Komatsu GALEO PC270-8 Operation & Maintenance Manual
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Komatsu GALEO PC270-8 Operation & Maintenance Manual

Komatsu GALEO PC270-8 Operation & Maintenance Manual

Hydraulic excavator
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Operation & Maintenance
Manual
PC270
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
March 2007
-8
PC270-8
20001
TEN00148-03
and up
Copyright 2007 Komatsu
Printed in U.S.A.
Komatsu America Corp
.

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  • Page 1 SERIAL NUMBERS and up This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • 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 FOREWORD FOREWORD 1 - 3...
  • Page 5 FOREWORD FOREWORD 1 - 4...

  • Page 6: Safety Information

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
  • Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

  • Page 8: Introduction

    BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.

  • Page 9: Product Information

    FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the bottom right of the operator's cab The design of the nameplate differs according to the territory.

  • Page 10: Service Meter Location

    FOREWORD PRODUCT INFORMATION SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 9...

  • Page 11: Table Of Contents

    FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE BREAKING-IN THE NEW MACHINE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS...
  • Page 12 FOREWORD CONTENTS FIRE EXTINGUISHER 3-110 MACHINE OPERATIONS AND CONTROLS 3-111 BEFORE STARTING ENGINE 3-111 STARTING ENGINE 3-128 AFTER STARTING ENGINE 3-131 STOPPING THE ENGINE 3-142 MACHINE OPERATION 3-143 STEERING THE MACHINE 3-147 SWINGING 3-149 WORK EQUIPMENT CONTROLS AND OPERATIONS 3-150 WORKING MODE 3-152 PROHIBITED OPERATIONS...
  • Page 13 FOREWORD CONTENTS RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 TIGHTENING TORQUE SPECIFICATIONS 4- 12 TIGHTENING TORQUE LIST 4- 12 SAFETY CRITICAL PARTS 4- 13 SAFETY CRITICAL PARTS LIST 4- 14 MAINTENANCE SCHEDULE 4- 15...
  • Page 14 2 - 1...
  • Page 15 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION Safety rules 2- 12 If problems are found 2- 12 Working wear and personal protective items 2- 12 Fire extinguisher and first aid kit 2- 12 Safety equipment 2- 12 Keep machine clean...

  • Page 16: Safety

    SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION 2- 21 STARTING ENGINE 2- 21 Checks before starting engine 2- 21 Safety rules for starting engine 2- 22 Starting engine in cold weather 2- 22 OPERATION 2- 23 Checks before operation 2- 23 Safety rules for changing machine directions 2- 23 Safety rules for traveling...

  • 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. 2 - 4...

  • Page 18: Location Of Safety Labels

    SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS : if equipped 2 - 5...

  • Page 19: Safety Labels

    SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution before operating (09802-03000) (3) Caution for leaving operator's seat (09654-03001) 2 - 6...
  • Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electric cables (09801-03001) (5) Caution for operating pattern (09822-03000) 2 - 7...
  • Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (6) Caution when opening or closing front window (09839-03000) (7) Caution when stowing front window (09803-03000) (8) Caution for high-temperature hydraulic oil (09653-03001) (9) Caution with high-temperature coolant (09668-03001) 2 - 8...
  • Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Caution for handling accumulator and gas spring (09659-53000) (11) Caution for adjusting track tension (09657-03003) (12) Caution for handling cable (09808-03000) (13) Stopping rotation for inspection and maintenance (09667-03001) (14) Emergency escape (09844-00050) 2 - 9...
  • Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (15) Caution against falling (09805-23000) (16) Caution against falling (09805-13000) (17) Caution against falling (09805-C0481) (18) Prohibited to enter within swing range (09133-23000) 2 - 10...
  • Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (19) Beware of work equipment (09134-A1681) (20) Caution when handling battery (09664-30082) (21) Prohibition of jump start (09842-A0481) (22) Engine hood lock (20Y-00-41480) 2 - 11...

  • Page 25: Safety Information

    SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

  • Page 26: Keep Machine Clean

    SAFETY SAFETY INFORMATION KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.

  • Page 27: Handrails And Steps

    SAFETY SAFETY INFORMATION HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe)

  • Page 28: Do Not Get Caught In Articulated Portion

    SAFETY SAFETY INFORMATION DO NOT GET CAUGHT IN ARTICULATED PORTION The clearance around the work equipment will change according to the movement of the link. If you get caught, this may lead to serious personal injury. Do not allow anyone to approach any rotating or telescoping part. BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when...

  • Page 29: Fire Prevention And Explosion Prevention

    SAFETY SAFETY INFORMATION FIRE PREVENTION AND EXPLOSION PREVENTION Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling.

  • Page 30: Action If Fire Occurs

    Always contact your Komatsu distributor for advice. ATTACHMENT INSTALLATION When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact your Komatsu distributor for advice.

  • Page 31: Unauthorized Modifications

    SAFETY INFORMATION UNAUTHORIZED MODIFICATIONS If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility.

  • Page 32: Distance To High Voltage Cables

    SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.

  • Page 33: Ventilation For Enclosed Area

    Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 20...

  • Page 34: 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 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 When traveling on level ground, keep the work equipment at a height of 40 to 50 cm (16 to 20 in) from the ground. If the work equipment blocks the view and it is difficult to travel in safety, raise the work equipment to a greater height.

  • Page 38: Operations On Slopes

    SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.

  • Page 39: Prohibited Operations

    SAFETY SAFETY MACHINE OPERATION PROHIBITED OPERATIONS Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine. Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall.

  • Page 40: Operations On Snow

    SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION When carrying out demolition work, do not carry out demolition above your head. There is a hazard of broken parts falling or of the building collapsing and causing serious injury or property damage.

  • Page 41: Parking Machine

    SAFETY SAFETY MACHINE OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine.

  • Page 42: Transportation

    SAFETY MACHINE OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.

  • Page 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 3-189)". Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.

  • 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 falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine.

  • Page 49: Two Workers For Maintenance When Engine Is Running

    SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. One worker must always sit in the operator's seat and be ready to stop the engine at any time.

  • Page 50: 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 Only authorized personnel can service and repair the machine.

  • Page 51: When Using Hammer

    SAFETY SAFETY MAINTENANCE INFORMATION WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury.

  • Page 52: Do Not Disassemble Recoil Springs

    If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. SAFETY RULES FOR HIGH-PRESSURE OIL The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.

  • Page 53: Precaution For High Voltage

    If it is necessary to touch the injector terminal or the inside of the engine controller, please contact your Komatsu distributor. WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials.
  • Page 54 3 - 1...

  • Page 55: Machine View Illustrations

    OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Boom cylinder Bucket cylinder Sprocket Track frame Track shoe Arm cylinder Boom (10) Idler 3 - 2...

  • Page 56: Controls And Gauges

    OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Radio (12) Fuel control dial Lock lever (13) Lamp switch Left work equipment control lever (14) Swing lock switch One-touch power max. switch (15) Revolving warning lamp switch (if equipped) Travel pedals (16) Large Capacity Airflow Air Conditioner Blower Travel levers Switch (if equipped)
  • Page 57 OPERATION MACHINE VIEW ILLUSTRATIONS Machine monitor AA: Screen for standard BB: Screen with all lamps lighted up CC: Maintenance time warning screen Wiper switch (16) Window washer switch Buzzer cancel switch (17) Air conditioner control switches Auto-deceleration switch (18) Engine oil pressure monitor Engine coolant temperature monitor (19) Charge level monitor...

