release the grease.
Page 205: Check Rubber Shoes
MAINTENANCE PROCEDURE CHECK RUBBER SHOES (Machine equipped with rubber shoes) If the rubber shoes are in the following condition, they must be repaired or replaced, so please contact your Komatsu distributor for repair or replacement. Lug Height If lug height "a" is reduced by wear, the drawbar pull will drop.
Page 206 If the length is less than 30 mm (1.18 in) (B) or the depth of the crack is less than 10 mm (0.39 in), there is no particular need to carry out repairs. When making judgement whether to replace, repair, or continue using rubber shoes, please contact your Komatsu distributor. 4 - 35...
Page 207: Check And Adjust Rubber Shoe Tension
When loosening plug (1), never loosen it more than one turn. Never loosen any part other than plug (1). Never put your face in line with the mount of plug (1). If the Rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor. 4 - 36...
Page 208 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 209: Replace Rubber Shoes
It is extremely dangerous to release the grease by any method except the procedure given below. If the rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.
Page 210 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2. Loosen plug (1) gradually to release the grease. 3. When loosening plug (1), turn it a maximum of one turn. 4. Insert steel pipes (2) in between the rubber shoe and track frame, rotate the sprocket in the reverse direction (A) so that steel pipes (2) make the rubber shoe come up the from the idler and then slide it in the side direction (B) to remove.
Page 211 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Insert steel pipes (2) in between the rubber shoe and track frame, rotate the sprocket in the reverse direction (A) again and set the rubber shoe to the idler securely. 5. Stop the rotation, and check that the rubber shoe is securely fitted to the sprocket and idler.
Page 212: Replace Bucket Teeth
MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, stop the engine, then set the lock lever securely to the LOCK position (L). The pin is knocked out by force, so there is danger of the pin flying out.
Page 213 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE Rubber (6) of the rubber pin lock is cut and the steel ball is about to come out. Steel ball (7) sinks in when it is pushed by hand. 4. Clean the surface of adapter (4) and remove the soil with a knife. 5.
Page 214 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 8. Insert lock pin (2) in the hole of the teeth (1) and hit it until its top is the same level as the surface of teeth (1). 9. After replacing a bucket tooth, always check the following. 1) After the lock pin (2) has been knocked in completely, check that it is secured by the teeth (1) and surface.
Page 215: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) If there is air in the window washer fluid, check the level of the fluid in window washer tank. Add automobile window washer fluid if necessary. REMARK Open the dirt cover.
Page 216: Check, Clean And Lubricate Cab Slide Door Rail And Roller
1. Spray rail (1) and roller (2) thoroughly with lubricant. 2. After spraying with lubricant, slide the door and check that the door opens and closes smoothly. If the movement is not smooth, contact your Komatsu distributor for repair. 4 - 45...
Page 217: Lubricating
MAINTENANCE MAINTENANCE PROCEDURE LUBRICATING BOOM SWING CYLINDER FOOT PIN (1 PLACE) Prepare a grease gun. 1. Open the engine rear cover and cooling cover. For details, see "COOLING COVER (PAGE 3-27)". 2. Remove bolts (1), then remove cover (2). 3. Please pierce grease to grease fitting (3) by using the grease gun.
Page 218: Bleeding Air From Hydraulic System
MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM NOTICE If the pump is operated without filling the pump case with hydraulic oil, there is danger that the pump may be prematurely damaged. Be sure to bleed the air completely. 1. Bleeding air from piston pump 1) Remove bolts (1) (M10 x 3), then remove triangular cover (2).
Page 219 MAINTENANCE MAINTENANCE PROCEDURE NOTICE After completing the air bleeding operation, stop the engine, and leave the machine for 5 minutes before starting operations. This will remove the air bubbles in the oil inside the hydraulic cylinders. Check that there is no leakage of oil and wipe off any oil that has been spilled. When the Operating Instructions are provided for the attachment by the attachment manufacturer, follow the instructions for air bleeding in the Operating Instructions.
Page 220: Check Swing Pinion Grease Level, Add Grease
(PAGE 2-36)" in the safety and maintenance sections thoroughly, and refer to the explanation for each part in Section "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-29)" when carrying out the operation. Or ask your Komatsu distributor to carry out the maintenance.
Page 221: Check Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-43)" in the OPERATION section. Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Check oil level in hydraulic tank, add oil Check dust indicator Check water separator...
Page 222: Every 100 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE LUBRICATING Accelerator cable rod end (1 place) Prepare a grease gun. 1. Open the engine rear cover and cooling cover. For details, see "ENGINE REAR COVER (PAGE 3-27)". 2. Please pierce grease to grease fitting (4) by using the grease gun.
