Operation & EEAM006011

Maintenance Manual

PC210, PC210LC-6K
PC240LC,PC240NLC-6K
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC210-6K - K34552 and up
PC210LC-6K - K34552 and up
PC240LC-6K - K34227 and up
PC240NLC-6K - K34227 and up

WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personel who
will come into contact with the machine.
 FOREWORD

FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this
manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can
not be read, request a replacement manual from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners.

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 for your machine or
for questions regarding information in this manual.

WARNING
● This operation & maintenance manual may contain
attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu dis-
tributor for those items you require.

● This machine complies with EC directive (89/392/EEC).

Machines complying with this directive display the CE
mark

● Improper operation and maintenance of this machine can

be hazardous and could result in serious injury or death.

● Operators and maintenance personnel should read this

manual thoroughly before beginning operation or main-
tenance.

● Some actions involved in operation and maintenance of

the machine can cause a serious accident, if they are not
done in a manner described in this manual.

● The procedures and precautions given in this manual

apply only to intended uses of the machine. If you use
your machine for any unintended uses that are not spe-
cifically prohibited, you must be sure that it is safe for
you and others. In no event should you or others engage
in prohibited uses or actions as described in this manual.

● Komatsu delivers machines that comply with all applica-

ble 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 specifica-
tions 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.

● The description of safety is given in see “SAFETY

INFORMATION” on page 2. and in "SAFETY" from
page 17.

1
SAFETY INFORMATION

SAFETY INFORMATION

SAFETY MESSAGES
Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.

To avoid accidents, read, understand and follow all precautions

and warnings in this manual and on the machine before perform-
ing operation and maintenance.

To identify hazards on the machine pictorial decals are used (see

“POSITION FOR ATTACHING SAFETY LABELS” on page 49).

RED WARNING TRIANGLE - This is used on safety labels

where there is a high probability of serious injury or death if the
hazard is not avoided. These safety messages or labels usually
describe precautions that must be taken to avoid the hazard. Fail-
ure to avoid this hazard may also result in serious damage to the
machine.

ORANGE WARNING TRIANGLE - This is used on safety

labels where there is a potentially dangerous situation which
could result in serious injury or death if the hazard is not avoided.
These safety messages or labels usually describe precautions
that must be taken to avoid the hazard. Failure to avoid this haz-
ard may also result in serious damage of the machine

YELLOW SAFETY TRIANGLE - This is used on safety

labels for hazards which could result in minor or moderate injury if
the hazard is not avoided. This word might also be used for a haz-
ard where the only result could be damage to the machine.

NOTICE
This word is used for precautions that must be taken to
avoid actions which could shorten the life of the machine.

Safety precautions are described in "SAFETY" from page 17.

Komatsu cannot predict every circumstance that might involve a

potential hazard in operation and maintenance. Therefore the
safety message 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, you must be sure that you and others can do such pro-
cedures and actions safely and without damaging the machine. If
you are unsure about the safety of some procedures, contact
Komatsu or your Komatsu distributor.

2
 SAFETY INFORMATION

NOISE PC210, PC210LC-6K

Valid until 31 December 2001

● Operator ears noise value (Sound pressure level)

LpA

77
95/27/EC

● Ambient noise value (Sound power level)

LWA

105
95/27/EC

Noise level indicated is the guaranteed value as specified in the

directive 86/662/EEC as amended by 95/27/EC

3
SAFETY INFORMATION

Valid as of 1 January 2002

● Sound pressure level at the operator's station, measured

according to ISO6396 (Dynamic test method, simulated work-
ing cycle)

● Sound power level emitted. This is the guaranteed value as

specified in European directive 2000/14/EC.

4
 SAFETY INFORMATION

NOISE PC240LC, PC240NLC-6K

Valid until 31 December 2001

● Operator ears noise value (Sound pressure level)

LpA

77
95/27/EC

● Ambient noise value (Sound power level)

LWA

105
95/27/EC

Noise level indicated is the guaranteed value as specified in the

directive 86/662/EEC as amended by 95/27/EC

5
SAFETY INFORMATION

Valid as of 1 January 2002

● Sound pressure level at the operator's station, measured

according to ISO6396 (Dynamic test method, simulated work-
ing cycle)

● Sound power level emitted. This is the guaranteed value as

specified in European directive 2000/14/EC.

VIBRATION
The weighted root mean square acceleration value to which the
operator’s arms are subjected does not exceed 2.5 m/s²

The weighted root mean square acceleration value to which the

operator’s body is subjected does not exceed 0.5 m/s²

These results were obtained by accelerometers during trench dig-

ging.

6
 INTRODUCTION

INTRODUCTION

INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used
mainly for the following work:

● Digging

● Smoothing work

● Ditching work

● Loading work

See the section “WORK POSSIBLE USING HYDRAULIC

EXCAVATOR” on page 129 for further details

FEATURES
● This Komatsu HYDRAULIC EXCAVATOR is equipped with
various controls based on an advanced electronics system.

● The monitor panel greatly facilitates daily maintenance and

self-diagnosis.

● Working mode, travel speed and swing priority are selectable.

● Digging and lifting force can be increased by light-touch con-

trol. (For details, see operation section.)

● Adjustable wrist control levers make operations smooth and

easy.

● Fresh filtered air conditioner assures comfortable operation.

● Low noise level and smart urban style design and colouring.

● Superb operation performance provided by powerful engine

and high-performance hydraulic pumps.

● Low fuel consumption controlled by an electronic control sys-

tem provides an environment-friendly machine.

7
INTRODUCTION

BREAKING IN YOUR NEW MACHINE

Your Komatsu machine has been thoroughly adjusted and tested
before shipment.

However, operating the machine under severe conditions at the

beginning can adversely affect the performance and shorten the
machine life.

