PC1250_7_OMM_SEAD046500

SEAM046500TOperation & Maintenance Manual PC1250-7 PC1250SP-7 PC1250LC-7 HYDRAULIC EXCAVATOR SERIAL NUMBERS PC1250- 20001 and up PC1250SP-20001 and up PC1250LC-20001 and up This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is out 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. Copyright 2002 Komatsu DataKom Publishing Division May 2002 BLANK PAGE . 1-1 . FOREWORD FOREWORD FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance. Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully. Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine. Storage location for the Operation and Maintenance Manual: magazine box on the left side of the operator's seat. 1-2 . FOREWORD FOREWORD 1-3 . FOREWORD FOREWORD 1-4 1-5 . Signal words The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. will result in death or serious injury. If you accidentally touch the control levers when they are not locked. the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know. Indicates a potentially hazardous situation which. In this manual and on machine labels. This word is used for information that is useful to know. if not avoided. this may cause a serious injury or death. This word is used also to alert against unsafe practices that may cause property damage. may result in minor or moderate injury. 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. Other signal words In addition to the above. always place the safety lock lever in the LOCK position.. could result in death or serious injury. the following signal words are used to express the potential level of hazard. Example of safety message using signal word When standing up from the operator's seat. Indicates an imminently hazardous situation which. if not avoided. Indicates a potentially hazardous situation which. This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine. if not avoided. SAFETY INFORMATION FOREWORD Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. The explanations. the safety messages in this manual and on the machine may not include all possible safety precautions.. Therefore. and the method of avoiding the hazardous condition at the bottom or right side. Safety pictograms show the type of hazardous condition at the top or left side. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. values. it is your responsibility to take the necessary steps to ensure safety. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. In addition. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle. If any procedures or actions not specifically recommended or allowed in this manual are used. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. In no event should you engage in prohibited uses or actions described in this manual. and illustrations in this manual were prepared based on the latest information available at that time. (For example: j -> (1)) 1-6 . Example of safety label using words Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. the terms front. left. FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work See the section "RECOMMENDED APPLICATIONS (PAGE 3-115)" for further details. DIRECTIONS OF MACHINE In this manual. 1-7 . rear. and right refer to the travel direction as seen from the operator's cab when the operator's cab is facing the front and the sprocket is at the rear of the machine.. please inform your Komatsu distributor of the following items. PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts.. MACHINE SERIAL NUMBER PLATE AND ITS LOCATION On the front bottom right of the operator's cab (side of upper frame) ENGINE SERIAL NUMBER PLATE AND ITS LOCATION This is at the top of the starting motor on the right side face of the engine (rear of machine) 1-8 . SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Distributor name Address Service Personnel Phone/Fax 1-9 . FOREWORD PRODUCT INFORMATION Under the exhaust manifold on the left side of the engine (rear of machine). Engine serial No.. 71 MACHINE OPERATIONS AND CONTROLS 3. 8 SERVICE METER LOCATION 1. 30 SAFETY MAINTENANCE INFORMATION 2. 36 EMERGENCY EXIT FROM OPERATOR'S CAB 3.. 27 BATTERY 2. 57 AUXILIARY ELECTRIC POWER 3. 1 FOREWORD 1. 8 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION 1. 41 DOOR LOCK 3. 34 WINDSHIELD 3. 72 1 . 19 OPERATION 2. 5 SWITCHES 3. 21 TRANSPORTATION 2. 44 RADIO 3. 5 INTRODUCTION 1.10 . 8 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1. 43 ASHTRAY 3. 28 CONTROL LEVERS AND PEDALS 3. 1 MACHINE VIEW ILLUSTRATIONS 3. 2 CONTROLS AND GAUGES 3. 64 CIRCUIT BREAKER 3. 72 BEFORE STARTING ENGINE 3. 5 MONITORING SYSTEM 3. 65 CONTROLLERS 3. 4 LOCATION OF SAFETY LABELS 2. 41 CAP WITH LOCK 3. 31 OPERATION 3. 28 TOWING 2. 11 SAFETY MACHINE OPERATION 2. 67 GREASE PUMP 3. 68 ACCUMULATOR 3. 19 STARTING ENGINE 2. 3 DETAILED CONTROLS AND GAUGES 3. 43 AIR CONDITIONER CONTROLS 3. 2 OVERALL MACHINE VIEW 3. 41 HOT AND COOL BOX 3. 7 PRODUCT INFORMATION 1. 2 SAFETY LABELS 2. 2 SAFETY INFORMATION 1. 9 SAFETY 2. 66 TOOL BOX 3. 5 SAFETY LABELS 2. 1 SAFETY INFORMATION 2. 63 FUSE 3. 7 DIRECTIONS OF MACHINE 1. 6 SAFETY INFORMATION 2. 9 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1. CONTENTS FOREWORD CONTENTS FOREWORD 1. 43 MAGAZINE BOX 3. 13 TIGHTENING TORQUE LIST 4..98 MACHINE OPERATION 3.13 SAFETY CRITICAL PARTS 4.8 WEAR PARTS LIST 4.9 PROPER SELECTION 4.11 .90 STOPPING THE ENGINE 3.4 ELECTRIC SYSTEM MAINTENANCE 4.4 HANDLING OIL.8 LUBRICANTS.9 TIGHTENING TORQUE SPECIFICATIONS 4.14 1 .2 LUBRICANTS.7 WEAR PARTS 4.1 MAINTENANCE INFORMATION 4.98 CHECK AFTER SHUT OFF ENGINE 3. AND PERFORMING OIL CLINIC 4.99 STEERING THE MACHINE 3-103 SWINGING 3-105 WORK EQUIPMENT CONTROLS AND OPERATIONS 3-106 WORKING MODE 3-107 PROHIBITED OPERATIONS 3-108 GENERAL OPERATION INFORMATION 3-110 TRAVELING ON SLOPES 3-112 ESCAPE FROM MUD 3-114 RECOMMENDED APPLICATIONS 3-115 BUCKET REPLACEMENT 3-116 PARKING MACHINE 3-118 MACHINE INSPECTION AFTER DAILY WORK 3-119 LOCKING 3-120 TRANSPORTATION 3-121 PRECAUTIONS FOR TRANSPORTATION 3-121 LIFTING MACHINE 3-121 SHIPPING MACHINE INFORMATION 3-122 TRANSPORTATION POSTURE 3-123 COLD WEATHER OPERATION 3-133 COLD WEATHER OPERATION INFORMATION 3-133 AFTER DAILY WORK COMPLETION 3-135 AFTER COLD WEATHER SEASON 3-135 LONG TERM STORAGE 3-136 BEFORE STORAGE 3-136 DURING STORAGE 3-136 AFTER STORAGE 3-136 TROUBLES AND ACTIONS 3-137 RUNNING OUT OF FUEL 3-137 PHENOMENA THAT ARE NOT FAILURES 3-137 TOWING THE MACHINE 3-138 SEVERE JOB CONDITION 3-138 DISCHARGED BATTERY 3-139 OTHER TROUBLE 3-143 MAINTENANCE 4. FUEL AND COOLANT SPECIFICATIONS 4.86 AFTER STARTING ENGINE 3. FOREWORD CONTENTS STARTING ENGINE 3. FUEL. COOLANT. COOLANT AND FILTERS 4. 1 SPECIFICATIONS 5. 41 EVERY 10 HOURS MAINTENANCE 4. 2 ATTACHMENT INSTALLATION 6. 15 MAINTENANCE PROCEDURE 4. 18 CHECK BEFORE STARTING 4. CONTENTS FOREWORD SAFETY CRITICAL PARTS LIST 4. 2 SAFETY FIRST 6. 78 EVERY 4000 HOURS MAINTENENCE 4. 3 ATTACHMENT GUIDE 6. 5 SELECTION OF TRACK SHOES 6. 17 WHEN REQUIRED 4. 68 EVERY 2000 HOURS MAINTENANCE 4.GENERAL INFORAMTION 6.. 2 ATTACHMENTS AND OPTIONS 6. 4 COMBINATIONS OF WORK EQUIPMENT 6.12 . 45 EVERY 500 HOURS MAINTENANCE 4. 1 ATTACHMENTS AND OPTIONS . 53 EVERY 1000 HOURS MAINTENANCE 4. 9 INDEX 7. 1 1 . 17 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) 4. 15 MAINTENANCE SCHEDULE CHART 4. 42 EVERY 100 HOURS MAINTENANCE 4. 80 EVERY 5000 HOURS MAINTENANCE 4. 81 SPECIFICATIONS 5. 17 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) 4. 44 EVERY 250 HOURS MAINTENANCE 4. 14 MAINTENANCE SCHEDULE 4. . 2-1 . . 14 Fire Prevention and Explosion Prevention 2. 17 Ensure Good Visibility 2. 17 Distance to High Voltage Cables 2. 5 SAFETY LABELS 2. 16 Cab Widow Glasses 2. 12 Handrails and Steps 2. 11 Keep Machine Clean 2. 18 Emergency Exit from Operator's Cab 2. 16 Attachment Combinations 2. 16 Safety at Jobsite 2. 13 No Persons on Attachments 2. 11 Fire Extinguisher and First Aid Kit 2. 16 Working on Loose Ground 2. 4 LOCATION OF SAFETY LABELS 2. 11 If Abnormalities are Found 2. 14 Action If Fire Occurs 2. 13 Mounting and Dismounting 2. 6 SAFETY INFORMATION Safety Rules 2. 16 Unauthorized Modifications 2. 12 Keep Operator's Compartment Clean 2. 12 Leaving Operator's Seat with Lock 2. SAFETY INFORMATION SAFETY SAFETY INFORMATION SAFETY LABELS 2. 18 Signalman's Signal and Signs 2. 13 Burn Prevention 2. 11 Working Wear and Personal Protective Items 2. 18 2-2 . 11 Safety Equipment 2. 18 Asbestos Dust Hazard Prevention 2. 17 Ventilation for Enclosed Area 2. 15 Windshield Washer Fluid 2. 15 Attachment Installation 2. Flying Objects and Intruding Objects Prevention 2. 15 Falling Objects. 35 Removing Battery Terminals 2. 31 Stop Engine Before Carrying Out Maintenance 2. 35 Do Not Disassemble Recoil Springs 2. 27 Battery 2. 36 Air Conditioner Maintenance 2. 33 Proper Tools 2. 19 Checks Before Starting Engine 2. SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION 2. 37 2-3 . 23 Operations on Slopes 2. 30 SAFETY MAINTENANCE INFORMATION 2. 25 Parking Machine 2. 28 Starting Engine with Booster Cables 2. 35 Safety First when Using High-pressure Grease to Adjust Track Tension 2. 32 Two Workers for Maintenance when Engine is Running 2. 35 Safety Rules for High-pressure Oil 2. 34 When Using Hammer 2. 21 Safety Rules for Traveling 2. 34 Personnel 2. 26 Transportation 2. 19 Safety Rules for Starting Engine 2. 29 Towing 2. 28 Battery Hazard Prevention 2. 36 Waste Materials 2. 36 Compressed Air 2. 31 Warning Tag 2. 34 Work Under the Machine 2. 24 Operations on Snow 2. 31 Appoint Leader when Working with Others 2. 34 Attachments 2. 36 Safety Handling High-pressure Hoses 2. 20 Operation 2. 27 Shipping the Machine 2. 21 Checks Before Operation 2. 34 Noise 2. 24 Prohibited Operations 2. 37 Periodic Replacement of Safety Critical Parts 2. 31 Keep Work Place Clean and Tidy 2. 22 Traveling on Slopes 2. 19 Starting Engine 2.. 21 Safety Rules for Changing Machine Directions 2. 35 Welding Works 2. 19 Starting Engine in Cold Weather 2. 30 Safety Rules for Towing 2. 33 Accumulator 2. be sure that they are in the correct place and always keep them clean. There are also other labels in addition to the warning signes and safety labels. lost. For details of the part numbers for the labels. When cleaning them.. Handle those labels in the same way. or cannot be read properly. If the labels are damaged. SAFETY LABELS SAFETY SAFETY LABELS The following warning signes and safety labels are used on this machine. These may cause the labels to peel off. see this manual or the actual label. Be sure that you fully understand the correct position and content of labels. and place an order with Komatsu distributor. To ensure that the content of labels can be read properly. do not use organic solvents or gasoline. 2-4 . replace them with new ones. . SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2-5 . inspection and (2) Precautions for before operation (09802-03000) maintenance (09651-03001) (3) Warning for leaving operator's seat (4) Warnings for high voltage (09801-03001) (09654-03001) 2-6 .. SAFETY LABELS SAFETY SAFETY LABELS (1) Precautions for operation. . SAFETY SAFETY LABELS (5)Warnings when opening front window (6)Warnings when stowing front window (09839-03000) (09803-03000) (7)Precautions for high-temperature oil (8)Precautions for high-temperature coolant (09653-03001) (09668-03001) 2-7 . SAFETY LABELS SAFETY (9)Precautions when handling accumulator (10)Precautions when adjusting track tension (09659-53000) (09657-03003) (11)Precautions when handling cable(09808-03000) (12)Stop rotation when performing testing and adjusting(09667-03001) 2-8 .. SAFETY SAFETY LABELS (13)Explanation of methods for emergency escape (14)Roll-over precautions (09805-23000) (20Y-00-31170) (15)Roll-over precautions(09805-13000) (16)Prohibited to enter within swing range (09133-23000) 2-9 .. 10 . SAFETY LABELS SAFETY (17)Warning for battery(09664-30082) 2 .. Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used. Do not operate the machine until the abnormality has been corrected.. wear safety glasses. or any abnormal display on the warning devices or monitor). there is a hazard that it may get caught up in the machine. SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. smoke. Understand the method of use of safety features and use them properly. If you are under the influence of alcohol or medication. If you have long hair and it hangs out from your hard hat. If the nature of the work requires it. ear plugs. gloves. Follow all safety rules. your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger. report to the person in charge and have the necessary action taken. Provide a first aid kit at the storage point. Have guards and covers repaired immediately if they are damaged. so tie your hair up and be careful not to let it get caught. Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies. When working with another operator or with a person on worksite traffic duty. oil leakage. WORKING WEAR AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories. SAFETY EQUIPMENT Be sure that all guards and covers are in their proper position. vibration..11 . IF ABNORMALITIES ARE FOUND If you find any abnormality in the machine during operation or maintenance (noise. Never remove any safety features. incorrect gauges. etc. Always keep them in good operating condition. Carry out periodic checks and add to the contents if necessary. 2 . be sure that all personnel understand all hand signals that are to be used. Always wear a hard hat and safety shoes. mask. FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. Check that all protective equipment functions properly before using it. and safety belt when operating or maintaining the machine. precautions and instructions when operating or performing maintenance on the machine. smell. There is a hazard that they may catch on control levers or other protruding parts. connectors).. always remove all mud and oil from the soles of your shoes. Never bring any dangerous objects such as flammable or explosive items into the operator's compartment. lower the work equipment completely to the ground. there is a hazard that the machine may suddenly move and cause serious injury or property damage. SAFETY INFORMATION SAFETY KEEP MACHINE CLEAN If water gets into the electrical system. your foot may slip and this may cause a serious accident. Do not use cellular telephones inside the operator's compartment when driving or operating the machine. Always keep the machine clean. Suction pads act as a lens and may cause fire. set safety lock lever (1) securely to the LOCK position. set safety lock lever (1) securely to the LOCK position. Do not use water or steam to wash the electrical system (sensors. When leaving the machine. LEAVING OPERATOR'S SEAT WITH LOCK Before standing up from the operator's seat (such as when opening or closing the front window or roof window. KEEP OPERATOR'S COMPARTMENT CLEAN When entering the operator's compartment. or that dirt or mud will get into your eyes. there is a hazard that you will slip and fall.12 . there is a hazard that it will cause malfunctions or misoperation. If you accidentally touch the levers when they are not locked. If inspection and maintenance is carried out when the machine is still dirty with mud or oil. then stop the engine. If you operate the pedal with mud or oil affixed to your shoes. or when adjusting the operator's seat). Do not leave parts or tools lying around the operator's compartment. and keep it in the specified place. always lower the work equipment completely to the ground. take it with you. Do not stick suction pads to the window glass. 2 . or when removing or installing the bottom window. then stop the engine. Always remove the key. Use the key to lock all the equipment. Repair any damage and tighten any loose bolts.. or mud on the handrails or steps (including the track shoe). To ensure safety. Never get on or off a moving machine. Do not grip the control levers when getting on or off the machine. always do as follows. Do not get on or off the machine while holding tools in your hand. There is a hazard of falling and suffering serious injury. grease. Before getting on or off the machine. SAFETY SAFETY INFORMATION HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine. If there is any oil. do not jump on to the machine and try to stop it. or other attachments. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine.13 . If the machine starts to move when there is no operator on the machine. Always keep these parts clean. NO PERSONS ON ATTACHMENTS Never let anyone ride on the work equipment. 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) to ensure that you support yourself. 2 . wipe it off immediately. check the handrails and steps (including the track shoe). Never climb on the engine hood or covers where there are no non-slip pads. MOUNTING AND DISMOUNTING Never jump on or off the machine. Diesel oil and gasoline may catch fire. Keep oil and fuel in the determined place and do not allow unauthorized persons to enter. wait for the oil to cool to at temperature where it is possible to touch the cap or plug by hand before starting the operation. or battery. Even when the oil has cooled down. Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids. always observe the following: Do not smoke or use any flame near fuel or oil. wipe up any spilled fuel or oil.. Hot oil To prevent burns from hot oil spurting out when checking or draining the oil. When washing parts with oil. Do not leave the machine while adding fuel or oil. move any flammable materials to a safe place before starting. FIRE PREVENTION AND EXPLOSION PREVENTION Fire caused by fuel or oil Fuel.14 . loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug. Even when the coolant has cooled down. Tighten all fuel and oil caps securely. use a non-flammable oil. exhaust manifold. and window washer liquid are particularly flammable and can be hazardous. Put greasy rags and other flammable materials into a safe container to maintain safety at the work place. so do not use them. loosen the cap slowly to relieve the pressure inside the radiator before removing the cap. oil. or inside the undercovers. SAFETY INFORMATION SAFETY BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant. Stop the engine before refueling. or any other flammable materials accumulated or affixed around the engine. Use well-ventilated areas for adding or storing oil and fuel. Fire caused by accumulation of flammable material. Remove any dry leaves. Do not spill fuel on overheated surfaces or on parts of the electrical system. When carrying out grinding or welding work on the chassis. chips. wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation. 2 . antifreeze. muffler. After adding fuel or oil. To prevent fire. dust. pieces of paper. there is danger of explosion that may cause serious injury. When taking the electrical power for the lighting from the machine itself. guards. consider the operating conditions and install the necessary guards to protect the operator. When carrying out the above operations. 2 . Use the handrails and steps to get off the machine. In addition. Tighten any loose connectors or wiring clamps. or intruding objects may hit or enter the operator's cab. always close the front window. and cushions are securely fixed in position. FALLING OBJECTS. but it may be necessary to add additional guards according to the operating conditions on the jobsite. install a front guard and use a laminated coating sheet on the front glass. This may lead to damage to the hoses. If they are loose. and cause high-pressure oil to spurt out. flying objects. always ensure that by standers are a safe distance away and are not in hazard from falling or flying objects.15 . Turn the start switch OFF to stop the engine. or coolant. battery electrolyte. install FOPS (Falling Objects Protective Structure) and a front guard. Methyl alcohol base washer liquid may irritate your eyes. When carrying out demolition or breaker operations. oil. and use a laminated coating sheet on the front glass.. leading to fire damage or serious injury. If such lighting equipment is not used. The above recommendations assume that the conditions are for standard operations. Always contact your Komatsu distributor for advice. escape from the machine as follows. Explosion caused by lighting equipment When checking fuel. Always keep electric wiring connections clean and securely tightened. window washer fluid. they may vibrate during operation and rub against other parts. FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION On jobsites where there is a hazard that falling objects. follow the instructions in this manual. always use lighting with anti-explosion specifications. Check the wiring every day for looseness or damage. so do not use it. SAFETY SAFETY INFORMATION Fire coming from electric wiring Short circuits in the electrical system can cause fire. Repair or replace any damaged wiring. ACTION IF FIRE OCCURS If a fire occurs. Fire coming from hydraulic line Check that all the hose and tube clamps. When working in mines or quarries where there is a hazard of falling rock. WINDSHIELD WASHER FLUID Use an ethyl alcohol base washer liquid. thereby deteriorating its protective characteristic. If there is a crack or damage caused by a fallen rock. If water lines. consult your Komatsu distributor. dry leaves or dry grass. CAB WINDOW GLASSES If a pane of the cab window on the work equipment side is broken. product failures or other property damages resulting from modifications made without authorization from Komatsu. Check the terrain and condition of the ground at the worksite. or high-voltage electrical lines may be buried under the worksite. When installing and using optional attachments. When traveling or operating in shallow water or on soft ground. stop the machine immediately and replace the broken pane with new one. or when any sign of them is noticed. contact each utility and identify their locations. and the general information related to attachments in this manual. 2 . In that case. check the shape and condition of the bedrock. UNAUTHORIZED MODIFICATIONS Any modification made without authorization from Komatsu can create hazards.. and the depth and speed of flow of the water before starting operations. Therefore contact your Komatsu distributor for advice. The ceiling window is made of organic glass (polycarbonate). and as such it is apt to break easily when receiving damage on the surface. thoroughly check the area for any unusual conditions that could be dangerous. the work equipment may directly hit the operator. Komatsu will not be responsible for any injuries. SAFETY AT JOBSITE Before starting operations. Be careful not to sever or damage any of these lines. Before making a modification. gas lines. Do not carry out operations at places where there is a hazard of landslides or falling rocks. so be careful when operating. Take necessary measures to prevent any unauthorized person from entering the operating area. read the instruction manual for the attachment. When carrying out operations near combustible materials such as thatched roofs. there may be problems with safety or legal restrictions. there is a hazard that the work equipment may hit the cab or other parts of the machine. there is a hazard of fire. Before using unfamiliar work equipment. check if there is any hazard of interference. ATTACHMENT COMBINATIONS Depending on the type or combination of work equipment. replace it with a new window. SAFETY INFORMATION SAFETY ATTACHMENT INSTALLATION When installing optional parts or attachments. accidents. or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. and operate with caution.16 . and determine the safest method of operation. accidents. Any injuries. . SAFETY SAFETY INFORMATION WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas. When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling. DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows. Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action. Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always Voltage of Cables Safety Distance maintain a safe distance (see the table on the right) between the 100 V - 200 V Over 2 m (7ft) machine and the electric cable. Check with the local power 6,600 V Over 2 m (7ft) company about safe operating procedure before starting 22,000 V Over 3 m (10 ft) operations. 66,000 V Over 4 m (14 ft) To prepare for any possible emergencies, wear rubber shoes 154,000 V Over 5 m (17 ft) and gloves. Lay a rubber sheet on top of the seat, and be careful 187,000 V Over 6 m (20 ft) not to touch the chassis with any exposed part of your body. 275,000 V Over 7 m (23 ft) Use a signalman to give warning if the machine approaches too close to the electric cables. 500,000 V Over 11 m (36 ft) When carrying out operations near high voltage cables, do not let anyone come close to the machine. If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone come close to the machine. ENSURE GOOD VISIBILITY Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely. Always do as follows. Position a signalman if there are areas at the rear of the machine where the visibility is not good. When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up additional lighting in the work area if necessary. Stop operations if the visibility is poor, such as in mist, snow, rain, or dust. 2 - 17 . SAFETY INFORMATION SAFETY VENTILATION FOR ENCLOSED AREA Exhaust fumes from the engine can kill. If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning. SIGNALMAN'S SIGNAL AND SIGNS Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman. Only one signalman should give signals. Make sure that all workers understand the meaning of all signals and signs before starting work. EMERGENCY EXIT FROM OPERATOR'S CAB If the cabin door does not open, open the rear window and use it as an emergency escape exit. For details, see "Emergency exit from operator's compartment" in this manual. ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste. Always observe the following. Spray water to keep down the dust when cleaning. Do not use compressed air for cleaning. If there is danger that there may be asbestos dust in the air, always operate the machine from an upwind position. All workers should use an approved respirator. 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 - 18 . 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 (1). 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. Remove all dirt from the lens surface of the front lamps and working lamp and check that they light up properly. When cleaning the working lamp (side face of boom), use equipment designed for working at high places. Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no damage or wear to the seat belt or mounting clamps. Check that the gauges work properly, check the angle of the lights and working lamps, and check that the control levers are all at the neutral position. Before starting the engine, make sure that the safety lock lever is in the LOCK position. Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. When adjusting, see "Rearview Mirrors (PAGE 3-82)". Check that there are no persons or obstacles above, below, or in the area around the machine. SAFETY RULES FOR STARTING ENGINE When starting the engine, sound the horn as a warning. Start and operate the machine only while seated. Do not allow anyone apart from the operator to ride on the machine. Do not short circuit the starting motor circuit to start the engine. Short circuit can cause fire. 2 - 19 . SAFETY MACHINE OPERATION SAFETY STARTING ENGINE IN COLD WEATHER Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery. Before charging or starting the engine with a different power source, melt the battery electrolyte and check for frost and leakage of battery electrolyte before starting. 2 - 20 . 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. If it does not match, replace it immediately with the correct control pattern card. Check the operation of the work equipment, traval system and swing system. Check for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel. If any abnormality is found, carry out repairs immediately. SAFETY RULES FOR CHANGING MACHINE DIRECTIONS Before traveling, position the upper structure so that the sprocket is at the rear of the operator's cab. If the sprocket is at the front of the operator's cab, the machine makes a movement reverse to the control lever movement (for example, forward becomes reverse, and left becomes right). Be careful to avoid such a reverse movement of the machine. Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles. Before travelling, sound the horn to warn people in the area. Always operate the machine only when seated. Do not allow anyone apart from the operator to ride on the machine. Check that the travel alarm (if equipped) works properly. Always lock the door and windows of the operator's compartment in position (open or closed). On jobsites where there is a hazard of flying objects or of objects entering the operator's compartment, check that the door and windows are securely closed. 2 - 21 . SAFETY MACHINE OPERATION SAFETY If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other machines or people when turning or swinging the machine. Always be sure to carry out the above precautions even when the machine is equipped with mirrors. SAFETY RULES FOR TRAVELING When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the area. When traveling on rough ground or steep slopes, if the machine is equipped with auto-deceleration, always turn the auto-deceleration switch OFF (cancel). Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side. When traveling or carrying out operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them. When passing over bridges or structures, check first that the structure is strong enough to support the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions. When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate slowly and be extremely careful not to let the work equipment hit anything. 2 - 22 and travel at low speed. If the engine stops when the machine is traveling on a slope. Keep the work equipment approx. When traveling up a steep slope. then travel on to the slope again. 2 . when travel down slopes. fallen leaves. When traveling downhill. When travel up slopes. or wet steel plates with low speed. set the operator's cab facing downhill.23 . keep the travel lever close to the neutral position. Traveling at an angle or across the slope is extremely dangerous. SAFETY SAFETY MACHINE OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side. Always go down to a flat place to change the position of the machine. lower the work equipment to the ground immediately to help stop the machine. In case of emergency. extend the work equipment to the front to improve the balance.. lower the engine speed. Always travel straight up or down a slope. always do as follows. set the operator's cab facing uphill. Travel on grass. 20 to 30 cm (8 to 12 in) above the ground. Do not turn on slopes or travel across slopes. Even with slight slopes there is a hazard that the machine may slip. keep the work equipment approximately 20 to 30cm (8 to 12 in) above the ground. Always check the firmness of the ground under the front of the machine when traveling. and travel at low speed. move the control levers immediately to the neutral position and start the engine again. 2 . Do not excavate too deeply under the front of the machine. pile the soil to make a platform that will keep the machine as horizontal as possible. there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded. so always provide a stable place when carrying out these operations. This operation is dangerous. and operate carefully. and may cause the machine to tip over. If the machine has to be used on a slope. The ground under the machine may collapse and cause the machine to fall. set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations.24 . PROHIBITED OPERATIONS Never dig the work face under an overhang.. To make it easier to escape if there is any problem. This may lead to serious injury or property damage. SAFETY MACHINE OPERATION SAFETY OPERATIONS ON SLOPES When working on slopes. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine. With frozen ground surfaces. There is a hazard of the machine tipping over or hitting covered objects. If the machine enters deep snow. the ground becomes soft when the temperature rises. swing.25 . When working on or from the top of buildings or other structures. SAFETY SAFETY MACHINE OPERATION Do not carry out demolition work under the machine. and do not operate the levers suddenly. OPERATIONS ON SNOW Snow-covered or frozen surfaces are slippery. There is a hazard of damage to the work equipment or a hazard of serious personal injury being caused by flying pieces of broken materials or the machine tipped over due to reaction from the impact. Do not use the impact force of the work equipment for breaking work. When operating on flat ground as well as on slopes. When carrying out demolition work. There is a hazard of broken parts falling or of the building collapsing and causing serious injury or property damage. the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear. do not carry out demolition above your head. and this may cause the machine to tip over. When using a breaker or other heavy work equipment. Do not suddenly extend or retract the boom cylinder. Even a slight slope may cause the machine to slip. or stop the work equipment. so always carry out operations carefully. the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. 2 . Do not suddenly lower.. There is a hazard of the building collapsing and causing serious injury or damage. When clearing snow. There is a hazard that impact will cause the machine to tip over. The load may spill or the bucket may hit the dump truck and cause serious injury or property damage. there is a hazard that it may tip over or become buried in the snow. There is a hazard that the machine may become unstable and tip over. Be careful not to leave the road shoulder or to get trapped in a snow drift. so be extremely careful when traveling or operating the machine. check the strength and the structure before starting operations. there is a hazard of the machine losing its balance and tipping over. Generally speaking. Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment. so be particularly careful when working on slopes. and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Lower the work equipment completely to the ground. When parking the machine on a public road. and leave it in the specified place. Always remove the key. Select a place where there is no hazard of falling rocks or landslides.26 .. always do as follows. If it is necessary to park the machine on a slope. Always close the operator's cab door. Set the bucket on the downhill side. set safety lock lever (1) to the LOCK position. take it with you. SAFETY MACHINE OPERATION SAFETY PARKING MACHINE Park the machine on firm. Put blocks under the tracks to prevent the machine from moving. set up signs and fences to prevent interference with passing traffic and to enable the machine to be seen clearly even at night. or of flooding if the land is low. then stop the engine. then dig it into the ground. level ground. When leaving the machine. 2 . so be sure to confirm the dimensions. SHIPPING THE MACHINE When shipping the machine on a trailer. and overall length of the machine differ according to the work equipment. see TRANSPORTATION (PAGE 3-121). transportation height. do as follows. SAFETY SAFETY MACHINE OPERATION TRANSPORTATION The machine can be divided into parts for transportation. 2 . check first with the relevant authorities and follow their instructions. check first that the structure is strong enough to support the weight of the machine.. so when transportating the machine. When traveling on public roads. The weight. please contact your Komatsu distributor to have the work carried out. When passing over bridges or structures on private land.27 . For details of the procedure when transporting the machine. SAFETY MACHINE OPERATION SAFETY BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid. For this reason. when installing the battery. and connect the ground last. Never smoke or use any flame near the battery. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. Install the battery securely to the determined place. flush them immediately with large amount of water and seek medical attention. always wear safety glasses and rubber gloves. Flammable hydrogen gas is generated when the battery is charged. and remove the battery caps before charging it. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.28 . always observe the following precautions. If acid gets into your eyes. connect the positive (+) terminal first. immediately flush the area with large amount of water. If you spill acid on your clothes or skin. As there is a hazard that sparks will be generated. Tighten the battery caps securely. Before working with batteries. take it to a well-ventilated place. Do not leave tools or other metal objects lying around near the battery. turn the starting switch to the OFF position. so remove the battery from the chassis. which may explode. and batteries generate flammable hydrogen gas. This may cause an explosion. Do not let tools or other metal objects make any contact between the battery terminals. Attach the battery terminal securely.. 