Page 2 This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
Page 3: Safety Information
Safety precautions are described in SAFETY from page 1-1. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 4: Intended Use
3. INTRODUCTION 3.1 INTENDED USE This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work: ‡ Digging work ‡ Smoothing work ‡ Ditching work ‡ Loading work See the section “12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.
Page 5 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION On the front bottom right of the operator's cab (side of upper frame) 4.2 ENGINE SERIAL NO. PLATE POSITION ‡ Under the engine breather on the left side of the engine (front of machine).
Page 6: Table Of Contents
5. CONTENTS 1. Foreword ............................0- 1 2. Safety information ..........................0- 2 3. Introduction ............................0- 3 4. Location of plates, table to enter serial No. and distributor ............0- 4 SAFETY 6. General precautions .......................... 1- 2 7. Precautions during operation ......................1-11 Before starting engine ......................
Page 7 5. CONTENTS 5. CONTENTS 12. Operation ............................2-31 12.1 Check before starting engine ....................2-31 12.2 Starting engine ........................2-44 12.3 Operations and checks after starting engine ............... 2-47 12.4 Moving machine off ........................ 2-54 12.5 Steering machine ........................2-57 12.6 Stopping machine ........................
Page 8 5. CONTENTS 5. CONTENTS MAINTENANCE 17. Guides to maintenance ........................3- 2 18. Outlines of service ..........................3- 5 18.1 Outline of oil, fuel, coolant ....................3- 5 18.2 Outline of electric system ...................... 3- 8 18.3 Outline of hydraulic system ....................3- 9 19.
Page 9 5. CONTENTS 5. CONTENTS OPTIONAL PARTS, ATTACHMENTS 26. General precautions .......................... 5- 2 26.1 Precautions related to safety ....................5- 2 26.2 Precautions when installing attachments ................5- 3 27. Handling bucket with hook ......................5- 4 27.1 Checking for damage to bucket with hook ................5- 4 27.2 Prohibited operations ......................
Page 10: Safety
SAFETY ¤ WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equip- ment and attachments.
Page 11: General Precautions
¤ WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. 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.
Page 12: Clothing And Personal Protective Items
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT ‡...
Page 13: Mounting And Dismounting
¤ WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. MOUNTING AND DISMOUNTING ‡ Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.
Page 14 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 6. GENERAL PRECAUTIONS FIRE PREVENTION FOR FUEL, OIL, AND ANTIFREEZE Fuel, oil, and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous.
Page 15: Asbestos Dust Hazard Prevention
ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers during demolition operations, always do as follows.
Page 16 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 6. GENERAL PRECAUTIONS ESCAPE FROM FIRE If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation, escape from the machine as follows. ‡...
Page 17: Protection From Falling Or Flying Objects
‡ The Komatsu FOPS fulfills the standards and regulations of all countries, but if it is damaged or deformed by falling objects or by the machine rolling over, its strength will be reduced and it will be unable to ensure its basic function.
Page 18: Indoor Ventilation
‡ When installing and using optional parts or attachments, read the instruction manual for the attachment and the information related to attachments in this manual. ‡ Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
Page 19: Emergency Exit From Operator's Cab
¤ WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. EMERGENCY EXIT FROM OPERATOR’S CAB ‡ If it should becomes impossible to open the cab door for any reason, open the rear window and use it as an emergency escape. ‡...
Page 20: Precautions During Operation
7. PRECAUTIONS DURING ¤ WARNING: Failure to follow these safety OPERATION precautions may lead to a serious accident. 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE ‡ Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Page 21: Fire Prevention
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. FIRE PREVENTION Every day before starting the engine for the first time, carry out the following checks. If these checks are not carried out properly, there is danger of serious injury. ‡...
Page 22: After Starting Engine
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.2 AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Page 23 ¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PRECAUTIONS WHEN SWINGING OR CHANGING DIRECTION OF TRAVEL Before operating the machine or the work equipment, always observe the following precautions in order to prevent serious injury or death.
Page 24 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN TRAVELING ‡ Never turn the starting switch to the OFF position when traveling. It is dangerous if the engine stops when the machine is traveling. It will be impossible to operate the steering.
Page 25: Traveling On Slopes
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. TRAVELING ON SLOPES ‡ Never jump on to a machine that is running away in order to stop it. There is danger of serious injury. ‡...
Page 26: Precautions For Operation
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS FOR OPERATION ‡ Be careful not to go close to the edge of a cliff by mistake. ‡ Use the machine only for its main purpose. Using it for other purposes will cause failures. Specified work See “12.14 WORK THAT CAN BE CARRIED OUT BY HYDRAULIC EXCAVATOR”.
Page 27: Working On Loose Ground
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. OPERATE CAREFULLY ON SNOW ‡ When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning.
Page 28 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PARKING MACHINE ‡ Park on level ground where there is no danger of falling rocks or landslides. When parking on low ground, park in a place where there is no problem of flooding. When parking the machine, lower the work equipment to the ground.
Page 29: Precautions In Cold Weather
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PRECAUTIONS IN COLD WEATHER ‡ After completing operations, remove any drops of water, snow, or mud stuck to the wiring harnesses, connector 1, switches, or sensors, and cover these parts. If drops of water get in and freeze, the machine may malfunction when it is next used, and this may lead to an unexpected accident.
Page 30: Transportation
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.3 TRANSPORTATION LOADING AND UNLOADING ‡ Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. ‡ When loading or unloading the machine, run the engine at low idling and travel at low speed. ‡...
Page 31: Battery
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.4 BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains dilute sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling can cause serious injury or fire. To prevent problems, always do as follows.
Page 32: Charging Battery
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION CHARGING BATTERY When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow the instructions for use of the battery and the instruction manual accompanying the charger, and do as follows.
Page 33: Towing
‡ If the engine on the problem machine will not start or there is a failure in the brake system, always contact your Komatsu distributor. ‡ Never go between the towing machine and the towed machine during the towing operation.
Page 34: Bucket With Hook
Lifting operations with a hydraulic excavator are permitted if they fulfill the following special conditions. Always follow these conditions. ‡ The specified special hook is installed to the bucket. For details, please contact your Komatsu distributor. ‡ If the special hook is installed, there are extra items for the check before starting and periodic inspection, and the recording and storage of the periodic self-inspection is required.
Page 35: Precautions For Maintenance
8.1 BEFORE CARRYING OUT MAINTENANCE CONTACT WHEN THERE IS FAILURE Carrying out maintenance that is not listed in the Komatsu Operation and Maintenance Manual may cause unexpected failure. Please contact your Komatsu distributor for repairs. WARNING TAG ALWAYS attach the “DO NOT OPERATE”...
Page 36: Radiator Water Level
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE NEAT CLEAN WORK PLACE Tidy any tools or hammers that are lying in the work place, wipe up any grease or oil or any other slippery substances, and clean the area to make it possible to carry out the operation in safety.
Page 37 ¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ‡ When carrying out inspection and maintenance, always stop the machine on firm, level ground where there is no danger of falling rocks and landslides, and where there is no danger of floods. Lower the work equipment to the ground and stop the engine.
Page 38: Proper Tools
The replacement of such safety critical parts requires skill and experience, so please contact your Komatsu distributor for replacement. ‡ Replace these components periodically with new ones, regardless of whether or not they appear to be defective.