Be sure to break in the machine for the initial 100 hours (as indi-
cated by the hour meter.)

During breaking in:

● Idle the engine for 5 minutes after starting it up.

● Avoid operation with heavy loads or at high speeds.

● Sudden starting or acceleration, unnecessarily abrupt braking

and sharp turning should be avoided except in cases of emer-
gency.

Additionally for the first 20 hours

● Avoid operating engine for prolonged periods at constant

speed (including idle.)

● Avoid high speed travelling for periods of more than 5 min-

utes.

Pay particular attention to oil pressure and temperature indicators

& check coolant and oil levels frequently during breaking in.

The precautions given in this manual for operating, maintenance,

and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a pur-
pose that is not listed in this manual, Komatsu cannot bear any
responsibility for safety. All consideration of safety in such opera-
tions is the responsibility of the user.

Operations that are prohibited in this manual must never be car-

ried out under any circumstances.

8
 LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR

LOCATION OF PLATES, TABLES TO ENTER SERIAL NO.

AND DISTRIBUTOR

MACHINE SERIAL NO. PLATE POSITION

On the front bottom right of the operator’s cab

AM088910

ENGINE SERIAL NO. PLATE POSITION

On the upper side of the engine cylinder head cover.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Manufacturers name: KOMATSU UK Ltd.

Address: Durham Road
Birtley
Chester-Le street
County Durham DH32QX
United Kingdom

Distributor
Address

Phone

9
LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR

MACHINE SERIAL PLATE.

MASS

Komatsu UK Ltd, Birtley, Co. Durham, United Kingdom

205-00-K1290

10
CONTENTS
FOREWORD ........................................................................................................................................................... 1

SAFETY INFORMATION ........................................................................................................................................ 2

SAFETY MESSAGES .................................................................................................................................. 2
NOISE PC210, PC210LC-6K ........................................................................................................................ 3
NOISE PC240LC, PC240NLC-6K ................................................................................................................ 5
VIBRATION ................................................................................................................................................... 6

INTRODUCTION ..................................................................................................................................................... 7
INTENDED USE ........................................................................................................................................... 7
FEATURES ................................................................................................................................................... 7
BREAKING IN YOUR NEW MACHINE ........................................................................................................ 8

LOCATION OF PLATES, TABLES TO ENTER SERIAL NO.

AND DISTRIBUTOR ............................................................................................................................................... 9
MACHINE SERIAL NO. PLATE POSITION .................................................................................................. 9
ENGINE SERIAL NO. PLATE POSITION .................................................................................................... 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................................ 9
MACHINE SERIAL PLATE. ........................................................................................................................ 10

SAFETY.............................................................................................................. 17
GENERAL PRECAUTIONS ................................................................................................................................. 18

PRECAUTIONS DURING OPERATION .............................................................................................................. 26

BEFORE STARTING ENGINE ................................................................................................................... 26
OPERATING MACHINE ............................................................................................................................. 28
TRANSPORTATION ................................................................................................................................... 35
BATTERY ................................................................................................................................................... 36
TOWING ..................................................................................................................................................... 37
BUCKET WITH HOOK ................................................................................................................................ 38

PRECAUTIONS FOR MAINTENANCE ................................................................................................................ 41

BEFORE CARRYING OUT MAINTENANCE ............................................................................................. 41
DURING MAINTENANCE ........................................................................................................................... 44

POSITION FOR ATTACHING SAFETY LABELS ................................................................................................ 49

POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 49

OPERATION....................................................................................................... 55
GENERAL VIEW .................................................................................................................................................. 56
GENERAL VIEW OF MACHINE ................................................................................................................. 56
GENERAL VIEW OF CONTROLS AND GAUGES ..................................................................................... 57

11
EXPLANATION OF COMPONENTS .................................................................................................................... 59
MACHINE MONITOR ................................................................................................................................. 59
METERS ..................................................................................................................................................... 65
SWITCHES ................................................................................................................................................. 70
CONTROL LEVERS, PEDALS ................................................................................................................... 76
AIR CONDITIONER .................................................................................................................................... 87
CAB RADIO ................................................................................................................................................ 90
FUSE .......................................................................................................................................................... 91
FUSIBLE LINK ............................................................................................................................................ 92
CONTROLLERS ......................................................................................................................................... 92
TOOL BOX .................................................................................................................................................. 92
REFUELLING PUMP .................................................................................................................................. 93
HANDLING THE ACCUMULATOR ............................................................................................................ 94

OPERATION ......................................................................................................................................................... 95
CHECK BEFORE STARTING ENGINE ...................................................................................................... 95
STARTING ENGINE ................................................................................................................................. 106
OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................................................... 108
MOVING MACHINE OFF .......................................................................................................................... 114
STEERING MACHINE .............................................................................................................................. 117
STOPPING MACHINE .............................................................................................................................. 119
SWINGING ............................................................................................................................................... 120
OPERATION OF WORK EQUIPMENT .................................................................................................... 121
HANDLING ACTIVE MODE ...................................................................................................................... 122
WORKING MODE SELECTION ............................................................................................................... 123
PROHIBITIONS FOR OPERATION ......................................................................................................... 125
PRECAUTIONS FOR OPERATION ......................................................................................................... 127
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS ................................................................. 128
HOW TO ESCAPE FROM MUD ............................................................................................................... 129
WORK POSSIBLE USING HYDRAULIC EXCAVATOR ........................................................................... 129
REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 131
PARKING THE MACHINE ........................................................................................................................ 133
CHECK AFTER FINISHING WORK ......................................................................................................... 134
STOPPING ENGINE ................................................................................................................................. 134
CHECK AFTER STOPPING ENGINE ...................................................................................................... 135

TRANSPORTATION ........................................................................................................................................... 137

LOADING, UNLOADING WORK .............................................................................................................. 137