2 . When working with batteries. Mistaken handling can lead to serious injury or fire. Always disconnect the negative (-) terminal (ground side) first when removing the battery. always do as follows. 2 . For details of the starting procedure when using booster cables. so always do as follows.. do not allow the two machines to touch. always use a normal machine with the same battery voltage as the problem machine. carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery). turn the starting switch OFF for both the normal machine and problem machine. Disconnect the negative (-) cable (ground side) first when removing them. There is a hazard that the machine will move when the power is connected. see "Starting Engine With Booster Cables (PAGE 3-141)" in the OPERATION section. Be sure to connect the positive (+) cable first when installing the 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. Always wear safety goggles and rubber gloves when starting the engine with booster cables. When connecting a normal machine to a problem machine with booster cables. When starting with a booster cable. When starting from another machine.29 . When removing the booster cables. When connecting the booster cables. be careful not to let the booster cable clips touch each other or to let the clips touch the machine. Always wear leather gloves when handling wire rope. reduced diameter (B). For towing. 2 . During the towing operation. see "TOWING THE MACHINE (PAGE 3-138)".30 .. There is danger that the rope may break during the towing operation. never stand between the towing machine and the machine being towed. Never use a wire rope which has cut strands (A). Fix the wire rope to the track frame. SAFETY MACHINE OPERATION SAFETY 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. or kinks (C). Never tow a machine on a slope. or touch or operate the work equipment control lever while you are performing service or maintenance. or other substances that will cause you to slip. KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. deteriorating polycarbonate in use. Attach additional warning tags around the machine if necessary. 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. Wipe up all grease. 09963-03000 Keep this warning tag in the tool box while it is not used. If others start the engine. If the work place is not kept claen and tidy. Always keep the work place clean and tidy to enable you to carry out operations safely. keep the tag in the operation manual pocket. there is the danger that you will trip. you could suffer serious injury or property damage. An organic solvent like benzene. slip. or fall over and injure yourself. appoint a leader and follow his instructions during the operation. Warning tag Part No.. toluene or methanol can invite a chemical reaction like dissolution and decomposition on the window glass. oil. When cleaning the ceiling window which is made of organic glass (polycarbonate). APPOINT LEADER WHEN WORKING WITH OTHERS When repairing the machine or when removing and installing the work equipment. use tap water and avoid use of organic solvents for cleaning. If there is not the tool box. 2 .31 . . SAFETY MAINTENANCE INFORMATION SAFETY STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm. Select a place where there is no hazard of falling rocks or landslides. and then push up safety lock lever (1) to the LOCK position.32 . level ground. Put blocks under the track to prevent the machine from moving. 2 . left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit. Operate the work equipment control lever back and forth. or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine. Turn the starting switch to the ON position. carry out the operation with at least two workers and do as follows. Do not touch any control levers.33 . do not carry out maintenance with the engine running. 2 . give a signal to the other workers to warn them to move to a safe place. low quality.. When carrying out operations near the fan. Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying. Using damaged. Set safety lock lever (1) to the LOCK position to prevent the work equipment from moving. so be careful not to come close. If maintenance must be carried out with the engine running. One worker must always sit in the operator's seat and be ready to stop the engine at any time. makeshift tools or improper use of the tools could cause serious personal injury. All workers must maintain contact with the other workers. faulty. there is a hazard of being caught in the parts. SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury. or other rotating parts. PROPER TOOLS Use only tools suited to the task and be sure to use the tools correctly. fan belt. If any control lever must be operated. Do not bring it near flame or dispose of it in fire. And take steps to prevent unauthorized persons from entering the storage area. or use a cutting torch. Never work under the work equipment or the machine. the work equipment or the machine will suddenly drop. support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine. If necessary. Do not make holes in it. Do not disassemble the accumulator. or subject it to any impact. When disposing of the accumulator. employ an observer. Place attachments that have been removed from the machine in a stable condition so that they do not fall. always observe the following precautions.. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. the gas must be released. WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance.34 . When handling the accumulator. SAFETY MAINTENANCE INFORMATION SAFETY ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas. or there is damage occurring to the hydraulic piping. careless procedure may cause an explosion which could lead to serious injury or property damage. If the noise from the machine is too loud. Do not hit or roll the accumulator. Do not allow unauthorized personnel into the area. Please contact your Komatsu distributor to have this work performed. it may cause temporary or permanent hearing problems. NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time. If any of the control levers is touched by accident. For this reason. weld it. wear ear covers or ear plugs while working. This is extremely dangerous. PERSONNEL Only authorized personnel can service and repair the machine. 2 . It is extremely dangerous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment. If it is disassembled by mistake.. There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area. REMOVING BATTERY TERMINALS When repairing the electrical system or when carrying out electrical welding. ask your Komatsu distributor to do the work. It contains a spring under high pressure which serves as a shock absorber for the idler.35 . remove the negative (-) terminal of the battery to prevent the flow of current. When hitting pins or bucket teeth. grease drain plug (1) may fly out and cause serious injury or property damage. or any other part of your body close to grease drain plug (1). or electrocution when carrying out welding. cutting edges. hands. there is a hazard that broken pieces might be sent flying and injure people in the surrounding area. so never allow any unqualified personnel to carry out welding. there is a hazard that pieces might be scattered and cause injury. SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment system under high pressure. When loosening grease drain plug (1) to loosen the track tension. the spring will fly out and cause serious injury. Never put your face. 2 . Loosen the grease drain plug slowly. Always wear safety goggles and gloves. If hard metal parts such as pins. fire. pins may fly out or metal particles may be scattered. This may lead to serious injury. bucket teeth. There is a hazard of gas. SAFETY SAFETY MAINTENANCE INFORMATION WHEN USING HAMMER When using a hammer. never loosen it more than one turn. When it becomes necessary to disassemble it. feet. DO NOT DISASSEMBLE RECOIL SPRINGS Never attempt to disassemble the recoils spring assembly. Always check that there is no one in the surrounding area. If the specified procedure for maintenance is not followed when making adjustment. Always do as follows. WELDING WORKS Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. or bearings are hit with a hammer. pay careful attention to the method of disposing of waste materials. wash the place with clean water. Frayed or cut covering or exposed reinforcement wire layer. if it touches your skin.. If any loose bolts are found. Always put oil drained from your machine in containers. Replace the hose if any of the following problems are found. so check for cracks in the piping and hoses and for swelling in the hoses. and consult a doctor immediately for medical attention. stop operations immediately and contact your Komatsu distributor.36 . Covering swollen in places. wear safety glasses and leather gloves. If any damaged hoses are found. Foreign material embedded in covering. Obey appropriate laws and regulations when disposing of harmful objects such as oil. so always do as follows. filters. or lakes. see "METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT (PAGE 4-40)". 2 . WASTE MATERIALS To prevent pollution. coolant. which may lead to serious injury. There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. Twisted or crushed movable portion. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes. it may cause fire or defective operation. If there is any leakage from the piping or hoses. AIR CONDITIONER MAINTENANCE If air conditioner refrigerant gets into your eyes. Never touch refrigerant. rivers. Never drain oil directly onto the ground or dump into the sewage system. and batteries. If the circuit is still under pressure. When carry out inspection. the sea. it will lead to serious injury. For details of the method of releasing the pressure. the surrounding area will be wet. always check that the pressure in the hydraulic circuit has been released. solvent. SAFETY MAINTENANCE INFORMATION SAFETY SAFETY RULES FOR HIGH-PRESSURE OIL The hydraulic system is always under internal pressure. it may cause blindness. If the circuit is still under pressure. stop work and tighten to the specified torque. do not carry out any inspection or replacement operation. fuel. Damaged or leaking hydraulic fitting. it may cause frostbite. SAFETY HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses. When inspecting or replacing piping or hoses. In order to further increase safety. such as hoses and seat belts. gloves. and fatigue. Replace or repair safety-critical parts if any defect is found. 2 . Replacement of safety critical parts: See "SAFETY CRITICAL PARTS (PAGE 4-14)". PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS In order for the machine to be operated safety for a long time. components with a strong relationship to safety. When using compressed air to clean elements or the radiator.37 . SAFETY SAFETY MAINTENANCE INFORMATION COMPRESSED AIR When carrying out cleaning with compressed air. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating. even when they have not reached the time specified interval. dust mask. there is a hazard of serious injury caused by flying particles. there is a hazard that these components may fail and cause serious injury or death. always wear safety goggles. must be replaced at periodic intervals. it is necessary to add oil and to carry out service and maintenance at periodic intervals. As a result. wear. and repeated use causes deterioration. The material of these components naturally changes over time.. and other protective equipment. so always replace them at the specified interval. .. 3-1 .. MACHINE VIEW ILLUSTRATIONS OPERATION MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW (1) Bucket (7) Boom cylinder (2) Bucket link (8) Sprocket (3) Bucket cylinder (9) Track frame (4) Arm (10) Track shoe (5) Arm cylinder (11) Idler (6) Boom (12) Overhead guard 3-2 .. . OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES 3-3 . MACHINE VIEW ILLUSTRATIONS OPERATION (1) Car radio (26) Wiper monitor (2) Large capacity airflow air conditioner blower switch (27) Engine pre-heating monitor (if equipped) (28) Swing lock monitor (3) Rotating lamp switch (if equipped) (29) Engine water temperature monitor (4) Lower wiper switch (machines equipped with fixed (30) Engine oil pressure monitor front window cab) (31) Engine water temperature gauge (5) Airconditioner control panel (32) Charge monitor (6) Safety lock lever (33) Radiator water level monitor (7) Left work equipment control lever (34) Working mode monitor (8) Travel pedal (35) Hydraulic oil temperature monitor (9) Travel lever (36) Hydraulic oil temperature gauge (10) Cigarette lighter (37) Maintenance interval monitor (11) Machine monitor (38) Service meter (12) Horn switch (39) Travel speed monitor (13) Right work equipment control lever (40) Engine oil level monitor (14) Starting switch (41) Air cleaner clogging monitor (15) Fuel control dial (42) Fuel gauge (16) Lamp switch (43) Fuel level monitor (17) Alarm buzzer stop switch (44) Auto-deceleration monitor (18) Swing lock switch (45) Display control switch (19) Machine push-up switch (46) Input control switch (20) Swing holding brake release switch (47) Window washer switch (21) Emergency pump drive switch (48) Wiper switch (22) Step light switch (49) Maintenance switch (23) Boom shockless control switch (50) Travel speed selector switch (24) . (51) Auto-deceleration switch (25) Working mode selector switch 3-4 .. OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of the devices needed for operating the machine. MONITORING SYSTEM A:Basic check Items D:Meter Display Portion B:Caution Items E:Monitor Switches C:Emergency Stop Items 3-5 . To carry out suitable operations correctly and safely.. it is important to understand fully the methods of operating the equipment and the meanings of the displays. After displaying the check before starting screen for 2 seconds. 3-6 . the screen returns to the normal screen. warning screen. After displaying the check before starting screen for 2 seconds. the screen changes to the maintenance interval warning screen. or error screen. DETAILED CONTROLS AND GAUGES OPERATION Basic Operation Of Machine Monitor If There Is Abnormality When Starting ngine If there is any abnormality when starting the engine. After displaying the maintenance interval warning screen for 30 seconds.. the check before starting screen changes to the maintenance interval warning screen. the screen changes to the warning screen or error screen. After displaying warning screen (1) for 2 seconds. OPERATION DETAILED CONTROLS AND GAUGES If Any Abnormality Occurs During Operation If any abnormality occurs during operation.. the screen automatically changes to warning screen (2). the normal operation screen changes to warning screen (1) or the error screen. 3-7 . If there is any abnormality. the monitor for the location of the abnormality will light up. 3-8 . the lamp lights up red. do not simply rely on the monitors. Always get off the machine and check each item directly.. A(1) Radiator coolant level monitor A(3) Maintenance interval monitor A(2) Engine oil level monitor Radiator Coolant Level Monitor This monitor (1) warns the operator that there has been a drop in the radiator water level. so check the water level in the radiator and the subtank. If the radiator water level is low. This displays the basic items among the check before starting items that must be checked before starting the engine. DETAILED CONTROLS AND GAUGES OPERATION Basic Check Monitors These monitors do not ensure that the machine is in good condition. When carrying out checks before starting (daily checks). and add water. the lamp lights up red. OPERATION DETAILED CONTROLS AND GAUGES Engine Oil Level Monitor This monitor (2) warns the operator that there has been a drop in the oil level in the engine oil pan. and add oil. 3-9 . so check the oil level in the engine oil pan. please consult your Komatsu distributor.. This monitor screen goes out after 30 seconds and returns to the normal operation screen. If the oil level in the engine oil pan is low. If it is desired to change the setting of the maintenance interval. For details of the method of checking the maintenance interval. see "Maintenance Switch (PAGE 3-23)". Maintenance interval Monitor This monitor (3) lights up to warning the operator that the set time has passed since the maintenance was last carried out. B(1) Charge level monitor B(4) Engine water temperature monitor B(2) Fuel level monitor B(5) Hydraulic oil temperature monitor B(3) Air cleaner clogging monitor Charge Level Monitor This monitor (1) warns the operator that there is an abnormality in the charging system when the engine is running. the lamp will remain lit and will go off once the engine is started. check for looseness of the V-belt. For details. If any abnormality is found. the lamp may light up and the buzzer may sound momentarily. it lights up red. it may lead to failure. When the engine is started or stopped with the starting switch at the ON position. the screen displays the item that needs immediate action. DETAILED CONTROLS AND GAUGES OPERATION Caution Monitors If the warning monitor lights up red.10 . If there is an abnormality. If the battery is not being charged properly while the engine is running. If it lights up red.. take the necessary action. 3 . see "OTHER TROUBLE (PAGE 3-143)" REMARK While the starting switch is ON. but this does not indicate any abnormality. If any abnormality occurs. These are items that should be observed while the engine is running. the monitor for the abnormal location lights up red. If the warning is ignored. stop operations as soon as possible and carry out inspection and maintenance of the applicable location. Continue the warming-up operation until monitor (5) changes to green. For details. Hydraulic Oil Temperature Monitor If this monitor (5) lights up white in low temperatures. Engine Water Temperature Monitor If this monitor (4) lights up white in low temperatures. If it lights up red. For details. OPERATION DETAILED CONTROLS AND GAUGES Fuel Level Monitor This monitor (2) lights up to warn that the operator that the level in the fuel tank is low. carry out the warming-up operation. so add fuel as soon as possible. see "Warming-Up Operation (PAGE 3-90)". Air Cleaner Clogging Monitor This monitor (3) warns the operator that the air cleaner is clogged. 3 .11 . Continue the warming-up operation until monitor (4) changes to green.26 US gal). stop the engine and inspect and clean the air cleaner.. If the remaining amount of fuel goes down to 300 liters (79. see "Warming-Up Operation (PAGE 3-90)". the light changes from green to red. carry out the warming-up operation. C(1) Engine water temperature monitor C(3) Engine oil pressure monitor C(2) Hydraulic oil temperature monitor Engine Water Temperature Monitor This monitor (1) warns the operator that the engine water temperature has risen. If there is an abnormality. stop the engine immediately or run it at low idling.12 . These are items that should be observed while the engine is running.. If the engine water temperature becomes abnormally high. the overheat prevention system is automatically actuated. the monitor lights up red. DETAILED CONTROLS AND GAUGES OPERATION Emergency Monitors If the monitor lights up red. 3 . the monitor for the abnormal location lights up red and the buzzer sounds. and the engine speed goes down. Stop operations and run the engine at low idling until monitor (1) changes to green. so carry out action immediately. then check the applicable location and carry out the necessary action. If it lights up red. Color when monitor lights up Type of monitor When When At low normal abnormal temperature Radiator coolant level monitor OFF Red - Engine oil level monitor OFF Red - Maintenance interval monitor OFF Red - Charge monitor OFF Red - Fuel level monitor Green Red - Air cleaner clogging monitor OFF Red - Engine water temperature monitor Green Red White Hydraulic oil temperature monitor Green Red White Engine oil pressure monitor OFF Red - 3 . OPERATION DETAILED CONTROLS AND GAUGES Hydraulic Oil Temperature Monitor This monitor (2) warns the operator that the hydraulic oil temperature has risen. caution items. and check the lubrication system and the level of oil in the oil pan. If it lights up red during operations.. run the engine at low idling or stop the engine and wait until the oil temperature goes down and the monitor changes to green. and emergency stop items is as follows. REMARK The color when the monitor lights up for the basic check items.13 . stop the engine. Engine Oil Pressure Monitor This monitor (3) lights up red if the engine lubrication oil pressure goes below the normal level. Engine Pre-heating Monitor This monitor lamp (1) indicates the pre-heating time required when starting the engine at an ambient temperature below 0°C (32°F). The monitor lamp lights when the starting switch is turned to HEAT position and flashes after about 30 seconds to show that the pre-heating is completed. (The monitor lamp will go off after about 10 seconds.14 .) 3 . the pilot display lights up when the display items are functioning.. DETAILED CONTROLS AND GAUGES OPERATION Meter Display Portion D(1) Engine pre-heating monitor D(6) Travel speed monitor D(2) Swing lock monitor D(7) Engine water temperature gauge D(3) Wiper monitor D(8) Fuel gauge D(4) Auto-deceleration monitor D(9) Hydraulic oil temperature gauge D(5) Working mode monitor D(10) Service meter Pilot Display When the starting switch is ON. 15 .. REMARK The swing motor is equipped with a disc brake that mechanically stops the rotation. A : A mode (for heavy-load operations) E : E mode (for operations with emphasis on fuel economy) X: Heavy-duty lift (boom lifting power increased when raising boom independently) Y: Swing priority mode (priority given to swing when operating boom and swing simultaneously) 3 . When ON lights up : Wiper moves continuously When INT lights up : Wiper moves intermittently OFF : Wiper stops Auto-deceleration Monitor This monitor (4) shows if the auto-deceleration function is being actuated. the monitor lamp lights up. Actuated: Lights up When the swing lock switch is turned ON (ACTUATED). Wiper Monitor This monitor (3) indicates the operating status of the wiper. The monitor display when the wiper switch is operated is as follows. the brake remains applied. This monitor flashes when the swing holding brake release switch is turned on. The monitor display when the working mode switch is operated is as follows. The monitor display when the auto-deceleration switch is operated is as follows. When the swing lock monitor lamp is lighted up. Auto-deceleration monitor ON : Auto-deceleration actuated Auto-deceleration monitor OFF : Auto-deceleration canceled Working Mode Monitor This monitor (5) displays the set working mode. OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Monitor This monitor (2) informs the operator that the swing lock is being actuated. if the indicator is at position (C). engine water temperature monitor lamp (C) lights up red.. carry out the warming-up operation. Lo : Low speed Hi : High speed Gauges and Meter Engine Water Temperature Gauge This meter (7) indicates the engine cooling water temperature. The overheat prevention system remains actuated until the indicator returns to the black range. During normal operations. the overheat prevention system is actuated. In this case. The monitor display when the travel speed selector switch is operated is as follows. see "Warming-Up Operation (PAGE 3-90)". If the indicator enters the red range during operations.16 . When the engine is started. Red range position (A): Engine water temperature monitor (1) lights up red Red range position (B): Engine speed is reduced to low idling. For details. 3 . DETAILED CONTROLS AND GAUGES OPERATION Travel Speed Monitor This monitor (6) displays the set mode for the travel speed. and the alarm buzzer sounds at same time. engine water temperature monitor (1) lights up white. The overheat prevention system acts as follows. the indicator should be in the black range. the indicator should be in the black range. During operations.. fuel level monitor (1) lights up red. If the indicator enters the red range.6°F). carry out the warming-up operation. but this is not an abnormality.26 US gal) of fuel remaining in the tank. so check and add fuel. REMARK When the indicator is in the red range (A). the indicator should be in the black range. Stop the engine or run it at low idling and wait for the hydraulic oil temperature to go down. 3 . For details. REMARK If the indicator enters red range (B). When the indicator is in the red range (A) to (B). do not carry out operations on steep slopes. If the indicator is at position (C) when the engine is started.17 . During operations. Hydraulic Oil Temperature Gauge This meter (9) displays the hydraulic oil temperature.48 US gal) of fuel remaining. the hydraulic oil temperature is as follows. If the indicator enters red range (A) during operations. the hydraulic oil temperature is more than 25°C (77°F). If the indicator enters red range (A) during operations. hydraulic oil temperature monitor (1) lights up red. see "Warming-Up Operation (PAGE 3-90)". Red range position (A):: More than 102°C (215. and hydraulic oil temperature monitor (1) lights up white. there is less than 300 liters (79. OPERATION DETAILED CONTROLS AND GAUGES Fuel Gauge This meter (8) displays the level of the fuel in the fuel tank. There is danger that the engine will stall. the hydraulic oil temperature as gone above 102°C (215. In this case. The correct fuel may not be displayed for a short time when the starting switch is turned ON. there is less than 210 liters (55.6°F) Red range position (B):: More than 105°C (221°F) When the indicator is in the red range (A) to (B). The service meter advances by 1 for every hour of operation. DETAILED CONTROLS AND GAUGES OPERATION Service Meter This monitor (10) displays the total time that the machine has been operated. the service meter advances even if the machine is not moving. 3 ..18 . When the starting switch is ON. regardless of the engine speed. Use the time display to set the maintenance interval. OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion E(1) Working mode selector switch (basic switch) E(7) - E(2) Auto-deceleration switch (selection switch) E(8) Back switch E(3) Travel speed selector switch E(9) Up switch E(4) Wiper switch E(10) Down switch E(5) Window washer switch E(11) Input confirmation switch E(6) Maintenance switch E(12) Adjusting brightness and contrast Working Mode Selector Switch (Basic Switch) This switch (1) is used to set the power and movement of the work equipment. Operations can be carried out more easily by selecting the mode to match the type of operation. the working mode is set automatically to A mode. The monitor display on the monitor display portion changes for each mode. it is possible to select the other modes. L.. 3 . please ask your Komatsu distributor to change the setting. A mode: For heavy-load operations E mode: For operations with emphasis on fuel economy Heavy-duty lift mode: boom lifting power increased when raising boom independently Swing priority mode: priority given to swing when operating boom and swing simultaneously When the engine is started. When the switch is pressed. or B mode (default options setting).19 . If it is desired to have the working mode set to start automatically in E. DETAILED CONTROLS AND GAUGES OPERATION REMARK When the mode selector switch is pressed.20 .. (The diagram on the left is an example of the display for the E mode. the mode is displayed in the center of the monitor display. and the engine speed is automatically lowered to reduce fuel consumption. the mode is displayed in the center of the monitor display.) Auto-deceleration Switch (Selection Switch) When this auto-deceleration switch button (2) is depressed. and the screen returns to the normal screen after 2 seconds. the auto-deceleration is actuated. 3 . Monitor display ON : Auto-deceleration actuated Monitor display OFF : Auto-deceleration canceled Each time that the switch is pressed. if the control levers are in the neutral position. and the screen returns to the normal screen after 2 seconds. the auto-deceleration switches between actuated and canceled. REMARK When the auto-deceleration switch is pressed and the auto-deceleration is actuated. . 3 . This switch (3) is used to set the travel speed to 3 stages. and the screen returns to the normal screen after 2 seconds. Never operate the travel speed selector switch during the loading or unloading operation. the display changes Lo → Mi → Hi → Lo in turn. Lo lights up : Low-speed travel Hi lights up : Hi-speed travel When the engine is started. the mode is displayed in the center of the monitor display. the speed automatically switches to low speed (Lo).21 . such as when traveling on soft ground or on slopes. The monitor display stays at Hi. REMARK Each time that the travel speed selector switch is operated. so there is no need to operate the switch. the machine may deviate to one side. the speed is automatically set to Lo. OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch When loading on or unloading from a trailer. even when traveling in a straight line. When traveling in high speed (Hi). Stop the machine before switching the travel speed. Each time that the switch is pressed. always travel at low speed (with the travel speed selector switch put at the Lo position). if travel power is needed. If the travel speed is switched between Hi and Lo when the machine is traveling. When the switch is released. and will then return to intermittent operation. 3 . window washer fluid is sprayed out on the front glass. If the wiper is moving intermittently and switch (4) is kept pressed continuously. the mode is displayed in the center of the monitor display. The screen returns to the normal screen after 2 seconds. and at the same time. Monitor display ON lighted up : Wiper moves continuously Monitor display INT lighted up : Wiper moves intermittently Monitor display OFF : Wiper stops REMARK Each time that the wiper switch is operated. it changes ON → INT → stop (OFF). the wiper will be actuated continuously. and at the same time.22 . the wiper will con-tinue to operate continuously for 2 cycles. the spray stops. When switch (4) is released. the window washer fluid will spray out. Window Washer Switch This switch (5) is kept continuously pressed.. When switch (4) is released. the wiper will continue to operate continuously for 2 cycles. and will then stop. If switch (4) is kept pressed when the wiper is stopped. DETAILED CONTROLS AND GAUGES OPERATION Wiper Switch This switch (4) operates the wiper for the front glass. thewindow washer fluid will spray out. Each time the switch is pressed. the wiper will be actuated con-tinuously. When this happens. carry out maintenance for that item also. White display : More than 30 hours remaining to maintenance Yellow display : Less than 30 hours remaining to maintenance Red display : Maintenance time has already passed NOTICE 1. When this switch (6) is pressed..Press switch (6) to display the maintenance screen and check that there is no abnormality in any other monitor. the screen on the monitor display changes to the maintenance screen shown in the diagram on the right.23 . carry out the maintenance. the monitor corresponding to the maintenance warning screen will light up red.If the monitor display changes to the maintenance warning screen when the engine is started or when the machine is being operated. After confirming the maintenance time. The time remaining to maintenance is indicated by the color of each monitor display. 2. stop operations immediately. 3 .If another monitor is lighted up red on the maintenance screen. 3. OPERATION DETAILED CONTROLS AND GAUGES Maintenance Switch This switch (6) is used to check the time remaining to maintenance. 24 . After selecting the monitor item. (The color of the monitor for the selected item is inverted to black. The method of checking the time remaining to maintenance is as follows. (Press back switch (8) to return to the previous screen. press input confirmation switch (11). DETAILED CONTROLS AND GAUGES OPERATION The maintenance display items are as follows. 3 . The screen will switch to the default setting screen. The display screen will switch to the time remaining to maintenance. The screen will return to the normal operation monitor screen. Look at the maintenance screen. press input confirmation switch (11). When canceling the time remaining to maintenance and returning to the default time setting. press up switch (9) or down switch (10) on the monitor switch portion. 1. and select the item.. please contact your Komatsu distributor.) 3. press back switch (8) twice.) 2. Check the time remaining to maintenance. (a) : Time remaining to maintenance (b) : Default setting for maintenance interval When only checking the time remaining to maintenance. screen (H) 01 Change engine oil 500 02 Replace engine oil filter 500 03 Replace fuel filter 500 04 Replace hydraulic oil filter 500 Replace hydraulic tank 05 1000 breather 06 Replace corrosion resistor 1000 07 Change PTC case oil 1000 08 Change final drive case oil 2000 Change swing machinery 09 1000 case oil 10 Change hydraulic oil 5000 If it is desired to change the setting for the maintenance interval. Monitor Default set Maintenance item No. Input Confirmation Switch Press this switch (11) to confirm the selected mode when in the maintenance mode. After checking the time on the default setting screen.25 . or right. Down Switch Press up switch (9) or down switch (10) when in the maintenance mode. or select mode. The screen will return to the previous screen on the monitor display. or select mode. down. brightness/contrast adjustment mode. 3 . brightness/contrast adjustment mode. brightness/contrast adjustment mode. (Press back switch (8) to return to the previous screen. OPERATION DETAILED CONTROLS AND GAUGES 4. press input confirmation switch (11). or select mode to move the cursor on the monitor display (colors of selected monitor are inverted) up.. The screen will return to the maintenance screen. left. Up Switch.) Back Switch Press this switch (8) when in the maintenance mode. Adjusting brightness and contrast 1.Use the brightness/contrast screen and press up switch (9) or down switch (10) to select the brightness monitor. DETAILED CONTROLS AND GAUGES OPERATION Adjusting Brightness And Contrast Press this switch (12) to adjust the brightness and contrast of the monitor display screen. Adjusting brightness 2. press up switch (9) or down switch (10) to adjust the brightness.After completing adjustment of the brightness. (The selected monitor is inverted to black..When the screen changes to the brightness adjustment screen. 4.) 3. the monitor display screen changes to the brightness/contrast screen shown in the diagram on the right.26 . press input confirmation switch (11). 3 .When monitor adjustment switch (12) is pressed. 27 .Use the brightness/contrast screen and press up switch (9) or down switch (10) to select the contrast monitor.After completing adjustment of the contrast.) 3. 3 .. OPERATION DETAILED CONTROLS AND GAUGES Adjusting contrast 2. press input confirmation switch (11). 4.When the screen changes to the contrast adjustment screen. (The selected monitor is inverted to black. press up switch (9) or down switch (10) to adjust the contrast. set the key to this position. HEAT (preheat) position When starting the engine in winter. start the engine by turning the key to the START position.Immediately after the pre-heating monitor flashes. Immediately after starting the engine. Keep the key at this position until the monitor lamp flashes.28 . release the key.The key automatically returns to the OFF position. It will automatically return to the ON position. 