Page 39: Use Of Lighting
¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. USE OF LIGHTING ‡ When checking fuel, oil, battery electrolyte, or window washing fluid, always use lighting with anti- explosion specifications. If such lighting equipment is not used, there is danger of explosion. ‡...
Page 40: During Maintenance
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE 8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can enter the area during the maintenance operation. If necessary, have a guard supervise the area. Extra precaution should be used when grinding, welding, and using a sledge-hammer.
Page 41: Precautions When Working On Machine
¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PRECAUTIONS WHEN WORKING ON MACHINE ‡ When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do as follows. •...
Page 42: Two Workers For Maintenance When Engine Is Running
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accidents, do not carry out maintenance with the engine running. If it is necessary to carry out maintenance with the engine running, always do as follows.
Page 43: Welding Repairs
‡ If necessary depending on the type of failure, please contact your Komatsu distributor for repairs. RULES TO FOLLOW WHEN ADDING FUEL OR OIL If flame is brought close to fuel or oil, there is danger that it will catch fire.
Page 44 ‡ Experience and skill is required when replacing high pressure hoses. The tightening torque is determined according to the type and size of the hose, so please contact your Komatsu distributor. ‡ If any of the following conditions are found, replace the part.
Page 45 If it is difficult to find the location, please contact your Komatsu distributor. ‡ If oil is leaking under high pressure from small holes, it is dangerous if it hits your skin or enters your eyes.
Page 46: Waste Materials
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE If inspection and maintenance items are forgotten or the function of the maintenance locations is not checked properly, unexpected problems may occur and this may lead to serious personal injury. Always do as follows.
Page 47: Position For Attaching Safety Labels
There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. POSITION FOR ATTACHING SAFETY LABELS 1-38...
Page 48 Follow instructions and warnings in manual and in labels on machine. Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual. 09651-03001 2. Warnings before operating machine 4. Warnings for high voltage (09802-03000) (09801-03000)
Page 49 9. POSITION FOR ATTACHING SAFETY LABELS 9. POSITION FOR ATTACHING SAFETY LABELS 5. Warnings when adjusting track tension 7. Warnings for handling accumulator (09657-03001) (09659-53000) Explosion hazard WARNING WARNING • Keep away from flame • Do not weld or drill 09659-53000 High pressure hazard at track adjuster.
Page 50 9. POSITION FOR ATTACHING SAFETY LABELS 9. POSITION FOR ATTACHING SAFETY LABELS 9. Warnings for hot water (09668-03001) WARNING Hot water hazard. To prevent hot water from spurting out: • Turn engine off. • Allow water to cool. • Slowly loosen cap to relieve pressure before removing.
Page 51 MEMO 1-42...
Page 52: Operation
OPERATION...
Page 53: General View
10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below.
Page 54: General View Of Controls And Gauges
10. GENERAL VIEW 10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 55: Explanation Of Components
11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. 11.1 MACHINE MONITOR This monitor system consists of monitor lamps (A, B, C), meter group D, switch group E.
Page 56 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS B. CAUTION ITEMS (11.1.2) ¤ CAUTION If these monitor items flash, check and repair the appropriate location as soon as possible. These are items which need to be observed while the engine is running.
Page 57: A: Basic Check Items
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.1.1 A: BASIC CHECK ITEMS NOTICE Do not rely on the “BASIC CHECK ITEMS” only for the check before starting. Always refer to the periodic maintenance items or “12. OPERA- TION” to carry out the checks. 1.
Page 58: B: Caution Items
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 3. HYDRAULIC OIL LEVEL This warns that the hydraulic oil level is too low. If the monitor lamp flashes, check the hydraulic oil level, and add oil. 4. CHANGE ENGINE OIL (SET MACHINE ONLY) After the engine oil has been changed, the lamp will light up after the set time (125, 250, 500H) has passed since the previous oil change.
Page 59: C: Emergency Stop Items
Stop the machine on level ground and check the monitor. ‡ Stop the engine, then turn the starting switch to the ON position and check that the monitor lights up for 3 seconds. If it does not light up, please contact your Komatsu distributor to have the monitor inspected.
Page 60: D: Meter Display Portion
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.1.4 D: METER DISPLAY PORTION PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. 1. ENGINE PRE-HEATING MONITOR This monitor lamp indicates the pre-heating time required when starting the engine at an ambient temperature below 0°C.
Page 61: Fuel Gauge
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS METERS 3. ENGINE WATER TEMPERATURE GAUGE This gauge indicates the engine cooling water temperature. If the temperature is normal during operation, the green range will light up. If the red range lights up during operation, the overheat prevention system will be actuated.
Page 62 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS Method of setting manually 1. At the time display, keep time switch 1 pressed for at least 2.5 seconds. 2. “TIME” will flash. 3. If H switch 2 is pressed, the hour will advance, and if M switch 3 is pressed, the minute will advance.
Page 63 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.1.5 E: SWITCHES 1. WORKING MODE SELECTOR SWITCH (Basic mode) This switch is used to set the movement or power for the work equipment. By selecting the mode to match the working conditions, it is possible to carry out operations more easily.
Page 64: Travel Speed Switch
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 2. AUTO-DECELERATION SWITCH (Selection switch) This switch acts to activate the function that automatically low- ers the engine speed and reduces fuel consumption when the control lever is at neutral. ON lights up: Auto-deceleration is actuated. OFF: Auto-deceleration is canceled.
Page 65 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 4. HEAVY LIFT SWITCH Operate this switch to increase the lifting power during opera- tions. When the switch is turned ON during independent operations of the boom, the boom lifting power is increased. 5.
Page 66: Switches
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.2 SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted or withdrawn. The switches for the electric system except the cab lamp and clock, are all turned off and the engine is stopped.
Page 67: Fuel Control Dial
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 2. FUEL CONTROL DIAL (WITH AUTO-DECELERATION MECHANISM) This adjusts the engine speed and output. 1 Low idling (MIN): Turned fully to the left 2 Full speed (MAX): Turned fully to the right AM089400 3.
Page 68 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 6. LAMP SWITCH This switch is used to turn on the front lamps, working lamps, additional lamp at the top front of the cab, rear lamps, and monitor lighting. AM089420 7. ALARM BUZZER STOP SWITCH This is used to stop the alarm buzzer if it sounds to warn of an abnormality during operation.
Page 69: Horn Switch
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11. HORN SWITCH Press the switch on the right work equipment control lever to sound the horn. At the same time, the flashing light (option) at the top front of the cab will flash for approx. 5 seconds to give a signal to the dump truck.
Page 70 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 13. ROOM LAMP SWITCH This is used to turn on the room lamp. ON: Lights up It is possible to turn on the room lamp even when the starting switch is at the OFF position, so be careful not to forget to turn it off. 14.
Page 71: Control Levers, Pedals
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS, PEDALS 1. SAFETY LOCK LEVER ¤ WARNING ‡ When leaving the operator's compartment, set the safety lock lever securely to the LOCK position. If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident.
Page 72 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS This lock lever is a hydraulic lock, so even if it is in the lock Lock position, the work equipment control lever and travel lever will move, but the work equipment, travel motor, and swing motor will not work.
Page 73: Door Lock
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 3. LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) ¤ WARNING If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when oper- ating the levers.
Page 74: Cap, Cover With Lock
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.5 CAP, COVER WITH LOCK The fuel filler, operator’s cab, engine hood, tool box cover, pump room door (right side of the machine body) and battery room door (left side of the machine body) are fitted with locks. Use the starting key to lock or unlock these places.