COLD WEATHER OPERATION ........................................................................................................................ 142

PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................... 142
PRECAUTIONS AFTER COMPLETION OF WORK ................................................................................ 143

LONG-TERM STORAGE .................................................................................................................................... 145

BEFORE STORAGE ................................................................................................................................. 145
DURING STORAGE ................................................................................................................................. 145
AFTER STORAGE .................................................................................................................................... 146
STARTING MACHINE AFTER LONG-TERM STORAGE ........................................................................ 146

12
TROUBLESHOOTING ........................................................................................................................................ 147
PHENOMENA THAT ARE NOT FAILURES ............................................................................................. 147
METHOD OF TOWING MACHINE ........................................................................................................... 147
USING METHOD FOR LIGHT-WEIGHT TOWING HOLE ........................................................................ 148
PRECAUTIONS ON PARTICULAR JOBSITES ....................................................................................... 148
IF BATTERY IS DISCHARGED ................................................................................................................ 149
OTHER TROUBLE ................................................................................................................................... 152

OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 ................................ 157
PRECAUTIONS WHEN OPERATING ...................................................................................................... 157
CHECK BEFORE STARTING .................................................................................................................. 163
OPERATION ............................................................................................................................................. 164
RAISING WORK EQUIPMENT ................................................................................................................. 165
WORKING RANGE AND USING RANGE OF BOOM .............................................................................. 165
WORKING RANGE AND RANGE OF USE OF BOOM ............................................................................ 166
TRANSPORTATION (HIGH REACH DEMOLITION) ............................................................................... 167

MAINTENANCE ............................................................................................... 169

GUIDES TO MAINTENANCE ............................................................................................................................. 170

OUTLINES OF SERVICE ................................................................................................................................... 173

OUTLINE OF OIL, FUEL, COOLANT ....................................................................................................... 173
EXPLANATION OF LUBRICATION CHART DECAL ............................................................................... 176
OUTLINE OF ELECTRICAL SYSTEM ..................................................................................................... 178
OUTLINE OF HYDRAULIC SYSTEM ....................................................................................................... 178

WEAR PARTS LIST ........................................................................................................................................... 180

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .................... 181

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..................................................................... 185

LIST OF NECESSARY TOOLS ................................................................................................................ 185
TORQUE LIST .......................................................................................................................................... 186

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 187

MAINTENANCE SCHEDULE CHART ............................................................................................................... 190

MAINTENANCE SCHEDULE CHART
190
MAINTENANCE WHEN USING HYDRAULIC BREAKER ....................................................................... 193

SERVICE PROCEDURE .................................................................................................................................... 194

INITIAL 250 HOURS SERVICE ................................................................................................................ 194
WHEN REQUIRED ................................................................................................................................... 194
CHECK BEFORE STARTING .................................................................................................................. 206
EVERY 100 HOURS SERVICE ............................................................................................................... 211
EVERY 250 HOURS SERVICE ................................................................................................................ 214
EVERY 500 HOURS SERVICE ................................................................................................................ 218

13
 EVERY 1000 HOURS SERVICE .............................................................................................................. 224
EVERY 2000 HOURS SERVICE .............................................................................................................. 227
EVERY 4000 HOURS SERVICE .............................................................................................................. 229
EVERY 5000 HOURS SERVICE .............................................................................................................. 229

SPECIFICATIONS ............................................................................................ 233

SPECIFICATIONS .............................................................................................................................................. 234
PC210-6K, PC210LC-6K .......................................................................................................................... 234

SPECIFICATIONS .............................................................................................................................................. 238

PC240LC-6K, PC240NLC-6K ................................................................................................................... 238
explanation of LIFTING CAPACITY CHART ............................................................................................ 241

OPTIONS, ATTACHMENTS ............................................................................ 251

PRECAUTIONS RELATED TO SAFETY ........................................................................................................... 252
PRECAUTIONS WHEN INSTALLING ATTACHMENTS .......................................................................... 253

HANDLING BUCKET WITH HOOK ................................................................................................................... 254

CHECKING FOR DAMAGE TO BUCKET WITH HOOK .......................................................................... 254
PROHIBITED OPERATIONS ................................................................................................................... 254
PRECAUTIONS DURING OPERATIONS ................................................................................................ 254

MACHINES READY FOR ATTACHMENTS ...................................................................................................... 255

EXPLANATION OF COMPONENTS ........................................................................................................ 255
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE .................................................................. 259

INTRODUCTION OF ATTACHMENTS .............................................................................................................. 264

SPECIFICATION, USE ............................................................................................................................. 264
ATTACHMENT INSTALLATION COMBINATION TABLE ........................................................................ 266
SELECTION OF TRACK SHOES ............................................................................................................. 268
SELECTION OF BUCKET TEETH ........................................................................................................... 270
HANDLING TRAPEZOIDAL BUCKET ...................................................................................................... 270
USING THE EXTENSION ARM ................................................................................................................ 272
HANDLING THE CLAMSHELL BUCKET ................................................................................................. 272

EXTENDING MACHINE SERVICE LIFE ............................................................................................................ 273

HYDRAULIC BREAKER ........................................................................................................................... 273
POWER RIPPER ...................................................................................................................................... 277
MAIN FIELDS OF APPLICATIONS .......................................................................................................... 277
FORK GRAB ............................................................................................................................................. 278
GRAPPLE BUCKET ................................................................................................................................. 280
SCRAP GRAPPLE .................................................................................................................................... 281
CRUSHER & SMASHER .......................................................................................................................... 283
HYDRAULIC PILE DRIVER ...................................................................................................................... 284
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE ................................................................. 286

14
2-PC BOOM .............................................................................................................................................. 288
6.4 M STRAIGHT BOOM .......................................................................................................................... 293
FRONT DOZER BLADE ........................................................................................................................... 298

15
16
 SAFETY

WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.