  • Page 58: Detailed Controls And Gauges

    OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITORING SYSTEM AA: Screen for standard BB: Screen with all lamps lighted up...
  • Page 59 OPERATION DETAILED CONTROLS AND GAUGES Basic Operation of Machine Monitor Starting Engine When Situation is Normal When the starting switch is turned to the ON position, the opening screen GG is displayed. After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen After the check before starting screen DD is displayed for 2 seconds, the screen switches to the working mode/travel mode display screen HH.
  • Page 60 OPERATION DETAILED CONTROLS AND GAUGES REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery condition. If this happens, the display on the machine monitor may momentarily go out, but this does not indicate any abnormality.
  • Page 61 OPERATION DETAILED CONTROLS AND GAUGES If There Is Abnormality When Starting Engine If there is any abnormality when starting the engine, the check before starting screen DD changes to the maintenance interval warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance interval warning screen CC.
  • Page 62 OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation If any abnormality occurs during operation, the standard screen BB changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2). 3 - 9...
  • Page 63 OPERATION DETAILED CONTROLS AND GAUGES REMARK The colors lighting up the monitors related to the emergency stop items, caution items, and basic check items are as follows. AA: Screen for standard BB: Screen with all lamps lighted up CC: Maintenance time warning screen Color when monitor lights up Type of monitor When...
  • Page 64 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
  • Page 65 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor This monitor (2) warns the operator that the hydraulic oil temperature has risen. If the hydraulic oil temperature becomes abnormally high, abnormality display (C) is shown. Stop operations and stop the engine or run it at low idling until the monitor changes to normal display (B).
  • Page 66 OPERATION DETAILED CONTROLS AND GAUGES Caution Monitors CAUTION If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running.
  • Page 67 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor If this monitor (2) shows low-temperature display (A), carry out the warm-up operation. For details, see "Hydraulic Equipment Warm Up (PAGE 3-134)". Carry out the warm-up operation for the hydraulic equipment until monitor (2) shows normal display (B).
  • Page 68 OPERATION DETAILED CONTROLS AND GAUGES Water Separator Monitor This monitor (6) warns the operator when water has accumulated inside the water separator. For details of the method of draining the water from the water separator, see "Check for Water and Sediment in Water Separator, Drain Water (PAGE 3-113)".
  • Page 69 OPERATION DETAILED CONTROLS AND GAUGES Basic Check Monitors CAUTION These monitors do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly.
  • Page 70 REMARK For details of the method of confirming the maintenance interval, see "Maintenance Selector Switch (PAGE 3-42)". If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 17...
  • Page 71 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Pilot display Gauge and Meter Engine pre-heating monitor (10) Engine coolant temperature gauge Swing lock monitor (11) Hydraulic oil temperature gauge Wiper monitor (12) Fuel gauge Auto-deceleration monitor (13) Service meter, clock Working mode monitor (14) ECO gauge...
  • Page 72 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Monitor This monitor (2) informs the operator that the swing lock is being actuated. Actuated: Lights up When the swing lock switch is turned ON (ACTUATED), the monitor lamp lights up. This lamp lights up when the swing parking brake release switch is set to the FREE position.
  • Page 73 OPERATION DETAILED CONTROLS AND GAUGES Working Mode Monitor This monitor (5) displays the setting of the working mode. The monitor display is as follows according to the operation of the working mode switch. P: P mode (for heavy-load operations) E: E mode (for operations with emphasis on fuel consumption) L: L mode (for fine control operations) B: B mode (for breaker operations) ATT: ATT mode (for crusher operations)
  • Page 74 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Monitor This monitor (8) displays the working status of the air conditioner. Monitor lighted up: Air conditioner ON Monitor off: Air conditioner OFF Idle Stop Guidance If the levers are not operated for more than five minutes, and the engine is idling, the idling stop message is displayed on the monitor.
  • Page 75 OPERATION DETAILED CONTROLS AND GAUGES Gauges and Meter Engine Coolant Temperature Gauge This meter (10) shows the engine coolant temperature. During normal operations, the indicator should be in the green range. If the indicator goes beyond red range (A) during operations, the overheat prevention system is actuated.
  • Page 76 OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Gauge This meter (11) shows the hydraulic oil temperature. During normal operations, the indicator should be in the green range. If the indicator enters the red range (A) during operations, the hydraulic oil temperature is 102°C (215.6°F) or more. Run the engine at low idling or stop it and wait for the hydraulic oil temperature to go down.
  • Page 77 OPERATION DETAILED CONTROLS AND GAUGES Service Meter, Clock This meter (13) shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even if the machine is not moving. The service meter advances 1 for every hour that the machine is working, regardless of the engine speed.
  • Page 78 OPERATION DETAILED CONTROLS AND GAUGES ECO Gauge This gauge (14) shows the working load status. When the gauge is in green range A, the work load is light to medium. When the gauge is in orange range B), the load is heavy. When the gauge enters the orange range, there is no abnormality on the machine, but to protect the environment, reduce the engine output to a point where there is no adverse...
  • Page 79 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion Working mode selector switch Window washer switch Auto-deceleration switch Buzzer cancel switch Travel speed selector switch Function switches Wiper switch Air conditioner switch Working Mode Selector Switch Use this switch (1) to set the movement or power of the work equipment.
  • Page 80 If you press F5 (No), the system starts up in E mode. If you want to have automatic setting of the P, E, L, B or ATT mode when starting (optional default setting), please ask your Komatsu distributor to change the setting. 3 - 27...
  • Page 81 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES Procedure for operation 1. If working mode selector switch (1) is pressed, the Working Mode screen is displayed on the monitor. 2. Press function switches F3 or F4 at the bottom of the screen or working mode selector switch (1) to change the mode selection one at a time.
  • Page 82 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES REMARK When setting the working mode to B mode, to ensure safety, the buzzer sounds and at the same time, the message in the illustration on the right is displayed. When setting to the breaker mode, always press function switch F6.
  • Page 83 OPERATION DETAILED CONTROLS AND GAUGES Auto-deceleration Switch If the control levers are at neutral, this switch (2) automatically lowers the engine speed and turns on the function to reduce fuel consumption. Auto-deceleration monitor ON: Auto-acceleration ON Auto-deceleration monitor OFF: Auto-acceleration OFF Each time the switch is pressed, the auto-deceleration is switched between actuated and canceled.
  • Page 84 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch WARNING When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (3) at the Lo position). Never operate travel speed selector switch (3) while loading or unloading. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
  • Page 85 OPERATION DETAILED CONTROLS AND GAUGES Wiper Switch This switch (4) actuates the front window wiper. Each time the switch is pressed, it changes ON → INT → stop (OFF). Wiper monitor INT lighted up: Wiper operates intermittently Wiper monitor ON lighted up: Wiper operates continuously Wiper monitor OFF: Wiper stops REMARK Each time wiper switch (4) is pressed, the mode is displayed in the...
  • Page 86 OPERATION DETAILED CONTROLS AND GAUGES Window Washer Switch This switch (5) is kept continuously pressed, window washer fluid is sprayed out on the front glass. When the switch is released, the spray stops. If switch (5) is kept pressed when the wiper is stopped, the window washer fluid will spray, and at the same time, the wiper will be actuated continuously.
  • Page 87 OPERATION DETAILED CONTROLS AND GAUGES Function Switches Function switches (7) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen. When the monitor display shows the standard screen, the functions are displayed as follows. F3: Camera screen selector switch (if equipped) F4: Service meter/time display selector switch F5: Maintenance mode switch...
  • Page 88 F3 is not displayed. Even if switch F3 is pressed, the screen will not switch to the camera screen display. A maximum of three cameras can be installed. If you want to install a camera, please consult your Komatsu distributor. 3 - 35...
  • Page 89 OPERATION DETAILED CONTROLS AND GAUGES Operations on Camera 1 Image Display Screen The following explanation describes the method of operation when it is desired to display only one camera screen on the monitor. On the standard screen, if switch F3 is pressed, the image display screen is displayed.
  • Page 90 OPERATION DETAILED CONTROLS AND GAUGES Operation of Image Display Screen When Two Camera Screens are Shown Simultaneously. The following explanation describes the method of operation when it is desired to display two camera screens at the same time on the monitor. On the No.
  • Page 91 OPERATION DETAILED CONTROLS AND GAUGES Other Mode Operations When Displaying Camera Image Even during the camera display, it is possible to operate other modes. The air conditioner can be operated. If the air conditioner switch is operated, the screen switches to the air conditioner control screen.
  • Page 92 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES Press the travel speed selector switch to change the travel speed mode. For details of the travel speed selector switch, see "Travel Speed Selector Switch (PAGE 3-31)". When the travel speed mode is changed, the screen returns to the standard screen.
  • Page 93 OPERATION DETAILED CONTROLS AND GAUGES Action When Warning is Generated When Displaying Camera Image If an error or alarm occurs while the camera image is being displayed, the error monitor or alarm monitor is displayed at the top left of the screen and flashes. If the error monitor or alarm monitor is displayed, press switch F6, return to the standard screen, and check the content of the error or alarm display.
  • Page 94 OPERATION DETAILED CONTROLS AND GAUGES Service Meter/Clock Display Selector Switch On the standard screen, it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor display. When the time is being displayed, press switch F4 to switch to the service meter display.
  • Page 95 OPERATION DETAILED CONTROLS AND GAUGES Maintenance Selector Switch When switch F5 is pressed on the standard screen, the monitor display screen switches to the maintenance mode screen. The items on the maintenance display are as follows. Engine oil change Engine oil filter change Fuel main filter change 1000 Fuel pre-filter change...
  • Page 96 If the time remaining until maintenance becomes 0 hours, the remaining time display is highlighted in red. If you want to change the setting for the maintenance interval, please consult your Komatsu distributor. 3 - 43...
  • Page 97 OPERATION DETAILED CONTROLS AND GAUGES Operations on Maintenance Interval Reset Screen On the maintenance list screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the maintenance time reset screen. Reset the remaining time on this screen. 1.
  • Page 98 OPERATION DETAILED CONTROLS AND GAUGES User Mode Selector Switch When the switch F6 is pressed, the monitor display screen switches to the setting mode screen for the machine. On the User Menu screen, it is possible to carry out the following operations with switches F3 to F6.
  • Page 99 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES F5: Returns to standard screen. F6: Switches to setting screen for selected item. If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the previous screen. The following items can be set.
  • Page 100 OPERATION DETAILED CONTROLS AND GAUGES Breaker/Attachment Setting On machines ready for attachment, it is possible on the breaker/attachment setting menu to adjust the oil flow in B mode and ATT mode to match the attachment. For machines that have no attachment, the breaker/attachment setting mode is not displayed.
  • Page 101 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. On the working mode selection screen shown on the right, select B Breaker and press switch F6. On the working mode selection screen shown on the right, it is possible to carry out the following operations with switches F3 to F6.
  • Page 102 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES On the Breaker Select Menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen.
  • Page 103 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2. On the Breaker Select screen, select one of the two set values for the oil flow, then press switch F6. The default values for the flow setting are both set to 180 liter/min, as shown in the illustration on the right.
  • Page 104 OPERATION DETAILED CONTROLS AND GAUGES Changing breaker flow setting 1. Select breaker flow setting (b) on the Breaker Select Menu screen, then press switch F6. 2. On the Breaker Oil Flow Setting screen, select one of the two set values for the oil flow, then press switch F6. The default values for the oil flow setting are both set to 180 liter/min, as shown in the illustration on the right.
  • Page 105 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES On the Breaker Select Menu and Breaker Oil Flow Setting screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up).
  • Page 106 OPERATION DETAILED CONTROLS AND GAUGES Changing Attachment Mode Setting 1. On the standard screen, press switch F6. 2. Select Breaker/Attachment Settings on the user menu, then press switch F6. 3 - 53...
  • Page 107 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. On the working mode selection screen shown on the right, select ATT 2-Way Attachment, then press switch F6. On the working mode selection screen shown on the right, it is possible to carry out the following operations with switches F3 to F6.
  • Page 108 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES On the 2-Way Attachment Select Menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up). F5: Returns to previous screen.
  • Page 109 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2. On the 2-Way Attachment Select Menu, select one of the two set values for the oil flow, then press switch F6. The default values for the oil flow setting are both set to 430 liters/min, as shown in the illustration on the right.
  • Page 110 OPERATION DETAILED CONTROLS AND GAUGES Changing attachment flow setting 1. Select 2-Way Attachment Oil Flow Setting (b) on the 2-Way Attachment Select menu screen, then press switch F6. 2. On the 2-Way Attachment Select Oil Flow Setting screen, select one of the two set values for the oil flow, then press switch F6.
  • Page 111 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES On the 2-Way Attachment Select Menu screen and 2-Way Attachment Select Menu screen, it is possible to carry out the following operations with switches F3 - F6. F3: Moves to next item (1 line down). F4: Moves to previous item (1 line up).
  • Page 112 DETAILED CONTROLS AND GAUGES Message Display (Machines equipped with KOMTRAX) On machines equipped with KOMTRAX, it is possible to see the messages from your Komatsu distributor on this message display menu. REMARK At present, there is no territory where it is possible to the use the message service.
  • Page 113 OPERATION DETAILED CONTROLS AND GAUGES Adjusting Screen Use this screen adjustment menu to adjust the brightness, contrast, and back light of the screen. 1. On the standard screen, press switch F6. 2. Select screen adjustment on the user menu, then press switch F6.
  • Page 114 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Select item to be adjusted (a) or (b) from the selection menu screen for screen adjustment, then press switch F6. The screen switches to the setting screen for the selected item. (a): Standard screen adjustment (b): Camera screen adjustment (only machines equipped with camera)
  • Page 115 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES On the screen for Items 1) and 2), it is possible to carry out the following operations with switches F2 to F6. F2: Resets all adjusted values to default value F3: Indicator of selected item moves 1 segment to left.
  • Page 116 OPERATION DETAILED CONTROLS AND GAUGES Clock Adjustment On this clock adjustment menu, it is possible to change the setting of the clock displayed on the pilot monitor of the standard display. 1. On the standard screen, press switch F6. 3 - 63...
  • Page 117 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2. Select "Clock Adjustment" on the user menu, then press switch F6. The screen switches to the time adjustment selection menu screen. The following three items can be changed. (a) Clock setting (b) 12/24 hour display mode (c) Daylight saving time 3 - 64...
  • Page 118 OPERATION DETAILED CONTROLS AND GAUGES 3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches F3 to F6. Time Adjust the hour setting. 1) If "Time" (a) is not highlighted in yellow, press switch F6 to highlight "Time"...
  • Page 119 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2) When minute display (c) is highlighted in orange, operate the switches as follows to adjust minute display (c). If it is not necessary to change the minute setting, press switch F6.
  • Page 120 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES Daylight Saving Time (Summer time) 1) If daylight saving time is turned ON (a), the clock display becomes 1 hour earlier. If daylight saving time is turned OFF (b), the clock display returns to the set time. The selected display mode is highlighted in green.
  • Page 121 OPERATION DETAILED CONTROLS AND GAUGES Language Selection On this language selection menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. Japanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish 1.
  • Page 122 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Select the language to use for the display, then press switch F6. The screen display changes to the selected language. On the language selection screen, it is possible to carry out the following operations with switches F3 to F6.
  • Page 123 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 2. Select "Economy Mode Adjustment" on the user menu, then press switch F6. The screen switches to the economy mode adjustment selection menu screen. 3. Select the desired E mode from the economy mode adjustment selection menu.

