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MAINTENANCE

MAINTENANCE PROCEDURE

CHANGE OIL IN FINAL DRIVE CASE

WARNING

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting
the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.

Refill capacity (each): 1.3 liters (0.34 US gal)
Prepare a hexagon wrench

1. Turn the sprocket so that plug (P) may come to the bottom.
2. Set the container to catch oil under plug (P).
3. Remove plugs (P), (G) and (F) with hexagonal wench to drain

the oil.

4. Tighten plug (P).
5. Add oil through the hole of plug (F) up to the refill level.
6. After the oil flows out of the hole plug (G), install plugs (G) and

(F).

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Summary of Contents for PC78MR-6

Page 1: ...cy 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 ...

Page 2: ... 1 1 ...

Page 3: ...hem fully Keep this manual in 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 Komats...

Page 4: ... FOREWORD FOREWORD 1 3 ...

Page 5: ... FOREWORD FOREWORD 1 4 ...

Page 6: ...ituation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This word is used also to alert against unsafe practices that may cause property damage Example of safety message using signal word WARNING When standing up from the operator s seat always place the lock lever in the LOCK posi...

Page 7: ... inside a triangle and the method of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual ...

Page 8: ...ching work Loading work Demolition work See the section RECOMMENDED APPLICATIONS PAGE 3 98 for further details DIRECTIONS OF MACHINE In this manual the terms front rear left and right refer to the travel direction as seen from the operator s seat when the operator s seat is facing the front and the sprocket is at the rear of the machine 1 7 ...

Page 9: ...your Komatsu distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE This is on the left side of the swing bracket mount The design of the nameplate differs according to the territory ENGINE SERIAL NUMBER PLATE AND ITS LOCATION On the upper side of the engine cylinder head cover 1 8 ...

Page 10: ...INFORMATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION This is on the side face of the intake air mount bracket EPA Environmental Protection Agency U S A SERVICE METER LOCATION On top of the machine monitor 1 9 ...

Page 11: ... FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Distributor name Address Service Personnel Phone Fax 1 10 ...

Page 12: ...ETY MACHINE OPERATION 2 21 STARTING ENGINE 2 21 OPERATION 2 23 TRANSPORTATION 2 29 BATTERY 2 30 TOWING 2 32 LIFTING OBJECTS WITH BUCKET 2 33 SAFETY MAINTENANCE INFORMATION 2 34 OPERATION 3 1 MACHINE VIEW ILLUSTRATIONS 3 2 OVERALL MACHINE VIEW 3 2 CONTROLS AND GAUGES 3 3 DETAILED CONTROLS AND GAUGES 3 4 MONITORING SYSTEM 3 4 SWITCHES 3 14 CONTROL LEVERS AND PEDALS 3 19 SUN ROOF 3 24 WINDSHIELD 3 25...

Page 13: ... 108 MACHINE INSPECTION AFTER DAILY WORK 3 109 LOCKING 3 109 ROAD LINERS AND RUBBER SHOES 3 110 TRANSPORTATION 3 115 TRANSPORTATION PROCEDURE 3 115 LOADING AND UNLOADING WITH TRAILER 3 115 LIFTING MACHINE 3 121 COLD WEATHER OPERATION 3 123 COLD WEATHER OPERATION INFORMATION 3 123 AFTER DAILY WORK COMPLETION 3 125 AFTER COLD WEATHER SEASON 3 125 LONG TERM STORAGE 3 126 BEFORE STORAGE 3 126 DURING S...

Page 14: ...ERY 50 HOURS MAINTENANCE 4 51 EVERY 100 HOURS MAINTENANCE 4 52 EVERY 250 HOURS MAINTENANCE 4 53 EVERY 500 HOURS MAINTENANCE 4 61 EVERY 1000 HOURS MAINTENANCE 4 68 EVERY 2000 HOURS MAINTENANCE 4 72 EVERY 4000 HOURS MAINTENANCE 4 73 EVERY 5000 HOURS MAINTENANCE 4 74 SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 ATTACHMENTS AND OPTIONS 6 1 ATTACHMENTS AND OPTIONS GENERAL INFORMATION 6 2 SAFETY FIRST 6 2 ATTA...

Page 15: ... ...

Page 16: ... 2 1 ...

Page 17: ... persons on attachments 2 15 Do not get caught in articulated portion 2 15 Burn prevention 2 16 Fire prevention and explosion prevention 2 16 Action if fire occurs 2 17 Windshield washer fluid 2 17 Falling objects flying objects and intruding objects prevention 2 17 Attachment installation 2 18 Attachment combinations 2 18 Cab window glasses 2 18 Unauthorized modifications 2 18 Safety at jobsite 2...

Page 18: ... towing 2 32 LIFTING OBJECTS WITH BUCKET 2 33 Safety rules for lifting objects 2 33 SAFETY MAINTENANCE INFORMATION 2 34 Warning tag 2 34 Keep work place clean and tidy 2 34 Appoint leader when working with others 2 34 Stop engine before carrying out maintenance 2 34 Two workers for maintenance when engine is running 2 35 Proper tools 2 36 Accumulator 2 36 Personnel 2 36 Attachments 2 36 Work under...

Page 19: ...e correct place and always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way If the labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the labels see this man...

Page 20: ... SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 2 5 ...

Page 21: ... SAFETY SAFETY LABELS SAFETY LABELS 1 Caution before operating or maintaining machine 09651 03001 2 Caution before operating 09802 03000 3 Warning for leaving operator s seat 09654 03001 2 6 ...

Page 22: ... SAFETY SAFETY LABELS SAFETY SAFETY LABELS 4 Warnings for high voltage 09801 03001 5 Caution for operating pattern 09822 03000 Standard machine 2 7 ...

Page 23: ...FETY LABELS 6 Caution for operating pattern if equipped Machine equipped with operating pattern selector valve 09822 03010 7 Caution when opening or closing front window 09839 03000 8 Caution when stowing front window 09803 03000 2 8 ...

Page 24: ...ABELS 9 Caution when window comes out breaks 20U 98 21910 10 Caution when switching operating pattern 22M 98 11181 Machine equipped with operating pattern selector valve if equipped 11 Caution with high temperature coolant 14X 98 11531 2 9 ...

Page 25: ...ETY SAFETY LABELS SAFETY SAFETY LABELS 12 Caution with high temperature hydraulic oil 09653 03001 13 Caution with high temperature parts 09817 A0753 14 Caution when adjusting track tension 09657 03003 2 10 ...

Page 26: ...S 15 Caution when handling cable 09808 03000 16 Stop rotation during inspection and maintenance 09667 03001 17 Prohibition to enter swing range 09133 23000 18 Caution when handling battery 09664 30082 19 Jump start prohibited 09842 A0481 2 11 ...

Page 27: ... SAFETY LABELS SAFETY SAFETY LABELS 20 Do not remove an additional weight 21W 98 48170 The safety labels 1 through 5 and 7 are a single seal In replacement place an order for it with Part No 22U 00 21290 2 12 ...

Page 28: ...hey may catch on control levers or other protruding parts If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful not to let it get caught Always wear a hard hat and safety shoes If the nature of the work requires it wear safety glasses mask gloves ear plugs and safety belt when operating or maintaining...

Page 29: ... pads act as a lens and may cause fire Do not use cellular telephones inside the operator s compartment when driving or operating the machine Never bring any dangerous objects such as flammable or explosive items into the operator s compartment 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 or when remov...

Page 30: ...ng the track shoe If there is any oil grease or mud on the handrails or steps including the track shoe wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts Do not get on or off the machine while holding tools in your hand MOUNTING AND DISMOUNTING Never jump on or off the machine Never get on or off a moving machine If the machine starts to move when t...

Page 31: ...e the following Do not smoke or use any flame near fuel or oil Stop the engine before refueling Do not leave the machine while adding fuel or oil Tighten all fuel and oil caps securely Do not spill fuel on overheated surfaces or on parts of the electrical system Use well ventilated areas for adding or storing oil and fuel Keep oil and fuel in the determined place and do not allow unauthorized pers...

Page 32: ...ne as follows Turn the start switch OFF to stop the engine Use the handrails and steps to get off the machine WINDSHIELD WASHER FLUID Use an ethyl alcohol base washer liquid Methyl alcohol base washer liquid may irritate your eyes so do not use it FALLING OBJECTS FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION On jobsites where there is a hazard that falling objects flying objects or intruding obj...

Page 33: ...hen any sign of them is noticed replace it with a new window UNAUTHORIZED MODIFICATIONS Any modification made without authorization from Komatsu can create hazards Before making a modification consult your Komatsu distributor Komatsu will not be responsible for any injuries accidents product failures or other property damages resulting from modifications made without authorization from Komatsu SAF...

Page 34: ...0 V Over 6 m 20 ft 275 000 V Over 7 m 23 ft 500 000 V Over 11 m 36 ft Even going close to high voltage cables can cause electric shock which may cause serious burns or even death Always maintain a safe distance see the table on the right between the machine and the electric cable Check with the local power company about safe operating procedure before starting operations To prepare for any possibl...

Page 35: ...gency escape For details see EMERGENCY ESCAPE HAMMER PAGE 3 30 in this manual When escaping remove all the pieces of glass from the window frame first and be careful not to cut yourself on the glass Be careful also not to slip on the broken pieces of glass on the ground ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbes...

Page 36: ...ner 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 check that the ...

Page 37: ...alarm works properly 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 ...

Page 38: ...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 war...

Page 39: ...n 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 fi...

Page 40: ...o improve the balance keep the work equipment approximately 20 to 30 cm 8 to 12 in above the ground and travel at low speed When traveling downhill lower the engine speed keep the travel lever close to the neutral position and travel at low speed Always travel straight up or down a slope Traveling at an angle or across the slope is extremely dangerous Do not turn on slopes or travel across slopes ...

Page 41: ...is dangerous and may cause the machine to tip over If the machine has to be used on a slope pile the soil to make a platform that will keep the machine as horizontal as possible PROHIBITED OPERATIONS Never dig the work face under an overhang There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine Do not excavate too deeply under the front of the machi...

Page 42: ...losing its balance and tipping over When operating on flat ground as well as on slopes Do not suddenly lower swing or stop the work equipment Do not suddenly extend or retract the boom cylinder There is a hazard that impact will cause the machine to tip over Do not pass the bucket over the head of other workers or over the operator s seat of dump trucks or other hauling equipment The load may spil...

Page 43: ...k lever 1 to the LOCK position then stop the engine Always close the operator s cab door and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine Always remove the key take it with you and leave it in the specified place If it is necessary to park the machine on a slope always do as follows Set the bucket on the downhill side then dig it into th...

Page 44: ...rect the direction then enter the ramps again The center of gravity of the machine will change suddenly at the joint between the ramps and the track or trailer and there is danger of the machine losing its balance Travel slowly over this point When loading or unloading to an embankment or platform make sure that it has suitable width strength and grade When swinging the upper structure on the trai...

Page 45: ...ith large amount of water If acid gets into your eyes flush them immediately with large amount of water and seek medical attention Before working with batteries turn the starting switch to the OFF position As there is a hazard that sparks will be generated always do as follows Do not let tools or other metal objects make any contact between the battery terminals Do not leave tools or other metal o...