This safety section also contains precautions for optional equip-

ment and attachments.

17
GENERAL PRECAUTIONS SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

GENERAL PRECAUTIONS
SAFETY RULES

● ONLY trained and authorised personnel can operate and

maintain the machine.

● Follow all safety rules, precautions and instructions when

operating or performing maintenance on the machine.

● When working with another operator or a person on worksite

traffic duty, be sure all personnel understand all hand signals
that are to be used.

● A seat belt must be worn at all times when operating machin-

ery.

SAFETY LABELS

● Please read and understand the safety labels stuck to the

machine.

● Always keep the safety labels clean.

● If the safety label comes off or is lost or damaged, stick it on

again or contact your Komatsu distributor and replace it with a
new part.

SAFETY FEATURES

● Be sure all guards and covers are in their proper position.

Have guards and covers repaired if damaged.

● Use safety features such as safety lock lever properly.

● NEVER remove any safety features. ALWAYS keep them in

good operating condition.

Safety lever, see “PARKING THE MACHINE” on page 133.

Seat belt → see “USING THE SEAT BELT” on page 103.

AB30576C
● Improper use of safety features could result in serious bodily
injury or death.

18
SAFETY GENERAL PRECAUTIONS

WARNING: Failure to follow these safety precautions may lead to a serious accident.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

● Avoid loose clothing, jewellery, and loose long hair. They can
catch on controls or in moving parts and cause serious injury
or death. Also, do not wear oily cloths because they are flam-
mable.

● Wear a hard hat, safety glasses, safety shoes, mask or

gloves when operating or maintaining the machine. Always
wear safety goggles, hard hat and heavy gloves if your job
involves scattering metal chips or minute materials <—> this
is so particularly when driving pins with a hammer and when
cleaning the air cleaner element with compressed air.

● Check also that there is no one near the machine.

Driving in pins, see “REPLACEMENT AND INVERSION

OF BUCKET” on page 131.

Cleaning of air cleaner element, see “WHEN REQUIRED”

on page 194.

UNAUTHORISED MODIFICATION

Any modification made without authorisation from Komatsu can

create hazards.

Before making a modification, consult your Komatsu distributor.

Komatsu will not be responsible for any injury or damage caused
by any unauthorised modification.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

● When standing up from the operator’s seat, always place the

safety lock lever securely in the LOCK position. If you acci-
dentally touch the travel or swing lever when they are not
locked, the work equipment may suddenly move and cause
serious injury or damage.

● When leaving the machine, lower the work equipment com-

pletely to the ground, set the safety lock lever to the LOCK
position, then stop the engine and use the key to lock all the
equipment. Always take the key with you.
AB30576C
Work equipment posture see “PARKING THE MACHINE”
on page 133.

19
GENERAL PRECAUTIONS SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

MOUNTING AND DISMOUNTING

● NEVER jump on or off the machine. NEVER get on or off a

moving machine.

● When mounting or dismounting, always face the machine and

use the handrails, machine or track frame steps, and track
shoes.

● Do not hold any control levers when getting on or off the

machine.

AM088940

● Ensure safety by always maintaining at least three-point con-

tact of hands and feet with the handrails, steps or track shoes.

● Always remove any oil or mud from the handrails, steps and
track shoes. If they are damaged, repair them and tighten any
loose bolts.

AM088950

● If grasping the door handrail when mounting or dismounting

or moving on the track, open and lock the door securely in the
open position. Otherwise, the door may move suddenly, caus-
ing you to lose balance and fall.

FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particu-

larly FLAMMABLE and can be HAZARDOUS.

● Keep flames away from flammable fluids.

● Stop the engine and do not smoke when refuelling.

20
SAFETY GENERAL PRECAUTIONS

WARNING: Failure to follow these safety precautions may lead to a serious accident.

● Tighten all fuel and oil caps securely.

● Refuelling and oiling should be carried out in well ventilated

areas.

● Keep oil and fuel in a secure place and do not allow unauthor-
ised persons to enter.

PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES

● Immediately after operations are stopped, the engine coolant,

engine oil, and hydraulic oil are at high temperatures, and are
still under pressure. Attempting to remove the cap, drain the
oil or water, or replace the filters may lead to serious burns.
Always wait for the temperature to go down, and follow the
specified procedures when carrying out these operations.

● To prevent hot water from spurting out:

❍ Turn engine off.

❍ Allow water to cool.

❍ Slowly loosen cap to relieve pressure before removing.

● To prevent hot oil from spurting out:

❍ Turn engine off.

❍ Allow oil to cool.

❍ Slowly loosen cap to relieve pressure before removing.

21
GENERAL PRECAUTIONS SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your health if it is inhaled.

Your Komatsu machine and genuine Komatsu spare parts do not

contain any asbestos. Use only genuine Komatsu spare parts. If
spare parts containing asbestos are used, the following precau-
tions must be observed:

● NEVER use compressed air for cleaning.

● Use water for cleaning to keep down the dust.

● Operate the machine with the wind to your back, whenever

possible.

● Use an approved respirator if necessary.

CRUSHING OR CUTTING PREVENTION

Do not enter, or put your hand or arm or any other part of your
body between movable parts such as between the work equip-
ment and cylinders, or between the machine and work equip-
ment.

If the work equipment is operated, the clearance will change and

this may lead to serious damage or personal injury.

FIRE EXTINGUISHER AND FIRST AID KIT

Know how to use fire extinguisher (if installed).

Provide a first aid kit at the storage point.

Know what to do in the event of a fire.

Be sure you know the phone numbers of persons you should con-
tact in case of an emergency.

22
SAFETY GENERAL PRECAUTIONS

WARNING: Failure to follow these safety precautions may lead to a serious accident.