Page 223: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE LUBRICATING Lubricating Swing Components WARNING When lubricating the swing circle and the swing pinion, do not swing the upper structure while carrying out the lubricating. NOTICE For the first 100 hours on new machines where the parts are settling in, carry out greasing every 10 hours. Prepare a grease pump 1.
Page 224 MAINTENANCE MAINTENANCE PROCEDURE Lubricating Work Equipment NOTICE When breaking in a new machine, carry out lubrication every 10 hours for the first 100 hours of operation. If any abnormal sound comes from the greasing point, carry out greasing regardless of the inspection and maintenance interval.
Page 225 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (13) Boom cylinder rod end (1 place) (14) Arm cylinder foot pin (1 place) (15) Arm cylinder rod end (1 place) (16) Boom - Arm connecting pins (1 place) (17) Bucket cylinder foot pin (1 place) 4 - 54...
Page 226: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
3. Remove drain plug (P) slowly to avoid getting oil on yourself, and drain the oil. 4. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 5. Install drain plug (P).
Page 227: Replace Fuel Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL FILTER CARTRIDGE WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. Prepare a filter wrench Prepare for cloth.
Page 228: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out.
Page 229: Clean,Check Radiator Fins,Oil Cooler Fins,Fuel Cooler Fins
MAINTENANCE MAINTENANCE PROCEDURE CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER FINS WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment. NOTICE When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins.
Page 230: Check And Adjust Cooling Fan Belt Tension
6. Check for damage to the pulleys, and wear of the V-groove and V-belt. Be particularly careful to check that the V-belt is not in contact with the bottom of the V-groove. 7. If the belt is stretched, leaving no allowance for adjustment, or if it is cut or cracked, contact your Komatsu distributor for replacement.
Page 231: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Carry out the maintenance for EVERY 500 HOURS SERVICE at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 232: Replace Hydraulic Oil Filter Element
MAINTENANCE MAINTENANCE PROCEDURE REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. NOTICE If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than during normal bucket operations.
Page 233: Check Engine Valve Clearance, Adjust
MAINTENANCE MAINTENANCE PROCEDURE CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. 4 - 62...
Page 234: Every 1500 Hours Maintenance
Check the diaphragm for damage and the spring for breakage. But a set of special tools are required for this work, so it is recommended to ask your Komatsu distributor for the inspection and cleaning service.
Page 235: Every 2000 Hours Maintenance
Before starting the operation to open the floor, read the precautions in "CAUTIONS FOR OPENING (TILTING) FLOOR (PAGE 2-36)" in the safety and maintenance sections thoroughly, and refer to the explanation for each part in "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-29)" when carrying out the operation. Or ask your Komatsu distributor to carry out the maintenance.
Page 236 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Open up dust cover (1) until it clicks into the securing position. See "MUD COVER (PAGE 3-28)") 6. Loosen bolt (2), then remove plate (3) to the upper side. 7. Remove the cap from oil filler (F), and release the internal pressure.
Page 237: Check Alternator, Starting Motor
CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or the bearing may have run out of grease. Contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 238 Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 239 MAINTENANCE MAINTENANCE PROCEDURE CHECKING FUNCTION OF ACCUMULATOR CAUTION When carrying out the inspection, check first that there is no person or obstacle in the surrounding area. Check the nitrogen gas charge pressure as follows. Carry out step 1 and 2 while the engine is running. 1.
Page 240 Please contact your Komatsu distributor for inspection. 7. This completes the inspection. After completion of the inspection, set the lock lever to the LOCK position and turn the starting switch to the OFF position.
Page 242 5 - 1...
Page 243: Specifications
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Item Unit PC45MR-3 PC55MR-3 Canopy specified 4,795 (10,573) 5,160 (11,378) Operating kg (lb) Weight Cab specified 4,915 (10,838) 5,280 (11,642) Bucket capacity (cu.yd) 0.14 (0.18) 0.16 (0.21) Komatsu Komatsu Name of engine 4D88E-6BP 4D88E-6BP diesel engine diesel engine...
Page 244 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC45MR-3 PC55MR-3 A Max. digging reach mm (ft in) 6,040 (19'10") 6,220 (20'5") B Max. digging depth mm (ft in) 3,670 (12'0") 3,800 (12'6") Canopy specified mm (ft in) 5,730 (18'10") 5,945 (19'6") C Max.
Page 246 6 - 1...
Page 247: Attachments And Options
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION SAFETY FIRST If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor first.
Page 248: Attachment Installation
If the correct procedure is not used when installing the boom and arm, it may lead to serious damage. Please consult your Komatsu distributor. When long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting other objects.