Page 46: ...hine There is a hazard that the machine will move when the power is connected Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground side first when removing them When removing 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 safety goggles and rubber glov...

Page 47: ...t the capacity of the wire rope used for towing is ample for the weight of the towed machine Never use a wire rope which has cut strands A reduced diameter B or kinks C There is danger that the rope may break during the towing operation Always wear leather gloves when handling wire rope Never tow a machine on a slope During the towing operation never stand between the towing machine and the machin...

Page 48: ...ing load For details of the maximum lifting load permitted for this machine see BUCKET WITH HOOK PAGE 6 4 It is dangerous if the load hits any worker or structure Always check carefully that the surrounding area is safe before swinging or turning the machine Do not start swing or stop the machine suddenly There is a hazard that the lifted load will swing Do not pull the load to the side or in towa...

Page 49: ... the work place clean and tidy to enable you to carry out operations safely If the work place is not kept claen and tidy there is the danger that you will trip slip or fall over and injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and avoid use of organic solvents for cleaning An organic solvent like benzene toluene or methanol can invite ...

Page 50: ...and do as follows One worker must always sit in the operator s seat and be ready to stop the engine at any time All workers must maintain contact with the other workers Set lock lever 1 to the LOCK position When carrying out operations near the fan fan belt or other rotating parts there is a hazard of being caught in the parts so be careful not to come close Do not touch any control levers If any ...

Page 51: ... not bring it near flame or dispose of it in fire Do not make holes in it weld it or use a cutting torch Do not hit or roll the accumulator or subject it to any impact When disposing of the accumulator the gas must be released Please contact your Komatsu distributor to have this work performed PERSONNEL Only authorized personnel can service and repair the machine Do not allow unauthorized personne...

Page 52: ...permanent hearing problems WHEN USING HAMMER When using a hammer pins may fly out or metal particles may be scattered This may lead to serious injury Always do as follows If hard metal parts such as pins bucket teeth cutting edges or bearings are hit with a hammer there is a hazard that pieces might be scattered and cause injury Always wear safety goggles and gloves When hitting pins or bucket tee...

Page 53: ...nder internal pressure When inspecting or replacing piping or hoses always check that the pressure in the hydraulic circuit has been released If the circuit is still under pressure it will lead to serious injury so always do as follows Always release the pressure before starting any inspection or replacement operation If there is any leakage from the piping or hoses the surrounding area will be we...

Page 54: ... touch refrigerant COMPRESSED AIR When carrying out cleaning with compressed air there is a hazard of serious injury caused by flying particles When using compressed air to clean elements or the radiator always wear safety goggles dust mask gloves and other protective equipment PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS For using the machine safely for an extended period of time replace safety ...

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Page 57: ...CHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW 1 2 3 4 5 6 7 Bucket Bucket cylinder Arm Arm cylinder Boom Boom cylinder Additional lamp if equipped 8 9 10 11 12 13 14 Working lamp Sprocket Track frame Track shoe Idler Blade cylinder Blade 3 2 ...

Page 58: ...nt control lever Cigarette lighter Blade control lever Starting switch Fuel control dial 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Lamp switch Alarm buzzer stop switch Pump drive emergency switch Emergency boom swing operation brake cancel switch Travel speed selector switch Working mode selector switch Charge level monitor Engine oil pressure monitor Engine coolant temperature gauge E...

Page 59: ...ces needed for operating the machine To perform suitable operations correctly and safely it is important to completely understand methods of operating the equipment and the meanings of the displays MONITORING SYSTEM A B Caution monitors Emergency monitors C D Meter display portion Monitor switches portion 3 4 ...

Page 60: ...or begins to flash and the alarming buzzer begins to sound 1 Charge level monitor 2 Fuel level monitor Charge Level Monitor This monitor 1 indicates a problem in the charging system while the engine is running If the monitor lamp flashes check the V belt tension If any problem is found see OTHER TROUBLE PAGE 3 135 REMARK This lamp will light up if the starting switch is turned ON when the engine i...

Page 61: ...ND GAUGES Fuel Level Monitor This monitor 2 warns against the reduced fuel level in the fuel tank When the remaining fuel reaches 30 liters 7 93 US gal level the fuel level monitor begins to flash Then refill fuel without delay 3 6 ...

Page 62: ...normal location on the monitor will lights up and the buzzer will sound Carry out the necessary repairs immediately 1 Engine coolant temperature monitor 2 Engine oil pressure monitor Engine Coolant Temperature Monitor This monitor 1 serves to warn against abnormal rise of the engine coolant temperature When the temperature abnormally goes up it begins to flash Then stop the work and keep the engin...

Page 63: ...ne and check the oil level in the oil pan and lubricating system REMARK This lamp will light up if the starting switch is turned ON when the engine is stopped but this does not indicate any problem When the engine is started or stopped with the starting switch at the ON position the lamp may light up and the buzzer may sound momentarily but this does not indicate any problem 3 8 ...

Page 64: ...switch is ON the pilot display lights up when display items are functioning Engine Pre heating Monitor This monitor 1 indicates the pre heating time required when starting the engine at an ambient temperature below 0 C 32 F The monitor lamp lights up when the engine starting switch is turned to the HEAT position and begins to flash after about 30 seconds to show that the pre heating is completed T...

Page 65: ...wait for the temperature to go down to the green range A After starting the engine continue to warm it up until the engine coolant temperature rises from white range C to green range A in the gauge REMARK When Segment D lights up engine coolant temperature monitor lamp F begins to flash too When Segment E lights up engine coolant temperature monitor lamp F begins to flash too At the same time the ...

Page 66: ...splays flash see Electronic Control System PAGE 3 139 Monitor indications Error mode E02 Pump control system error E03 Swing brake system error Boom swing system error E05 Governor system error Service Meter This meter 6 shows the total operation hours of the machine Set the periodic maintenance intervals using this display The service meter advances while the engine is running even if the machine...

Page 67: ... 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 E goes off Active mode for heavy load operations E lights up E mode for operations with emphasis on fuel economy The working mode is changed every time the switch is depressed REMARK When starting the engine the active mode for heavy load operations is au...

Page 68: ...ghts up The wiper works continuously INT lights up The wiper works intermittently OFF The wiper stops The wiper operation mode is changed in the order of stop intermittent continuous stop ever time the switch is depressed Window Washer Switch This switch 4 is kept continuously pressed window washer fluid is sprayed out on the front glass When the switch is released the spray stops If switch 4 is k...

Page 69: ...tion Electric current flows in the charging and lamp circuits Keep the starting switch key at the ON position while the engine is running START position This is the engine start position Keep the key at this position during cranking Immediately after starting the engine release the key It will automatically return to the ON position HEAT pre heat position When starting engine in cold weather set t...

Page 70: ...eleration function Swift Deceleration Switch WARNING Always return the work equipment and travel levers to the neutral position before operating the swift deceleration switch If the switch is operated when any lever is being operated the engine torque will suddenly change This switch 3 is used to activate the system to lower the engine speed and reduce the fuel consumption when the engine output i...

Page 71: ...ondition of the switch If the starting switch is turned OFF position when the swift deceleration switch is ON the deceleration function is canceled Horn Switch Press switch 4 at the center of the knob of the right work equipment control lever to sound the horn Lamp Switch This switch 5 lights up the working lamp and monitor illumination Alarm Buzzer Stop Switch This switch 6 is used when the engin...

Page 72: ...ossible to carry out swing operations temporarily if any abnormality should occur in the swing brake system and to make it possible to carry out boom swing operations if any abnormality should occur in the boom swing system It is not intended for permanent use Repair the cause of the abnormality immediately If this switch is moved to the EMERGENCY position by mistake and operations are carried out...

Page 73: ...e room lamp lights up so do not forget to turn it off Cigarette Lighter This switch 10 is used when lighting cigarettes When the cigarette lighter is pushed in it will return to its original position after several seconds so pull it out to use it If the cigarette lighter is removed the socket can be used as a power source NOTICE This cigarette lighter is of a 24 V type Hence do not use this as a p...

Page 74: ...the lever is as shown in the diagram When pulling the lock lever up be careful not to touch the work equipment control lever When pushing the lock lever down be careful not to touch the work equipment control lever This lever 1 is a locking device for locking operation of the work equipment and attachments swing and travel The lever is put to the LOCK position when it is pulled up This lock lever ...

Page 75: ...ame time to the operating plate that matches the movement of the machine The place to attach the operating plate is on the right side of the operator s cab This left work equipment control lever 2 is used to operate the arm and upper structure Swing operation a Swing to right b Swing to left Arm operation c Arm IN d Arm OUT N Neutral The upper structure and arm are held in that position when they ...

Page 76: ...l be reversed When operating the travel levers check if the track frame is facing the front or the rear If sprocket A is at the rear the track frame is facing the front Take good care when traveling or steering the machine using the pedal Use this lever 5 to change the direction of travel between forward and reverse Pedal operation a FORWARD This lever is pushed forward This pedal is angled forwar...

Page 77: ...the bucket is wider than the standard bucket there is danger that the bucket will contact the operator s cab when swinging the boom to the left with the work equipment pulled in Check the distance between the bucket and the cab during the operation and operate the work equipment slowly This pedal 7 swings the boom to the left and right a Right swing b Left swing N Neutral Boom is stopped and held ...

Page 78: ...or details of the travel speed values see SPECIFICATIONS PAGE 5 2 REMARK The acceleration pedal works when the travel speed shifting switch in the monitor panel is at low speed position Lo lamp lights up The travel speed does not change even if the pedal is depressed if the switch is at high speed position Hi lamp lights up 3 23 ...

Page 79: ...atch carry out the operation on horizontal ground If you open or close the hatch when the footing conditions are poor there is danger that you may fall Opening 1 Set the lock lever securely to the LOCK position 2 Release lock A provided on both side of the ceiling and check that it moves freely Then push it up to open holding handle B Closing Pull the ceiling down holding handle B and set locks A ...

Page 80: ...ld the grip securely with both hands pull up and do not let go until the automatic lock catch is locked When closing the front window hold the handle with your both hands and close it firmly It is possible to stow pull up the front window in the roof of the operator s compartment Opening 1 Stop the machine on level ground lower the work equipment completely to the ground then stop the engine 2 Set...

Page 81: ... it against lock catch E at the rear of the cab securely to lock the window 6 Check that lock lever B is securely at the LOCK position The lock is engaged if the arrow on lock case F matches the position of the arrow on lock lever B Check visually If the arrow on lock case F does not match the position of the arrow on lock lever B the lock is not engaged Repeat the operation in Step 5 to engage th...

Page 82: ...el ground lower the work equipment completely to the ground then stop the engine 2 Set the lock lever securely to the LOCK position 3 Grip left and right handles A and pull down lock lever B to release the lock 4 Grip handle C at the bottom of the front window with your left hand and handle D at the top with your right hand push to the front then lower slowly 3 27 ...

Page 83: ...d if the arrow on lock case F matches the position of the arrow on lock lever B Check visually If the arrow on lock case F does not match the position of the arrow on lock lever B the lock is not engaged Repeat the operation in Step 5 to engage the lock Removing Lower Windshield 1 Open the front window then hold grip A pull up and remove the bottom window 2 After removing the bottom window stow it...