  • Page 124: Switches

    OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch One-touch power max. switch Fuel control dial Room lamp switch Cigarette lighter Emergency pump drive switch Swing lock switch (10) Swing parking brake releasel switch Lamp switch (11) Revolving warning lamp switch (if equipped) Horn switch (12) Large capacity airflow air conditioner blower...
  • Page 125 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial Dial (2) adjusts the engine speed and output. (a)Low idling (MIN): Turned fully to the left (b)Full speed (MAX): Turned fully to the right Cigarette Lighter This switch (3) is used when lighting cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, so pull it out to use it.
  • Page 126 OPERATION DETAILED CONTROLS AND GAUGES Lamp Switch This switch (5) is used to light up the working lamp and monitor lighting. (a) Night position: Lamps light up and monitor illumination is set to night mode (b) Day position: Lamps light up and monitor illumination is set to day mode (c) OFF position: Lamps go out.
  • Page 127 OPERATION DETAILED CONTROLS AND GAUGES Emergency Pump Drive Switch NOTICE This switch is provided to enable you to carry out operation temporarily, when any problem occurs on the pump control system. Do not use it except in emergency. Furthermore, remove the cause of the problem immediately. If this switch is depressed and moved to the EMERGENCY position by mistake, thereby engaging the machine in the work, while the machine is in normal condition, an "E02"...
  • Page 128 OPERATION DETAILED CONTROLS AND GAUGES Large Capacity Airflow Air Conditioner Blower Switch (If equipped) When this switch (12) is pressed, the additional blower motor is actuated and the air flow from the air conditioner vents increases. (a) ON: Large-capacity air conditioner blower is actuated (b) OFF: Large-capacity air conditioner blower is stopped 3 - 75...