3 . START position This is the engine-start position. The switches for the electric system except the room lamp. the pre-heating monitor lightsup. Keep the key at this position during cranking. ON position Electric current flows in the charging and lamp circuits. Then. release the key. OFF position The key can be inserted or withdrawn. are all turned off and the engine is stopped.. Keep the starting switch key at the ON position while the engine is running. Whenthe key is set to the HEAT position. DETAILED CONTROLS AND GAUGES OPERATION SWITCHES (1) Starting switch (10) Pump drive emergency switch (2) Fuel control dial (11) Swing holding brake release switch (3) Cigarette lighter (12) Rotating lamp switch (if equipped) (4) Swing lock switch (13) Lower wiper switch (machines equipped with (5) Lamp switch fixed front window cab) (6) Alarm buzzer stop switch (14) Large capacity airflow air conditioner blower (7) Machine push-up switch switch (if equipped) (8) Horn switch (15) Boom shockless control switch (9) Room lamp switch (16) Step light switch Starting Switch This switch (1) is used to start or stop the engine. the weight of the work equipment may cause the upper structure to swing if the swing control lever is operated in the downhill direction. the swing lock lamp lights up. OFF position (canceled) : The swing lock is applied only when all the control levers of the work equipment are at neutral. By removing the cigarette lighter. it is cancelled. even when the swing lock switch is at the ON position. current is 85 W (24V x 3. On slopes. In this condition. After a few seconds it will spring back. Pull out the lighter and light your cigarette. in traveling. the socket is available as a power source for the yellow flashing lamp. and the upper structure will not swing even if the swing is operated. To use. OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Dial This dial(2) adjusts the engine speed and output.5 A). e.29 . This switch (4) is used to lock the upper structure so that it cannot swing. when any of the control levers is operated. Swing Lock Switch When not using the swing operation. ON position (actuated) : The swing lock is always applied. put the swing lock switch to the OFF position.g. The swing lock is actuated approx. push the lighter in.. Max. (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 to light cigarettes. 3 . 5 seconds after all the control levers are placed in the neutral position. the alarm buzzer stops and the switch automatically returns to its original position. Alarm Buzzer Stop Switch This switch (6) is used (when the engine is running) to stop the alarm buzzer when it has sounded to warn of an abnormality in a warning item. nd digging operations can be carried out smoothly. This switch (7) is used to switch the safety valve set pressure at the head end of the boom cylinder to two levels. DETAILED CONTROLS AND GAUGES OPERATION Lamp Switch This switch (5) is used to light up the front lamps. REMARK This switch is an automatic reset type. rear lamp.. additional lamp at the top front of the cab. This is used for general digging operations on normal ground. (a)Low pressure setting: The boom thrust force is weak. If the STOP position is pressed. so it is easy to twist and swing or escape from soft ground. so set to the high-pressure setting.It is effective in carrying out digging operations using the bucket and the weight of the machine in confined areas. soft rock.30 . or blasted rock. (b)High pressure setting: The thrusting force of the boom becomes more powerful. Machine Push-up Switch When using the boom thrust force to push up the chassis when moving down from a bench. 3 . so the swaying of the chassis is small during digging operations. there is danger that the machine may suddenly go down and turn over. working lamp. and monitor lighting. . This switch (9) is used to light up the room lamp.31 . so be careful not to forget to turn it off. Room Lamp Switch NOTICE It is possible to turn on the room lamp even when the starting switch is at the OFF position. This switch (10) is used to make it possible to carry out opera-tions temporarily if any abnormality should occur in the pump control system (when the display shows E02). ON position: Lights up OFF position: Goes out It will also light up even when the engine is not running. the horn will sound. move the switch up to make it possible to carry out work. Pump Drive Emergency Switch NOTICE The emergency pump driving switch is provided to make it possible to carry out work for a short time when there is a failure in pump control system. It is necessary to repair the abnormal location as soon as possible. OPERATION DETAILED CONTROLS AND GAUGES Horn Switch When the button (8) at the tip of the right work equipment control lever is pressed. 3 . (a) When normal : Move switch down (b) When abnormal : Move switch up If the display shows E02. (a) Release: Position for abnormality (switch moved up) (b) Normal: Normal position (switch moved down) When the display is "E03". ON position: Lower wiper is actuated OFF position: Lower wiper stops 3 .32 . Do not use this switch except in emergencies. Rotating Lamp Switch (If Equipped) This switch (12) is used to light up the yellow rotating lamp on top of the cab.. This switch (11) is used to make it possible to carry out operations temporarily if any abnormality should occur in the swing brake system (when the display shows E03). Repair the abnormality as soon as possible. Lower Wiper Switch This switch (13) operates the lower wiper. DETAILED CONTROLS AND GAUGES OPERATION Swing Holding Brake Release Switch NOTICE This switch makes it possible to carry out swing operations for a short time even when there is an abnormality in the swing brake system. When the switch is set to the Release (a) position. the swing lock monitor flashes. move this switch up to make it possible to carry out operations. When the switch is pressed. Boom Shockless Control Switch This switch (13) controls the shaking of the work equipment when the boom is stopped. 3 . Step Light Switch Use this switch (16) when getting off the machine at night. OPERATION DETAILED CONTROLS AND GAUGES Large Capacity Airflow Air Conditioner Blower Switch (if equipped) This switch (14) operates the large-capacity airflow air conditioner blower. Effect The shaking and spillage of load from the bucket is reduced. REMARK When the switch is at the ON position and the boom is stopped. Be careful when using this operation until you become accustomed to it. so operations can be carried out in safety. 60 seconds. The boom drifts down and it is difficult to position it. the step light will light up for approx. Even if the starting switch key is at the OFF position. so set this switch to the OFF position when carrying out operations with a raised load. 60 seconds when the switch is pressed. Operator fatigue when operating for long periods is reduced. the movement of the boom until it stops will increase slightly..33 . the step light will light up for approx. set the safety lock lever securely to the LOCK position. be careful not to touch the work equipment control lever. If the safety lock lever is not at the LOCK position and the control levers are touched by mistake.. DETAILED CONTROLS AND GAUGES OPERATION CONTROL LEVERS AND PEDALS (1) Safety lock lever (4) Right work equipment control lever (2) Travel levers (with auto-deceleration device) (Machines with pedal) (3) Left work equipment control lever (with auto-deceleration device) Safety Lock Lever When leaving the operator's compartment. it may lead to serious personal injury. When pulling the safety lock lever up. When pushing the safety lock lever down. Check that the condition of the lever is as shown in the diagram.34 . 3 . be careful not to touch the work equipment control lever. Be extremely careful when operating the pedal for travel or steering operations.) Lever (2) is used to change the direction of travel between forward and reverse. swing. If the pedal is depressed by mistake. (If the sprocket is at the rear.35 .) When operating the travel levers. travel. Travel Levers (with Pedals) Do not rest your foot on the pedal during operations. 3 . the machine may suddenly move and cause a serious accident. This lock lever is a hydraulic lock. the direction of travel operations will be reversed when the travel lever is operated. the work equipment control lever and travel lever will move. check if the track frame is facing the front or the rear. but the work equipment. and attachment (if equipped) control levers. the alarm sounds to warnthat the machine is starting to advance. travel motor. so even if it is in the lock position. If the track frame is facing the rear. the left and right directions will also be reversed. (a)FORWARD:The lever is pushed forward (The pedal is angled forward) (b)REVERSE:The lever is pulled back (The pedal is angled back) N (Neutral):The machine stops REMARK Machines equipped with travel alarm (If equipped) If the lever is shifted to the advance or reverse position from the neutral position. (The machine will travel forward when operated in reverse. OPERATION DETAILED CONTROLS AND GAUGES This lever (1) is a device to lock the work equipment. ( ) shows the pedal operation. the track frame is facing the front. and swing motor will not work. When you are not using the pedal. Push the lever down to apply the lock. and in reverse when operated forward. do not rest your foot on it.. bottom window. hold the grip securely with both hands. Boom operation (a) RAISE (b) LOWER Bucket operation (c) DUMP (d) CURL N (Neutral) : The boom and bucket are held in position and do not move. or door. REMARK The engine speed for all control levers (travel. If one of these levers is operated. pull up. 4 seconds. attachment) is changed as follows by the auto-deceleration mechanism. When opening the front window. DETAILED CONTROLS AND GAUGES OPERATION Work Equipment Control Lever (With Auto-deceleration Device) This Left work equipment control lever (3) is used to operate the arm and upper structure. 100 rpm. Hold the grips securely with both hands when closing it. always set the safety lock lever to the LOCK position. WINDSHIELD (Pull up cab spectiications) (if equipped) When opening or closing the front window. and do not let go until the automatic lock catch is locked. 1300 rpm). This Right work equipment control lever(4) is used to operate the boom and bucket. the engine speed will rise to the speed set by the fuel control dial. the window will move quicker under its own weight. lower the work equipment completely to the ground. even if the fuel control dial is above midrange speed. this may lead to a serious accident. the engine speed will go down to a midrange speed. When the travel lever and work equipment control levers are at the neutral position. 3 . If the control levers are not locked and they are touched by accident.36 . work equipment. the engine speed goes down approx. When closing the front window. It is possible to stow (pull up) the front window in the roof of the operator's compartment. then carry out the operation. 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. the engine speed goes down to the deceleration speed (approx. If all the control levers are at the neutral position. When opening or closing the window at the front of the cab. stop the machine on horizontal ground. then after approx.. stop the engine. 4.37 .. Stop the machine on level ground. Grip handles (A) at the top right and left of the front window. 3. Set the safety lock lever securely to the LOCK position. then stop the engine. The top of the front window will come out. Check that the wiper blade is stowed in the right stay. lower the work equipment completely to the ground. OPERATION DETAILED CONTROLS AND GAUGES Opening 1. 2. 3 . and pull lock lever (B) toward yourself to release the lock at the top of the front window. Check that lock lever (B) is securely at the LOCK position. DETAILED CONTROLS AND GAUGES OPERATION 5. Hold lower knob (C) with your left hand from inside the operator's cab. and push it against lock catch (E) at the rear of the cab securely to lock the window.. 6.Check visually. grip top knob (D). The lock is engaged if the arrow on lock case (F) matches the position of the arrow on lock lever (B). the lock is not engaged. Repeat the operation in Step 5 to engage the lock. and with your right hand.38 . If the arrow on lock case (F) does not match the position of the arrow on lock lever (B). 3 . pull it up. . Set the safety lock lever to the LOCK position without fail. 3 . and pull down lock lever (B) to release the lock. then stop the engine. 4. OPERATION DETAILED CONTROLS AND GAUGES Closing When closing the window. 1. push to the front. then lower slowly. 2. Grip handle (C) at the bottom of the front window with your left hand and handle (D) at the top with your right hand. Grip left and right handles (A). 3. Stop the machine on level ground. lower the work equipment completely to the ground.39 . lower it slowly and be careful not to get your hand caught. then hold grip (A). When the bottom of the window reaches the top of the bottom window. If the arrow on lock case (F) does not match the position of the arrow on lock lever (B). Open the front window. Repeat the operation in Step 5 to engage the lock.Check visually. store it at the rear of the operator's cab and lock it securely with left and right locks (B).40 . push the top of the window to the front to push it against left and right lock catches (G) and engage the lock. When removing. and remove the bottom window. pull up. 3 . 6. 2. Removing Lower Windshield 1. After removing the bottom window. DETAILED CONTROLS AND GAUGES OPERATION 5. Check that lock lever (B) is securely at the LOCK position.. always hold the glass with one hand and release the lock with the other hand. The lock is engaged if the arrow on lock case (F) matches the position of the arrow on lock lever (B). the lock is not engaged. 41 . the cab door does not open. If the key is turned before it is inserted all the way. doors and covers. Insert the key as far as it will go to the shoulder. left side door of the machine. 2. OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY EXIT FROM OPERATOR'S CAB If for some reason. radiator sub tank cover. 3. When fixing the door in position.. hydraulic tank filler. maintenance floor entrance cover. Do not remove the rear window except when using it as an emergency exit. When the corner of the front window glass is pushed strongly. Remove the rear window as follows. it can be removed to the outside.Tool box cover. push down the lever(2) on the left of the operator's seat to release the catch. fix it firmly to the catch. battery box cover. CAP WITH LOCK Locks are fitted to the fuel tank filler. DOOR LOCK Use the door lock to fix the door in position after opening it. 2. it may break. Use the starting key to open and close the caps. When closing the door. Pull ring (1) and completely remove seal (2) from the rubber core. remove the rear window and use it as an emergency escape. operator's cab. 3 . 1. 1. Push the door against catch (1) to fix it in position. front engine hood. for the B type. then open the cap. turn clockwise) and take the key out. align the key slot with the match mark on the cap. DETAILED CONTROLS AND GAUGES OPERATION Opening and Closing Caps with Lock Opening the Cap 1. 2. 2. for the B type. then insert the key into the key slot. Turn the key counterclockwise and open the cover by pulling the cover grip. Turn the cap until tight. Locking the Cap 1. Turn the key clockwise (but. 3 . Turn the key clockwise and take the key out. turn counterclockwise). Turn the key counterclockwise (but. Opening and Closing Cover with Lock Opening the Cover (Locked Cover) 1..42 . Close the cover and insert the key into the key slot. Insert the key into the key slot. Locking the Cover 1. 2. Insert the key into the key slot. 2. then put it in the ashtray and close the lid. 3 . OPERATION DETAILED CONTROLS AND GAUGES HOT AND COOL BOX This is on the right side at the rear of the operator's seat. Keep the Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary. MAGAZINE BOX (with cup holder) This is on the left side of the operator's seat. ASHTRAY This is under the machine monitor at the front right of the operator's compartment..43 . Always make sure that you extinguish your cigarette. It is interconnected with the air conditioner:it stays warm when the heating is used.and stays cool when the cooling is used. When OFF switch (1) is pressed.. 3 . and operation stops. DETAILED CONTROLS AND GAUGES OPERATION AIR CONDITIONER CONTROLS Air Conditioner Control Panel (1) OFF switch (6) FRESH/RECIRC selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Defroster selector lever (5) Auto switch OFF Switch This switch (1) is used to stop the fan and air conditioner. the set temperature and air flow display on display monitor (7) and the lamps above auto switch (5) and air conditioner switch (8) go out.44 . 9°F). cooling Adjusts temperature inside cab to set 18. The temperature can be set in stages of 0.4°F) and 32°C (89. the air flow is automatically adjusted. Press the ∧ switch to raise the set temperature.5 to 31. press the ∨ switch to reduce the air flow.5°C (0..45 .6°F). heating 3 . Temperature Control Switch This switch (3) is used to control the temperature inside the cab. The temperature can be set between 18°C (64. OPERATION DETAILED CONTROLS AND GAUGES Fan Switch This switch (2) is used to adjust the air flow. Press the ∧ switch to increase the air flow. During auto operation.0 Max.5 temperature 32. press the ∨ s witch to lower the set temperature. <Monitor display and the function> Monitor display (°C) Set temperature 18. The air flow can be adjusted to six levels. The temperature is generally set at 25°C (77°F).0 Max. . During automatic operation. When switch (4) is pressed. the vents are automatically selected. DETAILED CONTROLS AND GAUGES OPERATION Vent Selector Switch This switch (4) is used to select the vents. the display on monitor display (7) switches and air blows out from the vents displayed. (A): Rear vents (4 places) (B): Face vent (1 place) (C): Foot vent (1 place) (D1): Front window vent (1 place) (D2): Front window vent (1 place) Front window vent (D2) can be opened or closed by hand. 3 .46 . the selection of inside air (RECIRC) and outside air (FRESH) is carried out automatically. Use this position to take in fresh air or when carrying out demisting. vents. RECIRC The outside air is shut off and only the air inside the cab is circulated. FRESH/RECIRC Selector Switch This switch (6) is used to switch the air source between recirculation of the air inside the cab and intake of air from the outside. the lamp at the top of the selector switch lights up to show that air is being blown out. then use temperature control switch (3) to set the temperature. the lamp at the top of the auto switch lights up. and air source (RECIRC/FRESH). vents.47 .. 3 . OPERATION DETAILED CONTROLS AND GAUGES Auto Switch With this switch (5). When switch (6) is pressed. During automatic operation. RECIRC The outside air is shut off and only the air inside the cab is circulated. the lamp at the top of the auto switch goes out. the air flow. Use this position to carry out rapid cooling of the cab or when the outside air is dirty. FRESH Outside air is taken into the cab. and run the air conditioner under automatic control. it is possible to operate the switch to change the air flow. press this switch. FRESH Outside air is taken into the cab. When the control is switched from automatic operation to manual operation. and air source (RECIRC/FRESH) are automatically selected according to the set temperature. When auto switch (5) is pressed. Normally. Use this position to carry out rapid cooling of the cab or when the outside air is dirty. Use this position to take in fresh air or when carrying out demisting. When the manual control is used. Air Conditioner Switch This switch (8) is used to turn the air conditioner (cooling. DETAILED CONTROLS AND GAUGES OPERATION Display Monitor This display monitor displays the status of temperature setting (a). and the air conditioner starts. the air conditioner is switched ON. and vents (c). heating) ON or OFF. the display of temperature setting (a) and air flow (b) goes out. 3 . and operation stops. When the fan is acutated (the display monitor shows (b)) and air conditioner switch (8) is pressed. When OFF switch (1) is pressed.48 . dehumidifying. air flow (b). When it is pressed again to the OFF position. the lamp at the top of the air conditioner switch goes out.. The air conditioner cannot be operated while the fan is stopped. the lamp at the top of the air conditioner switch lights up. and the air conditioner is operated automatically to provide the set temperature.49 . and selection of fresh or recirculated air is automatically selected according to the set temperature. combination of vents. OPERATION DETAILED CONTROLS AND GAUGES Defroster Selector Lever This switch (9) is used in cold or rainy weather to remove the mist that forms on the front glass. Select the method of operation as desired. Automatic Operation 1.. Selector lever forward: To defroster (open) Selector lever back: Closed The defroster can be used when the vent selector switch is set to face or face and foot. The air flow. Method Of Operation The air conditioner can be operated automatically or manually. Use temperature set switch (3) to set to the desired temperature. Turn auto switch (5) ON. 3 . The lamp at the top of switch (5) lights up. 2. The set temperature (a) and air flow (b) are displayed on the monitor. Manual Operation 1.50 . Stopping Automatic Operation Press OFF switch (1). and the engine water temperature is low. check that temperature setting (a) and air flow (b) are displayed on the display monitor. 3 . and the operation stops. DETAILED CONTROLS AND GAUGES OPERATION REMARK When vent display monitor (c) displays (d) or (e). Press fan switch (2) and adjust the air flow. and the lamps above auto switch (5) and air conditioner switch (8) go out. the air flow is automatically limited to prevent cold air from blowing out.. The displays for temperature setting (a) and air flow (b) on the display monitor. When doing this. 4. the display for vent (c) of the display monitor changes according to the selection. 5. OPERATION DETAILED CONTROLS AND GAUGES 2. When this is done. Check that the lamp at the top of the air conditioner switch lights up. 3 .. Press the temperature setting switch and adjust the temperature inside the cab. Press RECIRC/FRESH selector switch (6) and select recirculation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH). Press vent selector switch (4) and select the desired vents.51 . Turn air conditioner switch (8) ON. 3. The displays for temperature setting (a) and air flow (b) on the display monitor. set as follows. 1. 2.52 .. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in the diagram on the right. 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. Press fan switch (2) and adjust the air flow. check that temperature setting (a) and air flow (b) are displayed on the display monitor. 3 . DETAILED CONTROLS AND GAUGES OPERATION Stopping Manual Operation Press OFF switch (1). and the lamps above auto switch (5) and air conditioner switch (8) go out. and the operation stops. When doing this. Check that the lamp at the top of the air conditioner switch lights up.. 3 .53 . temperature setting switch (3) and FRESH/RECIRC selector switch (8) to the desired positions. OPERATION DETAILED CONTROLS AND GAUGES 3. check that temperature setting (a) and air flow (b) are displayed on the display monitor. Defroster Operation 1. When doing this. Adjust fan switch (2). Turn air conditioner switch (8) ON. 4. Press fan switch (2) and adjust the air flow. (B). and (D2) so that the air blows onto the window glass. (Vents (C) and (D1) are fixed and cannot be adjusted.54 . Press vent selector switch (4) and set the vent display on the display monitor to the display shown in (f) or (g) in the diagram on the right..) 3 . 3. 5. Press temperature setting switch (3) and set the set temperature display on the display monitor to the maximum heating temperature of 32. DETAILED CONTROLS AND GAUGES OPERATION 2.0. Press FRESH/RECIRC selector switch (6) and set it to take in fresh air. Adjust vents (A). 4. It will cause failure of the air conditioner. set the temperature so that it feels slightly cool when entering the cab (5 . Temperature Control When the cooler is on. so be careful not to let water get on these parts. This temperature difference is considered to be the most suitable for your health. always keep the sunlight sensor clean and do not leave anything around the sunlight sensor that may interfere with its sensor function. OPERATION DETAILED CONTROLS AND GAUGES When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air. For the auto function of the air conditioner to work properly. so always be careful to adjust the temperature properly. turn the lever to the FRESH position once an hour to carry out ventilation and cooling. never bring any flame near these parts. If water gets into the control panel or sunlight sensor. Ventilation If you smoke when the cooler is on. Other Functions Self-diagnostic Function It is possible to carry out troubleshooting of the various sensors and equipment used on the air conditioner.. 2. 1. it may lead to unexpected failure. so open the window and turn the lever to FRESH for a while to remove the smoke while continuing the cooling. 3 . In addition. the troubleshooting mode is displayed on the liquid crystal display portion. Never start the air conditioner when the engine is running at high speed. Use Air Conditioner With Care NOTICE When running the air conditioner. turn air conditioner switch (8) ON.55 . The temperature setting and air flow display on the liquid crystal display portion go out and operation stops.6 °C lower than the outside temperature). When running the air conditioner for a long time. Press OFF switch (1). always start with the engine running at low speed. If the "∨" and "∧" parts of temperature setting switch (3) are kept pressed at the same time for at least 3 seconds. the smoke may start to hurt your eyes. No failure E11 Disconnection in recirculated air sensor E12 Short circuit in recirculated air sensor E13 Disconnection in fresh air sensor E14 Short circuit in fresh air sensor E15 Disconnection in water temperature sensor E16 Short circuit in water temperature sensor E18 Short circuit in sunlight sensor E21 Disconnection in vent sensor E22 Short circuit in vent sensor E43 Abnormality in vent damper E44 Abnormality in air mix damper E45 Abnormality in FRESH/RECIRC air damper E51 Abnormality in refrigerant pressure Function To Switch Set Temperature Display Between Fahrenheit And Celsius It is possible to switch the set temperature display between °F and °C.. DETAILED CONTROLS AND GAUGES OPERATION <Monitor display and failure mode> Display Failure mode E-.0 to 32.0 °F 63 to 91 3 .) Liquid crystal display range °C 18. (Note that the unit is not displayed. If the "∨" and "∧" portions of temperature setting switch (3) are pressed at the same time for more than 5 seconds while the fan is running. the temperature display will switch between °F and °C.56 . 57 .. 3 . OPERATION DETAILED CONTROLS AND GAUGES RADIO Control Panel (1) Power switch/volume knob (6) Seek button (2) Tone control knob (7) Tuning button (3) Display (8) Preset button (4) Display selector button (CLOCK) (9) FM/AM selector button (BAND) (5) Station selector button (AST) Power Switch/Volume Knob When this knob (1) is turned clockwise from the OFF position. If it is turned further clockwise. a click is heard and the power is turned on. the sound from the speakers will gradually increase. the frequency is displayed. If this button is kept pressed for 2 seconds. Station Selector Button (AST) When this button (5) is pressed. DETAILED CONTROLS AND GAUGES OPERATION Tone Control Knob When this knob (2) is turned clockwise. press the button again to stop it. Display This display (3) shows the time and the frequency of the signal being received. Display Selector Button (CLOCK) When this button (4) is pressed. the high tone is emphasized. If it is pressed again. When the desired broadcasting station is reached. the preset stations are called up in turn.. 3 .58 . when it is turned counterclockwise. it switches to auto memory. the display switches to the clock display. the high tone is reduced. When it finds a station that can be received. FM/AM Selector Button (BAND) When this button (9) is pressed. it automatically searches for stations that can be received. the frequency goes up. it stops. Each time the button is pressed. OPERATION DETAILED CONTROLS AND GAUGES Seek Button (SEEK) When this button (6) is pressed.. the band switches between FM and AM.59 . For details of the method of presetting. it switches AM → FM → AM. Tuning Button When the ∨ part of this button (7) is pressed. when the ∧ part of this button (7) is pressed. the frequency changes continuously. Preset Button When this button (8). If the button is kept pressed. 3 . see "Controls Of Radio (PAGE 3-60)". it is possible to preset one station each for FM and AM. the frequency goes down. . DETAILED CONTROLS AND GAUGES OPERATION Controls Of Radio Listening To Radio 1. Turn the starting switch ON, then turn radio power switch (1) ON. 2. Use BAND button (9) to select AM or FM. 3. Select the channel with PRESET STATION button (8) or TUNE button (7). 4. Turn volume knob (1) and TONE knob (2) to set to the desired volume and tone. 5. To turn the radio OFF, turn the power switch counterclockwise until a click is heard. Selecting Channel Automatically When SEEK button (6) is pressed, the frequency will move up to a channel that can be received, and then will stop automatically. Selecting Channel Manually If the ∨ part of TUNE button (7) is pressed, the frequency will go up; if the ∧ part of the button is pressed, the frequency will go down. If the button is kept pressed, the frequency will move up or down continuously. 3 - 60 . OPERATION DETAILED CONTROLS AND GAUGES Method Of Setting Preset Buttons 1. Select the desired preset station. Use BAND button (9) to select FM or AM, then use TUNE button (7) to select the frequency of the broadcasting station. 2. Decide one of preset buttons (8) to be used for the preset station, and keep it pressed for 2 seconds. The number of the button will be shown on display (3) and the presetting is completed. 3. Repeat Steps 1 - 2 to preset the other broadcasting stations. To change the setting of a preset button to another station, repeat Steps 1 - 2. If the battery is replaced or the power is switched off, all the preset settings are deleted. Carry out the presetting operation again. It is possible to preset 6 FM and 6 AM stations. Method Of Using Automatic Memory If AST button (5) is kept pressed for two seconds, the broadcasting stations that can be received in the area are called up in turn, and the broadcasting stations are automatically saved in the preset memory. Adjusting Time 1. Turn the starting switch ON, then turn the radio power switch ON. If the display is showing the frequency, press CLOCK button (4) to display the time. 2. To set the time, keep the CLOCK button (4) pressed, and Press the ∨ part of TUNE button (7) to change the minutes Press the ∧ part of TUNE button (7) to change the hours 3 - 61 . DETAILED CONTROLS AND GAUGES OPERATION Automatic Switching Reception Of Monaural/Stereo If the reception of the FM stereo broadcast is weak (when you are far from the broadcasting station or are surrounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference. When the stereo broadcast becomes stronger, it automatically switches back to stereo broadcasting. Antenna NOTICE Always retract the antenna before transporting the machine or driving the machine into a work shop or garage. Use Radio With Care 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 radio, it may lead to an unexpected failure, so be careful not to get water on the equipment. Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a cloth soaked in alcohol if the equipment is extremely dirty. When the battery is replaced, the settings for the preset buttons are all cleared, so set them again. 3 - 62 . OPERATION DETAILED CONTROLS AND GAUGES AUXILIARY ELECTRIC POWER 24V power source NOTICE Do not use this as the power source for 12V epuipment. Pull out the connector plug for taking out electric power from the rear side of the panel. Maximum usable electric power is 85 W (24 V x 3.5 A). 12V power source (if equipped) This power source can be used up to a capacity of 60W (12V x 5A). 3 - 63 . DETAILED CONTROLS AND GAUGES OPERATION 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. Replace the fuse with another of the same capacity. Fuse Capacities and Circuit Names Fuse No. Circuit capacity (1) 10A Prolix circuit (2) 10A Electromagnetic valve (3) 10A PPC hydraulic lock solenoid (4) 20A Window washer, cigarette lighter (5) 10A Horn, flash lamp light (if equipped) (6) 10A Auto greasing system (if equipped) (7) 10A Rotating lamp (if equipped) (8) 10A Spare (9) 10A Radio (10) 10A Spare (11) 25A Air conditioner unit (12) 20A VHMS (if equipped) (13) 20A Spare (14) 10A Optional power source (1) (15) 10A Optional power source (2), 12V power port (16) 10A Radio backup (17) 10A network pass (direct from battery) (18) 20A VHMS (if equipped)(direct from battery) (19) 10A Room lamp (20) 10A Step light 3 - 64 . OPERATION DETAILED CONTROLS AND GAUGES CIRCUIT BREAKER NOTICE When resetting the circuit breaker, always turn the starting switch OFF first. If the starting switch does not work even when the starting switch is turned ON, open the circuit breaker box inside the grease pump box at the front right of the machine and carry out inspection. If an excess current is generated, the circuit breaker cuts off the electric circuit to protect the electrical components and wiring from damage. To reset the circuit breaker after it has shut off, push in buttons (1) to (11) until a click is heard. REMARK The circuit breaker is a circuit protection device installed to circuits where large current flows. It protects the electrical components and wiring from damage caused by an abnormal current in the same way as a normal fuse. After repairing and restoring the location of the abnormality, there is no need to replace the breaker. It can be used again. If the starting motor does not work even when the starting switch is turned to the ON position, breaker (8), (9) has probably cut off the circuit, so check and restore circuit breaker (8), (9). If the electrical equipment does not work even when the fuse is replaced, breaker (1) or (11) has probably cut off the circuit, so check and restore circuit breaker (1) or (11). Fuse No. Circuit name capacity 1 40A Fuse box 2 20A circuit breaker No.4 - 7 3 10A circuit breaker No.8 - 11 3 - 65 right front light of 5 20A machine 6 20A Pump controller 7 20A Cab upper head lamp 8 20A Starting switch 9 20A Engine controller (direct from battery) 10 20A Monitor (direct from battery) 11 20A Fuse box (direct from battery) CONTROLLERS controller installed. This will cause failure. mud.66 . Circuit name capacity 4 20A Monitor Working lamp. NOTICE Be careful not to get water. Contact your Komatsu distributor for repairs.. 3 . If any abnormality occurs in the controller. do not disassemble it yourself. DETAILED CONTROLS AND GAUGES OPERATION Fuse No. or juice on the controller. 67 .. 3 . OPERATION DETAILED CONTROLS AND GAUGES TOOL BOX (Cloth bag) This is inside the storage box inside the cover (1) on the left side at the rear of the cab. Method of Use 1. 3 . rotate the lever of valve (2) downward 90° to set it to the (B) position. After using. When the lever of grease gun (3) is released. 5.68 . 2. the supply of grease stops.. When the lever of grease gun (3) is pulled. 3. grease is discharged and the pump also starts automatically. Rotate the lever of valve (2) upward 90° to set it to the (A) position. Open cover (1). 4. DETAILED CONTROLS AND GAUGES OPERATION GREASE PUMP This is stored inside the grease pump box on the right side of the chassis. Set so that the nipple and the nozzle at the tip of the grease gun are perpendicular. When removing the nozzle at the tip of the grease gun from the nipple. 3 . carefully angle the tip of the nozzle slightly and remove it. always rotate the lever of valve (2) down 90° to set it to the (B) position to prevent internal pressure from forming inside grease gun (3). When there is only a small amount of grease left in the grease can. OPERATION DETAILED CONTROLS AND GAUGES Precautions when Using NOTICE When not using the grease pump. the pump will not pump out grease.69 . so move the grease to the center or fill the can with new grease.. Fill the hollow in the center of the follow plate with grease before setting the following plate on top of the grease. then tighten 3 wing bolts (2) uniformly to hold in position. DETAILED CONTROLS AND GAUGES OPERATION Supplying Grease 1. If there is ample grease. REMARK Put the spare grease can beside the grease pump in the grease pump box at the right side of the machine. 2. The standard grease can contains 16 liters (4.23 US gal). and pump out all the grease which has air in it from hole (6) at the bottom of check valve (5). 3. but the first grease includes air inside the pump. If an 18 liters (4. but the pump does not pump out any grease. so set it in position again correctly. air will be sucked in and it may not be possible to use all the grease.the follow plate may not be correctly set in position. there will be more grease left. 3 . 