Page 75: Hot And Cool Box
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.6 HOT AND COOL BOX This is on the right side at the rear of the operator’s seat. It is interconnected with the air conditioner: it stays warm when the heating is used, and stays cool when the cooling is used. 11.7 LUGGAGE BOX This is on the left side at the rear of the operator’s seat.
Page 76: Fuse
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.10 FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 77: Fusible Link
‡ If a fault occurs in the controller, do not attempt repair, but consult your Komatsu distributor. 11.13 TOOL HOLDER (CLOTH BAG) This is inside the storage box inside the cover on the left side at the rear of the cab.
Page 78: Method Of Use
11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.14.1 METHOD OF USE 1. Open cover 1. 2. Rotate the lever of valve 2 upward 90° to set it to the OPEN position. 3. When the lever of grease can 3 is pulled, grease is discharged and the pump also starts automatically.
Page 79 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 3. Fill grease can 1 with new grease, then set follow plate 4 on top of the grease. ‡ Fill the hollow in the center of the follow plate with grease before setting the following plate on top of the grease.
Page 80: Handling Accumulator
‡ Do not weld any boss to the accumulator. ‡ When disposing of the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor. This machine is equipped with the accumulator in the control circuit.
Page 81 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.15.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR 1. Place the work equipment on the ground. Close the crusher attachment jaws, etc. 2. Stop the engine. 3. Move the safety lock lever to the free position. Move the work equipment control lever and the attachment control pedal (op- tion) to full stroke back and forth, right and left so as to release the pressure in the control circuit.
Page 82: Operation
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Page 83 Check that there is no abnormality in the seat belt (option) or mounting clamps. If there is any damage, replace with new parts. 10. Check bucket with hook (option) for damage. Check the hook, catcher and hook foot for damage. If damage is found, contact your Komatsu distributor for repair. 2-32...
Page 84: Check Before Starting
12. OPERATION 12. OPERATION 12.1.2 CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD WATER ¤ WARNING ‡ Do not open the radiator cap unless necessary. When check- ing the coolant, always check the radiator reserve tank when the engine is cold.
Page 85: Check Fuel Level, Add Fuel
12. OPERATION 12. OPERATION 4. The oil level should be between the H and L marks on dipstick If the oil level is below the L mark, add engine oil through oil filler NOTICE For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 86: Check Oil Level In Hydraulic Tank, Add Oil
12. OPERATION 12. OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ¤ WARNING ‡ When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before remov- ing the cap. ‡...
Page 87: Check Oil Level In Swing Machinery Case, Add Oil
12. OPERATION 12. OPERATION CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL ¤ WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance. 1. Remove dipstick G and wipe the oil from the dipstick with a cloth.
Page 88: Check Air Cleaner For Clogging
CLOSE position, start the engine and wait for 1 or 2 minutes, then press the horn switch again to check if it sounds. If the horn still does not sound, please contact your Komatsu distributor for repairs. 2-37...
Page 89: Drain Water And Sediment From Fuel Tank
3 seconds and that the alarm buzzer sounds for approx. 1 second. If any lamp does not light up during this time or the buzzer does not sound, there is probably a blow bulb or disconnection, so please contact your Komatsu distributor for inspection. 2-38...
Page 90 12. OPERATION 12. OPERATION 12.1.3 ADJUSTING BEFORE STARTING OPERATION ADJUST OPERATOR’S SEAT WARNING ‡ Adjust the seat position before starting operations or after changing the operator. ‡ Adjust the seat so that the brake pedal can be depressed fully with the operator’s back against the backrest. A: Fore-and-aft adjustment Pull up lever 1, set to the desired position, then release the lever.
Page 91 12. OPERATION 12. OPERATION D: Up-down adjustment of armrest (wrist control lever type) 1. Remove 2 bolts 8 at the rear face of armrest 4. 2. Lift up or push down armrest 4 and align it with the hole in inside bracket 9.
Page 92 12. OPERATION 12. OPERATION ADJUSTMENT OF MIRRORS A: Adjusting left mirror (side of cab) To adjust the angle, loosen mounting nut 1 and move the mirror; and to adjust the height, loosen 2 bolts 2, and adjust the mirror to a position where it can be seen easily from the operator’s seat.
Page 93: Operations And Checks Before Starting Engine
Engine oil change monitor (set machine only) F ‡ If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or disconnection in the monitor wiring, so contact your Komatsu distributor for repairs. 2-42...
Page 94 Fuel gauge A (2) Press lamp switch G to turn on the head lamps. If the lamps do not light up, there is probably a broken bulb or disconnection in the wiring, so contact your Komatsu distributor for repairs. AM090290...
Page 95: Starting Engine
12. OPERATION 12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING ¤ WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 96: Starting In Cold Weather
12. OPERATION 12. OPERATION 12.2.2 STARTING IN COLD WEATHER (When using APS) When starting the engine in cold weather, do as follows. ¤ WARNING If a starting aid fluid is used when starting the engine, there is danger of explosion. Never use any starting aid. NOTICE Do not crank the starting motor continuously for more than 20 seconds.
Page 97 12. OPERATION 12. OPERATION 4. Turn preheating switch 4 to the ON position. Preheating moni- tor 3 on the monitor panel will light up. (Preheating is automati- cally started.) 5. Maintain this condition until preheating monitor 3 on the moni- tor panel goes out.
Page 98: Operations And Checks After Starting Engine
12. OPERATION 12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE 12.3.1 RUNNING-IN OPERATION This machine has been thoroughly inspected and adjusted be- fore it was shipped, but if it is not used carefully at the beginning, its performance will drop quickly and the life will be shortened. To avoid this, carry out the breaking-in operation for the first 100 hours (the time shown on the service meter).
Page 99: When Normal
12. OPERATION 12. OPERATION 12.3.2 WHEN NORMAL ¤ WARNING ‡ Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. ‡ If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so...
Page 100 12. OPERATION 12. OPERATION 3. Set the safety lock lever 3 to the FREE position, and raise the bucket from the ground. Lock Free AM090430 4. Operate bucket control lever 4 and arm control lever 5 slowly Arm operation Bucket operation to move the bucket cylinder and arm cylinder to the end of the DUMP stroke.
Page 101 12. OPERATION 12. OPERATION 12.3.3 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30°C), the warming-up operation is carried out automatically.
Page 102 12. OPERATION 12. OPERATION 2. Press working mode switch 2 on the monitor panel until the H.O (heavy-duty operation) mode lamp lights up. 3. Turn fuel control dial 1 to the medium speed position. Medium speed Low idling AM090410 4. Set safety lock lever 3 to the FREE position and raise the bucket from the ground.
Page 103 12. OPERATION 12. OPERATION 7. Turn fuel control dial 1 to the full speed (MAX) position and carry out the operation is Step 6 for 3 – 5 minutes. 8. Repeat the following operation 3 – 5 times and operate slowly. Full speed RAISE ↔...
Page 104 12. OPERATION 12. OPERATION NOTICE Canceling automatic warming-up operation If it becomes necessary in an emergency to lower the engine speed to low idling, cancel the automatic warming-up operation as fol- lows. 1. Turn fuel control dial 1 to the full speed (MAX) position and hold it for 3 seconds.