PROTECTION AGAINST FALLING OR FLYING OBJECTS

If there is any danger of falling or flying objects hitting the opera-

tor, install protective guards in place to protect the operator as
required for each particular situation.

● For work with breakers, install a front guard on the wind-

shield. Also, place a laminate coating sheet over the wind-
shield.

● For demolition or shear work, install a front guard on the

windshield and a top guard on the cab. Also, place a laminate
coating sheet over the windshield.

● For work in mines, quarries, demolition, tunnels or other

places where there is danger of falling rocks, put FOPS (fall-
ing object protective structure) in place. Also, place a lami-
nate coating sheet over the windshield.

The above comments are made with regards to typical work-

ing conditions. By all means you should put on other guards if
required by conditions at your particular site.

For details of safety guards, please contact your Komatsu dis-

tributor.

Also, even for other types of work, if there is any danger of

being hit by falling or flying objects or of objects entering the (B)
operator’s cab, select and install a guard that matches the
working conditions.
(C)
Be sure to close the front window before commencing work.

Level 1 acceptance is intended for protection from small fall-

ing rocks, flying objects and other debris encountered in oper-
ations such as highway maintenance, landscaping and light
construction site services
AB30052C

Level 1 Guards:

❍ Fitted directly onto the roof and front of the cab.

(B): Top guard (C): Front guard (I)

23
GENERAL PRECAUTIONS SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

When carrying out the above operations, make sure to keep

all persons other than the operator outside the range of falling
or flying objects. Be particularly sure to maintain a proper dis- (A)
tance when carrying out shear operations.

(A): FOPS (B) Front guard (B)

Level 2 acceptance is intended for protection from large fall-

ing rocks, flying objects and other debris encountered in oper-
ations such as demolition work, building constructions and AB30053C
general heavy site work.

Level 2 Guards

❍ Fops fitted directly to the revolving frame

❍ Front guard fitted directly to front of the fops

NOTE: The above guards are the minimum required for typical
working conditions as described above and are in
accordance with the latest requirements of ISO/DIS
10262 (draft standard).

PRECAUTIONS FOR ATTACHMENTS

● When installing and using an optional attachment, read the

instruction manual for the attachment and the information
related to attachments in this manual.

● Do not use attachments that are not authorised by Komatsu

or your Komatsu distributor. Use of unauthorised attachments
could create a safety problem and adversely affect the proper
operation and useful life of the machine.

● Any injuries, accidents, product failures resulting from the use

of unauthorised attachments will not be the responsibility of
Komatsu.

MACHINES WITH ACCUMULATOR

On machines equipped with an accumulator, for a short time after

the engine is stopped, the work equipment will lower under its
own weight when the work equipment control lever is shifted to
LOWER. After the engine is stopped, set the safety lock lever to
the lock position (and also lock the attachment pedal with the lock
pin).

When releasing the pressure inside the work equipment circuit on

machines equipped with an accumulator, follow the procedure
given in the inspection and maintenance section.
AB30576C
Method of releasing pressure see “HANDLING THE
ACCUMULATOR” on page 94.

The accumulator is filled with high-pressure nitrogen gas, and it is

extremely dangerous if it is handled in the wrong way. Always
observe the following precautions.

24
SAFETY GENERAL PRECAUTIONS

WARNING: Failure to follow these safety precautions may lead to a serious accident.

● Never make any hole in the accumulator or expose it to flame

or fire.

● Do not weld anything to the accumulator.

● When carrying out disassembly or maintenance of the accu-

mulator, or when disposing of the accumulator, it is necessary
to release the gas from the accumulator. A special air bleed
valve is necessary for this operation, so please contact your
Komatsu distributor.

Gas in accumulator see “HANDLING THE ACCUMULA-

TOR” on page 94.

EMERGENCY EXIT

● When exit by normal means is prevented in an emergency

you can get out through the emergency exit (rear window).

● Pull the ring at the bottom of the window and remove strip.
This will allow you to push out glass.

ROTATING BEACON (Option)

When the machine is operated on or beside a road, a rotating

beacon is required to avoid a traffic accident.

Contact your Komatsu distributor to install beacon lamp.

ELECTROMAGNETIC INTERFERENCE

When this machine is operating close to a source of high electro-

magnetic interference, such as a radar station, some abnormal
phenomena may be observed.

● The display on the monitor panel may behave erratically.

● The warning buzzer may sound.

These effects do not signify a malfunction and the machine will

return to normal as soon as the source of interference is removed.

25
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

PRECAUTIONS DURING OPERATION

BEFORE STARTING ENGINE

SAFETY AT WORKSITE

● Before starting the engine, thoroughly check the area for any
unusual conditions that could be dangerous.

● Before starting the engine, examine the terrain and soil condi-
tions of the worksite. Determine the best and safest method
of operation.

● Make the slope as horizontal as possible before continuing

operations.

● If you need to operate on a street, protect pedestrians and

cars by designating a person for worksite traffic duty or by
installing fences around the worksite.

● If water lines, gas lines, and high-voltage electrical lines may

be buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or cut any of these
lines.

● Check the depth and flow of water before operating in water

or crossing a river. NEVER be in water which is in excess of
the permissible water depth.

Permissible water depth see “PRECAUTIONS FOR

OPERATION” on page 127. AE341030A

FIRE PREVENTION

● Thoroughly remove wood chips, leaves, paper and other

flammable things accumulated on the engine compartment.
They could cause a fire.

● Check fuel, lubrication, and hydraulic systems for leaks. Have

any leaks repaired. Wipe up any excess oil, fuel or other flam-
mable fluids.

Check point see “WALK-AROUND CHECK” on page 95.

● Be sure a fire extinguisher is present and working.