5. Insert the pump into the packing at the center of follow plate (4).76 US gal) can is used.70 . so it is cloudy white and not suitable for use. 7. then remove cover (3) from the pump. Remove 3 wing bolts (2) from grease can (1). be extremely careful not to let sand or dirt stick to the follow plate or pump suction portion. set cover (3) on grease can (1). After bleeding the air inside the pump. pull the lever of the grease gun to completely discharge the grease mixed with air inside the hose and grease gun. 4. close check valve (5) securely. Remove follow plate (4) inside the grease can. When filling with grease. The pump will operate for a short time and then stop. Loosen check valve (5). then set follow plate (4) on top of the grease. Fill grease can (1) with new grease. After bleeding the air.. 6. REMARK If the hollow in the center of the follow plate is not fully filled with grease. Move the safety lock lever to the free position. do not stand in the direction that the oil spurts out when carrying out the operation. Do not disassemble the accumulator. then carry out the operation in Step 3. Set the safety lock lever to the LOCK position. The accumulator is a device to store oil pressure for the control circuit. and lock the work equipment levers and attachment control pedal.3 times) 6. Close the crusher attachment jaws.3 seconds. loosen the screws slowly.. if the control lever is moved in the lowering direction. Stop the engine. Due to this device. right and left so as to release the pressure in the control circuit. Place the work equipment on the ground. and when it is installed. the control circuit can be actuated for a short time even after the engine is stopped. 3 . When removing the hydraulic equipment. This machine is equipped with an accumulator in the control circuit. Do not bring it near flame or dispose of it in fire. The accumulator is installed to the position shown in the diagram on the right. Do not hit it. Releasing Hydraulic Pressure With Accumulator 1. 2 . Please contact your Komatsu distributor to have this work carried out. 2. Do not make holes in it or weld it. etc. always do as follows. the gas must be released. When handling the accumulator. 3. Note that the pressure cannot be completely released. the work equipment lowers under its own weight. so if the accumulator in the control circuit is removed. so mistaken operation may cause an explosion which will lead to serious injury or damage. and do not stand in the direction where the oil spurts out. (Approx. Loosen the bolts slowly. Move the work equipment control lever and the attachment control pedal to full stroke back and forth. OPERATION DETAILED CONTROLS AND GAUGES ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas. roll it. or subject it to any impact. stop the engine after 2 . Continue the operation in Step 4 until the hissing noise of pressure oil can no longer be heard. Start the engine again.71 . When disposing of the accumulator. 5. 4. The pressure in the control circuit cannot be completely removed. Check that there is no abnormality in the gauges and monitor in the operator's cab. idler. Check for damage. If any abnormality is found. or hose. replace with new parts. hoses. twigs. or leakage of oil. look around the machine and under the machine to check for loose nuts or bolts. battery. If it is damaged. Check the undercarriage (track. play in work equipment. repair it. Check stopper plate Check that there is no abnormality in the stopper plate. or other high temperature engine parts. wear.. Tighten any loose bolts.72 . Clean off any dirt on the surface. play. Remove the dirt from around the engine. cylinders. Remove any flammable materials from around the battery or engine muffler. If any dirt or flammable materials are found. 3. or play in the work equipment. Clean the surface of the mirror and adjust the angle so that the area at the rear can be seen from the operator's seat. repair the place where the oil is leaking. If any abnormality is found. excessive wear. and accumulation of dust at places which reach high temperatures.) around the battery. loose bolts. If there is any damage. and check the condition of the work equipment and hydraulic system. or coolant. Check carefully. replace it with a new mirror. cylinders. Check that there is no dirt accumulated around the engine or radiator. 2. turbocharger. If any abnormality is found. Carry out the following inspections and cleaning every day before starting the engine for the day's work. clean it or replace it with a new part. replace the parts. or leakage of oil from rollers. hoses Check that there are no cracks. Seat belt and mounting clamps Check that there is no abnormality in the seat belt or mounting clamps. and radiator. 4. hydraulic tank. Check also that there is no flammable material (dry leaves. loose bolts. Leakage of fuel or oil will cause the machine to catch fire. sprocket. linkage. and be sure to repair any abnormalities. If any abnormality is found. If any abnormality is found. 6. repair it. Check for abnormality in handrails. Check for oil leakage from hydraulic equipment. linkage. Check for leakage of water or oil around engine Check that there is no leakage of oil from the engine or leakage of water from the cooling system. 8. wear. Check also for loose wiring. engine muffler. joints Check that there is no oil leakage. remove them. 9. If any abnormality is found. repair it. MACHINE OPERATIONS AND CONTROLS OPERATION MACHINE OPERATIONS AND CONTROLS BEFORE STARTING ENGINE Walk-Around Checks Before starting the engine. turbocharger. repair it. or other high temperature parts of the engine. 1. or please contact your Komatsu distributor. guard) for damage. etc. Clean. monitor. 3 . steps. 5. check rear view mirror Check that there is no damage to the rear view mirror. 7. Check for abnormality in gauges. If any abnormality is found. 10. fuel. and check that the coolant level is between the FULL and LOW lines on the two sub tanks (2). OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. If the cap is removed to check the coolant level in this condition. If the cooling water is insufficient. Add Water Do not open the radiator cap unless necessary. 1. When checking the coolant. always wait for the engine to cool down and check the sub tank. If the coolant level is low. If the sub-tank is empty. supply water to the radiator and then to the sub-tank. Open cover (1) of the sub tank inspection window at the front of the radiator side (right side of machine) of the engine hood. After adding water. the coolant is at a high temperature and the radiator is under high internal pressure. then turn the cap slowly to release the pressure before removing it. 3.. add water through the water filler to sub tanks (2) to the FULL level. tighten the cap securely. 2. Wait for the temperature to go down.73 . there is a hazard of burns. and check the water level in the radiator. Immediately after the engine is stopped. Check Coolant Level. 3 . check for water leakage. see "COLD WEATHER OPERATION (PAGE 3-133)" 3 . then loosen radiator cap (4) slowly. add water through the water filler port.74 . If the water level is low. then loosen it further and remove it.. When operating in cold areas. push in the cap. After checking that the pressure has been released. After adding water. install radiator cap (4). Check that the level of the coolant is above the hatched portion in the diagram on the right. keep it pushed in. remove cover (3). MACHINE OPERATIONS AND CONTROLS OPERATION REMARK When adding water to the radiator. Insert dipstick (G) fully in the oil filler pipe. 1. Add Oil The parts and oil are at high temperature immediately after the engine is stopped. 5. and wipe the oil off with a cloth. tighten the oil filler cap securely and close the engine hood. OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level In Engine Oil Pan.. Wait for the temperature to go down before starting the operation. 2. If the engine oil level is higher than the H mark. If the machine is at an angle. drain the excess through drain plug (P). The oil level should be between the H and L marks on dipstick (G). 6. then take it out again. add engine oil through oil filler (F). wait for at least 15 minutes after stopping the engine before checking. REMARK When checking the oil level after the engine has been operated. If the oil level is below the L mark. 3. and may cause serious burns. 3 . 4. Open the front cover in the center of the engine hood.75 . make it horizontal before checking. If the oil level is correct. and check the level again. Remove dipstick (G). Use sight gauge (G) at the front face of the fuel tank to check that the tank is filled with fuel. tighten the cap securely. This may cause a fire. Never bring flames near fuel because it is highly flammable and dangerous. Within 15 seconds after stopping the engine. 2. and stop the engine. travel) fully in each direction to release the internal pressure. turn the starting switch to the ON position. watch sight gauge (G) from fuel filler port (F) while adding fuel.. 1. the pressure inside the tank will go down and the fuel may not flow.76 . MACHINE OPERATIONS AND CONTROLS OPERATION Check Fuel Level. Add Fuel When adding fuel. run the engine at low speed. so turn the cap slowly to release the internal pressure before removing the cap. never let the fuel overflow. 1. After adding fuel. Add Oil When removing the oil filler cap. then lower the boom. Check Oil Level In Hydraulic Tank. and operate the control levers (work equipment. start the engine. retract the arm and bucket cylinders. If any fuel is spilled.31 US gal) 3. Fuel tank capacity: 1360 liters (359. If the work equipment is not in the condition shown in the diagram on the right. If the level is not within the sight gauge. therefore clean the breather hole from time to time. REMARK If breather hole (1) in the cap becomes clogged. wipe it up completely. 2. set the bucket teeth in contact with the ground. oil may spurt out. 3 . After draining the oil. The oil level should be within the specified range for that oil temperature. OPERATION MACHINE OPERATIONS AND CONTROLS 3. and drain the excess oil as follows. If the level is below the correct line. add oil through filler port (F) at the top of the hydraulic tank. tighten drain plugs (P1) and (P2). 4. 3 . NOTICE Do not add oil above the correct line. the oil level should be within the blue range of gauge label (a) in the diagram on the right. stop the engine. 5. When the hydraulic oil is at high temperature (50°C to 80°C). loosen bottom drain plug (P1). then loosen the side drain plug (P2) and drain the oil. the oil level should be within the red range of gauge label (b) in the diagram on the right. It will damage the hydraulic circuit and cause the oil to spurt out. The proper way to check the hydraulic oil level is as follows. Check oil level gauge (G) at the rear of the hydraulic tank on the right side of the machine. wait for the hydraulic oil to cool down.77 . If the oil level is low.. If oil is added to above the correct line. add oil. If the oil is above the H level. then drain the excess oil from drain plug (P1). When the hydraulic oil is at normal temperature (15°C to 30° C). When draining the oil. 78 . Add Oil The parts and oil are at high temperature immediately after the engine is stopped. After adding oil. if the oil level is between the H and L marks of the gauge. and wipe the oil off with a cloth. If the oil level exceeds the H mark on the dipstick. 3. Insert dipstick (G) fully in the guide. loosen drain valve (P) to drain the excess oil. Remove dipstick (G) of the front and rear machine. 6. When dipstick (G) is pulled out. If the oil level is below the L mark on dipstick (G). insert dipstick (G) into the dipstick guide and install air bleed plug (1) (at the front of the machine only) 3 . 5. oil level is proper. 1. 4.. MACHINE OPERATIONS AND CONTROLS OPERATION Check Oil Level In Swing Machinery Case. remove air bleed plug (1) (at the front of the machine only). 2. Wait for the temperature to go down before starting the operation. and may cause serious burns. add engine oil through dipstick guide (F) to the correct level. After checking the oil level and adding oil. and may cause serious burns. After waiting for more than 30 minutes after stopping the engine.T. Check Air Cleaner For clogging 1. check the oil level. The oil level should be between the L and H marks. 3 . If it flashes. 2. Add Oil The parts and oil are at high temperature immediately after the engine is stopped. CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-18)". Confirm that the air cleaner clogging monitor does not flash. For details of method of cleaning the element. immediately clean or replace the element. see "CHECK. OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level In P. If necessary.O Case. 1. NOTICE Park the machine on flat ground and stop the engine. Open the cover at the front of the engine room and check the level with dipstick (F).79 . add engine oil at the dipstick guide hole. 2. Wait for the temperature to go down before starting the operation.. wash the battery cap to clean the breather hole. please contact your Komatsu distributor for repairs. 2. In addition. starting motor. then press the horn switch again to check if it sounds. remove it. When only clean fuel comes out. When doing this. breakage. If it is clogged with dirt or dust. 3. that a fuse of the specified capacity is being used. 3 . Press the horn switch and check that the horn sounds immediately. and alternator. Note that if the air tank is empty or the water drain valve in the air tank is at the OPEN position. 4. Prepare a container to catch the fuel that is drained. or contact your Komatsu distributor for repairs. or short circuit in the electric wiring. if any flammable material is accumulated around the battery. the horn will not sound. that there are no signs of any disconnection. Check that the water drain Valve is at the CLOSE position. locate the cause immediately and carry out repairs. Check Function Of Horn 1. Turn the starting switch to the ON position. Carry out this procedure before operating the machine as a daily maintenance. Open drain valve (1) at the bottom of the aftercooler and drain the water and sediment gathered at the bottom of the tank together with fuel. Check that there is no damage to the fuse. be careful not to get fuel on yourself. check for any loose terminals. and tighten any loose terminals that are found. Be particularly careful to check the wiring for the battery.80 . 2. For repairs or investigation of the cause. close drain valve (1). Tank drain hose (2) out through the hole in cover (3) . If the horn still does not sound. Drain Water And Sediment From Fuel Tank NOTICE Never use trichlene for washing the inside of the tank.. please contact your Komatsu distributor. 1. Keep the top surface of the battery clean and check the breather hole in the battery cap. MACHINE OPERATIONS AND CONTROLS OPERATION Check Electric Wirings If the fuses frequently blow or if there are traces of short circuits on the electrical wiring. Use diesel fuel only. start the engine and wait for 1 or 2 minutes. OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment Adjust the seat position before starting operations or after changing the operator. Seat Adjustment (A) Fore-and-aft adjustment Pull lever (1) up. then release the lever. Armrest adjustment angle: 25°. the seat back may suddenly move forward. but the reclining angle is reduced when the seat is moved back. keep the lever pushed up and apply your weight to the rear of the seat. keep the lever pushed up and apply your weight to the front of the seat. Rear tilt Pull lever (4) up to adjust the angle of the rear of the seat. Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the backrest. To lower the angle at the front of the seat. After setting the forward tilt or rear tilt to the desired height. Sit with your back against the seat back when adjusting.3 in) (16 stages) (B) Adjusting reclining NOTICE The seat can be reclined to a large angle when the seat is pushed fully forward. so when moving the seat to the rear. Fore-and-aft adjustment: 160 mm (6. If your back is not touching the seat back. To lower the angle at the rear of the seat.81 . 3 .4 in) (D) Adjusting armrest angle Armrest (5) can be made to spring up by hand approx. Height adjustment: 60 mm (2. Pull up lever (2) and set the seat back to a position which is comfortable for operation.keep the lever (3) pulled up and stand up slightly to remove your weight from the seat. then release the lever. set the seat to the desired position.. (4 stages) To raise the angle at the front of the seat. (4 stages) To raise the angle at the rear of the seat. by turning the bottom (6) of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle. (C) Adjusting seat tilt Forward tilt Push lever (3) up to adjust the angle of the front of the seat.keep the lever (3) pulled up and apply your weight to the Amount of tilt: Up 13°. In addition. return the seat back to its original position. operate the opposite part to set the seat horizontal then secure in position. down 13° Adjusting seat height It is possible to move the seat up or down by combining adjustments forward tilt and rear tilt. 90°. set to the desired position. Fore-and-aft adjustment:180 mm (7. then release the lever. In this case.. REMARK To obtain the optimum adjustment. MACHINE OPERATIONS AND CONTROLS OPERATION REMARK If the seat back is tipped to the front without raising the armrest(5). Mounting position X : 350 mm (13. the armrest will rise automatically. left and right control levers.1 in) (9 stages) F:Adjusting suspension Turn knob (8) to the right to make the suspension harder. and safety lock lever all slide together. Rearview Mirrors Loosen nut (1) and bolt (2) mounting the mirror.82 . and adjust to the position which gives the best view from the operator's seat of the blind spot to the left and right sides at the rear of the machine.3ft) or a diameter of 30cm(12in)) at the rear left and right of the machine Install the mirror to the dimensions listed in the table below. (E) Overall fore-and-aft adjustment of seat Move lever (7) to right. the operator's seat. turn the knob (8) so that the indicator of the weight display (kg) in the transparent portion of knob (8) is the same as the operator's weight.8 in) Range of view Y (right side) : 3500 mm (11 ft 6 in) Range of view Z (left side) : 3500 mm (11 ft 6 in) Mirror A : Must be able to see hatched area (A) Mirror B : Must be able to see hatched area (B) 3 . Recognition areas are also shown in the table for reference. Adjust the mirror mount so that it is possible to see people (or objects with a height of 1m(3. Adjust the reading of the dial to match the operator's weight and select the optimum suspension.or to the left to make the suspension softer. The belt is automatically wound in. and remove tongue (3) from buckle (4). pull the belt lightly to check that it is properly locked. check that the belt is not twisted. Hold grip (2) and pull the belt out from wind-in device (1). Fit the seat belt so that it is not twisted. so it is not necessary to adjust the length. then insert tongue (3) into buckle (4) securely. If it is worn or damaged. Always wear the seat belt during operations. Press button (5) in buckle (4).. 3 . The date of manufacture of the belt is shown on the back of the belt. Even if no abnormality can be seen in the belt.83 . check that there is no abnormality in the belt mount bracket or mounting belt. replace the seat belt. so hold grip (2) and return the belt slowly to wind-in device (1). When doing this. Fastening and Removing This seat belt has a wind-in device. OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Before fitting the seat belt. replace the seat belt every 3 years. . MACHINE OPERATIONS AND CONTROLS OPERATION Operations Before Starting Engine When starting the engine, check that the safety lock lever is securely at the LOCK position. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious accident. 1. Check that safety lock lever (1) is at the LOCK position. 2. Check the position of each levers. Set the control lever to the neutral position. 3. Insert the key in starting switch (2), turn the key to the ON position, then carry out the following checks. 1) The buzzer sounds for approx. 1 second, and the following monitors and meters light up for approx. 3 seconds. Radiator water level monitor (4) Engine oil level monitor (5) Charge monitor (6) Fuel level monitor (7) Engine water temperature monitor (8) Engine oil pressure monitor (9) Engine water temperature gauge (10) Fuel gauge (11) Air cleaner clogging monitor (12) If the monitors do not light up or the buzzer does not sound, there is probably a failure in the monitor, so contact your Komatsu distributor for repairs. 3 - 84 . OPERATION MACHINE OPERATIONS AND CONTROLS 2) After approx. 3 seconds, the screen switches to the working mode/travel speed display monitor. Then it switches to the normal screen. Fuel level monitor (7) Engine water temperature monitor (8) Engine water temperature gauge (10) Fuel gauge (11) Hydraulic oil temperature gauge (13) Hydraulic oil temperature monitor (14) 3) If the hydraulic oil temperature gauge goes out and caution lamp (15) stays lighted up red, carry out inspection immediately for the item which is lighted up red. 4) If there are any items where the maintenance time has passed, maintenance interval monitor (16) lights up for 30 seconds. Press maintenance switch (17), check the item, then carry out maintenance immediately. For details of the method of checking the maintenance interval, see "Maintenance Switch (PAGE 3-23)" in the Explanation of components. 5) Press lamp switch (18) and check that the front lamp lights up. If it does not light up, there is probably a blown bulb or disconnection, so contact your Komatsu distributor for repairs. 3 - 85 . MACHINE OPERATIONS AND CONTROLS OPERATION STARTING ENGINE Normal Starting Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation. NOTICE Before starting the engine, check that the fuel control dial is at the low idling (MIN) position. If the fuel control dial is at the FULL position, the engine will accelerate suddenly and cause damage to the engine parts. Do not crank the starting motor continuously for more than 20 seconds. If the engine does not start, wait for at least 2 minutes before trying again. REMARK If the engine is stopped when it is not fully warmed up and it is started again a few minutes later, there may be a delay in the engine rotation during cranking. This is caused by fuel gas remaining inside the cylinder; it does not indicate any abnormality. In addition, even if this phenomenon occurs, there is no problem with the reliability or durability of the engine or other parts. 1. Check the safety lock lever (1) is at the LOCK position. If the safety lock lever is in the FREE position, the engine does not start. 2. Set fuel control dial (2) at the low idling (MIN) position. If it is at the high idling (MAX) position, always change it to the low idling (MIN) position. 3 - 86 . OPERATION MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to the START position. The engine will start. 4. When the engine starts, release the key in starting switch (3). The key will return automatically to the ON position. 5. Even after the engine is started, do not touch the work equipment control levers and the travel pedals, while the engine hydraulic pressure monitor lamp is still lighted. NOTICE If the engine oil pressure monitor does not go out even after 4 to 5 seconds have passed, stop the engine immediately. Check the oil level, check for leakage of oil, and take the necessary action. 3 - 87 . MACHINE OPERATIONS AND CONTROLS OPERATION Starting Engine In Cold Weather Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explosions. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation. NOTICE Before starting the engine, check that fuel control dial (2) is at the low idling (MIN) position. If the fuel control dial is at the FULL position, the engine will accelerate suddenly and cause damage to the engine parts, so set it to an intermediate or low speed position. Do not keep the strating motor rotating continuously for more than 20 seconds. If the engine fails to start,wait for about 2 minutes and repeat from Step 2. When starting in low temperatures, do as follows. 1. Check the safety lock lever (1) is at the LOCK position. If the safety lock lever is in the FREE position, the engine does not start. 2. Set fuel control dial (2) at a low idling (MIN) position. Do not set fuel control dial (2) at the high idling (MAX) position. 3 - 88 . OPERATION MACHINE OPERATIONS AND CONTROLS 3. Hold the key in starting switch (3) at the HEAT position, and check that preheating monitor (4) lights up. After about 30 seconds, preheating monitor lamp (4) will flash to indicate that preheating is finished. REMARK The monitors and gauges will light up also when the key is turned to the HEAT position, but this is not an abnormality. If the temperature is low, the monitor screen may become dark or it may take time for the display to appear, but this is not an abnormality. 4. When preheating monitor (4) goes out, turn the key in starting switch (3) to the START position to start the engine. 5. When the engine starts, release the key in starting switch (3). The key will return automatically to the ON position. 6. After starting the engine, do not touch the work equipment control lever or travel pedal while the engine oil pressure monitor lamp is lighted up. 3 - 89 so always carry out the warming-up operation. During this time. During breaking-in operations. Do not suddenly accelerate the engine before the warming-up operation is completed. sudden acceleration.. Breaking-In The New Machine Your Komatsu machine has been thoroughly adjusted and tested before shipment. avoid sudden starts. apply a load from time to time or run the engine at a mid-range speed. Particularly in cold areas. operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.90 . be sure to carry out the warming-up operation fully. Warming-Up Operation NOTICE When the hydraulic oil is at a low temperature. Do not run the engine at low idling or high idling continuously for more than 20 minutes. This will cause leakage of oil from the turbocharger oil supply piping. Be sure to breaking-in the machine for the initial 100 hours (as indicated by the service meter). follow the precautions described in this manual. 3 . and sudden changes in direction. unnecessary sudden stops. turn the starting switch key to the OFF position. do not operate the control levers or fuel control dial. Idle the engine for 5 minutes after starting it up. and the work equipment may not move as the operator desires. If the work equipment is operated without warming the machine up sufficiently. MACHINE OPERATIONS AND CONTROLS OPERATION AFTER STARTING ENGINE If there has been any Emergency stop. do not carry out operations or move the levers suddenly. the hydraulic oil temperature monitor display will be white. Run the engine at idling for 15 seconds after starting it. abnormal actuation or trouble. the response of the work equipment to the movement of the control lever will be slow. This will help to extend the machine life. However. Avoid operation with heavy loads or at high speeds. Immediately after starting the engine. Always carry out the warming-up operation. If it is necessary to run the engine at idling. REMARK If the hydraulic oil temperature is low. do not immediately start operations. Operate the bucket for 30 seconds and the arm for 30 seconds in turn fully for 5 minutes. Set fuel control dial (2) to a point midway between low idling (MIN) and full throttle (MAX). Operate bucket control lever (3) and arm control lever (4) slowly to move the bucket cylinder and arm cylinder to the end of the stroke.. take care that it does not interfere with the machine body or ground. 3 . First. 4.91 . carry out the following operations and checks. 1. OPERATION MACHINE OPERATIONS AND CONTROLS After starting the engine. 3. 2. Set safety lock lever (1) to the FREE position and raise the bucket from the ground. and run the engine at a mid-range speed under no load until the engine water temperature monitor enters the green display. NOTICE When the work equipment is retracted. noise. check that all the gauges on machine monitor (6) and the caution lamps are in the following conditions. After carrying out the warming-up operation. 7.92 .. or vibration. contact your Komatsu distributor. Use working mode switch (19) on machine monitor (6) to select the working mode to be used. 8. If any abnormality is found. For details of the method of cleaning the element. CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-18)". see "CHECK. clean or replace the element immediately. Radiator water level monitor (7): OFF Engine oil level monitor (8): OFF Charge monitor (9): OFF Fuel level monitor (10): Green display Engine water temperature monitor (11): Green display Engine oil pressure monitor (12): OFF Engine water temperature gauge (13): Indicator in black range Fuel gauge (14): Indicator in black range Preheating monitor (15): OFF Air cleaner clogging monitor (16): OFF Hydraulic oil temperature gauge (17): Indicator in black range Hydraulic oil temperature monitor (18): Green display 6. If air cleaner clogging monitor (16) is lighted up. 3 . MACHINE OPERATIONS AND CONTROLS OPERATION 5. Check that there is no abnormal exhaust gas color. . OPERATION MACHINE OPERATIONS AND CONTROLS Working mode monitor display 1) A mode For heavy-load operations 2) E mode For operations with emphasis on fuel economy 3) Heavy-duty lift boom lifting power increased when raising boom independently 4) Swing priority mode priority given to swing when operating boom and swing simultaneously 3 - 93 . MACHINE OPERATIONS AND CONTROLS OPERATION In Cold Weather Areas (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30°C), the warming-up operation is carried out automatically. The automatic warming-up operation is canceled if the engine water temperature reaches the specified temperature (30°C) or if the warming-up operation is continued for 10 minutes. If the engine water temperature or hydraulic oil temperature are low after the automatic warming-up operation, warm the engine up further as follows. NOTICE Do not suddenly accelerate the engine before the warming-up operation is completed. Do not run the engine at low idling or high idling continuously for more than 20 minutes.This will cause leakage of oil from the turbocharger oil supply piping. If it is necessary to run the engine at idling, apply a load from time to time or run the engine at a mid-range speed. Never carry out operations or operate the levers suddenly when the hydraulic oil is still at low temperature. Always continue the warming-up operation until the work equipment monitor display is green. This will extend the service life of the machine. REMARK If the hydraulic oil temperature is low, the hydraulic oil temperature monitor display will be white. 1. Turn fuel control dial (2) to the medium speed position. 2. Set safety lock lever (1) to the FREE position and raise the bucket from the ground. 3 - 94 . OPERATION MACHINE OPERATIONS AND CONTROLS 3. Operate bucket control lever (3) and arm control lever (4) slowly to move the bucket cylinder and arm cylinder to the end of the stroke. 4. Operate the bucket for 30 seconds and the arm for 30 seconds in turn fully for 5 minutes. NOTICE When the work equipment is retracted, take care that it does not interfere with the machine body or ground. 5. After carrying out the warming-up operation, check that each gauge and monitor lamp is in the following condition. Radiator water level monitor (7): OFF Engine oil level monitor (8): OFF Charge monitor (9): OFF Fuel level monitor (10): Green display Engine water temperature monitor (11): Green display Engine oil pressure monitor (12): OFF Engine water temperature gauge (13): Indicator in black range Fuel gauge (14): Indicator in black range Preheating monitor (15): OFF Air cleaner clogging monitor (16): OFF Hydraulic oil temperature gauge (17): Indicator in black range Hydraulic oil temperature monitor (18): Green display 6. Check that there is no abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 7. If air cleaner clogging monitor (16) is lighted up, clean or replace the element immediately. For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-18)". 3 - 95 . MACHINE OPERATIONS AND CONTROLS OPERATION 8. Turn fuel control dial (2) to the full speed (MAX) position and carry out the operation is Step 6. for 3 to 5 minutes. 9. Repeat the following operation 3 - 5 times and operate slowly. Boom operation RAISE ←→ LOWER Arm operation IN ←→ OUT Bucket operation CURL ←→ DUMP Swing operation LEFT ←→ RIGHT Travel (Lo) operation FORWARD ←→ REVERSE REMARK If the above operation is not carried out, then may be a delay in response when starting or stopping the actuation of the travel, swing, or work equipment. 10. Use working mode switch (19) on machine monitor (6) to select the working mode to be used. Working mode monitor display 1) A mode For heavy-load operations 2) E mode For operations with emphasis on fuel economy 3 - 96 . OPERATION MACHINE OPERATIONS AND CONTROLS 3) Heavy-duty lift boom lifting power increased when raising boom independently 4) Swing priority mode priority given to swing when operating boom and swing simultaneously NOTICE Canceling automatic warming-up operation If it becomes necessary in an emergency to cancel the automatic warming-up operation or to lower the engine speed to low idling, do as follows. 1] Turn fuel control dial (2) to the full speed (MAX)position and hold it for 3 seconds. 2] When fuel control dial (2) is returned to the low idling (MIN) position,the engine speed will drop. 3 - 97 . MACHINE OPERATIONS AND CONTROLS OPERATION STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it. 1. Run the engine at low idling for about 5 minutes to cool down gradually. 2. Turn the key in starting switch (1) to the OFF position and stop the engine. 3. Remove the key from starting switch (1). CHECK AFTER SHUT OFF ENGINE 1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. 2. Fill the fuel tank. 3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. 4. Remove any mud affixed to the undercarriage. REMARK After stopping the engine, if the starting switch is turned within approx. 10 seconds to the ON or START position to start the engine again, the monitor display is not reset, and the screen before the starting switch was turned OFF is displayed. 3 - 98 the direction of movement of the machine will be the opposite of the direction of operation of the travel lever (forward/reverse. OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION Preparations For Moving The Machine Off Before operating the control lever. Operate the levers carefully. If the track frame is facing the rear (when the sprocket is at the front). check the direction that the track frame is facing. so be particularly careful when travel in reverse. If the lever is moved inside the deceleration range. Remove all obstacles from the travel path of the machine.99 . and sound the horn before moving. Turn fuel control dial (3) towards the full speed position to increase the engine speed. 3 . Set swing lock switch (1) to the ON (actuated) position and confirm that swing lock monitor lamp (2) lights up. For machines equipped with a travel alarm (if equipped). left/right). check that the warning equipment works properly. Do not allow anyone in the area around the machine. 1. check that the area around the machine is safe.. 2. engine speed will rise suddenly. When moving off. The rear of the machine is a blind spot. if the machine travel speed is not normal. If the alarm does not sound. if the undercarriage is clogged with mud and the machine travel speed is not normal. 3 . MACHINE OPERATIONS AND CONTROLS OPERATION Moving Machine Forward 1. check that the alarm sounds. 2. For machines equipped with a travel alarm.. 3. please contact your Komatsu distributor for repairs. Set safety lock lever (4) in the FREE position. REMARK In cold temperatures. When the sprocket (A) is at the rear of the machine Push levers (5) forward slowly or depress the front part of pedals (6) slowly to move the machine off. When the sprocket (A) is at the front of the machine Pull levers (5) backward slowly or depress the rear part of pedals (6) slowly to move the machine off. Operate right and left travel levers (5) or right and left travel pedals (6) as follows. fold the work equipment. remove the soil and mud from the undercarriage. and raise it 40 to 50 cm (16 to 20 in) from the ground. In addition. carry out the warming-up operation thoroughly.100 . Operate right and left travel levers (5) or right and left travel pedals (6) as follows. Set safety lock lever (4) in the FREE position. 