  • Page 129: Control Levers And Pedals

    OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Left work equipment control lever Travel levers (with auto-deceleration system) (with pedal and auto-deceleration system) Right work equipment control lever (with auto-deceleration system) Lock Lever WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position. If the lock lever is not at the LOCK position and the control levers or control pedals are touched by mistake, it may lead to serious personal injury.
  • Page 130 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers WARNING Do not rest your foot on the pedal during operations. If the pedal is depressed by mistake, the machine may suddenly move and cause a serious accident. Be extremely careful when operating the pedal for travel or steering operations. When you are not using the pedal, do not rest your foot on it.
  • Page 131 OPERATION DETAILED CONTROLS AND GAUGES Work Equipment Control Lever Left work equipment control lever (3) is used to operate the arm and upper structure. Arm operation (a) Arm OUT (b) Arm IN Swing operation (c) Swing to right (d) Swing to left N (Neutral) : The upper structure and arm are held in position and do not move.

  • Page 132: Sun Roof

    OPERATION DETAILED CONTROLS AND GAUGES SUN ROOF WARNING When leaving the operator's seat, set the lock lever securely to the LOCK position. If the lock lever is at the FREE position and the control levers or control pedals is touched by mistake, this may lead to a serious accident.
  • Page 133 OPERATION DETAILED CONTROLS AND GAUGES Opening 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2. Set the lock lever (1) securely to the LOCK position (L). 3. Check that the wiper blade is stowed in the right stay. 4.
  • Page 134 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. Hold lower knob (C) with your left hand from inside the operator's cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
  • Page 135 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 136 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 5. When the bottom of the window reaches the top of the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock. 6.
  • Page 137 OPERATION DETAILED CONTROLS AND GAUGES Removing Lower Windshield 1. Open the front window, then hold grip (1), pull up, and remove the bottom window. If sand or dust is collected at the bottom of the front window, it will be difficult to remove the window. In addition, when stowing, the sand and dust stuck to the glass will be carried inside the cab.

  • Page 138: Emergency Escape Hammer

    OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY ESCAPE HAMMER 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 139: Cap With Lock

    OPERATION DETAILED CONTROLS AND GAUGES CAP WITH LOCK Use the starting switch key to open and close the locks on the caps and covers. For details of the locations of the caps and covers with locks, see "LOCKING (PAGE 3-169)". Insert the key as far as it will go to the shoulder (A).
  • Page 140 OPERATION DETAILED CONTROLS AND GAUGES Opening and Closing Cover with Lock Opening the Cover (Locked Cover) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. (A): Open (B): Lock Locking the Cover 1.

  • Page 141: Drink Box

    OPERATION DETAILED CONTROLS AND GAUGES DRINK BOX This is on the right side at the rear of the operator's seat. It keeps drinks and other things hot or cold. Hot or cold air blows into the box according to the setting of the air conditioner.

  • Page 142: Air Conditioner Controls

    OPERATION DETAILED CONTROLS AND GAUGES AIR CONDITIONER CONTROLS Air Conditioner Control Panel OFF switch FRESH/RECIRC selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Sunlight sensor Auto switch OFF Switch Switch (1) is used to stop the fan and air conditioner. REMARK Even if this switch (1) is pressed, the monitor screen does not switch to the air conditioner adjustment screen.
  • Page 143 OPERATION DETAILED CONTROLS AND GAUGES Fan Switch Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the E switch to increase the air flow; press the R switc h to decrease the air flow. During auto operation, the air flow is automatically adjusted.
  • Page 144 OPERATION DETAILED CONTROLS AND GAUGES Vent Selector Switch Switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. During automatic operation, the vents are automatically selected.
  • Page 145 OPERATION DETAILED CONTROLS AND GAUGES Auto Switch With switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under automatic control.
  • Page 146 OPERATION DETAILED CONTROLS AND GAUGES Air Conditioner Switch Switch (8) is used to turn the air conditioner (cooling, dehumidifying, heating) ON or OFF. Press air conditioner switch (8) when the fan is operating (when display (b) is shown on the display monitor). The air conditioner is switched ON and starts to work.
  • Page 147 OPERATION DETAILED CONTROLS AND GAUGES Method of Operation The air conditioner can be operated automatically or manually. Select the method of operation as desired. Automatic Operation 1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed.
  • Page 148 OPERATION DETAILED CONTROLS AND GAUGES Stopping Automatic Operation Press OFF switch (1). Operation stops. Manual Operation 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7).
  • Page 149 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Press temperature setting switch (3) and adjust temperature inside the cab. 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
  • Page 150 OPERATION DETAILED CONTROLS AND GAUGES Stopping Manual Operation Press OFF switch (1). Operation stops. Operation with Cold Air to Face and Warm Air to Feet To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. 1.
  • Page 151 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Turn air conditioner switch (8) ON. 4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired positions. 3 - 98...
  • Page 152 OPERATION DETAILED CONTROLS AND GAUGES Defroster Operation 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7). 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the right.
  • Page 153 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air. 4. Press temperature setting switch (3) and set temperature on the display (7) monitor to maximum heating. 5.
  • Page 154 If any abnormality is detected in any equipment or sensor used on the air conditioner, "A/C Controller Error" is displayed on the air conditioner monitor screen. If "A/C Controller Error" is displayed, please ask your Komatsu distributor to carry out inspection and repair. 3 - 101...

  • Page 155: Radio

    OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel Power switch, Volume control knob, Balance AS/PS button control knob Preset station buttons (1,2,3,4,5,6) SEL button Display FM/AM selection button Time reset button Display selection button Tuning button Power switch, Volume control knob, Balance control knob Press this knob (1) to turn the power for the radio on.
  • Page 156 OPERATION DETAILED CONTROLS AND GAUGES Display Selection Button (TIME) On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4) and the display will show the present time for 5 seconds. After 5 seconds pass, the display returns automatically to the frequency display.
  • Page 157 OPERATION DETAILED CONTROLS AND GAUGES Controls of Radio Method of Setting with Preset Button 1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. 3.
  • Page 158 OPERATION DETAILED CONTROLS AND GAUGES Method of Operating Mode (BAS) Bass adjustment: When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned counterclockwise, the bass sound is reduced.
  • Page 159 OPERATION DETAILED CONTROLS AND GAUGES Antenna Before transporting the machine putting it inside a building, stored the antenna to prevent any interference. Stow the antenna as follows. 1. Loosen antenna mounting bolt (1) and store the antenna at position (A). 2.

  • Page 160: Auxiliary Electric Power

    OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 24V Power Source NOTICE Do not use this as the power supply for 12V equipment. It will cause failure of the equipment. Pull out the connector plug for taking out electric power from the rear side of the panel.

  • Page 161: Fuse

    OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuse holder is at the rear right of the operator's seat. The fuses protect the electrical equipment and wiring from burning out.

  • Page 162: Fusible Link

    Do not let water, mud, or juice spill on the controller. This will cause failures. If any problem occurs in the controller, do not repair it by yourself. Please contact your Komatsu distributor for repairs. TOOL BOX Store the tools in this box.

  • Page 163: Fire Extinguisher

    OPERATION DETAILED CONTROLS AND GAUGES FIRE EXTINGUISHER (If equipped) A fire extinguisher is prepared at the rear part inside the operator's cab. The directions are described on the nameplate affixed to it. Just in case, carefully read and grasp them beforehand. 3 - 110...