Page 105: Moving Machine Off
12. OPERATION 12. OPERATION 12.4 MOVING MACHINE OFF 12.4.1 MOVING MACHINE FORWARD ¤ WARNING ‡ Before operating the travel levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. ‡...
Page 106: Moving Machine Backward
Pull levers 5 backward slowly or depress the rear part of pedals 6 slowly to move the machine off. 5. For machines equipped with the travel alarm (option), check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repairs. 12.4.2 MOVING MACHINE BACKWARD ¤...
Page 107 Push levers 5 forward slowly or depress the front part of pedals 6 to move the machine off. 5. For machines equipped with the travel alarm (option), check that the alarm sounds. If the alarm does not sound, please contact your Komatsu distributor for repairs. 2-56...
Page 108: Steering Machine
12. OPERATION 12. OPERATION 12.5 STEERING MACHINE 12.5.1 STEERING (CHANGING DIRECTION) ¤ WARNING Before operating the travel levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levers is reversed. Use the travel levers to change direction. Avoid sudden changes of direction as far as possible.
Page 109 12. OPERATION 12. OPERATION When making counter-rotation turn (spin turn) When turning left using counter-rotation, pull the left travel lever back and push the right travel lever forward. REMARK When turning right using counter-rotation, pull the right travel lever back and push the left travel lever forward. 2-58...
Page 110: Stopping Machine
12. OPERATION 12. OPERATION 12.6 STOPPING 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 111: Swinging
12. OPERATION 12. OPERATION 12.7 SWINGING ¤ WARNING When operating the swing, check that the area around the machine is safe. 1. Before operating the swing, turn swing lock switch 1 OFF (CANCELED). NOTICE Check that swing lock monitor 2 goes out at the same time. 2.
Page 112: Operation Of Work Equipment
12. OPERATION 12. OPERATION 12.8 OPERATION OF WORK EQUIPMENT ¤ WARNING If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when oper- ating the levers. The work equipment is operated by the left and right work equipment control levers.
Page 113: Handling Working Mode
12. OPERATION 12. OPERATION 12.9 HANDLING WORKING MODE WORKING MODE The mode selector switch can be used to switch the mode to match the operating conditions and purpose, thereby enabling work to be carried out efficiently. Make effective use of each mode as follows. When the starting switch is turned ON, the working mode is set to the most commonly used general operation mode, so normal operations can be carried out without setting the mode.
Page 114: Prohibitions For Operation
12. OPERATION 12. OPERATION 12.10 PROHIBITIONS FOR OPERATION ¤ WARNING ‡ If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine before operating the work equipment control lever. ‡ If the lever is moved inside the deceleration range, engine speed will suddenly rise.
Page 115 12. OPERATION 12. OPERATION Prohibited operations using dropping force of machine Do not use the dropping force of the machine for digging. Digging rocky ground It is better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce damage to the machine but make for better economy.
Page 116: Precautions For Operation
12. OPERATION 12. OPERATION 12.11 PRECAUTIONS FOR OPERATION INCORRECT PRECAUTIONS WHEN TRAVELING When traveling over obstacles such as boulders or tree stumps, the machine (in particular, the undercarriage) is subjected to a large shock, so reduce the travel speed and travel over the obstacle at the center of the tracks.
Page 117: Precautions When Traveling Up Or Down Hills
12. OPERATION 12. OPERATION 12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS ¤ WARNING ‡ When traveling, raise the bucket approx. 20 – 30 cm (8 – 12 in) from the ground. Do not travel downhill in reverse. ‡ When traveling over ridges or other obstacles, keep the work equipment close to the ground and travel slowly.
Page 118 12. OPERATION 12. OPERATION Braking when traveling downhill To brake the machine during downhill runs, put the travel lever in the neutral position. This will cause the brake to be automatically applied. If shoes slip When traveling uphill, if the shoes slip or it is impossible to travel uphill using the force of the track only, it is possible to use the pulling force of the arm to help the machine travel uphill.
Page 119: How To Escape From Mud
12. OPERATION 12. OPERATION 12.13 HOW TO ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, use the following procedures to get the machine out. Be careful not to get stuck in mud when operating. If you do get stuck in mud, do as follows to escape.
Page 120: Work Possible Using Hydraulic Excavator
12. OPERATION 12. OPERATION 12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.14.1 BACKHOE WORK When condition of the machine is as shown in the diagram at right, each cylinders maximum pushing excavation force is obtained when the bucket cylinder and link, arm cylinder and arm are at 90°.
Page 121: Replacement Of Bucket
12. OPERATION 12. OPERATION 12.15 REPLACEMENT OF BUCKET ¤ WARNING ‡ When knocking the pin in with a hammer, metal particles may fly and cause serious injury, particularly if they get into your eyes. When carrying out this operation, always wear goggles, helmet, gloves, and other protective equipment.
Page 122: Parking Machine
12. OPERATION 12. OPERATION 12.16 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 123: Check After Finishing Work
12. OPERATION 12. OPERATION 3. Lower the bucket horizontally until the bottom touches the ground. 4. Set safety lock lever 3 in the LOCK position. Lock Free AM088930 12.17 CHECK AFTER FINISHING WORK Check the engine water temperature, engine oil pressure and fuel level on the monitor.
Page 124: Stopping Engine
12. OPERATION 12. OPERATION 12.18 STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop 1.
Page 125: Check After Stopping Engine
12. OPERATION 12. OPERATION 12.19 CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, paint- work, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. 2. Fill the fuel tank. 3.
Page 126: Transportation
13. TRANSPORTATION 13.1 PRECAUTIONS FOR TRANSPORTATION ¤ WARNING ‡ Determine the route for transporting the machine by taking into account the width, height and weight of the machine. ‡ Always check that the door on the cab is closed and locked before transporting the machine.
Page 127 13. TRANSPORTATION 13. TRANSPORTATION 1. Lifting machine Fit wires to boom foot pins 1 and lifting holes 2 in the revolving frame, then lift the machine. ‡ The lifting load is 65 tons. 2. Remove covers 1 and 2 and frame 3. 3.
Page 128: Precautions For Loading
13. TRANSPORTATION 13. TRANSPORTATION 13.3 PRECAUTIONS FOR LOADING ¤ WARNING When loading the machine, park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine. After loading to the specified position, secure the machine as follows.
Page 129: Transportation Posture
13. TRANSPORTATION 13.4 TRANSPORTATION POSTURE This machine can be divided into three units or four units for transportation. When transporting the machine please contact your Komatsu distributor. Four units for transportation Posture for each unit (dimensions in diagram are in mm.) ‡...
Page 130 13. TRANSPORTATION 13. TRANSPORTATION ‡ Undercarriage PC1100-6 Unit PC1100LC-6 Remarks PC1100SP-6 30,500 38,000 with Weight (67,250 lb) (83,790 lb) single (kg) (15,250x2 pieces) (19,000x2 pieces) roller (33,625 lb (41,895 lb guard x 2 pieces) x 2 pieces) If any warning tag is attached to the work equipment control levers, do not start the engine.
Page 131 13. TRANSPORTATION 13. TRANSPORTATION ‡ Work equipment (1) Boom PC1100-6 Unit PC1100SP-6 PC1100LC-6 A (mm) 9,475 8,170 B (mm) 2,894 3,095 Overall 1,474 1,474 width (mm) 11,500 11,300 Weight (kg) (25,360 lb) (24,920 lb) 2-80...