IN OPERATOR’S CAB

● Do not leave tools or spare parts lying around in the opera-

tor’s compartment. They may damage or break the control
levers or switches. Always put them in the tool box on the left
or right side of the machine.

26
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

● Keep the cab floor, controls, steps and handrails free of oil,
grease, snow, and excess dirt.

Handling seat belt →see “USING THE SEAT BELT” on

page 103.

VENTILATION FOR ENCLOSED AREAS

● If it is necessary to start the engine within an enclosed area,

provide adequate ventilation. Exhaust fumes from the engine
can KILL.

PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS

● Remove all dirt from the surface of the windows and lights to
ensure that you can see well.

● Adjust the rear view mirror so that you can see clearly from
the operator’s seat, and always keep the surface of the mirror
clean. If any glass is broken, replace it with a new part.

● Check that the head lamps and working lamps are installed to
match the operating conditions. Check also that they light up
properly.

PRECAUTIONS WHEN HANDLING (TWO PIECE BOOM)

When operating the boom arm 2-piece type, select a specialist

operator and do not allow any other person to operate the
machine.

● Check that the ground inside the operating range is flat and
firm.

● Always operate the work equipment slowly.

WARNING
Especially when lowering the work equipment, move it as
slowly as possible to prevent any shock to the machine
(operate the work equipment in the same way as when oper-
ating a crane).

● Pay attention to warning decal in the cab.

27
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

WARNING
If the bucket is operated in a certain way, it comes in contact
with the machine body (operator’s cab, upper boom, cylin-
ders and undercarriage). When operating the work equip-
ment, take sufficient care not to bring it in contact with the
machine body.
Interference

Interference

OPERATING MACHINE

WHEN STARTING THE ENGINE

● Walk around your machine again just before mounting it, to

check for people and objects that might be in the way.

● NEVER start the engine if a warning tag has been attached to

the wrist control.

● When starting the engine, sound the horn as an alert.

● Start and operate the machine only while seated.

● Fasten your seat belt securely at all times during operation.

● Do not allow anyone other than the operator to ride in the cab
or on the machine body.

● For machines equipped with a travel alarm buzzer, check that

the warning device operates correctly.

28
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

CHECK DIRECTION BEFORE STARTING MACHINE

Before operating the travel lever, check the direction of the track
frame. If the sprocket is at the front, the travel lever must be oper-
ated in the opposite direction.

Travel operations see “MOVING MACHINE OFF” on

page 114.

CHECK THAT NO ONE IS IN THE AREA BEFORE SWINGING

OR TRAVELLING IN REVERSE
Sprocket AN112970A

● Always position a signalman in places in dangerous places or

places where the view is not clear.

● Make sure that no one comes inside the swing radius or

direction of travel.

● Before starting to move, sound the horn or give a signal to

warn people not to come close to the machine.

● There are blind spots behind the machine, so if necessary,

swing the upper structure to check that there is no one behind
the machine before travelling in reverse.

PRECAUTIONS WHEN TRAVELLING

● Fold in the work equipment as shown in the diagram below,

and keep it at a height of 40-50 cm from the ground level
before starting to travel.

● When travelling, do not operate the work equipment control

levers. If the work equipment control levers have to be oper-
ated, never operate them suddenly.

AM089000A

29
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

● When travelling on rough ground, travel at low speed, and

avoid sudden changes in direction.

● Avoid travelling over obstacles as far as possible. If the

machine has to travel over an obstacle, keep the work equip- INCORRECT
ment as close to the ground as possible and travel at low
speed. Never travel over obstacles which make the machine
tilt strongly (10o or more).

AM089010A

TRAVELLING ON SLOPES

● Travelling on hills, banks or slopes that are steep could result

in the machine tipping over or slipping. Downhill

AD338730A

● On hills, banks or slopes, carry the bucket closer to the

ground, approximately 20 to 30 cm above the ground. In case Uphill
of emergency, quickly lower the bucket to the ground to help
the machine stop and prevent it from tipping over.

AD338740A

● Do not turn on slopes or travel across slopes. Always go

down to a flat place to perform these operations. INCORRECT CORRECT
Method of travelling on slopes see “PRECAUTIONS
WHEN TRAVELLING UP OR DOWN HILLS” on page 128.

● Do not travel up and down on grass, fallen leaves, and wet

steel plates. These materials may allow the machine to slip, if
it is travelling sideways. Keep travel speed very low.

30
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

PROHIBITED OPERATIONS
INCORRECT
● Do not dig the work face under an overhang. This may cause
the overhang to collapse and fall on top of the machine.

AN113010A

● Do not carry out deep digging under the front of the machine.
The ground under the machine may collapse and cause the
machine to fall. INCORRECT

AN113020A

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

● Going close to high-voltage cables can cause electric shock.

Always maintain the safe distance given below between the
machine and the electric cable.

● The following actions are effective in preventing accidents.

1) Wear shoes with rubber of leather soles.

2 ) Us e a s i g na lm a n to gi v e w ar n in g i f t he m a c hi ne
approaches too close to the electric cable.
AD338770A
● If the work equipment should touch the electric cable, the
operator should not leave the operator’s compartment.

● When carrying out operations near high voltage cables, do

not let anyone come close to the machine.

● Check with the electricity company about the voltage of the Voltage Min. Safety distance
cables before starting operations.
6.6 kV 3m

33.0 kV 4m

66.0 kV 5m

154.0 kV 8m

275.0 kV 10 m

31
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

DO NOT HIT WORK EQUIPMENT

● When working in places where there are height limits, such as

in tunnels, under bridges, under electric cables, or in garages,
be extremely careful not to hit the boom or arm.

ENSURE GOOD VISIBILITY

● When working in dark places, install working lamps and head

lamps, and set up lighting in the work area if necessary.