2. fold the work equipment.. When the sprocket (A) is at the rear of the machine Pull levers (5) backward slowly or depress the rear part of pedals (6) to move the machine off. OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Backward 1. and raise it 40 to 50 cm (16 to 20 in) from the ground. please contact your Komatsu distributor for repairs. check that the alarm sounds. 3 . If the alarm does not sound.101 . For machines equipped with a travel alarm. When the sprocket (A) is at the front of the machine Push levers (5) forward slowly or depress the front part of pedals (6) to move the machine off. 3. Put the left and right travel levers (1) in the neutral position. 1.. MACHINE OPERATIONS AND CONTROLS OPERATION Stopping Machine Avoid stopping suddenly. Give yourself ample room when stopping. then stop the machine. 3 .102 . 3 . REMARK When turning to the right. Use the travel levers to change direction. check the direction of the track frame (i.103 .. the machine moves in the reverse direction to the operation of the travel lever. when carrying out counter-rotation (spin turn). Operate two travel levers (1) as follows. and pull it back to turn left when traveling in reverse. Steering the Machine when Stopped When turning to the left: Push the right travel lever forward to turn to the left when traveling forward. If the sprocket is at the front. OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering Before operating the travel control levers. In particular. position of the sprocket) first. Avoid sudden changes of direction as far as possible. operate the left travel lever in the same way.e. stop the machine first before turning. the machine will turn to the left. pull the left travel lever back and push the right travel lever forward. Counter-rotation Turn (Spin Turn) When using counter-rotation (spin turn) to turn left. pull the right travel lever back and push the left travel lever forward. REMARK When turning to the right.104 . MACHINE OPERATIONS AND CONTROLS OPERATION Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position. 3 . operate the right travel lever in the same way. REMARK When using counter-rotation to turn right.. Before operating the swing. 3. 2.. turn swing lock switch (1) OFF and check that swing lock monitor (2) has gone out.105 . Check that swing lock monitor (2) lights up. Before starting the swing operation. 1. When not using the swing. 3 . check that the area around the machine is safe. Operate left work equipment control lever (3) to swing the upper structure. turn swing lock switch (1) ON. OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING The tail of the machine extends outside the tracks. this operation can also be used to release the remaining pressure in the hydraulic cylinder circuit or to lower the boom after the machine has been loaded onto a trailer. The movements of the lever and work equipment are as shown in the diagrams on the right. 3 . even if the fuel control dial is set to FULL. it is possible to operate the levers to lower the work equipment to the ground. the work equipment will move quickly. so if less than 15 seconds has passed since the engine was stopped. If the work equipment control lever is operated quickly. MACHINE OPERATIONS AND CONTROLS OPERATION WORK EQUIPMENT CONTROLS AND OPERATIONS If the lever is operated when the auto-deceleration is being actuated. if the lever is operated slowly. the work equipment will move slowly. when the starting switch is turned to the ON position even when the engine is stopped. When the levers are released. If the work equipment control levers are returned to the neutral position when the machine is stopped.. an accumulator is installed in the operating circuit. The work equipment is operated by the left and right work equipment control levers. The left work equipment control lever operates the arm and swing. REMARK With this machine. they automatically return to the neutral position and the work equipment is held in place.106 . the auto-deceleration mechanism will act to reduce the engine speed to a mid-range speed. In addition. and the right work equipment control lever operates the boom and bucket. so be careful when operating the lever. the engine speed will suddenly rise. loading operations E mode (operation with emphasis on fuel economy) Normal digging. OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE Working Mode The mode selector switch can be used to switch the mode to match the operating conditions and purpose. Use the working mode switch to set the mode to the most efficient mode to match the type of work. When the starting switch is turned ON. Make effective use of each mode as follows. thereby enabling work to be carried out efficiently. Working mode Applicable operations Normal digging. loading operations A mode (Operations with emphasis on productivity) Normal digging. loading operations mode (priority given to swing when operating boom and swing simultaneously) 3 . loading operations Heavy-duty lift (boom lifting power increased when raising boom independently) Swing priority Normal digging. the working mode is set to A mode (digging).107 .. stop the machine. so be careful when operating. If any lever is operated when the auto-deceleration is being actuated. MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITED OPERATIONS If it is necessary to operate the work equipment control lever when the machine is traveling. but will also markedly reduce the life of the machine.108 . and given impact by some external force. 3 . This is not only dangerous. Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends If the work equipment is used with the cylinder rod operated to its stroke end. causing personal injury.. the hydraulic cylinders will be damaged. Operations Using Travel Force Do not dig the bucket into the ground and use the travel force to carry out excavation. then operate the control lever. Avoid operations with the hydraulic cylinder fully retracted or fully extended. This will damage the machine or work equipment. Operations Using Swing Force Do not use the swing force to compact soil or break objects. the engine speed will suddenly increase. or pile driver. This will markedly reduce the life of the machine. or use the dropping force of the bucket as a pickaxe. (3) Avoid sudden lever shifting change such as sudden stopping from near top speed (lever release operation). breaker. OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging. Sudden Lever Shifting High Speed Travel (1) Never carry out sudden lever shifting as this may cause sudden starting.109 . This will not only reduce damage to the machine but make for better economy.. Operations Using Machine Dropping Force Do not use the dropping force of the machine for digging. (2) Avoid sudden lever shifting from forward to reverse (or from reverse to forward). 3 . Digging Hard Rocky Ground It is better to excavate hard rocky ground after breaking it up by some other means. When traveling at high speed. keep the work equipment close to the ground. 3 . For this reason. When operations are carried out continuously with the cylinder operated slightly. tree stumps. travel at Lo speed. Precautions when carrying out operations continually with the work equipment in the same posture Precautions when carrying out operations continually with the work equipment in the same posture. or other obstacles will cause a big shock to the chassis (and in particular to the tracks).. If there is no way to avoid traveling over an obstacle. High Speed Travel On uneven roadbeds such as rock beds or uneven roads with large locks. or Hi on the monitor display. always remove any obstacles or travel around them. MACHINE OPERATIONS AND CONTROLS OPERATION GENERAL OPERATION INFORMATION Traveling Traveling over boulders. To switch the travel speed. This will prevent loss of grease at the pins. reduce the travel speed. and this will cause damage to the machine. The travel speed is displayed as Lo. or take other steps to avoid traveling over such obstacles as far as possible.110 . operate the cylinder occasionally by a large amount to ensure greasing of the work equipment pins. set the idler in the forward direction. and try to travel so that the center of the track passes over the obstacle. Mi. press travel speed selector switch (1). . OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth When driving the machine out of water. 3 . Do not drive the machine in water deepen than of the center of carrier roller(1). if the angle of the machine exceeds 15°.111 . Supply grease to the parts which have been under water for a long time until the used grease is projected out of the bearings (around the bucket pin. and water will be thrown up by the radiator fan. This may cause the fan to break. Be extremely careful when driving the machine out of water. in particular). the rear of the upper structure will go under water. 2. Always go down to a flat place to perform these operations. There is danger that the machine may turn over. When traveling down a steep hill of more than 15°. if the shoes slip or it is impossible to travel uphill using only the force of the tracks. Never turn on slopes or travel across slopes. but it will ensure safety. There is danger that the machine may turn over. Do not travel downhill in reverse. If the machine travels down with the sprocket side up. When traveling.112 . 1. the track tends to become loose. It may be longer. It is particularly dangerous to swing downhill when the bucket is loaded. When traveling down steep hills. When traveling uphill. use the travel lever and fuel control dial to keep the travel speed low.. so avoid such operations. Always operate or travel in such a way that it is possible to stop safely at any time if the machine slips or becomes unstable. do not use the pulling force of the arm to help the machine travel uphill. set the work equipment to the posture shown in the diagram on the right. If such operations have to be carried out. MACHINE OPERATIONS AND CONTROLS OPERATION TRAVELING ON SLOPES Turning or operating the work equipment when working on slopes may cause the machine to lose it balance and turn over. and lower the engine speed. set the work equipment to the posture shown in the diagram on the right. When traveling up a steep hill of more than 15°. 20 to 30cm (8 to 12 in) from the ground. 3 . pile soil to make a platform on the slope so that the machine can be kept horizontal when operating. REMARK Travel down fills with the sprocket side down. Do not travel up or down steep slopes. and that can cause skipping pitches. raise the bucket approx. 113 . extend the work equipment to the front to improve the balance. Cab Doors on Slope If the engine stops when the machine is on a slope. The upper structure will swing under its own weight. 3 . lower the bucket to the ground. Take good care when opening or closing the sliding door (the cab specification). There is the danger that it will likely gain momentum due to its own weight and open or shut suddenly. and travel at low speed. OPERATION MACHINE OPERATIONS AND CONTROLS When traveling up a steep slope. Traveling Downhill Put the travel lever in the neutral position.. stop the machine. never use the left work equipment control lever to carry out swing operations. then start the engine again. keep the work equipment approximately 20 to 30cm (8 to 12 in) above the ground. Engine Stopped on Slope If the engine stops when traveling uphill. move the travel levers to the neutral position. This will cause the brake to be automatically applied. do as follows to get the machine out. Stuck Both Sides Of Tracks When the tracks on both sides are stuck in mud and they slip. use the bucket to raise the track. MACHINE OPERATIONS AND CONTROLS OPERATION ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. Stuck One Side Of Track NOTICE When using the boom or arm to raise the machine. If the machine does get affixed in mud. then lay boards or logs and drive the machine out. When only one side is affixed in mud. Then pull in the arm as in normal digging operations and put the travel levers in the FORWARD position to pull the machine out. and dig the bucket into the ground in front. This will increase the pushing power of the boom and make it easier to escape. lay boards or logs as explained above. Place the machine push-up switch at position (1). 3 . making it impossible for the machine to move. The same applies when using the bucket installed in the reverse direction.. always have the bottom of the bucket in contact with the ground. The angle between the boom and arm should be 90° to 110°.114 . . OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following. Loading Work In places where the swing angle is small. 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.115 . use this angle effectively to optimize your working efficiency. 3 . When the condition of the machine is as shown in the diagram on the right (angle between [bucket cylinder and link] and [arm cylinder and arm] is 90o). it is possible to further increase the range of applications by using various attachments. the maximum excavation force is obtained from the pushing force of each cylinder. Backhoe Work A backhoe is suitable for excavating areas that are lower than the machine. When excavating. but try to stay within the above range rather than operating the cylinder to the end of its stroke. There may be some differences depending on the excavation depth. The range for excavating with the arm is from a 45o angle away from the machine to a 30o angle towards the machine. work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator. first dig both sides and then finally remove the center portion. Ditching Work Ditching work can be performed efficiently by attaching a bucket which matches the digging operation and then setting the tracks parallel to the line of the ditch to be excavated. To excavate a wide ditch. place the bucket so that it is in light contact with the ground. When performing joint work. When carrying out this operation. hard hat. gloves. When the bucket is removed.116 . always wear goggles. REMARK When removing the pins. When removing or inserting pins. there is a hazard that the pin may fly out and injure people in the surrounding area. NOTICE When removing the bucket. MACHINE OPERATIONS AND CONTROLS OPERATION BUCKET REPLACEMENT When pins are knocked in with a hammer. Never insert your fingers into the pin holes when aligning the holes. place it in a stable condition. Replacement 1. pieces of metal may fly and cause serious injury. be extremely careful not to put your foot under the bucket while standing at the side for the work. 3 . be extremely careful not to get your fingers caught. the resistance will be increased and it will be difficult to remove the pins. When removing the pins. If the bucket is lowered strongly to the ground. If pins are hit with a strong force. appoint a conductor and follow that person's instructions and signals.. do not stand behind the bucket. Make sure that there is no one in the surrounding area before starting the operation. In addition. Place the bucket in contact with a flat surface. set the bucket cylinder facing down as shown in the diagram in the right to prevent the front link from jumping up under the weight of the bucket cylinder. and other protective equipment. Stop the machine on a firm and flat surface and do the work. 3 . Install the stopper bolts and nuts for each pin. so be careful not to damage them.. fit the O-ring correctly in the groove. then insert grease-coated pins (A) and (B) into hole (1) and hole (2) respectively. and remove the bucket. REMARK Carry out installation in the reverse order to removal. Dust seals are fitted at both ends of the bushings. When installing the bucket. then remove pins (A) and (B). OPERATION MACHINE OPERATIONS AND CONTROLS 2. it is easy to damage the O.117 . so fit the O-ring to the arm in the position shown in the diagram on the right. then grease the pin. make sure that mud or sand does not get on them. Align the arm with holes (1) of the replacement bucket and the link with holes (2). After inserting the pin. Remove the stopper bolts and nuts. NOTICE After removing the pins. 3.ring. insert blocks underneath the track shoes. The machine stops. always set the safety lock lever securely to LOCK position. select flat hard ground and avoid dangerous places.118 . the work equipment or the machine may move suddenly. MACHINE OPERATIONS AND CONTROLS OPERATION PARKING MACHINE Avoid stopping suddenly. If the control lever is touched by accident.. When stopping the machine. Give yourself ample room when stopping. and this may lead to a serious accident. thrust the bucket into the ground. Put left and right travel levers (1) in the neutral position. 1. Turn fuel control dial (2) to lower the engine speed to low idling. As an additional safety measure. If it is unavoidably necessary to park the machine on a slope. 2. 3 . Before leaving the operator's compartment. OPERATION MACHINE OPERATIONS AND CONTROLS 3. and fuel level on the machine monitor. Lower the bucket horizontally until the bottom touches the ground. 3 . 4.. MACHINE INSPECTION AFTER DAILY WORK Check the engine water temperature. Set safety lock lever (3) in the LOCK position.119 . engine oil pressure. (2)Fuel tank filler port (3) Door of engine roomi3 placej (4)Battery box cover (5) Left side door of the machine (pump room 1 place) (6) Tool box upper cover (7)Hydraulic tank filler port (8) Maintenance floor entrance REMARK Use the starting switch key to open and close all these places. (1)Door of operator's cab Always remember to close the window.120 . MACHINE OPERATIONS AND CONTROLS OPERATION LOCKING Always lock the following places.. 3 . Combination of wire length The length of the wire is the length from the pin and center of the hole. and be careful to assure safety. OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine. select a wire length that will bring the lifting position directly above the center of gravity of the machine. 1. There is danger that the machine may lose its balance. Never try to lift the machine in any posture other than the posture given in the procedure below. PRECAUTIONS FOR TRANSPORTATION This machine must be divided into several units for transportation.30in) (G):center of gravity.. LIFTING MACHINE Never carry out the lifting operation with any person on the machine. When using the following wire. 3 . When transporting the machine. Lifting machine (Upper structure) Fit wires to boom foot pins (1) and lifting (2) in the reolving freame. carry out the operation on flat ground as follows. The lifting load is 24. please consult your Komatsu distributor. When lifting the machine. When lifting the machine. then lift then lift the machine. use wire of more than the length given below. observe all related laws and regulations. Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine.3 tons. 2. Pin diameter at lifting position : 160mm(6.pay careful attention to the center of gravity to maintain the balance.121 . In addition. secure it according to the following procedure. 1. choose firm level ground. Keep well away from the road shoulder. Lock each control lever with the safety lock lever securely. After the machine comes off the ground. TRANSPORTATION OPERATION Unit Combination (A) mm (ft in) 7000 (22'12") (B) mm (ft in) 8000 (26'3") 3. Run the engine at low speed and operate slowly.122 .. After placing the machine on the specified position of the trailer. SHIPPING MACHINE INFORMATION When loading the machine. 3 . and then lift slowly. check the hook condition and the lifting posture. .123 . Four units for transportation (A) Upper structure (C) Work equipment (B) Undercarriage (D) Others 3 . OPERATION TRANSPORTATION TRANSPORTATION POSTURE This machine can be divided into four units for transportation. 124 .) Upper Structure Secure the upper structure to the platform with a chain and block. Unit PC1250LC-7 Overall mm 3490 (11'5") width (ft in) kg Weight 24.. PC1250-7.582) (lb) 3 . TRANSPORTATION OPERATION Posture for each unit (dimensions in diagram are in mm. PC1250SP-7.300 (53. OPERATION TRANSPORTATION Undercarriage If there is a warning tag hanging on the work equipment control PC1250-7.626 lb X 2) 3 .250 X 2) (33. do not start the engine. PC1250SP-7. Unit PC1250LC-7 Q'ty .253 lb) Weight kg (lb) (15.500 (67. 2 30.125 .. lever. .783) 3 .004) 12600 (27. Unit PC1250SP-7 PC1250LC-7 A mm (ft in) 9475 (31'1") 8170 (26'10") B mm (ft in) 2894 (9'6") 3095 (10'2") Overall mm (ft in) 1474 (4'10") 1474 (4'10") width Weight kg (lb) 12700 (28. TRANSPORTATION OPERATION Work Equipment Boom PC1250-7.126 . .112) Bucket (except side cutter.127 .246) (13.671) 6400 (14. Unit PC1250SP-7 PC1250LC-7 A mm (ft in) 4895 (16'1") 4914 (16'1") B mm (ft in) 1626 (5'4") 1683 (5'6") Overall mm (ft in) 890 (2'11") 890 (2'11") width Weight kg (lb) 6200 (13. Unit PC1250SP-7 PC1250LC-7 A mm (ft in) 2580 (8'6") 2527 (8'3") B mm (ft in) 2276 (7'6") 2420 (7'11") Overall mm (ft in) 2250 (7'5") 2520 (8'3") width 5100 6000 Weight kg (lb) (11.230) 3 . shroud) PC1250-7. OPERATION TRANSPORTATION Arm PC1250-7. 308 lb) 3 .292 lb) Weight kg (lb) (1200 X 2) (2.646 lb X 2) Boom cylinder Unit same for all models A mm (ft in) 3950 (12'12") Weight kg (lb) 1500 (3.128 .. TRANSPORTATION OPERATION Arm cylinder Unit same for all models A mm (ft in) 3810 (12'6") 2400 (5. 690) 3 . OPERATION TRANSPORTATION Others Center frame PC1250-7APC1250SP-7..129 . Unit PC1250LC-7 Weight kg (lb) 18000 (39.389) Counterweight PC1250-7. Unit PC1250LC-7 Weight kg (lb) 9700 (21. PC1250SP-7. . Unit PC1250LC-7 Weight kg (lb) 80 (176) 3 . PC1250SP-7. TRANSPORTATION OPERATION Radiator duct (same for all models) PC1250-7.130 . 131 .49) Catwalk (left. front) : (same for all models) PC1250-7.. OPERATION TRANSPORTATION Catwalk (right) : (same for all models) PC1250-7. PC1250SP-7. Unit PC1250LC-7 Weight kg (lb) 17 (37. Unit PC1250LC-7 Weight kg (lb) 150 (331) 3 . PC1250SP-7. . TRANSPORTATION OPERATION Catwalk (left. PC1250SP-7. rear) : (same for all models) PC1250-7. Unit PC1250LC-7 Weight kg (lb) 160 (353) 3 .132 . and the coolant may freeze. the cooling water must be changed twice a year (spring and fall). see "LUBRICANTS. ask the supplier of that antifreeze for information. When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator. (Such antifreeze can be used for the winter season only. antifoam agent.) However. If it should get into your eyes or on your skin.. For details of the antifreeze mixture when changing the coolant. in such a case. wash it off with large amount of fresh water and see a doctor at once. If it is doubtful that an available antifreeze meets the standard requirements. see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-21)". Fuel And Lubricants Change to fuel and oil with low viscosity for all components. Cooling System Coolant Antifreeze is toxic. Do not smoke when handling antifreeze. Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor. please contact your Komatsu distributor. OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION INFORMATION If the temperature becomes low.133 . it becomes difficult to start the engine. so do as follows. Be careful not to get it into your eyes or on your skin. With permanent antifreeze. so do not let it flow into drainage ditches or spray it on to the ground surface. or propanol-based antifreeze. 3 . Do not mix different types of antifreeze. Antifreeze is flammable. so use permanent antifreeze as far as possible. it is possible to use antifreeze whose main component is ethylene glycol and does not contain any corrosion inhibitor. For details of the specified viscosity. ethanol. Standard requirements for permanent antifreeze SAE J1034 FEDERAL STANDARD O-A-548D REMARK In areas where permanent antifreeze is not available. Never use any water-leakage prevention agent or any antifreeze containing such an agent. no change of coolant is required for a year. FUEL AND COOLANT SPECIFICATIONS (PAGE 4-9)".) meeting the standard requirements as shown below. Antifreeze is toxic. NOTICE Never use methanol. etc. so do not bring any flame close. wash it off immediately with water.28 1. Maintain the battery charge as close as possible to 100%.29 1.134 . cover the battery or remove it from the machine.27 75 1. If the battery electrolyte is frozen. the capacity of the battery will also drop. so do not bring fire or sparks near the battery. COLD WEATHER OPERATION OPERATION Battery The battery generates flammable gas.30 1. Battery electrolyte is toxic. If it gets on to the bodywork.31 90 1.29 80 1.25 1. There is danger that the battery may explode. If it gets in your eyes or on your skin. Battery electrolyte is dangerous.28 1. 3 . Battery electrolyte dissolves paint. If the electrolyte level is low.. If the battery charge ratio is low.26 1.27 1. and insulate it against cold temperature so that the machine can be started easily the next morning.23 1. wash it off with large amount of water. and consult a doctor.26 As the battery capacity drops markedly in low temperatures. so do not let it flow into drainage ditches or spray it on to the ground surface. and install it again the next morning. keep it in a warm place.24 1.26 1. the battery electrolyte may freeze. Do not add the water after the day's work so as to prevent fluid in the battery from freezing in the night.25 1. Temperature (°C) 20 0 -10 -20 Charging Rate(%) 100 1. do not charge the battery or start the engine with a different power source.24 1. REMARK Measure the specific gravity and calculate the rate of charge from the following conversion table. When the ambient temperature drops. add distilled water in the morning before beginning work. do as follows. or the undercarriage from freezing and making it impossible for the machine to move on the following morning. OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION Performing idle-running of the tracks is dangerous. If for any reason permanent antifreeze cannot be used. and fill with fresh soft water. 3 .. If this is impossible. AFTER COLD WEATHER SEASON When season changes and the weather becomes warmer. After operation in water or mud. 1. The boards help protect the tracks from being frozen in soil and the machine can start next morning. Swing 90° with engine at low idling and bring the work equipment to the side of the track. Replace the fuel and oil for all parts with oil of the viscosity specified. Open the drain valve and drain any water collected in the fuel system to prevent it from freezing. park the machine on wooden boards. remove water from undercarriage as described below to extend undercarriage service life. see "LUBRICANTS. Park the machine on hard. so stay well away from the tracks. 2. Repeat this procedure on both the left and right sides. Rotate the track under no load. In particular. and an ethyl glycol base antifreeze (winter. FUEL AND COOLANT SPECIFICATIONS (PAGE 4-9)". drain the cooling system completely. then clean out the inside of the cooling system thoroughly. For details.135 . one season type) is used instead. To prevent mud. dry ground. always observe the following precautions. Jack up the machine until the track is raised slightly from the ground. wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water. or if no antifreeze is used. water. Remove all the mud and water from the machine body. change the oil. When a machine is stored for a long period. then store the machine indoors. Add oil and grease to all places. keep the work equipment in the posture shown at right. LONG TERM STORAGE OPERATION LONG TERM STORAGE BEFORE STORAGE NOTICE To protect the hydraulic cylinder piston rod while in storage.. When using the machine after long-term storage. If the machine has to be stored outdoors. open the doors and windows to improve ventilation and prevent gas poisoning. (This prevents rust from developing on the piston rod) When putting the machine in storage for a long time. also charge the battery. always operate the machine once a month so that a new film of oil will be coated over movable parts and component surfaces. select level ground and cover the machine with a sheet. Clean and wash all parts. Install the blind plugs to the elbows. If there is water in the oil. Rotate the tracks. Completely fill the fuel tank. please contact your Komatsu distributor. For machines equipped with an air conditioner. At the same time. DURING STORAGE If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors. lubricate and change the oil before storage. moisture in the air will get into the oil. During storage. do as follows before using it. 3 . Set the selector valve on the machines which can install attachments to the "Where no attachment is mounted" position. Wipe off the grease from the hydraulic cylinder rods. AFTER STORAGE NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out. do as follows. run the air conditioner. Check the oil before and after starting the engine. Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately. Apply a thin coat of grease to the metal surface of the hydraulic piston rods. Set the stop valve to the "lock" position on machines ready for attachments. Lock each control lever and pedal with the safety lock lever and pedal lock.136 . When the bucket control lever is operated to the CURL position and the work equipment is lowered under no load from a high position. fill with fuel and bleed the air from the fuel system before stating. a noise will be emitted from the travel motor brake valve. The bucket or arm will fluctuate by itself during heavy. For details of bleeding the air. noise will be emitted from the brake valve.duty digging operations.. the arm speed will drop momentarily when the arm is more or less at the vertical position. see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-53)". OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting after running out of fuel. When starting or stopping the swing. the bucket speed will drop momentarily when the bucket teeth are more or less at the horizontal position.137 . 3 . When going down a steep slope at low speed. PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the work equipment is lowered under no load from a high position. After greasing. or if the drawbar pull of the excavator is being used to tow a heavy object. use a wire rope that has ample strength for the weight of the machine that is being towed. TROUBLES AND ACTIONS OPERATION TOWING THE MACHINE When towing the machine. If the machine sinks in mud and cannot get out under its own power.138 . For heavy-duty operations and deep digging. arm and bucket several times. carry out greasing every time the operation is carried out. At this time. if the work equipment mounting pin goes into the water. operate the boom. Place pieces of wood between wire ropes and body to prevent damage to ropes and body.. Do not apply a sudden load to the wire rope. never use the hole for light-weight towing. use a wire rope as shown in the diagram on the right. carry out greasing of the work equipment mounting pins every time before operation. SEVERE JOB CONDITION When carrying out digging operations in water. then grease again. 3 . .139 . always wear protective goggles and rubber gloves. stop the engine and turn the starting switch key to the OFF position. install the positive (+) terminal first.2. first disconnect the cable from the ground (normally the negative (-) terminal). and this may cause the battery to catch fire and explode. The battery generates hydrogen gas. If it gets on your clothes or on your skin. Do not bring lighted cigarettes near the battery.8 . When installing the battery. remove the ground cable (normally connected to the negative (-) terminal). When removing the battery. fix the battery securely in position with the battery mounting clamp. so be extremely careful. if the battery is not handled correctly. If a tool touches the positive terminal and the chassis. Battery electrolyte is dilute sulphuric acid. Tightening torque of mounting bolt: 9. When removing or installing the terminals. and do as follows. set it to less than the rated battery capacity. Be sure to fix the clips securely. If any tool touches between the positive terminal and the chassis. and it will attack your clothes and skin.14. If the terminals are loose. OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY When checking or handling the battery. Set the voltage of the charger to match the voltage of the battery to be charged. Connect the positive (+) charger clip of the charger to the positive (+) terminal of the battery.0 kgf·m. wash it out with fresh water.6 N·m (1. When installing. connected the ground cable last. or do anything that will cause sparks. Set the charging current to 1/10 of the value of the rated battery capacity. the electrolyte will leak or dry up. 3 . If the voltage is not selected correctly. when carrying out rapid charging. check which is the positive (+) terminal and which is the negative (-) terminal. there is a hazard that the battery may explode.0 . there is a hazard of sparks being generated. wash it immediately off with large amount of water. the charger may overheat and cause an explosion. and consult a doctor.19. When handling batteries. then connect the negative (-) charger clip of the charger to the negative (-) terminal of the battery. When replacing the battery.2 . so there is a hazard of explosion. If the charger current is too high. Always follow the instructions of "DISCHARGED BATTERY (PAGE 3-139)" and the instruction manual accompanying the charger. Battery Removal And Installation Before removing the battery. there is danger that the defective contact may generate sparks that will cause an explosion.5 lbft) Battery Charges When charging the battery. 7. If it gets in your eyes. there is danger that it will cause a spark. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line. 3 . This may cause an explosion..140 . TROUBLES AND ACTIONS OPERATION If the battery electrolyte is frozen. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery electrolyte and cause the battery to explode. Connect one clip of booster cable (A) to the positive (+) terminal of the problem machine. If hydrogen gas explodes. When starting the engine with a booster cable. never contact the positive (+) and negative (-) terminals. 1. 4. The battry of the normal machine must be the same capacity as that of the engine to be started. 2. exercise good care so that the booster cable clips may not contact each other. Connect the booster cable as follows. For the normal machine. Check that each lever is in the NEUTRAL position. In the last connection (to the upper structure frame). so connect the cable to a spot as far away from the battery as possible. OPERATION TROUBLES AND ACTIONS Starting Engine With Booster Cables When starting the engine with a booster cable. always wear safety glasses. however. Be careful not to let the normal machine and problem machine contact each other.141 . 3 .. Check that the safety lock levers and parking brake levers of both machine are in the LOCK position. also use a 24V battery. in the order of the numbers marked in the diagram. Connect the other clip of booster cable (B) to the revolving frame of the problem machine. because it is not a good conductor) ?When removing the booster cable. 5. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. The size of the booster cable and clip should be suitable for the battry size. do as follows: Connecting and Disconnecting Booster Cables When connecting the cables. Be careful not to make a mistake when connecting a booster cable. 3. Booster Cable Connection Keep the starting switch of the normal machine and problem machine are both at the OFF position. or they contact the chassis. (Avoid the work equipment. a spark will be caused. Connect the other clip of booster cable (A) to the positive (+) terminal of the normal machine. Make sure that the cables and clips are firmly connected. Connect one clip of booster cable (B) to the negative (-) terminal of the normal machine. it could cause serious injury. NOTICE The starting system for this machine uses 24 V. Check the cables and clips for damage or corrosion. 1. 3 . Remove one clip of booster cable (B) from the revolving frame of the problem machine. 3. try again after 2 minutes or so. 1.. Remove the other clip of booster cable (A) from the positive (+) terminal of the problem machine. 2. Make sure the clips are firmly connected to the battery terminals. Turn the starting switch of the problem machine to the START position and start the engine. Start the engine of the normal machine and keep it to run at high idling speed.142 . TROUBLES AND ACTIONS OPERATION Starting the Engine Always check that the safety lock lever is set to the LOCK position. disconnect the booster cables in the reverse of the order in which they were connected. Check also that all the control levers are at the HOLD or neutral position. Booster Cable Disconnection After the engine has started. 3. 4. regardless of whether the machine is working normally or has failed. If the engine doesn't start at first. Remove one clip of booster cable (A) from the positive (+) terminal of the normal machine. 