Page 132 13. TRANSPORTATION 13. TRANSPORTATION (2) Arm PC1100-6 Unit PC1100SP-6 PC1100LC-6 A (mm) 4,895 4,914 B (mm) 1,626 1,683 Overall width (mm) 5,700 6,100 Weight (kg) (12,570 lb) (13,450 lb) (3) Bucket (excluding side cutter and shroud) PC1100-6 Unit PC1100SP-6 PC1100LC-6 A (mm) 2,703 2,714...
Page 133 13. TRANSPORTATION 13. TRANSPORTATION ‡ Others (1) Counterweight (same for all models) Weight: 17,400 kg (38,370 lb) (2) Radiator duct (same for all models) Weight: 80 kg (175 lb) (3) Catwalk (right) (same for all models) Weight: 50 kg (110 lb) (4) Catwalk (left, front) (same for all models) Weight: 150 kg...
Page 134 13. TRANSPORTATION 13. TRANSPORTATION (5) Catwalk (left, rear) (same for all models) Weight: 160 kg (350 lb) 2-83...
Page 135: Cold Weather Operation
14. COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “20.
Page 136 14. COLD WEATHER OPERATION 14. COLD WEATHER OPERATION 14.1.3 BATTERY ¤ WARNING ‡ To avoid gas explosions, do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.
Page 137: Precautions After Completion Of Work
14. COLD WEATHER OPERATION 14. COLD WEATHER OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. ‡...
Page 138: Long-Term Storage
15. LONG-TERM STORAGE 15.1 BEFORE STORAGE NOTICE To protect the cylinder rod when the machine is not being used, set the work equipment in the posture shown in the diagram. (This prevents rusting of the cylinder rod) When putting the machine in storage for a long time, do as follows.
Page 139: During Storage
15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. ‡...
Page 140: Troubleshooting
16. TROUBLESHOOTING 16.1 WHEN MACHINE RUNS OUT OF FUEL If the machine has run out of fuel, add fuel then bleed the air from the system before starting the engine. For details of the method of bleeding the air, see “24.7.1 RE- PLACE FUEL FILTER CARTRIDGE”.
Page 141: If Battery Is Discharged
16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.5 IF BATTERY IS DISCHARGED ¤ WARNING ‡ When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. ‡ The battery generates hydrogen gas, so there is danger of explosion.
Page 142: Removal And Installation Of Battery
16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.5.2 REMOVAL AND INSTALLATION OF BATTERY ‡ When removing the battery, remove the cable from the ground side first (normally the negative - terminal). If any tool contacts between the positive + terminal and the chassis, a spark will be caused. This is dangerous. ‡...
Page 143: Starting Engine With Booster Cable
16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.5.3 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: Precautions when connecting and disconnecting booster cable ¤ WARNING INCORRECT ‡ When connecting the cables, never contact the positive + and negative .
Page 144 16. TROUBLESHOOTING 16. TROUBLESHOOTING Connecting the booster cables Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Make sure that the starting switches of the normal machine and Battery of the Battery of the problem machine are both at the OFF position.
Page 145 16. TROUBLESHOOTING 16. TROUBLESHOOTING Disconnecting the booster cables After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected. 1. Remove one clip of booster cable B from the engine block of the Battery of the Battery of the problem machine.
Page 146: Other Trouble
16.6 OTHER TROUBLE 16.6.1 ELECTRICAL SYSTEM ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even ‡...
Page 147 16. TROUBLESHOOTING 16.6.2 CHASSIS ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, ‡...
Page 148 16. TROUBLESHOOTING 16.6.3 ENGINE ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor ‡...
Page 149 16. TROUBLESHOOTING 16. TROUBLESHOOTING ENGINE (cont'd) (16.6.3) Problem Main causes Remedy Exhaust gas is white or blue ‡ Defective fuel injectin pump or (‡ Replace pump or nozzle) nozzle ‡ Too much oil in oil pan ‡ Add oil to specified level, see CHECK BEFORE STARTING ‡...
Page 150 16.6.4 APS (Automatic Priming System) ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine does not start at all ‡...
Page 151: Electronic Control System
16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.6.5 ELECTRONIC CONTROL SYSTEM If an error code is displayed on the machine monitor display (normally this displays the time), follow the self-diagnostic remedy table below. Machine monitor failure display Monitor display Failure mode Remedy TVC valve system error When pump prolix switch is turned ON, normal operations become normal, but carry out inspection immediately.
Page 152: Maintenance
MAINTENANCE ¤ WARNING Before carrying out maintenance, always attach the WARNING TAG to the control lever in the operator‘s cab.
Page 153: Guides To Maintenance
Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 154 17. GUIDES TO MAINTENANCE 17. GUIDES TO MAINTENANCE Warning tag: Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who is not aware of the circumstances from starting the engine. Obey precautions: During the operation, always obey the precautions on the safety label attached to the machine. Welding instructions: ‡...
Page 155 17. GUIDES TO MAINTENANCE 17. GUIDES TO MAINTENANCE Pre-and post-work checks: Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness. Wash the machine immediately after the work to protect components from rusting. Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.
Page 156: Outlines Of Service
When changing the oil, always replace the related filters at the same time. ‡ We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.
Page 157 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. ‡ Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 158: Storing Oil And Fuel
‡ When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor. ‡ Do not open packs of spare filters until just before they are to be used.
Page 159: Outline Of Electric System
‡ Since the controller for the control system may cause malfunction due to external wave interference, before installing a radio receiver and a walkie-talkie or citizen band, consult your Komatsu distributor. ‡ When working on the seashore, carefully clean the electric system to prevent corrosion.
Page 160: Outline Of Hydraulic System
18. OUTLINES OF SERVICE 18. OUTLINES OF SERVICE 18.3 OUTLINE OF HYDRAULIC SYSTEM ‡ During operation and immediately after operation is ended, the temperature of the hydraulic system still remains high. In addition, high hydraulic pressure is applied to the system. Take care when inspecting and maintaining the hydraulic system.
Page 161: Wear Parts List
The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts should be used. When ordering parts, please check the part number in the parts book.
Page 162: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY KIND OF RESERVOIR FLUID –22 –4 86 104˚F Specified Refill –30 –20 –10 4 0 ˚ C SAE 30 55 ¬...
Page 163 ‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping.
Page 164 (The 15W40 oil SAE80, 90, 140 NLGI No. 2 Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT (Winter, one EO15-40CD season type) Diesel sigma S Super dieselmulti- AGIP Rotra MP GR MU/EP –...
Page 165 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Coolant SAE10W, 30, 40 Gear Oil Grease Supplier [Ethylene Glycol 10W30, 15W40 [GL-4 or GL-5] [Lithium-Base] Base] (The 15W40 oil SAE80, 90, 140 NLGI No.
Page 166: Standard Tightening Torques For Bolts And Nuts
For greasing work Nozzle 07951–11400 Grease cartridge 07950–90403 (Lithium base grease, 400 g) Hammer 09039–00150 Pinch bar 09055–10390 Tube 207-26-31220 (Swing machinery oil drain) If any of the above tools are broken, please order them from your Komatsu distributor. 3-15...
Page 167: Torque List
The tightening torque is determined by the width across the flats b of the nut and bolt. 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 168: Periodic Replacement Of Safety Critical Parts
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. 3-17...