● Stop operations if the visibility is poor, such as in mist, snow,

or rain, and wait for the weather to improve to a condition that
allows the operation to be carried out safely.

OPERATE CAREFULLY ON SNOW

● When working on snow or icy roads, even a slight slope may

cause the machine to slip to the side, so always travel at low
speed and avoid sudden starting, stopping, or turning.

● When there has been heavy snow, the road shoulder and
objects placed beside the road are buried in the snow and
cannot be seen, so always carry out snow-clearing operations
carefully.

WORKING ON LOOSE GROUND

● Avoid operating your machine too close to the edge of cliffs,

overhangs and deep ditches. If these areas collapse, your
machine could fall or tip over and result in serious injury or
death. Remember that the soil after heavy rain or blasting is
weakened in these areas.

● Earth laid on the ground and the soil near ditches are loose.
They can collapse under the weight or vibration of your
machine.

● Install the HEAD GUARD (FOPS) if working in areas where

there is danger of falling rocks and dirt.

TWO PIECE BOOM

● Positioner cylinder rod and boom rod being extended and

bucket being retracted, pay utmost attention to base boom
lifting since, after a short run, the bucket reaches the cab area
and, consequently, danger of collision becomes possible.

● Do not operate the control levers suddenly.

● Do not start or stop the swing suddenly.

● Do not use the swing force for hitting operations.

CHECK BEFORE STARTING

Always carry out the following inspection and maintenance before

starting work each day.

32
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

1. Greasing

● Supply grease to the greasing points shown in the diagram

below (total: 16 places).

1 2 A C 3 4 5

B
DE

8
7 6

1. Arm cylinder (1 place) 5. Boom foot pin (2 places)

2. 3 places for A, B C 6. Boom cylinder (2 places)

3 Boom cylinders (2 places: D, E) 7. Backhoe and link (3 places)

4 Positioning cylinder (1 place) 8. Bucket cylinder (2 places)

2. Check for cracks, furrows in the base metal.

OPERATIONS ON SLOPES

● When working on slopes, there is danger that the machine

may lose its balance and turn over when the swing or work INCORRECT
equipment are operated. Always carry out these operations
carefully.

● Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous.
(See the upper diagram on the right.)
AN113040A

33
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

● If the machine has to be used on slope, pile the soil to make a

platform that will keep the machine as horizontal as possible.
(See the lower diagram on the right.)

Piled soil on slope see “PRECAUTIONS WHEN TRAVEL-

LING UP OR DOWN HILLS” on page 128.
CORRECT
Platform

AN113050A

PARKING THE MACHINE

● Park on level ground whenever possible. If not possible, block

the tracks, lower the bucket to the ground and thrust the
CORRECT
bucket in the ground.

● When parking on public roads, provide fences and signs,

such as flags or lights, on the machine to warn passers-by to
be careful. Be sure that the machine, flags or lights do not 120
obstruct traffic.
Block
Parking procedure, see “PARKING THE MACHINE” on
AN113060A
page 133. Thrust the bucket

● When leaving the machine, lower the work equipment com-

pletely to the ground, set the safety lock lever to the LOCK Method of locking
position, then stop the engine and use the key to lock all the
equipment. Always take the key with you.

W o r k e q u i p m e n t p o s t u r e : s e e “ PA R K I N G T H E
MACHINE” on page 133.

Places to lock : see “LOCKING” on page 136.

AB30576C

34
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

TRANSPORTATION

LOADING AND UNLOADING

● Loading and unloading the machine always involves potential

hazards. EXTREME CAUTION SHOULD BE USED.
Ramp
● When loading or unloading the machine, run the engine at
low idling and travel at low speed. Block

● Perform loading and unloading on firm, level ground only.

Maintain a safe distance from the edge of a road.

● ALWAYS block the wheels of the hauling vehicle and place Blocks
blocks under both ramps before loading and unloading.
Distance between ramps
AD052900B
● ALWAYS use ramps of adequate strength. Be sure the ramps
are wide and long enough to provide a safe loading slope.

● Be sure that the ramps are securely positioned and fastened,

and that the two sides are at the same level as one another.

● Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials. Remove dirt from the machine tracks.

● NEVER correct your steering on the ramps. If necessary,

drive away from the ramps and climb again.

● Swing the upper structure with extreme care on the trailer to

avoid a possible accident caused by body instability.

● After loading, block the machine tracks and secure the

machine with tie-downs.

Loading and unloading : see “TRANSPORTATION” on

page 137.

Tie-downs : see “TRANSPORTATION” on page 137.

SHIPPING

● When shipping the machine on a hauling vehicle, obey all

state and local laws governing the weight, width, and length
of a load. Also obey all applicable traffic regulations.

● Determine the shipping route while taking into account the

width, height and weight of the load.

35
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

BATTERY
BATTERY HAZARD PREVENTION

● Battery electrolyte contains sulphuric acid and can quickly

burn the skin and eat holes in clothing. If you spill acid on
yourself, immediately flush the area with water.

● Battery acid could cause blindness if splashed into the eyes.

If acid gets into the eyes, flush them immediately with large
quantities of water and see a doctor at once.

● If you accidentally drink acid, drink a large quantity of water or

milk, beaten egg or vegetable oil. Call a doctor or poison pre-
vention centre immediately.

● When working with batteries. ALWAYS wear safety glasses or

goggles.

● Batteries generate hydrogen gas. Hydrogen gas is very

EXPLOSIVE, and is easily ignited with a small spark or flame.

● Before working with batteries, stop the engine and turn the
starting switch to the OFF position.

● Avoid short-circuiting the battery terminals through accidental

contact with metallic objects, such as tools, across the termi-
nals.

● When removing or installing, check which is the positive (+)

terminal and negative (-) terminal.

● Tighten the battery cap securely.

● Tighten the battery terminals securely. Loosened terminals

can generate sparks and lead to an explosion.

