Pc78us-6 O&m

SEAM044600
Operation & Maintenance

Manual
PC78US-6
HYDRAULIC EXCAVATOR
SERIAL NUMBER PC78US - 4001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is out policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on
products sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It
is recommended that customers contact their distributor for information on the latest revision.
Copyright 2001 Komatsu

DataKom Publishing Corporation
December 2001
.
1-1
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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing
operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Storage location for the Operation and Maintenance Manual:

A magazine box provided on the left side of operator's seat
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FOREWORD FOREWORD
1-3
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FOREWORD FOREWORD
1-4
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation 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. It may also be used to alert against unsafe practices.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the levers when they are not locked, this may cause a serious injury or damage.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is are useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
1-5
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SAFETY INFORMATION FOREWORD
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram

Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous
condition is displayed 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 are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: j -> (1))
1-6
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FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Leveling work
Ditching work
Loading work
Demolition work
See the section "RECOMMENDED APPLICATIONS (PAGE 3-96)" 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 cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.
1-7
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PRODUCT INFORMATION FOREWORD
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION

On the bottom right of the operator's cab
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION

On the upper side of the engine cylinder head cover
EPA: Environmental Protection Agency, U.S.A.
1-8
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FOREWORD PRODUCT INFORMATION
SERVICE METER LOCATION

On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.
Engine serial No.
Distributor name
Address
Service Personal
Phone/Fax
1-9
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
DIRECTIONS OF MACHINE 1- 7
PRODUCT INFORMATION 1- 8
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION 1- 8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1- 8
SERVICE METER LOCATION 1- 9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 9
SAFETY 2- 1
WARNING LABELS AND PICTOGRAMS 2- 4
WARNING LABELS AND PICTOGRAMS - LOCATION 2- 5
WARNING LABELS AND PICTOGRAMS - ACTUAL 2- 6
SAFETY MACHINE OPERATION 2- 19
STARTING ENGINE 2- 19
OPERATION 2- 21
TRANSPORTATION 2- 27
BATTERY 2- 28
TOWING 2- 30
LIFTING OBJECTS WITH BUCKET 2- 31
SAFETY MAINTENANCE INFORMATION 2- 32
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- 15
CONTROL LEVERS AND PEDALS 3- 20
SUN ROOF 3- 24
WINDSHIELD 3- 25
SLIDING DOOR 3- 30
EMERGENCY ESCAPE HAMMER 3- 31
CAP WITH LOCK 3- 32
ENGINE HOOD 3- 33
MUD COVER 3- 34
BATTERY INSPECTION COVER 3- 35
FUSE 3- 36
FUSIBLELINK 3- 37
AUXILIARY ELECTRIC POWER 3- 37
CONTROLLERS 3- 37
HEATER AND DEFROSTAR CONTROLS 3- 38
AIR CONDITIONER CONTROLS 3- 43
RADIO 3- 49
OPERATION MANUAL STORAGE 3- 54
TOOL BOX 3- 54
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FOREWORD CONTENTS
GREASE PUMP HOLDER 3- 54

ASHTRAY 3- 54
FIRE EXTINGUISHER 3- 55
MACHINE OPERATIONS AND CONTROLS 3- 56
BEFORE STARTING ENGINE 3- 56
AFTER STARTING ENGINE 3- 75
STOPPING THE ENGINE 3- 78
CHECK AFTER SHUT OFF ENGINE 3- 78
MACHINE OPERATION 3- 79
STEERING THE MACHINE 3- 83
SWINGING 3- 85
WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 86
WORKING MODE 3- 88
PROHIBITED OPERATIONS 3- 89
GENERAL OPERATION INFORMATION 3- 91
TRAVELING ON SLOPES 3- 93
ESCAPE FROM MUD 3- 95
RECOMMENDED APPLICATIONS 3- 96
BUCKET REPLACEMENT AND INVERSION 3- 98
PARKING MACHINE 3-100
MACHINE INSPECTION AFTER DAILY WORK 3-101
LOCKING 3-101
ROAD LINERS AND RUBBER SHOES 3-102
TRANSPORTATION 3-107
TRANSPORTATION PROCEDURE 3-107
LOADING AND UNLOADING WITH TRAILER 3-107
LIFTING MACHINE 3-113
COLD WEATHER OPERATION 3-115
COLD WEATHER OPERATION INFORMATION 3-115
AFTER DAILY WORK COMPLETION 3-117
AFTER COLD WEATHER SEASON 3-117
LONG TERM STORAGE 3-118
BEFORE STORAGE 3-118
DURING STORAGE 3-118
AFTER STORAGE 3-118
TROUBLES AND ACTIONS 3-119
RUNNING OUT OF FUEL 3-119
PHENOMENA THAT ARE NOT FAILURES 3-119
TOWING THE MACHINE 3-119
SEVERE JOB CONDITION 3-120
DISCHARGED BATTERY 3-120
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY 3-124
OTHER TROUBLE 3-125
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
LUBRICANTS, COOLANT AND FILTERS 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
ELECTRIC SYSTEM MAINTENANCE 4- 7
WEAR PARTS 4- 8
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CONTENTS FOREWORD
WEAR PARTS LIST 4- 8

LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 4- 9
PROPER SELECTION 4- 9
TIGHTENING TORQUE SPECIFICATIONS 4- 13
TIGHTENING TORQUE LIST 4- 13
SAFETY CRITICAL PARTS 4- 14
SAFETY CRITICAL PARTS LIST 4- 14
MAINTENANCE SCHEDULE 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 16
MAINTENANCE PROCEDURE 4- 17
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4- 17
WHEN REQUIRED 4- 18
CHECK BEFORE STARTING 4- 49
EVERY 50 HOURS MAINTENANCE 4- 50
EVERY 4000 HOURS MAINTENENCE 4- 72
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION 6- 2
SAFETY FIRST 6- 2
ATTACHMENT INSTALLATION 6- 3
BUCKET WITH HOOK 6- 4
HOOK CONDITION 6- 4
PROHIBITED OPERATIONS 6- 4
MACHINE READY FOR ATTACHMENT 6- 5
LOCATIONS 6- 5
HYDRAULIC CIRCUIT 6- 7
ATTACHMENT OPERATIONS 6- 8
LONG TERM STORAGE 6- 10
SPECIFICATIONS 6- 10
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) 6- 11
CONTROL PATTERN CHANGE PROCEDURE 6- 11
MACHINE CONTROL PATTERNS 6- 12
ATTACHMENT GUIDE 6- 13
OTHER ATTACHMENTS 6- 13
ATTACHMENT COMBINATIONS 6- 14
RECOMMENDED ATTACHMENT OPERATIONS 6- 15
HYDRAULIC BREAKER 6- 15
INDEX 7- 1
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SAFETY INFORMATION SAFETY
SAFETY INFORMATION
WARNING LABELS AND PICTOGRAMS 2- 4
WARNING LABELS AND PICTOGRAMS - LOCATION 2- 5
WARNING LABELS AND PICTOGRAMS - ACTUAL 2- 6
SAFETY INFORMATION
Safety rules 2- 11
If abnormalities are found 2- 11
Working wear and personal protective items 2- 11
Fire extinguisher and first aid kit 2- 11
Safety equipment 2- 11
Keep machine clean 2- 12
Keep operator's compartment clean 2- 12
Leaving operator's seat with lock 2- 12
Handrails and steps 2- 13
Mounting and dismounting 2- 13
No persons on attachments 2- 13
Do not get c aught in articulated position 2- 13
Burn prevention 2- 14
Fire prevention and explosion prevention 2- 14
Action if fire occurs 2- 15
Windshield Washer Fluid 2- 15
Falling objects, flying objects and intruding objects prevention 2- 15
Attachment installation 2- 16
Attachment combinations 2- 16
Cab widow glasses 2- 16
Unauthorized modifications 2- 16
Safety at jobsite 2- 16
Working on loose ground 2- 16
Distance to high voltage cables 2- 17
Ensure good visibility 2- 17
Ventilation for enclosed area 2- 17
Signalman's signal and signs 2- 18
Emergency exit from operator's cab 2- 18
Asbestos dust hazard prevention 2- 18
2-2
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SAFETY SAFETY INFORMATION
SAFETY MACHINE OPERATION 2- 19

Checks before starting engine 2- 19
Safety rules for starting engine 2- 19
Starting engine in cold weather 2- 20
OPERATION 2- 21
Checks before operation 2- 21
Safety rules for changing machine directions 2- 21
Safety rules for traveling 2- 22
Traveling on slopes 2- 23
Operations on slopes 2- 24
Prohibited operations 2- 24
Operations on snow 2- 25
Parking machine 2- 26
TRANSPORTATION 2- 27
Loading and unloading 2- 27
Shipping the machine 2- 27
BATTERY 2- 28
Battery hazard prevention 2- 28
Starting engine with booster cables 2- 29
TOWING 2- 30
Safety rules for towing 2- 30
LIFTING OBJECTS WITH BUCKET 2- 31
Safety rules for lifting objects 2- 31
SAFETY MAINTENANCE INFORMATION 2- 32

Warning tag 2- 32
Keep work place clean and tidy 2- 32
Appoint leader when working with others 2- 32
Stop engine before carrying out maintenance 2- 32
Two workers for maintenance when engine is running 2- 33
Proper tools 2- 34
Personnel 2- 34
Attachments 2- 34
Work under the machine 2- 34
Noise 2- 34
When using hammer 2- 35
Welding works 2- 35
Removing battery terminals 2- 35
Safety first when using high-pressure grease to adjust track tension 2- 35
Do not disassemble recoil springs 2- 35
Safety rules for high-pressure oil 2- 36
Safety handling high-pressure hoses 2- 36
Waste materials 2- 36
Air conditioner maintenance 2- 36
Compressed air 2- 37
Periodic replacement of safety critical parts 2- 37
2-3
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WARNING LABELS AND PICTOGRAMS SAFETY
WARNING LABELS AND PICTOGRAMS

The following warning signes and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly. Be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline, there may cause the labels to
peel off.
There are also other labels in addition to the warning signes 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 manual or the actual label, and place an order with Komatsu distributor.
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SAFETY WARNING LABELS AND PICTOGRAMS
WARNING LABELS AND PICTOGRAMS - LOCATION
2-5
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WARNING LABELS AND PICTOGRAMS - ACTUAL

(1) Precautions for operation, inspection and (2) Precautions for before operation (09802-03000)
maintenance (09651-03001)
(3) Warning for leaving operator's seat (09654-03001) (4) Warnings for high voltage (09801-03001)
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(5) Precautions for operating pattern (6) Precautions for operating pattern (if equipped)
Standard machine (09822-03000) Machine equipped with operating pattern selector
valve (21W-98-44220)
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(7) Precautions for opening the window (8) Precautions for stowage (09803-03000)
(09839-03000)
(9) Precautions for broken or becomes dislodged to (10) Precautions when switching operating pattern
the window (20U-98-21910) (22M-98-11180)
(machines equipped with operating pattern
selector valve)
2-8
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(11) Precautions for high-temperature cooling water (12) Precautions for high-temperature hydraulic oil
(14X-98-11531) (09653-03001)
(13) Precautions for high-temperature parts (14) Precautions for check and adjust track tension
(09817-A0753) (09657-03003)
2-9
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(15) Precautions for handling electric wires (16) Precautions for opening engine hood
(09808-03000) (09667-03001)
(17) Prohibited to enter range of swing (09133-23000) (18) Precautions when handling battery
(09664-30082)
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 - 10
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SAFETY INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.
If Abnormalities are Found

If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been
corrected.
Working Wear and Personal Protective Items

Do not wear loose clothing and accessories. There is a hazard
that they 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 the machine.
Check that all protective equipment functions properly before
using it.
Fire Extinguisher and First Aid Kit

Always follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read the
labels to ensure that you know how to use them in emergencies.
Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
Provide a first aid kit at the storage point. Carry out periodic
checks and add to the contents if necessary.
Safety Equipment
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
2 - 11
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Keep Machine Clean

If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. Do not use water or
steam to wash the electrical system (sensors, connectors).
If inspection and maintenance is carried out when the machine
is still dirty with mud or oil, there is a hazard that you will slip and
fall, or that dirt or mud will get into your eyes. Always keep the
machine clean.
Keep Operator's Compartment Clean

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
Do not leave parts or tools lying around the operator's compartment.
Do not stick suction pads to the window glass. Suction 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 cab.
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
removing or installing the bottom window, or when adjusting the
operator's seat), lower the work equipment completely to the
ground, set safety lock lever (1) securely to the LOCK position,
then stop the engine. If you accidentally touch the levers when
they are not locked, there is a hazard that the machine may
suddenly move and cause serious injury or property damage.
When leaving the machine, always lower the work equipment

completely to the ground, set safety lock lever (1) securely to the
LOCK position, then stop the engine. Use the key to lock all the
equipment. Always remove the key, take it with you, and keep it
in the specified place.
2 - 12
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Handrails and Steps

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the handrails and steps marked by arrows in the diagram on
the right when getting on or off the machine.
To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands and
one foot) with the handrails and steps (including the track shoe)
to ensure that you support yourself.
Do not grip the control levers when getting on or off the machine.
Never climb on the engine hood or covers where there are no
non-slip pads.
Before getting on or off the machine, check the handrails and
steps (including 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 there is no operator on the machine, do not jump on to the machine and try
to stop it.
No Persons on Attachments
Never let anyone ride on the bucket, grapple, clamshell, or other attachments. There is a hazard of falling and
suffering serious injury.
Do Not Get Caught In Articulated Portion

The clearance around the work equipment will change according to the movement of the link. If you get caught, this
may lead to serious personal injury. Do not allow anyone to approach any rotating or telescoping part.
2 - 13
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Burn Prevention
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to at temperature where
it is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the
cap or plug slowly to relieve the internal pressure before
removing the cap or plug.
Fire Prevention and Explosion Prevention

Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
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 persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
2 - 14
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Fire coming from electric wiring

Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair
or replace any damaged wiring.
Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the
hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may
cause serious injury.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.
Action If Fire Occurs

If a fire occurs, escape from the machine 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 objects may hit or enter the operator's cab,
consider the operating conditions and install the necessary guards
to protect the operator.
When carrying out demolition or breaker operations, install a
front guard and use a laminated coating sheet on the front glass.
When working in mines or quarries where there is a hazard of
falling rock, install FOPS (Falling Objects Protective Structure)
and a front guard, and use a laminated coating sheet on the front
glass.
When carrying out the above operations, always close the front
window. In addition, always ensure that by standers are a safe
distance away and are not in hazard from falling or flying
objects.
The above recommendations assume that the conditions are for
standard operations, but it may be necessary to add additional
guards according to the operating conditions on the jobsite.
Always contact your Komatsu distributor for advice.
2 - 15
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Attachment Installation
When installing optional parts or attachments, there may be problems with safety or legal restrictions, Therefore
contact your Komatsu distributor for advice.
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be
the responsibility of Komatsu.
When installing and using optional attachments, read the instruction manual for the attachment, and the general
information related to attachments in this manual.
Attachment Combinations
Depending on the type or combination of work equipment, there is a hazard that the work equipment may hit the cab
or other parts of the machine. Before using unfamiliar work equipment, check if there is any hazard of interference,
and operate with caution.
Cab Window Glasses

If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact the
operator's body directly. Stop operation immediately and replace the glass.
Unauthorized Modifications
Any modification mode without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications made
without authorization from Komatsu.
Safety at Jobsite
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there
is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not carry out operations at places where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
Working on Loose Ground

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after
earthquakes is weak in these areas.
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the
machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe
and to prevent the machine from rolling over or falling.
2 - 16
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Distance to High Voltage Cables

Do not travel or operate the machine near electric cables. There is
a hazard of electric shock, which may cause serious injury or
property damage. On jobsites where the machine may go close to
electric cables, always do as follows.
Before starting work near electric cables, inform the local power
company of the work to be performed, and ask them to take the
necessary action.
Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death. Always Voltage of
Safety Distance
maintain a safe distance (see the table on the right) between the
Cables
machine and the electric cable. Check with the local power
Voltage
100 V - 200 V Over 2 m (7ft)
Low
company about safe operating procedure before starting
6,600 V Over 2 m (7ft)
operations.
To prepare for any possible emergencies, wear rubber shoes 22,000 V Over 3 m (10 ft)
Extra-high Voltage
and gloves. Lay a rubber sheet on top of the seat, and be careful 66,000 V Over 4 m (14 ft)
not to touch the chassis with any exposed part of your body. 154,000 V Over 5 m (17 ft)
Use a signalman to give warning if the machine approaches too
187,000 V Over 6 m (20 ft)
close to the electric cables.
275,000 V Over 7 m (23 ft)
When carrying out operations near high voltage cables, do not
let anyone come close to the machine. 500,000 V Over 11 m (36 ft)
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.
Ensure Good Visibility

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure
that operations and travel can be carried out safely. Always do as follows.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
Ventilation for Enclosed Area

Exhaust fumes from the engine can kill.
If it is necessary to start the engine within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to
prevent gas poisoning.
2 - 17
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Signalman's Signal and Signs

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
Emergency Exit from Operator's Cab

If for any reason, it becomes impossible to open the cab door, use the hammer supplied to break the window and
use it as an emergency escape.
For details, see "EMERGENCY ESCAPE HAMMER (PAGE 3-31)" 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 asbestos when working on jobsites handling
demolition work or work handling industrial waste. Always observe
the following.
Spray water to keep down the dust when cleaning. Do not use
compressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position. All
workers should use an approved respirator.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use
genuine Komatsu parts.
2 - 18
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SAFETY SAFETY MACHINE OPERATION
SAFETY MACHINE OPERATION

STARTING ENGINE
If there is a warning tag hanging from the work equipment control
lever, do not start the engine or touch the levers .
Checks Before Starting Engine

Carry out the following checks before starting the engine at the beginning of the day's work.
Remove all dirt from the surface of the window glass to ensure a good view.
Remove all dirt from the surface of the lens of the working lamps, and check that they light up correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check
for damage to the electric wiring.
Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no damage
or wear to the seat belt or mounting clamps.
Check that the gauges work properly, check the angle of the lights and working lamps, and check that the control
levers are all at the neutral position.
Before starting the engine, make sure that the safety lock lever is in the LOCK position.
Adjust the angle of the rearview mirror so that viewed from the operator's seat, the rear lower part of the machine
(whose view is usually blocked by the engine hood) can be clearly seen. For this adjustment, see the section of
"Rearview Mirrors (PAGE 3-66)" in this manual.
Check that there are no persons or obstacles above, below, or in the area around the machine.
Safety Rules for Starting Engine

When starting the engine, sound the horn as a warning.
Start and operate the machine only while seated.
Do not allow anyone apart from the operator to ride on the machine.
Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause
damage to the equipment.
2 - 19
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SAFETY MACHINE OPERATION SAFETY
Starting Engine in Cold Weather

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check for
frost and leakage of battery electrolyte before starting.
2 - 20
.
OPERATION
Checks Before Operation

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
Always fasten your seat belt.
Check that the movement of the machine matches the display on the control pattern card. If it does not match,
replace it immediately with the correct control pattern card.
Check the operation of the work equipment, traval system and swing system.
Check for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check also that there
is no leakage of oil or fuel.
If any abnormality is found, carry out repairs immediately.
Safety Rules for Changing Machine Directions

Position the upper structure so that the sprocket is at the rear of
the operator's cab before traveling.
If the sprocket is at the front of the operator's cab, the direction
of operations is reversed (for example, forward becomes
reverse, and left becomes right).
Before travelling, check again that there is no one in the
surrounding area, and that there are no obstacles.
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the
machine.
Check that the travel alarm works properly.
Always lock the door and windows of the operator's
compartment in position (open or closed).
On jobsites where there is a hazard of flying objects or of objects
entering the operator's compartment, check that the door and
windows are securely closed.
If there is an area to the rear of the machine which cannot be
seen, position a signal person. Take special care not to hit other
machines or people when turning or swinging the machine.
2 - 21
.
Safety Rules for Traveling

It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply.
When traveling on level ground, keep the work equipment at a
height of 40 to 50 cm (1.6 to 2.0 in) from the ground.
When traveling on rough ground, travel at low speed and do not
operate the steering suddenly. There is danger that the machine
may turn over. The work equipment may hit the ground surface
and cause the machine to lose its balance, or may damage the
machine or structures in the area.
Avoid traveling over obstacles when possible. If the machine

has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side.
When traveling or carrying out operations, always keep a safe
distance from people, structures, or other machines to avoid
coming into contact with them.
When passing over bridges or structures, check first that the
structure is strong enough to support the weight of the machine.
When traveling on public roads, check first with the relevant
authorities and follow their instructions.
When operating in tunnels, under bridges, under electric wires,
or other places where the height is limited, operate slowly and
be extremely careful not to let the work equipment hit anything.
2 - 22
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Traveling on Slopes
To prevent the machine from tipping over or slipping to the side,
always do as follows.
Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above
the ground. In case of emergency, lower the work equipment to
the ground immediately to help stop the machine.
When travel up slopes, set the operator's cab facing uphill, when
travel down slopes, set the operator's cab facing downhill.
Always check the firmness of the ground under the front of the
machine when traveling.
When traveling up a steep slope, extend the work equipment to

the front to improve the balance, keep the work equipment
approximately 20 to 30cm (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. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low
speed. Even with slight slopes there is a hazard that the
machine may slip.
If the engine stops when the machine is traveling on a slope,
move the control levers immediately to the neutral position and
start the engine again.
2 - 23
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Operations on Slopes
When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing
or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable
place when carrying out these operations, and operate carefully.
Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation 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 machine. The
ground under the machine may collapse and cause the machine
to fall.
To make it easier to escape if there is any problem, set the

tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations.
2 - 24
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Do not carry out demolition work under the machine. There is a

hazard that the machine may become unstable and tip over.
When working on or from the top of buildings or other structures,
check the strength and the structure before starting operations.
There is a hazard of the building collapsing and causing serious
injury or damage.
When carrying out demolition work, do not carry out demolition

above your head. There is a hazard of broken parts falling or of
the building collapsing and causing serious injury or property
damage.
Do not use the impact force of the work equipment for breaking
work. There is a hazard of personal injury or property damage
being caused by flying pieces of broken material or damage to
the work equipment.
Generally speaking, the machine is more liable to overturn when
the work equipment is at the side than when it is at the front or
rear.
When using a breaker or other heavy work equipment, there is a hazard of the machine 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 spill or the bucket may hit the dump truck and cause serious injury or property damage.
Operations on Snow
Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be
seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations
carefully.
2 - 25
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Parking Machine
Park the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground.
When leaving the machine, set safety lock 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 the
ground.
Put blocks under the tracks to prevent the machine from
moving.
2 - 26
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TRANSPORTATION
The machine can be divided into parts for transportation, so when transportating the machine, please contact your
Komatsu distributor to have the work carried out.
Loading and Unloading

When loading or unloading the machine, mistaken operation may
bring the hazard of the machine tipping over or falling, so particular
care is necessary. Always do as follows.
Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
Never use the work equipment to load or unload the machine.
There is danger that the machine may fall or tip over.
Always use ramps of adequate strength. Be sure that the ramps
are wide, long, and thick enough to provide a safe loading slope.
Take suitable steps to prevent the ramps from moving out of
position or coming off.
Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove dirt from
machine-tracks. On a rainy day, in particular, take extremely careful since the ramp surface is slippery.
Run the engine at low speed and travel slowly.
When on the ramps, do not touch any other parts.
Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the
ramps again.
The center of gravity of the machine will chenge 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 trailer, the trailer is unstable, so pull in the work equipment and swing
slowly. And turn swing lock switch ON to apply swing lock after loading machine.
For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-107)".
After the loading, fasten the machine securely with a wire rope and wooden blocks to prevent the machine from
moving.
Shipping the Machine

When shipping the machine on a trailer, do as follows.
The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
When passing over bridges or structures on private land, check first that the structure is strong enough to support
the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their
instructions.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-107)" in the OPERATION section.
2 - 27
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BATTERY
Battery Hazard Prevention

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause
an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte
level to the UPPER LEVEL line.
When working with batteries, always wear safety glasses and rubber gloves.
Never smoke or use any flame near the battery.
If you spill acid on your clothes or skin, immediately flush the

area with 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 objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.
2 - 28
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Starting Engine with Booster Cables

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting switch
OFF for both the normal machine and problem machine. 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 gloves when starting
the engine with booster cables.
When connecting a normal machine to a problem machine with
booster cables, always use a normal machine with the same
battery voltage as the problem machine.
For details of the starting procedure when using booster cables,
see Starting Engine With Booster Cables (PAGE 3-122) in the
OPERATION section.
2 - 29
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TOWING
Safety Rules for Towing

Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection
or inspection of the wire rope.
For towing, see "TOWING THE MACHINE (PAGE 3-119)".
Always wear leather gloves when handling wire rope.
Fix the wire rope to the track frame.
During the towing operation, never stand between the towing
machine and the machine being towed.
Never tow a machine on a slope.
Put a wooden block in between the wire ropes and the machine
to prevent damage to the machine due to friction.
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.
2 - 30
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LIFTING OBJECTS WITH BUCKET
Safety Rules for Lifting Objects

Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable.
Use wire rope that conforms to the specified standard.
Do not exceed the specified lifting 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 towards the machine.
Do not leave the operator's seat when there is a raised load.
2 - 31
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SAFETY MAINTENANCE INFORMATION SAFETY
SAFETY MAINTENANCE INFORMATION

Warning Tag
Always attach the "DO NOT OPERATE" warning tag to the work
equipment control lever in the operator's cab to alert others that
you are performing service or maintenance on the machine.
Attach additional warning tags around the machine if necessary.
Warning tag Part No. 09963-03001
Keep this warning tag in the tool box while it is not used. If there
is not the tool box, keep the tag in the operation manual pocket.
If others start the engine, or touch or operate the work
equipment control lever while you are performing service or
maintenance, you could suffer serious injury or property
damage.
Keep Work Place Clean and Tidy

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that
will cause you to slip. Always keep the work place clean the 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.
Appoint Leader when Working with Others

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.
Stop Engine Before Carrying Out Maintenance

Stop the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and stop
the engine.
2 - 32
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SAFETY SAFETY MAINTENANCE INFORMATION
Set safety lock lever (1) to the LOCK position.
Put blocks under the track to prevent the machine from moving.
Two Workers for Maintenance when Engine is Running

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and do as
follows.
One worker must always sit in the operator's seat and be ready
to stop the engine at any time. All workers must maintain
contact with the other workers.
Set safety 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 extremely careful.
Do not touch any control levers. If any control lever must be
operated, give a signal to the other workers to warn them to
move to a safe place.
Never drop or insert tools or other objects into the fan or fan belt.
Parts may break or be sent flying.
2 - 33
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Proper Tools
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
Personnel
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
Attachments
Appoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine in
a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.
Work Under the Machine

If it is necessary to go under the work equipment or the machine
to carry out service and maintenance, support the work
equipment and machine securely with blocks and stands strong
enough to support the weight of the work equipment and
machine.
It is extremely dangerous to work under the machine if the track
shoes are off the ground and the machine is supported only by
the work equipment. If the control levers are touched by
mistake, or there is a hazard to the hydraulicline, the work
equipment or the machine may suddenly descend. This is
extremely dangerous. Never work under the machine if the
machine is not properly supported by blocks or stands.
Noise
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers
or ear plugs while working.
2 - 34
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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 teeth, there is a hazard that broken
pieces might be sent flying and injure people in the surrounding
area. Always check that there is no one in the surrounding area.
If pins are hit with strong force, there is a hazard that the pin may
fly out and injure people in the surrounding area.
Welding Works
Welding operations must always be carried out by a qualified welder and in a place equipped with a proper
equipment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
Removing Battery Terminals

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the
battery to prevent the flow of current.
Safety First when Using High-pressure Grease to Adjust Track Tension

Grease is pumped into the track tension adjustment system
under high pressure.
If the specified procedure for maintenance is not followed when
making adjustment, grease drain plug (1) may fly out and cause
serious injury or property damage.
When loosening grease drain plug (1) to loosen the track
tension, never loosen it more than one turn. Loosen the grease
drain plug slowly.
Never put your face, hands, feet, or any other part of your body
close to grease drain plug (1).
Do Not Disassemble Recoil Springs

The recoil spring assembly is used to reduce the impact on the idler. It contains a spring under high pressure, so
if it is disassembled by mistake, the spring will fly out and cause serious injury or even death. Never disassemble
the recoil spring.
2 - 35
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Safety Rules for High-pressure Oil

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury or property damage, 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 wet, so check for cracks in the piping
and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small holes
may penetrate your skin or cause blindness if it contacts your
eyes directly. If you are hit by a jet of high-pressure oil and suffer
injury to your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.
Safety Handling High-pressure Hoses

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or property damage. If any loose bolts are found, stop work and tighten to the specified torque. If any
damaged hoses are found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement layer of wire.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
Waste Materials
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
Air Conditioner Maintenance

(If equipped)
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.
2 - 36
.
Compressed Air
When carrying out cleaning with compressed air, there is a hazard of serious injury or property damage 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

To enable the machine to be used safely for long periods, always periodically add oil and carry out inspection and
maintenance. However, to further increase safety, periodically replace the seat belt, hoses, and other parts which
have a close relationship to safety.
See Replacing critical parts: SAFETY CRITICAL PARTS (PAGE 4-14)
The material of these components naturally changes over time, and repeated use causes deterioration, wear, and
fatigue. As a result, there is a hazard that these components may fail and cause serious injury or property
damage. It is difficult to judge the remaining life of these components from external inspection or the feeling when
operating, so always replace them at the specified interval.
Replace or repair safety critical parts if any defect is found, even when they have not reached the time specified
interval.
2 - 37
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.
3-1
.
MACHINE VIEW ILLUSTRATIONS OPERATION
MACHINE VIEW ILLUSTRATIONS

OVERALL MACHINE VIEW
(1) Bucket (8) Working lamp

(2) Bucket cylinder (9) Sprocket
(3) Arm (10) Track frame
(4) Arm cylinder (11) Track shoe
(5) Boom (12) Idler
(6) Boom cylinder (13) Blade cylinder
(7) Additional lamp (if equipped) (14) Blade
3-2
.
OPERATION MACHINE VIEW ILLUSTRATIONS
CONTROLS AND GAUGES
(1) Car radio (19) Alarm buzzer stop switch

(2) Heater control panel (20) Emergency pump drive switch
(3) Safety lock lever (21) Swing brake cancel switch
(4) Left work equipment control lever (22) Travel speed selector switch
(5) Swift deceleration switch (23) Working mode selector switch
(6) Traveling accelerator pedal (24) Charge level monitor
(7) Travel pedals (25) Engine oil pressure monitor
(8) Travel levers (26) Engine coolant temperature gauge
(9) Attachment control pedal (if equipped) (27) Engine coolant temperature monitor
(10) Ashtray (28) Display (for failure display)
(11) Machine monitor (29) Fuel level monitor
(12) Horn button (30) Fuel gauge
(13) Right work equipment control lever (31) Service meter
(14) Cigarette lighter (32) Pre-heating monitor
(15) Blade control lever (33) Swift deceleration pilot lamp
(16) Starting switch (34) Wiper switch
(17) Fuel control dial (35) Window washer switch
(18) Lamp switch
3-3
.
DETAILED CONTROLS AND GAUGES OPERATION
DETAILED CONTROLS AND GAUGES

The following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the
equipment and the meanings of the displays.
MONITORING SYSTEM
A: Caution monitors C: Meter display portion

B: Emergency monitors D: Monitor switch portion
3-4
.
OPERATION DETAILED CONTROLS AND GAUGES
Caution Monitors
CAUTION
If the warning monitor flashes, check the problem point as soon as possible and carry out maintenance. Failure to repair the
problem will lead to failure of the machine.
These are items which need to be observed when the engine is running. If any abnormality occurs, the item needing
immediate repair is display.
If any abnormality occurs on the machine, the relative monitor 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 an abnormality in the charging system
while the engine is running.
If the monitor lamp flashes, check the V-belt tension. If any
abnormality is found, see "OTHER TROUBLE (PAGE 3-125)".
If the monitor flashes, stop the engine immediately or run at low

idling, then inspect the problem point immediately and repair the
problem.
REMARK
This lamp will light up if the starting switch is turned ON when
the engine is stopped, but this does not indicate any
abnormality.
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 abnormality.
3-5
.
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
.
Emergency Monitors
CAUTION
If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point immediately and repair the
problem.
These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal
location on the monitor will lights up and the buzzer will second. 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
cooling water temperature.
When the temperature abnormally goes up, it begins to flash. Then
stop the work and keep the engine running at low idling until after
the engine cooling water temperature gauge returns to the green
range.
3-7
.
Engine Oil Pressure Monitor

If the engine lubricating pressure is below the normal value, this
monitor (2) flashes. If it flashes, stop the engine, 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
abnormality.
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 abnormality.
3-8
.
Meter Display Portion
Pilot Display Meter

(1) Engine pre-heating monitor (3) Engine coolant temperature gauge
(2) Swift deceleration monitor (4) Fuel gauge
(5) Display
(6) Service meter
Pilot Display
When the starting switch is ON, the pilot display lights up when the 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. (The monitor
lamp will go off after about 10 seconds)
Swift Deceleration Monitor

This monitor (2) informs the operator that the swift deceleration
function is being actuated.
Actuated: Lights up
Canceled: Goes off
When the swift deceleration switch is pressed, the swift

deceleration display monitor lights up. When it is pressed again,
the monitor goes off.
3-9
.
REMARK
When the swift deceleration monitor is lights up, the engine speed remains at low idling even if the fuel control dial
is operated.
Gauges and Meter
Engine Coolant Temperature Gauge

This meter (3) shows the engine cooling water temperature.
During normal operation, the lamp should light up in the green
range (A).
If the lamp in the red range (B) lights up during operation, run the
engine at low idling and wait for the temperature to go down to the
green range (A).
After starting the engine, continue to warm it up until the engine
cooling water temperature rises from white range (C) to green
range (A) in the gauge.
REMARK
When Segment (D) lights up, engine cooling water temperature
monitor lamp (F) begins to flash, too.
When Segment (E) lights up, engine cooling water temperature
monitor lamp (F) begins to flash, too. At the same time, the
alarming buzzer begins to sound.
Fuel Gauge
This meter (4) shows the fuel level in the fuel tank. During normal
operation, the lamp should light up in the green range (A).
If the lamp in the red range (B) flashes during operation, there isles
than 42 liters (11.10 US gal) of fuel remaining, so check and add
fuel.
The correct level may not be displayed for a short time after the
starting switch is turned to the ON position, but this is not an
abnormality.
REMARK
When red range (B) in the fuel gauge lights up, fuel level monitor
(C) begins to flash, too.
3 - 10
.
Display
This monitor (5) serves to display failure contents, if any
abnormality occurs on the machine.
REMARK
If the machine has a fault, error information appears while the
starting switch is ON. The monitor flashes and displays all error
information sequentially.
If the right displays flashes, see "Electronic Control System (PAGE

Monitor
3-129)". Error mode
indications
E02 Pump control system error
E03 Swing brake 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 id
the machine is not traveling.
The meter will advance by 1 for each 1/10 hour of operation

regardless of the engine speed
3 - 11
.
Monitor Switches Portion
(1) Working mode selector switch (3) Wiper switch

(2) Travel speed selector switch (4) Window washer switch
Working Mode Selector Switch

This switch (1) is used to set the power and movement of the work
equipment.
Operations can be carried out more easily by selecting the mode
to match the type of operation.
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 automatically set.
3 - 12
.
Travel Speed Selector Switch
WARNING
When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the
loading or unloading operation.
If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even
when traveling in a straight line.
Stop the machine before switching the travel speed.
This switch (2) is used to select high or low travel speed.
Lo position: Low speed travel

Hi position: High speed travel
The travel speed is changed every time the switch is depressed.
REMARK
When the engine is started, it is automatically set to Lo speed
travel.
When traveling at high speed (Hi), if travel power is needed
when traveling on soft ground or slopes, the travel speed is
automatically set to low speed travel (Lo), so there is no need to
operate this switch. On the monitor display, the Hi (high speed)
lamp stays lighted up.
Wiper Switch
This switch (3) actuates the front window wiper.
ON lights 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 → inter

mittent → continuous → stop, ever time the switch is depressed.
3 - 13
.
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 kept pressed when the wiper is stopped,

thewindow washer fluid will spray out, and at the same time, the
wiper will be actuated continuously. When switch (4) is released,
the wiper will continue to operate continuously for 2 cycles, and
will then stop.
If the wiper is moving intermittently and switch (4) is kept
pressed continuously, the window washer fluid will spray out,
and at the same time, the wiper will be actuated con-tinuously.
When switch (4) is released, the wiper will con-tinue to operate
continuously for 2 cycles, and will then return to intermittent
operation.
3 - 14
.
SWITCHES
(1) Starting switch (6) Alarm buzzer stop switch

(2) Fuel control dial (7) Emergency pump drive switch
(3) Swift deceleration switch (8) Swing brake cancel switch
(4) Horn button (9) Room lamp switch
(5) Lamp switch (10) Cigarette lighter
Starting Switch
This switch (1) is used to start or stop the engine.
OFF position
The key can be inserted or withdrawn. The switches for the electric
system except the room lamp and service meter are all turned off
and the engine is stopped.
ON position
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 (preheat) position

When starting engine in cold weather, set the key to this position. When the key is set to the HEAT position, the
pre-heating monitor lights up. Keep the key at this position until the monitor lamp flashes. Immediately after the
pre-heating monitor flashes, release the key. The key automatically returns to the OFF position. Then, start the
engine by turning the key to the START position.
3 - 15
.
REMARK
The engine does not start, if the safety lock lever is not in the LOCK
position. Make sure first that the safety lock lever is in the LOCK
position, and then move the engine starting switch.
Fuel Control Dial

This dial (2) is used to control engine speed and output.
(a) Low idling position: The dial is turned to the left
(counterclockwise) fully.
(b) High idling position: The dial is turned to the right (clockwise)
fully.
REMARK
When the swift deceleration monitor is lighted up, the engine speed
will remain at low idling even if the dial is operated. To restore
engine speed, press swift deceleration switch on the left work
equipment control lever to cancel the deceleration 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 is not required, such as when the travel levers, travel pedals and work equipment control levers are
at the neutral position.
When the swift deceleration switch in the center of the knob of the
left work equipment control lever is pressed, the swift deceleration
monitor lights up and the engine speed goes down to low idling.
When the swift deceleration switch is pressed again, the
deceleration monitor goes off, and the engine speed turns to the
speed set by the fuel control dial.
3 - 16
.
REMARK
When fuel control dial is at the low idling position, the engine speed will not go down any lower even if this switch
is pressed.
If the engine speed does not rise, it is possible that this switch is ON. Lock at the swift deceleration monitor to
check the condition 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 engine is running) to stop the
alarm buzzer when it has sounded to warn of an abnormality in a
warning item.
3 - 17
.
Pump Drive Emergency Switch

NOTICE
This switch is installed to make it possible to carry out operation temporarily if any abnormality should occur in the pump
control system. It is not intended for permanent use. Repair the cause of the abnormality immediately.
If this switch is depressed and moved to the EMERGENCY position by mistake, thereby engaging the machine in the work,
while the machine is in normal condition, an "E02" mark is shown in the display.
If "E02" is displayed during the work, check that the switch is in the NORMAL position.
This switch (7) is used to make it possible to carry out opera-tions

temporarily if any abnormality should occur in the pump control
system (when the display shows "E02").
(a) EMERGENCY: When abnormal (move switch up)

(b) NORMAL: When normal (move switch down)
If the display shows "E02", move the switch up to make it possible

to carry out work.
Swing Brake Cancal Switch

NOTICE
This switch is installed to make it possible to carry out operation temporarily if any abnormality should occur in the swing brake
system. It is not intended for permanent use. Repair the cause of the abnormality immediately.
If this switch is depressed and moved to the EMERGENCY position by mistake, thereby engaging the machine in the work,
while the machine is in normal condition, an "E03" mark is shown in the display.
If "E03" is displayed during the work, check that the switch is in the NORMAL position.
This switch (8) is used to make it possible to carry out operations

temporarily if any abnormality should occur in the swing brake
system (when the display shows "E03").
(a) EMERGENCY: When abnormal (move switch up)

(b) NORMAL: When normal (move switch down)
If the display shows "E03", move the switch up to make it possible

to carry out work.
3 - 18
.
Room Lamp Switch

NOTICE
Be sure to switch the lamp to the OFF position after use.
If the switch is left at the ON position, the battery will run down.
This switch (9) is used to light up the room lamp.

ON position: Lights up
OFF position: Goes off
REMARK
Even when the engine-starting switch is in the OFF position, the
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 origi-nal 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 power
source for electric equipment of 12 V type, otherwise they will likely be
damaged.
The capacity of this cigarette lighter is 85 W (24 V X 3.5 A).
3 - 19
.
CONTROL LEVERS AND PEDALS
(1) Safety lock lever (4) Blade control lever

(2) Left work equipment control lever (5) Travel levers (machines with travel pedals)
(3) Right work equipment control lever (6) Traveling accelerator pedal
Safety Lock Lever
WARNING
When leaving the operator's cab, be sure to move the safety lock lever to the LOCK position. If the safety lock lever is not in
the LOCK position and a control lever is touched accidentally, that may cause a serious bodily injury.
If the safety lock lever is not secured in the LOCK position, it may cause a serious bodily injury. Check that the lever is in the
illustrated position.
Be careful not to accidentally touch the work equipment control lever while pulling up the safety lock lever.
Be careful not to accidentally touch the work equipment control lever while pushing down the safety lock 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 safety lock lever is of a hydraulic locking type. Even if it is put
to the LOCK position, the work equipment control lever and travel
control lever can be moved, but neither machine nor the work
equipment moves.
REMARK
position. Make sure first that the safety lock lever is in the LOCK
position, and then move the engine starting switch.
3 - 20
.
Work Equipment Control Lever
WARNING
The operating pattern is set to the standard operating pattern (ISO
pattern).
When changing the operating pattern, please contact your Komatsu
distributor.
The method of using operating patterns other than the ISO pattern is
given in the ATTACHMENT AND OPTIONS section. Always read and
understand the contents before operating the machine.
When changing the operating pattern, change the operating plate at the
same 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.
Arm operation Swing operation
(a) Swing to right
(b) Swing to left
(c) Arm IN
(d) Arm OUT
N (Neutral): The upper structure and arm are held in position and
do not move.
This Right work equipment control lever(3) is used to operate the

arm and upper structure.
Boom operation Bucket operation
(e) RAISE
(f) LOWER
(g) DUMP
(h) CURL
N (Neutral): The boom and bucket are held in position and do not
move.
3 - 21
.
Blade Control Lever

This lever (4) is used to control the blade.
(a): LOWER
(b): RAISE
Travel Levers
WARNING
Do not put your foot on the pedal unless the machine is traveling. If you
leave your foot on the pedal and press it by mistake, the machine will
move suddenly, and this may lead to a serious accident. Do not rest a
foot on the pedal except when traveling or steering the machine, using
the pedal.
If the track frame is facing the rear, the direction of travel operations will
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.
( ): This indicates operation of the pedal.

(a) FORWARD: This lever is pushed forward
(This pedal is angled forward)
(b) REVERSE: This lever is pulled back
(The pedal is angled back)
N (Neutral): The machine stops
REMARK
Machines equipped with travel alarm
If the lever is shifted to the advance or reverse position from the
neutral position, the alarm sounds to warn that the machine is
starting to advance
3 - 22
.
Traveling Accelerator Pedal

If the pedal (6) is depressed, the machine speed will increase.
For 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
.
SUN ROOF
WARNING
When leaving the operator's compartment, set the safety lock lever securely to the LOCK position.
If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident.
When opening or closing the roof hatch, 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 safety 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). If the locks do not engage properly, open the ceiling once
again and try to shut it.
3 - 24
.
WINDSHIELD
WARNING
When opening or closing the front window, bottom window, or door,
always set the safety lock lever to the LOCK position.
If the control levers are not locked and they are touched by accident,
this may lead to a serious accident.
When opening or closing the window at the front of the cab, stop the
machine on horizontal ground, lower the work equipment completely to
the ground, stop the engine, then carry out the operation.
When opening the front window, hold 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, the window will move quicker under its
own weight. Hold the grips securely with both hands when closing it.
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.
3. Check that the wiper blade is stowed in the right stay.
4. Grip knobs (A) at the top, bottom, left, and right of the front
window, and pull lock lever (B) to release the lock at the top of
the front window. The top of the front window will come out.
3 - 25
.
5. Hold lower knob (C) with your left hand from inside the
operator's cab, and with your right hand, grip top knob (D), pull
it up, and push it against lock catch (E) at the rear of the cab
securely to lock the window.
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 the lock.
3 - 26
.
Closing
WARNING
When closing the window, lower it slowly and be careful not to get your hand caught.
1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine.
3. Grip left and right knobs (A), and pull down lock lever (B) to
release the lock.
4. Grip knob (C) at the bottom of the front window with your left
hand and knob (D) at the top with your right hand, push to the
front, then lower slowly.
3 - 27
.
5. When the bottom of the window reaches the top of the bottom
window, push the top of the window to the front to push it
against left and right lock catches (G) and engage the lock.
6. 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 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 on the inside left of

the operator's cab, then lock securely in position with lock lever
(B). The procedure for stowing is as follows.
3 - 28
.
1) Set the hollow in the glass at the front face, set the
protruding part of grip (A) on the inside, and insert between
the left switch lever box and magazine 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 the LOCK (CLOSED) position.
3 - 29
.
SLIDING DOOR
CAUTION
Be sure to check that the sliding door is locked in position both when it
is open and when it is closed.
Always stop the machine on level ground when opening or closing the
door.
If the door is opened or closed on a slope, there is danger that the
operating effort will suddenly change. Do not open or close the door on
slopes.
When opening or closing the door, always use door handle (1) and knob
(2).
Be careful not to get your hands caught between the front pillar or
center 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.
3 - 30
.
EMERGENCY ESCAPE HAMMER

CAUTION
When you are obliged to break the window glass pane with a hammer, take good care not to get hurt with flying glass shards.
Before getting out of the operator's cab, remove glass fragments remained in the windowsills not to get hurt with them.
Moreover watch your step not to slip over the broken glasses scattered on the ground.
To prevent injury from pieces of glass, remove all the broken glass from the window frame. Be careful also not to slip on the
broken glass that has fallen to the ground.
If it should become impossible to open the cab door for any reason,
and it is necessary to make an emergency escape from the
operator's compartment, use hammer (A) to escape.
To escape from the operator's cab, use hammer (A) to break the
glass and escape through the window.
3 - 31
.
CAP WITH LOCK

Use the starting key to open and close the locks on the caps and
covers.
For details of the locations of the caps and covers with locks, see
"LOCKING (PAGE 3-101)".
Insert the key as far as it will go, then turn it. If the key is turned
before it is inserted fully, it may break.
Opening and Closing Caps with Lock
Opening 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 open the cover by pulling
the cover grip.
Locking the Cover

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and take the key out.
3 - 32
.
ENGINE HOOD
WARNING
Never attempt to climb on the engine hood. There is the danger that you may slip off.
When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine
hood open.
NOTICE
Always keep 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 (3), fit it
securely in the lever lock, then lower the hood slowly and push
it down to lock it.
3 - 33
.
MUD COVER
WARNING
Never attempt to climb on the cover. There is the danger that you may slip off.
When carrying out inspection and maintenance inside the cover, always use the cover support lever to hold the cover open.
NOTICE
Always keep 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 mud cover.

(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 cover (2), remove cover support lever (3) or (4),
fit it securely in the lever lock, then lower the cover slowly and
push it down to lock it.
3 - 34
.
BATTERY INSPECTION COVER

CAUTION
When carrying out inspection and maintenance inside the cover, always use the cover support lever to hold the cover open.
NOTICE
Always keep the door locked except when opening it.
1. Release lock (1) of door.
(PAGE 3-32)".)
2. Put a finger in hook (2) and pull cover (3) open.
3. To open cover (3), pull it toward yourself, then detach cover

support lever (4) from spring catcher (5) and push it in the
frame hole.
4. To close cover (3), lift up cover support lever (4), fix it to spring
catcher (5) and close it.
5. Do not forget to lock the door.
3 - 35
.
FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
The fuse box is provided behind the left console box.
Fuse Capacities and Circuit Names
Fuse
No. Name of circuit
capacity
(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 PPC oil pressure lock solenoid
(13) 10A Monitor panel
(14) 10A Spare
(15) 15A Key stop solenoid
(16) 5A Radio back up
(17) 10A Air conditioner back up
(18) 10A Monitor, KOMTRAX
(19) 5A Room lamp
(20) 30A Starting switch (B)
3 - 36
.
FUSIBLELINK
If power is not supplied even after turning the engine starting switch
ON, fusible link (1) is suspected of disconnection. In that case,
open up the dust cover on the right side of the machine, check and
replace it if necessary.
REMARK
A fusible link refers to the large-sized fuse wiring installed in the
high current flow portion of the circuit to protect electrical
components and wiring from burning, in the same way as an
ordinary fuse.
AUXILIARY ELECTRIC POWER

NOTICE
When installing electrical not supplied by Komatsu, use 24 V specifications with a maximum of 600 W (equivalent to 25 A). If
equipment is to be installed with a capacity greater than this, please contact your 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) Terminal

Body Rear holder AVS 0.5 - 1.25 AVS 2 - 3
Komatsu part No. 08055-00212 08055-00230 08055-00040 08055-00041
REMARK
Power may be sourced from the cigarette lighter, too. For the details, see the section of "Cigarette Lighter (PAGE
3-19)" in this manual.
CONTROLLERS
NOTICE
Do not let water, mud, or juice spill on the controller.This will cause
failures.
If any abnormality occurs in the controller,do not repair it by yourself.
Please contact your Komatsu distributor for repairs.
The controller is installed behind the operator's seat.
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HEATER AND DEFROSTAR CONTROLS
Heater and Defroster Control Panel
(1) Vent selector switch (4) Air flow selector switch

(2) FRESH/RECIRC selector switch (5) OFF switch
(3) Temperature control switch (6) 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 - 38
.
Vent Selector 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 - 39
.
FRESH/RECIRC Selector Switch (Fresh)

When switch (2) is pressed, fresh air is taken into the cab during
heating. This position is used to bring in clean fresh air into the cab
or to remove the mist from the cab windows.
FRESH/RECIRC Selector Switch (Recirclate)

When switch (2) is pressed, the air inside the cab is recalculated
and no fresh air is taken in from outside. This position is used when
heating the cab quickly 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)

Use switch (3) to reduce the temperature.
Press this switch to reduce the temperature of the air sent from the
heater.
The more times the switch is pressed, the lower the blowing wind
temperature becomes, as the indicator light moves to the left.
3 - 40
.
Temperature Control Switch (Warm)

Use switch (3) to increase the temperature.
Press this switch to increase the temperature of the air sent from
the heater.
The more times the switch is pressed, the upper the blowing wind
temperature becomes, as the indicator light moves to the right.
Air Flow Selector Switch

The further it is moved into the LO range (rear of machine), the
smaller the air flow becomes; the further it is moved into the HI
range (front of machine), the greater the air flow becomes.
he 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 Flow Selector Switch (Hi)

Switch (2) is used to set the flow of air from the heater to High.
Press this switch to increase the air flow. The further it is moved
into the HI range (front of machine), the greater the air flow
becomes.
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.
Off Switch
Switch (5) is used to stop operation of heater function.
Defroster Selector Lever

Switch (6) is used to remove the mist from the front glass during
cold or rainy weather.
Selector lever to front: To defroster (open)
Selector lever to rear: Closed
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 heater for a long time, carry out ventilation and cooling together once an hour.
3 - 42
.
AIR CONDITIONER CONTROLS

(If equipped)
Air Conditioner Control Panel
(1) Vent selector switch (5) Air conditioner switch

(2) FRESH/RECIRC selector switch (6) Off switch
(3) Temperature control switch (7) Defroster selector lever
(4) Air flow selector switch
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 - 43
.
Vent Selector Switch (ir Flow to Upper Part of Body and 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 - 44
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Air Circulation Selector Switch (External Air Circulation)

When switch (2) is pressed, fresh air is taken into the cab during
heating or cooling.
This position is used to bring in clean fresh air into the cab or to
remove the mist from the cab windows.
Air Circulation Selector Switch (Internal Air Circulation)

When switch (2) is pressed, the air inside the cab is recalculated
and no fresh air is taken in from outside. This position 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 changes sleeplessly.
Use switch (3) to reduce the temperature.

Press this switch to reduce the temperature of the air sent from the
air conditioner.
temperature becomes, as the indicator light moves to the "C".
3 - 45
.
Temperature Control Switch (Heating)

Use switch (3) to increase the temperature.
Press this switch to increase the temperature of the air sent from
the air conditioner.
temperature becomes, as the indicator light moves to the "H".
Aie Flow Selector Switch

The further it is moved into the LO range (rear of machine), the
smaller the air flow becomes; the further it is moved into the HI
range (front of machine), the greater the air flow becomes.
he 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)

Switch (2) is used to set the flow of air from the air conditioner to
High.
Press this switch to increase the air flow. The further it is moved
into the HI range (front of machine), the greater the air flow
becomes.
3 - 46
.
Air Conditioner Switch

Switch (5) is used to switch the air conditioner functions ON/OFF.
Off Switch
Switch (6) is used to stop operation of the fan.
Defroster Selector Lever

Switch (7) is used to remove the mist from the front glass during
cold or rainy weather.
Selector lever to front: To defroster (open)
Selector lever to rear: Closed
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.
3 - 47
.
Use Air Conditioner With Care
Ventilation
If you smoke when the cooler 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 cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 to 6°C (41 to 42.8
°F) lower than the outside temperature). This temperature difference is considered to be the most suitable for your
health, so always be careful to adjust the temperature properly.
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 4-17)".
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.
RADIO
(If equipped)
Control Panel
(1) Power switch/volume control (SW-VOLUME) and (5) Manual tuning button (TUNING)
Balance (Pull BAL) Knob (6) Preset station buttons (1, 2, 3, 4, 5, 6)
(2) Tone control knob (TONE) (7) Display
(3) FM/AM selection button (AM/FM) (8) Time reset button
(4) Display selection button (TIME) (9) Stereo indicator (ST)
Power Switch/Volume Control (SW-VOLUME) and Balance (Pull BAL) Knob

Press this knob (1) to turn the power for the radio on. The
frequency is displayed on display (7). Press again to turn the power
off.
Turn the knob to adjust the volume as follows.
Turn CLOCKWISE to INCREASE volume
Turn COUNTERCLOCKWISE to REDUCE volume
If the knob is pulled until it locks, it can be turned to the left or right
to adjust the balance of the left and right speakers.
Turn CLOCKWISE to increase volume from RIGHT speaker
Turn COUNTERCLOCKWISE to increase volume from LEFT
speaker
After adjusting the left and right balance, press lightly to return the
knob to its original position. (If it is left pulled out, the overall volume
cannot be adjusted.)
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.
Tone Control Knob (TONE)

Turn the knob(2) to adjust the tone as follows.
Turn CLOCKWISE to emphasize the high sounds.
Turn COUNTERCLOCKWISE to suppress the high sounds.
FM/AM Selection Button (AM/FM)

Press this button(3) and select the desired band.
Each time the button is pressed, it switches AM C FM C AM ...
Display Selection Button (TIME)

This equipment gives priority to the frequency display. If the button
(4) is pressed when the frequency is displayed, display will give the
present time for 5 seconds. After 5 seconds pass, the display will
automatically return to the frequency display. If any button other
than TIME SET (H, M, SET) is pressed within the 5 seconds, the
display will return to the frequency display.
Manual tuning button (TUNING)

Use the buttons(3) to change the frequency.
Up button (∧): Each time the button is pressed, the frequency will
go up in steps (FM: 0.1 MHz, AM: 9 kHz).
Down button (∨): Each time the button is pressed, the frequency
will go down in steps (FM: 0.1 MHz, AM: 9 kHz).
3 - 50
.
Preset Station Buttons (1, 2, 3, 4, 5, 6)

If these buttons(6) are set to the frequency of the desired
broadcasting station, the station can be selected at a touch.
For details of the method of presetting, see "Preset Station Buttons
(PAGE 3-52)".
Display
In this display (7), receiving band, frequency, preset No. and time
are shown.
Time Reset Button

This button(8) is used to correct the time.
H: Hour
M: Minute
SET: Sets to start of hour (00 minutes)
Stereo Indicator (ST)

This lamp(9) lights up when a stereo broadcasting is picked up
when receiving an FM broadcasting station.
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Controls Of Radio
Preset Station Buttons

1. Press power switch (1) and display the frequency on display
(7).
2. Turn the tuning button(5) (manual, auto) to adjust to the
desired frequency.
3. Select a preset button to use for recording the frequency
setting, and keep that button pressed for at least 1.5 seconds.
The sound will disappear, but when the setting is recorded, the
sound will appear and the preset number will appear on display
(7) to show that the station has been preset.
After completion of presetting, press preset button (6), and
release it within approx. 1.5 seconds. The setting will change
to the frequency of the broadcasting station recorded for that
button. One AM station and one FM station can be recorded for
each preset button.
Manual Tuning
Press tuning button (5) and set to the desired frequency.
Each time the button is pressed, the frequency will move up or down in steps of 9 kHz (AM) or 0.1 MHz (FM).
∨ button: Move to a lower frequency station
∧ button: Move to a higher frequency station
If the frequency reaches the top or bottom limit, it will automatically change as follows: top limit → bottom limit,
or bottom limit → top limit
Automatic Tuning
Keep tuning button (5) pressed for at least 0.5 seconds. When a broadcasting station is picked up, it will
automatically stop. To search for the next station, press tuning button (5) again for at least 0.5 seconds.
∨ button: Move to a lower frequency station
∧ button: Move to a higher frequency station
If tuning button (5) is pressed during auto tuning, the auto tuning will be canceled and the frequency at the point
where it is canceled will be picked up.
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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) and adjust the hour and
minute.
H button: Adjusts hour (advances one hour each time it is
pressed)
M button: Adjusts minute (advances one minute each time it is
pressed)
If the H or M button are kept pressed, the time will advance
continuously until the button is released.
SET button: Sets to start of hour (when it is pressed, the minute
returns to 00)
If the minute display is between 0 and 05, and the SET button
is pressed, the minute reading will return to 00. If it is pressed
when the minute display is between 55 and 59, the minute
display will return to 00 and the hour will advance by 1. If the
minute display is between 06 to 54, can not adjust.
Example
10:05 → 10:00
10:59 → 11:00
10:26 → 10:26
Press the H, M, and SET buttons to set to the correct time.
Antenna
NOTICE
When transporting the machine or parking it in a garage, always fully
retract the antenna to avoid the possibility of breakage.
If the receiving wave is weak or generates noise, extend the

antenna. If the wave is too strong, adjust the sensitivity by
retracting the antenna.
Use Radio With Care

To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation.
If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a
cloth soaked in alcohol if the equipment is extremely dirty.
When the battery is replaced, the settings for the preset buttons are all cleared, so set them again.
3 - 53
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OPERATION MANUAL STORAGE

A magazine box is provided on the left side of the operator's seat
for safekeeping the operation and maintenance manual and oil
chart.
Always keep the Operation and Maintenance Manual in this pocket
so that 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 battery inspection cover. Tool box is inside.

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 operator's seat.
Be sure to extinguish your cigarette, then close the lid.
3 - 54
.
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.
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MACHINE OPERATIONS AND CONTROLS OPERATION
MACHINE OPERATIONS AND CONTROLS

BEFORE STARTING ENGINE
Walk-Around Checks
Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or
leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for
loose wiring, play, and accumulation of dust at places which reach high temperatures.
WARNING
When carrying out check or maintenance work inside the engine hood or dust cover, be sure to open them up to the upper end
and secure them with a stopper.
Remove any flammable materials from around the battery or engine muffler, or other high temperature engine parts. Leakage
of fuel or oil will cause the machine to catch fire. Check carefully, and sure to repair any abnormalities, or please contact your
Komatsu distributor.
If the machine is at an angle, make it horizontal before checking.

Always check the items in this section before starting the engine each day.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If
any abnormality 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.) accumulated around
the battery or high temperature engine parts, such as the
engine muffler. Remove all such dirt or flammable material.
Check thoroughly if there is any dust stuck particularly
between exhaust muffler (1) and exhaust muffler cover (2).
3. Check for leakage of water or oil around engine

Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any
abnormality is found, repair it.
4. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, joints
Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking.
5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers.
If any abnormality is found, repair it.
6. Check for abnormality in handrails, steps, loose bolts.

If any abnormality is found, repair it. Tighten any loose bolts.
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.
OPERATION MACHINE OPERATIONS AND CONTROLS
7. Check for abnormality in gauges and monitor

Check that there is no abnormality in the gauges and monitor in the operator's cab. If any abnormality is found,
replace the parts. Clean off any dirt on the surface.
8. Check for damage or displaced window

Check that there is no damage or displacement of the window. If any damage is found, replace with a new part.
If the window comes out of position or breaks during operations, do not continue operations. Stop immediately
and repair the window.
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 belt and mounting clamps

Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new
parts.
11. Check bucket with hook (if equipped) for damage.

Check that there is no damage to the hook, guide, or hook mount. If any abnormality is found, please contact
your Komatsu distributor for repair.
3 - 57
.
Checks Before Starting

Always carry out the items of the checks in this section before starting the engine each day.
Cooling System Coolant Level - Check/Add
WARNING
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check
the sub tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to check the coolant level in this condition, there is a hazard of burns. 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 cooling water level
is between the FULL and LOW marks on radiator reserve 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 reserve tank
(1) to the FULL level.
2. After adding water, tighten the cap securely.
3. If the sub tank is empty, there is probably leakage of water.
After inspecting, repair any abnormality immediately. If there is
no abnormality, check the water level in the radiator. If the
water level is low, add water to the radiator, then fill the reserve
tank(1).
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.
Engine Crankcase Oil Level - Check/Add
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.
1. Open engine hood.

2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out again.
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 at an angle, make it horizontal before checking.
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine before checking.
3 - 59
.
Fuel Level - Check/Refill
WARNING
When adding fuel, never spill the fuel or let it overflow. It will cause fire.
If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
Fuel is highly flammable and dangerous. 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, tighten the cap securely.
3 - 60
.
Hydraulic Oil Level - Check/Add
WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for the temperature to go down
before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Check the oil level in the hydraulic tank, keeping the machine in the following conditions.
1) If the machine is not in a posture shown in the illustration A
at right, start the engine and retract the arm and bucket
cylinder, then lower the boom, set the bucket teeth in
contact with the ground, and stop the engine.
2) If the machine is not in a posture shown in the illustration B

at right, start the engine and extend the arm and bucket
cylinder, while keeping the engine running at low idling.
Then as the boom end reached the highest position, stop
the engine.
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.
2. Open battery inspection cover (1) and check sight gauge (G)
for the oil level. If it stays within the following range, it is
regarded as appropriate.
In Machine Condition A: Within the range a

In Machine Condition B: Within the range b
NOTICE
Do not add oil above the H line. This will damage the hydraulic circuit or
cause the oil to spurt out.
If oil has been added to adobe the H level, stop the upper structure so that
the drain plug (P) under the hydraulic tank will be between both tracks, and
stop the engine and wait for 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 176°F))
4. When oil is refilled with the machine in Condition A, fully extend

each cylinder of the boom, arm and bucket as illustrated at
right, then screw the oil filler cap again after it was removed,
and pressurize the hydraulic tank interior.
NOTICE
Be sure to pressurize the hydraulic tank. If it is not pressurized, the pump
will suck in air, and this will adversely affect the equipment.
3 - 62
.
Air Cleaner Dust Indicator - Check

1. Open the engine hood and check that the red piston is not
showing in dust indicator (1).
2. If the red piston has appeared, clean or replace the element
immediately.
For details of the method of cleaning the element, see "Air
Cleaner Element - Check/Clean/Replace (PAGE 4-18)".
3. After checking, cleaning, and replacing, press the knob of dust

indicator (1) to return the red piston to its original position.
Water Separator - Check

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 ring (3), then remove element
cup (4) and throw out the water inside it.
3. Fill element cup (4) with fuel, install it to the filter holder, then
tighten ring (3).
4. Set handle (2) to the OPEN position (b).
5. rain any water or sediment from fuel tank. For details, see "Fuel
Tank - Drain (PAGE 4-50)".
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.
Electric Wiring - Inspect
WARNING
If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the cause immediately and carry
out repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check that there is no damage to the fuses and that a fuse of the correct capacity is being used. Check that there
are no disconnections or traces of short circuits on the electrical wiring, and no damage to the covering. Check also
that there are no loose terminals.
Be particularly careful to check the wiring of the battery, starting motor, and alternator.
Always check also that there is no flammable material accumulated around the engine. Remove any such
flammable material.
Please contact your Komatsu distributor for advice on investigation and correction of the cause.
Horn Function - Check

1. Turn the starting switch to the ON position.
2. Confirm that the horn sounds immediately when the horn

button is pressed.
If the horn does not sound, please contact your Komatsu
distributor for repair.
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.
Adjustment
WARNING
Adjust the seat position before starting operations or after changing the operator.
Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the
backrest.
Seat Adjustment
(A) Fore-and-aft adjustment
Move lever (1) to the upper, set the operator's seat at the desired
position, then release the lever.
Fore-and-aft adjustment: 50 mm (2.0 in) (5 stages)
(B) Adjusting reclining
REMARK
The seat can be reclined more when the seat is pushed to the front.
The amount of reclining decreases as the seat is pushed back, so
when moving the seat back, return the seatback to the upright
position.
Pull up lever (2) and set the seat back to a position which is
comfortable for operation, then release the lever.
Sit with your back against the seat back when adjusting. If your
back is not touching the seat back, the seat back 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 automatically.
(D) Overall fore-and-aft adjustment of seat

Move lever (5) to right. After the seat is set to the desired position, release the lever (5). In this case, the operator's
seat, left and right control levers, and safety lock lever all slide together.
Fore-and-aft adjustment: 100mm (3.9 in) (5 stages)
(E)Adjusting suspension
Adjust the weight adjusting dial to your own weight by turning knob (6) under the operator's seat.
The weight can be adjusted to 50 to 120 kg (110 to 265 lb).
If you want to make the seat softer, turn the weight adjustment to a lower weight; if you want to make the seat harder,
adjust to a higher weight.When operating on uneven surfaces, adjust the seat to a harder setting.
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Rearview Mirrors
Adjust the angle of the mirrors so that the area to the bottom rear
of the operator's seat (the area hidden by the engine hood) can be
seen clearly.
Seat Belt
WARNING
Before fastening the seat belt, check that there is no abnormality in the securing brackets or belt. If there is any wear or
damage, replace.
Even if there appears to be no abnormality in the seat belt, replace the seat belt once every 3 years. The date of manufacture
is woven on the reverse side of the belt.
Adjust and fasten the seat belt before operating the machine.
Always use the seat belt when operating the machine.
Do not use the seat belt with either half of the belt twisted.
Check that the bolts of the clamp 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).
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, with the operator's back against the backrest.
2. After adjusting the seat poaition, sit in the seat. Grip buckle (1)
and tongue (2) in each hand and insert tongue (2) into buckle
(1). Confirm by pulling the belt that the tongue is securely
locked to the buckle.
3. Depress the red button on buckle (1) to unfasten the seat belt.
Fasten belt along your body without kinking it. Adjust the lengths of the belt on the tongue sides.
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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.
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Wind-in Type Seat Belt

(If equipped)
WARNING
Before fitting the seat belt, check that there is no abnormality in the belt mount bracket or mounting belt. If it is worn or
damaged, replace the seat belt.
Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown
on the back of the belt.
Always wear the seat belt during operation.
Fit the seat belt so that it is not twisted.
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 insert tongue (3) into buckle (4)
securely.
When doing this, pull the belt lightly to check that it is properly
locked.
Removing belt
Press button (5) in buckle (4), and remove tongue (3) from buckle
(4).
The belt is automatically wound in, so hold grip (2) and return the
belt slowly to wind-in device (1).
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Operations Before Starting Engine

WARNING
When standing up from the operator's seat, always set the safety lock lever
to the LOCK position, regardless of whether the engine is running or
stopped.
1. Check the safety lock lever (1) is at the LOCK position.
REMARK
position.
2. Check that each control lever is in the NEUTRAL position.
3. Insert the key in starting switch (2), turn the key to the ON
position, then carry out the following checks.
1) The buzzer 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)
Swift deceleration monitor (9)
Pre-heating monitor (10)
If the monitors or gauges do not light up or the buzzer does
not sound, there is probably a blown bulb or disconnection,
so please contact your Komatsu distributor for repair.
After approx. 3 seconds, the following monitors and
gauges will remain on and the others will go out.
Charge level monitor (3)
Engine oil pressure monitor (4)
Engine coolant temperature gauge (5)
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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.
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STARTING ENGINE
Normal Starting
WARNING
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
NOTICE
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 to
start the engine again.
1. Check the safety lock lever (1) is at the LOCK position. If the
safety lock lever is in the FREE position, the engine does not
start.
2. Set fuel control dial (2) at the low idling position.
3. Turn the key in starting switch (3) to the START position. The
engine will start.
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4. When the engine start, release the key in the starting switch
(3). The key will return automatically to the ON position.
5. Keep the engine idling 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.
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Starting Engine In Cold Weather

WARNING
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Never use starting aid fluids as they may cause explosions.
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 from Step
2.
When starting in low temperatures, do as follows.

1. Check the safety lock lever (1) is at the LOCK position. If the
safety lock lever is in the FREE position, the engine does not
start.
2. Before starting the engine, check that fuel control dial (2) is at the low position.
3. Turn fuel control dial (2) to the center position between LOW
IDLING and HIGH IDLING.
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4. Hold the key in starting switch (3) at the HEAT position, and
check that pre-heating monitor (4) lights up.
After about 30 seconds, pre-heating monitor (4) will flash 10
seconds to indicate that 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 abnormality.
5. When 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 engine idling 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.
8. Check that charge level monitor (5) and engine oil pressure
monitor (6) goes off.
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AFTER STARTING ENGINE

WARNING
Emergency stop
If there has been any abnormal action or trouble, turn the starting switch key to the OFF position.
If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the
movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always carry out
the warming- up operation, Particularly in cold areas, be sure to carry out the warming-up operation fully.
For operation patterns other 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 breaking-in the machine for the initial 100 hours (as indicated by the service meter).
During breaking-in operations, follow the precautions described in this manual.
Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.
Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.
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Warming-Up Operation
NOTICE
When the hydraulic oil is at a low temperature, do not carry out operations or move the lever suddenly. Always carry out the
warming-up operation. This will help to extend the machine life.
Do not suddenly accelerate the engine before the warming-up operation is completed.
Do not run the engine at low idling or high idling continuously for more than 20 minutes. (Oil down) If it is necessary to run
the engine at idling, apply a load from time to time or run the engine at a mid-range speed.
After starting the engine, do not immediately start operations. First,

carry out the following operations and checks.
1. Turn fuel control dial (1) to the center position between LOW
IDLING and HIGH IDLING and run the engine at medium
speed for about 5 minutes with no load.
2. Set safety lock lever (2) to the FREE position, and raise the
bucket from the ground.
3. Operate bucket control lever (3) and arm control lever (4)
slowly to move the bucket cylinder and arm cylinder to the end
of the stroke.
4. Operate the bucket for 30 seconds and the arm for 30 seconds
in turn fully for 5 minutes.
NOTICE
When the work equipment is retracted, take care that it does not interfere
with the machine body or ground.
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5. After carrying out the warming-up operation, check that

machine monitor (5) is in the following condition.
Engine coolant temperature gauge (6): Inside green range
Fuel gauge: Inside green range
Engine coolant temperature monitor (8): OUT
Engine oil pressure monitor (9): OUT
Charge level monitor (10): OUT
Fuel level monitor (11): OUT
Pre-heating monitor (12): OUT
Display (13): OUT
6. Check that there is no abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your
7. Move safety 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 panel (5)

to the actual working mode.
When monitor lamp (E) lights up: E Mode (for work focusing
on fuel consumption ratio)
When monitor lamp (E) does not light up: Active Mode (for
heavy-duty work)
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STOPPING THE ENGINE

NOTICE
If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly
stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop
it.
1. Run the engine at low idling 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, and check also
for leakage of oil or water. If any abnormalities are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.
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MACHINE OPERATION
WARNING
Before operating the steering levers, check the direction of the track frame.
If the sprocket is at the front, the operation of the travel levers is reversed.
When moving off, check that the area around the machine is safe, and sound the horn before moving.
Do not allow anyone in the area around the 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 Off

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 switch
deceleration switch is ON. Check the swift deceleration display
lamp. For details of operation of the swift deceleration switch, see
"Swift Deceleration Switch (PAGE 3-16)".
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Moving Machine Forward

1. Set safety lock lever (2) to the FREE position, then raise the
work equipment 40 to 50 cm (1.6 to 2.0 in) from the ground.
2. Raise the blade.

3. Operate right and left travel control levers (3) or right and left travel pedals (4) in the following manner.
When sprocket (A) is situated at the rear of the machine;
Start 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 if the speed, see "SPECIFICATIONS (PAGE 5-2)".
5. Check that the travel alarm sounds.

If the alarm dose not sounds, please contact your Komatsu distributor for repairs.
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Moving Machine Backward

1. Set safety lock lever (2) to the FREE position, then raise the
work equipment 40 to 50 cm (1.6 to 2.0 in) from the ground.
2. Raise the blade.

3. Operate right and left travel control levers (3) or right and left travel pedals (4) in the following manner.
When sprocket is situated at the rear of the machine;
Start 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 if the speed, see "SPECIFICATIONS (PAGE 5-2)".
5. Check that the travel alarm sounds.

If the alarm dose not sounds, please contact your Komatsu distributor for repairs.
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.
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.
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STEERING THE MACHINE
Steering
WARNING
Before operating the travel levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel
levers is reversed.
Use the travel levers to change direction.

Avoid sudden changes of direction as far as possible. In particular,
when carrying out counter-rotation (spin turn), stop the machine
first 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 traveling in reverse.
REMARK
When turning to the right, operate the left travel lever in the same
way.
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Changing Direction of the Machine

When turning to the left:
If the left travel lever is returned to the neutral position, the machine
will turn to the left.
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.
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SWINGING
WARNING
When operating the swing, check that the area around the machine is safe.
1. Operate left work equipment control lever (1) to swing the

upper structure.
2. When not using the swing, set left work equipment control lever
(1) to the N position.
The swing holding brake will be applied.
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WORK EQUIPMENT CONTROLS AND OPERATIONS

WARNING
For operation patterns other than the standard one (ISO pattern), refer to the chapter of ATTACHMENTS AND OPTIONS in this
manual.
If the work equipment control lever is operated quickly, the work equipment will move quickly; and if it is operated slowly, the
work equipment will move slowly.
Use the control levers to operate the work equipment.

Note that when the levers are released, they return to the HOLD position and the work equipment is held in that
position.
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 to the front or rear
to operate the boom.
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.
Bucket control
Move the right work equipment control lever to the left or right to
operate the bucket.
Blade control (blade specification)

Move the lever on the right side of the operator's seat to the front
or rear to operate the blade.
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WORKING MODE
By using the working mode selector switch to select a working mode that matches the operating condition, it is
possible to carry out operations efficiently.
Use the following procedure to make effective use of each working mode.
Active Mode (for heavy-duty work) and E Mode (for work focusing
on fuel consumption ratio) are alternated, every time the working
mode switch is depressed.
REMARK
Active Mode (for heavy-duty work) is automatically selected, when
the engine is started.
Working mode Lamp (E) Applicable operations Set rotation during work* (rpm)
Active mode
Goes off Normal digging, loading operations 2,020 ± 50
(for heave-load operations)
E mode Normal digging, loading operations
(For work focusing on fuel Lights up (When importance is placed on fuel 1,850 ± 100
consumption ratio) consumption ratio)
*: This is the engine rotation when the fuel adjusting dial is set at the FULL position and no load is applied.
REMARK
When the working mode is switched from Active Mode to E Mode with the fuel adjusting dial set at the FULL position,
the engine rotation somewhat drops, but that is nothing unusual.
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PROHIBITED OPERATIONS
WARNING
Do not attempt to operate the work equipment control lever, while the machine is traveling.
Operations Using Swing Force

Do not use the swing force to compact soil or break objects. This
is not only dangerous, but will also markedly reduce the life of the
machine.
Operations Using Travel Force

Do not dig the bucket into the ground and use the travel force to
carry out excavation. This will damage the machine or work
equipment.
Operations Using Hydraulic Cylinder Stroke Ends

If the cylinder is used when the cylinder rod has been operated to
the end of its stroke during operations, external force will cause
impact to the work equipment, and this will damage the hydraulic
cylinders. Avoid carrying out operations with the hydraulic cylinder
fully retracted or fully extended.
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Operations Using Bucket Dropping Force

Do not use the dropping force of the machine for digging, or use the
dropping force of the bucket as a pickaxe, breaker, or pile driver.
This will markedly reduce the life of the machine.
Operations Using Machine Dropping Force

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

When using the blade as an outrigger, never suport the machine
with only one end of the blade.
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GENERAL OPERATION INFORMATION
Traveling
Traveling over boulders, tree stumps, or other obstacles will cause
a big shock to the chassis (and in particular to the tracks), and this
will cause damage to the machine. For this reason, always remove
any obstacles or travel around them, or take other steps to avoid
traveling over such obstacles as far as possible.
If there is no way to avoid traveling over an obstacle, reduce the
travel speed, keep the work 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.
Folding In Work Equipment

When folding in the work equipment to the travel or transportation
posture, be careful not to let the bucket hit the blade.
Avoid Hitting Blade

Be careful not to hit the blade against rocks or boulders. This will
cause premature damage to the blade or cylinders.
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Blade During Backhoe Operations

When carrying out deep digging operations with the blade at the
front, be careful not to the boom cylinder hit the blade. Always
position the blade at the back unless it is needed at the front.
Permissible Water Depth
CAUTION
When driving the machine out of water, if the angle of the machine exceeds
15°, the rear of the upper structure will go under water, and water will be
thrown up by the radiator fan. This may cause the fan to break.
Be extremely careful when driving the machine out of water.
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 in water for a long
time, pump in grease until the old grease comes out from the
bearings. (Around the bucket pins)
Digging Hard Rocky Ground

It is better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce damage
to the machine but make for better economy.
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TRAVELING ON SLOPES
WARNING
When traveling, raise the bucket approx. 20 to 30cm (8 to 12 in) from the
ground.
Do not travel downhill in reverse.
When traveling over ridges or other obstacles, keep the work equipment
close to the ground and travel slowly.
Never turn on slopes or travel across slopes.
Always go down to a flat place to 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.
Turning or operating the work equipment when working on slopes may
cause the machine to lose it balance and turn over, so avoid such
operations.
It is particularly dangerous to swing downhill when the bucket is loaded.
If such operations have to be carried out, pile soil to make a platform on
the slope so that the machine can be kept horizontal when operating.
Do not travel up or down steep slopes. There is danger that the machine
may turn over.
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 that the machine may
turn over.
1. When traveling down steep hills, use the travel lever and fuel
control dial to keep the travel speed low. When traveling down
a steep hill of more than 15°, with the sprocket (1) side down,
and set the work equipment to the posture shown in the
diagram on the right, and lower the engine speed.
REMARK
Travel down fills with the sprocket (1) side down.
If the machine travels down with the sprocket (1) side up, the track
tends to become loose, and that can cause skipping pitches.
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.
2. When traveling up a steep hill of more than 15°, set the work
equipment to the posture shown in the diagram on the right.
Traveling Downhill
To brake the machine during downhill runs, put the travel lever in the neutral position. This will cause the brake to
be automatically applied.
Engine Stopped on Slope

If the engine stops when traveling uphill, move the travel levers to the neutral position, stop the machine, then start
the engine again.
Cab Doors on Slope

Do not open or close the sliding door on slopes when traveling or operating. The operating effort may change
suddenly.
Always keep the sliding door locked.
Be extremely careful when opening or closing the sliding door when the machine is stopped on a slope. There
is danger that the weight of the door may cause it to open or close suddenly.
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ESCAPE FROM MUD

Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get
the machine out.
Stuck One Side Of Track
NOTICE
When using the boom or arm to raise the machine, always have the bottom
of the bucket in contact with the ground. (Never push with 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.
Stuck Both Sides Of Tracks

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 bucket into the ground at the front, operate the arm in the
same way as when digging, and set the travel lever to FORWARD
to pull the machine out.
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RECOMMENDED APPLICATIONS
In addition to the following, it is possible to further increase the range of applications by using various attachments.
Backhoe Work
A backhoe is suitable for excavating at a position lower than the
machine.
When the condition of the machine is as shown in the diagram at
right, each cylinder's maximum pushing excavation force is
obtained when the bucket cylinder and link, arm cylinder and arm
are at 90°.
When excavating, use this angle effectively to optimize your 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 attaching the bucket in the
reverse direction.
Ditching Work
Ditching work can be performed efficiently by attaching a bucket
which matches the digging operation and then setting the tracks
parallel to the line of the ditch to be excavated.
To excavate a wide ditch, first dig both sides and then finally
remove the center portion.
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Loading Work
In places where the swing angle is small, work efficiency can be
enhanced by locating the dump truck in a place easily visible to the
operator.
Loading 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.
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BUCKET REPLACEMENT AND INVERSION

WARNING
When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury.
When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment.
When the bucket is removed, place it in a stable condition.
If pins are hit with a strong force, there is a hazard that the pin may fly out and injure people in the surrounding area. Make sure
that there is no one in the surrounding area before starting the operation.
When removing the pins, do not stand behind the bucket. In addition, be extremely careful not to insert your foot from the side
when working.
When removing or inserting pins, be extremely careful not to get your fingers caught.
Never insert your fingers into the pin holes when aligning the holes.
Stop the machine on a firm, flat surface. When performing joint work, make clear signals to each other and work
carefully for safety's sake.
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, 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. Align the arm with holes (1) and the link with holes (2), then
install grease cooting pins (A) and (B).
REMARK
Install the bucket exactly in reverse order to dismantling.
When installing the bucket, the O-rings are easily damaged, so
fit the O-rings on the boss of the arm end as shown in the
diagram (3) on the right. When knocking in the pins, move the
O-ring down to the regular groove (4).
4. Install the stopper bolts and nuts for each pin, then grease the pin.
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.
Inversion
WARNING
When reversing a bucket, there is the danger that the bucket tooth tip
overruns the normal trajectory and interferes with the cab, thus causing a
serious trouble. Pay good attention to the work when reversing a bucket so
that the bucket and the cab may not interfere with each other.
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, 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. After removing the bucket, turn it.

After turning the bucket, align the mounting pin holes with the
arm and link, align the arm with the link mounting hole, then
align the link with the arm mounting hole and install.
4. Align the arm with holes (1) and the link with holes (2), then
install grease cooting pins (A) and (B).
REMARK
Install the O-ring into retaining hole (1) of the arm and bucket.
When installing the bucket, the O-rings are easily damaged, so fit
the O-rings on the boss of the arm end as shown in the diagram (3)
on the right. When knocking in the pins, move the O-ring down to
the regular groove (4).
5. Install the stopper bolts and nuts for each pin, then grease the pin.
3 - 99
.
PARKING MACHINE
WARNING
Park the machine on the firm, level ground.
Avoid parking the machine on slopes.
If it is unavoidably necessary to park the machine on a slope, put blocks
under the tracks and dig the work equipment into the ground surface to
stop the machine from moving.
If the control levers are touched by accident, the work equipment or
machine may move suddenly, and this may lead to a serious accident.
Before standing up from the operator's seat, always set the safety 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 3-82)".
2. Set fuel control dial (2) to the low idling position and lower the
engine speed.
3. Lower the bucket horizontally until the bottom touches the

ground.
4. Lower the blade to the ground.
3 - 100
.
5. Set safety lock lever (2) in the LOCK position.
MACHINE INSPECTION AFTER DAILY WORK

Check the engine water 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 open and close all these places.
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.
ROAD LINERS AND RUBBER SHOES

(Machine equipped with road liner or rubber shoe)
Road Liners And Rubber Shoes Information

Road liners and rubber shoes have excellent properties that are not found in steel shoes. However, if they are used
in the same way as steel shoes, full use cannot be made of their advantages.
Be sure to operate without straining the road liners and rubber shoes in a way that matched the conditions of the
jobsite and the nature of the work.
Comparision Of Road Liners, Rubber Shoes and Steel shoes

Road liner Rubber shoe Steel shoe
Little vibration Excellent Excellent Average
Smooth travel
Good Excellent Good
(No creaks)
Little noise Excellent Excellent Average
No damage of paves
Excellent Excellent Average
surface
Easy to handle Average Excellent Average
Easily damage Good Average Excellent
Strong drawber pull Excellent Excellent Excellent
Considering the properties of the 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 and rubber shoes to
the maximum. Before using road liners and rubber shoes, always read "Using Road Liners And Rubber Shoes
(PAGE 3-103)".
Warranty For Road Liners And Rubber Shoes

It is important to inspect and maintain the tracks at the correct tension. Furthermore, these shoes must not be used
near objects where they are likely to suffer damage, such as the corners of steel plates, U-shaped ditch liners,
blocks, on crushed rock or the sharp edges of rocks, iron beams, or scrap iron.
Any damage resulting from the customer's mistaken use of the machine shall not be included in the scope of the
warranty.
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.
Using Road Liners And Rubber Shoes
Prohibited Works
Do not carry out the following types of work.
Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near
the edges of steel plates will cause damage to the road liners and rubber shoes.
In places such as river beds where there are large numbers of large and small boulders, the stones may get
caught and damage the road liners and rubber shoes or make the shoes come off. If dozing operations are carried
out when the shoes are slipping, this will reduce the life of the road liners and rubber shoes.
Be careful not to get oil, fuel, or chemical solvent on the road liners and rubber shoes. If such a substance should
get on the shoes, remove it immediately. Furthermore, do not travel on road surfaces where oil has collected.
When putting the machine into long-term storage (3 months or more), store the machine indoors where it is
protected from direct sunlight or rain.
Do not use the machine in high-temperature areas, such as areas where there is burning wood, steel plates that
have been left under the hot sun, or places where asphalt has been laid.
Do not move the machine with the crawler on one side raised using the work equipment. This will cause damage
to the rubber shoes and may cause the rubber shoes to come off.
When the rubber parts of the road liner are so worn or broken that the head of the mounting bolts are scratched,
replace the shoe immediately. If the bolt heads are broken, the bolt cannot be removed.
When installing road liners, always install them to all links on both sides. If they are installed to only one part of
the links, their durability will be greatly reduced.
Long 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 there is a big difference in height. When traveling
over obstacles or places where there is a difference in height, drive the machine at right angles to the obstacle
to prevent the shoes from coming off.
If the machine has been raised using the bucket, lower it slowly.
Avoid doing work with materials that produce oil when crushed (soya beans, corn, or remains of vegetables
squeezed for oil); or wash the machine after use.
Avoid handling materials that will attack the adhesion of the steel core, such as salt, ammonium sulphate,
potassium chloride, potassium sulphate, or calcium superphosphate; or wash the machine after use.
The adhesion of the core will be attacked by salt, so avoid using the machine in coastal areas.
When handling salt, sugar, wheat, or soybeans, if there is any deep cut in the road liners and rubber shoes, these
substances may get into the lugs or cut portion of the rubber. Always repair the rubber before use.
Do not carry out work that involves scraping against walls or concrete embankments.
Road liners and rubber shoes slip extremely easily on snow or frozen roads. Be careful not to slip when traveling
or working on slopes.
The properties of road liners and rubber shoes change when working in extremely cold places, and this will
reduce the life of the road liners and rubber shoes.
Because of the properties of rubber, use the road liners and rubber shoes within a range of -25°C to +65°C (-13
°F to +149°F).
When carrying out bucket operations, be careful not to damage the road liners and rubber shoes with the bucket.
3 - 103
.
Always maintain the rubber shoes at the proper tension to prevent them from coming off.
If the tension is low, the rubber shoes will come off under the following conditions.
Even if the tension is correct, be extremely careful when carrying out operations.
1. Avoid operating the steering when traveling over curbs, rocks,
or places where there is a big difference in height (more than
approx. 20cm (8 in)). When traveling over such objects, 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 flat ground. To avoid damage to the road liners and
rubber shoes, travel with the tracks on both sides on flat
ground.
4. If the machine is operated as explained in 1 to 3 above, the

rubber shoes is slackened. Do not steer the machine in the
positions shown in the figure.
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.
Mechanism of rubber shoe coming off track

1) When traveling over an obstacle, a gap is formed between
the track roller and the rubber shoe. In this condition, the
rubber shoe may come off.
2) Furthermore, if the machine travels in reverse, a gap is

formed between the track roller, 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 condition, the rubber

shoe will come off.
3 - 105
.
If the machine is turned in this condition, the rubber shoe will

come off.
3 - 106
.
OPERATION TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
As a basic rule, transport the machine by trailer.
Select the trailer to match the weight and dimensions given in "SPECIFICATIONS (PAGE 5-2)".
Note that the value for the weight and transportation dimensions given in SPECIFICATIONS may differ according
to the type of shoe or type of arm or other attachments.
LOADING AND UNLOADING WITH TRAILER

WARNING
When loading a machine to a trailer or unloading from it, be sure to
travel the machine at low speed. Never attempt to change the speed or
depress the accelerator.
Run the engine at low idling, set to low speed, and operate the machine
slowly when loading or unloading.
Select firm, level ground when loading or unloading the machine.
Maintain a safe distance from the edge of the road.
Use ramps with ample width, length, thickness, and strength and install
them at a maximum slope of 15°.
When using piled soil, compact the piled soil fully 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 direction, then enter the
ramps again.
Do not use the work equipment for loading and unloading operations. It
is dangerous.
When on the ramps, do not operate any lever except the travel lever.
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 swinging the upper structure on the trailer, the trailer is unstable,
so pull in the work equipment and swing slowly.
If the sliding door of the cab is closed or open, always check that it is
locked in position. The operating effort when opening or closing the
door suddenly changes when the machine is on a ramp or platform, so
never open or close the door in such conditions.
When loading or unloading, always use ramps or a platform and carry out the operation as follows.
3 - 107
.
TRANSPORTATION OPERATION
Loading
1. Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of a road.
2. Properly apply the brakes on the trailer and put blocks under
the tires to ensure that the trailer does not move.
Then fix the ramps in line with the center of the trailer and the
machine.
Be sure that the two sides are on the same level.
Make the slope of the ramps a maximum of 15°.
Set the distance between the ramps to match the center of the
tracks.
3. Turn the travel speed selector switch to low speed travel (Lo
lamp lights 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. Align the direction of travel with the ramps 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.
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.
7. Do not the 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 - 109
.
Securing Machine
After placing the machine on the specified position of the trailer, secureit according to the following procedure.
NOTICE
To prevent damage to the bucket cylinder during transportation, fit a
wooden block at one end of the bucket cylinder to prevent it from touching
the floor.
1. Lower the blade.

2. Extend the bucket and arm cylinders fully, then lower the boom
slowly.
3. Stop the engine, then remove the key from the starting switch.
4. Lock each control lever with the safety lock lever securely.
5. Lock the sliding door (cab specification) and covers with locks.
6. Put blocks under both ends of the tracks to prevent the
machine from moving during transportation, and tie the
machine down securely with chains or wire rope of suitable
strength.
Be particularly careful to fix the machine in position securely so
that it does not slip to the side.
3 - 110
.
Unloading
1. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road.
2. Properly apply the brakes on the trailer and put blocks under
the tires to ensure that the trailer does not move.
Then fix the ramps in line with the center of the trailer and the
machine.
Be sure that the two sides are on the same level.
Make the slope of the ramps a maximum of 15°.
Set the distance between the ramps to match the center of the
tracks.
3. Remove the chains or wire rope holding the machine.
4. Start the engine.
Warm the engine up fully.
5. Set the safety lock lever to the FREE position.
6. Run the engine at low speed.

7. Raise the blade.
8. Turn the travel speed selector switch to low speed travel (Lo
lamp lights up).
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.
9. Raise the work equipment, align the direction of travel with the
ramp, and travel slowly.
Lower the work equipment as far as possible without causing
interference.
When on the ramps, operate only the travel lever. Do not
operate any other lever or pedal.
10. Do not the operate the accelerator pedal.
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.
LIFTING MACHINE
WARNING
Never raise the machine with any worker on it.
Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine.
Never try to lift the machine in any posture other than the posture given in the procedure below.
There is a hazard that the machine may lose its balance.
Never lift the machine with the upper structure swung to the side. Swing the work equipment so that it is at the sprocket end
and set the undercarriage and upper structure parallel before lifting.
When lifting, keep the machine horizontal.
Never go under the machine when it is raised.
NOTICE
For the details on the machine weight, see the section of "SPECIFICATIONS (PAGE 5-2)".
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your
Komatsu distributor for information.
When lifting the machine, carry out the operation on flat ground as follows.
3 - 113
.
1. Start the engine, then swing the upper structure so that the
work equipment is at sprocket (1) end with the track frame and
upper structure set parallel.
2. Extend the bucket cylinder and arm cylinder fully, then lower
the work equipment to the ground as shown in the diagram on
the right using the boom cylinder.
3. Lower the blade to the ground.
4. Operate the safety lock lever to the LOCK position.
5. Stop the engine, check that there is nothing around the operator's compartment, then get off the machine.
Close the cab door and front glass securely.
6. Pass wire ropes between the 1st and 2nd track rollers from the
front and between the 1st and 2nd track rollers from the rear.
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.
7. Set the lifting angle of the wire rope to 30° to 40°, then lift the
machine slowly.
8. After the machine comes off the ground, check carefully that
the machine is balanced, then lift slowly.
3 - 114
.
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION

COLD WEATHER OPERATION INFORMATION
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
Fuel And Lubricants

Change to fuel and oil with low viscosity for all components. For details of the specified visicosity, see
"LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS (PAGE 4-9)".
Cooling System Coolant

WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash
it off with large quantities of fresh water and see a doctor at once.
Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing antifreeze or when handling
coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer. Be careful not to let
the water flow into drainage ditches or spray on to the ground surface.
Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
Never use methanol, ethanol, or propanol-based antifreeze.
Never use any water-leakage prevention agent or any antifreeze containing such an agent.
Do not mix different types of antifreeze.
For details of the antifreeze mixture when changing the coolant, see "Cooling System Coolant - Clean/Change
(PAGE 4-22)".
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the
standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If
it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for
information.
Standard requirements for permanent antifreeze
SAE J1034
FEDERAL STANDARD O-A-548D
REMARK
In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main component is
ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the winter season
only.) However, in such a case, the cooling water must be changed twice a year (spring and fall), so use permanent
antifreeze as far as possible.
3 - 115
.
COLD WEATHER OPERATION OPERATION
Battery
WARNING
The battery generates flammable gas, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
When the ambient temperature drops, the capacity of the 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%, and insulate it against cold
temperature so that the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Temperature
(°C) 20 0 -10 -20
Charging
Rate(%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine,
keep it in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add the water after
the day's work so as to prevent fluid in the battery from freezing in the night.
3 - 116
.
OPERATION COLD WEATHER OPERATION
AFTER DAILY WORK COMPLETION

WARNING
Performing idle-running of the tracks is dangerous, so stay well away from the tracks.
After completion of operations, fill the fuel tank to prevent the formation of water caused by condensation of moisture in the
empty space in the tank when the temperature goes down.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, always observe the following precautions.
Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused
by mud or dirt getting inside the seal with frozen drops of water.
Park the machine on hard, dry ground.
If this is impossible, park the machine on wooden boards.
The boards help protect the tracks from being frozen in soil and the machine can start next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
After operation in water or mud, remove water from undercarriage as described below to extend undercarriage
service life.
1. Swing 90° with engine at low idling and bring the work
equipment to the side of the track.
2. Jack up the machine until the track is raised slightly from the
ground. Rotate the track under no load. Repeat this procedure
on both the left and right sides.
AFTER COLD WEATHER SEASON

When season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see "LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS (PAGE 4-9)".
If for any reason permanent antifreeze cannot be used, and an ethyl glycol base antifreeze (winter, one season
type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the inside
of the cooling system thoroughly, and fill with fresh soft water.
3 - 117
.
LONG TERM STORAGE OPERATION
LONG TERM STORAGE

BEFORE STORAGE
NOTICE
To protect the cylinder piston rod when the machine is not being used, set
the work equipment in the posture shown in the diagram.
(This prevents rusting of the cylinder rod.)
When putting the machine in storage for a long time, do as follows.

Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level
ground and cover the machine with a sheet.
Completely fill the fuel tank, lubricate and change the oil before storage.
Apply a thin coat of grease to the metal surface of the hydraulic piston rods.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water, so there is no need to change the
density for temperatures above -10°C (14°F).
If the temperature goes below -10°C (14°F), adjust the density. For details, see "Cooling System Coolant -
Clean/Change (PAGE 4-22)".
Lock each control lever and pedal with the lock lever and pedal lock.
Set the stop valve to the "lock" position on machines ready for attachments. Install the blind plugs to the elbows.
Set the selector valve on the machines which can install attachments to the "Crusher or general attachment"
position.
DURING STORAGE
WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors, open the doors and windows
to improve ventilation and prevent gas poisoning.
Operate the engine and move the machine for a short distance once a month so that a new film of oil will be coated
over movable parts and component surfaces. At the same time, also charge the battery.
For machines equipped with an air conditioner, run the air conditioner.
Rotate the tracks.
AFTER STORAGE
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu
distributor.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease to all places.
When a machine is stored for a long period, moisture in the air will get into the oil. Check the oil before and after
starting the engine. If there is water in the oil, change the oil.
3 - 118
.
OPERATION TROUBLES AND ACTIONS
TROUBLES AND ACTIONS

RUNNING OUT OF FUEL
When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.
For details of bleeding the air, see "Air Bleeding (PAGE 4-60)".
PHENOMENA THAT ARE NOT FAILURES

Note that the following phenomena are not failures:
When the arm control lever is operated to the IN position and the
work equipment is lowered under no load from a high position,
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 position.
When starting or stopping the swing, noise will be emitted from the brake valve.
When going down a steep slope at low speed, a noise will be emitted from the travel motor brake valve.
TOWING THE MACHINE

WARNING
When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed.
Do not apply a sudden load to the wire rope.
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.
Places pieces of wood between the wire ropes and the body to
prevent the wire ropes from damaging the body.
3 - 119
.
TROUBLES AND ACTIONS OPERATION
SEVERE JOB CONDITION

When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry out
greasing every time the operation is carried out.
For heavy-duty operations and deep digging, carry out greasing of the work equipment mounting pins every time
before operation.
After greasing, operate the boom, arm, bucket, and blade (machine equipped with blade) several times, then grease
again.
DISCHARGED BATTERY
WARNING
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do anything that will
cause sparks.
Battery electrolyte is dilute sulphuric acid, and it will attack your clothes
and skin. If it gets on your clothes or on your skin, wash it immediately
off with large amounts of water. If it gets in your eyes, wash it out with
fresh water, and consult a doctor.
When handling batteries, always wear protective goggles and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger
that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
Green rust around the terminals is a cause of self-discharge of the
battery. Polish the terminals with sandpaper. After removing the rust,
coat the terminals thinly with grease before installing.
3 - 120
.
Battery Removal And Installation
Removal of Battery
1. Open up dust cover (1) and battery inspection cover (2).
2. Loosen bolts (3) to remove sheet (4) installed above the

battery.
3. Disconnect cable (5) from the negative (-) terminal (grounding

side) first.
4. Disconnect connection cable (6) and cable (7) from the
positive (+) terminal.
5. Loosen securing nuts (8) to remove fixtures (9).
6. Take out the battery through battery inspection cover (2).
Installing 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) to the positive (+) terminal of the battery.
4. Connect connecting cable (6) first to the positive (+) terminal of the battery.
5. Connect cable (5) to the negative terminal (-) (grounding side).
6. Install sheet (4).
7. Close battery inspection cover (2) and dust cover (1).
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.
Battery Charges
When charging the battery, if the battery is not handled correctly,
there is a hazard that the battery may explode. Always follow the
instructions of "DISCHARGED BATTERY (PAGE 3-120)" and the
instruction manual accompanying the charger, and do as follows.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the voltage is not selected correctly, the
charger may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the negative (-)
charger clip of the charger to the negative (-) terminal of the
battery. Be sure to fix 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 charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery electrolyte and cause the battery to explode.
Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause
an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte
level to the UPPER LEVEL line.
Starting Engine With Booster Cables

When starting the engine with a booster cable, do as follows:
Connecting and Disconnecting Booster Cables
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, always wear safety
glasses.
Be careful not to let the normal machine and problem machine contact
each other. This prevents sparks from generating near the battery which
could ignite the hydrogen gas given off by the battery. If hydrogen gas
explodes, it could cause serious injury.
Make sure you do not make a mistake in connecting the booster cables.
Make the final connection to the frame, be aware that sparks might be
generated when this is done, so connect to a place as far as possible
from the battery. (However, avoid connecting the cable to the work
equipment, as conduction is poor.)
Use care when removing the cables from the machine that has been
started. To avoid hydrogen explosion, do not allow the cable ends to
contact each other or the machine.
3 - 122
.
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 sure that the cables and clips are firmly connected.
Check that the safety lock levers and parking brake levers of both machines are in the LOCK position.
Check that each lever is in the NEUTRAL position.
Booster Cable Connection

Keep the starting switch of the normal machine and problem
machine are both at the OFF position.
Connect the booster cable as follows, in the order of the numbers
marked in the diagram.
1. Connect one clip of booster cable (A) to the positive (+)
terminal of the problem machine.
2. Connect the other clip of booster cable (A) to the positive (+)
terminal of the normal machine.
3. Connect one clip of booster cable (B) to the negative (-)
4. Connect the other clip of booster cable (B) to the engine block
of the problem machine.
Starting the Engine
CAUTION
Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has
failed. Check also that all the control levers are at the HOLD or neutral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to run at high idling speed.
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 the booster cables in the
reverse of the order in which they were connected.
1. Remove one clip of booster cable (B) from the engine block of
the problem machine.
2. Remove the other clip of booster cable (B) from the negative (-)
3. Remove one clip of booster cable (A) from the positive (+)
4. Remove the other clip of booster cable (A) from the positive (+)
terminal of the problem machine.
3 - 123
.
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY

WARNING
Before loosening the plug, thoroughly check safety under the work equipment and the blade.
Never allow anyone to go under the work equipment or the blade.
While the work equipment is descending, keep holding the plug with 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 work equipment is lowered on the ground, tighten
plug (2).
Tightening torque: 34 to 44 N·m (3.5 to 4.5 kgf·m, 25.3 to 32.5
lbft)
3 - 124
.
OTHER TROUBLE
Electrical System
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.
Problem Main causes Remedy

Lamp dose not glow brightly even Defective wiring ( Check, repair loose terminals,
when the engine runs at high speed disconnections)
Defective adjustment of fan belt Adjust fan belt tension
Lamp flickers while engine is For details, see EVERY 250
running HOURS SERVICE
Charge level monitor dose not go Defective alternator ( Replace)
out even when engine is running Defective wiring ( Check, repair)
Abnormal noise is generated from Defective alternator ( Replace)
alternator
Starting motor dose not turn when Defective wiring ( Check, repair)
starting switch is turned to ON Insufficient battery charge Charge
Starting motor pinion repeatedly Insufficient battery charge Charge
moves in and out (makes ratting
sound)
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
Starting motor disengages before Defective wiring ( Check, repair)
engine start Insufficient battery charge Charge
Pre-heating monitor dose not lights Defective wiring ( Check, repair)
up Defective monitor ( Replace)
Oil pressure monitor dose not lights Defective monitor ( Replace)
up when engine is stopped Defective oil pressure switch ( Replace)
(starting switch at ON position)
While the deceleration monitor Defective relay ( Replace)
lamp is not lighted, the fuel Defective accelerator motor ( Replace)
adjusting dial does not work. Defective controller ( Replace)
The engine speed does not stop or Defective wiring ( Check, repair)
rise, even if the deceleration switch Blown fuse ( Check, repair)
is depressed.
3 - 125
.
Chassis
repairs.

Lack of hydraulic oil Adding oil to specified level,
Speed of travel, swing, boom, arm
see CHECK BEFORE
and bucket is slow
STARTING
Clogged strainer in hydraulic tank Clean, see EVERY 5000
Pump generates abnormal noise
HOURS SERVICE
Loose fan belt Adjust fen belt tension, see
Excessive rise in hydraulic oil EVERY 250 HOURS SERVICE
temperature Lack of hydraulic oil Add oil to specified level, see
CHECK BEFORE STARTING
Track comes off Track too loose Adjusting track tension, see
Abnormal wear of sprocket WHEN REQUIRED
Lack of hydraulic oil Adding oil to specified level,
Bucket rises slowly, dose not rise see CHECK BEFORE
STARTING
The swift deceleration switch is Turn off the swift deceleration
The engine speed does not
turned ON. monitor lamp in the monitor
change, even if the fuel adjusting
panel by depressing the swift
dial is turned
deceleration switch.
3 - 126
.
Engine
( ): Always contact your Komatsu distributor when dealing with these items.
repairs.

Oil level low in oil pan (sucking Add oil to specified level, see
air in) CHECK BEFORE STARTING
Clogging oil filter cartridge Replace cartridge, see EVERY
Engine oil pressure monitor lights 500 HOURS SERVICR
up Defective tightening of oil pipe, ( Check, repair)
pipe joint, oil leakage from
damaged point
Defective monitor ( Replace)
Cooling water level low, leakage Check, add water, repair, see
of water CHECK BEFORE STARTING
Steam spurts out from top of Loose fan belt Adjust fan belt tension, see
radiator (pressure valve) EVERY 250 HOURS SERVICE
Dirt scale accumulated in cooling Change coolant, flush inside of
system cooling system, see WHEN
RERUIRED
Clogging radiator fins or Clean or repair, see EVERY
damages fins 500 HOURS SERVICE
Red range of engine water Defective thermostat ( Replace thermostat)
temperature gauge lights up Loose radiator filler cap (high Tightening cap or replace
altitude operations) packing
Defective water level sensor ( Replace sensor)
White range of engine water Defective thermostat ( Replace thermostat)
temperature gauge in light up even
after operating for long time
Lack of fuel Add fuel, see CHECK BEFORE
STARTING
Air in fuel system Repair place where air in
sucked in, see EVERY 500
Engine dose not start when starting HOURS SERVICE
motor is turned Defective fuel injection pump or ( Replace pump or nozzle)
defective nozzle
Starting motor cranks engine See ELECTRICAL SYSTEM
sluggishly
Pre-heating monitor dose not See ELECTRICAL SYSTEM
light up
Defective compression
Defective valve clearance ( Adjust valve clearance)
Too mach oil in oil pan Set oil in specified level, see
Improper fuel Change to specified fuel
Exhaust gas is white or blue
Rapid acceleration right after the Avoid rapid acceleration until
engine start-up in cold after the engine warming-up
temperature
Clogging air cleaner element Clean or replace, see WHEN
Exhaust gas sometimes becomes REQUIRED
black Defective nozzle ( Replace nozzle)
Defective compression ( See "Defective compression")
Combustion noise occasionally Defective nozzle ( Replace nozzle)
make breathing sound
3 - 127
.

Low grade fuel being used Change to specified fuel
Overheating See "Red range of engine
Abnormal noise generated water temperature gauge lights
(combustion or mechanical) up"
Damage inside muffler Replace muffler
Excessive valve clearance ( Adjust valve clearance)
Clogging feed pump pre-filter Replace filter cartridge
Engine stops while in work
Defective engine and fuel line ( Check, repair)
3 - 128
.
Electronic Control System

If an error code appears on the machine monitor display (1) (normally displays TIME), follow the countermeasure
table as shown below in the self-diagnosis.
Machine Monitoring System

Monitor display Error mode Countermeasure
If emergency pump drive switch is set to the ON position,
E02 Pump control system error operation can be carried out. However, immediately have the
system inspected by your Komatsu distributor. (*)
Turn the swing brake cancel switch ON to release the brake.
Depending on the cause of the failure, it may be possible to
E03 Swing brake system error
release the brake. In ant case, have the system inspected
immediately by your Komatsu distributor. (*)
Fuel adjusting dial is inoperative. Either or both of
acceleration or deceleration cannot be operated, depending
E05 Governor system error
on a failure mode. In any case, call for inspection service
immediately.
Have the machine inspected immediately by Have the machine inspected immediately by your Komatsu
your Komatsu distributor. distributor.
(*): For details of handling the emergency pump drive switch, swing holding brake cancel switch, and emergency
work equipment actuation switch, "SWITCHES (PAGE 3-15)".
3 - 129
.
.
4-1
.
MAINTENANCE INFORMATION MAINTENANCE
MAINTENANCE INFORMATION
Do not carry out any inspection and maintenance operation that is not found in this manual.
Service Meter Reading

Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried
out.
Komatsu Genuine Replacement Parts

Use Komatsu genuine parts specified in the Parts Book as replacement parts.
Komatsu Genuine Lubricants

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient
temperature.
Windshield Washer Fluid

Use automobile window washer fluid, and be careful not to let any dirt get into it.
Fresh and Clean Lubricants

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
Check Drained Oil and Used Filter

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large
quantities of 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 200V continuously.
Connect grounding cable within 1m (3.3 ft) from the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may have troubles.
Avoid seals or bearings from being between the area to be welded and the position of grounding point.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
Do Not Drop Things Inside Machine

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead
to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
.
MAINTENANCE MAINTENANCE INFORMATION
Dusty Jobsite
When working at dusty worksites, do as follows:
Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
Avoid Mixing Lubricants

Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with
the new type of oil.
Locking the Inspection Covers

Lock inspection cover in position securely with a lock bar. If inspection or maintenance is carried out with the
inspection cover open and not locked in position, there is a hazard that it may be suddenly blown shut by the wind
and cause injury to the worker.
Hydraulic System - Air Bleeding

When hydraulic equipment has been repaired or replaced, or the hydraulic piping has been removed and installed
again, the air must be bled from the circuit. For details, see "Hydraulic System - Bleed Air (PAGE 4-46)".
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 them or bend them into loops with a small radius.
This will cause damage to the hose and markedly reduce its service life.
Checks After Inspection and Maintenance Works

If you forget to carry out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do as follows.
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been carried out correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside machine and get caught in the lever linkage mechanism.
Is there any leakage of water or oil? Have all the bolts been tightened?
Checks when operating engine
For details of the checks when operating the engine, see "Two Workers for Maintenance when Engine is
Running (PAGE 2-33)" and pay careful attention to safety.
Are the inspection and maintenance items working properly?
Is there any leakage of oil when the engine speed is raised and load is applied to the oil pressure?
4-3
.
LUBRICANTS, COOLANT AND FILTERS MAINTENANCE
LUBRICANTS, COOLANT AND FILTERS

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
Oil
Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high
pressure), and is deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil after 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 machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
At the time of shipping from the factory, SAE1OWCD is used for hydraulic type of oil. When HO46-hydraulic oil
is going to be used, change specified amount of oil (whole amount). The hydraulic oil that is not recommended
by Komatsu can cause clogging of oil filter, so do not use it. The portion of the oil that remains in the piping or
cylinders will not be a problem even though it will be mixed into new oil.
Fuel
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5
°F)). It is necessary to change for the fuel that is suitable for the temperature.
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
If there is any foreign material in the fuel tank, wash the tank and fuel system.
4-4
.
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS
Cooling System Coolant

River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine
and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.
Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in
hot areas.
Anti-freeze is flammable, so be extremely careful not to expose it to flame or fire.
The proportion of anti-freeze to water differs according to the ambient temperature.
For details of the mixing proportions, see "Cooling System Coolant - Clean/Change (PAGE 4-22)".
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in the
coolant.
Grease
Grease is used to prevent twisting and noise at the joints.
The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not need
grease.
If any part becomes stiff or generates noise after being used for a long time, grease it.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.
4-5
.
LUBRICANTS, COOLANT AND FILTERS MAINTENANCE
Carrying out KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and down-time. With KOWA, the
oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other
abnormalities.
Periodic use of KOWA makes the following possible:
It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.
It enables repair schedules to be planned, leading to improved machine availability.
KOWA analysis items

Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.
Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of large iron particles in the oil.
Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.
Oil sampling
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Carry out sampling regularly at fixed intervals.
Do not carry out sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
Oil And Fuel Storage

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the
side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the
oldest oil or fuel first).
4-6
.
MAINTENANCE LUBRICANTS, COOLANT AND FILTERS
Filters
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are found,
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 electrical leakage and may lead to malfunction of the machine. Do not wash the inside of the operator's
cab with water. When washing the machine, be careful not to let water get into the electrical components.
Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and
check of battery fluid level.
Never install any electric components other than there specified by Komatsu.
External electrical interference may cause malfunction of the control system controller, so before installing a radio
receiver or other wireless equipment, please contact your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
When installing electrical equipment, connect it to the special power source connector.
Do not connect the optional power source to the fuse, starting switch, or battery relay.
4-7
.
WEAR PARTS MAINTENANCE
WEAR PARTS
Replace filter elements, bucket teeth, and other wear parts at the specified interval or before they reach the wear
limit.
Replacing wear parts correctly ensures more economical use of the machine.
When replacing parts, always use high-quality Komatsu genuine parts.
When ordering parts, the parts differ according to the serial number of the machine, so please inform your Komatsu
distributor of the machine serial number.
WEAR PARTS LIST

The parts in parentheses are to be 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
21W-60-41121 Element 1 EVERY 1000 HOURS
Hydraulic oil filter
(07000-12135) (O-ring) (1) SERVICE
Water separator 21W-04-41480 Element 1 -
Air cleaner 600-185-1300 Element assembly 1 -
Additional filter for breaker Element
201-973-7480 1 -
(if equipment) (incl. O-ring)
Vertical pin type
20X-70-23160 Tooth 4
-
(203-70-43212) (Pin) (4)
(203-70-43220) (Pin) (4)
Horizontal pin type
Bucket 20X-70-14160 Tooth 4 -
(20X-70-00100) (Pin assembly) (4)
201-70-74171 Side cutter (left) 1
201-70-74181 Side cutter (right) 1
-
(21W-70-21810) (bolt) (6)
(01803-02228) (Nut) (6)
4-8
.
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS

PROPER SELECTION
*1: ASTM D975 No. 1
Swing
Engine oil Final drive PTO gear Hydraulic Cooling
machinery Fuel tank
pan case case system system
case
Specified liter 7.5 2.0 1.3 0.4 110 125 10.5
capacity US gal 1.98 0.53 0.34 0.11 29.06 33.03 2.77
Refill liter 7.0 2.0 1.3 0.4 64 - -
capacity US gal 1.85 0.53 0.34 0.11 16.91 - -
4-9
.
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS MAINTENANCE
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°
F) more or less during the day.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and
hydrauric work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Insitute
Fuel suiphur content Charge interval of oil in
0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval
4 - 10
.
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
4 - 11
.
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS MAINTENANCE
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETROFIN FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
E FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze
Sunoco GL5
17 SUN - 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
4 - 12
.
MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE LIST
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and
this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
The tightening torque is determined by the width across the flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was
replaced.

· · · ·
"% %"& $% %'!%# % '%& %#'%
" " "% "% #'"! %'"%& %"' &%"
# %# !%& &$'#! %'#%& !"%!'&!%
$ " %& "% $' " %' %& # %"'$%!
! ## "% &#'$ %' % &%#'!!%#
! #$ %& % !&'"$ &%'"%& %' #%
# " "$ % "!"'! & "&%'!"%& &"% '"!%
" &!$ & !&% !$' &%' % "%#'!!%!
" #!& # &!$%# ' $ #%&'!%& !% '%
! " $ # $!%& "%& !'" !%'&% #%'#&$%&
# ! " "&% $#%& '!# %'&% %'&%
" ! # #&% &% & '$ &&%'$&% %'!%!
"" & &% #%! $' !& %' &% !!%'%"
" && #& % &% !&'"! &%'"% %"' ! %
"$ " ""&% ! "% $'"" $&%'"#% ""%#' #%
Apply the following table for Hydraulic Hose.
Width Tightening torque

Nominal -
across
No. of Target value Permissible range
flats (b)
threads (a)
(mm) N·m kgf·m lbft N·m kgf·m lbft
9/16 -18UNF 19 44 4.5 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0
11/16 -16UN 22 74 7.5 54.2 54- 93 5.5- 9.5 39.8 - 68.7
13/16 -16UN 27 103 10.5 75.9 84- 132 8.5- 13.5 61.5 - 97.6
1 -14UNS 32 157 16.0 115.7 128- 186 13.0- 19.0 94.0 - 137.4
13/16 -12UN 36 216 22.0 159.1 177- 245 18.0- 25.0 130.2 - 180.8
4 - 13
.
SAFETY CRITICAL PARTS MAINTENANCE
SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out
periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next page
must also be replaced at the specified interval. These parts are particularly closely connected to safety and fire
prevention, so please contact your Komatsu distributor to have them replaced.
With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult
to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.
In addition, carry out the checks for the hydraulic hoses other than periodic replacement parts. If any abnormality
is found, tighten the clamps or replace the parts.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
Ask your Komatsu distributor to replace the 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
2 Fuel hose (water separator - feed pump pre-filter) 1
3 Fuel hose (feed pump pre-filter - fuel filter) 1
4 Fuel hose (fuel filter - injection pump) 1
5 Fuel hose (fuel tank - stop valve) 1
6 Fuel hose (fuel tank - air bleed tube) 1
7 Fuel return hose (injection pump - fuel filler port hose) 2
8 Spill hose (nozzle - fuel filler port hose) 1 Every 2 years or 4000
9 Fuel hose (fuel tank - fuel filler port) 2 hours, whenever comes
10 Fuel hose (fuel filler port - fuel filler post hose) 1 sooner
11 Hydraulic hose (main pump delivery) 3
12 Hydraulic hose (main pump suction) 3
13 Hydraulic hose (boom cylinder - control valve) 4
14 Hydraulic hose (arm cylinder - control valve) 4
15 Hydraulic hose (bucket cylinder - control valve) 4
16 Hydraulic hose (swing motor - control valve) 2
17 Hydraulic hose (blade cylinder - control valve) 4
18 Seat belt 1 Every 3 years
4 - 14
.
MAINTENANCE MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For
details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-16)" to confirm the correct
maintenance schedule when carrying out maintenance.
MAINTENANCE SCHEDULE CHART
Initial 250 Hours Maintenance (Only after the first 250 hours)
Fuel Filter Cartridge - Replace 4- 60
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge 4- 61
When Required
Air Cleaner Element - Check/Clean/Replace 4- 18
Cooling System Coolant - Clean/Change 4- 22
Water Separator Element - Replace 4- 24
Fuel Tank - Clean 4- 25
Track Shoe Bolts - Check/Tighten 4- 26
Track Tension - Check/Adjust 4- 27
Road Liners or Rubber Shoes - Check 4- 29
Rubber Shoe Tension - Check/Adjust 4- 31
Road Liners - Replace 4- 32
Rubber Shoes - Replace 4- 33
Steel Shoes or Road Liners to Rubber Shoes - Change 4- 35
Bucket Teeth (Vertical Pin Type) - Replace 4- 36
Bucket Teeth (Horizontal Pin Type) - Replace 4- 39
Bucket Clearance - Adjust 4- 40
Windshield Washer Fluid Level - Check/Add 4- 41
Air Conditioner - Check/Maintenance 4- 42
Cab Slide Door Rail And Roller - Check/Clean/Lubricate 4- 43
Breaker Circuit Additional Oil Filter Element - Replace 4- 44
Wash Washable Floor 4- 45
Hydraulic System - Bleed Air 4- 46
Checks Before Starting
Every 50 Hours Maintenance

Fuel Tank - Drain 4- 50

Lubricating 4- 51

Lubricating 4- 52
Final Drive Case Oil Level - Check/Add 4- 54
Battery Electrolyte Level - Check 4- 55
Cooling Fan Belt Tension - Inspect/Adjust 4- 57
Air Conditioner Compressor Belt Tension - Inspect/Adjust 4- 59
4 - 15
.
MAINTENANCE SCHEDULE MAINTENANCE

Fuel Filter Cartridge - Replace 4- 60
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge 4- 61
Air Conditioner Air Filter (If Equipped) - Clean 4- 62
Radiator Fins, Oil Cooler Fins, Condensor Fins - Clean/Replace 4- 64
Swing Circle - Lubricate 4- 66
Swing Pinion Gear Oil Level - Check/Add 4- 66

Hydraulic Filter Element - Replace 4- 67
Swing Machinery Case Oil - Change 4- 69
Final Drive Case Oil - Change 4- 70

PTO Gear Case Oil Level - Check/Add 4- 71
Alternator and Starting Motor - Inspect 4- 71
Engine Valve Clearances - Inspect 4- 71

Water Pump - Inspect 4- 72

Change Oil In Hydraulic Tank, Clean Strainer 4- 73
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER

For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging
operations, so set the maintenance intervals as follows.
Replace hydraulic filter element

On a new machine, replace the element after the first 100 to 150
hours, then carry out further replacement of the element
according to the table on the right.
Change oil in hydraulic tank

Change the oil according to the table on the right.
Replacing additional filter element for breaker (if equipped)

Use a guideline of 250 hours for use of the breaker (operating
ratio for the breaker: 50 % or more), and replace the element
according to the table on the right.
4 - 16
.
MAINTENANCE MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
Carry out the following maintenance only after the first 250 hours.
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 - 17
.
MAINTENANCE PROCEDURE MAINTENANCE
WHEN REQUIRED
Air Cleaner Element - Check/Clean/Replace

WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and the engine will
suffer damage. Always stop the engine before carrying out these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.
Checking
Whenever the red piston in dust indicator (1) appears, clean the air
cleaner element.
NOTICE
Do not clean the air cleaner element before the dust indicator becomes red.
If the element is cleaned frequently before the dust indicator becomes red,
the performamce of the aie cleaner is not used perfectly and the cleaning
effect is lowered. In addition, dust sticking to the element falls into the
inner element each time the element is cleaned.
Outer Element - Clean

1. Open up the engine hood cover, then release clips (2) at three
points and detach cover (3).
NOTICE
Never remove inner element (5). If it is removed, dust will enter and cause
an engine trouble.
2. Remove outer element (4).
3. Clean the interior of the air cleaner body, cover (3) and vacuater valve (6).
4 - 18
.
NOTICE
The inner element must not be cleaned and used again. When replacing
the outer element, replace the inner element at the same time.
4. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm , 99.4

PSI)) from the inside of the outer element along its folds. Then
below with air along the folds from the outside, and finally blow
again from the inside.
1) Replace any outer element, which has been 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 checked by shining a light through it after cleaning, replace
the element.
NOTICE
When cleaning the element, do not hit or beat it against anything.
Do not use an element whose folds, gasket or seal are damaged.
6. Set the cleaned outer element (4) in position.
4 - 19
.
7. Set the arrow mark on cover (3) at the top, install to the air
cleaner body, then secure with clip (2).
8. Press the button of dust indicator (1) to return the red piston to
its original position.
Replacing element
1. Open up the engine hood cover, then release clips (2) at three
points 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
vacuater valve (6).
4. Remove inner element (5), then install a new inner element
immediately.
5. Set the new outer element (4) in position.
4 - 20
.
6. 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 - 21
.
Cooling System Coolant - Clean/Change

WARNING
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to drain the coolant in this condition, 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.
Cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set the safety lock lever to
the LOCK position.
For details of starting the engine, see"BEFORE STARTING ENGINE (PAGE 3-56)" and "STARTING ENGINE (PAGE 3-71)" in the
OPERATION section.
The engine is operated when washing, so it is dangerous if the machine moves when you are standing behind it. Never stand
behind the machine when the engine is running.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor agent KI according to
the table below.
Cleaning inside of
Adding corrosion
Kind of coolant cooling system and
resistor agent KI
changing coolant
Every year (autume)or
Permanent type antifreeze
every 2000 hours
(All season type)
whichever comes first
Nom permanent type Every 6 months (spring, Every 1000 hours and
antifreeze containing autume) when cleaning the inside
ethylene glycol (winter, (Drain antifreeze in spring, of the cooling system and
one season type) add antifreeze in autume) ahen changine coolant.
Every 6 months or every
When not using antifreeze 1000 hours whichever
comes first
Stop the machine on level ground when cleaning or changing the coolant.
Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.
Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corrosion
resistor agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liter (0.065 oz/US gal).
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing
rate table given below.
It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate.
Mixing rate of water and antifreeze
Min. °C Above -10 -15 -20 -25 -30

atmospheric
temperature °F Above 14 5 -4 -13 -22
Amount of Liter 3.8 3.8 4.3 4.8 5.3

antifreeze US gal 0.85 1.00 1.14 1.27 1.40
Amount of Liter 7.3 6.7 6.2 5.7 5.2
water US gal 1.93 1.77 1.64 1.51 1.37
4 - 22
.
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 quantities of fresh water and see a doctor at once.
Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare a container to catch the drained coolant (Min 11 liters (2.91 US gal) capacity).
Prepare a water inlet hose.
1. Stop the engine.

3. Check that the cooling water temperature has gone down
enough to make it possible to touch the radiator cap surface by
hand, then turn radiator cap (1) slowly until it contacts the
stopper to release the pressure.
4. Following this, push radiator cap (1), turn it until it contacts the
stopper, then remove it.
5. Set the container under drain valve (2) and drain plug (3) to
catch the coolant mixture.
6. After draining the antifreeze solution, close drain valve (2) and
tighten drain plug (3), then fill with clean water. After the
radiator is filled with water, start and run the engine at low idling
speed. After the water temperature rises above 90°C (194°
F), run the engine for about 10 minutes.
7. Stop the engine and open drain valve (2) and remove drain
plug (3) to drain the water.
8. After draining the water, clean the radiator with detergent.
For the cleaning method, follow the instruction of detergent.
9. Close drain valve (2). Wind seal tapes onto drain plug (3), then
tighten it.
10. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze.
11. After the engine warming up, check that each gauge and caution lamp are in normal condition. If any abnormality
is found, carry out adjustment or repairs.
Operate the machine under a light load until the engine water temperature gauge (2) points to the white range
(monitor panel spec.) or the green range(gauge panel spec.).
To remove the air in the cooling water, run the engine for 5 minutes at low idling, then for another 5 minutes at
high idling. (While doing this, leave the radiator cap removed)
4 - 23
.
12. Drain the cooling water inside sub-tank (4), clean the inside of
the sub-tank, then fill again with cooling water to a point
midway betwee the FULL and LOW marks.
13. Stop the engine. About 3 minutes later, supply city water up to
the water filler, then close radiator cap.
Water Separator Element - Replace

WARNING
Do not bring any fire or flame close.
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 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 air.
For details of the method for bleeding the air, see "Air Bleeding
(PAGE 4-60)".
4 - 24
.
Fuel Tank - Clean

NOTICE
Never use trichlene for washing the inside of the tank. Use diesel fuel only.
Carry out this procedure before operating the machine as a daily maintenance.
1. Drain fuel in the fuel tank, referring to the steps 1. through 3. of the section of "Fuel Tank - Drain (PAGE 4-50)"
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
.
Track Shoe Bolts - Check/Tighten

(Machine equipped with steel shoes, road liners)
If the machine is used with track shoe bolts (1) loose, they will
break, so tighten any loose bolts immediately
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.
Method for further tightening of steel shoe

1. First tighten to a tightening torque of 118 ± 19.6 N·m (12 ± 2 kgf
·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°.
Order for tightening

Tighten the bolts in the order shown in the diagram on the right.
After tightening, check that the nut and shoe are in close contact
with the link mating surface.
4 - 26
.
Track Tension - Check/Adjust

(Machine equipped with steel shoes, road liners)
The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil, so
inspect the track tension frequently in order to maintain the standard tension.
Stop the machine on firm, horizontal ground when carrying out the inspection and maintenance.
Checking
1. Run the engine at low idling, 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 track and the bottom surface of the wooden block.
Standard deflection
Deflection "a" should be 10 to 30 mm (0.4 to 1.2in).
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 in the
mounting direction of plug (4).
If the track tension cannot be loosened with the procedure given here,
Increasing Track Tension

Prepare a grease gun.
1. Pump in grease through grease fitting (5) with a grease pump.
2. To check that the track tension is correct, run the engine at low
idling, move the machine forward a distance equal to the length
of track on ground, then stop the machine.
3. Check the track tension again, and if the tension is not correct,
adjust it again.
4 - 27
.
4. Continue to pump in grease until dimension S becomes zero

(0). If the tension is still loose, the pin and bushing are
excessively worn, so they must be either turned or replaced.
Please contact your Komatsu distributor for repairs.
Loosening Track Tension
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If the track tension is not relieved by this procedure, please contact your Komatsu distributor 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).
6. Check the track tension again, and if the tension is not correct,
adjust it again.
4 - 28
.
Road Liners or Rubber Shoes - Check

(Machine equipped with road liner or rubber shoe)
If the road liners and rubber shoes are in the following condition, they must be repaired or replaced, so please
contact your 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 5mm (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 side is cut, replace
with a new part.
4 - 29
.
Rubber Shoe Core Separations

If the rubber core has separated at one place or more, replace with
a new part.
Rubber Shoe Tension

If the rubber shoe is still slack even when grease is pumped in, replace with a new part or replace the seal inside
the cylinder.
If the track tension can only be increased to a level where the rubber shoe may come off, there may be not 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. 60mm (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 30mm (1.18 in) or the depth of the crack
is less than 10mm (0.39 in), there is no particular need to carry out
repairs.
When making judgement whether to replace, repair, or continue using road liner and rubber shoe, please contact
your Komatsu distributor.
4 - 30
.
Rubber Shoe Tension - Check/Adjust

The wear of the rubber shoe will vary with the work conditions and type of soil, so inspect the wear and track tension
whenever necessary. Stop the machine on firm, horizontal ground when carrying out the inspection and
maintenance.
In particular, on new machines or after new tracks have been installed and the tension has been set to the specified
value, the track tension will become loose in the first 5 to 30 hours when the machine has been used for a certain
amount of repeated
travel. If the track tension is adjusted frequently until the initial loosening no longer occurs, this will prevent the shoes
from coming off due to insufficient track tension.
If operations are carried out when the rubber shoe is loose, the track will come off and it will cause premature wear
of the core.
Checking
1. Run the engine at low idling, 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 wooden block.
Standard deflection
Deflection "a" should be 1 to 3 m (3 ft 3 in to 9 ft 10 in).
If the track tension is not at the standard value, adjust it in the following manner.
Adjustment
WARNING
There is danger of the plug (4) flying out under the high internal pressure
of the grease. When loosening plug (4), never loosen it more than one turn.
Never loosen any part other than plug (4). Never put your face in line with
the mount of plug (4).
If the Rubber shoe tension is not relieved by this procedure, please contact
your Komatsu distributor.
4 - 31
.
Increasing Track Tension

NOTICE
The standard value is low, so be careful not to tighten the rubber shoe too much.

1. Pump in grease through grease fitting (5) with a grease pump.
3. Check the rubber shoe tension again, and if the tension is not
correct, adjust it again.
4. If the tension is still low after supplied grease, the rubber shoe
needs to be replaced or the seal in the cylinder needs to be
replaced. Ask your Komatsu distributor for replacement.
Loosening Track Tension
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not
relieved by this procedure, please contact your Komatsu distributor.

3. If the grease does not come out smoothly, move the machine
forwards and backwards a short distance.
4. Tighten plug (4).
6. Check the rubber shoe tension again, and if the tension is not
correct, adjust it again.
Road Liners - Replace

(Machine equipped with road liner)
When replacing all the road liner for the machine, please contact your Komatsu distributor to have the
replacement carried out.
When replacing only part of the road liner, use the special road liner removal tool. Please order the tool from your
4 - 32
.
Rubber Shoes - Replace

WARNING
Carry out this operation with two workers. The operator must move the
machine in accordance with the signals from the other worker.
The rubber shoes are replaced with the machine raised, so it is
extremely dangerous if the machine is lowered by mistake during the
replacement operation. During the replacement operation, never move
the rubber shoe track except the rubber shoe track to be replaced.
In addition, never go under or put any part of your body under the rubber
shoe or track frame during the replacement operation.
To check that the track tension is correct, run the engine at low idling,
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 steel pipe
Rubber Shoes Removal
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If the rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor for repairs.
Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.
1. Raise the chassis with the boom and arm.

When doing this, operate the levers slowly.
4 - 33
.

4. Fit the steel pipes inside the 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.
4 - 34
.
4. Fit a steel pipe in the rubber shoe, then rotate the sprocket
again and fit the rubber shoe securely on the idler.
5. Stop the rotation, and check that the rubber shoe is securely
fitted to the sprocket and idler.
6. Adjust the tension of the rubber shoe.

For details, see "Rubber Shoe Tension - Check/Adjust (PAGE 4-31)".
7. Check that the track tension is correct and that the rubber shoe is correctly meshed on the sprocket and idler,
then lower the machine to the ground.
Steel Shoes or Road Liners to Rubber Shoes - Change

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. Remove idler guard mounting bolts (1), then remove idler
guard (2).
2. Remove the steel shoe or road liner and install the rubber
shoe.
Changing from Rubber Shoes to Steel Shoes or Road Liners

1. Remove the rubber shoe and install the steel shoe or road liner.
2. Install idler guard (2) with idler guard mounting bolts (1).
4 - 35
.
Bucket Teeth (Vertical Pin Type) - Replace

WARNING
It is dangerous if the work equipment moves by mistake when the teeth
are being replaced.
Set the work equipment in a stable condition, then stop the engine and
set the safety lock lever securely to the LOCK position.
If the pin is knocked out with strong force, there is a hazard that the pin
may fly out. Check that there is no one in the surrounding area.
There is a hazard that pieces will fly during the replacement operation,
so always wear safety glasses, gloves, and other protective equipment.
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 safety 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 the drift is
set against rubber pin lock (3) when it is hit, the rubber pin lock
may break. Set it against the back of the pin.)
3. After removing lock pin (2) and rubber pin lock (3), check them.
If lock pins and rubber pin locks with the following defects are used, the teeth may come off the bucket. Replace
them with new ones.
The lock pin is too short.
4 - 36
.
The rubber of the rubber pin lock is torn, and the steel balls may
come out.
The steel balls are buried when they are pressed by hand.
4. Clean the surface of adapter (4) and remove the soil with a knife.
5. Use your hand or a hammer to push rubber pin lock (3) into the
hole of the adapter.
When doing this, be careful that the rubber pin lock does not fly
out from the adapter surface.
6. Clean the inside of teeth (1), then install it to 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 of the hole for the pin of teeth (1) is protruding
to the front from the rear face of the pin hole for adapter (4), do
not try to knock the pin in.
There is something preventing teeth (1) from entering adapter
(4) fully, so remove the obstruction. When teeth (1) enters
adapter (4) fully, knock in lock pin (2).
4 - 37
.
8. Insert lock pin (2) in the hole of the teeth and hit it until its top
is the same level as the surface of teeth (1).
9. After replacing a bucket tooth, always check the following.
1) After the lock pin has been knocked in completely, check
that it is secured by the point and surface.
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.
Replace the rubber pin lock and locking pin at the same time as replacing the teeth. This makes it possible to prevent
the teeth from falling out.
4 - 38
.
Bucket Teeth (Horizontal Pin Type) - Replace

WARNING
It is dangerous if the work equipment moves by mistake when the teeth
are being replaced.
Set the work equipment in a stable condition, then stop the engine and
set the safety lock lever securely to the LOCK position.
If the pin is knocked out with strong force, there is a hazard that the pin
may fly out. Check that there is no one in the surrounding area.
There is a hazard that pieces will fly during the replacement operation,
so always wear safety glasses, gloves, and other protective equipment.
Replace the bucket teeth before the adapter starts to wear.

1. In order to enable tooth (1) pin 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 safety 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, then remove tooth (2).
REMARK
If it cannot be removed by this method, for safety reasons,
always contact your Komatsu distributor to have the
replacement carried out.
3. Clean the mounting face. Fit a new tooth (2) in the adapter,
push in pin (1) partially by hand, then lock it with a hammer to
install the tooth to the bucket.
4 - 39
.
Bucket Clearance - Adjust

WARNING
It is dangerous if the work equipment moves by mistake when the
clearance is being adjusted.
Set the work equipment in a stable condition, then stop the engine and lock
the safety lock lever securely.
It is dangerous if the work equipment moves by mistake when the
clearance is being adjusted.
Set the work equipment in a stable condition, then stop the engine and lock
the safety lock lever securely.
1. Set the work equipment to the position shown in the diagram

on the right, then stop the engine and set the lock lever to the
LOCK position.
2. Shift O-ring (1) of the linkage and measure the amount of play
"a".
Measurement is easier of you move the bucket to one side
(right side of the diagram) or the other so all the play 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) as corresponding to the play
amount "a". A set of shims is composed of two pieces and the
thickness of each shim (4) is 0.5 mm (0.020 in). In case the play
amount "a" is smaller than a shim, tighten bolt (2) for the
adjustment.
5. Tighten the four bolts (2).
If the bolts (2) are too stiff to tighten, pull out pin stopper bolt (5)
for easier tightening.
4 - 40
.
Windshield Washer Fluid Level - Check/Add

If there is air in the window washer fluid, check the level of the fluid
in window washer tank (1). Add automobile window washer fluid if
necessary.
When adding fluid, be careful not to let any dust get in.
Washer Fluid Dilution Ratio

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

Washer fluid 1/3: -10°C
Normal
water 2/3 (14°F)
Washer fluid 1/2 : -20°C
Winter in cold area
water 1/2 (-4°F)
Winter in extremely -30°C

Pure washer fluid
cold area (-22°F)
There are two types depending on the freezing temperature:

-10°C (14°F) (general use) and -30°C (-22°F) (cold area use), so select according to the area and season.
4 - 41
.
Air Conditioner - Check/Maintenance

(If equipped)
Air Conditioner Refrigerant (Gas) Level - Check
WARNING
If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the
refrigerant. Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is leaking.
If there is a lack of refrigerant (gas), the cooling performance will be

poor. When operating the cooler at high speed with the engine at
full throttle, use the receiver sight glass (inspection window) to
check the condition of the refrigerant gas (Freon R134a) flowing in
the refrigerant circuit.
No bubbles in refrigerant flow: Suitable
Some bubbles in flow (bubbles pass continuously): Lack of
refrigerant
Colorless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant gas level is low, so contact
your refrigerant dealer 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, run the compressor at low speed for 3 to 5 minutes once a month to prevent the loss
of the oil film at the lubricated parts of the compressor.
Inspection and Maintenance Items

Check, maintenance Guideline for
Content of check, maintenance
items maintenance interval
Twice a year (spring,
Refrigerant (gas) Charge amount
autumn)
Condenser Clogged fins Every 500 hours
Compressor Operating condition Every 4000 hours
V-belt Damage, tension Every 250 hours
Operating condition (does it When required
Blower motor, fan When required
make abnormal noise?)
Operating condition (does it function
Control mechanism When required
normally?)
Mounting condition, looseness at
Piping mounts tightening or connecting portions, leakage When required
of gas, damage
4 - 42
.
Cab Slide Door Rail And Roller - Check/Clean/Lubricate
Checking
When opening or closing the slide door, it may sometimes not slide
smoothly due to mud stuck to the rail. In that case clean and
lubricate slide door rail (1) and roller (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 is not smooth, contact your Komatsu distributor for repair.
4 - 43
.
Breaker Circuit Additional Oil Filter Element - Replace

(If equipped)
WARNING
After the engine is stopped, the parts and oil are at high temperature, so there is danger of burns. Wait for the temperature to
go down before starting the operation.
When removing the cap from oil filler port (F), turn it slowly to release the internal pressure, then remove it carefully.
NOTICE
For details of the replacement interval for the element, "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-16)".
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 install new element (2) and
O-ring (4).
5. When installing, bring the case into contact with the filter
holder, then tighten a further 1/2 turns.
4 - 44
.
Wash Washable Floor

With the washable floor, it is possible to flush out the dirt on the cab floor directly with water.
WARNING
When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out
the operation.
If the control levers are touched by mistake, the work equipment or machine may suddenly move, and this may lead to a serious
accident. Always set the safety lock lever securely to the LOCK position before standing up from the operator's seat.
When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out
the operation.
If the control levers are touched by mistake, the work equipment or machine may suddenly move, and this may lead to a serious
accident. Always set the safety lock lever securely to the LOCK position before standing up from the operator'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. Swing the upper structure slowly so that water drain holes (1)
in the cab floor are at a low position.
2. Lower the work equipment to the ground and set the machine
in a stable condition.
3. Set the safety lock lever to the LOCK position and stop the
engine.
4. Remove the floor mat.

5. Remove cap (2).
6. Flush out the dirt on the floor directly with water through water
drain hole (1).
7. After completing the washing operation, install cap (2) and floor
mat.
4 - 45
.
Hydraulic System - Bleed Air

For details, see "STARTING ENGINE (PAGE 3-71)". If it is necessary to refer to the items for starting the engine,
moving the machine off, steering, or stopping, see the OPERATION section.
1. Bleeding air from pump

NOTICE
If the pump is operated without filling the pump case with hydraulic oil, there is danger that the pump may be prematurely
damaged. Be sure to bleed the air completely.
1) Loosen air bleed plug (1) installed to the drain port and
check that oil oozes out (air bleeding is completed).
2) After completion of the air bleeding operation, tighten the
air bleed plug.
2. Bleeding air between pump and hydraulic tank

NOTICE
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 3-71)".
2) Operate the work equipment slowly for approx. 5 minutes to bleed the air.
3. Bleeding air from LS circuit

(This work is to be conducted only when any of the hydraulic pump, valve and hoses in the LS circuit is replaced)
NOTICE
Unless air is bled from the LS circuit, malfunction of the work equipment may be invited.
1) Loosen air bleeder (2) installed at the LS port of the

hydraulic pump.
2) Idle the engine for two minutes.
3) Continue to operate the bucket for approx. two minutes
(extension and retraction to each stroke end).
4) Tighten air bleeder (2) after air bleeding has been finished.
4 - 46
.
4. Bleeding air from cylinders

NOTICE
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder may
cause damage to the piston packing.
1) Run the engine at a mid-range speed (1650rpm) and extend and retract the cylinders 4 to 5 times to a point
100 mm(3.9in) from the end of the stroke. (Be careful not to operate to the end of the stroke.)
2) Next, operate each cylinder 3 to 4 times to the end of its stroke.
3) Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely 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
slowly to the right and left more than twice each
6. Bleeding air from swing PPC circuit

Bleed air through air bleeder (4) installed to the main valve
inside the cover on the right side of machine.
7. Bleeding air from travel motor

(only when oil inside travel motor case has been drained)
1) Run the engine at low idling, remove hose (5) from port D,
then when the oil has flowed out, tighten it again.
4 - 47
.
2) Run the engine at low idling and swing the work equipment
90° to bring it to the side of the track.
3) Jack up the machine until the track is raised slightly from
the ground. Rotate the track under no load for 2 minutes.
Repeat this procedure on both the left and right sides.
8. Bleeding air from attachment (when installed)

NOTICE
If the attachment 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 idling 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 machine for 5 minutes before starting operations.
This will remove the air bubbles in the oil inside the hydraulic cylinders.
Check that there is no leakage of oil and wipe off any oil that has been spilled.
4 - 48
.

For details of the following items, see "Checks Before Starting (PAGE 3-58)" in the OPERATION section.
Cooling System Coolant Level - Check/Add
Engine Crankcase Oil Level - Check/Add
Fuel Level - Check/Refill
Hydraulic Oil Level - Check/Add
Air Cleaner Dust Indicator - Check
Water Separator - Check
Electric Wiring - Inspect
Check Function Of Horn
4 - 49
.
EVERY 50 HOURS MAINTENANCE
Fuel Tank - Drain

Carry out this procedure before operating the machine.
Prepare a container to catch the 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 - 50
.

Maintenance for every 50 hours service should be carried out at the same time.
Lubricating
NOTICE
If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval.
Carry out greasing every 10 hours for the first 50 hours on a new machine.
After the machine was subjected to jobs in the water, be sure to grease the wet pins.

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.
(1) Arm-Bucket coupling pin (1 point)
4 - 51
.

Maintenance for every 50 hours service should be carried out at the same time.
Lubricating
NOTICE
If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval.
Carry out greasing every 10 hours for the first 50 hours on a new machine.
After the machine was subjected to jobs in the water, be sure to grease the wet pins.

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.
(Only machines with blade specification)

(1) Blade cylinder foot pin (1 point)
(2) Blade cylinder rod end pin (1 point)
(3) Blade foot pin (2 points)
(4) Boom foot pin (2 points)

(5) Boom cylinder foot pin (1 point)
4 - 52
.
(6) Boom cylinder rod end pin (1 point)

(7) Arm cylinder foot pin (2 points)
(8) Arm cylinder rod end pin (1 point)
(9) Boom-Arm coupling pin (1 point)
(10) Bucket cylinder foot pin (1 point)
(11) Arm link pin (1 point)
(12) Link coupling pin (2 points)

(13) Bucket cylinder rod end pin (1 point)
(14) Bucket-Link coupling pin (2 points)
(15) Arm-Bucket coupling pin (1 point)
4 - 53
.
Final Drive Case Oil Level - Check/Add

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.
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 plug (F), until oil flows out of level
plug hole (G).
5. After checking the oil level, install plugs (F) and (G).
4 - 54
.
Battery Electrolyte Level - Check

Carry out this check before operating the machine.
WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion.
The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before starting operations 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. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the
UPPER LEVEL (U.L) and LOWER LEVEL (L.L) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.
3. If the electrolyte level is below the midway point between the

U.L and L.L lines, remove cap (2) and add distilled water to the
U.L line.
4. After adding distilled water, tighten cap (2) securely.
REMARK
If distilled water is added to above the U.L line, use a pipette to
lower the level to the U.L line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.
4 - 55
.
When It is Impossible to Check Electrolyte Level from Side of Battery

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Open battery inspection cover (1) and remove a sheet installed
above the battery.
2. Remove cap (2) at the top of the battery, look though the water
filler port, and check the electrolyte surface. If the electrolyte
does not reach the sleeve, add 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 pipette to lower the level to the bottom of the
sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount
of water or consult your Komatsu distributor or battery maker.
When It is Possible to Use Indicator to Check Electrolyte Level

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
4 - 56
.
Cooling Fan Belt Tension - Inspect/Adjust
Inspection
The belt should deflect approx. 8 mm(0.3 in) when pressed with "a"
finger force of approx. 58.8 N (6 kgf) at a point midway between the
alternator pulley and fan pulley.
4 - 57
.
Adjustment
Prepare a bar.
Prepare a wooden block.
1. Detach fan guard (1).
2. Insert a bar in between alternator (2) and the cylinder block to

secure alternator (2). At that time put a wooden block between
the bar and alternator (2) to avoid damage to alternator (2).
3. Loosen alternator securing bolts (3) and adjusting bolt (4).
4. Push 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 stretched and there is no allowance for adjustment, or if it
is cut or cracked, please contact your Komatsu distributor for
replacement.
6. Install fan guard (1).
4 - 58
.
Air Conditioner Compressor Belt Tension - Inspect/Adjust

(If equipped)
Inspection
Press the belt at a point midway between the fan pulley and
compressor pulley with a finger force of approx. 58.8 N (6 kgf) and
check that the deflection is 10 to 12 mm (0.4 to 0.5 in).
Adjustment
1. Loosen bolts (1) and (2).
2. Loosen nut (3) and tighten bolt (4) until fan belt deflection of 10
to 12 mm (0.4 to 0.5 in) (approx. 58.8 N or 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 territory to replace the belts with new ones.
• The fan belt has elongated, leaving little allowance for adjustment.
• A cut or crack is found on the belt.
• Slipping or creaking sound is heard to come from the belt.
When the new V-belt is set, readjust it after operation for an hour.
4 - 59
.

Maintenance for every 50, 100 and 250 hours service should be carried out at the same time.
Fuel Filter Cartridge - Replace

WARNING
Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing
the filter.
Do not bring fire or sparks near the fuel.
Prepare a filter wrench for fuel filter element.

Prepare for cloth.
1. Spread the cloth beneath the filter cartridge.
2. Using a filter wrench, turn filter cartridge (1) counterclockwise
to remove it.
3. Clean the filter holder, fill a new filter cartridge with clean fuel,
coat the packing surface with engine oil, then install it to the
filter holder.
4. When installing, screw in cartridge until seal comes in contact
with sealing surface, then tighten approx. 2/3 turn.
NOTICE
If the filter cartridge is tightened too far, the packing will be damaged and
this will lead to leakage of fuel. 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 4-60)".
6. After replacement of the filter cartridge, start the engine and check it for possible oil seepage from the filter seal.
If oil leaks, check the filter cartridge tightening condition and retighten it. Should oil still leak, remove the filter
cartridge again in the sequence of Item 1 and 2 above, and check the packing surface for any damage or
whether some foreign material has got caught.
If any of the cases is noticed, replace the packing with new one and repeat the steps in Item 3 through 6 above.
Air Bleeding
1. Fill the fuel tank.
2. Loosen air bleed plug (1) and joint bolt (2).
3. Loosen knob of feed pump (3), pump it up and down, and
continue to make the fuel overflow until no more bubbles come
out from joint bolt (2).
4. Tighten joint bolt (2) and air bleed plug (1).
REMARK
When the machine has run out of fuel, carry out the same
procedure, to bleed the air.
4 - 60
.
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.
Refill capacity: 7 liters (1.85 US gal)

Filter wrench
1. Set a container to catch the oil immediately under the drain

plug (P) at the bottom of the machine.
2. Remove drain plug (P) slowly to avoid getting oil on yourself,
and drain the oil.
3. Check the drained oil, and if there are excessive metal
particles or foreign 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 the packing portion of the new filter cartridge with clean engine
oil (or coat thinly with grease), and install.
REMARK
Confirm that no remnants of old packing still adhere to the filter holder as this may result in oil leakage.
Check that there is no old packing affixed to the filter holder. If there is any old packing affixed to the filter, it will cause
leakage of oil.
7. When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten a
further 1/2 turns.
4 - 61
.
8. After replacing the filter cartridge, add engine oil through oil filler port (F) so that the oil level is between the H
and L marks on dipstick (G).
9. Run the engine idle for a while, then stop the engine and confirm that the oil level is between the H and L lines
according to "Engine Crankcase Oil Level - Check/Add (PAGE 3-59)".
Air Conditioner Air Filter (If Equipped) - Clean

(If equipped)
WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury.
Always wear safety glasses, dust mask, and other protective equipment.
NOTICE
The guide for cleaning 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.
Internal Filter - Clean

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 internal filter (3) 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 (3), close cover (2) and spread floor mat (1)
flat.
4 - 62
.
External Filter - Clean

1. Pull up pop-up rivet (4) of the air intake duct at the left rear of
the operator's seat. Cover (5) will be released automatically.
2. Pull up external filter (6).
3. Clean external filter (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 attention to the top and bottom sides.
4 - 63
.
Radiator Fins, Oil Cooler Fins and Condensor Fins - Clean/Check

WARNING
If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard
of serious injury. Always use safety glasses, dust mask, or other protective equipment.
NOTICE
When use the compressed air, keep a distance from 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
(If equipped)
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).
Fins - Clean
2. Remove cover (1).
3. Remove condenser securing bracket (2).

4. Loosen two condenser securing bolts (3) in the innermost part
and tilt condenser (4).
4 - 64
.
5. Remove two oil cooler securing bolts (5) on the upper side and
bracket (6).
6. Loosen two oil cooler securing bolts (7) on the lower side.
7. Tilt oil cooler (8) to create some space between oil cooler (8)
and radiator (9).
8. Apply compressed air to radiator fin (9), oil cooler fin (5) and
condenser fin (4) to blow off the clogged dirt, dust and shreds
of dry 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 ageing.
Further, check hose clamps for looseness.
11. Install all the detached parts again as originally installed.
4 - 65
.
Swing Circle - Lubricate

1. Lower the work equipment to the ground.
2. Using a grease gun, pump in grease through the grease fittings
shown by arrows. (2 points)
Swing Pinion Gear Oil Level - Check/Add

Prepare a scale.
1. Loosen bolts (1) to remove bolt (2).
2. Detach cover (3) by pull it down.
3. Remove bolts (2 bolts) on the top of the revolving frame and

remove cover (4).
4. Check that grease is inside.
5. Check if the grease is milky white. If it is milky white, it is
necessary to change the grease. Please contact your
The total amount of grease is 5.5 liters (5 kg) [1.45 US gal,

(11.03 lb)].
6. Install grease filler cover (4) and cover (3).
4 - 66
.

Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time.
Hydraulic Oil Filter Element - Replace

WARNING
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 4-16)" when carrying out
maintenance.
1. Retract the arm and bucket cylinders, then lower the boom and
put the teeth in contact with the ground.
2. Lower the blade.
3. Open mud cover (1).

4. Remove the cap from oil filler (F), and release the internal
pressure.
4 - 67
.
5. Loosen 3 bolts, then remove cover (2). When doing this , may
fly out under, the force of spring (3), so hold the cover down
when removing the bolts.
6. After removing spring (3) and vlve (4),take out element (5).
7. Clean the rempved parts in diesel oil.
8. Install the new element in the place where old element (5) was
installed.
Check the O-ring fitted to cover (2), and if it is scratched or
damaged, replace it with a new O-ring.
9. Set valve (4) and spring (3) on top of the element.
10. Set cover (2) in position, push it down by hand, and install the
cover (2) with the mounting bolts.
11. Install oil filler cap (F), then install cover (1).
12. To bleed the air, start the engine according to "STARTING
ENGINE (PAGE 3-71)" and run the engine at low idling for 10
minutes.
13. Stop the engine.
REMARK
Wait for at least 5 minutes after stopping the eigine to eliminate bubbles in the oil inside the tank.
14. Check for oil leakage and wipe off any spilled oil.
4 - 68
.
Swing Machinery Case Oil - Change

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to
go down before starting the operation.
Refill capacity: 2.0 liters (0.53 US gal)
1. Set a container to catch the oil immediately under the drain

plug (P) at the bottom of the machine.
2. Loosen drain plug (P) under the body, drain the oil, and then
tighten the drain valve again.
tightening torque of drain plug (P): 44.1 to 93.2 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. Insert dipstick (G) fully in the oil filler pipe, then take it out again.
7. 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).
8. If the oil is above the H mark, drain the excess engine oil from
drain plug (P), and check the oil level again.
4 - 69
.
Final Drive Case Oil - Change

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.
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).
4 - 70
.

Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time.
PTO Gear Case Oil Level - Check/Add

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature
to go down before starting the operation.
Refill capacity: 0.4 liters (0.11 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).
Alternator and Starting Motor - Inspect

The brush may be worn or the bearing may have run out of grease, so contact your Komatsu distributor for
inspection or repair.
If the engine is started frequently, have this inspection carried out every 1000 hours.
Engine Valve Clearances - Inspect

As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for service.
4 - 71
.
EVERY 4000 HOURS MAINTENENCE

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
Water Pump - Inspect

Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any abnormality is
found, please contact your Komatsu distributor for repairs or replacement.
4 - 72
.

Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time.
Change Oil In Hydraulic Tank, Clean Strainer

WARNING
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 4-16)" 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 the middle between the left and right tracks.
2. Retract the arm and bucket cylinders, then lower the boom and
put the teeth in contact with the ground.
3. Lower the blade.
4. Set the safety lock lever to the LOCK position and stop the
engine.
5. Open mud cover (1), then remove the cap of oil filler (F) to
release the internal pressure.
6. Set the oil container under the drain plug under the machine.
Using the handle, remove drain plug (1) and drain the oil.
Check the O-ring installed to plug (1), and if it is damaged,
replace the O-ring. After draining the oil, tighten drain plug (1).
Tightening torque of drain plug: 68.6 ± 9.81 N·m (7 ± 1 kgf·m,
51 ± 7 lbft).
Take care not to get oil on yourself when you remove drain plug
(P).
4 - 73
.
7. Loosen 4 bolts, then remove cover (2).

When doing this, the cover may fly out under the force of spring
(3), so push the cover down when removing the bolts.
8. Pull up the top of rod (4), and remove spring (3) and strainer
(4).
9. Remove the dirt stuck to strainer (5), then wash it in clean
diesel 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 the sight gauge.
For details of oil level check, see "Hydraulic Oil Level -
Check/Add (PAGE 3-61)".
13. Extend the boom, arm, and bucket cylinder fully as shown in
the diagram on the right, remove the oil filler cap, then install
the cap and pressurize the inside of the tank.
NOTICE
Be sure to pressurize the hydraulic tank. If it is not pressurized, the pump
will suck in air, and this will adversely affect the equipment.
14. After replacing hydraulic oil and cleaning or replacing filter

element and strainer, bleed air from the circuit.
For details of the method of bleeding the air, see "Hydraulic
System - Bleed Air (PAGE 4-46)".
4 - 74
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit Steel shoe specified Road linre speicified
Operating weight kg (lb) 7,190 (15,854) 7,220 (15,920)
3
Bucket capacity m (cu/yd) 0.28 (0.37)
Name of engine - Komatsu 4D95LE-2 diesel engine
Engine horsepower kW (HP)/rpm 40.5 (54.0)/1,850
A Overall length mm (ft in) 5,770 (18' 11") 5,770 (18' 11")
B Overall height mm (ft in) 2,730 (8' 11") 2,750 (9 '0")
C Overall width mm (ft in) 2,330 (7' 8") 2,330 (7' 8")
D Track width mm (ft in) 450 (1' 6") 450 (1' 6")
E Radius of upper structure mm (ft in) 1,240 (4' 1") 1,240 (4' 1")
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") 2,235 (7' 4")
Min. ground clearance mm (ft in) 360 (1' 2") 400 (1' 4")
Travel speed (Low/High) km/h (MPH) 3.0/4.5 (1.9/2.8)
Continuous swing speed rpm 10.0
5-2
.
SPECIFICATIONS SPECIFICATIONS
Working ranges Unit PC78US-6

A Max. digging reach mm (ft in) 6,380 (20' 11")
B Max. digging depth mm (ft in) 4,100 (13' 5")
C Max. digging height mm (ft in) 7,300 (23' 11")
D Max. vertical wall depth mm (ft in) 3,610 (11' 10")
E Max. dumping height mm (ft in) 5,180 (16' 12")
F Min. swing radius of work equipment mm (ft in) 1,750 (5' 9")
G Max. reach ground level mm (ft in) 6,240 (20' 6")
H Max. blade lifting height mm (ft in) 380 (1' 3")
I max. blade lowering depth mm (ft in) 245 (10")
5-3
.
.
6-1
.
ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION ATTACHMENTS AND OPTIONS
ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION

SAFETY FIRST
If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the
machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor
first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.
WARNING
General precautions
Read the instruction manual for the attachment thoroughly, and do not use this attachment unless you are sure that you have
understood the guides completely.
If you lose the instruction manual, always ask the manufacturer or your Komatsu distributors for a new copy.
Depending on the attachment, install the necessary front guard to the machine.
Depending on the attachment, the impact noise may make it difficult for fellow workers to transmit instructions for the
operation. Before starting operation, decide a leader and determine the signals to be used.
Do not carry out swinging operations to the side with a heavy load on the attachment. This is particularly dangerous on slopes.
Comparing with a machine equipped with a bucket, a machine equipped with a breaker has a heavy load at the front of the work
equipment and is unstable. To avoid a hazard of tipping over, do not carry out operations with the attachment swung to the
side.
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 caused by misoperation, do not put your foot on the pedal except when operating the pedal.
Precautions for removal and installation operations

When removing or installing the attachments, obey the following precautions and take care to ensure safety during the operation.
Carry out the removal and installation operation on a flat, firm ground surface.
When the operation is carried out by two or more workers, determine the signals and follow these during the operation.
When carrying heavy objects (more than 25kg or 55 lb), use a crane.
When removing heavy parts, always support the part before removing it.
When lifting such as heavy parts with a crane, always pay careful attention to the position of the center of gravity.
It is dangerous to carry out operations with the load kept suspended. Always set the load on a stand, and check that it is safe.
When removing or installing attachments, make sure that it is in a stable condition and will not fall over.
Never go under a load suspended from a crane.
Always stand in a position that is safe even if the load should fall.
NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified person.
For details of removal and installation operations, contact your Komatsu distributor.
6-2
.
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION
ATTACHMENT INSTALLATION
WARNING
Long work equipment or heavy work equipment cause the machine to have
poor stability, so there is danger of the machine losing its balance and
tipping over when traveling down steep hills or when swinging on slopes.
Never do any of the following. They are extremely dangerous.
Traveling downhill with the work equipment raised
Traveling across slopes
Swinging upper structure on slopes
If heavy-load work equipment is installed, there will be excessive
overrun when swinging (the distance 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 correct procedure is not used when installing the boom and arm,
it may lead to serious damage. Please consult your Komatsu
distributor.
When long work equipment is installed, the working range will suddenly
become larger, so there is danger of mistaking the distance and hitting
other objects. Allow an ample margin between the work equipment and
surrounding obstacles when operating.
6-3
.
BUCKET WITH HOOK ATTACHMENTS AND OPTIONS
BUCKET WITH HOOK

HOOK CONDITION
Check that there is no damage to the hook, stopper, or hook mount. If there is any abnormality, contact your
PROHIBITED OPERATIONS
Operations with Care

When carrying out lifting operations, reduce the engine speed
and operate slowly.
Depending on the operating 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 steer 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.
If you are planning to install a hook, contact your Komatsu
distributor.
6-4
.
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT
MACHINE READY FOR ATTACHMENT

LOCATIONS
(1) Stop valve (4) Lock pin

(2) Selector valve (5) Breaker circuit additional oil filter
(3) Attachment control pedal
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.
6-5
.
MACHINE READY FOR ATTACHMENT ATTACHMENTS AND OPTIONS
Selector Valve
This valve (2) switches the flow of hydraulic oil.
Position (a): When using breaker
Position (b): When using general attachment (crusher, etc.)
Attachment Control Pedal

This pedal (3) is used to operate the attachment.
Lock Pin
This pin (4) locks the control pedal.
Position (a): Lock
Position (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 the hydraulic oil
when using the breaker.
The oil flows through this only when the selector valve is at the
breaker position.
6-6
.
HYDRAULIC CIRCUIT
Hydraulic Circuit Connection

When connecting the attachment, connect the hydraulic circuit as follows.
1. Check that the stop valve is at the LOCK position, then remove
the plug.
Be careful not to lose or damage any part that is removed.
2. Connect the piping for the attachment provided by the

attachment maker.
The dimensions on the stopper valve side are as indicated at
right. For those on the attachment side, confer with each
manufacturer of attachment and determine.
3. After connecting the piping, bleed the air from the circuit.
1) Start the engine and run it at low idling for 10 minutes. For
details, see "STARTING ENGINE (PAGE 3-71)". Then
carry out the following operation.
2) Run the engine at low idling 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 bleeding procedure for the
attachment itself, follow the specified procedure to bleed the air.
3) After completing the bleeding of the air, stop the engine,

and wait for at least 5 minutes before starting operations.
This will release the bubbles in the oil inside the tank.
4) Check that there is no oil leakage, and wipe off any oil that
has been spilled.
6-7
.
ATTACHMENT OPERATIONS
WARNING
Do not put your foot on the pedal except when operating the pedal. If rest your foot on the pedal during operations, and it is
depressed by accident, the attachment may move sudden and cause serious damage or injury.
Operate the attachment as follows.
When Using Breaker
NOTICE
Never attempt to use the breaker with lock pin (1) set at the full stroke
position (c). That will likely cause damage to the hydraulic equipment and
engine overheating.
1. If the pedal is depressed forward with lock pin (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.
For details of pther precautions when handling the breaker, read and use correctly the instruction manual
provided by the breaker manufacturer.
When breaker is used, the hydraulic oil degrades faster than in normal operation. Shorten the maintenance
interval of the hydraulic oil and filter element.
See "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-16)".
6-8
.
When Using General Attachment Such As Crusher

1. If the pedal is depressed with lock pin (1) set at the full stroke
position (c), the attachment 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.
Confirm that the selector valve is set to the position for general
attachments such as the crusher.
For other precautions when using the attachment, see the instruction manual provided by the attachment
manufacture.
6-9
.
LONG TERM STORAGE

If the equipment is not to be used for a long time, do as follows.
Set the stop valve in the LOCK condition.
Install a plug to the valve.
Install a plug to the stopvalve.
Set the selector valve to the position for general attachments 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.
SPECIFICATIONS
Hydraulic specifications
Oil flow
Oil flow (liter/min)

Lock Pin position
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 MPa (175 kg/cm , 2490.0 PSI)
When using other attachment: 26.51 MPa (270 kg/cm , 3830.0 PSI)
6 - 10
.
ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE

VALVE EQUIPPED)
WARNING
When changing the operating pattern of the machine, set the machine in the parking posture, stop the engine, check that the
safety lock lever is at the LOCK position, then change the operating pattern.
To prevent personal injury caused by mistaken operation, test operate the machine and check that the display on the operating
pattern card is the same as the movement of the machine.
If it is not the same, replace the operating pattern card immediately with the card that matches the operating pattern.
When checking 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 safety 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) Loosen wing nut (1).
2) Select a new operation pattern with a notch on lever (2)
and then move lever (2) downward so that the notch will
match a dark triangular mark (F) on the valve.
3) After the switching, tighten wing nut (1).
4. Change to an operating pattern card (insert it in the holder) that matches the selected operating pattern.
5. Start the engine, set the safety lock lever to the FREE position, operate the work equipment levers slowly, and
check that the operating pattern has changed.
6 - 11
.
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) ATTACHMENTS AND OPTIONS
MACHINE CONTROL PATTERNS

WARNING
After changing the operating pattern, always change the operating pattern
card in the operator's compartment.
ISO pattern
J/D pattern
6 - 12
.
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE
ATTACHMENT GUIDE
WARNING
Please read the instruction manual for the attachment and the sections of this manual related to attachments and options.
When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor
before installing.
Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety, but
may also have an adverse effect on the operation of the machine and the life of the equipment.
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 operator. Always use this when operating
on jobsites where there is danger from rocks or sand or other
flying objects. (Breaker operations, etc.)
6 - 13
.
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS
ATTACHMENT COMBINATIONS
WARNING
Depending on the type or combination of work equipment, there is danger that the work equipment may hit the cab or machine
body.
When using unfamiliar work equipment for the first time, check before starting if there is any danger of interference, and operate
with caution.
This table lists the combination of bucket which can be installed to the standard arm and long arm.
¡: Can be used
H: Can be used only for light duty work
Í: Cannot be used
NOTICE
When the long arm is equipped, if the bucket is pulled in to the machine body, the arm interferes with the body. Operate the long
arm carefully.
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
Tooth Capacity Outside width Outside width

Standard
Name mounting (m3) (bucket body) (side cutter) Use Long arm
arm
pin SAE/CECE mm (in) mm (in)
Narrow
Narrow bucket Vertical 0.09/0.08 350 (13.8") 450 (17.7) ¡ ¡
digging
Narrow
Narrow bucket Vertical 0.13/0.11 450 (17.7) 550 (21.7) ¡ ¡
digging
Narrow
Narrow bucket Vertical 0.20/0.18 550 (21.7) 650 (25.6) ¡ ¡
digging
Standard Vertical General Ï
0.28/0.25 650 (25.6) 750 (29.6) ¡
bucket Horizontal digging
Light duty Ï
Vertical 0.34/0.30 760 (29.9) - Loading ¡
bucket
6 - 14
.
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS
RECOMMENDED ATTACHMENT OPERATIONS

This section describes the necessary precautions to be observed when operating a hydraulic excavator equipped
with an attachment.
NOTICE
Select the attachment most suited to the machine body.
The machine models to which attachments can be mounted vary. For selection of attachment and machine model, consult your
HYDRAULIC BREAKER
Main Applications
Crushed rock
Demolition work
Road construction
This attachment can be used for a wide range of work including
demolition of buildings, breaking up of road surfaces, tunnel work,
breaking up slag, rock crushing, and breaking operations in
quarries.
Keep the chisel pushed perpendicularly against the impact surface

when carrying out breaking operations.
When applying impact, push the chisel against the impact surface
and operate so that the chassis rises approx. 5 cm (2 in) off the
ground. Do not let the machine come further off the ground than
this amount.
6 - 15
.
RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS
When applying continuous impact to the same impact surface, if

the chisel does not penetrate or break the surface within 1 minute,
change the point of impact and carry out breaking operations
closer to the edge.
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 there is no
resistance.
6 - 16
.
Prohibited Works
To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate
the machine in any of the following ways.
Do not operate all cylinders to the end of their strokes. Always leave approx. 5cm (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 - 17
.
RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS
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 - 18
.
Greasing
Supply grease in the correct position.
NOTICE
If grease is supplied in an incorrect position, the breaker is filled with more
grease than necessary. As a result, soil and sand will enter the hydraulic
circuit and can damage the hydraulic devices while the breaker is used.
Accordingly, be sure to supply grease in the correct position.
6 - 19
.
.
INDEX
INDEX
<A> Escape From Mud 3- 95

Air Conditioner Controls 3- 43
Ashtray 3- 54 <F>
Attachment Guide 6- 13 Fire Extinguisher 3- 55
Attachment Combinations 6- 14 Forword 1- 2
Other Attachments 6- 13 Fuse 3- 36
Attachments And Options - General Infor- Fusiblelink 3- 37
mation 6- 2
Attachment Installation 6- 3 <G>
Safety First 6- 2 General Operation Information 3- 91
Auxiliary Electric Power 3- 37 Grease Pump Holder 3- 54
<B> <H>
Battery Inspection Cover 3- 35 Handling Oil, Fuel, Coolant, And Performing
Bucket Replacement And Inversion 3- 98 Oil Clinic 4- 4
Bucket With Hook 6- 4 Heater and Defroster Controls 3- 38
Hook Condition 6- 4
Prohibited Operations 6- 4 <I>
Introduction 1- 7
<C>
Cap With Lock 3- 32 <L>
Changing Machine Control Pattern (If Locking 3-101
Pattern Change Valve Equipped) 6- 11 Long term storage 3-118
Control Pattern Change Procedure 6- 11 After Storage 3-118
Machine Control Patterns 6- 12 Before Storage 3-118
Cold Weather Operation 3-115 During Storage 3-118
After Cold Weather Season 3-117 Lubricants, Coolant And Filters 4- 4
After Daily Work Completion 3-117 Lubricants, Fuel And Coolant Specifica-
Cold Weather Operation Information 3-115 tions 4- 9
Control Levers And Pedals 3- 20 Proper Selection 4- 9
Controllers 3- 37
Controls And Gauges 3- 3 <M>
Machine Inspection After Daily Work 3-101
<D> Machine Operation 3- 79
Detailed Controls And Gauges 3- 4 Machine Operations And Controls 3- 56
Directions Of Machine 1- 7 Machine Ready For Attachment 6- 5
Attachment Operations 6- 8
<E> Hydraulic Circuit 6- 7
Electric System Maintenance 4- 7 Locations 6- 5
Emergency Escape Hammer 3- 31 Long term storage 6- 10
Engine, After Starting 3- 75 Specifications 6- 10
Engine, Before Starting 3- 56 Machine Serial No. Plate And Its Location 1- 8
Engine Hood 3- 33 Machine View Illustrations 3- 2
Engine Serial No. Plate And Its Location 1- 8 Machine, Steering The 3- 83
Engine, Check After Shut Off 3- 78 Maintenance Information 4- 2
Engine, Starting 3- 71
Engine, Stopping The 3- 78
7-1
.
INDEX
Maintenance Procedure 4- 17 Safety Maintenance Information 2- 32

Check Before Starting 4- 49 Service Meter Location 1- 9
Every 50 hours 4- 50 Sliding Door 3- 30
Every 100 hours 4- 51 Specifications 5- 2
Every 250 hours 4- 52 Sun Roof 3- 24
Every 500 hours 4- 60 Swinging 3- 85
Every 1000 hours 4- 67 Switches 3- 15
Every 2000 hours 4- 71
Every 4000 Hours 4- 72 <T>
Every 5000 hours 4- 73 Tightening Torque Specifications 4- 13
Initial 250 hours (First 250 hours only) 4- 17 Tightening Torque List 4- 13
When required 4- 18 Tool Box 3- 54
Maintenance Schedule 4- 15 Transportation 3-107
Maintenance Interval For Hydraulic Lifting Machine 3-113
Breaker 4- 16 Loading And Unloading With Trailer 3-107
Maintenance Schedule Chart 4- 15 Transportation Procedure 3-107
Monitoring System 3- 4 Traveling On Slopes 3- 93
Mud Cover 3- 34 Troubles And Actions 3-119
Battery, Discharged 3-120
<O> How to Lower Work Equipment When
Road Liners and Rubber Shoes 3-102 Engine Stops Due to Abnormality 3-124
Operation Manual Storage 3- 54 Other Trouble 3-125
Overall Machine View 3- 2 Phenomena That Are Not Failures 3-119
Running Out Of Fuel 3-119
<P> Severe Job Condition 3-120
Parking Machine 3-100 Towing The Machine 3-119
Product Information 1- 8
Prohibited Operations 3- 89 <W>
Warning Labels And Pictograms 2- 4
<R> Warning Labels And Pictograms -
Radio 3- 49 Actual 2- 6
Recommended Applications 3- 96 Warning Labels And Pictograms -
Recommended Attachment Operations 6- 15 Location 2- 5
Hydraulic Breaker 6- 15 Wear Parts 4- 8
Wear Parts List 4- 8
<S> Windshield 3- 25
Safety Critical Parts 4- 14 Work Equipment Controls And Operations 3- 86
Safety Critical Parts List 4- 14 Working Mode 3- 88
Safety Information 1- 5
Safety Information 2- 2 <Y>
Safety Information 2- 11 Your Machine Serial Numbers And Distribu-
Safety Machine Operation 2- 19 tor 1- 9
Battery 2- 28
Lifting Objects With Bucket 2- 31
Operation 2- 21
Starting Engine 2- 19
Towing 2- 30
Transportation 2- 27
7-2
.
.
PC78US-6 HYDRAULIC EXCAVATOR
Form No. SEAM044600T
©
2001 KOMATSU
All Right Reserved
Printed in Japan 10-01

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SEAM044600

Operation & Maintenance

SERIAL NUMBER PC78US - 4001 and up

Copyright 2001 Komatsu

Storage location for the Operation and Maintenance Manual:

FOREWORD SAFETY INFORMATION

Example of safety message using signal word

Other signal words

This word is used for information that is useful to know.

SAFETY INFORMATION FOREWORD

Example of safety label using words

Safety labels using pictogram

PRODUCT INFORMATION FOREWORD

MACHINE SERIAL NUMBER PLATE AND ITS LOCATION

ENGINE SERIAL NUMBER PLATE AND ITS LOCATION

EPA: Environmental Protection Agency, U.S.A.

FOREWORD PRODUCT INFORMATION

SERVICE METER LOCATION

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Engine serial No.

GREASE PUMP HOLDER 3- 54

WEAR PARTS LIST 4- 8

SAFETY INFORMATION SAFETY

SAFETY SAFETY INFORMATION

SAFETY MACHINE OPERATION 2- 19

SAFETY MAINTENANCE INFORMATION 2- 32

WARNING LABELS AND PICTOGRAMS SAFETY

WARNING LABELS AND PICTOGRAMS

SAFETY WARNING LABELS AND PICTOGRAMS

WARNING LABELS AND PICTOGRAMS - LOCATION

WARNING LABELS AND PICTOGRAMS SAFETY

WARNING LABELS AND PICTOGRAMS - ACTUAL

SAFETY WARNING LABELS AND PICTOGRAMS

WARNING LABELS AND PICTOGRAMS SAFETY

SAFETY WARNING LABELS AND PICTOGRAMS

WARNING LABELS AND PICTOGRAMS SAFETY

SAFETY SAFETY INFORMATION

If Abnormalities are Found

Working Wear and Personal Protective Items

Fire Extinguisher and First Aid Kit

SAFETY INFORMATION SAFETY

Keep Machine Clean

Keep Operator's Compartment Clean

Leaving Operator's Seat with Lock

When leaving the machine, always lower the work equipment

SAFETY SAFETY INFORMATION

Handrails and Steps

To ensure safety, always face the machine and maintain

Mounting and Dismounting

Do Not Get Caught In Articulated Portion

SAFETY INFORMATION SAFETY

Fire Prevention and Explosion Prevention

Fire caused by accumulation of flammable material.

SAFETY SAFETY INFORMATION

Fire coming from electric wiring

Fire coming from hydraulic line

Explosion caused by lighting equipment

Action If Fire Occurs

Windshield Washer Fluid