Page 169 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (fuel injection pump – fuel filter) Spill hose (nozzle – fuel tank) Spill hose (between nozzles) Fuel hose (for APS) Fuel hose (fuel strainer –...
Page 170: Maintenance Schedule Chart
23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 100 HOURS SERVICE (only after the first 100 hours) Clean strainer of P.T.O lubricating oil filter 3-23 INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge 3-23 Change oil in swing machinery case 3-23...
Page 171 23. MAINTENANCE SCHEDULE CHART 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE (CHECK BEFORE STARTING) Check air cleaner for clogging 3-44 Check electric wirings 3-44 Check function of horn 3-44 Drain water and sediment from fuel tank 3-45 Check central monitor 3-45 CHECK EVERY 10 HOURS SERVICE Lubricating...
Page 172 23. MAINTENANCE SCHEDULE CHART 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE Replace drain filter cartridge 3-51 Change oil in engine oil pan, replace engine oil filter cartridge 3-52 Replace hydraulic filter element 3-53 Replace pilot filter element 3-55 Check, clean fuel strainer 3-56 Check and tighten track shoe bolts 3-56...
Page 173 23. MAINTENANCE SCHEDULE CHART 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 2000 HOURS SERVICE Change oil in final drive case 3-75 Change oil in hydraulic tank, clean strainer 3-76 Clean engine breather 3-82 Clean, check turbocharger 3-82 Check alternator, starting motor 3-82 Check engine valve clearance, adjust 3-82...
Page 174: Service Procedure
24. SERVICE PROCEDURE 24.1 INITIAL 100 HOURS SERVICE Carry out the following maintenance only after the first 100 hours. ‡ CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER For detail of method of replacing or maintaining, see the section on EVERY 500 HOURS SERVICE. 24.2 INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours.
Page 175: When Required
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3 WHEN REQUIRED 24.3.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ¤ WARNING ‡ Never clean or replace the air cleaner element with the engine running. ‡ When using pressure air to clean the element wear safety glasses or goggles to protect the eyes.
Page 176 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 5. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE Do not use an element whose folds or gasket or seal are damaged.
Page 177: Clean Inside Of Cooling System
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.2 CLEAN INSIDE OF COOLING SYSTEM ¤ WARNING ‡ Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water. ‡ Since cleaning is performed while the engine is running, it is very dangerous to enter the rear side of the machine as the machine may suddenly start moving.
Page 178 Antifreeze is flammable, so keep it away from any flame. ‡ Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. ‡ We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 179 7. After draining the water, clean with a flushing agent. We recommend use of a Komatsu genuine cleaning agent. For details of the cleaning method, see the instructions given with the cleaning agent.
Page 180 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 10. When the water is completely clean, stop the engine, close drain valves 5 and 6. 11. Replace the corrosion resistor cartridge and open valves 1. For details of replacement of the corrosion resistor, see "24.8.5 EVERY 1000 HOURS SERVICE".
Page 181: Check And Tighten Track Shoe Bolts
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.3 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. AM091210 Tightening NOTICE Coat the bolt seat face with LMP (Molybdenum disulphide SE lubricant), then tighten the bolts.
Page 182: Check And Adjust Track Tension
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.4 CHECK AND ADJUST TRACK TENSION ¤ WARNING Carry out this operation with two workers. The operator must move the machine in accordance with the signals from the other worker. The track tension is checked with the chassis raised, so it is extremely dangerous if the machine is lowered by mistake during the inspection.
Page 183 If the grease does not come out, move the machine backwards and forwards slightly. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. When increasing tension Prepare a grease gun. 1. Pump in grease through grease fitting 1 with a grease gun.
Page 184: Check Electrical Intake Air Heater
24.3.5 CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. Remove the electrical intake air heater from the engine intake connection, and check it for possible open-circuits and dirt.
Page 185: Replace Bucket Teeth
24. SERVICE PROCEDURE 24. SERVECE PROCEDURE 24.3.6 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the teeth before the wear reaches the adapter. ¤ 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 apply the locks securely to the safety lock lever 1.
Page 186: Adjust Bucket Clearance
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.7 ADJUST BUCKET CLEARANCE ¤ WARNING It is dangerous if the work equipment moves by mistake when the clearance is being adjusted. Set the work equipment in a stable condition, then stop the engine and lock the safety lock lever 1 securely. If there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.
Page 187: Check Window Washer Fluid Level, Add Fluid
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.8 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If air is ejected with the window washer fluid, check the fluid level in window washer tank 1. If showing under the level, fill with automobile window washer fluid. When adding fluid, be careful not to let dirt or dust get in.
Page 188 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.9 CHECK AND MAINTENANCE AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) CHECK LEVEL OF REFRIGERANT (GAS) WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite, so never loosen any part of the refrigerant circuit.
Page 189 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.10 CLEAN LINE FILTER, REMOVE DIRT If there is any abnormality in the pumps or other hydraulic equipment, remove the dirt from the inside of the line filter as follows. Before removing the line filter, release the pressure inside the hydraulic circuit.
Page 190 (59°F), engine cooling water temperature below 13°C (55.4°F)). If it is necessary to inspect the APS when the engine cooling water is above 13°C (55.4°F), so please contact your Komatsu distributor. 1. Open fuel valve 1 of the APS and remove hoses 2 of the nozzle inlet.
Page 191: Check Before Starting
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.4 CHECK BEFORE STARTING 24.4.1 CHECK COOLANT LEVEL, ADD WATER ¤ WARNING ‡ Do not open the radiator cap unless necessary. When check- ing the coolant, always check the radiator reserve tank when the engine is cold. ‡...
Page 192 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 4. The oil level should be between the H and L marks on dipstick If the oil level is below the L mark, add engine oil through oil filler NOTICE For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 193 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.4.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ¤ WARNING ‡ When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before remov- ing the cap.
Page 194 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.4.5 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL ¤ WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance.
Page 195 CLOSE position, start the engine and wait for 1 or 2 minutes, then press the horn switch again to check if it sounds. If the horn still does not sound, please contact your Komatsu distributor for repairs. 3-44...
Page 196 3 seconds and that the alarm buzzer sounds for approx. 1 second. If any lamp does not light up during this time or the buzzer does not sound, there is probably a blow bulb or disconnection, so please contact your Komatsu distributor for inspection. 3-45...
Page 197: Every 10 Hours Service
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.5 EVERY 10 HOURS SERVICE ¤ WARNING If any abnormal noise comes from the greasing points of the work equipment, apply grease regardless of the service interval. 24.5.1 LUBRICATING 1. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop the engine.
Page 198 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 2. Boom foot pin (2 points) 3. Boom cylinder rod end pin (2 points) 4. Arm cylinder foot pin (1 point) 5. Boom-Arm coupling pin (1 point) 6. Bucket cylinder foot pin (2 points) 7.
Page 199: Every 100 Hours Service
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.6 EVERY 100 HOURS SERVICE Maintenance for every 10 hours service should be carried out at the same time. 24.6.1 LUBRICATING SWING CIRCLE (4 points) Apply grease to the grease fittings shown by arrows. 3-48...
Page 200: Every 250 Hours Service
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7 EVERY 250 HOURS SERVICE Maintenance for every 10 hours service should be carried out at the same time. 24.7.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD ¤ WARNING ‡ The oil is at high temperature immediately after the machine has been operated.