  • Page 164: Machine Operations And Controls

    Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor.
  • Page 165 Check for damage or wear to the seat belt and mounting clamps. If there is any damage, replace with new parts. 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.
  • Page 166 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Drain Water And Sediment from Fuel Tank 1. Open the door at the right of the machine. 2. Set a container under drain hose (1) to catch the drained fuel. 3.
  • Page 167 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK If transparent cap (2) is dirty or it is difficult to see the inside, clean transparent cap (2) when replacing fuel pre-filter cartridge (1). When the drain valve (4) has been removed during the cleaning operation, coat the O-ring with grease and tighten until it contacts the bottom.
  • Page 168 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 169 OPERATION MACHINE OPERATIONS AND CONTROLS 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. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns.
  • Page 170 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
  • Page 171 Check Electric Wiring CAUTION If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
  • Page 172 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 173 Check that the working lamps and lamps inside the instruments light up properly. Check also that there is no dirt or damage. If any lamp does not light up, the bulb is probably blown up or there is a disconnection, so ask your Komatsu distributor to carry out repairs.
  • Page 174 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Seat Adjustment WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's back against the backrest.
  • Page 175 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS (D) Adjusting armrest height The height of armrest (5) can be adjusted up or down by changing the position of adjustment bolt (6) at the rear of the armrest. Armrest height adjustment: 33 mm (1.3 in) (E) Overall fore-and-aft adjustment of seat Move lever (7) to right, set to the desired position, then release the lever.
  • Page 176 OPERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Mirror (A) Adjust the mirror mount so that it is possible to see people at the rear left of the machine.
  • Page 177 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Mirror (B) Adjust the mirror mount so that it is possible to see people at the rear right of the machine. Install the side view mirror in the location indicated in the figure at right.
  • Page 178 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace the seat belt. Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt.
  • Page 179 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When starting the engine, check that the lock lever is securely at the LOCK position. If the lock lever is not locked securely and the control levers or control pedal are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
  • Page 180 If any monitor does not light up or the buzzer does not sound, there is probably a failure in the monitor, so please contact your Komatsu distributor for repairs. 2) After approx. 2 seconds, the screen will change to the working mode/travel speed display monitor.

  • Page 181: Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
  • Page 182 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to ON position (B). If the ambient temperature is low, the preheating monitor lights up and automatic preheating is carried out. Keep the key in starting switch (3) at the ON position until the preheating monitor goes out.
  • Page 183 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK Regardless of the ambient temperature, it is possible to start the engine preheating manually. 1. Turn the key in starting switch (3) to the left from OFF position (A). The preheating monitor lights up and engine preheating starts.

  • Page 184: After Starting Engine

    In that case, ask your Komatsu distributor to check the engine as soon as possible.
  • Page 185 OPERATION MACHINE OPERATIONS AND CONTROLS Engine Warm Up NOTICE Do not accelerate the engine suddenly until the warm-up operation has been completed. Do not run the engine at low idling or high idling under no load for more than 20 minutes. This will have an adverse effect on the environment, and will also have an adverse effect on the internal structure of the engine.
  • Page 186 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white If the engine coolant temperature monitor displays the correct temperature, the engine warm-up operation is completed.
  • Page 187 OPERATION MACHINE OPERATIONS AND CONTROLS Hydraulic Equipment Warm Up WARNING Before carrying out the warm-up operation for the hydraulic equipment, turn the swing lock switch ON, check on the monitor that the swing lock monitor lights up to show that the swing lock is actuated, then start the warm-up operation.
  • Page 188 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. Turn swing lock switch (2) ON and check that the swing lock monitor lights up. 3. To complete the warm-up operation of the hydraulic equipment more quickly, set the working mode to P mode (heavy-duty mode).
  • Page 189 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS NOTICE When the work equipment is retracted, take care that it does not interfere with the machine body or ground. 6. Move right work equipment control lever (5) slowly in the direction to pull in the bucket (D).
  • Page 190 Fuel level monitor (18): Displays appropriate level 14. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. In cold temperatures (ambient temperature below 0 °C (32 °F)), even when the hydraulic oil temperature monitor displays the correct temperature, carry out additional Step 15 to warm up all the hydraulic equipment.
  • Page 191 OPERATION MACHINE OPERATIONS AND CONTROLS For both normal temperatures and cold temperatures, carry out the following operation. 16. Check that fuel control dial (4) is at a point midway between low idling (MIN) and full speed (MAX). If it is not at the midway position, set it to the midway position and run the engine at a mid-range speed before operating.
  • Page 192 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS For attachment operations (if equipped), change the working mode to the attachment mode. One way (A) ←→ Other way (B) Attachment operation 18. Check that hydraulic oil temperature monitor (7) is displaying the correct temperature.
  • Page 193 OPERATION MACHINE OPERATIONS AND CONTROLS Operation After Completion Of Warm-Up Operation 1. Check that hydraulic oil temperature monitor (7) displays the correct temperature. (A) Display when temperature is correct: Monitor background (C) is blue (B) Display when temperature is low: Monitor background (C) is white 2.
  • Page 194 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3) L mode For operations requiring fine control 4) B mode For breaker operations 5) ATT mode For operations with crusher or other double-acting action attachment 3 - 141...

  • Page 195: 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 196: Machine Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction from the operation of the travel levers or travel pedals (front and rear travel is reversed, left and right steering is reversed).
  • Page 197 Start the machine either by pulling lever (5) back slowly or by stepping on the rear part of pedal (6) slowly. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
  • Page 198 Slowly push the levers (5) forward, or slowly depress the front part of the pedals (6) to move the machine backward. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, please contact your Komatsu distributor for repair.
  • Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. 1. Put the left and right travel levers (1) in the neutral position, then stop the machine. 3 - 146...

  • Page 200: Steering The Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the direction of operation of the travel levers or control pedals is the opposite from the direction of movement of the machine.
  • Page 201 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 202: Swinging

    OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully.

  • Page 203: Work Equipment Controls And Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly rise, operate the levers carefully. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
  • Page 204 OPERATION MACHINE OPERATIONS AND CONTROLS If the work equipment control levers are returned to the neutral position when the machine is stopped, even if the fuel control dial is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a mid-range speed.

  • Page 205: Working Mode

    OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode Use working mode selector switch (1) to select the working mode that matches the operating conditions or purpose. This will make it possible to carry out operations efficiently. Use the following procedure to select the most efficient working mode. When the starting switch is turned ON, the working mode is set to the mode that was in operation when the starting switch was last turned OFF.
  • Page 206 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. Press switches F3 or F4 at the bottom of the screen or the working mode selector switch to select the appropriate mode. 3. After selecting the desired mode, press switch F6 to accept the change.

  • Page 207: Prohibited Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate the control lever. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating.
  • Page 208 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as s pickaxe, breaker, or pile driver. This will drastically reduce the life of the machine. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging.

  • Page 209: 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 210 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth NOTICE When driving the machine out of water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, and water will be thrown up by the cooling fan. This may cause the fan to break. Be extremely careful when driving the machine out of water.

  • Page 211: 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 212 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground, and travel at low speed.

  • Page 213: Escape From Mud

    OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out. 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 214: Recommended Applications

    OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine.
  • Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS Loading Work In places where the swing angle is narrow, work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator. Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.

  • Page 216: Bucket Replacement And Inversion

    OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT AND INVERSION 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 217 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket, for arm pin portion (A), fit O-ring (3) to bucket (4) in the position shown in the diagram on the right. After inserting the pin, fit it in the standard groove. For link pin portion (B), install the bucket with O-ring (3) fitted in the standard groove.
  • Page 218 OPERATION MACHINE OPERATIONS AND CONTROLS Inversion 1. Place the bucket in contact with a flat surface. REMARK When removing the pins, place the bucket so that it is in light contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.
  • Page 219 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS REMARK When reversing, do not install an O-ring. Keep the O-ring in a safe place until using it next. 5. Install the stopper bolts and nuts for each pin, then grease the pin.

  • Page 220: Parking Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes.

  • Page 221: Machine Inspection After Daily Work

    OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Set lock lever (3) in the LOCK position (L). 5. Check the engine cooling water temperature and engine oil pressure with the machine monitor.

  • Page 222: Locking

    OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Operator's cab door Always close the window. (2) Fuel tank filler port (3) Engine hood (4) Battery box cover (5) Left side door of the machine (6) Right side door of the machine (7) Hydraulic tank filler port (8) Air conditioner FRESH filter intake port REMARK...

  • Page 223: Transportation

    Note that the weight and dimensions given in SPECIFICATIONS may differ according to the type of shoe or arm, or other attachments. Please consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard installed for the operator's cab.