Page 249: Bucket With Hook
ATTACHMENTS AND OPTIONS BUCKET WITH HOOK BUCKET WITH HOOK HOOK CONDITION Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu distributor. PROHIBITED OPERATIONS Operations with Care Do not exceed the following loads when carrying out lifting operations.
Page 250: Air Conditioner
ATTACHMENTS AND OPTIONS AIR CONDITIONER AIR CONDITIONER (Machine equipped with cab) CONTROL PANEL AND COMPONENTS Temperature control switch FRESH/RECIRC selector lever Air flow selector switch Vent Air conditioner switch Temperature Control Switch This switch (1) continuously adjusts the temperature between high and low.
Page 251: Air Conditioner Controls
ATTACHMENTS AND OPTIONS AIR CONDITIONER Air Conditioner Switch This switch (3) is used as the ON/OFF switch for the air conditioner. Each time this switch is pressed, it switches between ON and OFF. When the switch is ON, the lamp inside the switch lights up. FRESH/RECIRC Selector Lever Use this lever (4) to switch between recirculation of the air inside the cab and intake of fresh air from outside.
Page 252: Phenomena That Are Not Failures
ATTACHMENTS AND OPTIONS AIR CONDITIONER PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the air conditioner is switched on, the work equipment operates and the machine travels somewhat slower than when it is switched off. This should not give you any concern as it is by no means a failure but due to lowered output of the hydraulic pump.
Page 253: Air Conditioner Maintenance
Colorless, transparent: No refrigerant (C) REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 254 ATTACHMENTS AND OPTIONS AIR CONDITIONER Every 250 Hours Maintenance CHECK AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION Checking The belt should deflect 5 to 6 mm (0.197 to 0.236 in) when pressed with (A) finger force of approx. 58.8 N (6 kg) at a point midway between the idle pulley (1) and compressor pulley (2).
Page 255 Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. If the belt is stretched and there is no allowance for adjustment, or if it is cut or cracked, please contact your Komatsu distributor for replacement.
Page 256 ATTACHMENTS AND OPTIONS AIR CONDITIONER Every 500 Hours Maintenance Clean Air Conditioner Condenser WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment. NOTICE When using compressed air, keep the air nozzle at a distance to prevent damage to the fins.
Page 257 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS AIR CONDITIONER AIR CONDITIONER 1. Loosen knob (1), then remove filter inspection cover (2). 2. Remove filter (3). 3. Clean the filter (3) with compressed air. If there is oil on the filter (3) or it is extremely dirty, wash it in water containing a neutral agent.
Page 258: Windshield Washer
ATTACHMENTS AND OPTIONS WINDSHIELD WASHER WINDSHIELD WASHER (Machine equipped with operator's cab) If the windshield washer is installed, operate it according to the following procedure. WINDSHIELD WASHER OPERATION Wiper and window washer When the wiper is working and the switch is kept pushed to position (B), washer fluid is sprayed out.
Page 259: Machine Ready For Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT LOCATIONS Plug Fuel control dial Selector Valve (machine equipped with proportional lever) Attachment Control Pedal (standard machine) Service switch (machine equipped with proportional lever) Attachment Lock Cover (standard machine) Attachment proportional switch (10) Working mode selector switch...
Page 260 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Selector Valve This valve (2) switches the flow of hydraulic oil. WARNING When the selector valve stopper is not installed, if a general attachment is being used, the movement of the attachment may not match the intention of the operator.
Page 261 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Attachment Lock Cover (standard machine) WARNING When attachment operation is not required, lock the attachment control pedal with the attachment lock cover. If the attachment control pedal is accidentally pressed while it is not locked, a serious accident may occur.
Page 262 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Horn Switch (machine equipped with proportional lever) Press switch (7) at the lower left on the knob of the right work equipment control lever to sound the horn. Fuel Control Dial (machine equipped with proportional lever) Use this dial (8) to control the engine rotating speed and output.
Page 263 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Working Mode Selector Switch (machine equipped with proportional lever) WARNING When not carrying out breaker operations or two way flow attachment operations, set this switch to the normal mode. If the working mode is selected, and the attachment proportional switch or breaker switch are pressed by mistake, it may cause a serious accident.
Page 264 (machine equipped with proportional lever) This monitor (12) lights up and the buzzer sounds if an abnormality occurs in the electronic system control. If it lights up, stop the engine and ask your Komatsu distributor to carry out inspection and repair. REMARK While the starting switch is ON, the lamp will remain lighted up.
Page 265: Hydraulic Circuit
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT HYDRAULIC CIRCUIT Hydraulic Circuit Connection NOTICE The pressure for the hydraulic equipment for the attachments used on this machine is set at 17.2 MPa (175 kg/cm ), so check the pressure resistance of the attachment Installed. When connecting the attachment, connect the hydraulic circuit as follows.