Page 201: Check Level Of Battery Electrolyte
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.2 CHECK LEVEL OF BATTERY ELECTROLYTE ¤ WARNING ‡ To avoid gas explosions, do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.
Page 202: Replace Drain Filter Cartridge
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.4 REPLACE DRAIN FILTER CARTRIDGE 1. Using a filter wrench, remove cartridge 1 by turning it counterclockwise. 2. Fill the new cartridge with engine oil and refit it after applying a dab of oil to the packing face. To refit the cartridge, place the packing face in contact with the seal face of the filter stand, then screw up the cartridge 1/2 to 3/4 turn.
Page 203: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
4. Inspect the drained oil, and if there is a large amount of metal particles or foreign material, please contact your Komatsu dis- tributor. 5. Open the front cover (on the right side of the muffler) on the left side of the engine hood, and using the filter wrench from above the engine, turn filter cartridge 4 to the left to remove it.
Page 204: Replace Hydraulic Filter Element
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE REMARK Confirm that no remnants of old packing still adhere to the filter holder as this may result in oil leakage. 7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up further 3/4 to 1 of a turn.
Page 205 24. SERVICE PROCEDURE If there are metal particles or foreign material inside strainer 5, please contact your Komatsu distributor. 4. Clean the removed parts in diesel oil. 5. Install a new element in the place where old element 4 was installed.
Page 206: Replace Pilot Filter Element
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.7 REPLACE PILOT FILTER ELEMENT ¤ WARNING The oil is at high temperature after engine has been operated. Wait for the oil to cool down before carrying out maintenance. 1. Loosen drain plug 1 and drain the oil. 2.
Page 207: Check, Clean Fuel Strainer
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.8 CHECK, CLEAN FUEL STRAINER 1. Open the cover at the front of the engine hood. 2. Remove cap 1 of the strainer case, take out the strainer, then wash the strainer and strainer case. 24.7.9 CHECK AND TIGHTEN TRACK SHOE BOLTS Shoe bolts 1 which secure track shoes to links will break if used in a loosened state, so loose bolts must always be retightened.
Page 208: Check Alternator Drive Belt Tension, Adjust
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.11 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST Checking The standard deflection for the drive belt is 10 – 15 mm (0.39 – 0.59 in) when pressed with a thumb [at approx. 58.8 N (approx. 6 kgf)] at a point midway between the drive pulley and alternator pulley.
Page 209: Check Air Conditioner Compressor Belt Tension, Adjust
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.12 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) Checking 1. Remove bolts 2, 3 and 4, then remove cover 1. 2. The standard deflection for the drive belt is 10 – 15 mm (0.39 – 0.59 in) when pressed with a thumb [at approx.
Page 210: Every 500 Hours Service
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8 EVERY 500 HOURS SERVICE Maintenance for every 10, 100 and 250 hours service should be carried out at the same time. 24.8.1 REPLACE FUEL FILTER CARTRIDGE ¤ WARNING ‡ Engine is at high temperature immediately after the machine has been operated.
Page 211 Steps 7 – 10 (but excluding Step 8) to bleed the air. Always use a genuine Komatsu part for the filter cartridge. After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter seal surface.
Page 212: Check Swing Pinion Grease Level, Add Grease
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE 1. Remove bolts 1 (4 bolts) on the top of the revolving frame and remove cover 2. 2. Insert a scale into the grease and check that the depth of the grease is approx.
Page 213: Clean Hydraulic Tank Strainer And Return Strainer
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8.3 CLEAN HYDRAULIC TANK STRAINER AND RETURN STRAINER ¤ WARNING ‡ When removing the cap F, turn it slowly to relieve inner pressure. ‡ When removing cover 1, undo the bolts (4 bolts) gradually to prevent the cover flying off under the force of spring 2.
Page 214 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8.4 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) ¤ WARNING If compressed air, steam, or water hit your body directly, there is danger of injury.
Page 215: Clean Fresh/Recirc Air Filters Of Air Conditioner (Only For Machines Equipped With Air Conditioner)
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8.5 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) 1. Pull up lock pin knob 3 of frame 1 at the top of the luggage box, then lift up frame 1. 2.
Page 216: Check Wear Of Fan Belt, Replace, Adjust
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8.7 CHECK WEAR OF FAN BELT, REPLACE, ADJUST Checking Check the V-belt and when the following conditions exist, re- place the V-belt: ‡ When the V-belt makes contact with the bottom of the groove in each pulley.
Page 217 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE Adjusting 1. Tighten adjustment screw 2 to bring the tip of the adjustment screw into contact with tension pulley lever 5, then tighten the adjustment screw a further 180° and secure with locknut 1. 2.
Page 218: Every 1000 Hours Service
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.9 EVERY 1000 HOURS SERVICE Maintenance for every 10, 100, 250 and 500 hours service should be carried out at the same time. 24.9.1 CHANGE OIL IN SWING MACHINERY CASE ¤ WARNING The oil is at high temperature immediately after the machine has been operated.
Page 219: Change Oil In P.t.o Case
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. 24.9.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 24.9.4 CHECK PLAY OF TURBOCHARGER ROTOR Ask Komatsu distributor to check the play of the turbocharger rotor. 3-68...
Page 220: Replace Corrosion Resistor Cartridge
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.9.5 REPLACE CORROSION RESISTOR CARTRIDGE ¤ WARNING The oil is at high temperature after the engine has been oper- ated, so never replace the cartridge immediately after finishing operations. Wait for the oil to cool down before replacing cartridge. ‡...
Page 221: Fan Pulley Assembly (1 Point)
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.9.7 GREASE FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY Add grease through the fittings marked by arrows. 1. Fan pulley assembly (1 point) 2. Tension pulley assembly (1 point) 3-70...
Page 222: Check Welded Structure (Color Check)
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.9.8 CHECK WELDED STRUCTURE (COLOR CHECK) Cracks in welded structures can be seen easily with a color check. Check the revolving frame, center frame, boom, and arm every 1000 hours. In particular, carry out a color check on the important check points ( marked portion).
Page 223 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE Center frame 3-72...
Page 224 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE Boom 3-73...
Page 225 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 3-74...
Page 226: Every 2000 Hours Service
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.10 EVERY 2000 HOURS SERVICE Maintenance for every 10, 100, 250, 500 and 1000 hours service should be carried out at the same time. 24.10.1 CHANGE OIL IN FINAL DRIVE CASE ¤WARNING ‡ The oil is at high temperature immediately after the machine has been operated.
Page 227 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.10.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT ¤WARNING When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully. 1.
Page 228 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER ¤ WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before chang- ing the oil. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully.
Page 229 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 6. Remove 4 bolts, then remove cover 4. When doing this, cover 4 may fly off because of the force of spring 5, so keep the cover pushed down when removing the bolts. 7. Hold the top of rod 6 and pull up to remove spring 5 and strainer 7.
Page 230 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE BLEEDING AIR FROM CIRCUIT After assembling piping disconnected during inspection and maintenance, always bleed the air from the circuit as follows. PRECAUTIONS WHEN BLEEDING AIR ‡ Bleed the air in order as follows. 1. Hydraulic pump and swing pump 2.
Page 231 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE Procedure for bleeding air Bleed the air from the various components in the order below (1 – 1. Bleeding air from pump 1. Loosen air bleed plug 1 and check that oil oozes out from the air bleeder.