  • Page 224: Loading And Unloading With Trailer

    OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING Always obey the following when loading or unloading the machine from a trailer. Select firm, level ground when loading or unloading the machine. Maintain a safe distance from the edge of the road. Always turn the auto-deceleration switch OFF (cancel).
  • Page 225 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer.
  • Page 226 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 6. If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it; if it has no work equipment, travel in reverse to load it. Follow instructions and signals of a conductor particularly when traveling in reverse.
  • Page 227 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 10. When the machine travels over the rear wheels of the trailer, it becomes unstable, drive slowly and carefully. (Never operate the steering.) 11. At the moment the machine passes the rear wheels, it tilts forward, be careful not to let the work equipment hit the trailer body.
  • Page 228 OPERATION TRANSPORTATION Securing Machine NOTICE Stow the radio antenna. Reassemble the mirrors so that they are within the width of the machine. To prevent damage to the bucket cylinder during transportation, put a wooden block under the tip of the bucket link to prevent the bucket cylinder from touching the floor.
  • Page 229 OPERATION TRANSPORTATION Stowing Radio Antenna Loosen bolt (2) of radio antenna (1) at the rear of the cab, lower the antenna, then tighten bolt (2) again to secure radio antenna (1) in position. When unloading the machine from the trailer and operating it, follow the opposite procedure from stowing to set radio antenna (1) vertical, then secure it in position with bolt (2).
  • Page 230 OPERATION TRANSPORTATION Removal Mirrors (A), (B) 1. Loosen mounting bolt (2), then remove mirror (1) from support (3). 2. Loosen bolt (4) and remove support (3) and clamp (5) from the handrail. Mirrors (C), (D) 3. Loosen locknut (2), then remove mirror (1) from bracket (3). 4.
  • Page 231 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer.
  • Page 232 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 8. Raise the work equipment, pull in the arm under the boom, then move the machine slowly. 9. When the machine is horizontal on top of the rear wheels of the trailer, stop the machine. NOTICE When unloading the machine, always keep the arm and boom at an angle of 90°...

  • Page 233: Lifting Machine

    This method of lifting applies to the standard specification machine. The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For weight, see "SPECIFICATIONS (PAGE 5-2)".
  • Page 234 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. However, for machines equipped with a full roller guard for the track roller, pass the wire rope under the track.
  • Page 235 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 6. As shown in the diagram on the right, select the wire rope so that lifting point (A) is directly above the center of gravity (B) (a point 490 mm (19.3 in) to the rear of the swing center). (A): Lifting point (B): Center of gravity (C): Swing center...

  • Page 236: Cold Weather Operation

    When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
  • Page 237 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 238: 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 239: Long Term Storage

    OPERATION LONG TERM STORAGE LONG TERM STORAGE BEFORE STORAGE NOTICE When storing the machine (1 month or more), set the machine in the posture shown in the diagram on the right to protect the cylinder rod. (To prevent rusting of the cylinder rod) When putting the machine in storage for a long time (more than one month), do as follows.

  • Page 240: After Storage

    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. Wipe off the grease from the hydraulic cylinder rods.

  • Page 241: 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. Procedure for Bleeding Air 1.

  • Page 242: Towing The Machine

    OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.

  • Page 243: Lightweight Towing Hole

    OPERATION TROUBLES AND ACTIONS LIGHTWEIGHT TOWING HOLE WARNING The shackle must always be used. Hold the wire rope level and direct it straight to the track frame. Move the machine slowly and be careful not to apply any sudden load to the wire rope. There is a hole in the track frame to fit the shackle when towing light objects.

  • Page 244: 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 245 OPERATION TROUBLES AND ACTIONS Battery Charges When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-191)" and the instruction manual accompanying the charger, and do as follows. Set the voltage of the charger to match the voltage of the battery to be charged.
  • Page 246 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 247 OPERATION TROUBLES AND ACTIONS Booster Cable Connection Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect the clip of booster cable (A) to the positive (+) terminal of battery (C) on the problem machine.

  • Page 248: 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 249 OPERATION TROUBLES AND ACTIONS Chassis ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
  • Page 250 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights...
  • Page 251 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Abnormal noise generated Low-grade fuel being used Change to specified fuel (combustion or mechanical) Overheating Refer to "Radiator coolant level monitor lights up" as above Damage inside muffler ( Replace muffler) Excessive valve clearance ( Adjust valve clearance) 3 - 198...
  • Page 252 REMARK If no point of contact telephone number has been registered, no telephone number is displayed. It is necessary to register the telephone number, please ask your Komatsu distributor to carry out the registration. 3 - 199...
  • Page 253 4 - 1...

  • Page 254: Maintenance

    Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
  • Page 255 MAINTENANCE MAINTENANCE INFORMATION Dusty Jobsite When working at dusty worksites, do as follows: Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. Replace the fuel filter more frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

  • Page 256: 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 257 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. For details, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)".
  • Page 258 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.

  • Page 259: 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 260: 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 261: 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 262 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT ASTM: American Society of Testing and Material Swing Final drive Engine oil Damper Hydraulic Cooling Fuel machinery case case system system tank case (each) Liter 25.4 0.65 20.6 Specified capacity US gal 6.71 2.17 2.38 0.17 64.46...

  • Page 263: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil

    3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%. RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. 4 - 11...

  • Page 264: 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 265: Safety Critical Parts

    Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. 4 - 13...

  • Page 266: Safety Critical Parts List

    MAINTENANCE SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST Safety critical parts for periodic replacement Q'ty Replacement interval Fuel hose (fuel tank - fuel pre-fillter) Fuel hose (fuel pre-fillter - supply pump) Fuel return hose, cooler (engine - fuel cooler) Fuel return hose (fuel cooler - fuel tank) Fuel hose (supply pump - fuel main fillter) Fuel return tube (injector, supply pump, fuel return merge tube from common rail)

  • Page 267: 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 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) REPLACE FUEL PRE-FILTER CARTRIDGE...
  • Page 268 MAINTENANCE MAINTENANCE SCHEDULE EVERY 1000 HOURS MAINTENANCE REPLACE HYDRAULIC OIL FILTER ELEMENT 4- 66 CHANGE OIL IN SWING MACHINERY CASE 4- 67 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4- 68 REPLACE FUEL MAIN FILTER CARTRIDGE 4- 69 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS 4- 71 REPLACE CORROSION RESISTOR CARTRIDGE 4- 71...

  • Page 269: 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 270: Maintenance Procedure

    MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Carry out the following maintenance only after the first 250 hours of operation on new machines. REPLACE FUEL PRE-FILTER CARTRIDGE For details of the method of maintaining, see EVERY 500 HOURS MAINTENANCE. INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) Carry out the following maintenance only after the first 500 hours of operation on new machines.