2. Remove the other clip of booster cable (B) from the negative (-) terminal of the normal machine. replace) Lamp flickers while engine is Loose fan belt Check fan belt tension. repair) Pre-heating monitor does not light Defective heater relay ( Replace) Defective monitor ( Replace) Oil pressure monitor does not light Defective monitor ( Replace) up when engine is stopped Defective caution lamp switch ( Replace) (starting switch at ON position) Defective wiring ( Check. OPERATION TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below. defective ring ( Check. please contact your Komatsu distributor for repairs. repair) Starting motor does not turn when Defective starting motor ( Replace) starting switch is turned to ON Insufficient battery charge Charge Pinion of starting motor keeps Insufficient battery charge Charge going and out Defective safety relay ( Replace) Starting motor turns engine Insufficient battery charge Charge sluggishly Defective starting motor ( Replace) Defective wiring. replace battery) Check fan belt tension. Problem Main causes Remedy Lamp does not glow brightly even Defective wiring.143 . repair) Outside of electrical heater is not Disconnection in electric heater ( Replace) warm when touched by hand Defective operation of heater ( Replace) relay switch 3 . repair loose terminals. repair) Starting motor disengages before gear pinion engine starts Insufficient battery charge Charge Defective wiring ( Check.. replace running Charge level monitor does not go Defective alternator ( Replace) out even when engine is running Defectivr wiring ( Check. repair) Abnormal noise is generated from Defective alternator ( Replace) alternator Defective wiring ( Check. deterioraion of ( Check. when the engine runs at high speed battery disconnections. Problem Main causes Remedy Speed of travel. see EVERY 500 HOURS Excessive rise in hydraulic oil SERVICE temperature Lack of hydraulic oil Add oil to specified level.. see WHEN Abnormal wear of sprocket REQUIRED Lack of hydraulic oil Add oil to specified level. lack of oil HOURS SERVICE Loose fan belt Check fan belt tension. swing. TROUBLES AND ACTIONS OPERATION Chassis ( ): Always contact your Komatsu distributor when dealing with these items. Lack of hydraulic oil Add oil to specified level. see CHECK BEFORE STARTING Track comes off Track too loose Adjust track tension. In cases of abnormalities or causes which are not listed below. see EVERY 2000 (sucking in air) tank strainer. Bucket rises slowly. does not rise CHECK BEFORE STARTING Does not swing Swing lock switch still applied Turn swing lock switch OFF 3 . please contact your Komatsu distributor for repairs. arm. replace Dirty oil cooler Clean. see bucket is slow CHECK BEFORE STARTING Pump generates abnormal noise Clogged element in hydraulic Clean.144 . boom. adjust. radiator (pressure valve) replace Dirt or scale accumulated in Change coolant. see WHEN REQUIRED Exhaust gas occasionally turns Defective nozzle ( Replace nozzle) black Defective compression ( See defective compression above) Defective turbocharger Clean or replace turbocharger Combustion noise occasionally Defective nozzle ( Replace nozzle) make breathing sound 3 . add water. flush inside of cooling system cooling system. see (sucking in air) CHECK BEFORE STARTING Clogged oil filter cartridge Replace cartridge. see EVERY 500 HOURS SERVICE Defective fuel injection pump or ( Replace pump or nozzle) Engine does not start when starting defective nozzle motor is turned Starting motor cranks engine See ELECTRICAL SYSTEM sluggishly Preheating monitor does not light See ELECTRICAL SYSTEM up Defective compression Defective valve clearance ( Adjust valve clearance) Too much oil in oil pan Set oil to specified level. see WHEN REQUIRED Clogged radiator fins or Clean or repair. please contact your Komatsu distributor for repairs. see CHECK BEFORE STARTING Air in fuel system Repair place where air is sucked in.. In cases of abnormalities or causes which are not listed below. ( Check. see EVERY 500 damaged fins HOURS SERVICE Defective thermostat ( Replace thermostat) Radiator water level monitor lights Loose radiator filler cap Tighten cap or replace packing up (high-altitude operations) Defective water level sensor ( Replace sensor) Defective monitor ( Replace monitor) Lack of fuel Add fuel.145 . see EVERY 500 HOURS SERVICE Engine oil pressure monitor lights Defective tightening of oil pipe. see of water CHECK BEFORE STARTING Steam spurts out from top of Loose fan belt Check fan belt tension. Problem Main causes Remedy Engine oil pan oil level is low Add oil to specified level. see Exhaust gas is white or blue CHECK BEFORE STARTING Improper fuel Change to specified fuel Clogged air cleaner element Clean or replace. oil leakage from damaged point Defective engine oil pressure ( Replace sensor) sensor Defective monitor ( Replace monitor) Cooling water level low. repair) up pipe joint. repair. OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. leakage Check. . TROUBLES AND ACTIONS OPERATION Low-grade fuel being used Change to specified fuel Overheating Refer to "Radiator water level Abnormal noise generated monitor lights up" as above (combustion or mechanical) Damage inside muffler Replace muffler Excessive valve clearance ( Adjust valve clearance) 3 .146 . Machine Monitoring System Monitor Error mode Remedy display E02 Error in pump control system When emergency pump drive switch is turned ON.147 . (*) E03 Error in swing brake system Turn swing holding brake cancel switch ON to cancel brake. In the case where the monitor will not Have inspection carried out immediately. display error codes and work equipment operation and swing operation cannot be carried out. and carry out inspection immediately. When applying swing brake.. operate swing lock switch manually. (*) For details of the method of handling the emergency pump drive switch and swing holding brake cancel switch. In the case of some failures. see SWITCHES (PAGE 3-28). immediately. OPERATION TROUBLES AND ACTIONS Electronic Control System If an error code appears on the machine monitor display (normally displays TIME). (*) E10 Error in fuel line and swing Have inspection carried out immediately. 3 . normal operations become possible but have inspection carried out immediately. sensor system (engine stop) E11 Error in engine controller Move machine to a safe posture. Error in sensor and engine It is possible to carry out normal driving operations. follow the countermeasure table as shown below in the self-diagnosis. but have E15 controller power source inspection carried out immediately. and carry out inspection system (engine protection. E0E Network error Move machine to a safe posture. In any case. output down) E14 Error in throttle system Move machine to a safe posture. and carry out inspection immediately. it may be impossible to cancel. have inspection carried out immediately. If it is necessary to register the point of contact telephone number. ask your Komatsu distributor to register it. TROUBLES AND ACTIONS OPERATION Point Of Contact To Telephone When Error Occurs If an error screen is displayed on the monitor. screen B is not displayed. 3 .. REMARK If the point of contact telephone number has not been registered. Error screen → screen A → screen B → screen C → error screen Check the point of contact telephone number on screen B.148 . the screen changes as follows each time input confirmation switch (1) is pressed. . 4-1 . bolts. Windshield Washer Fluid Use automobile window washer fluid. and be careful not to let any dirt get into it. always remove it immediately. Dusty Jobsite When working at dusty worksites. Welding Instructions Turn off the engine starting switch. Connect grounding cable within 1m (3. Carry only things which are necessary for inspection. If you drop anything inside the machine. If such things are dropped inside the machine. Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. be careful not to drop nuts. If grounding cable is connected near instruments. etc. and carry out suitable action. Service Meter Reading Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out. Choose oils and grease with proper viscosities specified for ambient temperature. MAINTENANCE INFORMATION MAINTENANCE MAINTENANCE INFORMATION Do not carry out any inspection and maintenance operation that is not found in this manual. change the grounding point to avoid such parts. and will lead to failure. Keep foreign materials away from oil and grease. keep the containers of the oil and grease clean. Do Not Drop Things Inside Machine When opening inspection windows or the oil filler port of the tank to carry out inspection. Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point. Also. If a seal or bearing happen to come between the welding part and grounding point. check the old oil and filters for metal particles and foreign materials. Komatsu Genuine Lubricants Use Komatsu genuine oils and grease. Do not put unnecessary things in your pockets. Fresh and Clean Lubricants Use clean oil and grease. Do not apply more than 200V continuously.3 ft) from the area to be welded. If large quantity of metal particles or foreign materials are found. do not remove it while fueling. Clean the radiator core frequently to avoid clogging. Clean the air cleaner element more frequently. it will cause damage and malfunction of the machine. Fuel Strainer If your machine is equipped with a fuel strainer. 4-2 .. connectors. the instruments may have troubles. or tools inside the machine. Check Drained Oil and Used Filter After oil is changed or filters are replaced.. do as follows: Check the clogging of the air cleaner more frequently with the dust indicator. always report to the person in charge. Is there any leakage of water or oil? Have all the bolts been tightened? Checks when operating engine For details of the checks when operating the engine. When installing the hoses. or the hydraulic piping has been removed and installed again. be careful not to forget to assemble the O-rings and gaskets. do not twist them or bend them into loops with a small radius. For details. clean the mounting surface. Are the inspection and maintenance items working properly? Is there any leakage of oil when the engine speed is raised and load is applied to the oil pressure? 4-3 . This will cause damage to the hose and markedly reduce its service life. Hydraulic System . see "BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE 4-37)". Always do as follows. move the machine to a place that is free of dust to prevent dirt from getting into the oil. Hydraulic Hose Installation When removing parts at locations where there are O-rings or gasket seals. there is a hazard that it may be suddenly blown shut by the wind and cause injury to the worker. Never mix different kinds of oil. lock it securely in position with the lock bar. especially the starting motor and alternator. When doing this. If inspection or maintenance is carried out with the inspection cover not locked in position. Clean electrical components. Avoid Mixing Lubricants If a different type of oil has to be added. the air must be bled from the circuit. drain the old oil and replace all the oil with the new type of oil. unexpected problems may occur. MAINTENANCE MAINTENANCE INFORMATION Clean and replace the fuel filter frequently. to avoid accumulation of dust.. When inspecting or changing the oil. Checks After Inspection and Maintenance Works If you forget to carry out the checks after inspection and maintenance. and replace with new parts. Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been carried out correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside machine and get caught in the lever linkage mechanism. see "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-33)" and pay careful attention to safety.Air Bleeding When hydraulic equipment has been repaired or replaced. Locking the Inspection Covers If inspection or maintenance has to be carried out with the inspection cover open. and this may lead to serious injury or property damage. it is necessary to bleed the air from the circuit. For those who wish to use this service. or if the filters have been replaced. so always be careful when handling it to prevent any impurities (water. dirt. please contact your Komatsu distributor. and if fuel containing water or dirt is used. it cannot work properly. It is necessary to change for the fuel that is suitable for the temperature. The hydraulic oil that is not recommended by Komatsu can cause clogging of oil filter. To prevent the moisture in the air from condensing and forming water inside the fuel tank. SAE1OWCD is used for hydraulic type of oil. always fill the fuel tank after completing the day's work. Be extremely careful not to let impurities get in when storing or adding fuel. At the time of shipping from the factory. Having too much oil or too little oil are both causes of problems. Always add the specified amount of oil. 4-4 . Take particular care not to let any impurities get in when storing or adding oil.. FUEL. The majority of problems with machine are caused by the entry of such impurities. COOLANT AND FILTERS HANDLING OIL. AND PERFORMING OIL CLINIC Oil Oil is used in the engine and work equipment under extremely severe conditions (high temperature.) from getting in. always change the oil after the specified interval. If the oil in the work equipment is not clear. When HO46-hydraulic oil is going to be used. always replace the related filters at the same time. Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5 °F)). When changing the oil. COOLANT AND FILTERS MAINTENANCE LUBRICANTS. If the engine runs out of fuel. LUBRICANTS. please contact your Komatsu distributor. We recommend you have an analysis made of the oil periodically to check the condition of the machine. high pressure). Fuel The fuel pump is a precision instrument. or when 10 minutes have passed after adding fuel. Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. COOLANT. Never mix oils of different grades or brands. Before starting the engine. etc. Always use the fuel specified in the Operation and Maintenance Manual. so do not use it. metal particles. change specified amount of oil (whole amount). and is deteriorates with use. drain the sediment and water from the fuel tank. Even if the oil is not dirty. The portion of the oil that remains in the piping or cylinders will not be a problem even though it will be mixed into new oil. Oil corresponds to blood in the human body. there is probably water or air getting into the circuit. In such cases. If the coolant level is low. grease it. it will cause overheating and will also cause problems with corrosion from the air in the coolant. 4-5 . Grease Grease is used to prevent twisting and noise at the joints. Periodic use of KOWA makes the following possible: It enables abnormalities to be detected early. it can be used as it is even in hot areas. For details of the mixing proportions. Therefore. leading to improved machine availability. The proportion of anti-freeze to water differs according to the ambient temperature. and this will cause defective heat exchange and overheating. With KOWA. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. scale will stick to the engine and radiator. The anti-freeze can be used continuously for two years or 4000 hours.. Carrying out KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and down-time. so if it is used. This enables early detection of wear of the machine drive parts and other abnormalities. MAINTENANCE LUBRICANTS. It enables repair schedules to be planned. wait for the engine to cool before adding coolant. so they do not need grease. If the engine overheats. When using anti-freeze. The nipples not included in the MAINTENANCE section are nipples used when overhauling. 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. COOLANT AND FILTERS Cooling System Coolant River water contains large amount of calcium and other impurities. always observe the precautions given in the Operation and Maintenance Manual. the oil is periodically sampled and analyzed. Anti-freeze is flammable. If any part becomes stiff or generates noise after being used for a long time. Do not use water that is not suitable for drinking. This anti-freeze is effective in preventing corrosion of the cooling system. so be extremely careful not to expose it to flame or fire. KOWA analysis items Analysis of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of metal wear particles in the oil. see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-21)". leading to reduction of repair costs and machine downtime. Always wipe off all of the old grease that is pushed out when greasing. When replacing oil filters. (To prevent moisture from being sucked in) If drum cans have to be stored outside.. Never try to clean the filters (cartridge type) and use them again. 4-6 . If any metal particles are found. Do not open packs of spare filters until just before they are to be used. To prevent any change in quality during long-term storage. please contact your Komatsu distributor. However. Oil sampling Sampling interval 250 hours: Engine 500 hours: Other components Precautions when sampling Make sure that the oil is well mixed before sampling.first out (use the oldest oil or fuel first). COOLANT AND FILTERS MAINTENANCE Measurement of particle quantity This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of large iron particles in the oil. Oil And Fuel Storage Keep indoors to prevent any water. put the drum on its side so that the filler port of the drum can is at the side. be sure to use in the order of first in . For details. or other impurities from getting in. check if any metal particles are affixed to the old filter. Always replace with new filters. Do not carry out sampling on rainy or windy days when water or dust can get into the oil. When keeping drum cans for a long period. cover them with a waterproof sheet or take other measures to protect them. Others Measurements are made of items such as the ratio of water or fuel in the oil. Always use Komatsu genuine filters. Filters Filters are extremely important safety parts. dirt. LUBRICANTS. For further details of KOWA. Carry out sampling regularly at fixed intervals. see the Operation and Maintenance Manual. and the dynamic viscosity. please contact your Komatsu distributor. Replace all filters periodically. replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems. when working in severe conditions. Never install any electric components other than those specified by Komatsu. When working at the seashore. starting switch. so before installing a radio receiver or other wireless equipment. When washing the machine. or battery relay. The optional power source must never be connected to the fuse. connect it to an independent power source connector. check of damage or wear in the fan belt and check of battery fluid level.. Do not wash the inside of the operator's cab with water. Service relating to the electric system is check of fan belt tension. MAINTENANCE LUBRICANTS. When installing an operator's cab cooler or any other electrical equipment. External electro-magnetic interference may cause malfunction of the control system controller. carefully clean the electric system to prevent corrosion. COOLANT AND FILTERS ELECTRIC SYSTEM MAINTENANCE It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. please contact your Komatsu distributor. This will cause electrical leakage and may lead to malfunction of the machine. 4-7 . be careful not to let water get into the electrical components. The wear parts should be replaced correctly in order to ensure more economic use of the machine. Part Name Q'ty frequency 07063-51383 Element 2 Every 500 Hydraulic oil filter (07000-15210) (O-ring) (2) hours service Every 500 Pilot filter 424-16-11140 Element 1 hours service Every 500 Drain filter 21N-60-12210 Cartridge 1 hours service Every 500 Engine oil filter 600-211-1231 Cartridge 2 hours service Every 500 Fuel filter 600-311-3110 Cartridge 2 hours service Every 1000 Corrosion resistor 600-411-1171 Cartridge 1 hours service 600-185-6100 Outer element assembly 1 Air cleaner – (600-184-1671) (O-ring) (1) Horizontal pin type 21N-72-14290 Tooth 5 (21N-72-14330) (Pin) (5) – Vertical pin type 21N-72-34150 Tooth 5 (21N-72-34180) (Pin) (5) Side cutter type Bucket 21N-70-14180 Side Cutter (left) 1 21N-70-14190 Side Cutter (right) 1 21N-09-11121 Bolt (12) 21N-09-11131 Nut (12) – Side Shroud type 427-70-13611 Side Shroud 4 21N-939-3330 Pin (8) (209-939-7110) (Sim) (16) (209-939-7120) (Sim) (8) 285-62-17320 Element 1 Every 1000 Hydraulic tank breather (20Y-60-21470) (Element) (1) hours service 21N-62-31221 Element 3 (07000-12055) (O-ring) (3) Line filter – (07000-12070) (O-ring) (3) (07001-02070) (backup ring) (3) 4-8 .. always use Komatsu genuine parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time. the part number may change. As a result of our continuous efforts to improve product quality. Replacement Item Part No. When replacing parts. WEAR PARTS MAINTENANCE WEAR PARTS Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before they reach the wear limit. so inform your Komatsu distributor of the machine serial number and check the latest part number when ordering parts. MAINTENANCE LUBRICANTS..99 Liters 55. - Refill US gal 14.81 177.01 .57 6. FUEL AND COOLANT SPECIFICATIONS PROPER SELECTION Reservoir Swing machinery Final drive Engine oil Hydraulic Cooling P.3 22 800 1360 140 Specified US gal 17.57 6.5 24.T.31 36.97 3.42 5. - 4-9 .5 13.36 359.5 24.66 3. FUEL AND COOLANT SPECIFICATIONS LUBRICANTS.O case case (Front & case Fuel tank pan system system rear) (each) Capacity Liters 68 13.3 22 670 .81 211.42 5. When starting the engine with an atmospheric temperature of lower than 0°C (32°F).5%. be sure to use engine oil of SAE10W. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30.5%. change oil in the oil pan according to every periodic maintenance hours described in this manual. SAE10W-30 and SAE15W-40.0% 1/2 of regular interval Above 1. Use API classification CD as engine oil and if API classification CC. Change oil according to the following table if fuel sulphur content is above 0. LUBRICANTS. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Insitute Change interval of oil in Fuel sulphur content engine oil pan 0.10 . We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydrauric work equipment applications.5 to 1. even though the atmospheric temperature goes up to 10°C (50° F) more or less during the day. Specified capacity: Total amount of oil including oil for components and oil in piping. reduce the engine oil change interval to half. but be sure to add single grade oil that matches the temperature range in the table. 15W-40). FUEL AND COOLANT SPECIFICATIONS MAINTENANCE REMARK When fuel sulphur content is less than 0..0% 1/4 of regular interval 4 . 15W-40 Mobilgrease special 4 .) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL 1 KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter. MAINTENANCE LUBRICANTS.2 Base] (The 15W40 oil Permanent Type marked * is CE. one EO15-40CD season type) Diesel sigma S super dieselmulti- 2 AGIP Rotra MP GR MU/EP - grade *Sigma turbo Multi-purpose gear PYKON premium 3 AMOCO *Amoco 300 - oil grease Litholine HEP 2 4 ARCO *Arcofleet S3 pius Arco HD gear oil - Arco EP moly D Gear oil EP 5 BP Vanellus C3 Energrease LS-EP2 Antifreeze Hypogear EP *RPM delo 400 Universal thuban Marfak all purpose 2 6 CALTEX AF engine coolant RPM delo 450 Universal thuban EP Ultra-duty grease 2 EP *Turbomax EPX MS3 7 CASTROL *RX super Hypoy Anti-freeze Spheerol EPL2 CRD Hypoy B Hypoy C 8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 - Universal gear 9 CONOCO *Fleet motor oil Super-sta grease - lubricant Multiperformance 3C Tranself EP 10 ELF . FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W. 140 NLGI No.11 .. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30. Glacelf Performance 3C Tranself EP type 2 Essolube D3 *Essolube XD-3 EXXON Gear oil GP 11 *Essolube XD-3 Extra Beacon EP2 All season coolant (ESSO) Gear oil GX *Esso heavy duty Exxon heavy duty Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and 12 GULF *Super duty plus lubricant Gulfcrown EP special coolant Delvac 1300 Mobilux EP2 Mobilube GX 13 MOBIL *Delvac super Mobilgease 77 - Mobilube HD 10W-30. 15W40 SAE80. 40 No. 90. 30. ) Multi-purpose white *Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and 14 PENNZOIL fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant grease PETROFIN FINA potonic N 15 FINA kappa TD FINA marson EPL2 FINA tamidor E FINA potonic NE Spirax EP 16 SHELL Rimura X Albania EP grease - Spirax heavy duty Sunoco ultra prestige Sunoco antifreeze Sunoco GL5 17 SUN . 15W40 SAE80.2 Base] (The 15W40 oil Permanent Type marked * is CE.12 . FUEL AND COOLANT SPECIFICATIONS MAINTENANCE Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W. 140 NLGI No. LUBRICANTS. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30. 90. 40 No.. 30. 2EP and summer gear oil Sun prestige 742 coolant *Ursa super plus Multifak EP2 Coda 2055 startex 18 TEXACO Multigear Ursa premium Starplex 2 antifreeze coolant Total EP Rubia S 19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze *Rubia X TM 20 UNION *Guardol MP gear lube LS Unoba EP - *Turbostar Multigear 21 VEEDOL *Diesel star Multigear B . Antifreeze MDC Multigear C 4 . 5) 11/16 -16UN 22 74 (7.24) -2B The torques marked * indicate the hightening torques for the hoses at the top of the swivel joint.310.0) 343 .5) 10 17 66 (6.13.0) 1960 .0 .6.0 .0) 662 .0) 22 32 745 (76..5) 24 36 927 (94.1910 (155.0) 3430 .34 (2.0 .1.4220 (350.20.14.0 .93 (5. MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE LIST If nuts.5) 20 30 549 (56.0 .0 .0) 42 65 3830 (390.35) 11.1470 (120.2 (1.0) 157 .3040 (250.5) 824 .5 .150.8 .5 .245 (18.5 .13 .19.63 (3.7 (1.5) 18 27 382 (39.0) 177 .12.5) 35 .0 .31.0) 2890 .829 (67.5) 13/16 -16UN 27 103 (10.123 (10.0) 16 24 279 (28.186 (13. If it is necessary to replace any nut or bolt.0 . and this will cause failure of the machine or problems with operation.0 .5 .84.0 .195. 4 .0 . Unless otherwise specified.0) The torques marked I indicate the tightening torques for the hoses at the top of the swivel joint.234 (18 .0 .0) 30 46 1720 (175.3630 (295.425 (35.132 (8. Always pay careful attention when tightening parts.25.9.430.5) 84 .74 (6.7) 59 .0) 128 .0) 27 41 1320 (135.5) 54 .0) 1·3/16 -12UN 36 216 (22.0) 36 55 2750 (280.43.196 (16.250.5) 14 22 177 (18.7. it will cause looseness or damage to the tightened parts. Width Tightening torque [N·m (kgf·m)] Thread across diameter a Target flat Permissible range (mm) value b(mm) 9/16 -18UNF 19 44 (4.309 (25.0) 33 50 2210 (225.5) 245 .8 . bolts.5) 12 19 113 (11.370.0 .1030 (84. tighten the metric nuts and bolts to the torque shown in the table below.0) 39 60 3280 (335.0) 1520 .0) *1-7/16-12UN 41 215 (22) 176 .0) 2450 .608 (50. always use a Komatsu genuine part of the same size as the part that was replaced.5) 1 -14UNS 32 157 (16.5) 98 .2) 27 .3.0) 1180 .105.5) 8 13 31 (3.2 . Thread Width Tightninig torque [N·m (kgf·m)] diameter across of bolt flats Target value Permissible range (a)(mm) (b)(mm) 6 10 13.0) 490 . or other parts are not tightened to the specified torque.0 .2450 (200.0 .62. as such abnormality requires. This is important to ensure that these parts maintain their full performance at all the time.3 pump outlet hose 2 9 No.2 pump outlet hose 2 8 No. Check the hydraulic hoses and the fuel hose. should anything abnormal be found on any of these parts.14 .1 and No. Also carry out the following checks with hydraulic hoses which need not be replaced periodically. the user of the machine must always carry out periodic maintenance. gaskets.2 pump outlet branch hose 2 7 No. it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. replace it with a new one even if the periodic replacement time for the parts has not yet arrived. These parts are particularly closely connected to safety and fire prevention.2 pump relay hose 2 14 Heater hose (engine . so please contact your Komatsu distributor to have them replaced. whichever 11 Left 5-spool inlet branch hose 1 comes sooner 12 Right 4-spool inlet branch hose 1 13 No. Furthermore.fuel tank) 1 5 No. However.fuel filter) 1 3 Fuel return hose ( engine . In addition. Tighten a loosened clamp again or replace a defective hose. and other such parts at the same time. replace such a defective clamp with a new one together with a defective hose. SAFETY CRITICAL PARTS MAINTENANCE SAFETY CRITICAL PARTS To ensure safety at all times when operating or driving the machine. SAFETY CRITICAL PARTS LIST No. When replacing the hoses..fuel cooler) 1 4 Fuel return hose (fuel cooler . when carrying out the following periodic inspections. to further improve safety. Hence it is required to replace them with new ones irrespective of their conditions after a certain period of usage.3 pump outlet branch hose 2 Every 2 years or 4000 10 No.1 pump outlet hose 2 6 No. Ask your Komatsu distributor to replace the critical parts. Safety critical parts for periodic replacement Q'ty Replacement interval 1 Fuel hose (fuel tank . If any of the hose clamps show deterioration like deformation or crack. 3 pump relay hose 1 hours. always replace the O-rings. the parts in the safety-critical parts list on the next page must also be replaced at the specified interval. too.fuel strainer) 1 2 Fuel hose (fuel strainer . Material quality of these parts can change as time passes and they are likely to wear our or deteriorate.heater) 2 15 Hydraulic pump suction hose 4 16 Swing line hose 4 17 Boom cylinder line hose (B/H) 4 18 Arm cylinder line hose (B/H) 7 19 Bucket cylinder line hose (B/H) 7 20 Seat belt 1 Every 3 years 4 . 46 LUBRICATING AFTER COOLER FAN MOUNT 4. ADD OIL 4. ADD FLUID 4. 21 CHECK AND TIGHTEN TRACK SHOE BOLTS 4.T. 40 CHECKS BEFORE STARTING EVERY 10 HOURS MAINTENANCE LUBRICATING 4. MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) CLEAN STRAINER OF P. 25 CHECK ELECTRICAL INTAKE AIR HEATER 4. 24 CHECK AND ADJUST TRACK TENSION 4.68 CHANGE OIL IN P.15 . 56 REPLACE HYDRAULIC OIL FILTER ELEMENT 4. 50 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION. 55 CLEAN HYDRAULIC TANK STRAINER AND RETURN STRAINER 4. 31 ADJUST BUCKET CLEARANCE 4.51 EVERY 500 HOURS MAINTENANCE REPLACE FUEL FILTER CARTRIDGE 4. ADJUST 4.69 CHANGE OIL IN FINAL DRIVE CASE 4. 28 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) 4. 18 CLEAN INSIDE OF COOLING SYSTEM 4.. 32 CHECK WINDOW WASHER FLUID LEVEL.42 EVERY 100 HOURS MAINTENANCE LUBRICATING SWING CIRCLE 4.78 WHEN REQUIRED CHECK. 36 BLEEDING AIR FROM HYDRAULIC SYSTEM 4.63 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) CHANGE OIL IN SWING MACHINERY CASE 4. 58 4 . REMOVE DIRT 4. CLEAN AND REPLACE AIR CLEANER ELEMENT 4. 53 CHECK SWING PINION GREASE LEVEL.T. 27 REPLACE BUCKET TEETH (VERTICAL PIN TYPE) 4. 49 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS 4. 34 CLEAN LINE FILTER. 45 CHECK LEVEL OF BATTERY ELECTROLYTE 4.O LUBRICATING OIL FILTER 4.44 EVERY 250 HOURS MAINTENANCE CHECK OIL LEVEL IN FINAL DRIVE CASE.O CASE 4. 49 CHECK ALTERNATOR DRIVE BELT TENSION. ADD GREASE 4. ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) 4. 37 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4. 33 CHECK AND ADJUST AIR CONDITIONER 4. CHECK TURBOCHARGER 4. CONDENSER FINS AND AFTER COOLER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER) 4. 65 CHANGE OIL IN ENGINE OIL PAN. CLEAN 4. 72 CHECK FUEL STRAINER. REPLACE ENGINE OIL FILTER CARTRIDGE 4. REPLACE.O CASE 4. 79 CHECK ENGINE INJECTOR SET LOAD. 80 CHECK VIBRATION DAMPER 4.O LUBRICATING OIL FILTER 4. 66 EVERY 1000 HOURS MAINTENANCE CHANGE OIL IN SWING MACHINERY CASE 4. ADJUST 4. ADJUST 4. 69 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER 4. ADJUST 4. 78 CLEAN ENGINE BREATHER 4. 59 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER 4. 60 REPLACE PILOT FILTER ELEMENT 4.82 4 . ADJUST 4. 79 CHECK PLAY TURBOCHARGER ROTOR 4.16 . 62 CLEAN STRAINER OF P. TENSION PULLEY ASSEMBLY 4. 64 REPLACE DRAIN FILTER CARTRIDGE 4. 73 CHECK WELDED STRUCTURE 4. 80 CHECK AIR COMPRESSOR.T.T. 79 CHECK ENGINE VALVE CLEARANCE. 80 CHECK FAN PULLEY AND TENSION PULLEY 4. 79 EVERY 4000 HOURS MAINTENANCE CHECK WATER PUMP 4.. 71 REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT 4. CLEAN STRAINER 4. 70 LUBRICATING FAN PULLEY ASSEMBLY. 80 EVERY 5000 HOURS MAINTENANCE CHANGE OIL IN HYDRAULIC TANK. STARTING MOTOR 4. 74 EVERY 2000 HOURS MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE 4. 69 REPLACE CORROSION RESISTOR CARTRIDGE 4. 79 CHECK ALTERNATOR. MAINTENANCE SCHEDULE MAINTENANCE CLEAN AND INSPECT RADIATOR FINS. 68 CHANGE OIL IN P. 63 CHECK WEAR OF FAN BELT. 79 CLEAN. OIL COOLER FINS. Change oil in swing machinery case Change oil in P. 4 . see EVERY 500 HOURS MAINTENANCE.O lubricating oil filter For details of the method of maintaining. see EVERY 500 HOURS.T. so contact your Komatsu distributor.. MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) Carry out the following maintenance only after the first 100 hours.17 .O case Change oil in final drive case Special tools are needed for inspection and maintenance.T. 1000 HOURS and 2000 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. Clean strainer of P. For details of the method of maintaining. If the element is cleaned frequently before the clogging monitor flashes. cleaning. and O-ring. Always wear protective glasses. NOTICE Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel flashes. Checking If air cleaner clogging monitor (1) of the monitor panel flashes. and the cleaning efficiency will also go down. more dirt stuck to the element will fall inside the inner element. Always stop the engine before carrying out these operations. REMARK Dust indicator (4) gives a guideline for the cleaning interval for the air cleaner element. it is time to clean the element. O-ring If one year has passed since installing the element or if air cleaner clogging monitor (1) on the monitor panel flashes immediately after the element is cleaned. the air cleaner will not be able to display its performance fully. If the yellow piston on the inside overlaps the red zone on the outside circumference of dust indicator (4). 4 . CLEAN AND REPLACE AIR CLEANER ELEMENT When using compressed air. or other protective equipment. there is danger of dirt flying and causing personal injury. If inspection. replace the outer element. In addition. clean the air cleaner element. dirt will enter the engine and cause damage to the engine. during the cleaning operation.18 . or maintenance is carried out with the engine running. MAINTENANCE PROCEDURE MAINTENANCE WHEN REQUIRED CHECK. it is dangerous to pull it out by force. be careful not to fall because of the reaction when pulling out the outer element.. dust mask. When working at high places or where the foothold is poor. inner element. Replacing Replacing element. When removing the outer element from the air cleaner body. cover the air connector inside the air cleaner body with a clean cloth or tape to prevent dirt or dust from entering. Wipe off or brush off the dirt stuck to cover (3) and the inside of the air cleaner body. do not leave or keep it in direct sunlight. 4. MAINTENANCE MAINTENANCE PROCEDURE Cleaning or replacing outer element 1. Do not use a screwdriver or other tool. It will allow dirt to enter and cause failure of the engine.. Hold the outer element. then remove cover (3). After removing the outer element. NOTICE Never remove the inner element. and rotate the element to the left and right to pull it out.19 . 4 . 2. 3. NOTICE Before and after cleaning the element. remove 6 hooks (2). rock it lightly up and down and to the left and right. Open the right door of the machine. 1) Remove one seal from the element whenever the element has been cleaned. After replacing the element. Clean the air cleaner body interior. replace the element. 3) Replace both inner and outer elements when the monitor lamp (1) flashed soon after installing the cleaned outer element even though it has not been cleaned 5 times. 99. 5. MAINTENANCE PROCEDURE MAINTENANCE 5. do not hit or beat it against anything. Direct dry compressed air (less than 0. Fit a new inner element to the connector and tighten it with nuts. then direct it from outside along its folds and again from inside.69MPa (7kgf/cm2.20 . 7.. Remove the cloth or tape cover installed in Step 3. Replace the inner element at the same time. 3. Do not use an element whose folds or gasket or seal are damaged. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning. Stick the seal in the position shown in the diagram on the right. 4 . Replacing inner element 1. The yellow piston will return to its original position. Install the outer element and the cover. Cover the air connector side (outlet side) with a clean cloth or tape. push the dust indicator button to reset it. 2.4PSI)) to the outer element(4) from inside along its folds. 4) When replacing the element. stick on seal (A) packed in the same box as the element. First remove the outer element. 6. 4. Do not clean and reinstall a inner element. 6. and then remove the inner element. then remove the cover installed in Step 2. 2) Replace the outer element which has been cleaned 5 times repeatedly or used throughout a year. NOTICE When cleaning the element. When deciding the ratio of antifreeze to water.5 95. MAINTENANCE MAINTENANCE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM Immediately after the engine is stopped. one season type) add antifreeze in autumn) when changing coolant Every 6 months or When no using antifreeze every 1000 hours.84 13. Use a permanent type of antifreeze. use an antifreeze containing ethylene glycol. When standing up or leaving the operator's seat.08 25.5 44. a minimum ratio of 30% by volume is necessary. Cleaning inside of cooling system Kind of coolant Replacing corrosionresistor and changing coolant Every year (autumn) or Permanent type antifreeze every 2000 hours. There is danger of touching the fan if the undercover is left removed.77 18. see"BEFORE STARTING ENGINE (PAGE 3-72)" and "STARTING ENGINE (PAGE 3-86)" in the OPERATION section. If the cap is removed to drain the coolant in this condition. but to obtain the corrosion resistance effect. (All season type) whichever comes first Every 1000 hours and when Non permanent type antifreeze Every 6 months (spring.49 4 . autume) cleaning the inside of the containing ethylene glycol (Drain antifreeze in spring.8 51. for some reason. Mixing rate of water and antifreeze Min.17 18. Clean the inside of the cooling system.2 57.2 88.49 liter 102. set the safety lock lever to the LOCK position. and decide from the mixing rate table given below. Never enter behind the machine when the engine is running. change the coolant and replace the corrosion resistor according to the table below. cooling system and (winter. Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.15 23.46 21.53 15. It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate. Cleaning is carried out with the engine running.8 82.21 . there is a hazard of burns. For details of starting the engine. check the lowest temperature in the past. The ratio of antifreeze to water depends on the ambient temperature..91 11. Wait for the temperature to go down. atmospheric °C -10 -15 -20 -25 -30 temperature °F 14 5 -4 -13 -22 liter 37. the coolant is at a high temperature and the radiator is under high internal pressure. it is impossible to use permanent type antifreeze. then turn the cap slowly to release the pressure before removing it.4 70 Amount of water US gal 27. If.4 70 Amount of antifreeze US gal 9. whichever come first Stop the machine on level ground when cleaning or changing the coolant. If river water. contact your Komatsu distributor. flush your eyes with large amount of fresh water and see a doctor at once. close valve (1) on corrosion resistor (2). We recommend use of an antifreeze density gauge to control the mixing proportions. When removing the drain plug. Use city water for the cooling water. 1.. Turn radiator cap (3) slowly to remove it.99 US gal) capacity. 2. be careful not to get water containing antifreeze on you. If it gets in your eyes. so keep it away from flame. 4 . Stop the engine.22 . Antifreeze is toxic. MAINTENANCE PROCEDURE MAINTENANCE Antifreeze is flammable. Prepare a container to catch drained coolant: Min 140 liters (36. well water or other such water supply must be used. Operate the machine under a light load until the engine water temperature gauge (2) points to the white range (monitor panel spec. and add water if the level is low. 6. then set a container to catch the coolant under drain valves (5) and (6). Add water through the water filler up to the filler port. 7. 10. and fill with tap water. start the engine and run at low idling. MAINTENANCE MAINTENANCE PROCEDURE 3. Replace the corrosion resistor. To remove the air in the cooling water. 8. Check the coolant level. Open drain valve (6) at the cylinder block to drain the water. After draining off the cooling water of reserve tank (7). (While doing this. run the engine for 5 minutes at low idling. then for another 5 minutes at high idling. check that each gauge and caution lamp are in normal condition. When the radiator is full. Stop the engine and tighten the cap. 9. tighten drain valves (5) and (6). If any abnormality is found. Install undercovers (4). clean the radiator with detergent. Stop the engine. 5.. see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-70)". For the cleaning method. open drain valves (5) and (6). Close drain valves (5) and (6). After the engine warming up. After draining the water. leave the radiator cap removed) 12. For details of the method for replacing the corrosion resistor cartridge.23 . and open valve (1). 13. Keep the engine running at low idling for 10 minutes until the water temperature reaches more than 90°C (194°F). carry out adjustment or repairs.). clean the inside of the reserve tank and refill the water between FULL and LOW level.) or the green range(gauge panel spec. 11. Open drain valve (5) at the bottom of the radiator to drain the water. 4 . 4. After draining the water. follow the instruction of detergent. and drain the water. Remove the under cover (4). 1.. they will break.6 ± 101.012. so tighten any loose bolts immediately Tightening 1.2 N.3 lbft). check that the nut and shoe are in close contact with the link mating surface. 2. tighten to a tightening torque of 1372 ± 137. After tightening.24 . First. MAINTENANCE PROCEDURE MAINTENANCE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose. Order for tightening Tighten the bolts in the order shown in the diagram on the right. After checking. 4 .m (140 ± 14 kgf.m. further tighten to the tightening torque of 150° ± 10°. then check that the nut and shoe are in tight contact with the link mating surface. Measure the maximum deflection between the bottom surface of the wooden bar and the top surface of the track shoe. 4 . Run the engine at low idling.. 3 roller (2). Place wooden bar (3) on top of the track from No. Checking 1. and "WORK EQUIPMENT CONTROLS AND OPERATIONS (PAGE 3-106)" in the OPERATION section.30 mm. "STARTING ENGINE (PAGE 3-86)". The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil. 2 roller (1) to No.25 . MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION For details of starting the engine and operating the work equipment. see "BEFORE STARTING ENGINE (PAGE 3-72)". Deflection a should be 10 . 2. so inspect the track tension frequently in order to maintain the standard tension. horizontal ground when carrying out the inspection and maintenance. then travel the machine forward for a distance equal to the track length on ground and stop the machine slowly. "AFTER STARTING ENGINE (PAGE 3-90)". Stop the machine on firm. 3. Continue to pump in grease until (A) becomes 200 mm (7. 3. Pump in grease through valve (1) using a grease gun. move the machine slowly forward and in reverse. so they must be either turned or replaced. If the tension is still loose. adjust it again. 4 . Please contact your Komatsu distributor. and if the tension is not correct. If the track is not loosened when using this procedure. Increasing Track Tension Prepare a grease gun.. Never loosen the valve more than one turn. MAINTENANCE PROCEDURE MAINTENANCE Adjustment There is danger that the valve may fly out under the internal pressure of the high-pressure grease. please contact your Komatsu distributor for repairs. 4. 2. Do not put your face in the direction of mounting of the valve. 1.9 in). the pin and bushing are excessively worn. To check that the tension is correct.26 . Check the track tension again. Never loosen any part other than the valve. move the machine backwards and forwards. If the grease does not come out smoothly. 1. 5. To check that the correct tension has been achieved. 4. adjust it again. Remove the electrical intake air heater from the engine intake manifold. move the machine forwards and backwards a short distance. Check the track tension again. Loosen plug (1) gradually to release the grease. and if the tension is not correct. please contact your Komatsu distributor for repairs. 4 . MAINTENANCE MAINTENANCE PROCEDURE Loosening Track Tension It is extremely dangerous to release the grease by any method except the procedure given below.. contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. replace the gasket with new one. 3. Tighten plug (1). 6.27 . When inspecting and replacing the electrical intake air heater. 2. CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year). Turn plug (1) a maximum of one turn. If the track tension is not relieved by this procedure. and check it for possible disconnections and dirt. If both sides only are replaced with new parts. Set the work equipment in a stable condition. MAINTENANCE PROCEDURE MAINTENANCE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the bucket tooth before it wears down to the adapter. (If the drift is set against rubber pin lock (3) when it is hit. then stop the engine and set the safety lock lever securely to the LOCK position.. the rubber pin lock may break. Replace them with new ones. Place a block under the bucket bottom to make it possible to knock the pin of tooth (1) out with a hammer. Use a hammer and drift (ESCO No. 4 . so always wear protective equipment like safety glasses and gloves. and set so that the bottom of the bucket is horizontal. Check that there is no one in the surrounding area. so there is a hazard that the pin may fly out.28 . It is dangerous if the work equipment moves by mistake when the teeth are being replaced. The lock pin is too short. the teeth may come off the bucket. The pins can be knocked out only with strong force. After removing lock pin (2) and rubber pin lock (3). There is a hazard that fragments will fly during the replacement work. MUS2267-1) to knock out lock pin (2). check them. When replacing the bucket teeth. 1. Set it against the back of the pin. If lock pins and rubber pin locks with the following defects are used. 2.) 3. do not replace only both sides with new parts. the bucket will easily deform. Use your hand or a hammer to push rubber pin lock (3) into the hole of the adapter. do not try to knock the pin in. so remove the obstruction. the rear face of the hole for the pin of the teeth is at the same level as the rear face of the hole for the pin of the adapter. and the steel balls may come out. If the rear face of the hole for the pin of teeth (1) is protruding to the front from the rear face of the pin hole for adapter (4). Clean the inside of teeth (1). MAINTENANCE MAINTENANCE PROCEDURE The rubber of the rubber pin lock is torn. 4. and there will not be proper contact at the mating portion. 4 . The steel balls are buried when they are pressed by hand. then install it to adapter (4). When doing this. When teeth (1) enters adapter (4) fully. and confirm that when the pointer is pressed strongly. be careful that the rubber pin lock does not fly out from the adapter surface.. 7.29 . Clean the surface of adapter (4) and remove the soil with a knife. 6. the teeth will not enter the adapter properly. There is something preventing teeth (1) from entering adapter (4) fully. knock in lock pin (2). Fit teeth (1) to adapter (4). 5. If there is mud affixed to it or if there are protrusions. and hit its sides from right and left. 9. This makes it possible to prevent the teeth from falling out.30 . 4 . 3) Lightly hit the tip of the point from above and below. Insert lock pin (2) in the hole of the teeth and hit it until its top is the same level as the surface of teeth (1). MAINTENANCE PROCEDURE MAINTENANCE 8. After replacing a bucket tooth. check that it is secured by the point and surface. Replace the rubber pin lock and locking pin at the same time as replacing the teeth.. 2) Lightly hit lock pin (2) in the reverse direction from which it was hit in. 1) After the lock pin has been knocked in completely. 4) Confirm that rubber pin lock (3) and lock pin (2) are set as shown in the figure. The life of the teeth can be lengthened and the frequency of its replacement can be reduced by turning it upside down so that it will wear evenly. always check the following. REMARK If it cannot be removed by this method.31 . so always wear protective equipment like safety glasses and gloves.. Place a block under the bucket bottom so that the pin (1) of tooth (2) can be knocked out with a hammer. Check that there is no one in the surrounding area. Clean the mounting face. There is a hazard that fragments will fly during the replacement work. 1. 2. push in pin (1) partially by hand. Fit a new tooth (2) in the adapter. 3. then lock it with a hammer to install the tooth to the bucket. Set the work equipment in a stable condition. so there is a hazard that the pin may fly out. MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the teeth before the wear reaches the adapter. for safety reasons. then stop the engine and set the safety lock lever securely to the LOCK position. Place a bar on the head of pin (1). 4 . Set so that the bottom face of the bucket is horizontal. The pins can be knocked out only with strong force. It is dangerous if the work equipment moves by mistake when the teeth are being replaced. hit the bar with a hammer to knock out the pin. then remove tooth (2). always contact your Komatsu distributor to have the replacement carried out. clearance (b) becomes larger. then set safety lock lever (1) securely to the LOCK position.0 mm (0.04 in). If there is excessive free play on the coupling section of the bucket and arm. 4. 2. 1. Set the work equipment to the position shown in the diagram on the right. When free play (a) is less than a thickness of shim. Tighten 3 bolts (2) and 6 bolts (3). plate (1) and plate (5). 6 bolts (3). With this adjustment. MAINTENANCE PROCEDURE MAINTENANCE ADJUST BUCKET CLEARANCE It is dangerous if the work equipment is mistakenly moved when adjusting the bucket clearance. but play (a) is removed. then stop the engine and set the lock lever to the LOCK position. 3.5 mm or 1. 4 .02 or 0. adjust the bucket clearance in the following manner. stop the engine.32 . Set the work equipment in a stable condition. Thickness of shim (4) is 0. do not compress the shims by tightening bolt (2). Loosen 3 bolts (2).. Take out shims (4) equivalent in size to free play (a). .33 .10°C (14°F) 1/3: water 2/3 Winter in cold Pure washer fluid . MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL.22°F) cold region There are two types depending on the freezing temperature: -10°C (14°F) (general use) and -30°C (-22°F) (cold area use). Operation area Freezing Mixture ratio and season temperature Pure washer fluid Normal . be careful not to let any dust get in.20°C (. When adding fluid. so dilute the washer fluid with water to the following proportions before adding.30°C (. Mixture ratio of pure washer fluid and water The proportion differs according to the ambient temperature. check the level of the fluid in window washer tank(1). so select according to the area and season. ADD FLUID If there is air in the window washer fluid. 4 . add automobile window washer fluid. and if it is low.4°F) region 1/2: water 1/2 Winter in extremely Pure washer fluid . it may cause loss of sight or frostbite. it will cause damage to the compressor. the refrigerant gas level is low. transparent: No refrigerant REMARK When there are bubbles. MAINTENANCE PROCEDURE MAINTENANCE CHECK AND ADJUST AIR CONDITIONER (Only for machines equipped with air conditioner) Check level of refrigerant (gas) If the refrigerant used in the cooler gets into your eyes or on your hands.34 . No bubbles in refrigerant flow: Suitable Some bubbles in flow (bubbles pass continuously): Lack of refrigerant Colorless. When operating the cooler at high speed with the engine at full throttle. If there is a lack of refrigerant (gas). 4 .. use the receiver sight glass (inspection window) to check the condition of the refrigerant gas (Freon R134a) flowing in the refrigerant circuit. Never loosen any part of the refrigerant circuit. If the air conditioner is run with the refrigerant gas level low. so contact your refrigerant dealer to have refrigerant added. Do not touch the refrigerant. Do not bring any flame close to any point where the refrigerant gas is leaking. the cooling performance will be poor. tension Every 250 hours Operating condition (does it When required Blower motor. looseness at Piping mounts tightening or connecting portions. maintenance items maintenance interval Twice a year (spring.. fan When required make abnormal noise?) Operating condition (does it function Control mechanism When required normally?) Mounting condition. damage 4 . maintenance Guideline for Content of check. operate the air conditioner for 3 . MAINTENANCE MAINTENANCE PROCEDURE Inspection During Off Season Even during the off-season. Refrigerant (gas) Charge amount autumn) Condenser Clogged fins Every 500 hours Compressor Operating condition Every 4000 hours V-belt Damage. leakage When required of gas.5 minutes once a month to maintain the oil film at all parts of the compressor. Inspection and Maintenance Items Check.35 . 2. clean off all dirt stuck to the side face of the case. MAINTENANCE PROCEDURE MAINTENANCE CLEAN LINE FILTER. For details. see "METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT (PAGE 4-40)". Using a bolt (∅10) in filter (1).. Tightening torque of cover: 107.36 . Wash the filter. replace O-rings (4) and (5) and backup ring (3). release the pressure inside the hydraulic circuit. remove the dirt from inside the line filter as follows. 4 . Before removing the line filter. bleed the air. Remove plug (2). For details. REMOVE DIRT If there is any abnormality in the pump or other hydraulic equipment. remove the filter. 1.9 ± 9. When washing the filter. When assembling the case again.8 N·m (11±1 kgf·m (79 ± 7 lbft)) After assembling the line filter again. see "BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE 4-37)". 3. Bleed the air from the various components in the order below (1 . Oil will come out when the drain hose is removed. or stopping. 4 . abnormal heat will be generated and this may cause premature damage to the pump. NOTICE If the drain hose is installed first. Do not suddenly stop and cause the cylinder pressure to rise or operate to the end of the stroke. remove the drain hose from the pump case. Use clean oil also for the oil jack. 3) After completing the air bleed operation. and operate the cylinders slowly. NOTICE Bleed the air as follows. Bleeding air from pump 1) Loosen air bleed plug (1) and check that oil oozes out from the air bleeder.. so secure the hose mouthpiece at a position higher than the level of the oil in the hydraulic tank. tighten air bleed plug (1) and install the drain hose. If it is necessary to refer to the items for starting the engine. Pump (work equipment. Work equipment circuit Run the engine at less than 1000 rpm.5). operate particularly slowly. MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM For details. and add hydraulic oil through drain port (2) to fill the pump case.37 . see the OPERATION section. steering. When operating the cylinder for the first stroke (extending and retracting). oil will spurt out from plug (1) hole. 1. swing) 2. so the work equipment will not move for at least 10 seconds. If the pump is operated without filling the pump case with hydraulic oil. When operating the cylinder for the first stroke. see "STARTING ENGINE (PAGE 3-86)". Be careful not to operate the lever to the end of the stroke. there is a large amount of air inside the circuit. moving the machine off. 1. Use clean oil of NAS7 class or above when filling the pump. 2) If no oil oozes out. remove air hose (1).38 . 5. stop the engine. 3) After completion of bleeding air. Starting engine Start the engine. NOTICE If the method of bleeding the air from the attachment itself is specified by the manufacturer. NOTICE If the air is not bled from the swing motor. operate each cylinder 3 to 4 times to the end of its stroke. (Stop the cylinder approx. This will remove the air bubbles in the oil inside the hydraulic cylinders. 4. NOTICE When doing this. 100 mm (3.. Bleeding air from swing motor (bleed the air only when the oil inside the swing motor case has been drained) 1) Run the engine at low idling. remove air hose (1). Bleeding air from cylinders 1) Run the engine at low idling. 3. and check that oil oozes out from air hose (1). the motor bearings may be damaged. 4 . Bleeding air from attachment (when installed) If an attachment has been installed. 4) Run the engine at low idling. taking care so that a cylinder may not be brought up to its stroke end. operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air. and leave the machine for 5 minutes before starting operations. run the engine at low idling and operate the attachment pedal repeatedly (approx.9 in) short of its stroke end) 2) Next. install air hose (1). then fill the motor case with hydraulic oil. 2) If the oil does not ooze out. stop the engine. and extend and retract each cylinder 4 to 5 times. then go on to the next operation. see "STARTING ENGINE (PAGE 3-86)". MAINTENANCE PROCEDURE MAINTENANCE 2. NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end. do not operate the swing. After completing the air bleeding operation. Run the engine for 10 minutes at low idling. bleed the air according to the specified procedure. air taken inside the cylinder may cause damage to the piston packing. Check that there is no leakage of oil and wipe off any oil that has been spilled. and slowly swing the upper structure at least 2 times uniformly to the left and right. 10 times) until the air has been bled from the attachment and circuit. For details. 3) Finally. 4) When no more cloudy white oil comes out from air bleed plug (2). Bleeding air from travel motor circuit If the piping has been removed from the travel motor circuit. 3) Carry out fine operation of the travel lever and set to FORWARD and REVERSE 4 . To bleed the air. then loosen air bleed plug (2) one turn. 4 . 2) Remove travel motor cover (1). run the engine at low idling and do as follows.5 times.. 1) Start the engine and run at low idling. MAINTENANCE MAINTENANCE PROCEDURE 6. bleed the air after reassembling. NOTICE Do not loosen plug (2) more than one turn. tighten air bleed plug (2).39 . 5) Install the travel motor cover. then operate each work equipment control lever 3 .6 seconds after stopping the engine. Operate each work equipment control lever to the full stroke within 5 .5 three times. high pressure oil may spurt out and cause serious personal injury. Set the lock lever at the FREE position. 3. Set the work equipment control levers to the HOLD position. If the pressure is not released. Operate each work equipment control lever to the full stroke within 5 . so when inspecting or replacing the piping or hoses. Wait for the temperature to go down before starting the operation. run for approx. The parts and oil are at high temperature after the engine is stopped. Stop the machine on firm horizontal ground. Do not loosen any piping until at least 1 minute has passed after relieving the internal pressure. When the oil filler cap is removed.4 times to the end of the stroke. lower the work equipment to the ground as shown in the diagram on the right. 1. Start the engine. 4. then stop the engine. Leave the starting switch at the ON position. Remove the cap of the hydraulic tank. SWING CIRCUIT. RELEASING PRESSURE IN ACCUMULATOR CIRCUIT After stopping the engine. the internal pressure will be relieved. Repeat Steps 4 .. 2.6 seconds after stopping the engine. always release the pressure in the circuit before starting. so turn the cap slowly to release the pressure before removing the cap. and may cause serious burns.40 . TRAVEL CIRCUIT The hydraulic system is always under internal pressure. 10 seconds. 4 . oil may spurt out. Do not run the engine at more than 1000 rpm. then stop the engine again. 5. After 1 minute. MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT. set safety lock lever (1) to the FREE position. Add Water Check Oil Level In Engine Oil Pan..O Case.T. Add Oil Check Air Cleaner For clogging Check Electric Wirings Check Function Of Horn Drain Water And Sediment From Fuel Tank 4 . Add Oil Check Fuel Level. Add Oil Check Oil Level In Swing Machinery Case. Add Fuel Check Oil Level In Hydraulic Tank. Check Coolant Level. MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items. see "Checks Before Starting (PAGE 3-73)" in the OPERATION section.41 . Add Oil Check Oil Level In P. MAINTENANCE PROCEDURE MAINTENANCE EVERY 10 HOURS MAINTENANCE LUBRICATING 1. pump in grease through the grease fittings shown by arrows. Set to the greasing posture below.42 . lower the work equipment to the ground. then stop the engine.. Using a grease pump. wipe off any old grease that was pushed out. (1)Boom cylinder foot pin (2 points) 4 . After greasing. 2. 3. 43 . MAINTENANCE MAINTENANCE 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 point) (7)Arm cylinder rod pin (1 point) (8)Arm-Link coupling pin (1 point) (9)Arm-Bucket coupling pin (2 point) (10)Link coupling pin (1 point) (11)Bucket cylinder rod end pin (2 point) (12)Bucket-Link coupling pin (1 point) 4 .. Lower the work equipment to the ground. pump in grease through the grease fittings shown by arrows. 3. MAINTENANCE PROCEDURE MAINTENANCE EVERY 100 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. 4 .44 . LUBRICATING SWING CIRCLE (4 points) 1. 2. Using a grease pump.. wipe off any old grease that was pushed out. After greasing. Prepare a handle. ADD OIL The parts and oil are at high temperature immediately after the engine is stopped. Wait for the temperature to go down before starting the operation. 1. and rotate the sprocket one turn. If the oil level is low.. Carry out the inspection for Procedure 2 again. MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 10 hours service should be carried out at the same time. install plug (F). operate the travel lever. Loosen the plug slowly to release the pressure.45 . travel in FORWARD or REVERSE. check again. remove plug (F) and check that the oil level is within a range of 10 mm (0. Set the TOP mark at the top. If the oil level is low. add engine oil through plug hole (F) until the oil overflows from plug hole (F). If there is still pressure remaining inside the case.4 in) below the bottom edge of the plug hole. 4. and may cause serious burns. Using a handle. After checking. CHECK OIL LEVEL IN FINAL DRIVE CASE. 3. 4 . with the UP mark and plug (P) perpendicular to the ground surface. 2. Install plug (F). 5. the oil or plug may fly out. MAINTENANCE PROCEDURE MAINTENANCE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this check before operating the machine. The battery generates flammable gas and there is danger of explosion. If the electrolyte level is too high.L) and LOWER LEVEL (L. NOTICE When adding distilled water in cold weather.L) lines. If the battery is wiped with a dry cloth. it may also cause an explosion. If it gets in your eyes or on your skin. 4 . check as follows. The batteries are installed at (A) part. In addition.. Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. static electricity may cause a fire or explosion. Use a wet cloth to clean the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL (U. add it before starting operations in the morning to prevent the electrolyte from freezing. Battery electrolyte is dangerous. Open cover (1) at the rear left side of the machine. When adding distilled water to the battery. Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below. so do not bring fire or sparks near the battery. wash it off with large amount of water and consult a doctor. it may leak and cause damage to the paint surface or corrode other parts.46 . 1. When checking electrolyte level from side of battery If it is possible to check the electrolyte level from the side of the battery. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. do not allow the battery electrolyte to go above the UPPER LEVEL line. then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. use a pipette to lower the level to the U. 3. MAINTENANCE MAINTENANCE PROCEDURE 2.. REMARK If distilled water is added to above the U.L line.L lines. 4 . If the electrolyte level is below the midway point between the U.47 .L and L. remove cap (1) and add distilled water to the U. Neutralize the removed fluid with baking soda (sodium bicarbonate).L line. After adding distilled water. tighten cap (1) securely.L line. tighten cap (1) securely. 1. Remove cap (1) at the top of the battery. and check if the electrolyte reaches the bottom of the sleeve. use a pipette to lower the level to the bottom of the sleeve. 2. MAINTENANCE PROCEDURE MAINTENANCE When it is impossible to check electrolyte level from side of battery If it is impossible to check the electrolyte level from the side of the battery. add distilled water so that the level reaches the bottom of the sleeve (UPPER LEVEL line) without fail. follow the instructions given. Use the diagram below for reference. and check the electrolyte surface. If the electrolyte does not reach the sleeve.. check as follows. Neutralize the removed fluid with baking soda (sodium bicarbonate). 4 .48 . When it is possible to use indicator to check electrolyte level If it is possible to use and indicator to check the electrolyte level. look through the water filler port. or there is no display of the UPPER LEVEL line on the side of the battery. After adding distilled water. REMARK If distilled water is added to above the bottom of the sleeve. then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. MAINTENANCE MAINTENANCE PROCEDURE LUBRICATING AFTER COOLER FAN MOUNT (1 place) 1..49 . After greasing. wipe off any old grease that was pushed out. Using a grease pump. Tightening torque: 3260 ± 370 N·m (333 ± 38 kgf·m. 2. 2410 ± 275 lbft) 4 . CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS Bolts (1) connecting the track frame and axle will break if they remain loose. so loose bolts must always be retightened. pump in grease through the grease fittings shown by arrows. MAINTENANCE PROCEDURE MAINTENANCE CHECK ALTERNATOR DRIVE BELT TENSION. 58. Insert a bar between alternator (6) and the cylinder block to hold alternator (6) in position. and wear of the V-belt. 6 kgf)] at a point midway between the drive pulley and alternator pulley. 2. If the V-belt is elongated and there is no more allowance for adjustment. or if the belt is cracked or cut.50 . Adjust the belt tension with nut (5) as follows: TIGHTEN to INCREASE tension LOOSEN to DECREASE tension 3. wear of the V-groove. Check each pulley for damage. Loosen the bolts and nuts in the order (1) to (5). 4 . Finally. adjust again after running for 1 hour. tighten the bolts and nuts in the order (5) to (1) (the opposite order from loosening). ADJUST Checking The standard deflection for the drive belt is 15 mm (0. When holding in position. Adjustment 1. tighten nut (5). and move alternator (6). put a wooden block between the bar and alternator (6) to prevent damage to alternator (6). replace the belt.8 N (approx. After adjusting the belt. When the V-belt has been replaced.. Check in particular that the V-belt does not contact the bottom of the V-groove.59 in) when pressed with a thumb [at approx. Remove bolts (2). 16 mm (59 in) when pressed with a thumb [at approx. The standard deflection for the drive belt is approx. 6 kgf)] at a point midway between the drive pulley and air conditioner compressor pulley.. 58. then remove cover (1). 2.8 N (approx.51 . MAINTENANCE MAINTENANCE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION. ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) Checking 1. 4 . (3) and (4). Check in particular that the V-belt does not contact the bottom of the V-groove. or if the belt is cracked or cut. adjust again after running for 1 hour. 3. wear of the V-groove.. and wear of the V-belt.52 . After adjusting the belt. When the V-belt has been replaced. Install cover (1). replace the belt. Loosen the bolts and nuts in the order (5) to (9). tighten nut (8). 4 . and move compressor. Check each pulley for damage. Adjust the belt tension with nut (9) as follows: TIGHTEN to INCREASE tension LOOSEN to DECREASE tension 2. Finally. tighten the bolts and nuts in the order (5) to (8) (the opposite order from loosening). If the V-belt is elongated and there is no more allowance for adjustment. MAINTENANCE PROCEDURE MAINTENANCE Adjustment 1. High pressure is generated inside the engine fuel piping system when the engine is running. 100 and 250 hours service should be carried out at the same time. In particular. NOTICE Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. Always avoid using substitute parts. 3. always use a genuine Komatsu part. Wait for all parts to cool down before starting the operation. The fuel filter is found by opening the engine side cover at the left of the machine. pay more attention than normal to the entry of dirt. wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter. 4 . When replacing the filter cartridge. Do not bring any fire or flame close.. Clean the filter holder. REPLACE FUEL FILTER CARTRIDGE After the engine has been operated. so be careful not to let dirt or dust get in. all parts are at high temperature. If any part other than a genuine Komatsu filter cartridge is used. NOTICE When filling with fuel. When replacing the filter. use clean fuel and be careful not to let any dirt or dust get in. 2. fill the new filter cartridge with clean fuel. When carrying out inspection or maintenance of the fuel system. the center area is the clean side. turn filter cartridge (1) counterclockwise to remove it. use fuel to wash it off completely.53 . If dirt is stuck to any part. 4. dust or dirt may get in and cause problems with the injection system. so do not replace the filter immediately. The HPI fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. Container to catch the oil Filter wrench 1. coat the packing surface thinly with engine oil. then install to the filter holder. MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 10. Using a filter wrench. Close fuel supply valve (2) at the bottom of the fuel tank at the rear of the machine. Set the container to catch the fuel under the filter cartridge. tighten until the packing surface contacts the seal surface of the filter holder. 4 . NOTICE Do not crank the starting motor continuously for more than 20 seconds. With this machine. the packing will be damaged and this will lead to leakage of fuel. After carrying out the operations in Steps 1 . so always tighten to the correct amount.. then tighten it up 1/2 to 3/4 of a turn.5. wait for at least two minutes before trying to start again. REMARK If the fuel piping has been removed. it is unnecessary to bleed the air. When installing. bleed the air also from the injection pump air bleed valve. MAINTENANCE PROCEDURE MAINTENANCE 5. If the filter cartridge is too loose. 6. If the filter cartridge is tightened too far. fuel will also leak from the packing.54 . turn the starting switch to the START position and start the engine. If the engine does not start. .5 kg) (14. If the grease is particularly milky due to ingress of water. Install cover (2) with bolts (1). 4 . etc.55 . MAINTENANCE MAINTENANCE PROCEDURE CHECK SWING PINION GREASE LEVEL. Insert a scale into the grease and check that the depth of the grease is approx. The total amount of grease is 55 liters (49. then remove bolts (3) and cover (4) from the bottom of the track frame and remove the grease..4 in). 36 mm (1. ADD GREASE Prepare a scale.5 US gal) (109 lb)). Remove bolts (1) (4 bolts) on the top of the revolving frame and remove cover (2). Insert the scale in the position shown in the diagram on the right when measuring. 3. Add grease if necessary. Replace all of the grease with new grease. 1. 2. then wash it in clean diesel oil or flushing oil. Clean hydraulic tank strainer 1. so loosen the 4 bolts slowly. Wait for the temperature to go down before starting the operation. replace it with a new part.56 . When installing. MAINTENANCE PROCEDURE MAINTENANCE CLEAN HYDRAULIC TANK STRAINER AND RETURN STRAINER After the engine is stopped. When removing cover (1). Install cover (1) with bolts. and install. insert it on to tank protrusion (5). so turn it slowly to release the internal pressure. 4 . Remove any dirt stuck to strainer (4). so there is danger of burns. 3. If strainer (4) is damaged. Remove cover (1) and lift up the top of rod (3) from above to take out spring (2) and strainer (4). 5. oil may spurt out. 2. then coat the surface of the O-ring with grease.. then remove it carefully. When the cap of the oil filler port is removed. the parts and oil are at high temperature. Remove cap (F) from the oil filler port at the top of the hydraulic tank. the cover may fly off under the force of spring (2). check that the O-ring at the bottom of strainer (4) is not out of place or twisted. 4. 3. 4 . 4. then remove return filter holder cover (2). If the strainer is damaged. set it in position. MAINTENANCE MAINTENANCE PROCEDURE Clean return strainer 1. hold it down with return strainer holder cover (2).57 . Remove (4) mounting bolts (1) of the return strainer holder cover at the top of the hydraulic tank.. Insert strainer (3). then tighten bolts (1). Remove strainer (3). replace it with a new part. then wash it with clean diesel oil or flushing oil. Remove any dirt stuck to strainer (3). 2. If there are metal particles or foreign material inside strainer (5). 8. Install the cap of oil filler port (F). 1. take out element (4). REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank. 4. so hold the cover down when removing the bolts. strainer (5) and spring (2) on top of the element. turn it slowly to release the internal pressure. Loosen 4 bolts. 6. To bleed the air. start the engine according to "STARTING ENGINE (PAGE 3-86)" and run the engine at low idling for 10 minutes. Check for oil leakage and wipe off any spilled oil.58 . 9. Wait for the temperature to go down before starting the work. the cover may fly out under the force of spring (2). and install the cover with the mouning bolts. 4 . When doing this. and release the internal pressure. 10. and may cause burns. 11. push it down by hand. Stop the engine. When removing the oil filler cap. please contact your Komatsu distributor. MAINTENANCE PROCEDURE MAINTENANCE REPLACE HYDRAULIC OIL FILTER ELEMENT The parts and oil are at high temperature after the engine is stopped. 3. Set valve (3). then remove it.. 7. valve (3) and strainer (5). then remove cover (1). Install the new element in the place where old element (4) was installed. Clean the removed parts in diesel oil. Set cover (1) in position. Remove the cap from oil filler (F). 2. After removing spring (2). 5. After cooler hose clamp tightening torque: 9. If the fins are damaged. dust or leaves clogging the radiator fins (E). irrespective of the maintenance interval. or steam hit your body directly. At the same time. CONDENSER FINS AND AFTER COOLER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER) If compressed air. Replace with a new one if the hose is found to have cracks or to be hardened by ageing.59 . Remove 3 bolts (3) to open duct (1) and 2 bolts (4) to open duct (2).36 lbft) 4 . OIL COOLER FINS. 2. dust mask. 1. Never blow the compressed air at right angles to the core. blow with compressed air at an angle of 45? with the nozzle at a distance of at least 300 mm (11.8 in).. In particular.49 N·m (1. Always use safety glasses. MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS. Steam or water may be used instead of compressed air. it may cause water leakage or overheating. On dusty jobsites. clean the net in front of the oil cooler. use from a distance to prevent damage to the fins. Further. 3. or other protective equipment. Check the rubber hose. check the fins daily.05 kgf·m. fuel cooler fins (B) and after cooler fins (C) using compressed air.0 ± 0. Clean the condenser fins (A) on machines equipped with air conditioner.81 ± 0. Open ducts (1) and (2) at the rear on the right side of the machine.2 ± 0. or they cause dirt or dust to be blown up. there is a hazard of serious injury. NOTICE When using compressed air. oil cooler fins (D). Blow off mud. high-pressure water. 7. with the fuel cooler and aftercooler. check hose clamps for looseness. 60 . dust mask. the filters should be cleaned every 500 hours. clean the filters more frequently. Clean the filter with compressed air. Remove wing bolts (1) from the inspection window at the bottom rear left on the inside of the operator's cab.. but on dusty jobsites. then remove the filter. If the clogging of the filter cannot be removed by blowing with air or washing in water. replace the filter with a new part. 2. Pull up the lock release lever under the door release lever to release the lock. 2. Cleaning fresh air filter 1. and there will be an abnormal noise from the air conditioner unit. there is danger that dirt may fly and cause personal injury. then take out the recirculated air filter. the air flow will be reduced. Open cover (2) at the bottom left of the operator's cab by hand. MAINTENANCE PROCEDURE MAINTENANCE CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER If compressed air is used. and other protective equipment. Cleaning reticulated air filter 1. pull out filter case (3) from the inside. NOTICE As a guideline. If there is oil on the filter. REMARK If the filter becomes clogged. wash it in a neutral agent. Always wear safety glasses. or if the filter is extremely dirty. 4 . dry it thoroughly before using it again. After rinsing it in water. dry it thoroughly before using it again. open the cover at the bottom left of the operator's cab by hand. MAINTENANCE MAINTENANCE PROCEDURE 3. After cleaning. check that the lock is applied. wash it in a neutral agent.. If the clogging of the filter cannot be removed by blowing with air or washing in water. If there is oil on the filter. replace the filter with a new part. or if the filter is extremely dirty. insert the filter in filter case (3) again. 4 . then close the cover. return the filter case to its original position. When doing this.61 . 4. After rinsing it in water. Clean the filter with compressed air. Wait for the oil to cool down before carrying out maintenance. Loosen bolt (2).62 . Tightening torque: 65 to 88 N·m (6. Tighten drain plug (1).6 to 9. 2. 3. Tighten bolt (2).0 kgf·m. 1. 4. Set a container under drain plug (1) to catch the oil. 5. 48 to 65 lbft) 4 . then install filter case (3) and tighten bolt (2).. then remove filter case (3). Remove element (4). Insert a new element. 6. MAINTENANCE PROCEDURE MAINTENANCE REPLACE PILOT FILTER ELEMENT The oil is at high temperature after engine has been operated. .O LUBRICATING OIL FILTER The parts and oil are at high temperature after the engine is stopped. Wait for the temperature to go down before cleaning the engine breather. Open the cover at the rear left of the machine. or other protective equipment. 4 . dust mask. 1. MAINTENANCE MAINTENANCE PROCEDURE CLEAN STRAINER OF P. Always use safety glasses. then wash it in flushing oil. When using compressed air. Install the strainer and filter case (1). If the strainer is damaged. remove any dirt stuck to the strainer. 2.63 . and may cause serious burns. 3.T. then remove filter case (1). Take out the strainer. there is a hazard that dirt may be blown up and cause serious injury. replace it with a new part. 50 cm (20 in)) in hole (4) (∅18 mm (0. Insert a bar (length approx. replace the V-belt: When the V-belt makes contact with the bottom of the groove in each pulley. 2. then loosen adjustment screw (2) and move them to bracket (3).. When the V-belt is worn. When cracking and peeling of the V-belt occurs. MAINTENANCE PROCEDURE MAINTENANCE CHECK WEAR OF FAN BELT. REPLACE. 4 . Replace 1.71 in)) of the tension pulley bracket.64 . ADJUST Checking Check the V-belt and when the following conditions exist. so remove the old belts and replace them with new belts. The spring will extend and the tension pulley will move to the inside. Always replace the V-belt as a set of 5 belts. then pull strongly to the front. Loosen locknut (1). and its surface is lower than the outer diameter of the pulley. 3. If wear is a gap between the tip of adjustment screw (2) and tension pulley lever (5) during operations. 4 . When installing it. Using a filter wrench. then tighten the adjustment screw a further 180° and secure with locknut (1)..65 . Tighten adjustment screw (2) to bring the tip of the adjustment screw into contact with tension pulley lever (5). adjust in the same way. MAINTENANCE MAINTENANCE PROCEDURE Adjustment 1. REPLACE DRAIN FILTER CARTRIDGE 1. turn the filter cartridge (1) to the left to remove it. then install it. bring the packing surface into contact with the seal surface of the filter holder. coat the packing surface with oil. If there is any squealing from the fan belt. 2. 2. repeat Step 1 to adjust again. Fill the new filter cartridge with hydraulic oil. then tighten a further 1/2 - 3/4 turns. Even if it is not loosened. Set the container immediately under drain valve (2) at the bottom of the engine to catch the oil. REPLACE ENGINE OIL FILTER CARTRIDGE The parts and oil are at high temperature immediately after the engine is stopped. Refill capacity: 51 liters (13. Install drain hose (4) (Part No: 21N-98-31490) to drain valve (2). 4. After draining the oil. MAINTENANCE PROCEDURE MAINTENANCE CHANGE OIL IN ENGINE OIL PAN. 4 . the oil will come out when the lever is operated. and drain the oil. raise the lever to close the valve. and may cause serious burns. 2.. Remove the 2 bolts of undercover (1) under the engine. Wait for the temperature to go down before starting the operation. 3. then open the undercover. Never loosen plug (a). Lower lever (3) of the drain valve slowly to avoid getting oil on yourself.5 US gal) Filter wrench 1.66 . Clean the filter holder. 8. then tighten a further 3/4 . 7. When installing. use a filter wrench from the top of the engine. A large amount of oil will come out immediately after the engine is stopped. MAINTENANCE MAINTENANCE PROCEDURE 5. Run the engine for a short time at low idling. so wait for 10 minutes after the engine is stopped before draining the oil. fill the new filter cartridge with clean engine oil. For details. coat the thread and packing surface of the new filter cartridge with clean engine oil (or coat it thinly with grease). see "Check Oil Level In Engine Oil Pan. then stop the engine. and remove it. add engine oil through oil filler port (F) so that the oil level is between the H and L marks on dipstick (G).. 9. bring the packing surface into contact with the seal surface of the filter holder.67 . turn filter cartridge (4) to the left. Open the front cover of the engine hood. If there is any old packing affixed to the filter. After replacing the filter cartridge. 4 .1 turn. REMARK Confirm that no remnants of old packing still adhere to the filter holder as this may result in oil leakage. Check that there is no old packing affixed to the filter holder. 6. then install it to the filter holder. Check that the oil level gauge is between the H and L marks. Add Oil (PAGE 3-75)". it will cause leakage of oil. 2. 6. 100.42 US gal X 2)) 1.6 liters (12. So operate for one hour. If the oil is above the H mark. install air bleed plug (1) of the front machinery. drain the oil.3 liters X 2 (6. 9. add engine oil through oil filler port (F). The oil level should be between H and L marks on the dipstick (G). After filling with oil. 8. Immediately after changing the oil. 250 and 500 hours service should be carried out at the same time. Loosen drain valve (P) under the machine body.. then take it out again. then tighten the drain plug again. 4. If the oil does not reach the L mark. MAINTENANCE PROCEDURE MAINTENANCE EVERY 1000 HOURS MAINTENANCE Maintenance for every 10. and check the oil level again. CHANGE OIL IN SWING MACHINERY CASE The parts and oil are at high temperature immediately after the engine is stopped. Set a container under drain hose under the machine body to catch the oil. oil level is variable. drain the excess engine oil from drain valve (P). 3. Wipe off the oil on the dipstick with a cloth.84 US gal) (24. Insert dipstick (G) fully in the oil filler pipe.68 . 7. Wait for the temperature to go down before starting the operation. and may cause serious burns. Refill capacity: 48. then add the specified amount of engine oil through dipstick guide (F). 4 . then check the oil level again. 5. Remove dipstick (G) and air bleed plug (1) (remove air bleed plug (1) only when supplying oil to the front machinery). Refill capacity: 13. tighten drain plug (1) and valve (2). 2.6 ± 9.T. remove drain plug (1). drain it to the specified amount to avoid overheating. MAINTENANCE MAINTENANCE PROCEDURE CHANGE OIL IN P. and may cause serious burns. After waiting for more than 30 minutes after stopping the engine. NOTICE Park the machine on flat ground and stop the engine.6 ± 7. NOTICE If excess oil is supplied. CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions of the turbocharger checked. 50. Refill the specified quantity of engine oil through oil filler (F). then install drain hose (3) (Part No. check the oil level. After draining the oil.5 liters (3. Open the oil filler for the engine oil.57 US gal) 1.. then loosen valve (2) and drain the oil.O CASE The parts and oil are at high temperature immediately after the engine is stopped. : 21N-98-31490).8 N·m (7 ± 1 kgf·m. Tightening torque: 68. Wait for the temperature to go down before starting the operation. 4 .2 lbft) Be careful not to loosen the drain valve too much or to deform the stopper pin inside the valve.69 . 2. coat the packing surface and thread of the new cartridge with engine oil. If the filter cartridge is tightened too far. 5. remove cartridge (2). so always tighten to the correct amount. so never try to replace the cartridge immediately after stopping the engine. After replacing the cartridge..70 . 4. When installing. then install it to the filter holder. Container to catch drained coolant Prepare a filter wrench for fuel filter element. If there is any water leakage. If the filter cartridge is too loose. check if the cartridge is tightened properly. Tighten 2 valves (1). Set a container to catch the coolant under the cartridge. the packing will be damaged and this will lead to leakage of coolant. Open valves (1) (2 places). start the engine and check for any leakage of water from the filter seal surface. 3. Using a filter wrench. 4 . 7. Clean the filter holder. tighten until the packing surface contacts the seal surface of the filter holder. coolant will also leak from the packing. then tighten it up 2/3 of a turn. 6. Always wait for the engine and other parts to cool down. MAINTENANCE PROCEDURE MAINTENANCE REPLACE CORROSION RESISTOR CARTRIDGE If the engine has been operated. all parts will be at a high temperature. 1. TENSION PULLEY ASSEMBLY Add grease through the fittings marked by arrows.. MAINTENANCE MAINTENANCE PROCEDURE LUBRICATING FAN PULLEY ASSEMBLY.71 . (1) Fan pulley assembly (1 point) (2) Tension pulley assembly (1 point) 4 . After removing snap ring (2) of breather assembly (1). 4. Replace filter element (4) with a new element. Remove cap assembly (F) of the filler port. 2. 4 . MAINTENANCE PROCEDURE MAINTENANCE REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT The parts and oil are at high temperature after the engine is stopped. take out cover (3). and may cause burns.72 . 3. then replace element (1) inside the cap. 1. Install cover (3) and snap ring (2). then remove it. Wait for the temperature to go down before starting the work.. turn it slowly to release the internal pressure. When removing the oil filler cap. 4 . 5.73 . 4. 2. Remove undercover (2) on the inside rear of the fuel tank. replace it with a new one. MAINTENANCE MAINTENANCE PROCEDURE CHECK FUEL STRAINER. Install the strainer and filter case (1). CLEAN 1. 3. clean off dirt clung to it.. Close fuel supply valve (1) at the bottom of the fuel tank. and wash it in clean light oil or diesel oil. If the strainer is damaged. Take out the strainer. Remove filter case (3). 1. 4. In particular.74 . Leave for 15 . developing solution) 2. color can be seen. and arm every 1000 hours. Clean the surface again. carry out the repair procedure to repair. 7. then clean the surface with a cloth. Prepare the materials needed for the color check. If there are any cracks. Revolving frame 4 . dry the area. carry out a color check on the important check points (marked with a circle). Spray with detergent. then spray with developing solution. 6. Spray with detergent and wash to remove all the dirt and oil from the place to be checked. MAINTENANCE PROCEDURE MAINTENANCE CHECK WELDED STRUCTURE (Color check) Cracks in welded structures can be seen easily with a color check. 5. center frame. penetrating agent. If there are any cracks. then spray with penetrating agent and leave for 5 . After washing. The procedure for the color check is as follows. then check visually for cracks. (Detergent..20 minutes.20 minutes. 3. Check the revolving frame. boom. MAINTENANCE MAINTENANCE PROCEDURE Center frame 4 .75 .. MAINTENANCE PROCEDURE MAINTENANCE Boom 4 ..76 . MAINTENANCE MAINTENANCE PROCEDURE Arm 4 .77 .. .78 . MAINTENANCE PROCEDURE MAINTENANCE EVERY 2000 HOURS MAINTENANCE Maintenance for every 10. When the oil overflows from the hole of plug (F). 4. Remove plugs (P) and (F) with the handle and drain the oil. and may cause serious burns. If necessary. Tighten plug (P). REMARK Check the O-rings in the plugs for damage. right 22 liters (5. install plug (F).8 US gal) Refill capacity: Left. the oil or plug may fly out. 1. 2. Tightening torque of plugs (P) and (F) : 68.8 US gal) each Prepare a handle. Add engine oil through the hole of plug (F). 50 ± 7 lbft) 4 . Refill capacity: each 22 liters (5. Set a container under plug (P) to catch the oil. 250. 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN FINAL DRIVE CASE The parts and oil are at high temperature immediately after the engine is stopped. 5. 100. Set the TOP mark at the top.6 ± 9. 3. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case. Loosen the plug slowly to release the pressure. with the TOP mark and plug (P) perpendicular to the ground surface.8 N·m (7 ± 1 kgf·m. 6. replace with new ones. CHECK ENGINE VALVE CLEARANCE. Remove bolt (2).79 . and install it. 4 . 2. then remove the hose. MAINTENANCE MAINTENANCE PROCEDURE CLEAN ENGINE BREATHER 1. coat with engine oil. ADJUST (ONLY AFTER THE 2000 HOURS) Contact your Komatsu distributor to have the play checked.or the bearing may have run out of grease. then remove breather (3). Replace the breather O-ring with a new part.. replace it with a new hose. CLEAN. CHECK ALTERNATOR. CHECK TURBOCHARGER Contact your Komatsu distributor for cleaning and inspection. you shall request Komatsu distributor for service. When the engine is frequently started. Check the breather hose. ask for inspection every 1000 hours or every 6 months. Loosen clamp (1). 4. whichever comes sooner. CHECK PLAY TURBOCHARGER ROTOR Please contact your Komatsu distributor to have the rotor play checked. CHECK ENGINE INJECTOR SET LOAD. 3. STARTING MOTOR The brushes may be worn. and if there is any oil sludge on the inside. then blow it dry with compressed air. ADJUST As special tool is required for removing and adjusting the parts. so contact your Komatsu distributor for inspection or repair. Wash the whole breather in diesel oil or flushing oil. . contact your Komatsu distributor for disassembly and repair or replacement. CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the vibration damper (1). If any cracks or peeling are found. ADJUST As special tool is required for checking and adjusting the parts. 500. contact your Komatsu distributor to have the parts replaced. 250. If there is any abnormality. request Komatsu distributor for service. CHECK AIR COMPRESSOR. CHECK WATER PUMP Check that there is no oil leakage. CHECK FAN PULLEY AND TENSION PULLEY Check the pulley for play and leakage of grease.80 . If any abnormality is found. 1000 and 2000 hours service should be carried out at the same time. 4 . MAINTENANCE PROCEDURE MAINTENANCE EVERY 4000 HOURS MAINTENENCE Maintenance for every 10. 100. water leakage. or clogging of the drain hole (1). please contact your Komatsu distributor for disassembly and repair or replacement. 500. 2000 and 4000 hours service should be carried out at the same time.. 100. MAINTENANCE MAINTENANCE PROCEDURE EVERY 5000 HOURS MAINTENANCE Maintenance for every 10. 4 .81 . 250. 1000. 82 . After draining the oil. 3. Refill capacity: 670 liters (177. then loosen plug (P2) and drain the oil. then remove it.. turn it slowly to release the internal pressure. CLEAN STRAINER The parts and oil are at high temperature after the engine is stopped. and may cause burns. Set the safety lock lever to the LOCK position and stop the engine. Wait for the temperature to go down before starting the work. Swing the upper structure so that the drain plug under the hydraulic tank will be between both tracks. 4 . MAINTENANCE PROCEDURE MAINTENANCE CHANGE OIL IN HYDRAULIC TANK. then lower the boom and put the teeth in contact with the ground. 5. Tightening torque: 70 ± 10 N·m (7 ± 1 kgf·m. Remove drain plug (P1). When removing the oil filler cap. Set the container to catch the oil under the drain plug at the bottom of the chassis. 4. 50 ± 7 lbft) When loosening drain plug (P2) be careful not to get oil on yourself. Retract the arm and bucket cylinders. tighten drain plugs (P1) and (P2).01 US gal) Prepare a handle for socket wrench set 1. 2. Remove the cap of oil filler (F) at the top of the hydraulic tank. or after changing the oil. Check that the oil level is within the correct range on the sight gauge. Hold the top of rod (6) and pull up to remove spring (5) and strainer (7). 10. If strainer (7) is broken. replace it with a new part. Bleed the air from the circuit after cleaning or replacing the filter element or strainer. insert strainer (7) into protruding part (8) of the tank. then remove cover (4). 7. cover (4) may fly off because of the force of spring (5). When installing. MAINTENANCE MAINTENANCE PROCEDURE 6. 4 . Remove any dirt stuck to strainer (7). so keep the cover pushed down when removing the bolts. then wash in clean diesel oil or flushing oil.83 . Fill with the specified amount of engine oil through oil filler port (F). and assemble. Remove 4 bolts. 8. 9.. When doing this. 11. .. . 5-1 . 1/3.8) 5.995 (16'5") 4.120 (13'6") 4.448) 113.800 485(651)/1.5 5.684) 109.800 A Overall length mm (ft in) 16.1/3.yd) 5.425 (21'1") 7.2 (6.0) Swing speed rpm 5. KOMATSU SA6D170E diesel engine Engine horsepower KW(HP)/rpm 485(651)/1.355 (17'7") D Track width mm (ft in) 700 (2'4") 700 (2'4") 700 (2'4") E Height of cab mm (ft in) 4.5 5-2 .0) 2.0) 2.60) 3 Bucket capacity m (cu.790 (48'6") 16.2 (1.800 485(651)/1.020 (52'7") B Overall height mm (ft in) 6.7 (8.265 (20'7") 6.355 (17'7") 5.020 (52'7") 14.355 (17'7") 5.120 (13'6") F Radius of upper structure mm (ft in) 4.970 (19'7") I Min.8) Name of engine .5 5.700 (239.040 (19'10") C Overall width mm (ft in) 5.500 (241.120 (13'6") 4.2 (6.870 (15'12") 4.200 (249.1/3.3/2..870 (15'12") G Length of track mm (ft in) 6.040 (19'10") 6.8) 6.2 (1.400 (24'3") H Tumbler center distance mm (ft in) 4.3/2.425 (21'1") 6.3/2.870 (15'12") 4.995 (16'5") 5. SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS PC1250-7 PC1250SP-7 PC1250LC-7 Item Unit PC1250-7 PC1250SP-7 PC1250LC-7 Operating weight kg (lb) 108. ground clearance mm (ft in) 990 (3'3") 990 (3'3") 990 (3'3") Travel speed (Lo/Hi) km/h (MPH) 2.2 (1. SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC1250-7 PC1250SP-7 PC1250LC-7 A Max.400 (43'12") D Max.350 (30'8") 7.070 (46'2") 15. digging height mm (ft in) 13.350 (50'4") 14.610 (24'12") E Max.. reach at ground level mm (ft in) 15.000 (49'3") 13.670 (44'10") 15. vertical wall depth mm (ft in) 7. dumping height mm (ft in) 8.350 (30'8") C Max. digging reach mm (ft in) 15.025 (16'6") 7. digging depth mm (ft in) 9.400 (43'12") 13.680 (28'6") 8.610 (24'12") 5.000 (49'3") 5-3 .450 (27'9") 8.000 (42'8") 13.350 (50'4") B Max.900 (25'11") 9.680 (28'6") F Max. . . 6-1 .. When removing or installing attachments. firm ground surface. Depending on the attachment. set up a fence around the machine to prevent people from entering. If you do not contact Komatsu. Carry out the removal and installation operation on a flat.GENERAL INFORAMTION SAFETY FIRST If attachments or options other than those authorized by Komatsu are installed. the impact noise may make it difficult for fellow workers to transmit instructions for the operation. the swing range and center of gravity of the machine are different. When the operation is carried out by two or more workers.GENERAL INFORAMTION ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS . do not put your foot on the pedal except when operating the pedal. 6-2 . If you lose the instruction manual. Precautions for removal and installation operations When removing or installing the attachments. but will also cause problems with safety. General precautions Read the instruction manual for the attachment thoroughly. contact your Komatsu distributor first. Never operate the machine when there are people near the machine. Before starting operations. Be sure that you understand the condition of the machine properly. Always stand in a position that is safe even if the load should fall. obey the following precautions and take care to ensure safety during the operation. contact your Komatsu distributor. When carrying heavy objects (more than 25kg or 55 lb). we cannot accept any responsibility for any accidents or failures. When installing attachments not listed in this Operation and Maintenance Manual. do not carry out operations with the attachment swung to the side. this will not only affect the life of the machine. a machine equipped with a breaker has a heavy load at the front of the work equipment and is unstable. When an attachment is installed. and the machine may move in an unexpected way.. When lifting such as heavy parts with a crane. install the necessary front guard to the machine. Always set the load on a stand. Do not carry out swinging operations to the side with a heavy load on the attachment. NOTICE Qualifications are required to operate a crane. always support the part before removing it. always ask the manufacturer or your Komatsu distributors for a new copy. use a crane. make sure that it is in a stable condition and will not fall over. Never allow the crane to be operated by an unqualified person. always pay careful attention to the position of the center of gravity. Before starting operation. and check that it is safe. and do not use this attachment unless you are sure that you have understood the guides completely. To prevent serious accidents caused by misoperation. Comparing with a machine equipped with a bucket. ATTACHMENTS AND OPTIONS . It is dangerous to carry out operations with the load kept suspended. determine the signals and follow these during the operation. decide a leader and determine the signals to be used. Never go under a load suspended from a crane. This is particularly dangerous on slopes. To avoid a hazard of tipping over. When removing heavy parts. For details of removal and installation operations. Depending on the attachment. this may lead to serious damage or injury. the machine may lose its balance and overturn. The following operations are particularly dangerous. or when going down a steep hill. so there is danger of mistaking the distance and hitting something. 6-3 . Always operate so that there is an ample margin to the stopping point. the working range will suddenly become larger. so if the swing is operated on a slope.GENERAL INFORAMTION ATTACHMENT INSTALLATION Long work equipment reduces the stability of the machine. Always follow the correct procedure when installing the boom and arm. so never operate the machine in these ways. so consult your Komatsu distributor before carrying out installation. it will gradually move down under its own weight). Always operate the work equipment so that there is ample space from any obstacles in the area. If the correct procedure is not followed. If heavy work equipment is installed. so there is danger of mistaking the distance and hitting something. the hydraulic drift also becomes larger (when the work equipment is stopped in mid-air. the overrun of the swing becomes greater (the distance from the point where the operator operates the control levers to stop the swing to the point where the upper structure stops completely). If long work equipment is installed.. ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS . Furthermore. there may be problems with safety. 6-4 . so please contact your Komatsu distributor before installing. Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety. but may also have an adverse effect on the operation of the machine and the life of the equipment.. or damage resulting from the use of unauthorized attachments or options will not be the responsibility of Komatsu. ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE 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. accidents. Any injuries. 880 4.280 2. and operate with caution.7 <8.8 in) (83.8> – (A) – (C) – – 3 (80. Model PC1250-7 PC1250SP-7 Standard boom SP boom Bucket width [mm (in)] Boom 9.8> 2.8> – – – – – (A) (89. ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE COMBINATIONS OF WORK EQUIPMENT Depending on the type or combination of work equipment.0 <5.220 5. arm.5 in) 2.500 1.1 in) (65.5> (A) – (C) – – – Bucket m <cb.110 5.. there is danger that the work equipment may hit the cab or machine body.7 <8.340 6.0 <6.8> 2.050 2.670 3. When using unfamiliar work equipment for the first time.8 in) (92. check before starting if there is any danger of interference. and bucket from the combinations shown in the table below.2> (B) – (A) – (C) – Work equipment (67.050 2.2 <6.280 2.4> – – (B) – (A) – (59.340 wide – – – – – (B) (89.4 <4.4 in) (74.2 in) 6.8 in) (92.yd> (80.1 in) 5.710 1. Select the combination of boom.1 in) 2.050 2.1 in) strong 2.2 in) strong 6-5 .2 <6.8 in) 1.8 in) (83.110 standard – (B) – (C) – – (80.8‚ Strong Excluding Including Standard Strong Semilong Long Arm Semilong SP arm side cutter side cutter arm arm arm arm arm side shroud side shroud 1.1‚ 7.8 in) (87. 5 in) 2.1 in) strong 2.5 t/m3 2.8 in) 1.yd> (80.8> – – – – (89.8 t/m3 3.4> – (B) – (A) (59.880 4.2 <6.050 2.2> (B) (A) – (C) Work equipment (67.8 in) (87.8> 2.2 <6.7 <8.1 in) 2.500 lb/yb3) .8 in) (83.8> 2.0 <5.500 lb/yb3) (C): Possible to use only for light work (density up to 1.280 2.110 standard – – (C) – (80.8 in) (92.1‚ Strong Excluding Including Standar Semilong Long Arm Semilong side cutter side cutter d arm arm arm arm side shroud side shroud 1.280 2.1 in) 5.1 in) (65.4 <4.050 2.670 3.710 1.340 6.1 t/m3 3.220 5.0 <6.8 in) (83.8> – – (C) – 3 (80.5> (A) (C) – – Bucket m <cb.340 wide – – – – (89..000 lb/yb3) (B): Possible to use only for heavy work (density up to 2.050 2. ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS Model PC1250LC-7 Standard boom Bucket width [mm (in)] Boom 9.8 in) (92.7 <8.110 5.500 1.2 in) strong (A): For standard operations (density up to 1.: Impossible to use 6-6 .2 in) 6.4 in) (74. 350 16.680 9.000 17.340 17.490 13.450 14.000 9.450 E height (ft in) (28'6") (28'6") (29'6") (29'6") (30'12") (27'9") Max.610 8.490 8.480 5.000 16.590 B depth (ft in) (30'8") (34'3") (34'3") (38') Max.350 10.680 8. reach at mm 15.440 8.910 C height (ft in) (43'12") (44'3") (44'3") (45'8") Max.400 13. digging mm 9.490 9. reach at mm 15.000 16.490 8. vertical mm 7. digging height (ft in) (43'12") (43'12") (44'3") (44'3") (45'8") (42'8") Max.350 16. digging depth (ft in) (30'8") (30'8") (34'3") (34'3") (38') (25'11") mm 13.490 9.490 13.000 15.400 13.000 16.000 9.340 17.480 D wall depth (ft in) (24'12") (27'10") (27'10") (31'1") Max.340 16.000 17.070 A Max.610 7.450 A reach (ft in) (50'4") (53'7") (53'7") (57'3") Max. ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE Working Range Diagram PC1250-7 PC1250-7 PC1250-7 PC1250-7 PC1250-7 PC1250SP-7 Working ranges Unit Standard Strong arm Semilong Strong Long arm SE arm arm arm Semilong arm mm 15.340 16.490 13.680 9.350 10. digging mm 13.130 F ground level (ft in) (49'3") (52'6") (52'6") (56'2") 6-7 .025 D depth (ft in) (24'12") (24'12") (27'10") (27'10") (31'1") (16'6") Max..440 11.910 13. vertical wall mm 7.350 15.440 10.610 8.000 16.130 13.900 B Max.000 9.350 9.000 9.440 10.000 C Max.440 11.590 7. digging mm 15.670 F ground level (ft in) (49'3") (49'3") (52'6") (52'6") (56'2") (44'10") PC1250LC-7 PC1250LC-7 PC1250LC-7 PC1250LC-7 Working ranges Unit Standard arm Semilong arm Strong Long arm Semilong arm Max. dumping mm 8. dumping mm 8.490 13.400 13.440 E height (ft in) (28'6") (29'6") (29'6") (30'12") Max. digging reach (ft in) (50'4") (50'4") (53'7") (53'7") (57'3") (46'2") mm 9. . ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS 6-8 . 13 (1.74) pressure category of use A B A B B 6-9 . carefully the conditions of use before Use only for ground where "B" recommending a suitable shoe width. when it is impossible to soft land necessary is used. If a wider shoe than B ground..96) 0.88) 0. select the such as boulders and fallen trees. on rough ground with obstacles restrictions on their use. Therefore. where there are large obstacles When selecting the shoe width.4 in) 700 (27.6 in) 1000 (39. there will be a large load avoid traveling over obstacles. necessary. loosening of the shoe bolts. or other problems. such as large boulders and fallen using.13 (1. narrowest shoe possible within the range Travel in Hi speed only on flat that will give no problem with flotation and Normal soil. Category Use Precautions when using Remarks Travel in Lo speed when traveling Categories "B" are wide shoes. check the restrictions and consider normal soil trees.6 in) 1000 (39. lower the travel speed to approx.35) 0. cracking of the links.07 (0. breakage of the pins.3 in) Overall width mm (in) 4600 (15'1") 4900 (16'1") 4600 (15'1") 4900 (16'1") 5100 (16'9") of crawler Ground MPa (kg/cm2) 0.09 (0.09 (0. give the customer guidance in Cannot be used on rough ground their use. ground pressure. before A river bed. on the shoe.4 in) 1200 (47. so there are Cocky ground. If sink and are impossible to use. Check the use in the table below.36) 0. and select the shoe from the table on the next page. the shoe. ATTACHMENTS AND OPTIONS SELECTION OF TRACK SHOES SELECTION OF TRACK SHOES Select the most suitable track shoe to match the operating conditions. Shoe Double grouser shoe Model PC1250-7 PC1250SP-7 PC1250LC-7 Shoe width mm (in) 700 (27. and this may lead to bending of half of Lo speed. .. 5 Machine Serial No.45 Engine.44 Grease Pump 3.41 Check Before Starting 4.71 General Operation Information 3-110 Air Conditioner Controls 3. Plate And Its Location 1.17 Emergency Exit From Operator's Cab 3.34 Controllers 3.68 Ashtray 3.43 Attachment Installation 6.43 Attachment Guide 6. Plate And Its Location 1.4 <H> Combinations of Work Equipment 6.66 <M> Controls And Gauges 3.64 When required 4.99 <D> Machine Operations And Controls 3.78 Escape From Mud 3-114 Every 4000 Hours 4. INDEX INDEX <A> <G> Accumulator 3.86 Every 1000 hours 4. Before Starting 3.41 Before Storage 3-136 Circuit Breaker 3. Stopping The 3. Starting 3.80 Every 5000 hours 4.7 Maintenance Procedure 4.41 Engine. 9 Cold Weather Operation Information 3-133 Proper Selection 4. 9 Control Levers And Pedals 3.81 <F> Initial 100 Hours 4.72 Every 100 hours 4.2 Electric System Maintenance 4.4 Information 6. Coolant And Filters 4.2 Hot And Cool Box 3. Fuel And Coolant After Daily Work Completion 3-135 Specifications 4.17 Fuse 3.5 Handling Oil.68 Engine. 7 <B> <L> Bucket Replacement 3-116 Locking 3-120 Long term storage 3-136 <C> After Storage 3-136 Cap With Lock 3.42 Engine.44 Engine Serial No.65 During Storage 3-136 Cold Weather Operation 3-133 Lubricants.2 Door Lock 3. After Starting 3. Check After Shut Off 3.53 Engine. Coolant.18 7-1 .17 Forword 1.3 Machine Inspection After Daily Work 3-119 Machine Operation 3.98 Every 500 hours 4.7 Machine View Illustrations 3.2 <I> Auxiliary Electric Power 3.98 Every 2000 hours 4. And Attachments And Options .72 Detailed Controls And Gauges 3.8 Directions Of Machine 1.2 Initial 500 Hours 4.41 Machine.63 Introduction 1.4 After Cold Weather Season 3-135 Lubricants.8 Every 250 hours 4.43 <E> Maintenance Information 4.3 Safety First 6.General Performing Oil Clinic 4. Fuel.90 Every 10 hours 4.. Steering The 3-103 Magazine Box 3. 6 Safety Machine Operation 2.13 Tool Box 3.21 Starting Engine 2.5 Troubles And Actions 3-137 Battery. 2 Phenomena That Are Not Failures 3-137 Running Out Of Fuel 3-137 <P> Severe Job Condition 3-138 Parking Machine 3-118 Towing The Machine 3-138 Product Information 1.27 Safety Maintenance Information 2. INDEX Maintenance Schedule 4..30 Transportation 2.9 Specifications 5.13 Tightening Torque List 4.8 Radio 3.14 <Y> Safety Critical Parts List 4.36 Recommended Applications 3-115 Work Equipment Controls And Operations 3-106 Working Mode 3-107 <S> Safety Critical Parts 4.67 Transportation 3-121 Lifting Machine 3-121 Precautions for Transportation 3-121 Shipping Machine Information 3-122 7-2 . 9 Safety Information 2.31 Selection Of Track Shoes 6.28 <T> Tightening Torque Specifications 4.4 Location Of Safety Labels 2.5 Distributor 1.28 Operation 2.2 Safety Information 2.9 Service Meter Location 1.19 Towing 2.14 Your Machine Serial Numbers And Safety Information 1.57 Windshield 3.15 Transportation Posture 3-123 Maintenance Schedule Chart 4.11 Safety Labels 2. Discharged 3-139 <O> Other Trouble 3-143 Overall Machine View 3.8 Prohibited Operations 3-108 <W> Wear Parts 4.19 Battery 2.8 <R> Wear Parts List 4.15 Traveling On Slopes 3-112 Monitoring System 3.2 Swinging 3-105 Switches 3.5 Safety Labels 2. . . PC1250SP-7. PC1250-7. SEAM046500T © 2002 KOMATSU All Rights Reserved Printed in Japan 05-02 . PC1250LC-7 HYDRAULIC EXCAVATOR Form No..