Page 232 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 4. Bleeding air from swing motor (Carry out this operation only when the oil in the swing motor case has been drained.) 1. Run the engine at low idling, remove air hose 1 and check that oil oozes out from air hose 1.
Page 233: Clean, Check Turbocharger
24.10.5 CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 234: Every 4000 Hours Service
24.11.1 CHECK WATER PUMP There may be oil leakage, water leakage, or clogging of drain hole 2, so please contact your Komatsu distributor to ask for disassembly and repair or replacement. 24.11.2 CHECK VIBRATION DAMPER There may be leakage of fluid from damper 3 or denting or face runout, so please contact your Komatsu distributor for replacement.
Page 235 MEMO 3-84...
Page 236: Specifications
SPECIFICATIONS...
Page 237 700 mm (27.6 in) 1,000 mm (39.4 in) 700 mm (27.6 in) width width width ENGINE ‡ Model Komatsu SAA6D170E-2 diesel engine ‡ Flywheel horsepower 331 kW (444 HP)/1,800 rpm ‡ Starting motor 24 V 7.5 kW x 2 pieces ‡ Alternator 24 V 50 A ‡...
Page 238 25. SPECIFICATIONS 25. SPECIFICATIONS PC1100-6 AVANCE PC1100SP-6 AVANCE...
Page 239 25. SPECIFICATIONS 25. SPECIFICATIONS PC1100LC-6...
Page 240 25. SPECIFICATIONS 25. SPECIFICATIONS PC1100-6 Never allow other person than the operator to enter the swing range (Max. swing range, Max. digging radius).
Page 241 25. SPECIFICATIONS 25. SPECIFICATIONS PC1100LC-6 Never allow other person than the operator to enter the swing range (Max. swing range, Max. digging radius).
Page 242 25. SPECIFICATIONS 25. SPECIFICATIONS PC1100SP-6 Never allow other person than the operator to enter the swing range (Max. swing range, Max. digging radius).
Page 243 MEMO...
Page 244: Optional Parts, Attachments
OPTIONAL PARTS, ATTACHMENTS...
Page 245: General Precautions
26. GENERAL PRECAUTIONS 26.1 PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, please contact your Komatsu distributor first.
Page 246: Precautions When Installing Attachments
‡ Always follow the correct procedure when installing the boom and arm. If the correct procedure is not followed, this may lead to serious damage or injury, so please consult your Komatsu distributor before carrying out installation.
Page 247: Handling Bucket With Hook
27. HANDLING BUCKET WITH HOOK 27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK Check that there is no damage to the hook, stopper, or hook mount. If any abnormality is found, please contact your Komatsu distributor. 27.2 PROHIBITED OPERATIONS INCORRECT The standard work equipment must not be used for lifting loads.
Page 248: Using Seat Belt
28. USING SEAT BELT 28.1 SEAT BELT WARNING ‡ Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets. ‡ Even if there appears to be no abnormality in the belt, always replace the seat belt once every 3 years.
Page 249 27. USING SEAT BELT 27. USING SEAT BELT 28.1.2 ADJUST THE BELT LENGTH To shorten the belt Pull the free end of the belt on either the buckle body or tongue side. AM091850 To lengthen the belt Pull the belt while holding it at a right angle to buckle or tongue. Inspect bolts and fittings on the chassis for tightness.
Page 250: Introduction Of Optional Parts, Attachments
29. INTRODUCTION OF OPTIONAL PARTS, ATTACHMENTS 29.1 COMBINATIONS OF WORK EQUIPMENT Select the combination of boom, arm, and bucket from the combinations shown in the table below. ‡ For dimensions A to G, see the working range diagram on the next page. Unit: mm PC1100-6 Model...
Page 251 29. INTRODUCTION OF OPTIONAL PARTS, ATTACHMENTS Working range diagram...
Page 252: Selection Of Track Shoes
29. INTRODUCTION OF OPTIONAL PARTS, ATTACHMENTS 29.2 SELECTION OF TRACK SHOES Select the most suitable track shoe to match the operating conditions. Check the use in the table below, and select the shoe from the table on the next page. Category Precautions when using Remarks...
Page 253 29. INTRODUCTION OF OPTIONAL PARTS, ATTACHMENTS Types of track shoe Shoe Double grouser shoe Model PC1100-6 PC1100SP-6 PC1100LC-6 1000 1000 1200 Shoe width (27.6 in) (STD) (39.4 in) (27.6 in) (STD) (39.4 in) (STD) (47.3 in) Overall width of 4600 4900 4600 4900...
Page 254: Handling Air Conditioner
30. HANDLING AIR CONDITIONER 30.1 HANDLING AIR CONDITIONER 30.1.1 GENERAL LOCATIONS ON CONTROL PANEL The pilot lamp for the switches light up to indicate that the switch is functioning. 1. VENT SELECTOR SWITCH This is used to select the vents which match the purpose of use. Purpose Sending breeze to Sending breeze to feet...
Page 255: Temperature Control Switch
30. HANDLING AIR CONDITIONER 30. HANDLING AIR CONDITIONER 2. FRESH/RECIRC SELECTOR SWITCH This switch is used to intake fresh air or recirculate the internal air. Recirculating internal air Taking in fresh air Use this position to heat Use this position when Purpose or cool the operator’s cab taking in clean, fresh air of use...
Page 256: Air Conditioner Switch
30. HANDLING AIR CONDITIONER 30. HANDLING AIR CONDITIONER A / C 5. AIR CONDITIONER SWITCH This is used to switch the air conditioner ON/OFF. 6. OFF SWITCH This switch is use to stop the fan. 7. DEFROSTER SELECTOR LEVER This is used to clear the mist from the front glass in cold or rainy conditions.
Page 257: Handling Car Radio
31. HANDLING CAR RADIO 31.1 HANDLING CAR RADIO 31.1.1 EXPLANATION OF COMPONENTS SW–VOLUME pull BAL PRESET STATION TIME TIME SET TUNING TONE AM089950 1. POWER SWITCH/VOLUME CONTROL KNOB (SW-VOLUME) BALANCE CONTROL KNOB (Pull BAL) Press this knob to turn the power for the radio on. The frequency is displayed on display 7.
Page 258 31. HANDLING CAR RADIO 31. HANDLING CAR RADIO 3. FM/AM SELECTOR BUTTON (AM/FM) Press this button and select the desired band. Each time the button is pressed, it switches AM → FM → AM ... AM089980 4. DISPLAY SELECTOR BUTTON (TIME) This equipment gives priority to the frequency display.
Page 259: Manual Tuning
31. HANDLING CAR RADIO 31. HANDLING CAR RADIO 9. STEREO INDICATOR (ST) This lamp lights up when a stereo broadcasting is picked up when receiving an FM broadcasting station. AM090040 31.1.2 METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS 1. Press power switch 1 and display the frequency on display 7. 2.
Page 260 31. HANDLING CAR RADIO 31. HANDLING CAR RADIO SETTING CORRECT TIME 1. Press display selector button 4 to display the time. After 5 seconds, the display will return to the frequency display and the time cannot be corrected. If this happens, press display selector button 4 again.
Page 261: Specifications
31. HANDLING CAR RADIO 31. HANDLING CAR RADIO 31.1.3 PRECAUTIONS WHEN USING ‡ To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation. ‡ If water gets into the speaker case or car radio (auto tuning), it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 262 MEMO 5-19...

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