Page 84: ...zine box on the inside left of the operator s cab 2 After inserting into groove D of the bottom frame rubber and rear frame rubber A push the bottom window against lock base C NOTICE If the window rise up on lock base C or is not in contact with lock lever B and it is attempted to engage the lock by force there is danger that the glass may break Check before applying the lock 3 Set lock lever B to...

Page 85: ...enter pillar If there is anyone inside the cab call out to that person before opening or closing the door Door Lock When closing the door pull the handle back to remove lock 3 then pull the door to the front EMERGENCY ESCAPE HAMMER CAUTION If it is necessary to break the window glass with the hammer be extremely careful not to injure yourself on the flying pieces of broken glass To prevent injury ...

Page 86: ... OPERATION DETAILED CONTROLS AND GAUGES OPERATION DETAILED CONTROLS AND GAUGES To escape from the operator s cab use hammer A to break the glass and escape through the window 3 31 ...

Page 87: ...ing the Cap 1 Insert the key into the key slot 2 Turn the key clockwise align the key slot with the match mark on the cap then open the cap Locking the Cap 1 Turn the cap until tight then insert the key into the key slot 2 Turn the key counterclockwise and take the key out Opening and Closing Covers with Lock Opening the Cover 1 Insert the key into the key slot 2 Turn the key counterclockwise and ...

Page 88: ...the hood locked except when opening it Check the direction of the key slot in the opening knob to check that it is locked 1 Release lock 1 of the engine hood For details see Opening and Closing Covers with Lock PAGE 3 32 2 Push engine hood opening knob 1 and open hood 2 3 After opening the hood use hood support lever 3 to secure the hood in position 4 When closing hood 2 remove hood support lever ...

Page 89: ...of the key slot in the opening knob to check that it is locked 1 Release lock 1 of the mud cover For details see Opening and Closing Covers with Lock PAGE 3 32 2 Push mud cover opening knob 1 and open cover 2 3 It can be secured in 2 positions by using cover support lever 3 or 4 After opening cover 2 set cover support lever 3 or 4 to the LOCK position to hold the cover in position 4 When closing c...

Page 90: ...ON COVER NOTICE Always keep the door locked except when opening it 1 Release lock 1 of door For details see Opening and Closing Covers with Lock PAGE 3 32 2 Put a finger in hook 2 and pull cover 3 open 3 Close cover 3 and do not forget to lock the door 3 35 ...

Page 91: ... left console box Fuse Capacities and Circuit Names No Fuse capacity Name of circuit 1 10A Controller 2 10A Pump solenoid free 3 10A Revolving lamp auxiliary electric power 4 10A Window washer cigarette lighter 5 5A Horn 6 15A Working lamp 7 10A Radio 8 25A Air conditioner Heater 9 15A Fuel governer control 10 5A Swing brake cancel 11 10A Deceleration switch controller 12 10A Spare 13 10A Monitor ...

Page 92: ...r Komatsu distributor An optional connector No K17 is fastened to a cable with an adhesive tape at the rear part of the cab s floor This is for taking out power for optional electrical equipment made by other than Komatsu If use of such electrical equipment becomes necessary use the connector after peeling the tape off The connector types are shown in the table below X type housing 2 terminal Term...

Page 93: ...tch external internal Temperature control switch Air flow selector switch 5 6 7 Air conditioner switch Off switch Defroster selector lever Vent Selector Switch Air Flow to Upper Part of Body If this switch 1 is pressed the air from the air conditioner is all directed to the face This can be used to send a cool breeze to the face during hot weather 3 38 ...

Page 94: ...nd Foot If this switch 1 is pressed the air from the air conditioner is directed to the face and feet Vent Selector Switch Air Flow to Foot If switch 1 is pressed the air from the air conditioner is all directed to the feet This can be used to send warm air to the feet during cold weather 3 39 ...

Page 95: ...sition is used when heating or cooling the cab quickly or when the outside air is dirty Temperature Control Switch Cooling The closer to the C mark the lighting up is in the range the lower the room temperature is Conversely the closer to the H mark the lighting up is in the range the higher the room temperature is The indicator range is divided into 11 levels but within each range the temperature...

Page 96: ...es the further it is moved into the HI range front of machine the greater the air flow becomes The range is divided into 4 levels Air Flow Selector Switch Low Switch 4 is used to set the flow of air from the air conditioner to Low Press this switch to reduce the air flow The further it is moved into the LO range rear of machine the smaller the air flow becomes Air Flow Selector Switch High This sw...

Page 97: ...Air Conditioner with Care Ventilation If you smoke when the air conditioner is on the smoke may start to hurt your eyes so open the window and turn the lever to FRESH for a while to remove the smoke while continuing the cooling When running the air conditioner for a long time turn the lever to the FRESH position once an hour to carry out ventilation and cooling Temperature Control When the air con...

Page 98: ...ED CONTROLS AND GAUGES Air Conditioner Maintenance When carrying out inspection and maintenance of a machine equipped with air conditioner see INITIAL 250 HOURS MAINTENANCE ONLY AFTER THE FIRST 250 HOURS PAGE 4 16 3 43 ...

Page 99: ...froster Control Panel 1 2 3 Vent selector switch FRESH RECIRC selector switch Temperature control switch 4 5 6 Air flow selector switch OFF switch Defroster selector lever Vent Selector Switch Sending Air to Face If this switch 1 is pressed the air from the heater is all directed to the face 3 44 ...

Page 100: ...ctor Switch Sending Air to Face and Feet If this switch 1 is pressed the air from the heater is directed to the face and feet Vent Selector Switch Sending Air to Feet If this switch 1 is pressed the air from the heater is all directed to the feet 3 45 ...

Page 101: ...kly or when the outside air is dirty Temperature Control Switch The closer to the left end the lighting up is in the range the lower the room temperature is Conversely the closer to the right end the lighting up is in the range the higher the room temperature is The indicator range is divided into 11 levels but within each range the temperature changes sleeplessly Temperature Control Switch Cool U...

Page 102: ...her it is moved into the HI range front of machine the greater the air flow becomes The range is divided into 4 levels Switch 4 is used to switch the heater functions ON Air Flow Selector Switch Lo Switch 4 is used to set the flow of air from the heater to Low Press this switch to reduce the air flow The further it is moved into the LO range rear of machine the smaller the air flow becomes Air Flo...

Page 103: ...osed The defroster can be used when the vent selector switch is set to send air to the face or to the face and the feet Precautions when Using Air Conditioner Ventilate the Cab from Time to Time when Using the Heater If you smoke when the heater is on the smoke may start to hurt your eyes so open the window and carry out ventilation and heating for a short time to remove the smoke When running the...

Page 104: ...the radio on The frequency is displayed on display 7 Press the knob again to turn the power off Turn the knob clockwise to increase the volume press counterclockwise to reduce the volume The range for the volume is VOL 0 VOL 40 SEL button Each time this button 2 is pressed the mode changes as follows VOL volume BAS bass TRE treble BAL balance The mode is displayed on display 7 For details of each ...

Page 105: ...If this button is pressed within 2 seconds it is possible to select one of the already preset stations Wait for 6 sec after pressing the button and then press the button again to select the next preset station If it is impossible to receive the preset frequency the selection advances after 1 second to the next preset station Preset Station Buttons 1 2 3 4 5 6 If this button 6 has been used to deci...

Page 106: ...d FM can be preset to each Preset button REMARK It is also possible to save to the Preset button by using the auto store button Method of Setting with Preset Button 1 Press power switch 1 and display the frequency on display 7 2 Use tuning button 9 to set to the desired frequency There are two methods for tuning auto tuning and manual tuning Manual tuning Press tuning button 9 until the frequency ...

Page 107: ... With each mode the display is returned automatically to its original setting after 5 seconds Setting Correct Time 1 Press display selector button 4 to display the time After 5 seconds the display will return to the frequency display and the time cannot be corrected If this happens press display selector button 4 again 2 Press time adjustment button 8 to set to Hour or Minute H button Adjusts the ...

Page 108: ...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 equ...

Page 109: ...t it is possible to read it at any time TOOL BOX NOTICE Except when opening the cover for some reason always keep the cover locked Open the mud cover at right side of machine Store the tools in this box GREASE PUMP HOLDER Open the mud cover at right side of machine Grease pump holder is inside When not using the grease pump fit it in the holder ASHTRAY This is on the right front side of the operat...

Page 110: ...D GAUGES FIRE EXTINGUISHER If equipped A fire extinguisher is prepared at the rear part inside the operator s cab The directions are described on the nameplate affixed to it Just in case carefully read and grasp them beforehand 3 55 ...

Page 111: ...rk equipment cylinders linkage and hoses Check that there are no cracks excessive wear or play in the work equipment cylinders linkage or hoses If any problem is found repair it 2 Remove dirt and dust from around engine battery and radiator Check if there is any dirt or dust accumulated around the engine or radiator Check also if there is any flammable material dead leaves twigs grass etc accumula...

Page 112: ...ion Do not attempt to continue to operate the machine without repair 9 Checking and cleaning rear view mirror Check the rear view mirror for any abnormality and replace it with new one if it is damaged Keep the mirror surface clean and adjust the angle so that the lower part of the machine at the rear a portion whose view is blocked by the engine hood can be seen from the operator s seat 10 Seat b...

Page 113: ...there is a hazard of burns Wait for the temperature to go down then turn the cap slowly to release the pressure before removing it 1 Open the engine hood and check that the coolant level is between the FULL and LOW marks on radiator sub tank 1 Shown in the diagram on the right If the water level is low add clean and soft water through the water filler of sub tank 1 to the FULL level 2 After adding...

Page 114: ...into filler pipe F then remove it 4 The oil level should be between the H and L marks on dipstick G If the oil level is below the L mark add engine oil through oil filler F 5 If the oil is above the H mark drain the excess engine oil from drain plug P and check the oil level again 6 If the oil level is correct tighten the oil filler cap securely and close the engine hood REMARK If the machine is a...

Page 115: ...oil or sand remove that soil or sand Fuel is highly flammable and dangerous Never bring flames near fuel 1 Insert the key into engine starting switch 1 and turn it to the ON position to light up monitor 2 2 Check fuel gauge 3 for the remaining fuel amount 3 If required refill fuel through fuel filler port F monitoring sight gauge G Fuel tank capacity 125 liters 33 03 US gal 4 After adding fuel tig...

Page 116: ...e in the following condition A or B 1 When checking in condition A in the diagram on the right start the engine run the engine at low speed lower the blade to the ground pull in the arm and bucket cylinders and swing the boom to the central position Then lower the boom set the bucket teeth in contact with the ground and stop the engine 2 When checking in condition B in the diagram on the right sta...

Page 117: ...r the hydraulic oil to cool down then drain the excess oil from drain plug P 3 If it is below the L level open the mud cover and add through filler port F REMARK The oil level will vary depending upon the oil temperature Accordingly use the following as the guide Before operation around L level Oil temperature 10 to 30 C 50 to 86 F Normal operation around H level Oil temperature 50 to 80 C 122 to ...