Page 266 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Bleeding Air After connecting the piping, bleed the air from the circuit. 1. Starting engine Start the engine according to "STARTING ENGINE (PAGE 3-57)" keep running the engine at low idle for 10 minutes, and carry out the following procedure.
Page 267: Attachment Operations
(standard machine) Depress the bottom of the pedal to operate the breaker. REMARK If it is necessary to adjust the oil flow, please ask your Komatsu distributor to carry out the adjustment. (machine equipped with proportional lever) Check that portion (b) of the working mode selector switch on the left console is lighted up and that the mode is set to the breaker mode.
Page 268 Bottom of pedal depressed: Oil flows to left side of arm (operator's seat side). REMARK If it is necessary to adjust the oil flow, please ask your Komatsu distributor to carry out the adjustment. (machine equipped with proportional lever) Check that portion (a) of the working mode selector switch on the left console is lighted up and that the mode is set to the ATT mode.
Page 269 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT The attachment proportional switch is used to operate the attachment. Right side of switch pressed: Oil flows to piping on right side of arm (hydraulic tank side) Left side of switch pressed: Oil flows to piping on left side of arm (operator's seat side) REMARK...
Page 270 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Adjusting Oil Flow (machine equipped with proportional lever) Use the working mode selector switch and the service switch to adjust the oil flow for the breaker mode and ATT mode of the working mode. It is necessary to adjust the oil flow, change the setting to match the attachment installed.
Page 271 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 2. The display on service meter (4) changes as shown in the figure on the right and goes to the oil flow adjustment mode. The value shows the stage of the fuel flow. The default value is "15"...
Page 272: Long Term Storage
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 2. The display on service meter (4) changes as shown in the figure on the right and goes to the oil flow adjustment mode. The values shows the stage of the fuel flow. The default value is '8"...
Page 273: Other Trouble
(machine equipped with proportional lever) Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 274 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT Service meter Failure code Problem on machine Action display Data transmitted from machine Network error monitor to control is not updated Move machine to safe Abnormality in permanent place and carry out E504 power source...
Page 275: Changing Machine Control Pattern (If Pattern Change Valve Equipped)
ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) WARNING When changing the operating pattern of the machine, set the machine in the parking posture, stop the engine, check that the lock lever is at the LOCK position, then change the operating pattern.
Page 276: Machine Control Patterns
ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) MACHINE CONTROL PATTERNS WARNING After changing the operating pattern, always change the operating pattern card in the operator's compartment. A: Machine equipped with canopy B: Machine equipped with cab ISO pattern Backhoe pattern 6 - 31...
Page 277: Attachment Guide
WARNING Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.
Page 278: Recommended Attachment Operations
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selection of optimum attachments. HYDRAULIC BREAKER...
Page 279 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge.
Page 280 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Prohibited Works To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. Do not operate all cylinders to the end of their strokes. Always leave approx. 5 cm (2 in) to spare. Using the mount to gather in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations...
Page 281 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 6 - 36...
Page 282 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Greasing Supply grease in the correct position. NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic components, while the breaker is in use.
Page 284: Index
INDEX INDEX <A> <E> AFTER STARTING ENGINE 3- 61 ELECTRIC SYSTEM MAINTENANCE AIR CONDITIONER EMERGENCY ESCAPE HAMMER 3- 24 AIR CONDITIONER CONTROLS ENGINE REAR COVER 3- 27 AIR CONDITIONER MAINTENANCE ENGINE SERIAL NUMBER PLATE AND CONTROL PANEL AND ITS LOCATION COMPONENTS EPA NAMEPLATE ASHTRAY...
Page 285 INDEX LONG TERM STORAGE 6- 27 SAFETY MACHINE OPERATION 2- 20 SPECIFICATIONS 6- 27 BATTERY 2- 30 MACHINE VIEW ILLUSTRATIONS LIFTING OBJECTS WITH BUCKET 2- 33 OVERALL MACHINE VIEW OPERATION 2- 23 MAINTENANCE INFORMATION STARTING ENGINE 2- 20 MAINTENANCE PROCEDURE 4- 18 TOWING 2- 32...
Page 286 INDEX <Y> YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 7 - 3...

This manual is also suitable for:

Pc55mr-3 Pc45mr-6243 Pc55mr-16609

Komatsu PC45MR-3 Operation And Maintenance Manual

Your Machine Serial Numbers and Distributor

Safety

Maintenance Schedule

Quick Links

Chapters

Related Manuals for Komatsu PC45MR-3

Summary of Contents for Komatsu PC45MR-3

This manual is also suitable for: