PC160 Excavadora

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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 a 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 in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Storage location for the Operation and Maintenance Manual:

magazine box on the left side of the operator's seat.
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FOREWORD FOREWORD
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FOREWORD FOREWORD
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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.
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. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in
the LOCK position.
If you accidentally touch the control levers when they are not locked, this
may cause a serious injury or death.
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 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.
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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: 1 -> (1))
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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 3-114)" for further details.
DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front and the sprocket is at the rear of the machine.
BREAKING-IN THE NEW MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points when
breaking in the machine.
Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
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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.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION

On top of the No. 3 (or No. 4) cylinder head cover.
(The EPA supplementary plate is on top of the No. 1 cylinder head cover.)
EPA: Environmental Protection Agency, U.S.A.
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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.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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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
BREAKING-IN THE NEW MACHINE 1- 7
PRODUCT INFORMATION 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 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
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 4
SAFETY LABELS 2- 5
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- 28
CONTROL LEVERS AND PEDALS 3- 33
SUN ROOF 3- 36
WINDSHIELD 3- 36
EMERGENCY EXIT FROM OPERATOR'S CAB 3- 41
DOOR LOCK 3- 41
CAP WITH LOCK 3- 42
HOT AND COOL BOX 3- 43
MAGAZINE BOX 3- 43
ASHTRAY 3- 43
AIR CONDITIONER CONTROLS 3- 44
RADIO 3- 59
AUXILIARY ELECTRIC POWER 3- 64
FUSE 3- 65
FUSIBLE LINK 3- 66
CONTROLLERS 3- 66
TOOL BOX 3- 66
GREASE GUN HOLDER 3- 66
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FOREWORD CONTENTS
ACCUMULATOR 3- 67
MACHINE OPERATIONS AND CONTROLS 3- 69
BEFORE STARTING ENGINE 3- 69
STARTING ENGINE 3- 84
AFTER STARTING ENGINE 3- 88
STOPPING THE ENGINE 3- 97
MACHINE OPERATION 3- 98
STEERING THE MACHINE 3-102
SWINGING 3-104
WORK EQUIPMENT CONTROLS AND OPERATIONS 3-105
WORKING MODE 3-107
PROHIBITED OPERATIONS 3-108
GENERAL OPERATION INFORMATION 3-110
TRAVELING ON SLOPES 3-111
ESCAPE FROM MUD 3-113
RECOMMENDED APPLICATIONS 3-114
BUCKET REPLACEMENT AND INVERSION 3-116
PARKING MACHINE 3-119
CHECK AFTER SHUT OFF ENGINE 3-120
MACHINE INSPECTION AFTER DAILY WORK 3-120
LOCKING 3-121
TRANSPORTATION 3-122
TRANSPORTATION PROCEDURE 3-122
LOADING AND UNLOADING WITH TRAILER 3-122
LIFTING MACHINE 3-129
COLD WEATHER OPERATION 3-131
COLD WEATHER OPERATION INFORMATION 3-131
AFTER DAILY WORK COMPLETION 3-134
AFTER COLD WEATHER SEASON 3-134
LONG TERM STORAGE 3-135
BEFORE STORAGE 3-135
DURING STORAGE 3-135
AFTER STORAGE 3-135
STARTING MACHINE AFTER LONG-TERM STORAGE 3-136
TROUBLES AND ACTIONS 3-137
RUNNING OUT OF FUEL 3-137
PHENOMENA THAT ARE NOT FAILURES 3-137
TOWING THE MACHINE 3-138
LIGHTWEIGHT TOWING HOLE 3-139
SEVERE JOB CONDITION 3-139
DISCHARGED BATTERY 3-140
OTHER TROUBLE 3-144
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
ELECTRIC SYSTEM MAINTENANCE 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 4- 9
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CONTENTS FOREWORD
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- 17
MAINTENANCE PROCEDURE 4- 18
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4- 18
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) 4- 18
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 44
EVERY 100 HOURS MAINTENANCE 4- 45
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
GENERAL PRECAUTIONS FOR SAFETY 6- 2
PRECAUTIONS WHEN SELECTING 6- 2
READ THE INSTRUCTION MANUAL THOROUGHLY 6- 2
PRECAUTIONS WHEN REMOVING OR INSTALLING 6- 2
PRECAUTIONS WHEN USING 6- 2
BUCKET WITH HOOK 6- 3
HOOK CONDITION 6- 3
PROHIBITED OPERATIONS 6- 3
MACHINE READY FOR ATTACHMENT 6- 4
LOCATIONS 6- 4
HYDRAULIC CIRCUIT 6- 7
ATTACHMENT REMOVAL AND INSTALLATION 6- 11
ATTACHMENT OPERATIONS 6- 13
LONG TERM STORAGE 6- 15
SPECIFICATIONS 6- 15
ATTACHMENT GUIDE 6- 16
OTHER ATTACHMENTS 6- 16
ATTACHMENT COMBINATIONS 6- 18
TRACK SHOES SELECTION 6- 19
BUCKET TEETH SELECTION 6- 20
RECOMMENDED ATTACHMENT OPERATIONS 6- 21
HYDRAULIC BREAKER 6- 21
INDEX 7- 1
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SAFETY INFORMATION SAFETY
SAFETY INFORMATION
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 4
SAFETY LABELS 2- 5
Safety Rules 2- 10
If Problems are Found 2- 10
Working Wear and Personal Protective Items 2- 10
Fire Extinguisher and First Aid Kit 2- 10
Safety Equipment 2- 10
Keep Machine Clean 2- 11
Keep Operator's Compartment Clean 2- 11
Leaving Operator's Seat with Lock 2- 11
Handrails and Steps 2- 12
Mounting and Dismounting 2- 12
No Persons on Attachments 2- 12
Burn Prevention 2- 13
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- 15
Attachment Combinations 2- 15
Cab Window Glasses 2- 15
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
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SAFETY SAFETY INFORMATION
Safety machine operation 2- 19

Starting engine 2- 19
Checks before starting engine 2- 19
Safety rules for starting engine 2- 20
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
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
Lifting work using bucket with hook 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- 33
Two workers for maintenance when engine is running 2- 34
Proper tools 2- 34
Accumulator 2- 35
Personnel 2- 35
Attachments 2- 35
Work under the machine 2- 35
Noise 2- 35
When using hammer 2- 36
Welding works 2- 36
Removing battery terminals 2- 36
Safety first when using high-pressure grease to adjust track tension 2- 36
Do not disassemble recoil springs 2- 36
Safety rules for high-pressure oil 2- 37
Safety handling high-pressure hoses 2- 37
Waste materials 2- 37
Air conditioner maintenance 2- 37
Compressed air 2- 38
Periodic replacement of safety critical parts 2- 38
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SAFETY LABELS SAFETY
SAFETY LABELS
The following warning signs 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. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
LOCATION OF SAFETY LABELS
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SAFETY SAFETY LABELS
SAFETY LABELS
(1) Caution before operating or maintaining machine
(09651-03001)
(2) Caution before operating (09802-03000)
(3) Warning for leaving operator's seat (09654-03001)
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(4) Warnings for high voltage (09801-03001)
(5) Caution when opening or closing front window

(09839-03000)
(6) Warning when stowing front window (09803-03000)
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(7) Warning for hot oil (09653-03001)
(8) Warning for hot cooling water (09668-03001)
(9) Caution for handling accumulator (09659-53000)
(10) Warning when adjusting track tension (09657-03003)
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(11) Warning for improper use of cables (09808-03000)
(12) Stop engine when performing inspection or maintenance

(09667-03001)
(13) Explanation of methods for emergency escape

(20Y-00-31170)
(14) Warning against falling off the edge (09805-23000)
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(15) Warning against falling (09805-13000)
(16) Keep off swing area (09133-23000)
(17) Warning when handling battery (09664-30082)
(18) Caution for broken or becomes dislodged to the window

(20U-98-21910)
(19) Jump start prohibited (09842-A0481)
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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 PROBLEMS ARE FOUND

If you find any problems 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 problem 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 in 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.
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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 compartment.
LEAVING OPERATOR'S SEAT WITH LOCK

Before standing up from the operator's seat (such as when
opening or closing the front window or roof window, or when
removing or installing the bottom window, or when adjusting the
operator's seat), lower the work equipment completely to the
ground, set lock lever (1) securely to the LOCK position (L), 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 lock lever (1) securely to LOCK
position (L), 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.
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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 or lock lever 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 work equipment, or other attachments. There is a hazard of falling and suffering serious
injury.
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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 a 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.
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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.
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.
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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.
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.
The ceiling window is made of organic glass (polycarbonate), and as such it is apt to break easily when receiving
damage on the surface, thereby deteriorating its protective characteristic. If there is a crack or damage caused
by a fallen rock, or when any sign of them is noticed, replace it with a new window.
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UNAUTHORIZED MODIFICATIONS
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
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.
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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 Cables Safety Distance
maintain a safe distance (see the table on the right) between the 100 V - 200 V Over 2 m (7 ft)
machine and the electric cable. Check with the local power 6,600 V Over 2 m (7 ft)
company about safe operating procedure before starting 22,000 V Over 3 m (10 ft)
operations. 66,000 V Over 4 m (14 ft)
To prepare for any possible emergencies, wear rubber shoes 154,000 V Over 5 m (17 ft)
and gloves. Lay a rubber sheet on top of the seat, and be careful
187,000 V Over 6 m (20 ft)
not to touch the chassis with any exposed part of your body.
275,000 V Over 7 m (23 ft)
Use a signalman to give warning if the machine approaches too
close to the electric cables. 500,000 V Over 11 m (36 ft)
When carrying out operations near high voltage cables, do not
let anyone come close to the machine.
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.
ENSURE GOOD VISIBILITY

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.
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.
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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 some reason, the cab door does not open, use the rear window as an emergency escape. For details, see
"EMERGENCY EXIT FROM OPERATOR'S CAB (PAGE 3-41)" in this manual.
ASBESTOS DUST HAZARD PREVENTION

Asbestos dust in the air can cause lung cancer if it is inhaled. There
is danger of inhaling asbestos when working on jobsites handling
demolition work or work handling industrial waste. Always observe
the following.
Spray water to keep down the dust when cleaning. Do not use
compressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position. All
workers should use an approved respirator.
Do not allow other persons to approach during the operation.

Always observe the rules and regulations for the work site and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use
genuine Komatsu parts.
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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 (1).
CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the day's work.
Remove all dirt from the surface of the window glass to ensure a good view.
Remove all dirt from the surface of the lens of the front lamps and 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 the operation of the instruments and gauges, check the angle of the mirror, and check that the control
levers are all at the Neutral position.
Before starting the engine, check that lock lever (1) is in LOCK
position (L).
Adjust the mirrors so that the rear of the machine can be seen
clearly from the operator's seat.
When adjusting, see "Rearview Mirrors (PAGE 3-79)".
Check that there are no persons or obstacles above, below, or
in the area around the machine.
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SAFETY MACHINE OPERATION SAFETY
SAFETY RULES FOR STARTING ENGINE

When starting the engine, sound the horn as a warning.
Start and operate the machine only while seated.
Do not allow anyone apart from the operator to ride on the machine.
Do not short circuit the starting motor circuit to start the engine. Short circuit can cause fire.
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 and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
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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 gauges and equipment, and check the operation of the bucket, arm, boom, travel
system, swing system, and steering system.
Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
If any problem is found, carry out repairs immediately.
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS

Before traveling, set the machine so that sprocket (1) is behind
the operator's seat.
If sprocket (1) is in front of the operator's cab, the machine
moves in the opposite direction from the operation of the lever
(front and rear travel is reversed, left and right steering is
reversed). Be extremely careful when operating the machine in
this situation.
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.
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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.
Always be sure to carry out the above precautions even when the
machine is equipped with mirrors.
SAFETY RULES FOR TRAVELING

When traveling on flat ground, keep the work equipment 40 to 50
cm (16 to 20 in) high above the ground.
When traveling on rough ground, travel at low speed and do not
operate the steering suddenly. There is danger that the machine
may turn over. The work equipment may hit the ground surface
and cause the machine to lose its balance, or may damage the
machine or structures in the area.
When traveling on rough ground or steep slopes, if the machine
is equipped with auto-deceleration, always turn the
auto-deceleration switch OFF (cancel).
Avoid traveling over obstacles when possible. If the machine
has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side.
When traveling or carrying out operations, always keep a safe
distance from people, structures, or other machines to avoid
coming into contact with them.
When passing over bridges or structures, check first that the
structure is strong enough to support the weight of the machine.
When traveling on public roads, check first with the relevant
authorities and follow their instructions.
When operating in tunnels, under bridges, under electric wires,
or other places where the height is limited, operate slowly and
be extremely careful not to let the work equipment hit anything.
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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 30 cm (8 to 12 in) above the ground, and
travel at low speed.
When traveling downhill, lower the engine speed, keep the
travel lever close to the neutral position, and travel at low speed.
Always travel straight up or down a slope. Traveling at an angle

or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. 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.
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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 (A) 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.
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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 damage to the work equipment, or a
hazard of serious personal injury being caused by flying pieces
of broken materials, or of the machine tipping over due to
reaction from the impact.
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.
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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 lock lever (1) to the LOCK
position (L), 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.
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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, be extremely careful since the ramp surface is slippery.
Turn the auto-decelerator switch OFF (auto-deceleration function released).
Run the engine at low speed and travel slowly.
When on the ramps, do not operate any lever except for the travel lever.
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 change suddenly at the joint between the ramps and the track or trailer,
and there is danger of the machine losing its balance. Travel slowly over this point.
When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
When swinging the upper structure on the trailer, the trailer is unstable, so pull in the work equipment and swing
slowly.
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 3-122)".
REMARK
(1) Blocks (2) Ramp (3) Center line of trailer (4) Angle for setting ramps
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 procedure when transporting the machine, see TRANSPORTATION (PAGE 3-122).
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. 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.
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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
3-142)" in the OPERATION section.
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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 3-138)".
Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
Always wear leather gloves when handling wire rope.

Never tow a machine on a slope.
During the towing operation, never stand between the towing machine and the machine being towed.
Operate the machine slowly and be careful not to apply any sudden load to the wire rope.
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LIFTING OBJECTS WITH BUCKET

As a basic rule it is prohibited to carry out operations lifting objects with this standard specification machine.
LIFTING WORK USING BUCKET WITH HOOK

As a basic rule, it is prohibited to carry out lifting operations. However, if the work fulfils the specified conditions and
only if it fulfils the specified conditions, it is permitted to carry out lifting operations using a bucket with a hook.
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 6-3)".
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.
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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. 09963-03000
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 and tidy to enable you to carry out operations safely.
If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.
When cleaning the ceiling window which is made of organic glass (polycarbonate), use tap water and avoid use
of organic solvents for cleaning. An organic solvent like benzene, toluene or methanol can invite a chemical
reaction like dissolution and decomposition on the window glass, deteriorating polycarbonate in use.
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.
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SAFETY SAFETY MAINTENANCE INFORMATION
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE

Stop the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and stop
the engine.
Turn the starting switch to the ON position. Operate the work
equipment control lever back and forth, left and right at the full
stroke 2 to 3 times to eliminate the remaining internal pressure
in the hydraulic circuit, and then push up lock lever (1) to the
LOCK position (L).
Put blocks under the track to prevent the machine from moving.
2 - 33
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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 lock lever (1) to the LOCK position (L) to prevent the work
equipment from moving.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts, so
be careful not to come close.
Do not touch any control levers. If any 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.
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.
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ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property
damage. For this reason, always observe the following
precautions.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be released.
Please contact your Komatsu distributor to have this work
performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized 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 lifted off the ground and the machine is supported
only with the work equipment. If any of the control levers is
touched by accident, or there is damage occurring to the
hydraulic piping, the work equipment or the machine will
suddenly drop. This is extremely dangerous. Never work under
the work equipment or the machine.
NOISE
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.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
2 - 35
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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.
There is a hazard that the pin hit with strong force 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 proper equipment.
There is a hazard of gas, 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

Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves
as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury.
When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work.
2 - 36
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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, so always do as follows.
For details of the method of releasing the pressure, see "METHOD FOR RELEASING INTERNAL PRESSURE
IN HYDRAULIC CIRCUIT (PAGE 4-42)". If the circuit is still under pressure, do not carry out 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. 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 wire layer.
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 air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.
2 - 37
.
COMPRESSED AIR
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, replace safety-critical parts like hoses and seat belts
periodically.
Replacement of safety-critical parts: See "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 death. 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 - 38
.
3-1
.
MACHINE VIEW ILLUSTRATIONS OPERATION
MACHINE VIEW ILLUSTRATIONS

OVERALL MACHINE VIEW
(1) Bucket (6) Boom cylinder

(2) Bucket cylinder (7) Sprocket
(3) Arm (8) Track frame
(4) Arm cylinder (9) Track shoe
(5) Boom (10) Idler
3-2
.
OPERATION MACHINE VIEW ILLUSTRATIONS
CONTROLS AND GAUGES
(1) Car radio (25) Engine coolant temperature monitor

(2) Rotating lamp switch (if equipped) (26) Engine oil pressure monitor
(3) Airconditioner control panel (27) Engine coolant temperature gauge
(4) Lock lever (28) Charge level monitor
(5) Left work equipment control lever (29) Radiator coolant level monitor
(6) Knob switch (30) Working mode monitor
(7) Travel pedal (31) Hydraulic oil temperature monitor
(8) Travel levers (32) Hydraulic oil temperature gauge
(9) Cigarette lighter (33) Maintenance interval monitor
(10) Machine monitor (34) Service meter
(11) Horn switch (35) Travel speed monitor
(12) Right work equipment control lever (36) Engine oil level monitor
(13) Starting switch (37) Air cleaner clogging monitor
(14) Fuel control dial (38) Fuel gauge
(15) Lamp switch (39) Fuel level monitor
(16) Alarm buzzer stop switch (40) One touch power up monitor
(17) Swing lock switch (41) Auto-deceleration monitor
(18) Swing brake cancel switch (42) Liquid crystal monitor adjustment switch
(19) Emergency pump drive switch (43) Up/down switch
(20) Select switch (44) Window washer switch
(21) Working mode selector switch (45) Wiper switch
(22) Wiper monitor (46) Maintenance switch
(23) Engine pre-heating monitor (47) Travel speed selector switch
(24) Swing lock monitor (48) Auto-deceleration switch
3-3
.
DETAILED CONTROLS AND GAUGES OPERATION
DETAILED CONTROLS AND GAUGES

The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
MONITORING SYSTEM
AA: Screen with all lamps lighted up

BB: Screen for normal operation
CC: Maintenance time warning screen
A: Basic check monitors D: Meter display portion,pilot display

B: Caution monitors E: Monitor switches portion
C: Emergency monitors
3-4
.
OPERATION DETAILED CONTROLS AND GAUGES
Basic Operation Of Machine Monitor
If There Is Abnormality When Starting Engine
If there is any abnormality when starting the engine, the check before starting screen DD changes to the
maintenance interval warning screen CC, warning screen FF, or error screen EE.
After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance
interval warning screen CC.
After displaying the maintenance interval warning screen CC for 30 seconds, the screen returns to the normal
screen BB.
After displaying the check before starting screen DD for 2 seconds, the screen changes to the warning screen
FF or error screen EE.
3-5
.
If Any Abnormality Occurs During Operation
If any abnormality occurs during operation, the normal operation screen BB changes to warning screen FF-(1) or
the error screen EE.
After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2).
3-6
.
Basic Check Monitors

CAUTION
These monitors DO NOT ensure that the machine is in good condition. When performing checks before starting (daily checks),
do not simply rely on the monitors. Always dismount the machine and check each item directly.
Displays basic items among the check before starting items that must be checked before starting the engine. If there
is any abnormality, monitor for the location of abnormality will light up.
A(1) Radiator coolant level monitor A(3) Maintenance interval monitor

A(2) Engine oil level monitor
Radiator Coolant Level Monitor

Monitor (1) warns the operator that there has been a drop in the
radiator coolant level.
If the radiator coolant is low, the lamp lights up red, so check
coolant level in the radiator and subtank, and add coolant.
3-7
.
Engine Oil Level Monitor

Monitor (2) warns the operator that the oil level in the engine oil pan
has dropped.
If oil level in the engine oil pan is low, the lamp lights up red, so
check the oil level, and add oil.
Maintenance Interval Monitor

Monitor (3) lights up to warn the operator that the set time has
passed since maintenance was last performed.
This monitor screen goes out after 30 seconds and returns to the
normal operation screen.
For details of the method of checking the maintenance interval,
see "Maintenance Switch (PAGE 3-22)" in the Detailed controls
and gauges.
If it is desired to change the maintenance interval settings, have

your Komatsu distributor change the interval settings.
3-8
.
Caution Monitors
CAUTION
If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the
applicable location. If the warning is ignored, it may lead to failure.
These are items that should be observed while the engine is running. If any abnormality occurs, the screen displays
the item that needs immediate action.
If there is an abnormality, the monitor for the abnormal location lights up red.
B(1) Charge level monitor B(4) Engine coolant temperature monitor

B(2) Fuel level monitor B(5) Hydraulic oil temperature monitor
B(3) Air cleaner clogging monitor
Charge Level Monitor

Monitor (1) warns the operator of a abnormality in the charging
system while the engine is running.
If the battery is not being charged properly while the engine is
running, monitor (1) lights up red.
If monitor lights up red, check the V-belt for looseness. If any
abnormality is found, perform the necessary actions. For details,
see "OTHER TROUBLE (PAGE 3-144)".
REMARK
While the starting switch is ON, the lamp will remain lit and will go off when the engine is started.
When the engine is started or stopped with the starting switch at the ON position, the lamp may light up and the
buzzer and horn may sound momentarily, but this does not indicate any abnormality.
3-9
.
Fuel Level Monitor

Monitor (2) lights up to warn the operator the fuel level in the tank
is low.
If the remaining amount of fuel goes down to 41 liters (10.83 US
gal), the light changes from green to red, so add fuel as soon as
possible.
If the indicator enters the red range, do not carry out operations on
steep slopes. There is danger that the engine will stall.
Air Cleaner Clogging Monitor

Monitor (3) warns the operator of a clogged air cleaner.
If the monitor lights up red, stop the engine, inspect and clean the
air cleaner.
Engine coolant Temperature Monitor

If monitor (4) lights up white in low temperatures, perform
warming-up operation. For details, see "Warming-up Operation
(PAGE 3-88)".
Continue warming-up operation until monitor (4) changes to green.
Hydraulic Oil Temperature Monitor

If monitor (5) lights up white in low temperatures, perform
warming-up operation. For details, see "Warming-up Operation
(PAGE 3-88)".
Continue warming-up operation until monitor (5) changes to green.
3 - 10
.
Emergency Monitors
CAUTION
If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary
actions.
These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal
location lights up red and buzzer sounds, perform action immediately.
C(1) Engine coolant temperature monitor C(3) Engine oil pressure monitor
C(2) Hydraulic oil temperature monitor
Engine Coolant Temperature Monitor

Monitor (1) warns operator that the engine coolant temperature
has risen.
If engine coolant temperature becomes abnormally high, monitor
lights up red, overheat prevention system is automatically
actuated, and the engine speed goes down.
Stop operations and run engine at low idle until monitor (1)
changes to green.
3 - 11
.
Hydraulic Oil Temperature Monitor

Monitor (2) warns operator that the hydraulic oil temperature has
risen.
If monitor lights up red during operations, run engine at low idle or
stop the engine and wait until the oil temperature goes down and
monitor (2) changes to green.
Engine Oil Pressure Monitor

Monitor (3) lights up red if the engine lubrication oil pressure goes
below normal level. If monitor lights up red, stop the engine
immediately, check the lubrication system and level of oil in the
engine oil pan.
REMARK
While the starting switch is ON, the lamp remains lit and goes off
once the engine is started. When the engine starts, the buzzer may
sound for a short time, however, this does not indicate a fault.
REMARK
Color when the monitor lights up for basic check items, caution items, and emergency stop items are as follows.
Color when monitor lights up

Type of monitor When When At low
normal abnormal temperature
Radiator coolant level monitor OFF Red -
Engine oil level monitor OFF Red -
Maintenance interval monitor OFF Red -
Charge monitor OFF Red -
Fuel level monitor Green Red -
Air cleaner clogging monitor OFF Red -
Engine coolant temperature monitor Green Red White
Hydraulic oil temperature monitor Green Red White
Engine oil pressure monitor OFF Red -
3 - 12
.
Meter Display Portion
D(1) Engine pre-heating monitor D(7) One touch power up monitor

D(2) Swing lock monitor D(8) Engine coolant temperature gauge
D(3) Wiper monitor D(9) Fuel gauge
D(4) Auto-deceleration monitor D(10) Hydraulic oil temperature gauge
D(5) Working mode monitor D(11) Service meter
D(6) Travel speed monitor
Pilot Display
When starting switch is ON, the pilot display lights up when display items are functioning.
Engine Pre-heating Monitor

Monitor lamp (1) indicates pre-heating time required when starting
the engine at an ambient temperature below 0°C (32°F).
The monitor lamp lights when the starting switch is turned to the
HEAT position and flashes after 30 seconds to show pre-heating
is completed. (Monitor lamp will go off after 10 seconds.)
3 - 13
.
Swing Lock Monitor

Monitor (2) informs the operator that the swing lock is being
actuated.
Actuated: Lights up
When the swing lock switch is turned ON (ACTUATED), the
monitor lamp lights up.
This monitor flashes when the swing holding brake release switch
is turned on.
REMARK
The swing motor is equipped with a disc brake that mechanically
stops the rotation. When the swing lock monitor is lighted up, the
brake remains applied.
Wiper Monitor
Monitor (3) indicates operating ststus of the wiper.
The monitor display when wiper switch is operated, as follows.
When ON lights up: Wiper moves continuously
When INT lights up: Wiper moves intermittently
OFF: Wiper stops
Auto-deceleration Monitor
Monitor (4) shows if the auto-deceleration is being actuated.
The monitor display when auto-deceleration switch is operated, as
follows.
Auto-deceleration monitor ON: Auto-deceleration actuated
Auto-deceleration monitor OFF: Auto-deceleration canceled
Working Mode Monitor

Monitor (5) displays the set working mode.
The monitor display when the working mode switch is operated is
as follows.
A: A mode (for heavy-load operations)
E: E mode (for operations with emphasis on fuel economy)
L: L mode (for fine-control operations)
B: B mode (for breaker operations)
3 - 14
.
Travel Speed Monitor

This monitor (6) displays the set mode for the travel speed.
The monitor display when the travel speed selector switch is
operated is as follows.
Lo: Low speed
Hi: High speed
One touch power up monitor

Meter (7) shows if the power max function is being actuated.
The monitor display when the knob switch on the left control lever
is operated is as follows.
Monitor lights up: Digging power is increased while knob switch is

kept pressed.
REMARK
The digging power is increased while the knob switch is being
pressed only for working modes A and E. Note that even if the knob
switch is kept pressed, the increase in power ends after 8.5
seconds.
Monitor goes out: Power max function stopped
Gauges and Meter
Engine Coolant Temperature Gauge

Gauge (8) indicates the engine coolant temperature.
During normal operations, indicator should be in the black range
(A) - (C). If indicator enters the red range (A) - (B) during
operations, the overheat prevention system is actuated.
REMARK
(A) - (B): Displays red range
(A) - (C): Displays black range
The overheat prevention system acts as follows.

Red range position (A): Engine coolant temperature monitor lamp (1) lights up red.
Red range position (B): Engine speed is reduced to low idle, engine coolant temperature monitor lamp (1) lights up
red, and the alarm buzzer sounds at the same time.
The overheat prevention system remains actuated until the indicator returns to the black range.
When the engine is started, if the indicator is at position (C), engine coolant temperature monitor (1) lights up white.
In this case, carry out the warming-up operation. For details, see "Warming-up Operation (PAGE 3-88)".
3 - 15
.
Fuel Gauge
Gauge (9) indicates the amount of fuel in the fuel tank.
During operations, the indicator should be in the black range.
If indicator enters red range (A) during operations, there is less
than 60 liters (15.85 US gal) of fuel remaining in the tank, check
and add fuel.
REMARK
REMARK
When the remaining fuel goes below 41 liters (10.83 US gal), fuel level monitor (1) lights up red.
The correct fuel level may not be displayed for a short time when the starting switch is turned ON, but this is not an
abnormality.
Hydraulic Oil Temperature Gauge

Meter (10) displays the hydraulic oil temperature.
During operations, the indicator should be in the black range.
If the indicator enters red range (A) during operations, the hydraulic
oil temperature has gone above 102°C (215.6°F).
Stop the engine or run it at low idle and wait for the hydraulic oil
temperature to go down.
REMARK
REMARK
Hydraulic oil temperature is as follows when the indicator enters the red range (A):
(A) position in the red range: 102°C (215.6°F) or over
(B) position in the red range: 105°C (221°F) or over
When the indicator is in the red range (A) - (B), hydraulic oil temperature monitor (1) lights up red.
If the indicator is on (C) position when starting the engine, it means that hydraulic oil temperature is 25°C (77°F) or
lower and the hydraulic oil temperature monitor (1) will be illuminated white. When this happens, refer to the section
"Warming-up Operation (PAGE 3-88)" and perform warm-up operation.
Service Meter
This monitor (11) displays the total time that the machine has been
operated.
Use the time display to set the maintenance interval. When the
starting switch is ON, the service meter advances even if the
machine is not moving.
The service meter advances by 1 for every hour of operation,
regardless of the engine speed.
3 - 16
.
Monitor Switches Portion
E(1) Working mode selector switch (basic switch) E(7) Select switch
E(2) Auto-deceleration switch (selection switch) E(8) Back switch
E(3) Travel speed selector switch E(9) Up switch
E(4) Wiper switch E(10) Down switch
E(5) Window washer switch E(11) Input confirmation switch
E(6) Maintenance switch E(12) Liquid crystal monitor adjustment switch
3 - 17
.
Working Mode Selector Switch (Basic Switch)

Switch (1) is used to set the power and movement of the work
equipment.
Operations can easily be performed by selecting the mode to
match the type of operation.
A mode: For heavy-duty operations
E mode: For operations prioritizing fuel consumption
L mode: For fine-control operations
B mode: For breaker operations
GG mode: Monitor display
When the engine is started, the working mode is set automatically to A mode. When switch (1) is pressed, it is
possible to select other modes. The monitor display on display portion (GG) changes for each mode.
If it is desired to have the working mode set to start automatically in E, L, or B mode (default option setting), have
your Komatsu distributor change the setting.
REMARK
When the mode selector switch is pressed, the mode is displayed
in the center of monitor display portion (GG), and the screen
returns to normal screen (BB) after 2 seconds. (Diagram on the
right is an example of display for the E mode.)
NOTICE
When using the breaker, do not use A mode. There is danger that the breaker may be damaged.
3 - 18
.
Auto-deceleration Switch (Selection Switch)

When switch (2) is pressed, the auto-deceleration is actuated, if
the control levers are in neutral position, the engine speed is
automatically lowered to reduce fuel consumption.
Monitor display portion GG ON : Auto-deceleration actuated
Monitor display portion GG OFF : Auto-deceleration canceled
Each time the switch is pressed, auto-deceleration switches
between actuated and canceled.
Auto-deceleration function
When the auto-deceleration function is ON, if the work equipment and travel levers are returned to the N position,
the engine speed will drop after 4 seconds from the operating speed to idling speed.
This makes it possible to reduce fuel consumption.
If any lever is operated when the machine is in this condition, engine speed will return to the previous operating
speed to make it possible to perform operations.
REMARK
When the auto-deceleration switch is pressed and the
auto-deceleration is actuated, the mode is displayed in the center
of display portion (GG), and the screen returns to normal screen
(BB) after 2 seconds.
3 - 19
.
Travel Speed Selector Switch
WARNING
When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (3) at the Lo position).
Never operate travel speed selector switch (3) while loading or unloading.
If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even
when traveling in a straight line.
Stop the machine before switching the travel speed.
This switch (3) is used to set the travel speed to 3 stages.

Lo lights up : Low-speed travel
Hi lights up : Hi-speed travel
When the engine is started, the speed is automatically set to Lo.
Each time that the switch is pressed, the display changes Lo J
Hi J Lo in turn.
When traveling in high speed (Hi), if travel power is needed, such as when traveling on soft ground or on slopes, the
speed automatically switches to low speed (Lo), so there is no need to operate the switch. The monitor display GG
stays at Hi.
REMARK
Each time that the travel speed selector switch is operated, the
mode is displayed in the center of display portion (GG), and the
screen returns to normal screen (BB) after 2 seconds.
3 - 20
.
Wiper Switch
Switch (4) operates the wiper for the front glass.
Each time the switch is pressed, it changes ON → INT → stop
(OFF).
Monitor display portion GG INT lighted up: Wiper moves
intermittently
Monitor display portion GG ON lighted up: Wiper moves
continuously
Monitor display portion GG OFF: Wiper stops
REMARK
Each time that the wiper switch is operated, the mode is displayed
in the center of display portion (GG). The screen returns to normal
screen (BB) after 2 seconds.
Window Washer Switch

Switch (5) is kept continuously pressed, window washer fluid is
sprayed onto the front glass. When the switch is released, spray
stops.
If switch (5) is kept pressed when the wiper is stopped, the

window washer fluid will spray, and at the same time, the wiper
will be actuated continuously. When switch (5) is released, the
wiper will continue to operate for 2 cycles, then stop.
If the wiper is moving intermittenly and switch (5) is kept pressed
continuously, window washer fluid will spray, and at the same
time, the wiper will be actuated continuously. When switch (5) is
released, the wiper will continue to operate for 2 cycles, then
return to intermittent operation.
3 - 21
.
Maintenance Switch
Switch (6) is used to check the time remaining until
maintenance.
When switch (6) is pressed, screen on the monitor display

changes to the maintenance screen, as shown in diagram on
the right.
The time remaining until maintenance is indicated by the color of
each monitor display. After confirming the maintenance time,
perform the maintenance.
White display: More than 30 hours remaining until maintenance
Yellow display: Less than 30 hours remaining until maintenance
Red display: Maintenance time has already passed
NOTICE
1. If monitor display portion GG changes to the maintenance timing
warning screen when the engine is started or when the machine is being
operated, stop operations immediately. When this happens, the monitor
corresponding to the maintenance time warning screen will light up red.
2. Press switch (6) to display the maintenance screen.
Perform maintenance for any location indicated by the monitor that has
lighted red.
Maintenance display items are as follows:
Monitor Default set

Maintenance item
No. screen (H)
01 Change engine oil 500
02 Change engine oil filter 500
03 Change fuel filter 500
04 Change hydraulic oil filter 1000
05 Change hydraulic tank breather 500
Change corrosion resistor
06 1000
(option for overseas)
07 Check damper case oil level, add oil 1000
08 Change final drive case oil 2000
09 Change swing machinery case oil 1000
10 Change hydraulic oil 5000
If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings.
3 - 22
.
The method of checking time remaining until maintenance is as follows:

1. Look at the maintenance screen, press up switch (9) or down
switch (10) on the monitor switch portion, and select the item.
(Color of the monitor for selected item is inverted to black.)
2. After selecting the monitor item, press input confirmation

switch (11). Display screen will switch to the time remaining
until maintenance.
(Press back switch (8) to return to the previous screen.)
3. Check the time remaining until maintenance.

(a): Time remaining until maintenance
(b): Default setting for maintenance interval
When only checking the time remaining until maintenance,

press back switch (8) twice.
The screen will return to the normal operation monitor screen.
When canceling time remaining until maintenance and
returning to the default time setting, press inout confirmation
switch (11). The screen will switch to the default setting screen.
4. After checking the time on the default setting screen, press
input confirmation switch (11).
The screen will return to the maintenance screen.
(Press back switch (8) to return to the previous screen.)
3 - 23
.
Select Switch
This switch (7) is used as a selector switch when setting the oil flow
for each working mode (A, E, B mode).
When working mode is A or E

(1) Press select switch (7) and the normal screen on the monitor
display changes to the flow setting screen shown in the diagram
on the right.
(2) Press up switch (9) or down switch (10) to adjust to the desired
flow.
Each segment on the scale is approx. 30 liters/min.
(3) After completing the flow setting, press input confirmation
switch (11).
The monitor display will return to the normal screen.
REMARK
The flow can be adjusted only when it is possible to install an
attachment. (if equipped)
When working mode is B mode

(1) Press select switch (7) and the normal screen on the monitor
display changes to the flow setting screen shown in the diagram
on the right.
flow.
switch (11).
(4) With the operation in Step (3), the flow setting screen changes
to the fine flow adjustment screen shown in the diagram on the
right.
flow.
Each segment on the scale is approx. 10 liters/min.
switch (11).
The monitor display will return to the normal screen.
3 - 24
.
Back Switch
Press this switch (8) when in the maintenance mode,
brightness/contrast adjustment mode, or select mode. The screen
will return to the previous screen on the monitor display.
Up Switch, Down Switch

Press up switch (9) or down switch (10) when in the maintenance
mode, brightness/contrast adjustment mode, or select mode to
move the cursor on the monitor display (colors of selected monitor
are inverted) up, down, left, or right.
Input Confirmation Switch

Press this switch (11) to confirm the selected mode when in the
maintenance mode, brightness/contrast adjustment mode, or
select mode.
3 - 25
.
Liquid Crystal Monitor Adjustment Switch

Press switch (12) to adjust the brightness or contrast of the display
monitor.
Adjusting brightness and contrast

1.When monitor adjustment switch (12) is pressed, the monitor
display screen changes to the brightness/contrast screen shown
in the diagram on the right.
Adjusting brightness
2. Use the brightness/contrast screen and press up switch (9) or
down switch (10) to select brightness of the monitor.
(The selected monitor is inverted to black.)
3.When the screen changes to the brightness adjustment screen,

press up switch (9) or down switch (10) to adjust the brightness.
4.After completing adjustment of the brightness, press input
confirmation switch (11).
3 - 26
.
Adjusting contrast
2.Use the brightness/contrast screen and press up switch (9) or
down switch (10) to select the contrast monitor.
(The selected monitor is inverted to black.)
3.When the screen changes to the contrast adjustment screen,

press up switch (9) or down switch (10) to adjust the contrast.
4.After completing adjustment of the contrast, press input
3 - 27
.
SWITCHES
(1) Starting switch (7) Horn switch

(2) Fuel control dial (8) Knob switch
(3) Cigarette lighter (9) Room lamp switch
(4) Swing lock switch (10) Emergency pump drive switch
(5) Lamp switch (11) Swing brake cancel switch
(6) Alarm buzzer stop switch (12) Rotating lamp switch (if equipped)
Starting Switch
Starting switch (1) is used to start or stop the engine.
(A): OFF position
The key can be inserted or withdrawn. Switches for the electrical
system (except room lamp), are all turned off and the engine is
stopped.
(B): ON position
Electric current flows through the charging and lamp circuits. Keep
starting switch key in the ON position while the engine is running.
(C): 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 (B).
(D): HEAT (pre-heat) position
When starting the engine in cold weather, turn the key to HEAT position (D), the pre-heating monitor lights up. Keep
the key at this position until the monitor lamp flashes. Immediately after the pre-heating lamp flashes, release the
key. The key automatically returns to OFF position (A). Then, start the engine by turning the key to START position
(C).
3 - 28
.
Fuel Control Dial

This dial (2) adjusts the engine speed and output.
(a) Low idle (MIN): Turned fully to the left
(b) Full speed (MAX): Turned fully to the right
Cigarette Lighter
This switch (3) is used to light cigarettes. To use, push the lighter
in. After a few seconds it will spring back.
Pull out the lighter and light your cigarette.
By removing the cigarette lighter, the socket is available as a
power source for the yellow flashing lamp. Max. current is 3.5 A (85
W).
Swing Lock Switch
WARNING
When not using the swing operation, e.g. in traveling, put the swing lock
switch to the OFF position.
On slopes, even when the swing lock switch is at the ON position, the
weight of the work equipment may cause the upper structure to swing
if the swing control lever is operated in the downhill direction.
Switch (4) is used to lock the upper structure so it will not swing.
(a) ON position: The swing lock is always applied, and the upper
structure will not swing even if the swing is
operated. In this condition, the swing lock lamp
lights up.
(b) OFF position: The swing lock is applied only when the swing
control lever is in the neutral position, and
released when operating the swing control lever.
The swing lock is actuated in 7 seconds after
putting the swing control lever in the neutral
position.
3 - 29
.
Lamp Switch
Switch (5) is used to turn on the front lamps, working lamps,
additional lamps at top front of the cab, and monitor lighting.
(a) ON: Lamps light up
(b) OFF: Lamps go off
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 a problem in a
warning item.
REMARK
The switch (6) is an automatic return switch. For this reason, if the
switch is pressed to position (a) and released, it will return to STOP
position (b), but this is not a problem.
Horn Switch
When the switch (7) at the tip of the right work equipment control
lever is pressed, the horn will sound.
Knob Switch
Use knob switch (8) on the left work equipment control lever to
activate the one-touch power max./slow-down function.
Press the switch and keep it pressed until the power max. function
is canceled.
In A mode or E mode, the power max. function is actuated for a
maximum of 8.5 seconds.
3 - 30
.
Room Lamp Switch

NOTICE
It is possible to turn on the interior cab room lamp even when starting
switch is in the OFF position, do not forget to turn it off.
Use this switch (9) to light up the room lamp.

Position (a) ON: Lights up
Position (b) OFF: Goes out
The room lamp lights up even when the starting switch is in the
OFF position.
Emergency Pump Drive Switch

NOTICE
Emergency pump drive switch is provided to make it possible to perform
work for a short time when there is a failure in the pump control system. It
is necessary to repair the abnormal location as soon as possible.
This switch (10) is used when there is a problem in the pump

control system (when the display shows "E02"). It makes it
possible to carry out operations for a short time.
(a) When there is problem: Move switch up
(b) When condition is normal: Move switch down
If the display shows "E02", move this switch up to make it
possible to carry out operations.
Swing Brake Cancel Switch

NOTICE
This switch makes it possible to perform swing operations for a short even
when there is a problem in the swing brake electric system. DO NOT use
this switch except in emergencies. Repair the problem as soon as
possible.
This switch (11) is used when there is a problem in the swing brake
cancel system (when the display shows "E03"). It makes it
possible to carry out swing operations for a short time.
(a) When there is problem: Move switch up
(b) When condition is normal: Leave switch down
If the display shows "E03", move this switch up to make it
possible to carry out swing operations.
3 - 31
.
Rotating Lamp Switch (If Equipped)

This switch (12) is used to light up the yellow rotating lamp on top
of the cab.
(a) ON: Lamps light up
(b) OFF: Lamps go off
3 - 32
.
CONTROL LEVERS AND PEDALS
(1) Lock lever (3) Left work equipment control lever

(2) Travel levers (with auto-deceleration system)
(with pedal and auto-deceleration system) (4) Right work equipment control lever
(with auto-deceleration system)
Lock Lever
WARNING
When standing up from the operator's seat, push lock lever (1) down
securely to set it to LOCK position (L). If lock lever (1) is not in LOCK
position (L) and the control levers are touched by mistake, it may lead
to serious personal injury.
Check lock lever (1) is placed securely at LOCK position (L).
Be careful not to touch the work equipment control levers when pulling
lock lever (1) up or pushing it down.
This lever (1) is a device to lock the work equipment, swing, travel, and attachment (if equipped) control levers.
Push the lever (1) down to apply the lock.
This lock lever (1) is a hydraulic lock, even if it is in the lock position (L), the work equipment control lever and travel
lever will move, but the work equipment, travel motor, and swing motor will not work.
3 - 33
.
Travel Levers
WARNING
Do not rest your foot on the pedal during operations. If the pedal is
depressed by mistake, the machine may suddenly move and cause a
serious accident. Be extremely careful when operating the pedal for
travel or steering operations. When you are not using the pedal, do not
rest your foot on it.
If the track frame is facing the rear, the direction of travel operations will
be reversed when the travel lever is operated. (The machine will travel
forward when operated in reverse, and in reverse when operated
forward; the left and right directions will also be reversed.)
When operating the travel levers, check if the track frame is facing the
front or the rear. (If the sprocket is at the rear, the track frame is facing
the front.)
Lever (2) is used to change the direction of travel between forward

and reverse. ( ) shows the pedal operation.
(a) FORWARD: The lever is pushed forward
(The pedal is angled forward)
(b) REVERSE: The lever is pulled back
(The pedal is angled back)
N (Neutral): The machine stops
REMARK
If the travel lever is operated from the Neutral position to the FORWARD or REVERSE position, the alarm sounds
to warn people in the surrounding area that the machine is about to move.
Work Equipment Control Lever

Left work equipment control lever (3) is used to operate the arm
and upper structure.
Arm operation
(a) Arm OUT
(b) Arm IN
Swing operation
(c) Swing to right
(d) Swing to left
N (Neutral) : The upper structure and arm are held in position and
do not move.
3 - 34
.
Right work equipment control lever (4) is used to operate the boom
and bucket.
Boom operation
(a) RAISE
(b) LOWER
Bucket operation
(c) DUMP
(d) CURL
N (Neutral) : The boom and bucket are held in position and do not
move.
3 - 35
.
SUN ROOF
WARNING
When standing up from the operator's seat, push lock lever (1) down
securely to set it to LOCK position (L).
If lock lever (1) is at the FREE position (F) and the control lever is touched
by mistake, this may lead to a serious accident.
Opening
1. Set lock lever (1) securely to LOCK position (L).
2. Check for any ceiling window movement by pulling lock knob
(A) located on front side, then push up and open the ceiling
window grasping grip (B).
Closing
Hold grasping grip (B), lower the ceiling window, and apply lock (A). If the lock cannot be applied, open the ceiling
window, then pull it in again and apply the lock.
WINDSHIELD
WARNING
When opening or closing the front window, bottom window, or door,
always set lock lever (1) to LOCK position (L).
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.
3 - 36
.
Opening
1. Stop the machine on level ground, lower the work equipment
completely to the ground, then stop the engine.
2. Push lock lever (1) down to set it securely to LOCK position (L).
3. Check that the wiper blade is stowed in the right stay.
4. Grip handles (A) at the top right and left of the front window,
and pull lock lever (B) toward yourself to release the lock at the
top of the front window. The top of the front window will come
out.
3 - 37
.
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 in 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 - 38
.
Closing
WARNING
When closing the window, lower it slowly and be careful not to get your hand caught.
1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine.
2. Push lock lever (1) down to set it securely to LOCK position (L).
3. Grip left and right handles (A), and pull down lock lever (B) to
release the lock.
4. Grip handle (C) at the bottom of the front window with your left
hand and handle (D) at the top with your right hand, push to the
front, then lower slowly.
3 - 39
.
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 in 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, store it at the rear of the

operator's cab and lock it securely with left and right locks (B).
When removing, always hold the glass with one hand and
release the lock with the other hand.
3 - 40
.
EMERGENCY EXIT FROM OPERATOR'S CAB

If for some reason, the cab door does not open, remove the rear
window and use it as an emergency escape.
Remove the rear window as follows.
1. Pull ring (1) and completely remove seal (2) from the rubber
core.
2. With pressure push on corner of the window, the glass will fall outside.
Do not remove the rear window except when using it as an emergency exit.
DOOR LOCK
WARNING
Before the releasing the door lock, always stop the machine on flat ground.
Never release the door lock on a slope. The door may suddenly close and cause injury.
When releasing the door lock, do not extend your body or hands outside the machine and do not put your hands on the door
frame. The door may suddenly close and cause injury.
Use the door lock to fix the door in position after opening it.
1. Push the door against catch (1) to lock it in position.
2. When closing the door, push down the lever (2) on the left of
the operator's seat to release the catch.
3. When attaching the door in position, lock it firmly to the catch.
3 - 41
.
CAP WITH LOCK

Locks are fitted to the fuel tank filler, hydraulic tank filler, operator's cab, engine hood, tool box cover, right side door
of the machine, and left side door of the machine. Use the starting key to open and close the caps, doors and covers.
Insert the key as far as it will go to the shoulder (A). If the key is
turned before it is inserted all the way, it may break.
Opening and Closing Caps with Lock
Opening the Cap

1. Insert the key into the key slot.
2. Turn the starting switch key counterclockwise, align the key
slot with the 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 starting switch key clockwise, then remove the key.
Opening and Closing Cover with Lock
Opening the Cover (Locked Cover)

1. Insert the key into the key slot.
2. Turn the key counterclockwise and open the cover by pulling
the cover grip.
(A): Open
(B): Lock
Locking the Cover

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and take the key out.
3 - 42
.
HOT AND COOL BOX

This is on the right side at the rear of the operator's seat. It is
interconnected with the air conditioner: it stays warm when the
heating is used, and stays cool when the cooling is used.
MAGAZINE BOX
(The cup holder is provided separately at the front of the magazine box.)
Located on left side of the operator's seat.
Keep the Operation and Maintenance Manual in this box so that it
can be taken out and read whenever necessary.
ASHTRAY
This is under the machine monitor at the front right of the operator's
compartment.
Always make sure that you extinguish your cigarette, then put it in
the ashtray and close the lid.
3 - 43
.
AIR CONDITIONER CONTROLS
Air Conditioner Control Panel
(1) OFF switch (6) FRESH/RECIRC selector switch

(2) Fan switch (7) Display monitor
(3) Temperature control switch (8) Air conditioner switch
(4) Vent selector switch (9) Sunlight sensor
(5) Auto switch
OFF Switch
Switch (1) is used to stop the fan and air conditioner.
When OFF switch (1) is pressed, the set temperature and air
flow display on display monitor (7), the lamps above auto switch
(5), and air conditioner (8) go out, and operation stops.
3 - 44
.
Fan Switch
Switch (2) is used to adjust the air flow.
The air flow can be adjusted to six levels.
Press the ∧ switch to increase the air flow; press the ∨ switch to
reduce the air flow.
During auto operation, the air flow is automatically adjusted.
A: Liquid crystal dispiay

B: Air flow
a: Air flow "low"
b: Air flow "medium 1"
c: Air flow "medium 2"
d: Air flow "medium 3"
e: Air flow "medium 4"
f: Air flow "high"
Temperature Control Switch

Switch (3) is used to control temperature inside the cab. The
temperature can be set between 18°C (64.4°F) and 32°C (89.6°
F).
Press the ∧ switch to raise the set temperature; press the ∨ s
witch to lower the set temperature.
The temperature is generally set at 25°C (77°F).
The temperature can be set in stages of 0.5°C (0.9°F).
<Monitor display and the function>
Monitor display (°C) Set temperature

18.0 Max. cooling
Adjusts temperature inside cab to set
18.5 to 31.5
temperature
32.0 Max. heating
3 - 45
.
REMARK
If the mode is set to auto mode and the temperature setting is set to 18.0 °C (64.4 °F) and 32.0 °C (89.6 °F), the air
flow from the fan is always set to HIGH and does not change even when the set temperature is reached.
Vent Selector Switch

Switch (4) is used to select the vents.
When switch (4) is pressed, the display on monitor display (7)
switches and air blows out from the vents displayed.
During automatic operation, the vents are automatically
selected.
(A): Rear vent (4 places)

(B1): Face vent (1 place)
(C): Foot vent (1 place)
(D): Front window glass vent (1 place)
(B2): Front window glass vent (1 place)
3 - 46
.
Auto Switch
With switch (5), the air flow, vents, and air source
(RECIRC/FRESH) are automatically selected according to the set
temperature.
When auto switch (5) is pressed, the lamp above the auto switch
lights up.
Press switch (5), then use temperature control switch (3) to set
the temperature, and run the air conditioner under automatic
control.
When the control is switched from automatic operation to
manual operation, it is possible to operate the to change air flow,
vents, and air source (RECIRC/FRESH). When manual control
is used, lamp above the auto switch goes out.
REMARK
When Auto Mode is selected, if the set temperature is set to 18.0 °C (64.4 °F) and 32.0 °C (89.6 °F), the air flow is
always set to High, but this is not a problem.
FRESH/RECIRC Selector Switch

Switch (6) is used to switch the air source between recirculation of
air inside the cab and intake of from the outside.
When switch (6) is pressed, the lamp above the selector switch
lights up to show that air is being blown out.
During automatic operation, the selection of inside air (RECIRC)
and outside air (FRESH) is performed automatically.
RECIRC Outside air is shut off and only air inside the cab is circulated.
Use this setting to perform rapid cooling of the cab or when outside air is dirty.
FRESH Outside air is taten into the cab.
Use this setting to take in fresh air when performing demisting.
Display Monitor
Monitor (7) displays the status of temperature setting (a), air flow
(b), and vents (c).
When OFF switch (1) is pressed, the display of temperature
setting (a) and air flow (b) goes out, and operation stops.
3 - 47
.
Air Conditioner Switch

Switch (8) is used to turn the air conditioner (cooling,
dehumidifying, heating) ON or OFF.
When the fan is actuated (display (b) is shown) and air
conditioner switch (8) is pressed, the air conditioner is switched
ON, lamp above the air conditioner switch lights up, and the air
conditioner starts.
When switch (8) is pressed again, the air conditioner is switched
OFF, lamp above the air conditioner switch goes out, and the air
conditioner stops.
Air conditioner cannot be operated while the fan is off.
Sunlight Sensor
This sensor (9) automatically adjusts the flow of air from the vents
to match the strength of the sun's rays. In addition, it automatically
detects changes in the temperature inside the cab caused by
changes in the strength of the sun's rays beforehand and
automatically adjusts the temperature.
3 - 48
.
Method of Operation
The air conditioner can be operated automatically or manually. Select the method of operation as desired.
Automatic Operation
1. Turn auto switch (5) ON.
The lamp above switch (5) lights up.
The set temperature (a) and air flow (b) are displayed on the
monitor.
2. Use temperature set switch (3) to set to the desired

temperature. The air flow, combination of vents, and selection
of fresh or recirculated air is automatically selected according
to the set temperature, and the air conditioner is operated
automatically to provide the set temperature.
REMARK
When vent display monitor (c) displays (d) or (e), and engine
coolant temperature is low, the air flow is automatically limited to
prevent cold air from blowing out.
3 - 49
.
Stopping Automatic Operation

Press OFF switch (1). The displays for temperature setting (a) and
air flow (b) on monitor (7), and lamps above auto switch (5) and air
conditioner switch (8) go out, the operation stops.
Manual Operation
1. Press fan switch (2) and adjust the air flow. When doing this,
check that temperature setting (a) and air flow (b) are displayed
on monitor (7).
2. Turn air conditioner switch (8) ON. Check that the lamp above
air conditioner switch lights up.
3 - 50
.
3. Press temperature setting switch (3) and adjust temperature

inside the cab.
4. Press vent selector switch (4) and select the desired vents.
When this is done, the display for vent (c) of the display monitor
changes according to the selection.
5. Press RECIRC/FRESH selector switch (6) and select

recirculation of the air inside the cab (RECIRC) or intake of
fresh air from outside (FRESH).
3 - 51
.
Stopping Manual Operation

Press OFF switch (1). The displays for temperature setting (a) and
air flow (b) on monitor (7), and lamps above auto switch (5) and air
conditioner switch (8) go out, the operation stops.
Operation with Cold Air to Face and Warm Air to Feet

To operate with cold air blowing to the face and warm air blowing
to the feet, set as follows.
on monitor (7).
2. Press vent selector switch (4) and set the vent display on the
display monitor to the display shown in the diagram on the
right.
3 - 52
.
3. Turn air conditioner switch (8) ON. Check that the lamp above
air conditioner switch lights up.
4. Adjust fan switch (2), temperature setting switch (3) and

RECIRC/FRESH selector switch (6) to the desired positions.
3 - 53
.
Defroster Operation
on monitor (7).
2. Press vent selector switch (4) and set vent display on the
display monitor to (f) or (g) as shown in diagram on the right.
3 - 54
.
3. Press RECIRC/FRESH selector switch (6) and set it to take in

fresh air.
4. Press temperature setting switch (3) and set temperature on

the display (7) monitor to maximum heating.
5. Adjust vents (A), (B1), and (B2) so that the air blows onto the
window glass.
(Vents (C) and (D) are fixed and cannot be adjusted.)
When operating in the rainy season or when it is desired to remove

the mist from the window glass or to dehumidify the air, turn air
conditioner switch (8) ON.
3 - 55
.
Use Air Conditioner with Care

NOTICE
When running the air conditioner, always start with the engine running at low speed. Never start the air conditioner when the
engine is running at high speed. It will cause failure of the air conditioner.
If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, be careful not to let water get on these
parts. In addition, never bring any flame near these parts.
For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean and do not leave anything
around the sunlight sensor that may interfere with its sensor function.
Ventilation
If you smoke when the air conditioner is on, the smoke may start to hurt your eyes, so open the window and turn
the lever to FRESH for a while to remove the smoke while continuing the cooling.
When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry out
ventilation and cooling.
Temperature Control
When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 or 6 °C (9 or 10.8
°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 of a machine equipped with an air conditioner, see the "CHECK AND MAINTENANCE
AIR CONDITIONER (PAGE 4-36)" and carry out inspection according to the table.
3 - 56
.
Other Functions
Self-diagnostic Function
It is possible to perform troubleshooting of various sensors and equipment used on the air conditioner.
1. Turn the starting switch key to the ON (B) position.
2. Press OFF switch (1). The temperature setting and air flow
display on the liquid crystal display portion go out and
operation stops.
3. If the "∨" and "∧" parts of temperature setting switch (3) are
kept pressed at the same time for at least 3 seconds, the
troubleshooting mode is displayed on the liquid crystal display
portion.
<Monitor display and failure mode>
Display Failure mode

E-- No failure
E11 Disconnection in RECIRC sensor
E12 Short circuit in RECIRC sensor
E15 Disconnection in water temperature sensor
E16 Short circuit in water temperature sensor
E18 Short circuit in sunlight sensor
E43 Abnormality in vent damper
E44 Abnormality in air mix damper
E45 Abnormality in RECIRC/FRESH damper
When more than one failure is detected, press the "∨" or "∧" portion of temperature setting switch (3) to display
the failures in turn.
After completing the troubleshooting, press OFF switch (1) again to return to the normal display.
If any problem is detected by the self-diagnostic function, contact your Komatsu distributot perform inspection and
repair.
3 - 57
.
Function to Switch Set Temperature Display Between Fahrenheit and Celsius

It is possible to switch the set temperature display between °F and
°C.
If the "∨" and "∧" portions of temperature setting switch (3) are
pressed at the same time for more than 5 seconds while the fan is
running, the temperature display will switch between °F and °C.
(Note that the unit is not displayed.)
Liquid crystal display range

°C 18.0 to 32.0
°F 63 to 91
3 - 58
.
RADIO
Control Panel
(1) Power switch, Volume control knob, Balance (5) AS/PS button
control knob (6) Preset station buttons (1,2,3,4,5,6)
(2) SEL button (7) Display
(3) FM/AM selection button (8) Time reset button
(4) Display selection button (9) Tuning button
Power switch, Volume control knob, Balance control knob

Press this knob (1) to turn the power for the radio on. The frequency is displayed on display (7). Press the knob
again to turn the power off.
Turn the knob clockwise to increase the volume; press counterclockwise to reduce the volume. The range for the
volume is VOL 0 - VOL 40.
SEL button
Each time this button (2) is pressed, the mode changes as follows: VOL (volume) J BAS (bass) J TRE (treble) J
BAL (balance). The mode is displayed on display (7). For details of each mode, see "Controls of Radio (PAGE
3-61)".
FM/AM Selection Button (AM/FM)

Press this button (3) to select the desired band.
Each time the button is pressed, the band changes FM J AM J FM . . .
3 - 59
.
Display Selection Button (TIME)

On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4)
and the display will show the present time for 5 seconds. After 5 seconds pass, the display returns automatically
to the frequency display. If any button other than TIME ADJ (H, M, ADJ) is pressed within 5 seconds, the display
returns to the frequency display. For details of the method of adjusting the time, see "Controls of Radio (PAGE
3-61)".
AS/PS button
This button (5) actuates the auto store and preset scan functions.
Auto store
If this button is pressed for more than 2 seconds during radio reception, a search is made automatically of the
6 station settings to find an unused preset number, and that frequency is stored in the preset memory.
Preset scan
If this button is pressed within 2 seconds, it is possible to select one of the already preset stations. Wait for 6 sec.
after pressing the button and then press the button again to select the next preset station. If it is impossible to
receive the preset frequency, the selection advances after 1 second to the next preset station.
Preset Station Buttons (1, 2, 3, 4, 5, 6)

If this button (6) has been used to decide which stations to preset, it is possible to select the desired station at a
touch. It is possible to preset 6 stations each for both AM and FM.
For details of the method of presetting the stations, see "Controls of Radio (PAGE 3-61)".
Display
In this display (7), receiving band, frequency, preset No. and time are shown.
Time Reset Button

Use this button (8) when adjusting the time. For details of the method of adjusting the time, see "Controls of Radio
(PAGE 3-61)".
H: Hour
M: Minute
ADJ: Sets to 00 minutes
Tuning Button (TUNING) Manual Tuning (MANUAL)

Use this button (9) to change the frequency.
For further details, see "Controls of Radio (PAGE 3-61)"
3 - 60
.
Controls of Radio
Preset Station Buttons

1. Press power switch (1) and display the frequency on display
(7).
2. Use tuning button (9) to set to the desired frequency. There are
two methods for tuning: auto tuning and manual tuning.
3. With the display (7) showing the desired frequency, keep the
desired Preset button No pressed for at least 1.5 seconds. The
reception sound will disappear, but when the presetting
operation (saving to memory) is completed, the sound will
appear again and the Preset No and frequency will be shown
on the display to show that the presetting operation has been
completed.
After completing the presetting, press Preset button (6) and
release it within approx. 1.5 seconds. This will make it possible
to receive the channel preset to that button. One channel each
for AM and FM can be preset to each Preset button.
REMARK
It is also possible to save to the Preset button by using the auto store button.
Method of Setting with Preset Button

1. Press power switch (1) and display the frequency on display (7).
2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual
tuning.
Manual tuning
Press tuning button (9) until the frequency is displayed on display (7).
< button: Frequency moves down
> button: Frequency moves up
When the frequency reaches the top or bottom frequency, it automatically continues as follows: Top J Bottom, or
Bottom J Top.
Auto tuning
Press tuning button (9) for at least 3 seconds. When a station is picked up, the tuning automatically stops. To
search for the next station, press the tuning button again for at least 3 seconds.
< button: Frequency moves down
> button: Frequency moves up
If this button is pressed during auto tuning, the auto tuning will be cancelled and the setting will return to the
frequency in use before the button was pressed.
3 - 61
.
Method of Operating Mode

(BAS) Bass adjustment button: When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned
clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned
counterclockwise, the bass sound is reduced.
(TRE) Treble adjustment button: When button (2) pressed, TRE is displayed on display (7). If knob (1) is turned
clockwise within 5 seconds, the treble sound is emphasized. If the knob is
turned counterclockwise, the treble sound is reduced.
(BAL) Balance adjustment button: When button (2) is pressed, BAL is displayed on display (7). If knob (1) is
turned clockwise within 5 seconds, the sound from the right speaker is
increased. If the knob is turned counterclockwise, the sound from the left
speaker is increased. When it is set to BAL 0, the sound from the left and right
speakers is balanced.
REMARK
With each mode, the display is returned automatically to its original setting after 5 seconds.
Setting Correct Time

1. Press display selector button (4) to display the time.
After 5 seconds, the display will return to the frequency display
and the time cannot be corrected. If this happens, press
display selector button (4) again.
2. Press time adjustment button (8) to set to Hour or Minute.
H button: Adjusts the hour (each time the button is pressed, the
time advances by one hour)
M button: Adjusts the minute (each time the button is pressed,
the time advances by one minute)
If the H or M button is kept pressed, the time will advance
continuously until the button is released.
ADJ button: When the ADJ button is pressed, the time is reset
as follows.
When display is 00 - 05 minutes, time is returned to 00 min.
00 sec. (No change in hour)
When display is 55 - 59 minutes, time is advanced to 00 min.
00 sec. (Hour advances)
When display is 06 - 54 minutes, time cannot be reset. (Time
stays same)
Example
10:05 J 10:00
10:59 J 11:00
10:26 J 10:26
Press the H, M, and ADJ buttons to set to the correct time.
3 - 62
.
Antenna
NOTICE
Before transporting the machine or putting it inside a building, stored the
antenna to prevent any interference.
Stow the antenna as follows.

1. Loosen antenna mounting bolt (1) and store the antenna at
position (A).
2. After storing the antenna, tighten bolt (1).
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.
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AUXILIARY ELECTRIC POWER
24V power source

NOTICE
Do not use this as the power source for 12 V equipment.
Pull out the connector plug for taking out electric power from the
rear side of the panel.
Maximum usable electric power is 85 W (24 V x 3.5 A).
12V power source

(if equipped)
This power source can be used up to a capacity of 60W (12V x 5A).
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FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
Fuse Capacities and Circuit Names
Fuse
No. Name of circuit
capacity
(1) 10A Controller
(2) 20A Electromagnetic valve
(3) 10A PPC hydraulic lock solenoid
(4) 10A Window washer, cigarette lighter
(5) 10A Horn
(6) 10A Spare
(7) 10A Rotating lamp( arm crane solenoid)
(8) 10A Light relay
(9) 10A Radio, speaker, left knob switch
(10) 10A Spare
(11) 20A Air conditioner unit
(12) 20A Monitor, wiper monitor
(13) 20A Light, light relay drive
(14) 10A 10 A Optional power source (1)
Optional power source (2),
(15) 10A
travel alarm, 12V power port
(16) 10A Radio backup
(17) 10A Spare
(18) 10A Starting switch, monitor (normal power source)
(19) 10A Room lamp
(20) 10A Spare
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FUSIBLE LINK
If the starting motor does not start even when the starting switch is
turned to the ON position, wire-shaped fusible link (1) (2 places)
has probably melted, so open the battery box cover on the right
side of the machine, check the fusible link, and replace 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.
CONTROLLERS
Controller installed.
NOTICE
Be careful not to get water, mud, or juice on the controller. This will
cause failure.
If any problem occurs in the controller, do not disassemble it yourself.
Contact your Komatsu distributor for repairs.
TOOL BOX
This is used for keeping the tools.
GREASE GUN HOLDER

This is inside the battery room door on the left side of the machine.
When not using the grease gun, fit it in this holder.
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ACCUMULATOR
WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to
serious injury or damage. When handling the accumulator, always do as follows.
The pressure in the control circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in
the direction that the oil spurts out when carrying out the operation.
Loosen the bolts slowly.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work
carried out.
This machine is equipped with an accumulator in the control circuit. The accumulator is a device to store oil pressure
for the control circuit. Because an accumulator is installed, the control circuit can be actuated for a short time even
after the engine is stopped. As a result, if the control lever is moved in the LOWER direction, the work equipment
will go down under its own weight.
The accumulator is installed to the position shown in the diagram
on the right.
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Releasing Hydraulic Pressure with Accumulator

1. Place the work equipment on the ground. Close the crusher
attachment jaws, etc.
2. Stop the engine.
3. Turn the starting switch to the ON position.
4. Set lock lever (1) to FREE position (F), then operate the work
equipment control levers and the attachment control pedal (if
equipped) fully to the front, rear, left, and right to release the
pressure in the control circuit.
5. Set lock lever (1) to LOCK position (L) to lock the control levers
and the attachment control pedal.
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OPERATION MACHINE OPERATIONS AND CONTROLS
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
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts.
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu
distributor.
Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check for cracks, excessive wear, play in wotk equipment, cylinders, linkage, and hoses. If any problem is
found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator.
Check for dirt accumulated around the engine and radiator. Also check for flammable material (dry leaves, twigs,
etc.) around the battery, engine muffler, turbocharger, or other high temperature engine parts. If any dirt or
flammable materials are found, remove them.
3. Check for coolant and oil leakage around the engine

Check for oil leakage from the engine and coolant leaks from the cooling system. If any problem is found, repair
it.
4. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, and joints
Check for oil leakage. If any problem is found, repair the area where oil is leaking.
5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers.
If any problem is found, repair it.
6. Check for problems in handrails, steps, loose bolts.

If any problem is found, repair it. Tighten any loose bolts.
7. Check for problem in gauges, monitor.

Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts.
Clean off any dirt from the surface.
8. Clean, check rear view mirror

Check for damage to the rear view mirror. If damaged, replace it with a new mirror. Clean surface of the mirror
and adjust angle so area at the rear can be seen from the operator's seat.
9. Seat belt and mounting clamps

Check for damage or wear to the seat belt and mounting clamps. If there is any damage, replace with new parts.
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MACHINE OPERATIONS AND CONTROLS OPERATION
10. Check bucket with hook (if equipped) for damage.

Check for damage to the hook, guide, and hook mount. If any problem is found, contact your Komatsu distributor
for repairs.
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Checks Before Starting

Always check the items in this section before starting the engine each day.
Check Coolant Level, Add Coolant
WARNING
Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in 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 door at the rear left of the machine, and check if the
coolant in sub-tank (1) (shown in the diagram on the right) is
between the FULL and LOW marks. If the coolant level is low,
add coolant to the FULL level through the filler port of sub-tank
(1).
2. After adding coolant, tighten the cap securely.
3. If the sub-tank (1) is empty, there is probably leakage of
coolant. After inspecting, repair any problem immediately. If
there is no problem, check the coolant level in the radiator. If
the coolant level is low, add coolant to the radiator, then fill the
sub-tank (1).
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Check Oil Level in Engine Oil Pan, Add Oil
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
1. Open the engine hood on the machine.

2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. The oil level should be between the H and L marks on dipstick
(G).
If the oil level is below the L mark, add engine oil through oil
filler (F).
5. If the oil is above the H line, open drain valve (P) at the bottom
of the engine oil pan, drain the excess engine oil, then check
the oil level again.
6. If oil level is correct, securely tighten the oil filler cap and close
the engine hood.
REMARK
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine
before checking.
If the machine is at an angle, make it to a horizontal position before checking.
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Check Fuel Level, Add Fuel
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames
near fuel because it is highly flammable and dangerous.
1. Open fuel filler cap (F) of the fuel tank.

2. If fuel filler cap (F) is opened, float gauge (G) rises to the fuel
level. Check that the fuel tank is full. Check the fuel level
visually and with float gauge (G).
3. If the fuel tank is not full, add fuel through the fuel filler until float
gauge (G) rises to the maximum position.
Fuel tank capacity: 280 liters (73.98 US gal)
Position of tip of float gauge (G) when tank is full: Approx. 50
mm (2 in) from top surface of fuel tank
4. After adding fuel, push float gauge (G) straight down with fuel
filler cap (F). Be careful not to get float gauge (G) caught in the
tab of fuel filler cap (F), and tighten fuel filler cap (F) securely.
REMARK
If breather hole (1) in the cap is clogged, the pressure in the tank
will drop and fuel will not flow. Clean the hole from time to time.
Drain Water And Sediment from Fuel Tank

1. Open the pump room door on the right side of the machine.
2. Set a container under drain hose (1) to catch the drained fuel.
3. Open drain valve (2) at the rear of the fuel tank and drain the
water and sediment accumulated at the bottom of the tank
together with the fuel.
4. When only clean fuel comes out, close drain valve (2).
5. Close the pump room door on the right side of the machine.
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Check for Water and Sediment in Water Separator, Drain Water

1. Open the pump room door at the left side of the machine.
2. Inspect the water separator, and check if the ring inside has
risen to the marked line.
3. If the ring has risen to the marked line, carry out the procedure
from Step 4.
4. Prepare a container to catch the drained fuel and set it under

the water separator.
5. Close fuel valve (6) at the bottom of the fuel tank.
6. Remove air bleed plug (5) at the top of the water separator.
7. Loosen drain valve (1) at the bottom of the water separator,
and drain the water and sediment into the container.
8. Loosen ring nut (2), then remove filter case (3).
9. Remove element (4) from the separator base.
10. Wash element (4) and filter case (3) in clean diesel oil.
11. Check element (4) and replace it if it is damaged.
12. When installing element (4), perform Steps 5 and 9 in the
opposite order.
Tightening torque of ring nut (2):
40 ± 3 N·m (4.1 ± 0.3 kgf·m, 29.7 ± 2.2 lbft)
13. Loosen air bleed plug (5) then Fill filter case (3) with fuel. When
the fuel comes out from air bleed plug (5), tighten air bleed plug
(5).
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Check Oil Level in Hydraulic Tank, Add Oil
WARNING
When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap.
1. If the work equipment is not in the condition shown in the

diagram on the right, start the engine, run the engine at low
speed, retract the arm and bucket cylinder rods fully, then
lower the boom, set the bucket teeth in contact with the ground,
and stop the engine.
2. Within 15 seconds after stopping the engine, move each
control lever (for work equipment and travel) to the full stroke
in all directions to release the internal pressure.
3. Check sight gauge (G) from the right window installed to the
operator's compartment. The oil level should be between the H
and L lines.
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 above the H level, stop
the engine and wait for the hydraulic oil to cool down, then drain the excess
oil from drain plug (P).
4. If the oil level is below the L line, add oil through oil filler (F) at
the top of the hydraulic tank.
REMARK
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:
Before starting operation: Between H and L levels
(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))
Check Working Lamp Switch

Turn the lamp switch to the ON position and check that the
working lamp light up.
If the lamps do not light up, there is probably a broken bulb or

disconnection in the wiring, contact your Komatsu distributor for
repairs.
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Check Electric Wiring
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately
perform 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; that fuses of the specified capacity are used; that there is no
disconnection or trace of short-circuiting in the electric wiring and no damage to the covering. Check also that there
is no loosened terminals. If any, tighten them.
Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and
alternator.
Be sure to check that there is no inflammable material accumulated around the battery. If present, remove it as soon
as possible.
Check Function of Horn

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, contact your Komatsu distributor for repair.
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Adjustment
Seat Adjustment
WARNING
When adjusting the position of the operator's seat, always set lock lever (1)
to LOCK position (L) to prevent the machine or work equipment from
moving if there is accidental contact with the control levers.
Always adjust the operator's seat before starting each operation

or when the operators change shift.
Adjust the operator's seat so control levers and switches can be
operated freely and easily with the operator's back against the
backrest.
(A) Fore-and-aft adjustment

Pull lever (1) up, set the seat to the desired position, then release
the lever.
Fore-and-aft adjustment: 160 mm (6.3 in) (16 stages)
(B) Adjusting reclining
NOTICE
The operator's seat can be reclined to a large angle when the seat is
completely pushed forward, but the reclining angle is reduced when the
seat is moved backward. So return the seat to its upright position before
moving the seat to the rear.
Pull up lever (2) and set the backrest to a position that is

comfortable for operation, then release the lever.
Sit with your back against the seat backrest when adjusting. If your
back is not against the backrest, the backrest may suddenly move
forward.
(C) Adjusting seat tilt

Forward tilt
Push lever (3) down to adjust angle of the front of seat. (4 stages)
To raise the angle at front of the seat, keep the lever pushed down and apply your weight to the rear of seat.
To lower the angle at front of the seat, keep the lever pushed down and apply your weight to the front of seat.
Rear tilt
Pull lever (4) up to adjust angle of the rear of seat. (4 stages)
To raise the angle at rear of the seat, keep lever (3) pulled up, and stand up slightly to remove your weight from
the seat.
To lower the angle at rear of the seat, keep lever (3) pulled up, and apply your weight to the seat.
Amount of tilt: Up 13°, down 13°
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Adjusting seat height

It is possible to move the seat up or down by combining adjustments forward tilt and rear tilt.
After setting the forward tilt or rear tilt to the desired height, operate the opposite part to set the seat horizontal then
secure in position.
Height adjustment: 60 mm (2.4 in)
(D) Adjusting armrest angle

Armrest (5) can be made to spring up by hand approx. 90°.
In addition, by turning the bottom (6) of the armrest by hand it is possible to make fine vertical adjustments of the
armrest angle.
Armrest adjustment angle: 25°.
REMARK
If the seat back is tipped to the front without raising the armrest(5), armrest will rise automatically.
(E) Overall fore-and-aft adjustment of seat

Move lever (7) to right, set to the desired position, then release the lever. In this case, the operator's seat, left and
right control levers, and lock lever all slide together.
Fore-and-aft adjustment:180 mm (7.1 in) (9 stages)
(F) Adjusting suspension (if equipped)

Turn knob (8) to the right to make the suspension harder,or to the left to make the suspension softer. Adjust the
reading of the dial to match the operator's weight and select the optimum suspension.
REMARK
To adjust the firmness to a suitable value, turn the knob until the weight indicator in the transparent portion inside
knob (8) indicates the same weight as the operator.
If the cable at the rear of armrest (5) is tense (when the seat back is tipped to the front), the angle of armrest (5)
cannot be adjusted by turning dial (6).
When adjusting the angle of armrest (5), set the backrest to a position where it is easy to carry out operations,
then adjust the armrest.
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Rearview Mirrors
Loosen nut (1) and bolt (2) mounting the mirror, and adjust to the
position which gives the best view from the operator's seat of the
blind spot to the left and right sides at the rear of the machine.
Adjust the mirror mount so that it is possible to see people (or
objects with a height of 1 m (3.3 ft) or a diameter of 30 cm (12 in))
at the rear left and right of the machine
Install the mirror to the dimensions listed in the table below.
Recognition areas are also shown in the table for reference.
Mounting position X : 100 mm (3.9 in)

Range of view Y (right side) : 1500 mm (4 ft 11in)
Range of view Z (left side) : 1830 mm (6 ft)
Mirror A : Must be able to see hatched area (A)

Mirror B : Must be able to see hatched area (B)
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Seat Belt
WARNING
Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged,
replace the seat belt.
Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on
the back of the belt.
Always wear the seat belt during operations.
Fit the seat belt so that it is not twisted.
Fastening and Removing

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, hold grip (2) and return the belt slowly to wind-in device (1).
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Operations Before Starting Engine

WARNING
Before starting the engine, check that lock lever (1) is in LOCK position (L).
If the control levers are not locked and they are touched by accident when
starting the engine, there is a hazard that the machine may move suddenly
and cause serious injury or property damage.
1. Check that lock lever (1) is at the LOCK position (L).
2. Check the position of each lever.

Set control lever to the neutral position.
3. Insert the key in starting switch (2), turn the key to the ON
position (B), then carry out the following checks.
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If a password has been set, the input display screen is shown on

the monitor screen.
After inputting the password, press input confirmation switch (3).
REMARK
For details of the method of setting, changing, or canceling the
password, see "PROCEDURE FOR SETTING, CHANGING, OR
CHANCELING PASSWORD".
1) The buzzer sounds for approx. 1 second, and the following

monitors and meters light up for approx. 3 seconds.
Radiator coolant level monitor (4)
Engine oil level monitor (5)
Charge level monitor (6)
Fuel level monitor (7)
Engine coolant temperature monitor (8)
Engine oil pressure monitor (9)
Engine coolant temperature gauge (10)
Fuel gauge (11)
Air cleaner clogging monitor (12)
If the monitors do not light up or the buzzer does not sound,
there is probably a failure in the monitor, so contact your
Komatsu distributor for repairs.
2) After approx. 3 seconds, the screen switches to the
working mode/travel speed display monitor. Then it
switches to the normal screen.
Fuel level monitor (7)
Engine coolant temperature monitor (8)
Engine coolant temperature gauge (10)
Fuel gauge (11)
Hydraulic oil temperature gauge (13)
Hydraulic oil temperature monitor (14)
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3) If the hydraulic oil temperature gauge goes out and caution

lamp (15) stays lighted up red, perform inspection
immediately for the item which is lighted up red.
4) If there are any items where the maintenance time has

passed, maintenance interval monitor (16) lights up for 30
seconds. Press maintenance switch (17), check the item,
then perform maintenance immediately.
For details of the method of checking the maintenance

interval, see "Maintenance Switch (PAGE 3-22)" in the
Detailed controls and gauges.
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STARTING ENGINE
Normal Starting
WARNING
Start the engine only after sitting down in the operator's seat.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause a serious bodily injury or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Before starting the engine, check that the fuel control dial is at the low idle (MIN) position.
If the fuel control dial is at the FULL position, the engine will accelerate suddenly and cause damage to the engine parts.
Do not crank the starting motor continuously for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes before trying again.
1. Check the lock lever (1) is at the LOCK position (L). If the lock
lever (1) is in the FREE position (F), the engine does not start.
2. Set fuel control dial (2) at the low idle (MIN) position.
If it is at the high idle (MAX) position, always change it to the
low idle (MIN) position.
3. Turn the key in starting switch (3) to the START position (C).
The engine will start.
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4. After the engine starts, release the key in starting switch (3).
The key will automatically return to the ON position (B).
5. Even after the engine is started, do not touch the work

equipment control levers and the travel pedals, while the
engine hydraulic pressure monitor lamp is still lighted.
NOTICE
If the engine oil pressure monitor does not go out even after 4 to 5 seconds
have passed, stop the engine immediately. Check the oil level, check for
leakage of oil, and take the necessary action.
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Starting Engine in Cold Weather

WARNING
Start the engine only after sitting down in the operator's seat.
Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury
or fire.
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Never use starting aid fluids as they may cause explosions.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
NOTICE
Before starting the engine, check that fuel control dial (2) is at the low
idle (MIN) position.
If the fuel control dial is at the FULL position, the engine will accelerate
suddenly and cause damage to the engine parts, set it to an
intermediate or low speed position.
Do not keep the strating motor rotating continuously for more than 20
seconds.
If the engine fails to start, wait for about 2 minutes and repeat from Step
2.
When starting in low temperatures, do as follows.

1. Check the lock lever (1) is at the LOCK position (L). If the lock
lever (1) is in the FREE position (F), the engine does not start.
2. Set fuel control dial (2) at a low idle (MIN) position.

Do not set fuel control dial (2) at the high idle (MAX) position.
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3. Hold the key in starting switch (3) in the HEAT position (D), and
check that engine pre-heating monitor (4) lights up. After about
30 seconds, engine pre-heating monitor lamp (4) will flash to
indicate that pre-heating is finished.
REMARK
The monitors and gauges will light up also when the key is
turned to the HEAT position, but this is not a problem.
If the temperature is low, the monitor screen may become dark
or it may take time for the display to appear, but this is not a
problem.
4. When engine pre-heating monitor (4) flashes, turn the key in

starting switch (3) to the START position (C) to start the engine.
5. After the engine starts, release the key in starting switch (3).
The key will automatically return to the ON position (B).
6. After starting the engine, do not touch the work equipment

control lever or travel pedal while the engine oil pressure
monitor lamp is lighted up.
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AFTER STARTING ENGINE

WARNING
If any trouble occurs, such as sudden stopping or abnormal operation, turn the starting switch to the OFF position.
If the work equipment is operated without carrying out the warming-up operation properly, the reaction of the work equipment
to the operation of the control lever will be slow and the work equipment may not move as the operator intends. To prevent such
problems, always be sure to carry out the warming-up operation fully. In cold weather particularly, be extremely careful to carry
out the warming-up operation fully.
Warming-up Operation
NOTICE
When the hydraulic oil is at a low temperature, do not perform
operations or move the levers suddenly. Always perform the
warming-up operation. This will help extend the machine life.
Do not suddenly accelerate the engine before the warming-up operation
is completed.
Do not run the engine at low or high idle continuously for more than 20
minutes. This will cause oil leaks from the turbocharger oil supply
piping. If it is necessary to run the engine at idle, apply a load from time
to time or run the engine at a mid-range speed.
REMARK
If the engine coolant temperature is above 30°C (86°F), to protect the turbocharger, the engine speed does not
rise for 2 seconds after starting, even if the fuel control dial is turned.
If the hydraulic oil temperature is low, the hydraulic oil temperature monitor display will be white.
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After starting the engine, do not immediately start operations. First, perform the following operations and checks.
1. Turn fuel control dial (2) to center position (a) between the low
idle (MIN) and high idle (MAX) positions and run the engine at
a mid-range speed under no load until the engine coolant
temperature monitor gives a green display.
2. Set lock lever (1) slowly and securely to FREE position (F),
then 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.
(A): Arm is pushed out
(B): Arm is pulled in
(C): Bucket is pushed out
(D): Bucket is pulled in
REMARK
If the swing lock switch (5) is set to the ON (actuated) position and
swing control lever (4) is operated at full stroke, oil temperaturerise
can be increased earlier.
(E): Left swing

(F): Right swing
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 performing the warming-up operation, check and be sure

all the gauges on machine monitor (6) and the caution lamps
are in the following conditions:
Radiator coolant level monitor (7): OFF
Engine oil level monitor (8): OFF
Charge level monitor (9): OFF
Fuel level monitor (10): Green display
Engine coolant temperature monitor (11): Green display
Engine oil pressure monitor (12): OFF
Engine coolant temperature gauge (13): Indicator in black
range
Fuel gauge (14): Indicator in black range
Engine pre-heating monitor (15): OFF
Air cleaner clogging monitor (16): OFF
Hydraulic oil temperature gauge (17): Indicator in black
range
Hydraulic oil temperature monitor (18): Green display
6. Check for abnormal exhaust gas color, noise, or vibration. If

any problem is found, contact your Komatsu distributor.
7. If air cleaner clogging monitor (16) lights up, clean or replace the element immediately.
For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER
ELEMENT (PAGE 4-19)".
8. Use working mode selector switch (19) on machine monitor (6)

to select the working mode to be used.
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.
Working mode monitor display

1) A mode
For heavy-load operations
2) E mode
For operations with emphasis on fuel economy
3) L mode
For fine-control operations
4) B mode
For breaker operations
3 - 91
.
In Cold Weather Areas

(AUTOMATIC WARMING-UP OPERATION)
When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine.
When the engine is started, if the engine water temperature is low (below 30°C (86°F), the warming-up operation
is performed automatically.
The automatic warming-up operation is canceled if the engine coolant temperature reaches the specified
temperature (30°C (86°F) or if the warming-up operation continues for 10 minutes. If the engine coolant or hydraulic
oil temperatures are low after 10 minutes, continue to warm the engine up as follows:
NOTICE
Do not suddenly accelerate the engine before the warming-up operation
is completed.
Do not run the engine at low or high idle continuously for more than 20
minutes. This will cause oil leaks from the turbocharger oil supply
piping. If it is necessary to run the engine at idle, apply a load from time
to time or run the engine at a mid-range speed.
Never perform operations or operate the control levers when the
hydraulic oil is still a low temperature. Always continue the warming-up
operation until the hydraulic oil temperature monitor display is green.
This will extend the service life of the machine.
REMARK
If the hydraulic oil temperature is low, the hydraulic oil temperature monitor display will be white.
1. Turn fuel control dial (2) to the low idle (MIN) position and run
the engine under no load until the engine coolant temperature
monitor gives a green display.
2. To raise the hydraulic oil temperature quickly, use the
operating mode switch on the machine monitor to set to A
mode (heavy-duty operation mode).
3. Turn fuel control dial (2) to the medium speed position (a).
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.
4. Set lock lever (1) slowly and securely to FREE position (F),
then raise the bucket from the ground.
5. 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.
6. Operate the bucket for 30 seconds and the arm for 30 seconds
in turn fully for 5 minutes.
(A): Arm is pushed out
(B): Arm is pulled in
(C): Bucket is pushed out
(D): Bucket is pulled in
REMARK
If the swing lock switch (5) is set to the ON (actuated) position and
swing control lever (4) is operated at full stroke, oil temperaturerise
can be increased earlier.
(E): Left swing

(F): Right swing
NOTICE
When the work equipment is retracted, take care that it does not interfere with the machine body or ground.
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.
7. After the warming-up operation is completed, check that each

gauge and monitor lamp is in the following condition:
Radiator coolant level monitor (7): OFF
Engine oil level monitor (8): OFF
Charge level monitor (9): OFF
Fuel level monitor (10): Green display
Engine coolant temperature monitor (11): Green display
Engine oil pressure monitor (12): OFF
Engine coolant temperature gauge (13): Indicator in black
range
Fuel gauge (14): Indicator in black range
Engine pre-heating monitor (15): OFF
Air cleaner clogging monitor (16): OFF
Hydraulic oil temperature gauge (17): Indicator in black
range
Hydraulic oil temperature monitor (18): Green display
8. Check for abnormal exhaust gas color, noise, or vibration. If

any problem is found, contact your Komatsu distributor.
9. If air cleaner clogging monitor (16) lights up, clean or replace the element immediately.
For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER
ELEMENT (PAGE 4-19)".
10. Turn fuel control dial (2) to the full speed (MAX) position and
carry out the operation is Step 5. for 3 to 5 minutes.
11. Repeat the following operation 3 - 5 times and operate slowly.
Boom operation RAISE ←→ LOWER

Arm operation IN ←→ OUT
Bucket operation CURL ←→ DUMP
Swing operation LEFT ←→ RIGHT
Travel (Lo) operation FORWARD ←→ REVERSE
REMARK
If the above operation is not carried out, then may be a delay in response when starting or stopping the actuation
of the travel, swing, or work equipment.
12. Use working mode selector switch (19) on machine monitor (6)
to select the working mode to be used.
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.
Working mode monitor display

1) A mode
For heavy-load operations
2) E mode
For operations with emphasis on fuel economy
3) L mode
For operations requiring fine control
4) B mode
For breaker operations
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.
NOTICE
Canceling automatic warming-up operation
If it becomes necessary in an emergency to cancel the automatic warming-up operation or to lower the engine speed to low idle,
do as follows.
1] Turn fuel control dial (2) to the full speed (MAX)

position and hold it for 3 seconds.
2] When fuel control dial (2) is returned to the low idle

(MIN) position, the engine speed will drop.
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.
STOPPING THE ENGINE

NOTICE
If the engine is stopped abruptly, service life of component parts of the
engine may be considerably reduced. Do not stop the engine abruptly
except in an emergency. If the engine has overheated, do not try to stop it
abruptly but run it at medium speed to allow it to cool down gradually, and
then stop it.
1. Run the engine at low idle for about 5 minutes to cool down
gradually.
2. Turn the key in starting switch (1) to the OFF position (A) and
stop the engine.
3. Remove the key from starting switch (1).
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.
MACHINE OPERATION
Preparations for Moving the Machine

WARNING
Before operating the control lever, check the direction of the track
frame. If the track frame is facing the rear (if the sprocket is at the front),
the machine moves in the opposite direction from the operation of the
travel lever (front and rear travel is reversed, left and right steering is
reversed).
Before starting the machine off, check that the area around the machine
is safe, and sound the horn.
Do not allow anyone to enter the area around the machine.
Clear any obstacles from the travel path.
There is a blind spot at the rear of the machine, so be particularly careful
when traveling in reverse.
If the control lever is operated when the auto deceleration is being
actuated, the engine speed will suddenly rise, so be careful when
operating.
Before starting the machine off, check that the alarm sounds normally.
1. Set swing lock switch (1) to the ON (actuated) position and

confirm that swing lock monitor lamp (2) lights up.
2. Turn fuel control dial (3) towards the full speed position to
increase the engine speed.
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.
Moving Machine Forward

1. Set lock lever (4) in the FREE position (F), fold the work
equipment, and raise it 40 to 50 cm (16 to 20 in) from the
ground.
2. Operate the right and left travel levers (5), or the right or left travel pedals (6) as follows:
When sprocket (A) is at the rear of the machine:
Slowly push the levers (5) forward, or slowly depress the front
part of the pedals (6) to move the machine forward.
When sprocket (A) is at the front of the machine:

Slowly pull the levers (5) backward, or slowly depress the rear
part of the pedals (6) to move the machine forward.
3. Check that the alarm sounds properly. If the alarm does not sound, please contact your Komatsu distributor for
repair.
REMARK
In cold temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation.
In addition, if the undercarriage is clogged with mud and the machine travel speed is not normal, remove the soil and
mud from the undercarriage.
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.
Moving Machine Backward

1. Set lock lever (4) to FREE position (F), set the work equipment
to the travel posture, then raise it 40 to 50 cm (16 to 20 in) from
the ground.
2. Operate the right and left travel levers (5), or the right or left travel pedals (6) as follows:
When sprocket (A) is at the rear of the machine:
Slowly pull the levers (5) backward, or slowly depress the rear
part of the pedals (6) to move the machine backward.
When sprocket (A) is at the front of the machine:

Slowly push the levers (5) forward, or slowly depress the front
part of the pedals (6) to move the machine backward.
3. Check that the alarm sounds properly. If the alarm does not sound, please contact your Komatsu distributor for
repair.
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.
Stopping Machine
Avoid stopping suddenly. Give yourself ample room when stopping.
1. Put the left and right travel levers (1) in the neutral position,
then stop the machine.
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.
STEERING THE MACHINE
Steering
WARNING
Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear,
the machine moves in the reverse direction to the operation of the travel levers.
Use the travel levers to change direction.

Avoid sudden changes of direction as much as possible.
Especially when performing counter-rotation (spin turn), stop the
machine before turning.
Operate two travel levers (1) as follows.
Steering the Machine when Stopped

When turning to the left:
Push the right travel lever forward to turn to the left when traveling
forward; and pull it back to turn left when traveling in reverse.
(A): Forward left turn
(B): Reverse left turn
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.
(A): Forward left turn
(B): Reverse left turn
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
The tail of the machine extends outside the tracks. Before operating the
swing, check that the area around the machine is safe.
1. Before starting the swing operation, turn swing lock switch (1)
OFF and check that swing lock monitor (2) has gone out.
2. Operate left work equipment control lever (3) to swing the

upper structure.
(A): Left swing
(B): Right swing
3. When not using the swing, turn swing lock switch (1) ON.
Check that swing lock monitor (2) lights up.
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.
WORK EQUIPMENT CONTROLS AND OPERATIONS

WARNING
If the lever is operated when the engine speed has been lowered by the auto-deceleration function, the engine speed will suddenly
rise, operate the levers carefully.
Use the control levers to operate the work equipment.

Note that when the levers are released, they return to the HOLD position and the work equipment is held in that
position.
The work equipment is operated by the left and right work equipment control levers. The left work equipment control
lever operates the arm and swing, and the right work equipment control lever operates the boom and bucket.
The movements of the lever and work equipment are as shown in the diagrams on the right. When the levers are
released, they automatically return to the neutral position and the work equipment is held in place.
If the work equipment control levers are returned to the neutral position when the machine is stopped, even if the
fuel control dial is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a
mid-range speed.
REMARK
With this machine, an accumulator is installed in the operating circuit, if less than 15 seconds has passed since the
engine was stopped, when the starting switch is turned to the ON position even with the engine stopped, it is
possible to operate the levers to lower work equipment to the ground.
In addition, this operation can also be used to release the remaining pressure in the hydraulic cylinder circuit or to
lower the boom after the machine has been loaded onto a trailer.
Arm operation
Swing operation
3 - 105
.
Boom operation
Bucket operation
3 - 106
.
WORKING MODE
Working Mode
The mode selector switch can be used to switch the mode to match operating conditions and purpose, thereby
enabling work to be performed efficiently.
Make effective use of each mode as follows.
When the starting switch is turned ON, the working mode is set to A mode.
Use the working mode switch to set the mode to the most efficient
mode to match the type of work.
Working
Applicable operations
mode
Normal digging, loading operations
A mode
(Operations with emphasis on productivity)
Normal digging, loading operations
E mode
(Operations with emphasis on fuel consumption)
When positioning work equipment exactly
L mode
(fine-control operations)
B mode Breaker operations
NOTICE
Do not use the heavy-duty operation mode for breaker operations. If breaker operations are carried out in the heavy-duty
operation mode, there is a hazard that the hydraulic equipment may be damaged or broken.
One-Touch Power Max. Switch

The one-touch power max. Switch can be used during operations to increase the power. Make effective use of this
function whenever necessary in combination with the working mode.
Press the left knob switch and keep it pressed. The power is
increased as long as the switch is being pressed. However, the
increased power is automatically canceled after 8.5 seconds.
This function is not actuated when the working mode is set to L

mode or B mode.
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.
WARNING
If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine, then operate
the control lever.
If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful
when operating.
Operations Using Swing Force

Do not use the swing force to compact soil or break objects. This
is not only dangerous, but will also drastically 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.
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends

If the work equipment is used with the cylinder rod operated to its
stroke end, and given impact by some external force, the hydraulic
cylinders will be damaged, causing personal injury. Avoid
operations with the hydraulic cylinder fully retracted or fully
extended.
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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 s pickaxe, breaker, or pile driver.
This will drastically reduce the life of the machine.
Operations Using Machine Dropping Force

Do not use the dropping force of the machine for digging.
Digging Hard Rocky Ground

Do not attempt to directly excavate hard rocky ground with the work equipment. It is better to excavate it after
breaking up by some other means. This will not only save the machine from damage but will make for better
economy.
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 (A) to reverse (B) (or
from reverse (B) to forward (A)).
(3) Avoid sudden lever shifting change such as sudden stopping
from near top speed (lever release operation).
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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

On uneven roadbeds such as rock beds or uneven roads with large
rocks, travel at Lo speed. When traveling at high speed, set the
idler in the forward direction.
To switch the travel speed, press travel speed selector switch
(1). The travel speed is displayed as Lo, Hi on the monitor
display GG.
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 drive the machine in water deeper than the center of carrier
roller (1).
Supply grease to the parts which have been under water for a long
time until the used grease is projected out of the bearings (around
the bucket pin, in particular).
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.
TRAVELING ON SLOPES
WARNING
Turning or operating the work equipment when working on slopes may
cause the machine to lose it balance and turn over, so avoid such
operations.
It is particularly dangerous to swing downhill when the bucket is loaded.
If such operations have to be performed, pile soil to make a platform (A)
on the slope so the machine is kept horizontal during operation.
Do not travel up or down steep slopes. There is a danger that the
machine may turn over.
When traveling, raise the bucket approx. 20 to 30 cm (8 to 12 in) from the
ground.
Do not travel downhill in reverse.
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.
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°, set the work equipment to the
posture shown in the diagram on the right, and lower the
engine speed.
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.
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.
When traveling up a steep slope, extend the work equipment to

the front to improve the balance, keep the work equipment
approximately 20 to 30 cm (8 to 12 in) above the ground, and
travel at low speed.
Traveling Downhill
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, lower the bucket to the
ground, stop the machine, then start the engine again.
Cab Doors on Slope

If the engine stops when the machine is on a slope, never use the left work equipment control lever to carry out
swing operations. The upper structure will swing under its own weight.
Take good care when opening or closing the sliding door (the cab specification). There is the danger that it will
likely gain momentum due to its own weight and open or shut suddenly.
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.
ESCAPE FROM MUD

Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get
the machine out.
Track on One Side Stuck

NOTICE
When using the boom or arm to raise the machine, always have the bottom
of the bucket in contact with the ground. The angle between the boom and
arm should be 90° to 110°.
The same applies when using the bucket installed in the reverse direction.
When only one side is stuck in mud, use the bucket to raise the
track, then lay boards or logs and drive the machine out.
Tracks on Both Sides Stuck

When the tracks on both sides are stuck in mud and they slip,
making it impossible for the machine to move, lay boards or logs as
explained above, and dig the bucket into the ground in front. Then
pull in the arm as in normal digging operations and put the travel
levers in the FORWARD position 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 areas that are lower than the
machine.
When the condition of the machine is as shown in the diagram on
the right (angle between [bucket cylinder and link] and [arm
cylinder and arm] is 90°), the maximum excavation force is
obtained from the pushing force of each cylinder.
When excavating, use this angle effectively to optimize your
working efficiency.
The range for excavating with the arm is from a 45° angle away
from the machine to a 30° angle towards the machine.
There may be some differences depending on the excavation
depth, but try to stay within the above range rather than operating
the cylinder to the end of its 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 narrow, work efficiency can be
enhanced by locating the dump truck in a place easily visible to the
operator.
Loading is easier and capacity greater if you begin from the front of
the dump truck body than if loading is done from the side.
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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 put your foot under the bucket
while standing at the side for the work.
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 and flat surface and do the work. When performing joint work, appoint a lead and follow
that person's instructions and signals.
Replacement
1. Place the bucket in contact with a flat surface.
REMARK
When removing the pins, place the bucket so that it is in light
contact with the ground.
If the bucket is lowered strongly to the ground, the resistance will
be increased and it will be difficult to remove the pins.
NOTICE
After removing the pins, make sure that mud or sand does not get on them.
Dust seals are fitted at both ends of the bushings, be careful not to damage
them.
2. Remove the double nut on the stopper bolt for arm pin (A) and
link pin (B), remove the bolt, pull out arm pin (A) and link pin (B),
and then remove the bucket.
3. Align the arm (5) with holes (1) of the replacement bucket and
the link (6) with holes (2), then insert grease-coated pins (A)
and (B) into hole (1) and hole (2) respectively.
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.
REMARK
When installing the bucket, for arm pin portion (A), fit O-ring (3) to
bucket (4) in the position shown in the diagram on the right. After
inserting the pin, fit it in the standard groove.
For link pin portion (B), install the bucket with O-ring (3) fitted in the
standard groove.
4. Install the stopper bolts and nuts for each pin, then grease the
pin.
REMARK
Lubricate with grease thoroughly until the grease comes out
from the end face.
When replacing the bucket, replace the dust seal if it has been
damaged. If a damaged seal is used without being replaced,
sand and dirt may enter the pin portion and cause abnormal
wear of the pin.
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.
Inversion
1. Place the bucket in contact with a flat surface.
REMARK
When removing the pins, place the bucket so that it is in light
contact with the ground.
If the bucket is lowered strongly to the ground, the resistance will
be increased and it will be difficult to remove the pins.
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, be careful not to damage
them.
2. Remove the double nut on the stopper bolt for arm pin (A) and
link pin (B), remove the bolt, pull out arm pin (A) and link pin (B),
and then remove the bucket.
3. Turn the removed bucket. After turning the bucket, align the
arm (5) with link mounting hole (1), then align the link with arm
mounting hole (2) and install.
4. Align the arm with holes (1) of the replacement bucket and the
link with holes (2), then insert grease-coated pins (A) and (B)
into hole (1) and hole (2) respectively.
REMARK
When reversing, do not install an O-ring. Keep the O-ring in a safe
place until using it next.
5. Install the stopper bolts and nuts for each pin, then grease the
pin.
REMARK
Lubricate with grease thoroughly until the grease comes out
from the end face.
When replacing the bucket, replace the dust seal if it has been
damaged. If a damaged seal is used without being replaced,
sand and dirt may enter the pin portion and cause abnormal
wear of the pin.
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.
PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
When stopping the machine, select flat hard ground and avoid
dangerous places.
If it is unavoidably necessary to park the machine on a slope, insert
blocks underneath the track shoes. As an additional safety measure,
thrust the bucket into the ground.
If the control lever is touched by accident, the machine may move
suddenly, and this may lead to a serious accident.
Before leaving the operator's compartment, always set the lock lever (3)
securely to LOCK position.
1. Put left and right travel levers (1) in the neutral position.
The machine stops.
2. Turn fuel control dial (2) to lower the engine speed to low idle.
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.
3. Lower the bucket horizontally until the bottom touches the

ground.
4. Set lock lever (3) in the LOCK position (L).
5. Stop the engine. For details on the procedure for stopping the engine, see "STOPPING THE ENGINE (PAGE
3-97)".
CHECK AFTER SHUT OFF ENGINE

Check the engine coolant temperature, engine oil pressure, and
fuel level on the machine monitor.
REMARK
After stopping the engine, if the starting switch is turned within
approx. 10 seconds to the ON or START position to start the
engine again, the monitor display is not reset, and the screen
before the starting switch was turned OFF is displayed.
MACHINE INSPECTION AFTER DAILY WORK

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for
any leakage of oil or coolant. If any problems are found, repair 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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.
LOCKING
Always lock the following places.
(1) Door of operator's cab
Always remember to close the window.
(2) Fuel tank filler port
(3) Engine hood
(4)Tool box
(5) Left side door of the machine
(6) Right side door of the machine
(7) Hydraulic tank filler port
REMARK
Use the starting switch key to lock and unlock all these places.
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.
TRANSPORTATION OPERATION
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
Always turn the auto-deceleration switch OFF (cancel) during loading
and unloading operations.
If the auto-deceleration switch is left ON, the machine may suddenly
start moving.
When loading or unloading the machine on a trailer, always travel at low
speed. Do not operate the travel speed selector switch.
Run the engine at low idle, set to Lo speed, and operate the machine
slowly when loading or unloading.
Do not carry out loading or unloading operations during the automatic
warming-up operation.
If the automatic warming-up operation is canceled before completion,
the travel speed may suddenly change.
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 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, grease,
oil, or ice.
Never correct your steering on the ramps. There is a hazard that the
machine may turn over.
If necessary, drive off the ramps, correct the direction, then enter the
ramps again.
It is dangerous to use the work equipment for loading and unloading
operations.
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 a hazard of the
machine losing its balance. Travel slowly over this point.
When swinging the upper structure on the trailer, the trailer is unstable,
pull in the work equipment and swing slowly.
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OPERATION TRANSPORTATION
Loading
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely, then put blocks (1) under the
tires to prevent the trailer from moving.
Set left and right ramps (2) parallel to each other and
equally spaced to the left and right of center (3) of the trailer.
Make angle of installation (4) a maximum of 15°. If the
ramps bend a large amount under the weight of the
machine, put blocks under the ramps to prevent them from
bending.
3. Set the travel speed selector switch to Lo (low speed travel).

Press travel speed selector switch (1) to set the travel
speed. The travel speed (Lo, Hi) is displayed on monitor
display GG.
4. Turn auto-deceleration switch (1) OFF and operate the fuel

control dial to set the engine speed to low idle.
Each time auto-deceleration switch (1) is pressed, it
switches OFF J ON J OFF in turn.
When auto-deceleration switch (1) is turned OFF, display
monitor (2) goes out.
5. Turn the swing lock switch ON to apply the swing lock.

When the swing lock switch is turned ON, display monitor
(3) lights up.
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.
6. If the machine is equipped with work equipment, set the work

equipment at the front, and travel forward to load it; if it has no
work equipment, travel in reverse to load it.
Follow instructions and signals of a conductor particularly
when traveling in reverse.
7. Before moving onto the ramps, make sure that the machine is
positioned in a straight line with the ramps and that the
centerline of the machine matches that of the trailer.
Align the direction of travel with the ramps and travel 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.
8. When the machine travels over the rear wheels of the trailer, it
becomes unstable, drive slowly and carefully. (Never operate
the steering.)
9. At the moment the machine passes the rear wheels, it tilts
forward, be careful not to let the work equipment hit the trailer
body. Drive the machine forward to the specified position, then
stop the machine.
10. Turn the swing lock switch OFF to release the swing lock, then
swing the upper structure slowly 180°.
11. Stop the machine at the specified position on the trailer.
12. Turn the swing lock switch ON to lock the swing lock.
When the swing lock switch is turned ON, display monitor
(3) lights up.
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.
Securing Machine
NOTICE
Stow the antenna and reassemble the mirrors so that they are within the width of the machine.
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.
Load the machine onto a trailer as follows:

1. Extend the bucket and arm cylinders fully, then lower the boom
slowly.
2. Set the lock lever securely to the LOCK position (L).

3. Stop the engine, then remove the key from the starting switch.
4. Lock the window glass, roof window, front window, operator's
seat door, side cover, engine hood, and battery box cover
securely.
5. Place blocks under both ends of the tracks to prevent the

machine from moving during transportation, and secure the
machine with chains or wire rope of suitable strength.
Be particulary careful to secure the machine in position so it
does not slip to the side.
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Rearview Mirrors
The mirrors are at the positions shown in the diagram on the right.
If they are damaged, or are to be removed for shipment, or are to
be installed again, use the following procedure.
Removal
1. Loosen locknut (2) of mirror (1), then remove mirror (1) from
support (3).
2. Loosen bolt (4) and remove support (3) and clamp (5) from the
handrail.
Installation
1. Install support (3) and clamp (5) to the handrail,then tighten
with bolt (4).
2. Install mirror (1) to support (3),then tighten locknut (2).
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.
Unloading
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely, then put blocks (1) under the
tires to prevent the trailer from moving.
Set left and right ramps (2) parallel to each other and
equally spaced to the left and right of center (3) of the trailer.
Make angle of installation (4) a maximum of 15°. If the
ramps bend a large amount under the weight of the
machine, put blocks under the ramps to prevent them from
bending.
3. Remove the chains and wire ropes fastening the machine.
4. Start the engine.
Warm the engine up fully.
5. Set the lock lever to FREE position (F).
6. Set the travel speed selector switch to Lo (low speed travel).

Press travel speed selector switch (1) to set the travel
speed. The travel speed (Lo, Hi) is displayed on monitor
display GG.
7. Turn auto-deceleration switch (1) OFF and operate the fuel

control dial to set the engine speed to low idle.
Each time auto-deceleration switch (1) is pressed, it
switches OFF J ON J OFF in turn.
When auto-deceleration switch (1) is turned OFF, monitor
display GG (2) goes out.
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.
8. Turn the swing lock switch OFF to release the swing lock.
When the swing lock switch is turned OFF, display monitor
(4) goes off.
9. Raise the work equipment, pull in the arm under the boom,
then move the machine slowly.
10. When the machine is horizontal on top of the rear wheels of the
trailer, stop the machine.
11. When moving from the rear of the trailer on to the ramps, set
the angle of the arm and boom to 90° to 110°, lower the bucket
to the ground, then move the machine slowly.
12. When moving down the ramps, operate the boom and arm
slowly to lower the machine carefully until it is completely off
the ramps.
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LIFTING MACHINE
WARNING
The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
Never raise the machine with any worker on it.
Always make sure that the wire rope is of ample strength for the weight of this machine.
When lifting, keep the machine horizontal.
When carrying out lifting operations, set the lock lever to the LOCK position to prevent the machine from moving unexpectedly.
Never enter the area under or around a raised machine.
Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting equipment other
than in the procedure below.
There is a hazard that the machine may lose its balance.
NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting
procedures, contact your Komatsu distributor.
For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".

When lifting the machine, carry out the operation on flat ground as follows.
1. Start the engine, then the swing the upper structure so that the work equipment will be on the side of sprocket
(1).
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. Set the lock lever securely to the LOCK position (L).
4. 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.
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.
5. Pass wire ropes between the 1st and 2nd track rollers from the
front and between the 1st and 2nd track rollers from the rear.
However, for machines equipped with a full roller guard for the
track roller, pass the wire rope under the track.
6. Set the lifting angle (A) of the wire rope to 30° to 40°, then lift
the machine slowly.
7. After the machine comes off the ground, check the hook
condition and the lifting posture, and then lift slowly.
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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 viscosity, 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 amounts of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
Use Komatsu Supercoolant wherever available, or use permanent type antifreeze coolant.
Never use methanol, ethanol, or propanol-based antifreeze.
Do not use any water leakage prevention agent, either alone, or in combination with antifreeze.
Do not mix one brand of antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-24)".
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 coolant must be changed twice a year (spring and autumn), so use permanent
antifreeze when possible.
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COLD WEATHER OPERATION OPERATION
Battery
WARNING
The battery generates flammable gas. Do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on 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.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
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%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte
Temperature
20 0 -10 -20
Charging (°C)
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 drastically drops in low temperatures, cover or remove the battery from the machine, store
the battery 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 water after the
day's work to prevent diluted electrolyte in the battery from freezing during the night.
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OPERATION COLD WEATHER OPERATION
Monitor
A feature of the liquid crystal monitor is that the screen becomes dark and is difficult to read in cold weather
(particularly with the starting switch ON).
In this case, adjust the brightness and contrast of the screen.
For details, see "Liquid Crystal Monitor Adjustment Switch (PAGE 3-26)".
If the screen is dark, increase the brightness and contrast (extend the scale in the + E direction) to make the screen
brighter and easier to read.
Brightness
Contrast
Guideline for bar display for brightness and contrast in cold weather
Ambient temperature Brightness Contrast

-10°C (14°F) 7 (max) 5-4
-20°C (-4°F) 7 7-6
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COLD WEATHER OPERATION OPERATION
AFTER DAILY WORK COMPLETION

WARNING
Performing idle-running of the tracks is dangerous, stay well away from the tracks.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, observe the following precautions.
Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to
prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
Park the machine on hard, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.
After operation in water or mud, remove water from undercarriage as described below to extend undercarriage
service life.
1. Swing 90° with engine at low idle 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 the 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 ethylene glycol base antifreeze (winter, one
season type) is used instead, or if no antifreeze is used, drain the cooling system completely. Thoroughly flush
out the cooling system and fill it with fresh coolant.
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OPERATION LONG TERM STORAGE
LONG TERM STORAGE

BEFORE STORAGE
NOTICE
When storing the machine (1 month or more), set the machine in the
posture shown in the diagram on the right to protect the cylinder rod.
(To prevent rusting of the cylinder rod)
When putting the machine in storage for a long time (more than one month), do as follows.
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 canvas.
Fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
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 "Where no attachment is mounted"
position.
To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type antifreeze
(density between 30% and 68%).
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat
moving parts. At the same time, also charge the battery.
For machines equipped with an air conditioner, run the air conditioner.
AFTER STORAGE
NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after
starting the engine. If there is water in the oil, change all the oil.
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LONG TERM STORAGE OPERATION
STARTING MACHINE AFTER LONG-TERM STORAGE

When starting the engine after the machine has been in storage for a long time, perform the automatic warming-up
operation.
If the engine is started according to the starting procedure for cold weather, the warming-up operation is performed
automatically.
(For details, see "Starting Engine in Cold Weather (PAGE 3-86)" and "In Cold Weather Areas (PAGE 3-92)".)
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.
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 stating.
For details on bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-56)".
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.
The bucket or arm will fluctuate by itself during heavy-duty
digging operations.
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.
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TROUBLES AND ACTIONS OPERATION
TOWING THE MACHINE

WARNING
Serious injury or death could result if a disabled machine is towed
incorrectly or if there is a mistake in the selection or inspection of the wire
rope.
Always check that the wire rope used for towing has ample strength for
the weight of the machine being towed.
Never use a wire rope which has cut strands (A), reduced diameter (B),
or kinks (C). There is danger that the rope may break during the towing
operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing machine
and the machine being towed.
Operate the machine slowly and be careful not to apply any sudden load
to the wire rope.
NOTICE
The maximum towing capacity for this machine is 120,600 N (12,300 kgf).
Always carry out towing operations within the maximum towing capacity.
If the machine sinks in mud and cannot get out under its own
power, or if the drawbar pull of the excavator is being used to tow
a heavy object, use a wire rope as shown in the diagram on the
right.
Place pieces of wood between wire ropes and body to prevent
damage to ropes and body.
Hold the wire rope level and direct it straight to the track frame.
When towing a machine, travel at a speed of less than 1 km/h for
a distance of only a few meters to a place that is suitable for
carrying out repairs.
This is for use only in emergencies.
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.
LIGHTWEIGHT TOWING HOLE

WARNING
The shackle must always be used.
Hold the rope level and direct it straight to the track frame.
Move the machine slowly in the Lo mode.
There is a hole in the track frame to fit the shackle when towing light
objects.
Permissible towing load: Max. 49,000 N (5,000 kgf)
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 and bucket several times, then grease again.
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DISCHARGED BATTERY
WARNING
It is dangerous to charge a battery when mounted on a machine. Make
sure that it is dismounted before charging.
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
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, immediately wash it
off with a large amount 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) (diagram A). When installing, install
the positive (+) terminal first (diagram B).
If a tool touches between at 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. Terminals should be
connected firmly.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
Battery Removal and Installation

Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal).
If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated.
When installing the battery, connect the ground cable last.
When replacing the battery, secure it with battery hold-down.
Tightening torque:Tightening battery terminal: 9.8 to 14.7 N·m (1 to 1.5 kgf·m, 7.2 to 10.8 lbft)
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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 3-140)" 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 correct voltage is not selected, 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 attach the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set
it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger 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. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level
to the UPPER LEVEL line.
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.
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.
Be careful not to make a mistake when connecting a booster cable. In
the last connection (to the upper structure frame), a spark will be
caused, connect the cable to a spot as far away from the battery as
possible. (Avoid the work equipment, however, because it is not a good
conductor)
When removing the booster cable, exercise good care so that the
booster cable clips may not contact each other, or they contact the
chassis.
NOTICE
The starting system for this machine uses 24V. For the normal machine, also use a 24V battery.
The size of the booster cable and clip should be suitable for the battry size.
The battery of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the lock levers of both machine are in the LOCK position.
Check that each lever is in the NEUTRAL position.
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Booster Cable Connection

Keep the starting switch of the normal machine and problem
machine in the OFF position.
Connect the booster cable as follows, in the order of the numbers
marked in the diagram.
1. Connect 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 upper
structure frame of the problem machine.
X: Battery on normal machine

Y: Battery on problem machine
Z: Upper structure frame on problem machine
Starting the Engine
WARNING
Always check that the 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 in the neutral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle 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 booster cables in the
reverse order in which they were connected.
1. Remove one clip of booster cable (B) from the revolving frame
of the problem machine.
2. Remove the other 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.
X: Battery on normal machine

Y: Battery on problem machine
Z: Upper structure frame on problem machine
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.
OTHER TROUBLE
Electrical System
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Main causes Remedy

Lamp does not glow brightly even Defective wiring, deterioration of ( Check, repair loose terminals,
when the engine runs at high speed battery disconnections, replace battery)
Lamp flickers while engine is Loose fan belt Check fan belt tension, replace
running
Charge level monitor does not go Defective alternator ( Replace)
out even when engine is running Defectivr wiring ( Check, repair)
Abnormal noise is generated from Defective alternator ( Replace)
alternator
Defective wiring ( Check, repair)
Starting motor does not turn when
Defective starting motor ( Replace)
starting switch is turned to ON
Insufficient battery charge Charge
Pinion of starting motor keeps Insufficient battery charge Charge
going and out Defective safety relay ( Replace)
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
Defective wiring, defective ring ( Check, repair)
Starting motor disengages before
gear pinion
engine starts
Insufficient battery charge Charge
Engine pre-heating monitor does
Defective heater relay ( Replace)
not light
Defective monitor ( Replace)
Oil pressure monitor does not light Defective monitor ( Replace)
up when engine is stopped Defective caution lamp switch ( Replace)
(starting switch at ON position)
Outside of electrical heater is not Disconnection in electric heater ( Replace)
warm when touched by hand Defective operation of heater ( Replace)
relay switch
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.
Chassis

Speed of travel, swing, boom, arm, Lack of hydraulic oil Add oil to specified level, see
bucket is slow CHECK BEFORE STARTING
Pump generates abnormal noise Clogged element in hydraulic Clean, see EVERY 2000
(sucking in air) tank strainer, lack of oil HOURS SERVICE
Excessive rise in hydraulic oil Loose fan belt Check fan belt tension, replace
temperature Dirty oil cooler Clean, see EVERY 500 HOURS
SERVICE
Lack of hydraulic oil Add oil to specified level, see
CHECK BEFORE STARTING
Track comes off Track too loose Adjust track tension, see WHEN
Abnormal wear of sprocket REQUIRED
Boom rises slowly, does not rise Lack of hydraulic oil Add oil to specified level,
Does not swing Swing lock switch still applied Turn swing lock switch OFF
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.
Engine

Engine oil pan oil level is low Add oil to specified level, see
(sucking in air) CHECK BEFORE STARTING
Clogged oil filter cartridge Replace cartridge, see EVERY
500 HOURS SERVICE
Engine oil pressure monitor lights Defective tightening of oil pipe, ( Check, repair)
up pipe joint, oil leakage from
damaged point
Defective engine oil pressure ( Replace sensor)
sensor
Defective monitor ( Replace monitor)
Coolant level low, leakage of Check, add coolant, repair, see
water CHECK BEFORE STARTING
Steam spurts out from top of Loose fan belt Check fan belt tension, adjust,
radiator (pressure valve) replace
Dirt or scale accumulated in Change coolant, flush inside of
cooling system cooling system, see WHEN
REQUIRED
Clogged radiator fins or Clean or repair, see EVERY 500
damaged fins HOURS SERVICE
Defective thermostat ( Replace thermostat)
Radiator coolant level monitor Loose radiator filler cap Tighten cap or replace packing
lights up (high-altitude operations)
Defective water level sensor ( Replace sensor)
Defective monitor ( Replace monitor)
Lack of fuel Add fuel, see CHECK BEFORE
STARTING
Air in fuel system Repair place where air is sucked
in, see EVERY 500 HOURS
SERVICE
Defective fuel injection pump or ( Replace pump or nozzle)
Engine does not start when starting
defective nozzle
motor is turned
Starting motor cranks engine See ELECTRICAL SYSTEM
sluggishly
Engine pre-heating monitor does See ELECTRICAL SYSTEM
not light up
Defective compression
Defective valve clearance ( Adjust valve clearance)
Too much oil in oil pan Set oil to specified level, see
Exhaust gas is white or blue CHECK BEFORE STARTING
Improper fuel Change to specified fuel
Clogged air cleaner element Clean or replace, see WHEN
REQUIRED
Exhaust gas occasionally turns Defective nozzle ( Replace nozzle)
black Defective compression ( See defective compression
above)
Defective turbocharger Clean or replace turbocharger
Combustion noise occasionally Defective nozzle ( Replace nozzle)
make breathing sound
3 - 146
.

Low-grade fuel being used Change to specified fuel
Overheating Refer to "Radiator coolant level
Abnormal noise generated
monitor lights up" as above
(combustion or mechanical)
Damage inside muffler Replace muffler
Excessive valve clearance ( Adjust valve clearance)
3 - 147
.
Electronic Control System

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

When emergency pump drive switch is moved up, normal
E02 Error in pump control system operations are possible, but have inspection carried out
immediately. (*)
Move swing holding brake release switch up to release
brake. When applying swing brake, operate swing lock
E03 Error in swing brake system switch manually. Depending on cause of failure, it may be
impossible to release brake. In any case, have inspection
carried out immediately. (*)
Governor controller does not work. Operate governor lever
manually. To secure at FULL position, there is a hole in the
E05 Error in governor system
bracket to install the lock bolt. In this case, have inspection
carried out immediately.
When no user code is displayed but work
Have inspection carried out immediately.
equipment and swing cannot be operated
(*): For details of the method of handling the emergency pump drive switch and swing holding brake cancel switch,
see "SWITCHES (PAGE 3-28)".
3 - 148
.
4-1
.
MAINTENANCE INFORMATION MAINTENANCE
MAINTENANCE INFORMATION
Do not perform 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
performed.
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
quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out
suitable action.
Fuel Strainer
If your machine is equipped with a fuel strainer, do not remove it while fueling.
Welding Instructions
Turn off the engine starting switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
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 may cause damage and/or 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 air cleaner clogging monitor frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
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

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

Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly blow 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 "BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE
4-40)".
Hydraulic Hose Installation

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist or bend them into loops with a small radius.
This will cause damage to the hose and drastically reduce its service life.
Checks After Inspection and Maintenance Works

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may
lead to serious injury or property damage. Always do the following:
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been performed correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
Are there any leakage of coolant or oil? Have all nuts and 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 2-34)" and pay careful attention to safety.
Are the inspection and maintenance items working properly?
Is there any leakage of fuel or oil when the engine speed is raised?
4-3
.
OUTLINE OF SERVICE MAINTENANCE
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
Oil
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and 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, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the 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
After completing the day's operations, fill the fuel tank to force out any air containing moisture. This will prevent
the moisture from condensing and mixing with the 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 use 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 OUTLINE OF SERVICE
Antifreeze Coolant and Water for Dilution

The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
When diluting the antifreeze coolant, use distilled water or tap water (soft water).
Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium,
magnesium, etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is deposited
inside the engine or radiator, it is extremely difficult to remove. It also causes overheating due to poor heat
exchange, so when you dilute the coolant, we recommend that you use water with an overall hardness of less
than 100 PPM.
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
Antifreeze coolant is flammable, so be sure to keep it away from flame.
The ratio of Supercoolant (AF-NAC) to water differs according to the ambient temperature.
For details of the ratio when mixing, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-24)".
Supercoolant (AF-NAC) may be supplied in premix. In this case, never add diluting water.
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 due to air entering
the coolant.
Grease
Grease is used to prevent seizure and noises 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
.
OUTLINE OF SERVICE MAINTENANCE
Carrying Out KOWA (Komatsu Oil Wear Analysis)

The oil clinic samples the oil periodically and analyzes it. This is a preventive maintenance service, which provides
early discovery of abnormal parts and wear of the drive parts of the machine. This then makes it possible to ensure
prevention of failures and reduction in downtime.
Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine
the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair
methods.
The oil clinic charges the customer only the actual costs, and provides an immediate report of the results of the
analysis and recommendations for action to take. This low-cost service can save you high costs and inconvenience
in the future, so we strongly recommend you to avail yourself of this service.
KOWA Analysis Items

Measurement of density of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of iron, copper, and other metal wear
particles in the oil.
Measurement of quantity of particles

This uses a particle quantifier index measurement machine to
measure the quantity of iron particles of 5µ or more, enabling
early detection of failures.
Others
Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of
fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
Oil Sampling
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling

Make sure that the oil is well mixed before sampling.
Perform sampling at regular fixed intervals.
Do not perform 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.
4-6
.
MAINTENANCE OUTLINE OF SERVICE
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 drums is at the side
to prevent moisture from being sucked in.
If drums 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).
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 attached to the old filter. If any metal particles are found,
contact your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Use of Komatsu genuine filter elements is strongly recommended.
ELECTRIC SYSTEM MAINTENANCE

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This
will cause an electrical short circuit 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 checking fan belt tension, checking damage or wear to the fan belt and
checking battery fluid level.
Never install any electric components other than those specified by Komatsu.
External electro-magnetic interference may cause malfunction of the control system controller, before installing
a radio receiver or other wireless equipment, contact your Komatsu distributor.
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 wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the
machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.
WEAR PARTS LIST

The parts in parentheses are to be replaced at the same time.
Item Part No. Part Name Q'ty Replacement frequency

Engine oil filter 6733-51-5141 Cartridge 1 Every 500 hours service
20Y-60-31121 Element 1
Hydraulic oil filter Every 1000 hours service
(07000-15160) (O-ring) (1)
Fuel filter 6732-71-6111 Cartridge 1 Every 500 hours service
Hydraulic tank breather 20Y-60-21470 Element 1 Every 500 hours service
Air cleaner 600-185-2500 Element assembly 1 -
Additional filter for 20Y-970-1820 Element 1
-
breaker (if equipped) (07000-12115) (O-ring) (1)
Electric heater 6732-11-4811 Gasket 2 -
Vertical pin type
205-70-74272 Tooth 5
Bucket -
(205-70-74281) (Pin) (5)
(205-70-74291) (Lock) (5)
4-8
.
MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS

PROPER SELECTION
Reservoir Swing Final drive

Engine oil Damper Hydraulic Cooling
machinery case Fuel tank
pan case system system
Capacity case (each)
Liters 14.3 4.5 4.5 0.75 190 280 18.6
Specified
US gal 3.78 1.19 1.19 0.20 50.20 73.98 4.91
Liters 14 4.5 4.5 - 121 - -
Refill
US gal 3.70 1.19 1.19 - 31.97 - -
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 the periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulfur 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
hydraulic 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 Institute
Fuel sulfur content Engine oil change interval

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
A 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.
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.
Thread Width Tightening torque

diameter across
Target value Service limit
of bolt flats
(a)(mm) (b)(mm) N·m kgf·m lbft N·m kgf·m lbft
6 10 13.2 1.35 9.8 11.8-14.7 1.2-1.5 8.7-10.8

8 13 31 3.2 23.1 27-34 2.8-3.5 20.3-25.3
10 17 66 6.7 48.5 59-74 6.0-7.5 43.4-54.2
12 19 113 11.5 83.2 98-123 10.0-12.5 72.3-90.4
14 22 172 17.5 126.6 153-190 15.5-19.5 112.1-141
16 24 260 26.5 191.7 235-285 23.5-29.5 170.0-213.4

18 27 360 37 267.6 320-400 33.0-41.0 238.7-296.6
20 30 510 52.3 378.3 455-565 46.5-58.0 336.3-419.5
22 32 688 70.3 508.5 610-765 62.5-78.0 452.1-564.2
24 36 883 90 651 785-980 80.0-100.0 578.6-723.3
27 41 1295 132.5 958.4 1150-1440 118.0-147.0 853.5-1063.3

30 46 1720 175.0 1265.8 1520-1910 155.0-195.0 1121.1-1410.4
33 50 2210 225.0 1627.4 1960-2450 200.0-250.0 1446.6-1808.3
36 55 2750 280.0 2025.2 2450-3040 250.0-310.0 1808.3-2242.2
39 60 3280 335.0 2423.1 2890-3630 295.0-370.0 2133.7-2676.2
Apply the following table for Hydraulic Hose.

The torques marked * indicate the tightening torques for the hoses at the top of the swivel joint.
Width Tightening torque [N·m (kgf·m)]

Thread
across
diameter a Target
flat Permissible range
(mm) value
b(mm)
9/16 -18UNF 19 44 (4.5) 35 - 54 (3.5 - 5.5)
11/16 -16UN 22 74 (7.5) 54 - 93 (5.5 - 9.5)
13/16 -16UN 27 103 (10.5) 84 - 132 (8.5 - 13.5)
1 -14UNS 32 157 (16.0) 128 - 186 (13.0 - 19.0)
1·3/16 -12UN 36 216 (22.0) 177 - 245 (18.0 - 25.0)
*1-7/16-12UN
41 215 (22) 176 - 234 (18 - 24)
-2B
4 - 13
.
SAFETY CRITICAL PARTS MAINTENANCE
SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, you are required to periodically replace the safety
(critical and fire prevention) related parts listed in the table of important parts on the following page.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is required
to replace them with new ones regardless of their condition after a certain period of usage. This is important to
ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the periodic
replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.
SAFETY CRITICAL PARTS LIST
No. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (Fuel tank - Water separator) 1
2 Fuel hose (Water separator - Fuel pump) 1
3 Fuel return hose (Fuel injection pump - Fuel tank) 1
4 Spill hose (Engine output connector - Fuel tank) 1
5 Pump outlet hose (Pump - Control valve) 2
6 Work equipment hose (Boom cylinder inlet) 4
7 Work equipment hose (Bucket cylinder line - Boom foot section) 2
8 Work equipment hose (Bucket cylinder inlet) 2 Every 2 years or 4000
9 Work equipment hose (Arm cylinder line - Boom foot section) 2 hours, whichever
10 Work equipment hose (Arm cylinder inlet) 2 comes sooner
11 Additional attachment line hose (Boom foot section) 2

12 Additional attachment line hose (Boom top section) 2
13 Swing line hose (Swing motor inlet) 2
14 Main suction hose 1
15 Heater hose 2
16 Travel line hose (Control valve - Swivel joint) 4
17 Travel line hose (Swivel joint - Travel motor) 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 4-17)" to confirm the correct
maintenance schedule when carrying out maintenance.
MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
REPLACE FUEL FILTER CARTRIDGE 4- 56
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 66
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 19
CLEAN INSIDE OF COOLING SYSTEM 4- 24
CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 27
CHECK AND ADJUST TRACK TENSION 4- 28
CHECK ELECTRICAL INTAKE AIR HEATER 4- 29
REPLACE BUCKET TEETH (VERTICAL PIN TYPE) 4- 30
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) 4- 33
ADJUST BUCKET CLEARANCE 4- 34
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 4- 35
CHECK AND MEINTENANCE AIR CONDITIONER 4- 36
WASH WASHABLE FLOOR 4- 37
BLEEDING AIR FROM HYDRAULIC SYSTEM 4- 40
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 4- 42
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit) 4- 43
CHECKS BEFORE STARTING
EVERY 100 HOURS MAINTENANCE

LUBRICATING 4- 45

CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL 4- 46
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 4- 47
CHECK LEVEL OF BATTERY ELECTROLYTE 4- 48
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 4- 51

LUBRICATING 4- 52
LUBRICATE SWING CIRCLE 4- 53
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 54
REPLACE FUEL FILTER CARTRIDGE 4- 56
CHECK SWING PINION GREASE LEVEL, ADD GREASE 4- 57
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER
COOLER FINS 4- 58
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS 4- 59
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK 4- 61
4 - 15
.
MAINTENANCE SCHEDULE MAINTENANCE

REPLACE HYDRAULIC OIL FILTER ELEMENT 4- 62
CHANGE OIL IN SWING MACHINERY CASE 4- 63
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4- 64
CHECK FAN BELT TENSION AND REPLACE FAN BELT 4- 64

CHANGE OIL IN FINAL DRIVE CASE 4- 65
CLEAN HYDRAULIC TANK STRAINER 4- 66
CHECK ALTERNATOR, STARTING MOTOR 4- 66
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 66

CHECK WATER PUMP 4- 67

CHANGE OIL IN HYDRAULIC TANK 4- 68
4 - 16
.
MAINTENANCE MAINTENANCE SCHEDULE
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER

For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging
operations, so set the maintenance intervals as follows.
REPLACE HYDRAULIC OIL FILTER ELEMENT

On new machines, 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.
REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER

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 - 17
.
MAINTENANCE PROCEDURE MAINTENANCE
MAINTENANCE PROCEDURE
Carry out the following maintenance only after the first 250 hours of operation on new machines.
Replace fuel filter cartridge
Special tools are needed for the inspection and maintenance, so please contact your Komatsu distributor to have
this work carried out.
For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS SERVICE.
Carry out the following maintenance only after the first 1000 hours of operation on new machines.
Check engine valve clearance, adjust
Special tools are needed for inspection and maintenance, so contact your Komatsu distributor.
For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.
4 - 18
.
MAINTENANCE MAINTENANCE PROCEDURE
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

WARNING
When using compressed air, there is danger of dirt flying and causing personal injury.
Always wear protective glasses, dust mask, or other protective equipment.
When removing the outer element from the air cleaner body, it is dangerous to pull it out by force. When working in high places
or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
Checking
If air cleaner clogging monitor (1) of the monitor panel flashes,
clean the air cleaner element.
Replacing
Replacing element, O-ring
If one year has passed since installing the element or if air
cleaner clogging monitor (1) on the monitor panel flashes
immediately after the element is cleaned, replace the outer
element, inner element, and O-ring.
Replacing evacuator valve
Replace it if it is damaged or the rubber is markedly deformed.
NOTICE
Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel flashes. If the element is cleaned
frequently before the clogging monitor flashes, the air cleaner will not be able to display its performance fully, and the cleaning
efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element.
Cleaning or Replacing Outer Element

1. Open a door located at the rear left side of the machine,
release hooks (2) at 3 locations and then detach cover (3).
NOTICE
Before and after cleaning the element, do not leave or keep it in direct
sunlight.
2. Hold the outer element, rock it lightly up and down and to the left and right, and rotate the element to the left and
right to pull it out.
4 - 19
.
NOTICE
Never remove the inner element (6). It will allow dirt to enter and cause
failure of the engine.
Do not use a screwdriver or other tool.
3. After removing the outer element (5), cover the inner element
(6) with a clean cloth or tape to prevent dirt or dust from
entering.
4. Wipe off or brush off the dirt stuck to cover (3) and the inside of
the air cleaner body (7).
5. Remove any dirt or dust that is accumulated to evacuator valve

(4) installed to cover (3).
6. Direct dry compressed air (less than 0.69 MPa (7 kgf/cm2, 99.4
PSI)) to the outer element from inside along its folds, then
direct it from outside along its folds and again from inside.
1) Remove one seal from the element whenever the element
has been cleaned.
2) Replace the outer element which has been cleaned 6
times repeatedly or used throughout a year. Replace the
inner element at the same time.
4 - 20
.
3) Replace both inner and outer elements when the monitor (1) lights up soon after installing the cleaned outer
element even though it has not been cleaned 6 times.
4) When replacing the element, stick on seal (A) packed in
the same box as the element. Stick the seal in the position
shown in the diagram on the right.
7. Remove the cloth or tape cover installed in Step 3.

8. If small holes or thinner parts are found on the element when
it is checked by shining a light through it after cleaning, replace
the element.
NOTICE
When cleaning the element, do not hit or beat it against anything.
Do not use an element whose folds or gasket or seal are damaged.
4 - 21
.
Install Air Cleaner Element

NOTICE
Do not use any damaged gasket or seal or element with damaged pleats.
Cleaning the element or O-ring after one year has passed and using them again will cause problems. Always replace them with
new parts.
The seal portion on imitation parts lacks precision, and allows the entry of dust, which leads to damage of the engine. Do not
use such imitation parts.
Do not run the engine with the inner element removed. It will cause damage to the engine.
1. Check that there is no dirt or oil stuck to the seal portion of the new element or cleaned element. Wipe off any
dirt or oil.
2. When the outer element has been removed, check that the inner element has not come out of position and is
not at an angle. If inner element is at an angle, insert your hand and push it in straight.
3. Push the outer element in straight with your hand when installing it to the air cleaner body.
If the element is held and rocked lightly up and down and to the left and right while pushing it in, the element can
be inserted easily.
NOTICE
When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is
assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when
assembling.
4. Install cover (3) as follows.

1) Align cover (3) with the element.
2) Hook the tip of hook (2) to the protruding part of the air
cleaner body and lock it in position.
3) When locking hooks (2) in position, apply the hooks in turn
on opposite sides (top, bottom, left, right) in the same way
as when tightening bolts.
4) Always install cover (3) so that the evacuator (4) is facing
the ground (A).
5) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too large.
If it is too large, install again.
4 - 22
.
Replacing Inner Element

1. First remove the outer element, and then remove the inner element.
2. Cover the air connector side (outlet side) with a clean cloth or tape.
3. Clean the air cleaner body interior, then remove the cover from the air intake port in Step 2.
4. Install a new inner element to the connector, then tighten the nut.
NOTICE
The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the
same time.
5. Set the outer element in position, then lock cover (3) with hooks
(2).
4 - 23
.
CLEAN INSIDE OF COOLING SYSTEM

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 lock lever (1) to the LOCK position
(L).
For details of starting the engine, see "BEFORE STARTING ENGINE
(PAGE 3-69)" and "STARTING ENGINE (PAGE 3-84)" in the OPERATION
section.
There is danger of touching the fan if the undercover is left removed.
Never enter behind the machine when the engine is running.
Clean the inside of the cooling system, change the coolant according to the table below.
Interval of cleaning inside of cooling system

Antifreeze coolant
and changing antifreeze coolant
Komatsu supercoolant Every two years or every 4000 hours

(AF-NAC) whichever comes first
Permanent type antifreeze Every year (autumn) or every 2000 hours

(All-season type, *) whichever comes first
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03.
Stop the machine on level ground when cleaning or changing the coolant.
The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
4 - 24
.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing
table given below.
It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio.
The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume
(antifreeze/total amount of coolant x 100).
The freezing temperature of undiluted antifreeze is -15°C (5°F). Do not store undiluted antifreeze at a temperature
of below -15°C (5°F).
Mixing rate of water and antifreeze

PC160
°C -10 -15 -20 -25 -30 -35 -40

Min. atmospheric temperature
°F 14 5 -4 -13 -22 -31 -40
Liters 5.6 6.7 7.6 8.6 9.3 10.1 10.8
Amount of antifreeze
US gal 1.48 1.77 2.01 2.27 2.46 2.67 2.85
Liters 13.0 11.9 11.0 10.0 9.3 8.5 7.8
Amount of water
US gal 3.43 3.14 2.91 2.64 2.46 2.25 2.06
Proportion by volume % 30 36 41 46 50 54 58
4 - 25
.
WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes,
flush your eyes with large amount of fresh water and see a doctor at once.
Use antifreeze and appropriate water for diluting. (for details, see "Antifreeze Coolant and Water for Dilution (PAGE
4-5)")
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to supply antifreeze coolant and water.
1. Turn radiator cap (1) slowly and remove it.
2. Remove the undercover, then set the container under drain
valve (2) to catch the coolant mixture.
Open drain valve (2) at the bottom of the radiator and drain the
coolant.
3. After draining the coolant, close drain valve (2), and fill with city
water. When the radiator is full, start the engine and run at low
idling to raise the temperature to at least 90°C (194°F), then
continue to run for approx. 10 minutes.
4. Stop the engine, open drain valve (2), and drain the water.
5. After draining the water, clean the radiator with detergent.
For the cleaning method, follow the instruction of detergent.
6. Close drain valve (2).
7. Install the undercover.
8. Add coolant mixed with antifreeze until it overflows from the
water filler.
Decide the proportions of antifreeze and water according to the
table for the mixing rate of water and antifreeze.
9. Run the engine idle at a low speed for 5 minutes, then at a high
speed for 5 minutes to bleed air mixed in the cooling water. (At
this time, keep the water filler cap removed.)
10. Drain the coolant from sub-tank (3), clean the inside of the
sub-tank, then add water until the coolant level is between the
FULL and LOW marks.
11. Stop the engine and tighten the cap. Check the coolant level,
and add water if the level is low.
4 - 26
.
CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts (1) loose, they will
break, so tighten any loose bolts immediately.
Tightening
Track shoe
1. First tighten to a tightening torque of 490 ± 49 N·m (50 ± 5 kgf·m, 360 ± 36 lbft) then check that the nut and shoe
are in close contact with the link contact surface.
2. After checking, tighten a further 120° ± 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 - 27
.
CHECK AND ADJUST TRACK TENSION

WARNING
For details on starting the engine and operating the work equipment, see "BEFORE STARTING ENGINE (PAGE 3-69)", "STARTING
ENGINE (PAGE 3-84)", "AFTER STARTING ENGINE (PAGE 3-88)", and "WORK EQUIPMENT CONTROLS AND OPERATIONS (PAGE
3-105)" in the OPERATION section.
Wear on pins and bushings of the undercarriage will vary with working conditions and type of soil, so inspect the
track tension every now and then in order to maintain the standard tension.
For carrying out inspection and adjustment of track shoes, park the machine on the flat and solid ground.
Checking
1. Run the engine at low idle, then move the machine forward for
a distance equal to the track length on ground, and slowly stop
the machine.
2. Put on the track shoe straight wooden bar (3) which stretches
from idler (1) to upper carrier roller (2).
3. Measure the maximum deflection between bottom surface of
the wooden bar and top surface of the track shoe.
Deflection "a" should be 10 - 30 mm (0.4 - 1.2 in).
If the track tension is not at the standard value, adjust it in the following manner.
Adjustment
WARNING
Grease inside the adjusting mechanism is under high pressure. Grease
coming from plug (1) under pressure can penetrate the body, causing
injury or death. For this reason, do not loosen plug (1) more than one turn.
Do not loosen any part other than plug (1). Furthermore, do not bring your
face in front of the plug (1).
If track tension is not relieved by this procedure, contact your Komatsu
distributor for repairs.
4 - 28
.
Increasing Track Tension

Prepare a grease pump.
1. Pump in grease through grease fitting (2) with a grease pump.
(Grease fitting (2) forms one part with plug (1).)
2. To check if the tension is correct, run the engine at low idle,
move the machine slowly forward (by an amount 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. 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 track tension is not relieved by this procedure, contact your Komatsu distributor for repairs.
1. Loosen plug (1) gradually to release the grease.

2. When loosening plug (1), 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 (1).
5. To check if the tension is correct, run the engine at low idle,
move the machine slowly forward (by an amount equal to the
length of track on ground), then stop the machine.
6. Check the track tension again, and if the tension is not correct,
adjust it again.
CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air
heater checked for dirt or disconnections.
4 - 29
.
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)

Replace the bucket teeth before the adapter starts to wear.
WARNING
It is dangerous if the work equipment is mistakenly moved when
replacing the teeth.
Set the work equipment in a stable condition, stop the engine, then set
lock lever (1) securely to the LOCK position (L).
As the locking pin is knocked out with force, there is danger that the pin
may fly out. Check that there is no one near the machine.
Broken pieces may fly during the replacement operation, so always
wear safety glasses, gloves, or other protective equipment.
1. To make it possible to knock out pin of tooth (1), put block (5)
under the bottom of the bucket, and set so that the bottom
surface 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 pin (2) and rubber pin lock (3) are used in the condition
below, it will cause tooth (1) to come off during operation.
Always replace them with new parts.
Lock pin (2) is too short.

Dimension (B) is less than 1/3 A when lock pin (2) is aligned at
bottom surface (C).
4 - 30
.
Rubber (6) of the rubber pin lock is cut and the steel ball is about
to come out.
Steel ball (7) sinks in when it is pushed 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 tooth (1) to adapter (4), and confirm that when the pointer is
pressed strongly, the rear face of the hole for the pin of the
teeth is at the same level as the rear face of the hole for the pin
of the adapter.
If the rear face of the pin hole of tooth (1) protrudes in front of
the rear face of the pin hole of adapter (4), do not knock the pin
in.
If this happens, there is something (C) preventing the tooth (1)
from fitting completely in adapter (4), locate the problem and
remove the obstruction. When tooth (1) fits completely in
adapter (4), knock in lock pin (2).
4 - 31
.
8. Insert lock pin (2) in the pin hole in the tooth (1), and knock it in
so that the top surface of lock pin (2) is the same height as the
surface of tooth (1).
9. After replacing the bucket tooth, always check as follows.
1) After lock pin (2) is completely knocked in, check that it is
secured in position at tooth (1) and the surface.
2) After knocking in the lock pin (2) from one direction, tap it
back lightly in the opposite direction.
3) Tap the tip of tooth (1) from the top and bottom, and the side
face from the left and right.
4) Rubber pin lock (3) and lock pin (2) must be as shown in the
diagram on the right.
REMARK
If the tooth is turned, the wear will become uniform. This will extend the service life of the tooth and reduce the
frequency of replacement.
When replacing the tooth, replace the rubber pin lock and lock pin with new parts at the same time. This will prevent
the tooth from falling out.
4 - 32
.
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)

Replace the teeth before the wear reaches the adapter.
WARNING
It is dangerous if the work equipment is mistakenly moved when
replacing the teeth.
Set the work equipment in a stable condition, stop the engine, then set
lock lever (1) securely to the LOCK position (L).
As the locking pin is knocked out with force, there is danger that the pin
may fly out. Check that there is no one near the machine.
Broken pieces may fly during the replacement operation, so always
wear safety glasses, gloves, or other protective equipment.
1. To make it possible to knock out pin (1) of tooth (2), put block
(5) under the bottom of the bucket, and set so that the bottom
surface of the bucket is horizontal.
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 the bucket teeth cannot be safely removed by this mothod,
have your Komatsu distributor replace the bucket teeth.
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 - 33
.
ADJUST BUCKET CLEARANCE

WARNING
It is dangerous if the work equipment is mistakenly moved when adjusting
the bucket clearance.
Set the work equipment in a stable condition, stop the engine, then set lock
lever (1) securely to the LOCK position (L).
1. Set the work equipment to the position shown in the diagram

on the right, then stop the engine and set the lock lever (1) to
the LOCK position (L).
2. Shift O-ring (1) and measure the amount of play "a".
Measurement is easier if you move the bucket to one side so
that all the play can be measured at one place (the left side in
the diagram).
Use a 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 shim (4) corresponding to the amount of play "a"
measured above.
[Example]
In the case of play of 3 mm (0.118 in), remove two 1.0 mm
(0.039 in) shims and one 0.5 mm (0.020 in) shim. Play
becomes 0.5 mm (0.020 in). For shim (4), two types of 1.0 mm
(0.039 in) and 0.5 mm (0.020 in) are used.
When play "a" is smaller than one shim, do not carry out any
maintenance.
5. Tighten the four bolts (2).
If the bolts (2) are too stiff to tighten, pull out pin stopper bolt (5)
for easier tightening.
(6): Arm
(7): Bucket
4 - 34
.
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

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

The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following
proportions before adding.
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), select according to the area and season.
4 - 35
.
CHECK AND MAINTENANCE AIR CONDITIONER
Check Level of Refrigerant (gas)
WARNING
If the refrigerant used in the air conditioner 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 the level of the refrigerant (gas) is low, the cooling effect will be
reduced. Run the engine at high idle, and check the flow of the
refrigerant gas (R134a) in the refrigerant circuit through the sight
glass (2) (inspection window) of the receiver (1) when the cooler is
running at high speed.
(A) No bubbles in refrigerant flow: Suitable
(B) Some bubbles in flow (bubbles pass continuously):
Lack of refrigerant
(C) Colorless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant gas level is low, so contact
your Komatsu distributors to have refrigerant added. If the air
conditioner is run with the refrigerant gas level low, it will cause
damage to the compressor.
Inspection During Off Season

Even during the off-season, operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all
parts of the compressor.
Inspection and Maintenance Items
Check, maintenance Guideline for maintenance

Content of check, maintenance
items interval
Refrigerant (gas) Charge amount Twice a year (spring, autumn)
Condenser Clogged fins Every 500 hours
Compressor Operating condition Every 4000 hours
V-belt Damage, tension Every 250 hours
Operating condition
Blower motor, fan When required
(does it when required make abnormal noise?)
Control mechanism Operating condition (does it function normally?) When required
Mounting condition, looseness at tightening or
Piping mounts When required
connecting portions, leakage of gas, damage
4 - 36
.
WASH WASHABLE FLOOR

WARNING
When setting the machine at an angle, use strong blocks to stabilize the
machine and be extremely careful when carrying out the operation.
If the control levers are touched by mistake, the machine may suddenly
move, and this may lead to a serious accident. Always set lock lever (1)
securely to LOCK position (L) before standing up from the operator's
seat.
NOTICE
When carrying out this operation, be careful not to get water on the monitor and connectors inside the operator's cab.
Never spray water above the pedestal of the operator's seat (2).
If any water splashes on the surrounding equipment, be sure to wipe it off.
With the washable floor, it is possible to flush out the dirt on the cab floor directly with water.
Washing Washable Floor Mat

1. Stop the machine on horizontal ground, lower the bucket to the ground, and then stop the engine.
2. When washing the floor mat, use a brush to remove the dust, or direct the water onto the mat and wash it with
a brush.
Method of Washing
1. Set the machine at an angle.
For details, see "Method of Setting Machine at Angle (PAGE 4-39)"
2. Swing the upper structure slowly so that water drain holes (3)
in the cab floor are at a low position.
4 - 37
.
3. Lower the work equipment to the ground and set the machine
in a stable condition.
4. Set lock lever (1) to LOCK position (L) and stop the engine.
5. Remove the floor mat holder plate (4).

6. Remove the floor mat.
7. Remove the cap from water drain port (3).
8. Flush out the dirt on the floor directly with water through water
drain port (3).
9. After completing the washing operation, install the cap in water drain port (3).
10. Fit the floor mat, then secure it with floor mat holder plate (4).
4 - 38
.
Method of Setting Machine at Angle
Method Using Slope
WARNING
Select a solid and smooth slope.
Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground.
1. Stop the machine so that the work equipment is on the downhill

side.
2. Put blocks under the track and dig the work equipment into the
ground.
Method Using Block
WARNING
Select a firm flat place.
Put strong blocks under the undercarriage to stabilize the machine and be extremely careful when carrying out the operation.
1. Raise the chassis with the boom and arm.

When doing this, operate the levers slowly.
2. Insert block (5) under the raised track to make the machine
stable.
3. Raise the boom slowly and lower the machine.

When doing this, check that the machine is always stable.
4 - 39
.
BLEEDING AIR FROM HYDRAULIC SYSTEM

For details, see "STARTING ENGINE (PAGE 3-84)". If it is necessary to refer to the items for starting the engine,
moving the machine off, steering, or stopping, see the OPERATION section.
1. Bleeding air from pump
1) Loosen air bleed plug (1) and check that oil oozes out from
the air bleeder.
2) If the oil does not ooze out, remove the drain hose from the
hydraulic pump case and fill the pump case completely
with hydraulic oil through drain port (2).
Hold the removed hose firmly, keeping the mouthpiece
higher than the oil level in the hydraulic tank so that oil will
not spill out of the hose.
3) After completing the air bleed operation, tighten air bleed
plug (1) and install the drain hose.
NOTICE
If the drain hose is installed first, oil will spurt out from plug hole (1).
If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be generated and this may cause an
unexpected damage to the pump.
2. Starting engine
Start the engine, referring to "STARTING ENGINE (PAGE 3-84)".
Run the engine at low idle for 10 minutes after starting, then start operations.
3. Bleeding air from cylinders
1) Run the engine at low idle, and extend and retract each cylinder 4 to 5 times, taking care that a cylinder is
not moved to the end of its stroke. (Stop the cylinder approx. 100 mm (3.9 in) short of its stroke end)
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.
NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder
may cause damage to the piston packing.
4. Bleeding air from swing motor

1) Run the engine at low idling, loosen hose (1) at port S, and
check that oil oozes out from port S hose (1).
NOTICE
Do not operate the swing under any circumstances.
2) If oil does not ooze out, stop the engine, remove port S hose (1), and fill the inside of the motor case with
hydraulic oil.
3) After completely bleeding the air, tighten port S hose (1).
4) Run the engine at low idle and slowly swing at least two times uniformly to the left and right. This will
automatically bleed the air.
4 - 40
.
NOTICE
If the air is not bled from the swing motor, the motor bearings may be damaged.
When replacing the travel motor safety valve, please contact your Komatsu distributor to have it replaced and to have the air
bled.
5. Bleeding air from travel motor

(Bleed the air only when the oil inside the travel motor case has
been drained.)
1) Run the engine at low idling, loosen air bleeder (1), and
check that oil flows out.
2) Run the engine at low idle 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, and
rotate the track equally both forward and in reverse.
6. Bleeding air from attachment (when installed)

If a breaker or other attachment has been installed, run the engine at low idle and operate the attachment pedal
repeatedly (approx. 10 times) until the air has been bled from the attachment circuit.
NOTICE
If the method of bleeding the air from the attachment itself is specified by the manufacturer, bleed the air according to the
specified procedure.
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.
After completing the air bleeding operation, inspect the oil level, and if the oil level is low, add oil.
4 - 41
.
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT

WARNING
The hydraulic circuit is always under pressure, so release the pressure inside the circuit before inspecting or replacing the
piping or hoses.
If the pressure is not released, high-pressure oil will spurt out and may cause serious personal injury.
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.
When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the internal pressure before removing
the cap.
1. Stop the machine on firm level ground.
2. Within 15 seconds after stopping the engine, turn the starting

switch to the ON position, and operate the control levers (work
equipment, travel) fully in each direction to release the internal
pressure.
3. Loosen oil filler cap (F) at the top of the hydraulic tank slowly to
release the internal pressure.
4 - 42
.
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)

NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release
the remaining pressure inside the hydraulic circuit if a failure occurs on the machine.
Check the nitrogen gas charge pressure as follows.

1. Set the work equipment to maximum reach as shown in the
diagram on the right.
2. Stop the engine and carry out the LOWER operation for the boom.
3. Check that the tip of the bucket drops at least 1 m (3 ft).
If the tip of the bucket drops less than 1 m (3 ft), the charge pressure inside the accumulator is low, so contact
your Komatsu distributor.
4 - 43
.

For details of the following items, see "Checks Before Starting (PAGE 3-71)" in the OPERATION section.
Check coolant level, add coolant
Check oil level in engine oil pan, add oil
Check fuel level, add fuel
Drain water and sediment from fuel tank
Check for water and sediment in water separator, drain water
Check oil level in hydraulic tank, add oil
Check working lamp switch
Check electric wiring
Check function of horn
4 - 44
.
LUBRICATING
1. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and 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 - Link coupling pin (1 place)

(2) Arm - Bucket coupling pin (1 place)
(3) Link coupling pin (2 places)

(4) Bucket cylinder rod end (1 place)
(5) Bucket - Link coupling pin (1 place)
4 - 45
.
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL

WARNING
1. Remove dipstick (G) and wipe the oil from the dipstick with a
cloth.
2. Fully insert dipstick (G) into the filler pipe.
3. When dipstick (G) is pulled out, if oil level is between the H and
L marks of the gauge, oil level is proper.
4. If the oil does not reach the L mark on dipstick (G), remove oil
filler (F), and add engine oil.
5. If the oil level exceeds the H mark on the dipstick, loosen drain
valve (P) to drain the excess oil.
6. After checking oil level or adding oil, insert the dipstick (G) into
the hole and install oil filler (F) cap.
4 - 46
.
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.
Prepare a handle.
1. Set the TOP mark at the top, with the UP mark and plug (P)
perpendicular to the ground surface.
2. Remove plug (F) using the handle. When the oil level reaches
a point 10 mm (0.4 in) below the bottom of the plug hole, the
correct amount of oil has been added.
3. If the oil level is too low, install plug (F), operate the travel
levers, and drive forward or in reverse to rotate the sprocket
one turn. Then repeat Step 2 to check again.
4. If the oil level is low, add engine oil through plug hole (F) until
the oil overflows from plug hole (F).
5. After checking, install plug (F).
The tightening torque for plugs (P) and (F) is 68.6 ± 9 N·m (7 ±
1 kgf·m , 50.6 ± 7.2 lbft).
REMARK
There are two plugs (F). Add oil through the one easier to fill oil and
through which no internal gears are to be seen.
4 - 47
.
CHECK LEVEL OF BATTERY ELECTROLYTE

Perform 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 cause an explosion.
The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
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.
1. Open the battery room door on the left side of the machine, then remove cover (1).
2. Remove cap (2) at the top of the battery, look through 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.
3. Clean the air hole in the battery cap (3), then tighten the cap
securely.
Wipe the top surface of the battery with a damp cloth to keep
it clean.
When adding distilled water in cold weather, add it before
starting operations in the morning to prevent the electrolyte
from freezing.
4 - 48
.
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. 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.
2. If the electrolyte level is below the midway point between the

U.L. and L.L. lines, remove cap (1) and add distilled water to
the U.L. line.
3. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the U.L. line, use a syringe 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 - 49
.
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. Remove cap (1) at the top of the battery, look through 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.
2. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the
sleeve. Neutralize the 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 an indicator to check the electrolyte level, follow the instructions given.
4 - 50
.
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
Checking
1. Remove radiator fan guard (A).
2. Press the belt at a point midway between the drive pulley and
compressor pulley with a finger force of approx. 58.8 N (6 kgf)
and check that the deflection is 5 - 8 mm (0.20 in - 0.31 in).
Adjustment
1. Loosen bolts (1) and (2).
Bracket (4) holds the compressor in place. When bolts (1)
and (2) are loosened, bracket (4) moves with the securing
position of bolt (2) as a fulcrum.
2. Loosen nut (5) attached to the fixed bracket (3) and then
tighten bolt (6).
Tighten bolt (6) so that the deflection of the belt will be 5 to
8 mm (0.20 to 0.31 in) (approx. 58.8N (6 kgf)).
3. Tighten bolts (1) and (2) to secure bracket (4).
4. Loosen bolt (6) to remove from bracket (4).
5. Tighten nut (5).
6. Check for damage to the pulleys, and wear of the V-groove and V-belt. Be particularly careful to check that the
V-belt is not in contact with the bottom of the V-groove.
7. If the belt has elongated and there is no more allowance for adjustment, or if the belt is cut or cracked, replace
the belt.
8. After replacing the V-belt, operate for one hour, then adjust again.
4 - 51
.

Maintenance for every 250 hours service should be carried out at the same time.
LUBRICATING
NOTICE
For the first 50 hours on a new machine, carry out greasing for greasing points 1 to 12 every ten hours. Carry out the greasing
for these points also at 250 hours and 500 hours on a new machine. After this, carry out the greasing every 500 hours or every
six months, whichever comes sooner.
After carrying out digging work in water, always greasing the pins that were under water.
When carrying out heavy-duty operations, such as hydraulic breaker operations, carry out the greasing every 100 hours.
1. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop
the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
(1) Boom cylinder foot pin (2 places)
4 - 52
.
(2) Boom foot pin (2 places)

(3) Boom cylinder rod end pin (2 places)
(4) Arm cylinder foot pin (1 place)
(5) Boom - Arm coupling pin (1 place)

(6) Arm cylinder rod end (1 place)
(7) Bucket cylinder foot pin (1 place)
LUBRICATE SWING CIRCLE

1. Lower the work equipment to the ground.
2. Using a grease pump, pump in grease through the grease
fittings shown by arrows. (2 places)
4 - 53
.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
Refill capacity of oil pan: 14 liters (3.70 US gal)

Filter wrench
1. Remove the inspection cover of the undercover directly under
drain plug (P) under the machine, then place a container to
catch the oil.
2. To prevent getting oil on yourself, lower the lever of drain valve
(P) slowly, drain the oil, then raise the lever to close the valve.
3. Open the cover at the rear right, then use a filter wrench to turn
filter cartridge (1) to the left to remove it.
4. Clean the filter holder, fill the new filter cartridge with clean engine oil, coat the thread and packing surface of the
new filter cartridge with clean engine oil (or coat it thinly with grease), then install it to the filter holder.
REMARK
Check that there is no old packing stuck to the filter holder. If there is any old packing stuck to the filter, it will cause
leakage of oil.
5. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it a
further 3/4 to 1 turn.
4 - 54
.
6. After replacing the filter cartridge, open the engine hood and
add engine oil through oil filler (F) to between the H and L
marks on dipstick (G).
7. Run the engine at idle for a short time, then stop the engine,
and check that the oil level is between the H and L marks on the
dipstick. For details, see "Check Oil Level in Engine Oil Pan,
Add Oil (PAGE 3-72)".
8. Install the undercover.
4 - 55
.
REPLACE FUEL FILTER CARTRIDGE

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

1. Set the container to catch the fuel under the filter cartridge.
2. Using a filter wrench, turn filter cartridge (1) counterclockwise
on remove it.
3. Clean the filter holder. Fill a new filter cartridge with clean fuel.
Coat the packing surface with engine oil. Then install the new
cartridge into the filter holder.
4. When installing, screw in cartridge until seal comes in contact
with sealing surface, then tighten approx. an additional 1/2
turn.
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,
always tighten to the correct amount.
5. After replacing the fuel filter cartridge, bleed the air from the
system.
Bleed the air as follows.
6. Fill the fuel tank with fuel (to the position where the float is at the
highest position).
7. After replacing filter cartridge (1), loosen air bleed plug (3).
8. Loosen the knob of feed pump (2), pump it up and down, and
continue to make the fuel overflow until no more bubbles come
out from air bleed plug (3). Then tighten the knob of feed pump.
9. Tighten air bleed pug (3).
Always use a genuine Komatsu filter cartridge.
After replacing the filter cartridge, start the engine and check for any leakage of oil from the filter seal surface.
REMARK
Use the feed pump to bleed air from the fuel system, when the machine has run out of fuel, too.
4 - 56
.
CHECK SWING PINION GREASE LEVEL, ADD GREASE

Prepare a scale.
1. Remove bolts (1) (2 bolts) on the top of the revolving frame and
remove cover (2).
2. Insert a scale into the grease and check that the height of the
grease in the portion where the pinion passes is at least 4 mm
(0.2 in). Add more grease if necessary.
3. Check if the grease is milky white. If it is milky white, it is
necessary to change the grease. Please contact your
Komatsu distributor.
The total amount of grease: 10.5 liters (2.77 US gal)
4. Install cover (2) with bolts (1).
4 - 57
.
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER
COOLER FINS
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 using compressed air for cleaning, blow it keeping some distance to avoid damaging the fins. Damage on the fins can cause
water leakage and overheating. In a dusty job site, check the fins every day, regardless of the maintenance interval.
1. Open the engine hood.

2. Loosen screw (3) and pull up net (2).
3. Clean net (2). (it is to be installed again, as instructed in the
step 8.)
4. Loosen the 3 cover bolts at the top on the engine side, then
slide the cover.
5. Inspect the front and rear of oil cooler fins (4), radiator fins (7),
after-cooler fins (8) and condenser fins (9) for dirt, dust, dry
leaves, etc. Blow them away with compressed air, if any.
Steam or water may be used instead of compressed air.
6. Check the rubber hose. Replace with a new one, if the hose
is found to have cracks or to be hardened by aging.
Further, check the hose cramps for looseness.
6. Check the rubber hose. Replace with a new one, if the hose is
found to have cracks or to be hardened by aging.
Further, check the hose cramps for looseness.
7. Remove cover (10) of the under cover and dispose of the dirt,
dust, dry leaves, etc. fallen on it.
8. Push in cleaned net (2) back to the original place and secure
it with screw (3).
4 - 58
.
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS

WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury.
Always wear protective glasses, dust mask, and other protective equipment.
NOTICE
As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner
unit.
Cleaning Reticulated Air Filter

1. Remove wing bolts (1) from the inspection window at the
bottom rear left on the inside of the operator's cab, then take
out the recirculated air filter.
2. Clean the filter with compressed air. If there is oil on the filter,
or if the filter is extremely dirty, wash it in a neutral agent. After
rinsing it in water, dry it thoroughly before using it again.
If the clogging of the filter cannot be removed by blowing with
air or washing in water, replace the filter with a new part every
year.
Cleaning Fresh Air Filter

1. Open cover (2) at the bottom left of the operator's cab by hand,
pull out filter case (3) from the inside, then remove the filter.
2. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash it in a neutral
agent. After rinsing it in water, dry it thoroughly before using it again.
If clogging of the filter cannot be removed by blowing with air or washing in water, replace the filter with a new
part every year.
3. After cleaning, return filter (3) to its original position and close the cover. Use the starting switch key to lock the
cover. Do not forget to remove the starting switch key.
4 - 59
.
REMARK
The FRESH filter must be installed facing in the correct direction.
When installing, insert the long (L) end of filter (3) into the filter case
first. If the short (S) end is installed first, cover (2) will not close.
4 - 60
.
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK

WARNING
When the oil filler cap is removed, oil may spurt out, turn the cap slowly to release the pressure before removing the cap.
1. Remove the cap of oil filler (F) at the top of the hydraulic tank.
2. Replace element (1) inside the cap.
4 - 61
.

Maintenance for every 250 and 500 hours service should be
carried out at the same time.
REPLACE HYDRAULIC OIL FILTER ELEMENT

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the
temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
NOTICE
If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than during normal bucket
operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)" when carrying out
maintenance.
1. Set the work equipment on the hard and flat ground in the
maintenance posture as shown in the figure, then lower it to the
ground and stop the engine.
2. Remove the cap from oil filler (F), and release the internal
pressure.
3. Loosen 6 bolts, then remove cover (1). When doing this, the
cover may fly out under the force of spring (2), so hold the
cover down when removing the bolts.
4. After removing spring (2), valve (3) and strainer (4), take out
element (5).
Inspect the bottom of the filter case for dirt, and remove it, if
any. Take good care then not to let fall the dirt into the
hydraulic tank.
5. Clean the removed parts in diesel oil.
6. Install the new element in the place where old element (5) was
installed.
7. Set valve (3), strainer (4) and spring (2) on top of the element.
8. Set cover (1) in position, push it down by hand, and install the
cover with the mouning bolts.
9. Screw in the oil filler cap and install the cover.
10. To bleed the air, start the engine according to "STARTING
ENGINE (PAGE 3-84)" and run the engine at low idle for 10
minutes.
11. Stop the engine.
4 - 62
.
CHANGE OIL IN SWING MACHINERY CASE

WARNING
Refill capacity: 6.6 liters (1.74 US gal)

1. Remove cover (A) of the inspection hole.
2. Set a container under drain valve (P) under the machine body
to catch the oil.
3. Loosen drain valve (P) under the body, drain the oil, then
tighten the drain valve again.
4. Remove the cap of oil filler (F), then add the replacement
amount of oil through oil filler (F).
5. Pull out dipstick (G) and wipe off oil on the dipstick with cloth.
6. Fully insert dipstick (G) into filler pipe (F), then remove it.
7. The oil level should be between H and L marks on the dipstick
(G). If the oil does not reach the L mark, add engine oil through
oil filler port (F).
8. If the oil is above the H mark, drain the excess engine oil from drain valve (P), and check the oil level again.
4 - 63
.
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

WARNING
NOTICE
Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the
oil level.
1. Open the cover on the right side of the machine.
2. Remove plug (G) and check the oil level. if the oil level is near
the bottom of the plug hole, the oil amount is at a proper level.
If found short, remove plug (F) and replenish oil through plug
(F) filler port up to the bottom of plug (G) hole.
NOTICE
If excess oil is supplied, drain it to the specified amount to avoid
overheating.
3. Install plugs (G) and (F).

4. Close the door.
CHECK FAN BELT TENSION AND REPLACE FAN BELT

Special tools are required for inspection and replacement of the fan belt. Contact your Komatsu distributors for
inspection and replacement.
REMARK
An installed auto fan belt tension adjuster, "Auto Tensional Fan Belt", dispenses with the belt deflection adjustment.
4 - 64
.

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN FINAL DRIVE CASE

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.
Set a container (capacity: min 4.5 liters (1.19 US gal)) in position to catch the drained oil.
Refill capacity (each): 4.5 liters (1.19 US gal)
Prepare a handle.
1. Set the TOP mark at the top, with the TOP mark and plug (P)
perpendicular to the ground surface.
2. Set a container under plug (P) to catch the oil.
3. Remove plugs (P) and (F) with the handle and drain the oil.
REMARK
Check the O-rings in the plugs for damage. If necessary, replace
with new ones.
4. Tighten plug (P).

5. Add engine oil through the hole of plug (F).
6. When oil begins to overflow from the plug (F) hole, install plug
(F).
Tightening torque of plugs (P) and (F):
68.6 ± 9.8 N·m (7 ± 1 kgf·m, 50.6 ± 7.2 lbft)
REMARK
There are two plugs (F). Add oil through the one easier to fill oil and
through which no internal gears are to be seen.
4 - 65
.
CLEAN HYDRAULIC TANK STRAINER

WARNING
1. Loosen 6 bolts, then remove cover (1). When doing this, the
cover may fly out under the force of spring (2), so push the
cover down when removing the bolts.
2. Hold the top of rod (3) and pull up to remove spring (2) and
strainer (4).
3. Remove any dirt stuck to strainer (4), then wash it in clean
diesel oil or flushing oil. If strainer (4) is damaged, replace it
with a new part.
4. When installing, insert strainer (4) into protruding part (5) of the
tank, and assemble.
5. Assemble so that the protruding part at the bottom of cover (1)
holds spring (2), then tighten with the bolt.
CHECK ALTERNATOR, STARTING MOTOR

The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection
and repairs.
If the engine is started frequently, have this inspection carried out every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST

Special tools are needed for inspection and maintenance, please contact your Komatsu distributor.
4 - 66
.

Maintenance for every 250, 500, 1000 and 2000 hours service should be carried out at the same time.
CHECK WATER PUMP

Since the pulley may have play, oil may leak, water may leak and
the drain hole (A) may be clogged, contact your Komatsu
distributor for inspection, overhaul or replacement.
4 - 67
.

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN HYDRAULIC TANK

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 4-17)" when carrying out
maintenance.
Refill, capacity: 121 liters (31.97 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. Set the lock lever to the LOCK position and stop the engine.
4. Remove the cap of oil filler port (F) at the top of the hydraulic
tank.
5. Set a container direct under the drain plug located on the
machine's underside to catch oil that is drained. Remove drain
plug (P) and drain the oil. Check an O-ring installed to Plug (P),
and if it has a scratch or damage, replace it with new one. After
draining the oil, tighten drain plug (P).
The specified tightening torque is 68.6 ± 9.81 N·m (7 ± 1 kgf
·m, 50.6 ± 7.2 lbft)
Take care not to get oil on yourself when you remove drain
plug (P).
6. 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 "Check Oil Level in Hydraulic
Tank, Add Oil (PAGE 3-75)".
4 - 68
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit PC160LC-7
Operating weight kg (lb) 16,400 (36,162)

3
Bucket capacity m (cu.yd) 0.6 (0.78)
Name of engine - KOMATSU SAA4D102E diesel engine
Engine horsepower kW (HP)/rpm 82.40 (110)/2,200
A Overall length mm (ft in) 8,525 (27' 12")
B Overall height mm (ft in) 3,027 (9' 11")
C Overall width mm (ft in) 2,490 (8' 2")
D Track width mm (ft in) 500 (1' 8")
E Height of cab mm (ft in) 3,000 (9' 10")
F Radius of upper structure mm (ft in) 2,436 (7' 12")
G Length of track mm (ft in) 3,980 (13' 1")
H Tumbler center distance mm (ft in) 3,170 (10' 5")
Min. ground clearance mm (ft in) 440 (1' 5")
Travel speed (Low/High) km/h (MPH) 3.4/5.5 (2.1/5.5)
Swing speed rpm 12.0
5-2
.
SPECIFICATIONS SPECIFICATIONS
Working ranges Unit PC160LC-7
A Max. digging reach mm (ft in) 8,960 (29' 5")

B Max. digging depth mm (ft in) 5,960 (19' 7")
C Max. digging height mm (ft in) 9,180 (30' 1")
D Max. vertical wall depth mm (ft in) 5,690 (18' 8")
E Max. dumping height mm (ft in) 6,370 (20' 11")
F Min. dumping height mm (ft in) 2,400 (7' 10")
G Max. reach at ground level mm (ft in) 8,800 (28' 10")
5-3
.
6-1
.
GENERAL PRECAUTIONS FOR SAFETY ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS FOR SAFETY

When installing attachments or options to the machine, it is necessary to pay attention to safety. Please obey the
following precautions strictly when selecting, installing, or using attachments or options.
PRECAUTIONS WHEN SELECTING

Please consult your Komatsu distributor before installing attachments or options to the machine. Depending on
the type of attachment or option, it may be necessary to install a front guard, overhead guard, or other safety
structure to the machine. There may also be problems of the attachment or option hitting the operator's cab.
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any
accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu.
READ THE INSTRUCTION MANUAL THOROUGHLY

Before installing or using any attachment or option, make sure that you thoroughly read and understand the
instruction manuals for the machine and the attachment or option.
If you lose the instruction manual or it is damaged, always obtain an new copy from the attachment manufacturer
or your Komatsu distributor.
PRECAUTIONS WHEN REMOVING OR INSTALLING

When removing or installing the attachment or option, 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, choose the leader and follow his instructions.
Use a crane when handling heavy objects (more than 25 kg (55 lb)). (The crane must be operated by a qualified
operator.)
Never go under a load raised by the crane.
Do not carry out operations with the load kept raised by the crane. Always use a stand to prevent the load from
falling.
When removing a heavy part, consider the balance after it is removed. To prevent the machine from tipping over,
set a support in position if necessary before removing the part.
Before installing or after removing the attachment or option, set it in a stable condition to prevent it from falling
over.
For details of the removal or installation operation, please consult your Komatsu distributor.
PRECAUTIONS WHEN USING

When long or heavy work equipment is installed, remember the following precautions. Before starting operations,
move the machine to a safe place and carry out a test operation to make sure that you fully understand the
movement, center of gravity, and working range of the machine.
Do not swing the work equipment if the machine is at an angle. If the work equipment is swung with the machine
at an angle, there is danger that the machine will tip over.
Always maintain a safe distance from obstacles in the surrounding area when operating. If long work equipment
is installed, the working range becomes larger.
If heavy work equipment is installed, pay careful attention to the following precautions.
The swing overrun (the distance the work equipment moves before completely stopping after the swing brake
is applied) will be greater. There is danger of hitting objects if the swing overrun is miscalculated, so allow extra
space to the swing position when swinging.
The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight
when it is stopped in a raised position) also becomes greater. Do not stop the work equipment in a raised
position; always lower it to the ground.
Do not swing, lower, or stop the work equipment suddenly. There is danger that the machine may tip over.
Do not suddenly extend or retract the boom cylinder. The shock may cause the machine to tip over.
6-2
.
ATTACHMENTS AND OPTIONS BUCKET WITH HOOK
BUCKET WITH HOOK

HOOK CONDITION
Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu
distributor.
Operations with Care

During lifting operations, reduce the engine speed and carry out
the operation in L mode.
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 travel the machine while lifting a load.
If the bucket with hook is turned and used for operations, it will
hit the arm during dumping operations, be careful when using it.
Do not exceed the following loads when carrying out lifting
operations.
When standard arm is installed: 990 kg (2,183 lb)
If you are planning to newly install a hook, contact your Komatsu
distributor.
6-3
.
MACHINE READY FOR ATTACHMENT ATTACHMENTS AND OPTIONS
MACHINE READY FOR ATTACHMENT

LOCATIONS
(1) Stop valve (5) Breaker circuit additional oil filter

(2) Selector valve (6) Accumulator (low-pressure)
(3) Attachment control pedal (7) Accumulator (high-pressure) (if equipped)
(4) Lock pin
Stop Valve
This valve (1) stops the flow of the hydraulic oil.
(a) FREE: Hydraulic oil flows.
(b) LOCK: Hydraulic oil stops.
When removing or installing attachments, set this valve to the
LOCK position.
6-4
.
ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT
Selector Valve
This valve (2) switches the flow of hydraulic oil.
It is automatically switched according to the selected working
mode. It is necessary to switch the working mode to match the
attachment that is installed. For details of switching the working
mode, see "HYDRAULIC CIRCUIT (PAGE 6-7)".
NOTICE
If a service circuit from the attachment maker has been added, the return
circuit may not switch automatically.
Attachment Control Pedal

This pedal (3) is used to control the attachment.
When the front, center (neutral), and rear of the pedal are
depressed, the movement of the attachment is as follows.
Hydraulic breaker
Front of pedal (A): Actuated
Center of pedal N: Stopped
Rear of pedal (B): Stopped
Regarding other attachments, hold a meeting with the attachment

maker at the time of installation to confirm the operation of the
pedal and attachment before using it.
REMARK
This pedal cover (3) differs in thickness at both ends. It can be stalled facing in either direction, so install it according
to your own preference.
Lock Pin
This pin (4) locks the control pedal.
Position (a): Locked
Position (b): Only front of pedal can be operated to full position
(rear is locked)
Position (c): Both front and rear of pedal can be operated to
full position
When using a breaker, select B mode on the monitor and set the
lock pin to position (b).
When not using the attachment, set the lock pin to position (a).
When using a Crasher, select A or E mode on the monitor and
set the lock pin to position (c).
NOTICE
When using a breaker, if the lock pin is set to position (c) and the rear portion (B) of the pedal is depressed, it will cause defective
operation or breakage of the breaker, so always set the lock pin to position (b) when using the breaker.
6-5
.
Breaker Circuit Additional Oil Filter

This filter (5) prevents deterioration of the hydraulic oil when using
a breaker.
Oil only flows when B mode is selected on the monitor.
NOTICE
Always install an additional filter in the return circuit on machines
equipped with a hydraulic breaker.
Accumulator
WARNING
The accumulator is charged with high-pressure nitrogen gas, so it is
extremely dangerous if it is handled incorrectly. For details of handling,
see "ACCUMULATOR (PAGE 3-67)".
This accumulator (6), (7) is installed to reduce the peak pressure

in the hydraulic circuit when a breaker is used. Normally, do not
touch it.
NOTICE
The need to install an accumulator depends on the breaker manufacturer. When installing a breaker made by another
manufacturer, please consult your Komatsu distributor.
Depending on the breaker manufacturer, it may be necessary to install the accumulator at the inlet or outlet port of the breaker.
6-6
.
HYDRAULIC CIRCUIT
NOTICE
When a breaker is installed, it is necessary to connect the return circuit directly to the return filter, so use only B mode. Do not
use any other mode.
The standard set pressure of the service valve safety valve depends on the mode selected when the machine is shipped from
the factory.
If B mode is selected: 20.6 MPa (210 kgf/cm2 , 2980 PSI)
If A or E mode is selected: 27.4 MPa (280 kgf/cm2 , 3980 PSI)
Adjustment may be needed depending on the attachment, so in such a case, please contact your Komatsu distributor.
Switching Hydraulic Circuit

Depending on the type of attachment, set the working mode on the monitor as follows.
The set pressure of the service valve safety valve and the hydraulic circuit switch is according to the working
mode selected.
Set pressure of service

Attachment Working mode Hydraulic circuit
safety valve
Return circuit automatically When shipped from
Breaker or other attachment
B mode switched so that it does not factory: 20.6 MPa (210
with one-way circuit
pass through control valve kgf/cm2 , 2980 PSI)
A mode Return circuit automatically When shipped from

Crusher or other attachment
or switched so that it passes factory: 27.4 MPa (280
with two-way circuit
E mode through control valve kgf/cm2 , 3980 PSI)
Adjusting Oil Flow

Depending on the attachment, it is necessary to change the oil flow in the service circuit.
For details of setting the oil flow, see "ATTACHMENT OPERATIONS (PAGE 6-13)".
Switching Between Breaker and General Attachment

When a possible attachment (if equipped) is installed and B mode is selected:
1) The circuit becomes a circuit for breaker operation (1-way circuit).
2) The hydraulic oil flowing in the breaker circuit flows to the additional filter for the breaker.
3) The relief valve is set to a lower pressure.
When shipped from factory: 20.6 MPa (210 kgf/cm2, 2980 PSI)
4) It is possible to adjust the maximum flow with the select mode.
When a possible attachment (if equipped) is installed and A mode or E mode is selected:
1) The circuit becomes a circuit for crusher operation (2-way circuit).
2) The hydraulic oil flowing in the crusher circuit does not flow to the additional filter for the breaker.
3) The relief valve is set to a higher pressure.
When shipped from factory: 27.4 MPa (280 kgf/cm2, 3980 PSI)
4) It is possible to adjust the maximum flow with the select mode.
6-7
.
Hydraulic Circuit Connection

When connecting the attachment, connect the hydraulic circuit as
follows.
1. Remove blind plug (1) at the end of the stop valve piping.
(Two spots on the left and right)
Be careful not to lose or damage any part that has been
removed.
2. Connect attachment piping (2) provided by the attachment

maker to the part from which the plug was removed Step 1.
For the mouthpiece size and accumulator add-on, the
action to take differs according to the attachment
manufacturer,
so please consult your Komatsu distributor.
6-8
.
Oil Flow Path

The direction of operation of the pedal and the path of the oil flow is as shown in the diagram below.
When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the rear
of the pedal is depressed, oil flows to the piping on the right side of the work equipment. (When a breaker is installed,
only the front of the pedal can be used.)
6-9
.
Replace Additional Breaker Filter Element

WARNING
Immediately after operating the engine, all parts still retain high
temperature. Never replace the filter in such condition.
Replace it only after each part has sufficiently cooled.
Prepare a container to catch the oil.

1. Place a container under the filter element to catch the oil.
2. Remove plug (3) and drain the oil from filter case (1).
3. Turn filter case (1) counterclockwise to remove it. Remove
element (2) from the case.
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.
NOTICE
For details of the replacement interval for the element, "MAINTENANCE
INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-17)".
6 - 10
.
ATTACHMENT REMOVAL AND INSTALLATION
Attachment Removal
1. Lower the attachment to the ground and stop the engine.
2. Turn the starting switch to the ON position (B), then set the lock
lever to the FREE position (F).
3. Operate each work equipment control lever and the
attachment control pedal back and forth, left and right at full
stroke 2 to 3 times to eliminate the internal pressure in the
hydraulic circuit.
4. Loosen slowly oil filler cap (F) on top of the hydraulic tank to
eliminate the internal pressure in the hydraulic circuit.
5. After checking that the oil has cooled down, turn the rotor on
the stop valve installed to the piping for the inlet port and outlet
port on the side face of the arm to the LOCK position (L).
6. Remove the hoses on the attachment side. Install the plugs to
the two outlets.
The plugs are used to prevent the attachment from incorrect
operation caused by mixing in of foreign matter. After the plugs
are correctly installed, store the attachment.
6 - 11
.
7. Pull out the mounting pins (2 places), remove the attachment,

then install the bucket.
For details of the procedure for installing the bucket, see
"BUCKET REPLACEMENT AND INVERSION (PAGE
3-116)".
8. After installing the bucket, check the oil level in the hydraulic
tank.
Attachment Installation
1. Remove the bucket.
For bucket dismounting procedure, see "BUCKET REPLACEMENT AND INVERSION (PAGE 3-116)".
2. Place the attachment in a horizontal position, then install to the
arm with pin (A) and then pin (B).
3. After confirming low oil temperature, remove the plug from the
outlet and inlet port respectively.
Take care that no dust, mud etc. adheres to the hose
mousepiece portions.
If O-ring is damaged, replace it with a new one.
4. Connect the hose at the attachment side.
When doing this, check the direction of flow of the oil and be
careful not to make any mistake.
5. Turn the rotor on the stop valve installed to the piping for the
inlet port and outlet port on the side face of the arm to the FREE
position (F).
6. After installing the attachment, check the oil level in the
hydraulic tank.
6 - 12
.
ATTACHMENT OPERATIONS
WARNING
Do not rest the foot on the pedal and depress it, when the auto deceleration switch is in ON position. The engine speed rises
all of sudden and the attachment will move suddenly and cause serious damage or injury.
Do not put your foot on the pedal except when operating the pedal. If rest your foot is the pedal during operations, and it is
depressed by accident, the attachment may move suddenly and cause serious damage or injury.
Operate the attachment as follows.
When Using Breaker

When the B mode control switch is ON and the lock pin position
makes only the front of the pedal free (a), if the front of the pedal is
depressed, the breaker is actuated.
1. Set the working mode to B mode.
2. When select switch (1) on the monitor is pressed, the screen
changes to screen (A). Select a suitable oil flow for the breaker
from among 140 liters/min, 100 liters/min, and 60 liters/min,
then press input confirmation switch (2).
3. The monitor screen changes to screen (B), so if it is necessary
to make fine adjustment, press up switch (3) or down switch (4)
to move the bar graph showing the oil flow up or down, then
press input confirmation switch (2).
It is possible to change the oil flow in segments of approx.
10 liters/min.
If fine adjustment is not necessary, simply press-input
The default setting is 140 lifters/min.
Even if the starting switch is turned OFF, the set oil flow
when the engine is next started will be the value set by the
above procedure.
Precautions when using

Check that the stop valve is at the FREE position.
Check that the working mode is B mode.
For details of the path of the oil, see "HYDRAULIC CIRCUIT
(PAGE 6-7)".
When considering whether it is necessary to install an
accumulator for the attachment circuit, contact the
attachment manufacturer and then decide.
For other precautions when handling the breaker, follow the
instruction manual from the breaker manufacturer and use
the breaker correctly.
6 - 13
.
The deterioration of the hydraulic oil when using the breaker is

much faster than for normal operations, so reduce the
maintenance interval for the hydraulic oil and element.
For details, see "MAINTENANCE INTERVAL FOR
HYDRAULIC BREAKER (PAGE 4-17)".
When Using General Attachment Such as Crusher

When the A mode or E mode control switch is ON and the lock pin
position makes both the front and the rear of the pedal free (b), if
the front or rear of the pedal is depressed, the attachment is
actuated.
1. Set the working mode to A mode or E mode.
2. When select switch (1) on the monitor is pressed, the screen
changes to screen (C), so press up switch (3) or down switch
(4) to move the bar graph showing the oil flow up or down, then
press input confirmation switch (2).
The default setting is the full flow (approx. 320 liters/ min).
Even if the starting switch is turned OFF, the set oil flow
when the engine is next started will be the value set by the
above procedure.
Precautions when using

Check that the stop valve is at the FREE position.
Check that the working mode is A mode or E mode.
For details of the path of the oil, see "HYDRAULIC CIRCUIT
(PAGE 6-7)".
For other precautions when handling the attachment, follow
the instruction manual from the attachment manufacturer
and use the attachment correctly.
6 - 14
.
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 the plug and O-rings to the valves.
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
Max. merging oil flow: 160 x 2 liters/min
6 - 15
.
ATTACHMENT GUIDE ATTACHMENTS AND OPTIONS
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
Rules and regulations
Name Use Remarks
to be followed
Overhead Protection from light
---
guard falling objects
ISO 10262 Level II: Protection from
Top (Operator Protective Guards) heavy falling
guard There are two levels for For details of
objects
Protective strength category weights, see
OPG
guard Level I (light-load protective Level I: Protection from "SPECIFICATIONS
Front guard) light flying objects (5-2 PAGE)".
guard Level II (heavy-load Level II: Protection from
protective guard) heavy flying objects
Other front Protection from light
-
guard flying objects
6 - 16
.
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE
Uses of protective guards
Content of work
Demolition, Quarries, mines, or other places
Types of protective guard Breaker
cutting where there is danger of falling rocks
operations
operations Light load Heavy load
Head guard {
Top guard
Level II {
OPG
Level I {
Front guard
Level II {
Other front guards Half guard {
6 - 17
.
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 attachments which can be installed to the long arm (standard), short arm and
extension arm.
{: Can be used
U: Can be used only for light duty work
: Cannot be used
NOTICE
When the extension arm is equipped, if the bucket is drawn to the machine body, the arm interferes with the body. Operate the
extension 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
For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durability
and high wear resistance be employed.
*:Equipped with side cutter
Capacity
Outside width Long arm Standard arm Short arm
Name of bucket m3 (cu.yd) Use
mm (ft in) 2.9 m (9' 6") 2.61 m (8' 7") 2.25 m (7' 5")
SAE/CECE
0.60/0.55 Narrow
*Narrow bucket 900 (2' 11") { { {
(0.78/0.72) digging
0.65/0.60 General
*Standard bucket 966 (3' 2") { {
(0.85/0.78) digging
0.70/0.65 Light duty
Light duty bucket 1,100 (3' 7") { {
(0.92/0.85) digging
6 - 18
.
ATTACHMENTS AND OPTIONS ATTACHMENT GUIDE
TRACK SHOES SELECTION

Select suitable track shoes to match the operating conditions.
Selection
Check the category from the uses in the table below, then select the shoes from the table below that.
Category of use B is the wide shoe, so there is limits on the use. Check the precautions for use, examine the
conditions of use thoroughly, and use the optimum shoes for the situation.
When selecting the shoe width, choose the narrowest shoes possible to bring the machine within the range
where there is no problem regarding the machine flotation and ground contact pressure. If wider shoes than
necessary are used, the load on the shoe will increase, so this may cause problems such as bending of the shoe,
cracking of the link, damage of the pin, and looseness of the shoe bolts.
Category Use Precautions when using

Rocky ground,
On rough ground with large obstacles such as boulders or fallen trees, travel
A riverbeds,
at low speed.
normal soil
These shoes cannot be used on rough ground where there are large
Normal soil, obstacles such as boulders or fallen trees.
B
soft ground Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid
going over obstacles, shift down and travel at half speed in Lo.
PC160LC-7
Specifications Category
Standard 500mm Triple A
Option 600mm Triple A
Option 700mm Triple B
6 - 19
.
BUCKET TEETH SELECTION

Depending on the working conditions, there is danger that an adapter and teeth may break, so select from the
vertical pin and horizontal pin teeth to give teeth that are suitable for the purpose.
While the standard teeth of both vertical and horizontal pin types may be used widely, the following kinds of teeth
are recommended depending on the working conditions.
Teeth Selection
Vertical Pin Type Tooth

General digging: Digging and loading normal soil, such as sand, gravel, clay, etc.
Light-duty digging: digging and loading dry and loose sandy soil, or muddy soil.
Loading: loading of dry and loose earth.
Horizontal Pin Type Tooth

Heavy-duty digging: Digging and hammering work on hard soil, soil with rocks, scraping or other heavy-duty work
The heavy-duty bucket is of a horizontal pin type and as such, use it for heavy duty-digging.
Long-life Tooth
Jobsites where long wear life is demanded, such as when loading hard rocks.
Jobsites where no penetration is needed, such as when working with crushed rocks after blasting or ripping.
Jobsites where heavy-duty operations are carried out, such as hitting or pulling up rocks with the tips of the teeth.
Self-sharpening Tooth
Jobsites demanding penetration such as digging and loading sandy or clayey soil.
Selection Guide for Horizontal or Vertical Pin Type Tooth

Applicable Work Site
Clayey soil,
Rock Crushed stone Decompressed Sand
weathered granite
→Heavy
Digging with
Work Contents
hammering Horizontal pin type teeth Vertical pin type teeth

work
Scraping down Horizontal pin type teeth Vertical pin type teeth
Light←
General excavation Vertical pin type teeth

Loading Vertical pin type teeth
6 - 20
.
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS
RECOMMENDED ATTACHMENT OPERATIONS

Below described are instructions which must be followed without fail when doing the work using a hydraulic
excavator equipped with an attachment.
NOTICE
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted.
Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can
be mounted will vary. Hence, consult your Komatsu distributor for the selection of optimum attachments.
HYDRAULIC BREAKER
Main Applications
Crushed rock
Demolition work
Road construction
This attachment can be used for a wide range of applications
including demolition of buildings, breaking up road surfaces or
slag, tunnel work, rock crushing and breaking operations in
quarries.
Keep the chisel pushed 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 - 21
.
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, 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 - 22
.
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. 5 cm (2 in) to spare.
Using the mount to gather in pieces of rock
Operations using the swing force
Moving the chisel while carrying out impacting operations
Holding the chisel horizontal or pointed up when carrying out

impacting operations
6 - 23
.
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 - 24
.
Greasing
Supply grease in the correct position.
NOTICE
If the breaker is greased in an improper posture, it is filled with more grease
than necessary. As a result, soil and sand will enter the hydraulic circuit
and can damage the hydraulic components, while the breaker is in use.
Therefore, be sure to grease the breaker, holding it in the right posture.
6 - 25
.
INDEX
INDEX
<A>
Accumulator 3- 67 <G>
Air Conditioner Controls 3- 44 General Operation Information 3-110
Ashtray 3- 43 General Precautions for Safety 6- 2
Attachment Guide 6- 16 Precautions when Removing or
Attachment Combinations 6- 18 Installing 6- 2
Bucket Teeth Selection 6- 20 Precautions when Selecting 6- 2
Other Attachments 6- 16 Precautions when Using 6- 2
Auxiliary Electric Power 3- 64 Read the Instruction Manual
Thoroughly 6- 2
<B> Grease Gun Holder 3- 66
Breaking-In The New Machine 1- 7
Bucket Replacement and Inversion 3-116 <H>
Bucket with Hook 6- 3 Handling Oil, Fuel, Coolant, and
Hook Condition 6- 3 Performing Oil Clinic 4- 4
Prohibited Operations 6- 3 Hot and Cool Box 3- 43
<C> <I>
Cap with Lock 3- 42 Introduction 1- 7
Cold Weather Operation 3-131
After Cold Weather Season 3-134 <L>
After Daily Work Completion 3-134 Locking 3-121
Cold Weather Operation Information 3-131 Long Term Storage 3-135
Control Levers and Pedals 3- 33 After Storage 3-135
Controllers 3- 66 Before Storage 3-135
Controls and Gauges 3- 3 During Storage 3-135
Starting Machine After Long-Term
<D> Storage 3-136
Detailed Controls and Gauges 3- 4 Lubricants, Fuel and Coolant
Directions of Machine 1- 7 Specifications 4- 9
Door Lock 3- 41 Proper Selection 4- 9
<E> <M>
Electric System Maintenance 4- 7 Machine Inspection After Daily Work 3-120
Emergency Exit from Operator's Cab 3- 41 Machine Operation 3- 98
Engine, After Starting 3- 88 Machine Operations and Controls 3- 69
Engine, Before Starting 3- 69 Machine Ready for Attachment 6- 4
Engine Serial No. Plate and Its Location 1- 8 Attachment Operations 6- 13
Engine, Check After Shut Off 3-120 Attachment Removal and Installation 6- 11
Engine, Starting 3- 84 Hydraulic Circuit 6- 7
Engine, Stopping the 3- 97 Locations 6- 4
Escape from Mud 3-113 Long Term Storage 6- 15
Specifications 6- 15
<F> Machine View Illustrations 3- 2
Foreword 1- 2 Machine, Steering the 3-102
Fuse 3- 65 Magazine Box 3- 43
Fusible Link 3- 66 Maintenance Information 4- 2
7-1
.
INDEX
Maintenance Procedure 4- 18 Safety Machine Operation 2- 19

Check Before Starting 4- 44 Battery 2- 28
Every 100 Hours 4- 45 Lifting Objects with Bucket 2- 31
Every 250 Hours 4- 46 Operation 2- 21
Every 500 Hours 4- 52 Starting Engine 2- 19
Every 1000 Hours 4- 62 Towing 2- 30
Every 2000 Hours 4- 65 Transportation 2- 27
Every 4000 Hours 4- 67 Safety Maintenance Information 2- 32
Every 5000 Hours 4- 68 Service Meter Location 1- 9
Initial 250 Hours (First 250 Hours Only) 4- 18 Specifications 5- 2
When Required 4- 19 Sun Roof 3- 36
Maintenance Schedule 4- 15 Swinging 3-104
Maintenance Interval for Hydraulic Switches 3- 28
Breaker 4- 17
Maintenance Schedule Chart 4- 15 <T>
Monitoring System 3- 4 Tightening Torque Specifications 4- 13
Tightening Torque List 4- 13
<O> Tool Box 3- 66
Outline of Service 4- 4 Transportation 3-122
Overall Machine View 3- 2 Lifting Machine 3-129
Loading and Unloading with Trailer 3-122
<P> Transportation Procedure 3-122
Parking Machine 3-119 Traveling on Slopes 3-111
Product Identification Number Troubles and Actions 3-137
(PIN)/Machine Serial No. Plate 1- 8 Battery, Discharged 3-140
Product Information 1- 8 Lightweight Towing Hole 3-139
Prohibited Operations 3-108 Other Trouble 3-144
Phenomena That are Not Failures 3-137
<R> Running Out of Fuel 3-137
Radio 3- 59 Severe Job Condition 3-139
Recommended Applications 3-114 Towing the Machine 3-138
Recommended Attachment Operations 6- 21
Hydraulic Breaker 6- 21 <W>
Wear Parts 4- 8
<S> Wear Parts List 4- 8
Safety Critical Parts 4- 14 Windshield 3- 36
Safety Critical Parts List 4- 14 Work Equipment Controls and Operations 3-105
Safety Information 1- 5 Working Mode 3-107
Safety Information 2- 2
Safety Information 2- 10 <Y>
Safety Labels 2- 4 Your Machine Serial Numbers And
Location of Safety Labels 2- 4 Distributor 1- 9
Safety Labels 2- 5
7-2
.
PC160LC-7 GALEO HYDRAULIC EXCAVATOR

Form No. TEN00096-01
©
2005 KOMATSU
All Rights Reserved
Printed in Japan 06-05

PC160 Excavadora

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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

BREAKING-IN THE NEW MACHINE

PRODUCT INFORMATION FOREWORD

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

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.

Product identification number (PIN)

SAFETY INFORMATION SAFETY

SAFETY SAFETY INFORMATION

Safety machine operation 2- 19

SAFETY MAINTENANCE INFORMATION 2- 32

SAFETY LABELS SAFETY

LOCATION OF SAFETY LABELS

SAFETY SAFETY LABELS

(2) Caution before operating (09802-03000)

(3) Warning for leaving operator's seat (09654-03001)

SAFETY LABELS SAFETY

(4) Warnings for high voltage (09801-03001)

(5) Caution when opening or closing front window

(6) Warning when stowing front window (09803-03000)

SAFETY SAFETY LABELS

(7) Warning for hot oil (09653-03001)

(8) Warning for hot cooling water (09668-03001)

(9) Caution for handling accumulator (09659-53000)

(10) Warning when adjusting track tension (09657-03003)

SAFETY LABELS SAFETY

(11) Warning for improper use of cables (09808-03000)

(12) Stop engine when performing inspection or maintenance

(13) Explanation of methods for emergency escape

(14) Warning against falling off the edge (09805-23000)

SAFETY SAFETY LABELS

(15) Warning against falling (09805-13000)

(16) Keep off swing area (09133-23000)

(17) Warning when handling battery (09664-30082)

(18) Caution for broken or becomes dislodged to the window

(19) Jump start prohibited (09842-A0481)

SAFETY INFORMATION SAFETY

IF PROBLEMS ARE FOUND

WORKING WEAR AND PERSONAL PROTECTIVE ITEMS

FIRE EXTINGUISHER AND FIRST AID KIT

SAFETY SAFETY INFORMATION

KEEP MACHINE CLEAN

KEEP OPERATOR'S COMPARTMENT CLEAN

LEAVING OPERATOR'S SEAT WITH LOCK

When leaving the machine, always lower the work equipment

SAFETY INFORMATION SAFETY

HANDRAILS AND STEPS