Page 118: ...Water Separator If red ring 5 of water separator is at the bottom of element cup 4 there is no water If red ring 5 is floating there is water up to the bottom of the ring so drain the water as follows Prepare the filter wrench for water separator 1 Open inspection cover 1 on the left side of the machine and set handle 2 of the filter inside to the CLOSED position a 2 Using the filter wrench loosen...

Page 119: ...fuses of the specified capacity are used that there is no disconnection or trace of short circuiting on the electric wiring and no damage to the covering Check also that there is no loosened terminals If any tighten them Moreover pay particular attention to the electric wiring when checking the battery engine starting motor and alternator Be sure to check that there is no inflammable material accu...

Page 120: ...ck is not against the backrest the backrest may suddenly move forward C Adjusting armrest angle Armrest 3 can be made to spring up by hand approx 90 In addition by turning the dial 4 at bottom of armrest by hand it is possible to make fine vertical adjustment of the armrest angle Armrest adjustment angle 25 REMARK If the seat back is tipped to the front without raising the armrest 3 the armrest wi...

Page 121: ... against the backrest the backrest may suddenly move forward C Adjusting armrest angle Armrest 3 can be made to spring up by hand approx 90 In addition by turning the dial 4 at bottom of armrest by hand it is possible to make fine vertical adjustment of the armrest angle Armrest adjustment angle 25 REMARK If the seat back is tipped to the front without raising the armrest 3 the armrest will rise a...

Page 122: ...lamp securing the belt to the chassis are not loose Tighten them if they are loose The tightening torque for the mounting bolt is 24 5 4 9 N m 2 5 0 5 kgf m 18 1 3 6 lbft Fastening and Removing Seat Belt This seat belt has a wind in device so it is not necessary to adjust the length Fastening seat belt Hold grip 2 and pull the belt out from wind in device 1 check that the belt is not twisted then ...

Page 123: ...are not loose Tighten them if they are loose The tightening torque for the mounting bolt is 24 5 4 9 N m 2 5 0 5 kgf m 18 1 3 6 lbft If the belt surface is scratched or frayed or if the fittings are broken or deformed replace the seat belt unit Fastening and Removing 1 Adjust the seat so that the operator still feels that there is sufficient knee room when fully depressing the pedal while seated w...

Page 124: ...PERATION MACHINE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end on the tongue side Lengthening Pull the seat belt with a tongue in the direction perpendicular to the tongue 3 69 ...

Page 125: ...ks 1 The buzzer will sound for approx 1 sec and the following monitors and gauges will light up for approx 3 sec Charge level monitor 3 Engine oil pressure monitor 4 Engine coolant temperature gauge 5 Engine coolant temperature monitor 6 Fuel level monitor 7 Fuel level gauge 8 Swift deceleration monitor 9 Engine pre heating monitor 10 If the monitors or gauges do not light up or the buzzer does no...

Page 126: ...ERATIONS AND CONTROLS 2 Press horn switch 11 to confirm that the horn will sound 3 Press lamp switch 12 to turn on the working lamps If it does not light up there is probably a blown bulb or disconnection so please contact your Komatsu distributor for repairs 3 71 ...

Page 127: ...as is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not try to start the engine with the fuel adjustment dial set near the full engine rotation Otherwise the engine parts may be damaged Do not keep the starting motor rotating continuously for more than 20 seconds If the engine will not start wait for at least 2 minutes before trying ...

Page 128: ...gine start release the key in the starting switch 3 The key will return automatically to the ON position 5 Keep the engine idle for the initial 15 seconds right after it has been started and do not operate any control lever or the fuel adjustment dial during that time 6 Check that battery charging level monitor 4 lamp and engine oil pressure monitor 5 lamp do not light up 3 73 ...

Page 129: ...t gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not try to start the engine with the fuel adjustment dial set near the full engine rotation Otherwise the engine parts may be damaged Do not keep the starting motor rotating continuously for more than 20 seconds If the engine fails to start wait for about 2 minutes and repeat fro...

Page 130: ...at pre heating is finished REMARK The monitor and gauge also light up when the key is at the HEAT position but this does not indicate any problem 5 When engine pre heating monitor 4 goes off turn the key in stating switch 3 to the START position to start the engine 6 When the engine start release the key in the starting switch 3 The key will return automatically to the ON position 7 Keep the engin...

Page 131: ... OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION MACHINE OPERATIONS AND CONTROLS 8 Check that charge level monitor 5 and engine oil pressure monitor 6 goes off 3 76 ...

Page 132: ...her than the standard one ISO pattern refer to the chapter of ATTACHMENTS AND OPTIONS in this manual Breaking in the New Machine CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment However operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life Be sure to break in the machine for the initial 1...

Page 133: ...r run the engine at a mid range speed After starting the engine do not immediately start operations First perform the following operations and checks 1 Turn fuel control dial 1 to the center position between LOW IDLE and HIGH IDLE and run the engine at medium speed for about 5 minutes with no load 2 Set lock lever 2 to the FREE position and raise the bucket from the ground 3 Operate bucket control...

Page 134: ... monitor 11 OUT Pre heating monitor 12 OUT Display 13 OUT 6 Check for abnormal exhaust gas color noise or vibration If any problem is found contact your Komatsu distributor 7 Move lock lever 2 to the LOCK position and confirm that none of the operations for the control levers work equipment blade if a blade is installed swing and travel can be made 8 Turn working mode changing switch 14 in monitor...

Page 135: ... and then stop it 1 Run the engine at low idle for about 5 minutes to cool down gradually 2 Turn the key of starting switch 1 to the OFF position to 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 also check for any leakage of oil or coolant If any problems are found repair...

Page 136: ... machine Remove all obstacles from the travel path of the machine The rear of the machine is a blind spot so be particularly careful when travel in reverse Check that the travel alarm works properly Preparations for Moving the Machine 1 Turn fuel control dial 1 towards the full speed position to increase the engine speed REMARK If the engine speed dose not rise it is possible that the swift decele...

Page 137: ... the machine either by pushing lever 3 forward slowly or by stepping on the front part of pedal 4 slowly When sprocket is situated at the front of the machine Start the machine either by pulling lever 3 back slowly or by stepping on the rear part of pedal 4 slowly 4 Travel speed will increase if traveling accelerator pedal 5 is depressed while traveling at low speed Lo lamp lights up For details i...

Page 138: ...the machine either by pulling lever 3 back slowly or by stepping on the rear part of pedal 4 slowly When sprocket A is situated at the front of the machine Start the machine either by pushing lever 3 forward slowly or by stepping on the front part of pedal 4 slowly 4 Travel speed will increase if traveling accelerator pedal 5 is depressed while traveling at low speed Lo lamp lights up For details ...

Page 139: ...N MACHINE OPERATIONS AND CONTROLS Stopping Machine WARNING Avoid stopping suddenly Give yourself ample room when stopping Put the left and right travel levers 1 in the neutral position then stop the machine 3 84 ...

Page 140: ...se the travel levers to change direction Avoid sudden changes of direction as much as possible Especially when performing counter rotation spin turn stop the machine before turning Operate two travel levers 1 as follows Steering the Machine when Stopped When turning to the left Push the right travel lever forward to turn to the left when traveling forward and pull it back to turn left when traveli...

Page 141: ...l turn to the left REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left pull the left travel lever back and push the right travel lever forward REMARK When using counter rotation to turn right pull the right travel lever back and push the left travel lever forward 3 86 ...

Page 142: ...erating the swing check that the area around the machine is safe 1 Operate left work equipment control lever 1 to swing the upper structure 2 When not using the swing set left work equipment control lever 1 to the N position The swing holding brake will be applied 3 87 ...

Page 143: ...te the work equipment Note that when the levers are released they return to the HOLD position and the work equipment is held in that position Arm control Move the left work equipment control lever to the front or rear to operate the arm Swing control Move the left work equipment control lever to the left or right to swing the upper structure Boom control Move the right work equipment control lever...

Page 144: ...Move the right work equipment control lever to the left or right to operate the bucket Boom swing operation The boom swing operation can be carried out with the boom swing control pedal Blade control Move the lever on the right side of the operator s seat to the front or rear to operate the blade 3 89 ...

Page 145: ...k is automatically selected when the engine is started Working mode Lamp E Applicable operations Set rotation during work rpm Active mode for heave load operations Goes off Normal digging loading operations 2 020 50 E mode For work focusing on fuel consumption ratio Lights up Normal digging loading operations When importance is placed on fuel consumption ratio 1 850 100 This is the engine rotation...

Page 146: ...ut excavation This will damage the machine or work equipment Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends If the work equipment is used with the cylinder rod operated to its stroke end and given impact by some external force the hydraulic cylinders will be damaged causing personal injury Avoid operations with the hydraulic cylinder fully retracted or fully extended Digging Ha...

Page 147: ...pping 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 2 Avoid sudden lever shifting from forward to reverse or from reverse to forward 3 Avoid sudden lever shifting change such as sudden stopping from near top speed lever release operation Support Blade on Both Sides Whe...

Page 148: ...k equipment close to the ground and try to travel so that the center of the track passes over the obstacle High Speed Travel When traveling the machine on the rocky and rough ground or on a rough travel path strewn with stones maintain slow speed Lo lamp lights up In traveling at high speed Hi lamp lights up meanwhile travel the machine in such a way that the idlers face the traveling direction Fo...

Page 149: ...machine out of water if the angle of the machine exceeds 15 the rear of the upper structure will go under water and water will be thrown up by the radiator fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not immerse the machine in water by more than the permissible depth under center of carrier roller 1 In addition for parts that have been immersed...

Page 150: ...o perform these operations It may be longer but it will ensure safety 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 When traveling uphill if the shoes slip or it is impossible to travel uphill using only the force of the tracks do not use the pulling force of the arm to help the machine travel uphill There is danger t...

Page 151: ...s to the neutral position stop the machine then start the engine again Cab Doors on Slope If the engine stops when the machine is on a slope never use the left work equipment control lever to carry out swing operations The upper structure will swing under its own weight Do not open or close the sliding door on slopes when traveling or operating The operating effort may change suddenly Always keep ...

Page 152: ...th the teeth The angle between the boom and arm should be 90 to 110 The same applies when using the inverting bucket When only one side is affixed in mud use the bucket to raise the track then lay boards or logs and drive the machine out Tracks on Both Sides Stuck If the track on both sides are in mud and the machine slips and cannot move use the procedure given above to lay logs or timber dig the...

Page 153: ... work efficiency The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle toward the machine There may be some differences depending on the digging depth not try to keep within the above range rather than operating to the end of the cylinder stroke Shovel Work A shovel is suitable for excavating at a position higher than the machine Shovel work is performed by a...

Page 154: ...ading dump trucks is easier and the loading capacity is greater if the hydraulic excavator loads from the rear of the dump truck rather than from the side Refill and Finishing Work When refilling after excavation and when smoothing the ground surface use the blade Side Ditching Work The machine can be used for side ditching in a confined worksite by combining the swing and boom swing operations 3 ...

Page 155: ...nal oil filter Stop Valve This valve 1 stops the flow of the hydraulic oil 1 Loosen bolt A and then detach stopper B 2 Turn spool C to open and close the valve d FREE Hydraulic oil flows e LOCK Hydraulic oil stops to flow Turn this valve to the LOCK position when mounting or dismantling the attachments 3 Install stopper B after reversing to prevent spool C from turning 3 100 ...

Page 156: ...ion b Pedal half stroke position When using an attachment like the slide arm requiring a small flow rate or a breaker Position c Pedal full stroke position When using an attachment like the crusher and power ripper requiring a large flow rate Keep the lock pin in the LOCK position when attachment is not used Breaker Circuit Additional Oil Filter This filter 5 is used to prevent deterioration of th...

Page 157: ...piping bleed the air from the circuit 1 Start the engine referring to STARTING ENGINE PAGE 3 72 and run it at low idle for the subsequent 10 minutes Then proceed to the next work 2 Run the engine at low idle until the air in the attachment circuit is completely removed then operate the attachment pedal repeatedly approx 10 times to bleed the air NOTICE If the attachment maker specifies an air blee...

Page 158: ... 1 set at the half stroke position b the breaker begins to work 2 After the work is finished return the lock pin to the LOCK position a to lock the pedal Precautions when using Check that the stopper valve is in the FREE position Check that the selector valve is in the position for using the breaker Check that selector valve locking bar 2 is properly installed at the position for breaker applicati...

Page 159: ...to the LOCK position a to lock the pedal Precautions when using Check that the stopper valve is in the FREE position Confirm that the selector valve is set to the position for general attachments such as the crusher Check that selector valve locking bar 2 is properly installed at the position for general attachment application For other precautions when using the attachment see the instruction man...

Page 160: ...ts such as the crusher Set the lock pin at the LOCK position If there is no breaker or general attachment installed operating the pedal may cause overheating and other problems Hydraulic Specifications Hydraulic specifications Oil flow Lock Pin position Oil flow liter min A B 1 Pedal lock 2 Half stroke 55 45 3 full stroke 110 90 Low pressure safety valve Cranking pressure When using breaker 17 17 ...

Page 161: ...rforming joint work appoint a lead and follow that person s instructions and signals Replacement 1 Place the bucket in contact with a flat surface REMARK When removing the pins place the bucket so that it is in light contact with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to remove the pins NOTICE After removing the pins mak...

Page 162: ...After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at both ends of the bushings so be careful not to damage them 2 Remove the stopper bolts and nuts then remove pins A and B and remove the bucket 3 Turn the removed bucket After turning the bucket align the arm with link mounting hole 1 then align the link with arm mounting hole 2 and install 4 Insert grea...

Page 163: ... the control levers are touched by accident the machine may move suddenly and this may lead to a serious accident Before standing up from the operator s seat always set the lock lever securely to the LOCK position Set the blade on the downhill side and lower it to the ground 1 Stop the machine For details see Stopping Machine PAGE 3 84 2 Set fuel control dial 2 to the low idle position and lower t...

Page 164: ...ION AFTER DAILY WORK Check the engine coolant temperature 1 engine oil pressure 2 and fuel level 3 on the machine monitor LOCKING Always look the following places 1 Door of operator s cab 2 Fuel tank filler port 3 Engine hood 4 Mud cover 5 Battery inspection cover REMARK Use the starting switch key to lock and unlock all these places 3 109 ...

Page 165: ... material used road liners and rubber shoes offer various advantages However their weak point is lack of strength Therefore it is important to understand the advantages of road liners and rubber shoes and to follow the precautions regarding handling and prohibited work This will extend the life of the road liners and rubber shoes and will enable the machine to display the advantages of road liners...

Page 166: ...ng Life Operations Be careful of the following points when carrying out work Avoid carrying out counterrotation turns on concrete surfaces There is danger that the concrete surface will scrape off the rubber from the shoe Avoid making sudden changes in direction This may cause premature wear or damage to the road liners and rubber shoes Avoid operating the steering when traveling over places where...

Page 167: ...s always travel at right angles to the object 2 When traveling in reverse up a slope do not turn when moving from flat ground onto the slope If it is necessary to turn on slopes be sure to turn gradually 3 Avoid traveling along the edge of slopes or on rough ground with the track on one side raised with the machine tilting at an angle of more than approx 10 and with the track on the other side on ...

Page 168: ...e if the machine travels in reverse a gap is formed between the track roller idler and rubber shoe When turning in a condition where the rubber shoe cannot move to the side because of the object it is passing over or because of some other object When the rubber shoe has moved out of alignment and the idler or track roller are not aligned with the core If the machine travels in reverse in this cond...

Page 169: ... OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION MACHINE OPERATIONS AND CONTROLS If the machine is turned in this condition the rubber shoe will come off 3 114 ...

Page 170: ...lly and take action to prevent the slope face from collapsing Remove all mud and dirt from the machine tracks before starting in order to prevent the machine from slipping on the ramps Be sure that the ramp surface is clean and free of water snow ice grease or oil Never correct your steering on the ramps There is danger that the machine may turn over If necessary drive off the ramps correct the di...

Page 171: ...s up 4 Run the engine at low speed 5 When loading set the work equipment at the front and the blade at the rear with the undercarriage and upper structure set parallel 6 Before moving onto the ramps make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer Align the direction of travel with the ramps and travel slo...

Page 172: ...TATION OPERATION TRANSPORTATION 7 Do not operate the accelerator pedal 8 Stop the machine at the specified place then swing the upper structure slowly 180 9 Stop the machine at the specified position on the trailer 3 117 ...

Page 173: ...er the blade 2 Extend the bucket and arm cylinders fully then lower the boom slowly 3 Set the lock lever securely to the LOCK position to lock the work equipment control levers 4 Stop the engine then remove the key from the starting switch 5 Close all doors windows and covers Lock the covers caps and doors fitted with locks 6 Place blocks under both ends of the tracks to prevent the machine from m...

Page 174: ... ramps make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer Make the slope of the ramps a maximum of 15 3 Remove the chains and wire ropes fastening the machine 4 Start the engine Warm the engine up fully 5 Set the lock lever to the FREE position 6 Run the engine at low speed 7 Raise the blade 8 Turn the trave...

Page 175: ...pment align the direction of travel with the ramp and travel slowly Lower the work equipment as far as possible without causing interference When on the ramps operate only the travel lever Do not operate any other lever or pedal 10 Do not operate the accelerator pedal 3 120 ...

Page 176: ...ne NOTICE The lifting procedure applies to machines with standard specifications The method of lifting differs according to attachments and options actually installed on the machine For the proper lifting procedures contact your Komatsu distributor For details of the weight see SPECIFICATIONS PAGE 5 2 When lifting the machine carry out the operation on flat ground as follows 1 Start the engine the...

Page 177: ...ne to prevent damage to the rope or machine NOTICE Do not attempt to lift up the machine by hanging a wire rope to the bracket that is provided for fastening the machine in transportation Such a practice will damage the machine 8 Set the lifting angle A of the wire rope to 30 to 40 then lift the machine slowly 9 After the machine comes off the ground check the hook condition and the lifting postur...

Page 178: ...anging the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator please contact your Komatsu distributor or request a specialist company to carry out the operation Antifreeze is toxic Do not let it flow into drainage ditches or spray it onto the ground surface Antifreeze is flammable Do not bring any flame close Do not smoke when handling antifree...

Page 179: ... battery will also drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 Insulate it against cold temperature to ensure the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the charging rate from the following conversion table Electrolyte Temperature C Charging Rate 20 0 10 ...

Page 180: ...round and allow the machine to be moved the next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing Fill the fuel tank to capacity This minimizes moisture condensation in the tank when the temperature drops After operation in water or mud remove water from undercarriage as described below to extend undercarriage service life 1 Swing 90 with en...

Page 181: ...all attachments to the Crusher or general attachment position To prevent corrosion be sure to fill the cooling system with Supercoolant AF NAC or permanent type antifreeze density between 30 and 68 DURING STORAGE WARNING If it is necessary to perform the rust prevention operation while the machine is indoors open the doors and windows to improve ventilation and prevent gas poisoning Operate the en...

Page 182: ...sition and the work equipment is lowered under no load from a high position the arm speed will drop momentarily when the arm is more or less at the vertical position When the bucket control lever is operated to the CURL position and the work equipment is lowered under no load from a high position the bucket speed will drop momentarily when the bucket teeth are more or less at the horizontal positi...

Page 183: ... out towing operations within the maximum towing capacity If the machine sinks in mud and cannot get out under its own power or if the drawbar pull of the excavator is being used to tow a heavy object use a wire rope as shown in the diagram on the right Place pieces of wood between wire ropes and body to prevent damage to ropes and body Hold the wire rope level and direct it straight to the track ...

Page 184: ...in your eyes wash it out with fresh water immediately and consult a doctor When handling batteries always wear protective goggles and rubber gloves When removing the battery first disconnect the cable from the grounding terminal normally the negative terminal When installing the battery connect the positive terminal first If a metallic tool touches the positive terminal and the chassis like a conn...

Page 185: ...stalling of Battery NOTICE After securing the battery check that it does not move If it moves tighten it again securely 1 Place the battery in the specified position 2 Fasten the battery firmly with fixtures 9 and securing nuts 8 Securing nut tightening torque 1st nut 4 9 to 5 9 N m 0 5 to 0 6 kgf m 3 6 to 4 3 lbft Between nuts 58 8 to 73 5 N m 6 0 to 7 5 kgf m 43 4 to 54 2 lbft 3 Connect cable 7 ...

Page 186: ...ative terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or dry up and this may cause the battery to catch fire and explode If the battery electrolyte is frozen do not charg...

Page 187: ...r cable clips may not contact each other or they contact the chassis NOTICE The size of the booster cable and clip should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the engine to be started The starting system for this machine uses 24 V For the normal machine also use a 24 V battery Check the cables and clips for damage or corrosion Make...

Page 188: ...3 Turn the starting switch of the problem machine to the START position and start the engine If the engine doesn t start at first try again after 2 minutes or so Booster Cable Disconnection After the engine has started disconnect booster cables in the reverse order in which they were connected 1 Remove one clip of booster cable B from the revolving frame of the problem machine 2 Remove the other c...

Page 189: ...h a tool so that the descent may be stopped any moment Should it become impossible to lower the work equipment take the following actions 1 Open the dust cover NOTICE Do not loosen the plug by more than 5 turns Otherwise the plug goes off and the hydraulic oil will spurt out 2 Loosen plug 1 of the main valve slowly to lower the work equipment Loosen the plug by approx 3 5 to 4 turns 3 When the wor...

Page 190: ...s turned to ON Defective wiring Insufficient battery charge Check repair Charge Starting motor pinion repeatedly moves in and out makes ratting sound Insufficient battery charge Charge Starting motor turns engine sluggishly Insufficient battery charge Defective starting motor Charge Replace Starting motor disengages before engine start Defective wiring Insufficient battery charge Check repair Char...

Page 191: ...5000 HOURS SERVICE Excessive rise in hydraulic oil temperature Loose fan belt Lack of hydraulic oil Adjust fen belt tension see EVERY 250 HOURS SERVICE Add oil to specified level see CHECK BEFORE STARTING Track comes off Track too loose Adjusting track tension see WHEN REQUIRED Abnormal wear of sprocket Bucket rises slowly dose not rise Lack of hydraulic oil Adding oil to specified level see CHECK...

Page 192: ...E Replace thermostat Tightening cap or replace packing Replace sensor Red range of engine coolant temperature gauge lights up White range of engine coolant temperature gauge in light up even after operating for long time Defective thermostat Replace thermostat Engine dose not start when starting motor is turned Lack of fuel Air in fuel system Defective fuel injection pump or defective nozzle Start...

Page 193: ...being used Overheating Damage inside muffler Excessive valve clearance Change to specified fuel See Red range of engine coolant temperature gauge lights up Replace muffler Adjust valve clearance Engine stops while in work Clogging feed pump pre filter Defective engine and fuel line Replace filter cartridge Check repair 3 138 ...

Page 194: ...re it may be possible to release the brake In ant case have the system inspected immediately by your Komatsu distributor E41 Boom swing system error If emergency boom swing operation brake cancel switch is set to the ON position operation can be carried out However immediately have the system inspected by your Komatsu distributor E05 Governor system error Fuel adjusting dial is inoperative Either ...

Page 195: ... ...

Page 196: ... 4 1 ...

Page 197: ...metal particles or foreign materials are found always report to the person in charge and carry out suitable action Fuel Strainer Do not remove the strainer from the filler port when adding fuel Welding Instructions Turn off the engine starting switch Do not apply more than 200 V continuously Connect grounding cable within 1 m 3 3 ft of the area to be welded If grounding cable is connected near ins...

Page 198: ...EDING AIR FROM HYDRAULIC SYSTEM PAGE 4 47 Hydraulic Hose Installation When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace with new parts When doing this be careful not to forget to assemble the O rings and gaskets When installing the hoses do not twist or bend them into loops with a small radius This will cause damage to the hose and dras...

Page 199: ... the grade and maximum and minimum ambient temperatures recommended in the Operation and Maintenance Manual Even if the oil is not dirty always change the oil at the specified interval Oil corresponds to blood in the human body so always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of problems with the machine are caused by the e...

Page 200: ... river water or well water hard water contains large amounts of minerals calcium magnesium etc and this makes it easier for scale to form inside the engine or radiator Once scale is deposited inside the engine or radiator it is extremely difficult to remove It also causes overheating due to poor heat exchange so when you dilute the coolant we recommend that you use water with an overall hardness o...

Page 201: ...asma analyzer to measure the density of iron copper and other metal wear particles in the oil Measurement of quantity of particles This uses a particle quantifier index measurement machine to measure the quantity of iron particles of 5µ or more enabling early detection of failures Others Measurements are made of items such as the ratio of water in the oil density of the antifreeze coolant ratio of...

Page 202: ... metal particles are attached to the old filter If any metal particles are found contact your Komatsu distributor Do not open packs of spare filters until just before they are to be used Always use Komatsu genuine filters ELECTRIC SYSTEM MAINTENANCE It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged This will cause an electrical short circuit...

Page 203: ... replaced at the same time Item Part No Part name Q ty Replacement frequency Engine oil filter 600 211 2110 Cartridge 1 EVERY 500 HOURS SERVICE Fuel filter 600 311 7460 Cartridge 1 EVERY 500 HOURS SERVICE Hydraulic oil filter 21W 60 41121 07000 12135 Element O ring 1 1 EVERY 1000 HOURS SERVICE Water separator 21W 04 41480 Element 1 Air cleaner 600 185 1300 Element assembly 1 Additional filter for ...

Page 204: ...d according to the ambient temperature in the chart below Specified capacity means the total amount of oil including the oil in the tank and the piping Refill capacity means the amount of oil needed to refill the system during inspection and maintenance When starting the engine in temperatures below 0 C 32 F be sure to use the recommended multi grade oil even if the ambient temperature may become ...

Page 205: ... American Society of Testing and Material API American Petroleum Institute Engine oil pan Swing machinery case Final drive case PTO gear case Hydraulic system Cooling system Fuel tank Specified capacity Liters 7 5 2 0 1 3 0 4 110 10 5 125 US gal 1 98 0 53 0 34 0 11 29 06 2 77 33 03 Refill capacity Liters 7 0 2 0 1 3 0 4 64 US gal 1 85 0 53 0 34 0 11 16 91 4 10 ...

Page 206: ...icorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu Supercoolant AF NAC is strongly recommended wherever available 2 For details of the ratio when diluting super coolant with water see CLEAN INSIDE OF COOLING SYSTEM PAGE 4 21 When the machine is shipped from the factory it may be filled with coolant containing 30 or more Supercoolant AF NAC I...

Page 207: ...3 5 6 0 7 5 10 0 12 5 15 5 19 5 8 7 10 8 20 3 25 3 43 4 54 2 72 3 90 4 112 1 141 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 52 3 70 3 90 191 7 267 6 378 3 508 5 651 235 285 320 400 455 565 610 765 785 980 23 5 29 5 33 0 41 0 46 5 58 0 62 5 78 0 80 0 100 0 170 0 213 4 238 7 296 6 336 3 419 5 452 1 564 2 578 6 723 3 27 30 33 36 39 41 46 50 55 60 1295 1720 2210 2750 3280 132 5 175 0 22...

Page 208: ...Tighten all loose clamps and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the critical parts SAFETY CRITICAL PARTS LIST No Safety critical parts for periodic replacment Q ty Replacement interval 1 Fuel hose fuel tank water separator 1 Every 2 years or 4000 hours whenever comes soo...

Page 209: ... Road Liners or Rubber Shoes 4 29 Check and Adjust Rubber Shoe Tension 4 31 Replace Road Liners 4 32 Replace Rubber Shoes 4 33 Change Steel Shoes or Road Liner to Rubber Shoes 4 35 Replace Bucket Teeth vertical pin type 4 36 Replace Bucket Teeth horizontal pin type 4 39 Adjust Bucket Clearance 4 40 Check Window Washer Fluid Level Add Fluid 4 41 Check and Adjust Air Conditioner 4 42 Check Clean and...

Page 210: ... Clearance Adjust 4 72 EVERY 4000 HOURS MAINTENANCE Check Water Pump 4 73 EVERY 5000 HOURS MAINTENANCE Change Oil in Hydraulic Tank Clean Strainer 4 74 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker the hydraulic oil deteriorates faster than for normal bucket digging operations so set the maintenance intervals as follows Replace hydraulic filter element On...

Page 211: ...INTENANCE ONLY AFTER THE FIRST 250 HOURS Perform the following maintenance only after the first 250 hours Replace fuel filter cartridge Change oil in engine oil pan replace engine oil filter cartridge For details of the method of maintaining see EVERY 500 HOURS MAINTENANCE 4 16 ...

Page 212: ...1 appears clean the air cleaner element NOTICE Do not clean the air cleaner element before the dust indicator becomes red If the element is cleaned frequently before the dust indicator becomes red the performance of the air cleaner is diminished and the cleaning effect is lowered In addition dust sticking to the element falls into the inner element each time the element is cleaned Cleaning or Repl...

Page 213: ...en cleaned 6 times or used for one year Replace the inner element at the same time 2 Replace both inner and outer elements when the dust indicator red piston appears soon after installing the cleaned outer element even though it has not been cleaned 6 times 3 Remove one seal from the element whenever the element has been cleaned 5 If small holes or thinner parts are found on the element when it is...

Page 214: ...turn the red piston to its original position Replacing Element 1 Open up the engine hood cover then release clips 2 at 3 places and detach cover 3 2 Remove outer element 4 Do not remove inner element 5 at this time however 3 Clean the interior of the air cleaner body cover 3 and evacuator valve 6 4 Remove inner element 5 then install a new inner element immediately 5 Set the new outer element 4 in...

Page 215: ... Replace O ring 7 for cover 3 with new one 7 Set the arrow mark on cover 3 at the top install to the air cleaner body then secure with clip 2 8 Replace the seal attached to cover 3 with new one 9 Return the red piston in the dust indicator 1 to its original position 4 20 ...

Page 216: ...ange the coolant according to the table below Antifreeze coolant Interval of cleaning inside of cooling system and changing antifreeze coolant Komatsu supercoolant AF NAC Every two years or every 4000 hours whichever comes first Permanent type antifreeze All season type Every year autumn or every 2000 hours whichever comes first Permanent type antifreeze shall meet the requirements of ASTM D3306 0...

Page 217: ...7 1 63 1 50 1 37 Volume ratio 30 36 41 46 50 WARNING Antifreeze is flammable so keep it away from flame Antifreeze is toxic When removing the drain plug be careful not to get water containing antifreeze on you If it gets in your eyes flush your eyes with large amount of fresh water and see a doctor at once Use antifreeze and appropriate water for diluting for details see COOLANT AND WATER FOR DILU...

Page 218: ...thod follow the instruction of detergent 10 Close drain valve 2 Wind seal tapes onto drain plug 3 then tighten it 11 Install the cover under the drain valve 12 Add coolant mixed with antifreeze until it overflows from the water filler Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze 13 To remove air in the cooling system run the engi...

Page 219: ...2 Using a filter wrench loosen ring 3 then remove element cup 4 and take out element 5 Be careful not to lose red ring 6 inside the case 3 Wash element cup 4 in diesel fuel or flushing oil 4 Install new element 5 5 Insert a red ring 6 into element cover 4 fill with fuel install to the filter holder then tighten ring 3 6 Set handle 2 to the OPEN position b 7 After replacing the element bleed the ai...

Page 220: ...in fuel in the fuel tank referring to the steps 1 through 3 of the section of DRAIN WATER FROM FUEL TANK PAGE 4 51 in this manual 2 Remove floor mat 3 Remove cover 1 4 Remove fuel sensor 2 5 Wash inside of the tank 6 After washing the tank tighten drain valve 3 and install fuel sensor 2 cover 1 and floor mat 7 Close inspection cover 4 4 25 ...

Page 221: ...f m 86 8 14 5 lbft then check that the nut and shoe are in close contact with the link contact surface 2 After checking tighten a further 90 10 Method for further tightening of road liner Tighten to a tightening torque of 196 19 6 N m 20 2 kgf m 144 7 14 5 lbft then check that the nut and shoe are in close contact with the link contact surface Order for tightening Tighten the bolts in the order sh...

Page 222: ...ck and the bottom surface of the wooden block Standard deflection Deflection a should be 10 to 30 mm 0 4 to 1 2 in If the track tension is not at the standard value adjust it in the following manner Adjustment WARNING There is danger of plug 4 flying out under the high internal pressure of the grease Never loosen plug 4 more than 1 turn Never loosen any part other than plug 4 Never put your face i...

Page 223: ... the procedure given below If track tension is not relieved by this procedure contact your Komatsu distributor for repairs 1 Loosen plug 4 gradually to release the grease 2 When loosening plug 4 turn it a maximum of one turn 3 If the grease does not come out smoothly move the machine forwards and backwards a short distance 4 Tighten plug 4 5 To check that the track tension is correct run the engin...

Page 224: ...our Komatsu distributor for repairs or replacement Lug Height If lug height a is reduced by wear the drawbar pull will drop If a is less than 5 mm 0 2 in replace with a new part If the lug wears and the steel cord inside the shoe is exposed for two links or more replace with a new part Machine equipped with rubber shoes Rubber Shoe Steel Code Cuts If more than half of the steel cord layer on one s...