  • Page 271: When Required

    MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
  • Page 272 MAINTENANCE MAINTENANCE PROCEDURE Cleaning Outer Element NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 1. Open the rear door at the left side of the machine, remove 4 hooks (2), then remove cover (3). NOTICE Never remove the inner element (6).
  • Page 273 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 3) Remove one seal from the element whenever the element has been cleaned. 8. 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.
  • Page 274 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling.
  • Page 275 MAINTENANCE MAINTENANCE PROCEDURE Replacing Element 1. Open the rear door at the left side of the machine, remove 4 hooks (2), then remove cover (3). 2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out.
  • Page 276 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE NOTICE Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element cylinder (face where no hole is drilled) (B), (C) is at cover (3) end. If the direction of installation is mistaken, there is danger that it will cause breakage of the air cleaner element or serious damage to the engine.
  • Page 277 Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. When no corrosion resistor is used, use the special cover (600-411-9000). Please consult your Komatsu distributor about the method of installing.
  • Page 278 When changing the coolant or draining the coolant from the radiator before carrying out repairs, ask a specialist company to handle any coolant containing antifreeze, or contact your Komatsu distributor. Antifreeze is toxic, so never pour it into drainage water ditches or drain it onto the ground surface.
  • Page 279 MAINTENANCE MAINTENANCE PROCEDURE 1. Stop the machine on level ground, then stop the engine. 2. Tighten valve (1) of the corrosion resistor (only for machines equipped with a corrosion resistor). 3. Check that the cooling water temperature has gone down enough to make it possible to touch the radiator cap surface by hand, then turn radiator cap (2) slowly until it contacts the stopper to release the pressure.
  • Page 280 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 14. Drain the coolant from sub-tank (4), clean the inside of the sub-tank, then add water until the coolant level is between the FULL and LOW marks. If the sub-tank is extremely dirty and it is difficult to clean, replace it with a new part.
  • Page 281 MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening Triple shoe, swamp shoe, flat shoe, rubber pad shoe 1. First tighten to a tightening torque of 490 ± 49 Nm (50 ± 5 kgm, 360 ± 36 lbft) then check that the nut and shoe are in close contact with the link contact surface.
  • Page 282 Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. Increasing Track Tension Prepare a grease pump.
  • Page 283 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 284 MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the bucket teeth before the adapter starts to wear. 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, then stop the engine and set the lock lever securely to the LOCK position. The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.
  • Page 285 MAINTENANCE MAINTENANCE PROCEDURE If lock pin (2) and rubber pin lock (3) are used in the condition below, it will cause tooth (1) to come off during operation. Always replace them with new parts. The lock pin (2) is too short. Dimension (B) is 1/3 or more of dimension (A) when locking pin (2) is aligned with bottom face (C).
  • Page 286 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 8. Fit tooth (1) to adapter (4), and confirm that when the pointer is pressed strongly, the rear face of the hole for the pin of the teeth (1) is at the same level as the rear face of the hole for the pin of the adapter (4).
  • Page 287 3. Place a bar on the head of pin (1), hit the bar with a hammer to knock out the pin, then remove tooth (2). REMARK If the bucket teeth cannot be safely removed by this mothod, have your Komatsu distributor replace the bucket teeth. 4 - 35...
  • Page 288 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket. 4 - 36...
  • Page 289 MAINTENANCE MAINTENANCE PROCEDURE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance. Set the work equipment in a stable condition, stop the engine, then set safety lock lever securely to the LOCK position (L). 1.
  • Page 290 MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding.
  • Page 291 (C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
  • Page 292 MAINTENANCE MAINTENANCE PROCEDURE WASH WASHABLE FLOOR WARNING When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation. If the control levers are touched by mistake, the machine may suddenly move, and this may lead to a serious accident. Always set the lock lever securely to the LOCK position before standing up from the operator's seat.
  • Page 293 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 3. Lower the work equipment to the ground and set the machine in a stable condition. 4. Set lock lever (1) to LOCK position (L) and stop the engine. 5. Remove the floor mat holder plate (4). 6.
  • Page 294 MAINTENANCE MAINTENANCE PROCEDURE Method of Setting Machine at Angle Method Using Slope WARNING Select a solid and smooth slope. Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground. 1. Stop the machine so that the work equipment is on the downhill side.
  • Page 295 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 296 MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-128)". If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see the OPERATION section. 1. Bleeding air from pump 1) Loosen air bleeder (1) and check that oil oozes out from the air bleeder.
  • Page 297 NOTICE If the air is not bled from the swing motor, the motor bearings may be damaged. When replacing the travel motor safety valve, please contact your Komatsu distributor to have it replaced and to have the air bled. 5. Bleeding air from travel motor (Bleed the air only when the oil inside the travel motor case has been drained.)

  • Page 298: Check Before Starting

    MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "Checks Before Starting (PAGE 3-113)" in the OPERATION section. Drain water and sediment from fuel tank Check for water and sediment in water separator, drain water Check oil level in hydraulic tank, add oil Check coolant level, add coolant Check oil level in engine oil pan, add oil Check electric wiring...

  • Page 299: Every 100 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE LUBRICATING NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval. Carry out greasing every 10 hours for the first 50 hours on a new machine. After the machine was subjected to jobs in the water, be sure to grease the wet pins.
  • Page 300 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE (8) Arm - Link coupling pin (1 place) (9) Arm-Bucket coupling pin (1 place) (10) Link coupling pin (2 places) (11) Bucket cylinder rod pin (1 place) (12) Bucket-Link coupling pin (1 place) 4 - 48...

  • Page 301: Every 250 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery.
  • Page 302 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 303 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. In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones. • The fan belt has elongated, leaving little allowance for adjustment.

  • Page 304: Every 500 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 100 and 250 hours should be carried out at the same time. LUBRICATE SWING CIRCLE 1. Lower the work equipment to the ground. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
  • Page 305 MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity of oil pan: 23.1 liters (6.10 US gal) Prepare a filter wrench 1.
  • Page 306 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. After replacing the filter cartridge, open the engine hood and add engine oil through oil filler (F) to between the H and L marks on dipstick (G). 7. Run the engine at idle for a short time, then stop the engine, and check that the oil level is between the H and L marks on the dipstick.
  • Page 307 The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 308 MAINTENANCE MAINTENANCE PROCEDURE 10. Clean the filter holder, fill the new filter cartridge with clean fuel, coat the packing surface thinly with oil, then install to the filter holder. NOTICE When adding fuel, do not remove cap (B). Always add fuel from the 8 small holes (A) on the dirty side.
  • Page 309 3. Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Please contact your Komatsu distributor. Total amount of grease: 33 liters (8.72 US gal) 4. Install cover (2) with bolts (1).
  • Page 310 MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner) WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury.
  • Page 311 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. Remove undercover (9) and blow the mud, dirt, and leaves that have been cleaned off to the outside. 7. Push in cleaned net (2) back to the original place and secure it with screw (3). 4 - 59...
  • Page 312 MAINTENANCE MAINTENANCE PROCEDURE CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. REMARK If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner unit.
  • Page 313 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE REMARK The FRESH filter must be installed facing in the correct direction. When installing, insert the long (L) end of filter (3) into the filter case first. If the short (S) end is installed first, cover (2) will not close. 4 - 61...
  • Page 314 MAINTENANCE MAINTENANCE PROCEDURE REPLACE BREATHER ELEMENT IN HYDRAULIC TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
  • Page 315 MAINTENANCE MAINTENANCE PROCEDURE REPLACE HYDRAULIC TANK ADDITIONAL BREATHER 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. 1.
  • Page 316 MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
  • Page 317 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 318: Every 1000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Carry out the EVERY 100 HOURS MAINTENANCE, EVERY 250 HOURS MAINTENANCE, and EVERY 500 HOURS MAINTENANCE at the same time. 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.

  • Page 319: Change Oil In Swing Machinery Case

    MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN SWING MACHINERY CASE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. Refill capacity: 8.2 liters (2.17 US gal) 1.

  • Page 320: Check Oil Level In Damper Case, Add Oil

    MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. NOTICE Park the machine on flat ground and stop the engine.

  • Page 321: Replace Fuel Main Filter Cartridge

    The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 322 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE Replace inner seal (3) with a new part. NOTICE Do not fill the new filter cartridge with fuel. Remove cap (B) and install the filter cartridge. 6. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn.

  • Page 323: Check All Tightening Points Of Engine Exhaust Pipe Clamps

    MAINTENANCE MAINTENANCE PROCEDURE CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS Please ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. REPLACE CORROSION RESISTOR CARTRIDGE (Machines equipped with corrosion resistor) WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.

  • Page 324: Every 2000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation 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 325: Clean Hydraulic Tank Strainer

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.

  • Page 326: Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)

    Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
  • Page 327 MAINTENANCE MAINTENANCE PROCEDURE CHECKING FUNCTION OF ACCUMULATOR CAUTION When carrying out the inspection, check first that there is no person or obstacle in the surrounding area. Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm, level ground. 2.
  • Page 328 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 329 MAINTENANCE MAINTENANCE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT 1. Place the work equipment on the ground. Close the crusher attachment jaws, etc. 2. Operate the work equipment lock lever to the LOCK position. 3. Insert the lock pin for the attachment control pedal in position (c) where it is possible to operate the pedal.

  • Page 330: Check Alternator

    Contact your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection carried out every 1000 hours. CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. 4 - 78...

  • Page 331: Every 4000 Hours Maintenance

    Carry out the periodic maintenance work of every 100,250, 500, 1000 and 2000 hours of operation at the same time. CHECK WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, please ask your Komatsu distributor to carry out disassembly, repair, or replacement. CHECK VIBRATION DAMPER For the check and replacement of the vibration damper, special tools are required.