Page 225: ... only elongation of the rubber shoe but also damage to the grease cylinder Rubber Shoe Cracks If the cracks between the rubber shoe lugs increase to a size of approx 60 mm 2 36 in the rubber shoe must be repaired Even if the crack is small and short if the steel cord can be seen inside carry out repairs immediately If the length is less than 30 mm 1 18 in or the depth of the crack is less than 10 ...

Page 226: ... off and it will cause premature wear of the core Checking 1 Run the engine at low idle move the machine forward a distance equal to the length of track on ground then stop the machine 2 Choose wooden block 3 that will reach from idler 1 to carrier roller 2 then place it on top of the track 3 Measure the maximum deflection between the top surface of the rubber shoe and the bottom surface of the wo...

Page 227: ...re given below If the track tension is not relieved by this procedure please contact your Komatsu distributor 1 Loosen plug 4 gradually to release the grease 2 When loosening plug 4 turn it a maximum of one turn 3 If the grease does not come out smoothly move the machine forwards and backwards a short distance 4 Tighten plug 4 5 To check that the track tension is correct run the engine at low idle...

Page 228: ...n is correct run the engine at low idle move the machine forward a distance equal to the length of track on ground then stop the machine NOTICE It is possible to change from the rubber shoe to the road liner and steel shoe However it is necessary to remove the idler guard and to carry out adjustment so always contact your Komatsu distributor to have the replacement carried out Prepare a grease gun...

Page 229: ... rubber shoe rotate the sprocket in reverse so that the steel pipes make the rubber shoe come up from the idler then to the side to remove Rubber Shoes Installation 1 Raise the chassis with the boom and arm When doing this operate the levers slowly 2 Mesh the rubber shoe with the sprocket and fit it over the idler 3 Rotate the sprocket in reverse then push in the rubber shoe and stop the rotation ...

Page 230: ...he machine to the ground CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES WARNING When charging from the steel shoe or road liner to the rubber shoe when changing from the rubber shoe to the steel shoe or road liner it is necessary to remove and adjust the idler cushion so contact your Komatsu distributor to have the change carried out Changing from Steel Shoes or Road Liners to Rubber Shoes 1 Rem...

Page 231: ... like safety glasses and gloves Replace the bucket teeth before the adapter starts to wear 1 To make it possible to knock out the pin of tooth 1 set the bottom surface of the bucket on a block check that the work equipment is in a stable condition then set the lock lever to the LOCK position Set so that thebottom face of the bucket is horizontal 2 Use a hammer and drift to knock out lock pin 2 If ...

Page 232: ...adapter 4 If there is mud affixed to it or if there are protrusions the teeth will not enter the adapter properly and there will not be proper contact at the mating portion 7 Fit teeth 1 to adapter 4 and confirm that when the pointer is pressed strongly the rear face of the hole for the pin of the teeth is at the same level as the rear face of the hole for the pin of the adapter If the rear face o...

Page 233: ...e 2 Lightly hit lock pin 2 in the reverse direction from which it was hit in 3 Lightly hit the tip of the point from above and below and hit its sides from right and left 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 Repl...

Page 234: ...gloves Replace the bucket teeth before the adapter starts to wear 1 In order to enable tooth pin 1 to be pulled out put a block under the bucket bottom and make sure that the work equipment rests on it securely Then move the lock lever to the LOCK position In that case ensure that the bucket is level on the block 2 Place a bar on the head of pin 1 hit the bar with a hammer to knock out the pin the...

Page 235: ...s easier of you move the bucket to one side right side of the diagram or the other so all the clearance can be measured in one place Use a gap clearance gauge for easy and accurate measurement 3 Loosen 4 plate mounting bolts 2 and loosen plate 3 The shim is a split type so the operation can be carried out without removing the bolts 4 Remove as many shims 4 corresponding to clearance amount a A pai...

Page 236: ...d and Water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the following proportions before adding Area season Proportions Freezing temperature Normal Washer fluid 1 3 water 2 3 10 C 14 F Winter in cold area Washer fluid 1 2 water 1 2 20 C 4 F Winter in extremely cold area Pure washer fluid 30 C 22 F There are two types depending on the freezin...

Page 237: ...o refrigerant REMARK When there are bubbles the refrigerant gas level is low so contact your Komatsu distributors to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor Inspection During Off Season Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of...

Page 238: ...oller 2 at three points Cleaning 1 Open and close the door and use a brush to remove any dirt from rail 1 2 Use a cloth to wipe off any dirt from rail 1 Greasing NOTICE Do not use high viscosity oil for the lubricant Use grease only 1 Spray rail 1 and roller 2 thoroughly with lubricant 2 After spraying with lubricant slide the door and check that the door opens and closes smoothly If the movement ...

Page 239: ... internal pressure then remove it carefully NOTICE For details of the replacement interval for the element MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER PAGE 4 15 Prepare a container to catch the oil 1 Place a container under the filter element to catch the oil 2 Turn filter case 1 to the left to remove it then take out element 2 3 Remove plug 3 from filter case 1 4 Clean the removed parts then insta...

Page 240: ...perator s seat NOTICE While cleaning the cab floor take care so that the connector air conditioner main body and filters may not be splashed with water Method of Washing 1 Set the machine at an angle For details see Method of Setting Machine at Angle PAGE 4 46 2 Swing the upper structure slowly so that water drain holes 1 in the cab floor are at a low position 3 Lower the work equipment to the gro...

Page 241: ...he track and dig the work equipment into the ground Method Using Block WARNING Select a firm flat place Put strong blocks under the undercarriage to stabilize the machine and be extremely careful when carrying out the operation 1 Raise the chassis with the boom and arm When doing this operate the levers slowly 2 Insert a block securely between the ground surface and the raised track and make sure ...

Page 242: ...ICE If the engine is run at high speed without bleeding the air between the pump and hydraulic tank there will be abnormal generation of heat and this will lead to premature failure of the pump 1 Start the engine and maintain it at a mid range speed 1650 rpm For details see STARTING ENGINE PAGE 3 72 2 Operate the work equipment slowly for approx 5 minutes to bleed the air 3 Bleeding air from LS ci...

Page 243: ...tely remove the air 5 Bleeding air from swing motor only after draining oil from swing motor case NOTICE If the air is not bled from the swing motor the motor bearings may be damaged 1 Loosen hose 3 while keeping the engine running at low idling Tighten it again once oil starts to flow out Do not attempt to make a swing movement at that time 2 Run the engine at low idling and make a swing movement...

Page 244: ...hment maker specifies an air bleeding procedure for the attachment itself follow the specified procedure to bleed the air If a breaker or other attachment has been installed run the engine at low idle and operate the attachment pedal repeatedly approx 10 times until the air has been bled from the attachment circuit NOTICE After completing the air bleeding operation stop the engine and leave the ma...

Page 245: ...ee Checks Before Starting PAGE 3 58 in the OPERATION section Check coolant level add coolant Check oil level in engine oil pan add oil Check fuel level add fuel Check oil level in hydraulic tank add oil Check dust indicator Check water separator Check electric wiring Check function of horn 4 50 ...

Page 246: ...he fuel that is drained 1 Swing the upper structure so that inspection cover 1 is between the tracks 2 Open the inspection cover 1 3 Open drain valve 2 and drain the sediment and water accumulated at the bottom together with the fuel When doing this be careful not to get fuel on yourself 4 When only clean fuel comes out close drain valve 2 5 Close the inspection cover 4 51 ...

Page 247: ...out greasing every 10 hours for the first 50 hours on a new machine After the machine was subjected to jobs in the water be sure to grease the wet pins Prepare a grease gun 1 Set the machine to the greasing posture shown on the right diagram lower the work equipment to the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing ...

Page 248: ...chine was subjected to jobs in the water be sure to grease the wet pins Prepare a grease gun 1 Set the machine to the greasing posture shown on the right diagram lower the work equipment to the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out Only machines with blade specificati...

Page 249: ...n 1 place 9 Boom Arm coupling pin 1 place 10 Bucket cylinder foot pin 1 place 11 Arm link pin 1 place 12 Link coupling pin 2 places 13 Bucket cylinder rod end pin 1 place 14 Bucket Link coupling pin 2 places 15 Arm Bucket coupling pin 1 place 16 Boom swing bracket pin 2 places 17 Boom swing cylinder rod end pin 1 place 18 Boom swing cylinder foot pin 1 place 4 54 ...

Page 250: ...t Loosen the plug slowly to release the pressure Prepare a container to catch drained oil Prepare a hexagon wrench 1 Turn the sprocket so that plug P may come to the bottom 2 Set the container to catch oil under plug P 3 Remove plug G with a hexagonal wrench Oil level shouldbe near the bottom of the plug hole G 4 If the oil is insufficient remove plug F with a hexagonal wrench then add oil through...

Page 251: ... in the morning to prevent the electrolyte from freezing Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below When Checking Electrolyte Level from Side of Battery If it is possible to check the electrolyte level from the side of the battery check as follows 1 Open battery inspection cover 1 and remove a sheet installed above the battery 2 U...

Page 252: ...d distilled water so that the level reaches the bottom of the sleeve UPPER LEVEL line without fail Use the diagram below for reference and check if the electrolyte reaches the bottom of the sleeve 3 After adding distilled water tighten cap 2 securely REMARK If distilled water is added to above the bottom of the sleeve use a syringe to lower the level to the bottom of the sleeve Neutralize the remo...

Page 253: ...LING FAN BELT TENSION Checking If deflection amount a shows approx 8 mm 0 3 in when the belt is pressed with a thumb of approx 58 8 N 6 kgf force at the midpoint between the alternator pulley and the fan pulley then it is the standard deflection amount 4 58 ...

Page 254: ...alternator 2 to the machine front side prying with the bar so that the fan belt deflects by approx 8 mm 0 315 in approx 58 5 N or 6 kgf and then tighten adjusting bolt 4 5 Tighten alternator securing bolts 3 NOTICE Check each pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove If the belt is stretch...

Page 255: ...r approx 6 kgf is obtained 3 Tighten bolts 1 and 2 to fasten the compressor 4 Tighten nut 3 after loosening bolt 4 by 2 to 3 turns and then retighten bolt 4 NOTICE Check each pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove In case any of the following occurs ask the Komatsu distributor in your t...

Page 256: ...cking will be damaged and fuel will leak If the filter cartridge is too loose fuel will also leak from the packing so always tighten to the correct amount 5 After replacing the fuel filter element bleed air For details of the procedure see Air Bleeding PAGE 4 61 6 After replacement of the filter cartridge start the engine and check it for possible oil seepage from the filter seal If oil leaks chec...

Page 257: ...ign material please contact your Komatsu distributor 4 Install drain plug P 5 Open the engine hood then using a filter wrench turn filter cartridge 1 counterclockwise to remove it REMARK Put a cloth in contact with the notched part of the oil container guide This makes it possible to prevent the area around the filter holder from becoming dirty 6 Clean the filter holder then coat the thread and th...

Page 258: ...ing the filter is 500 hours but if the machine is used on an extremely dusty jobsite reduce the maintenance interval and clean the filter more frequently When washing the floor be careful not to get water on the air conditioner system Cleaning Reticulated Air Filter 1 Roll up floor mat 1 on the front left part of the floor in the operator s cab and open cover 2 2 Take out internal filter 3 3 Clean...

Page 259: ...6 by blowing it with compressed air If there is oil stuck to the filter or it is extremely dirty wash it in a neutral agent After washing dry it thoroughly before using it again REMARK If the clogging of the filter cannot be removed by blowing it with compressed air or washing in water replace the filter with a new one 4 Install cleaned filter 6 and then fix cover 5 NOTICE Insert filter 6 paying a...

Page 260: ...rom air nozzle to prevents damage to the fins To prevent damage to the fins apply compressed air from and appropriate distance Damaged fins may cause water leakage or overheating In a dusty site check the fins daily irrespective of the maintenance interval Net Clean 1 Open engine hood 2 Remove screws 1 and take out net 2 3 Clean net 2 put it back to the original position and fix it with screw s 1 ...

Page 261: ...mpressed air to radiator fins 9 oil cooler fins 8 and condenser fins 4 to blow off the clogged dirt twigs and leaves Steam or water may be used instead of compressed air 9 Detach machine undercover 10 and sweep out the dirt dust and shreds of dry leaves fallen on the bottom 10 Check the rubber hose Replace with a new one if the hose is found to have cracks or to be hardened by aging Also check hos...

Page 262: ...HECK SWING PINION GREASE LEVEL ADD GREASE Prepare a scale 1 Remove bolt 1 then remove cover 2 2 Remove bolts 3 2 bolts on the top of the revolving frame and remove cover 4 3 Check that grease is inside 4 Check if the grease is milky white If it is milky white it is necessary to change the grease Please contact your Komatsu distributor The total amount of grease is 5 5 liters 5 kg 1 45 US gal 11 03...

Page 263: ...iller cap turn it slowly to release the internal pressure then remove it NOTICE If the machine is equipped with a hydraulic breaker the hydraulic oil will deteriorate much faster than during normal bucket operations For details see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER PAGE 4 15 when carrying out maintenance 1 Retract the arm and bucket cylinders then lower the boom and put the teeth in conta...

Page 264: ... ring fitted to cover 2 and if it is scratched or damaged replace it with a new O ring 10 Set valve 4 and spring 3 on top of the element 11 Set cover 2 in position push it down by hand and install the cover 2 with the mounting bolts 12 Install oil filler cap F then install cover 1 13 To bleed the air start the engine according to STARTING ENGINE PAGE 3 72 and run the engine at low idle for 10 minu...

Page 265: ...ne underside to drain oil and tighten it again after the draining Tightening torque of drain plug P is 44 to 93 N m 4 5 to 9 5 Kgf m 32 5 to 68 7 lbft 3 Loosen bolt 1 and slide cover 2 4 Add the specified amount of engine oil through dipstick G insert port 5 Wipe off oil on the dipstick G with cloth 6 Fully insert dipstick G into filler pipe F then remove it 7 The oil should be between the H and L...

Page 266: ...ase the oil or plug may fly out Loosen the plug slowly to release the pressure Refill capacity each 1 3 liters 0 34 US gal Prepare a hexagon wrench 1 Turn the sprocket so that plug P may come to the bottom 2 Set the container to catch oil under plug P 3 Remove plugs P G and F with hexagonal wench to drain the oil 4 Tighten plug P 5 Add oil through the hole of plug F up to the refill level 6 After ...

Page 267: ... 11 US gal 1 Remove oil inspection plug G and check that the oil is near the bottom of the check hole If the oil level is low add oil through oil filler F until the oil level is close to the bottom of the hole of plug hole 2 Install plug G CLEAN CHECK TURBOCHARGER Contact your Komatsu distributor for cleaning and inspection CHECK ALTERNATOR STARTING MOTOR The brushes may be worn or the bearing may...

Page 268: ...0 100 250 500 1000 and 2000 hours service should be carried out at the same time CHECK WATER PUMP Check that there is no play in the pulley leakage of oil or water or clogging of the drain hole If any problem is found please contact your Komatsu distributor for repairs or replacement 4 73 ...

Page 269: ...move it NOTICE If the machine is equipped with a hydraulic breaker the hydraulic oil will deteriorate much faster than during normal bucket operations For details see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER PAGE 4 15 when carrying out maintenance Refill capacity 64 liters 16 91 US gal Prepare a handle for the socket wrench 1 Swing so that the drain plug at the bottom of the hydraulic tank is in...

Page 270: ...esel oil or flushing oil If strainer 5 is damaged replace it with a new one 10 Refit strainer 5 by inserting it into tank projecting part 6 11 Install cover 2 with bolts Check the O ring installed to cover 2 and if it is damaged replace the O ring 12 Add the specified amount of new and clean engine oil for hydraulic system through oil filler port F Check that the oil level is between H and L on th...

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Page 273: ...epower kW HP rpm 40 5 54 0 1 850 A Overall length mm ft in 6 200 20 4 6 230 20 5 B Overall height mm ft in 2 730 8 11 2 750 9 C Overall width mm ft in 2 330 7 8 D Track width mm ft in 450 1 6 E Radius of upper structure mm ft in 1 310 4 4 F Length of track mm ft in 2 840 9 4 2 900 9 6 G Tumbler canter distance mm ft in 2 235 7 4 Min ground clearance mm ft in 360 1 2 400 1 4 Travel speed Low High k...

Page 274: ... 4 160 13 8 C Max digging height mm ft in 6 570 21 7 D Max vertical wall depth mm ft in 2 900 9 6 E Max dumping height mm ft in 4 515 14 10 F Min swing radius of work equipment Min swing radius at boom swing mm ft in 2 775 9 1 2 125 6 12 G Max reach ground level mm ft in 6 750 22 2 H Max blade lifting height mm ft in 380 1 3 I Max blade lowering depth mm ft in 245 10 5 3 ...

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Page 277: ... When an attachment is installed the swing range and center of gravity of the machine are different and the machine may move in an unexpected way Be sure that you understand the condition of the machine properly Before starting operations set up a fence around the machine to prevent people from entering Never operate the machine when there are people near the machine To prevent serious accidents c...

Page 278: ...stance from operating to stop the swing to the point where the swing stops completely so there is danger of mistaking the distance and hitting other objects Allow a margin to the stopping point when operating In addition the hydraulic drift the gradual downward movement caused by the weight of the work equipment when the work equipment is stopped in a raised condition will also increase If the cor...

Page 279: ...posture there is danger that the wire or ring may come off the hook To prevent this pay careful attention to the angle of the hook Never travel the machine while lifting a load If the bucket with hook is turned and used for operations it will hit the arm during dumping operations so be careful when using it Do not exceed the following loads when carrying out lifting operations When standard arm is...

Page 280: ...ift up the machine keeping it level 1 Loosen 4 screws 1 to detach rear nameplate 2 2 Remove 3 corks 3 3 Using a crane install extra counterweight 4 to the back of the standard counterweight REMARK The optimum length of a wire rope for lifting should be as follows A Wire rope Overall length 800 mm 31 5 in Diameter 9 mm 0 355 in B Eyebolt Weight of extra counterweight 220 kg 485 lb 4 Fasten the extr...

Page 281: ...NTS AND OPTIONS METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT ATTACHMENTS AND OPTIONS METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT 6 Install plastic cap 7 7 Fix nameplate 2 with 4 screws 1 6 6 ...

Page 282: ... the movement of the machine check carefully that the surrounding area is safe and operate slowly CONTROL PATTERN CHANGE PROCEDURE 1 After setting the machine in the parking posture set the lock lever to the LOCK position then stop the engine 2 Open the inspection cover on the left side of the machine The selector valve is inside 3 Follow the steps explained below when switching the patterns 1 Loo...

Page 283: ...NG MACHINE CONTROL PATTERN IF PATTERN CHANGE VALVE EQUIPPED MACHINE CONTROL PATTERNS WARNING After changing the operating pattern always change the operating pattern card in the operator s compartment ISO pattern Backhoe pattern 6 8 ...

Page 284: ...achments 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 Any injuries accidents or damage resulting from the use of unauthorized attachments or options will not be the responsibility of Komatsu OTHER ATTACHMENTS Front half guard This is to protect the ope...

Page 285: ...When the boom is fully lowered during oblique digging the boom interferes with the undercarriage Operate the boom carefully Categories of use For general digging Digging or loading sand gravel clay etc For light duty digging Digging or loading dry uncaked earth and sand mud etc For loading work Loading dry loose earth and sand Name Tooth mounting pin Capacity m3 cu yd SAE CECE Outside width bucket...

Page 286: ... on the track shoe will increase so this may cause problems such as bending of the shoe cracking of the link damage of the pin and looseness of the shoe bolts Category Use Precautions when using A Rocky ground riverbeds normal soil On rough ground with large obstacles such as boulders or fallen trees travel at low speed B Normal soil soft ground These shoes cannot be used on rough ground where the...

Page 287: ...ill vary Hence consult your Komatsu distributor for the selection of optimum attachments HYDRAULIC BREAKER Main Applications Crushed rock Demolition work Road construction This attachment can be used for a wide range of applications including demolition of buildings breaking up road surfaces or slag tunnel work rock crushing and breaking operations in quarries Keep the chisel pushed perpendicularl...

Page 288: ...surface within 1 minute change the point of impact and carry out breaking operations closer to the edge The direction of penetration of the chisel and the direction of the breaker body will gradually move out of line with each other so always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly to prevent using the impact force when the...

Page 289: ... do not operate the machine in any of the following ways Do not operate all cylinders to the end of their strokes Always leave approx 5 cm 2 in to spare Using the mount to gather in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations 6 14 ...

Page 290: ...TTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 6 15 ...

Page 291: ...n NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result soil and sand will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use Therefore be sure to grease the breaker holding it in the right posture 6 16 ...

Page 292: ...tenance 4 7 Emergency Escape Hammer 3 30 Emission Control Information Label and Its Location 1 9 Engine After Starting 3 77 Engine Before Starting 3 56 Engine Hood 3 33 Engine Serial No Plate and Its Location 1 8 Engine Check After Shut Off 3 80 Engine Starting 3 72 Engine Stopping the 3 80 Escape from Mud 3 97 F Fire Extinguisher 3 55 Forword 1 2 Fuse 3 36 Fusible Link 3 37 G General Operation In...

Page 293: ...s List 4 13 Safety Information 1 5 Safety Information 2 2 Safety Information 2 13 Safety Labels 2 4 Location of Safety Labels 2 5 Safety Labels 2 6 Safety Machine Operation 2 21 Battery 2 30 Lifting Objects with Bucket 2 33 Operation 2 23 Starting Engine 2 21 Towing 2 32 Transportation 2 29 Safety Maintenance Information 2 34 Service Meter Location 1 9 Sliding Door 3 30 Specifications 5 2 Sun Roof...

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Page 295: ... PC78MR 6 GALEO HYDRAULIC EXCAVATOR Form No TEN00074 00 2005 KOMATSU All Right Reserved Printed in Japan 04 05 ...

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