  • Page 332: Replace Accumulator (For Control Circuit)

    Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.

  • Page 333: Check For Looseness Of High-Pressure Piping Clamp, Hardening Of Rubber

    Check visually and touch by hand to check that there is no hardening of the rubber and no loose bolts of the mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail. If there are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out replacement.

  • Page 334: Check Operating Condition Of Compressor

    1. When the air conditioner switch is turned ON-OFF, do the compressor and magnet clutch also turn ON-OFF? 2. Is any abnormal noise generated by the clutch or compressor body? If any problem is found, contact your Komatsu distributor to have the parts disassembled, repaired, or replaced. 4 - 82...

  • Page 335: Every 5000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time. CHANGE OIL IN HYDRAULIC TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

  • Page 336: Every 8000 Hours Maintenance

    Maintenance for every 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPRAY PREVENTION CAP Contact your Komatsu distributor to have the fuel spray prevention cap replaced. 4 - 84...
  • Page 337 5 - 1...

  • Page 338: Specifications

    PC270-8 Operating weight kg (lb) 27,220 (60,020) Bucket capacity (cu.yd) 1.26 (1.65) Name of engine KOMATSU SAA6D107E-1 diesel engine Engine horsepower kW (HP)/rpm 140 (187)/2,050 A Overall length mm (ft in) 9,860 (32' 4") B Overall height mm (ft in) 3,195 (10' 6")
  • Page 339 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working range Unit PC270-8 A Max. digging reach mm (ft in) 10,100 (33' 2") B Max. digging depth mm (ft in) 6,460 (21' 2") C Max. digging height mm (ft in) 10,000 (32' 10") D Max. vertical wall depth mm (ft in) 5,650 (18' 6") E Max.
  • Page 340 6 - 1...

  • Page 341: Attachments And Options

    There may also be problems of the attachment or option hitting the operator's cab. Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu. READ THE INSTRUCTION MANUAL THOROUGHLY Before installing or using any attachment or option, make sure that you thoroughly read and understand the instruction manuals for the machine and the attachment or option.

  • Page 342: 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 During lifting operations, reduce the engine speed and carry out the operation in L mode.

  • Page 343: Machine Ready For Attachment

    ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT LOCATIONS Stop valve Breaker circuit additional oil filter Selector valve Accumulator(for low pressure) Attachment control pedal Accumulator(for high pressure: if equipped) Lock pin Stop Valve This valve (1) stops the flow of the hydraulic oil. (a) FREE: Hydraulic oil flows.
  • Page 344 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Selector Valve This valve (2) switches the flow of hydraulic oil. It is automatically switched according to the selected working mode. It is necessary to switch the working mode to match the attachment that is installed. For details of switching the working mode, see "HYDRAULIC CIRCUIT (PAGE 6-8)".
  • Page 345 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Lock Pin This pin (4) locks the control pedal. Position (a): Locked Position (b): Only front of pedal can be operated to full position (rear is locked) Position (c): Both front and rear of pedal can be operated to full position When not using the attachment, set the lock pin to position (a).
  • Page 346 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 347: Hydraulic Circuit

    , 2980 PSI); when ATT mode is selected, it is set to 27.4 MPa (280 kgf/cm , 3980 PSI). Depending on the attachment, adjustment may be necessary. In such a case, please ask your Komatsu distributor to carry out the adjustment.
  • Page 348 3. After removing plug (3), connect the attachment piping (4) is provided by the attachment manufacturer. For the mouthpiece size and accumulator add-on, the action to take differs according to the attachment manufacturer, so please consult your Komatsu distributor. 6 - 9...
  • Page 349 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Oil Flow Path The direction of operation of the pedal and the path of the oil flow is as shown in the diagram below. When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the rear of the pedal is depressed, oil flows to the piping on the right side of the work equipment.
  • Page 350 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Replace Additional Breaker Filter Element WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the operation. If compressed air is used, there is danger of dirt flying and causing personal injury.
  • Page 351 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 4. Set the lock lever to LOCK position (L). 5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit. 6.
  • Page 352 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Replace Additional Breaker Pilot Filter Element WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the operation. If compressed air is used, there is danger of dirt flying and causing personal injury.
  • Page 353 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 4. Set the lock lever to LOCK position (L). 5. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit. 6.

  • Page 354: Attachment Removal And Installation

    ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT ATTACHMENT REMOVAL AND INSTALLATION Attachment Removal 1. Lower the attachment to the ground and stop the engine. 2. Turn the starting switch to the ON position (B), then set the lock lever to the FREE position (F). 3.
  • Page 355 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 6. After checking that the hydraulic oil temperature has gone down, set the rotor of the stop valve (installed to the piping for the outlet port and inlet port on the side face of the arm) to LOCK position (b).
  • Page 356 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Attachment Installation 1. Remove the bucket. For bucket dismounting procedure, see "BUCKET REPLACEMENT AND INVERSION (PAGE 3-163)". 2. Place the attachment in a horizontal position, then install to the arm with pin (A) and then pin (B). 3.
  • Page 357 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 7. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit. 8. After checking that the hydraulic oil temperature has gone down, remove the plugs from 2 places at the outlet port and inlet port.

  • Page 358: Attachment Operations

    ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT ATTACHMENT OPERATIONS WARNING If the pedal is operated when the auto-deceleration is being actuated and the engine speed has dropped, the engine speed will suddenly rise, so be careful when operating. If you leave your foot resting on the pedal and depress the pedal by mistake, there is danger that the attachment may suddenly move and cause serious personal injury.
  • Page 359 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT 1. Press working mode selector switch (1) or press switches F3 or F4 to select breaker mode B. 2. With breaker mode B highlighted in yellow, do one of the following to accept the selection.
  • Page 360 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT If the working mode pilot monitor does not display ATT for the attachment mode, press working mode selector switch (1) and set to the attachment mode as follows. If P, E, or L mode are selected, the attachment is not actuated.

  • Page 361: Long Term Storage

    In addition, valves with a safety valve relief set pressure of 24.5 MPa (250 kgf/cm , 3550 PSI) and relief valve cracking pressure of 20.1 MPa (205 kgf/cm , 2911 PSI) are also avilable so please contact your Komatsu distributor. 6 - 22...

  • Page 362: 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 363: Track Shoes Selection

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE TRACK SHOES SELECTION Select the appropriate track shoe to match the operating conditions. Selection Check the category from the uses in the table below, then select the shoes from the table below that. Category of use B and C are the wide shoe, so there are limits on the use. Check the precautions for use, examine the conditions of use thoroughly, and use the optimum shoes for the situation.

  • Page 364: Bucket Teeth Selection

    ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE BUCKET TEETH SELECTION Depending on the working conditions, there is danger that an adapter and teeth may break, so select from the vertical pin and horizontal pin teeth to give teeth that are suitable for the purpose. While the standard teeth of both vertical and horizontal pin types may be used widely, the following kinds of teeth are recommended depending on the working conditions.

  • Page 365: 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 366 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 367 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations 6 - 28...
  • Page 368 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS Extending the bucket cylinder fully and thrusting to raise the machine off the ground 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.

  • Page 369: 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 370: Index

    INDEX INDEX <A> <G> AFTER STARTING ENGINE 3-131 GENERAL OPERATION INFORMATION 3-156 AIR CONDITIONER CONTROLS 3- 89 GENERAL PRECAUTIONS FOR ASHTRAY 3- 88 SAFETY ATTACHMENT GUIDE 6- 23 PRECAUTIONS WHEN REMOVING ATTACHMENT COMBINATIONS 6- 23 OR INSTALLING BUCKET TEETH SELECTION 6- 25 PRECAUTIONS WHEN SELECTING AUXILIARY ELECTRIC POWER...
  • Page 371 TOWING THE MACHINE 3-189 AND LUBRICANT RECOMMENDED BRANDS, <W> RECOMMENDED QUALITY FOR WEAR PARTS PRODUCTS OTHER THAN WEAR PARTS LIST KOMATSU GENUINE OIL 4- 11 WINDSHIELD 3- 79 WORK EQUIPMENT CONTROLS AND <S> OPERATIONS 3-150 SAFETY CRITICAL PARTS 4- 13...
  • Page 372 INDEX <Y> YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 7 - 3...

Table of Contents