● When removing battery cap wear rubber groves to prevent

electrolyte contact with skin.

STARTING WITH BOOSTER CABLES

● ALWAYS wear safety glasses or goggles when starting the

machine with booster cables.
INCORRECT
● When starting from another machine, do not allow the two
machines to touch.

● Be sure to connect the positive (+) cable first when installing

the booster cables. Disconnect the ground or negative (-)
cable first when removing them.

● If any tool touches between the positive (+) terminal and the A0067320A
chassis, it will cause sparks. This is dangerous, so be sure to
work carefully.

● Connect the batteries in parallel: positive to positive and neg-

ative to negative.

36
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

● When connecting the ground cable to the frame of the

machine to be started, be sure to connect it as far as possible
from the battery.

Starting with booster cables :see “IF BATTERY IS DIS-

CHARGED” on page 149.

TOWING
WHEN TOWING, ATTACH WIRE TO FRAME

● Injury or death could result if a disabled machine is towed

incorrectly.

● If you machine is towed by another machine, ALWAYS use a

wire rope with a sufficient towing capacity.

● NEVER allow a disabled machine to be towed on a slope.

● Do not use a kinked or frayed wire rope.

● Do not straddle the towing cable or wire rope.

● When connecting up a towing machine, do not let anyone

enter the area between the towing machine and the equip- CORRECT
ment being towed.

● Set the towing machine and the towing connection of the

equipment being towed in a straight line when connecting it.

AB30598C

● Place pieces of wood between the wire ropes and body to

protect them from wear of damage. INCORRECT
● Never tow the machine using the light-duty towing hole.

Towing method see “METHOD OF TOWING MACHINE”

on page 147.

37
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

BUCKET WITH HOOK

GENERAL PRECAUTIONS

SPECIAL HOOK

● When carrying out lifting work, the special lifting hook is nec-
essary.

● The following operations are prohibited.

❍ Lifting loads with a wire rope fitted around the bucket

teeth.

❍ Lifting loads with the wire rope wrapped directly around

the boom or arm.

CHECKING HOOK

● When lifting a load, carry out the following checks to confirm

that there is no abnormality before starting operations.

❍ Check that there are no cracks or deformation in the lift-

ing equipment.

❍ Check that there is no abnormality in the stopper device.

HOOKING WIRE ROPE SECURELY TO HOOK

● When performing lifting operation, securely hook the wire

rope onto the special lifting hook.

PRECAUTIONS FOR MACHINE INSTALLATION

● After carrying out a preliminary inspection of ground condi-

tions, select a flat, solid location. Confirm that the machine
can be safely operated without toppling or rolling.

PROHIBITED OPERATIONS OTHER THAN MAIN APPLICA-

TIONS

● When performing lifting operation, never raise or lower a per-

son.

NO PERSONS SHALL BE PERMITTED TO ENTER THE

WORKING AREA

● Due to the possible danger of the load falling or of collision

with the load, no persons shall be allowed in the working
area.

OPERATION SUPERVISOR

● Before performing lifting operation, designate an operation

supervisor.

38
SAFETY PRECAUTIONS DURING OPERATION

WARNING: Failure to follow these safety precautions may lead to a serious accident.

Always execute operation according to his instructions.

❍ Execute operating methods and procedures under his

direction.

❍ Select a person responsible for signalling. Operate only

on signals given by such person.

HANDLING OF WIRE ROPES ETC.

● Wear leather gloves when handling wire ropes.

HANDLING OF FLUIDS

● Some oils and other fluids, such as Antifreeze, can be harm-

ful to you and the environment, you should therefore always
follow the manufacturers instructions regarding storage, han-
dling and disposal.

HANDLING OF USED ENGINE OILS

● Avoid contact with used engine oils.

● Refer to engine oils data sheet for handling and storage pre-
cautions.

HANDLING OF OILS

● For diesel oils, hydraulic oils and oils used in the swing
machinery, PTO, transmission axles and hubs avoid pro-
longed or frequent contact with skin.

● Refer to manufacturers data sheet for handling and storage

precautions.

HANDLING OF FLUIDS

● For antifreeze and grease refer to manufacturers data sheet

for handling and storage precautions.

PROTECTING EYES

● Some oils and fluids can damage eyes. Refer to manufac-

tured data sheet for handling and storage instructions.

PRECAUTIONS FOR LIFTING OPERATION

GRADUAL LIFTING OPERATION

● When carrying out lifting operations, run the engine at low

idling and use the L.O. (lifting operation mode).

● Avoid sudden lever shifting and acceleration.

● Swing speed is three to four times that of movable cranes.

Therefore, be especially careful when performing swing oper-
ation.

39
PRECAUTIONS DURING OPERATION SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

NEVER LEAVE THE OPERATOR’S SEAT

● Never leave the operator’s seat while lifting a load.

NEVER CARRY OUT EXCESSIVE OPERATIONS

● Operation exceeding machine performance may result in

accident or failure. INCORRECT
● Carry out lifting operation within specified load limit.

● Never carry out operations which may damage the machine

such as overload or over-impact-load.

AM089130A

● Never drag a load laterally or longitudinally, nor retract the

arm, otherwise, a dangerous situation may result. INCORRECT

NEVER TRAVELLING WHILE LIFTING A LOAD

● Never travel while carrying a load.

OPERATING POSTURE
AM089140A
● If the machine posture is not correct, the wire ropes or ring
may detach from the hook. Confirm that the hook angle is cor-
rect to avoid this.

BE CAREFUL NOT TO HIT THE OBJECT BEING HANDLED

● Always keep the proper distance between the work being

handled and the operator’s cab when carrying out operations.

40
SAFETY PRECAUTIONS FOR MAINTENANCE

WARNING: Failure to follow these safety precautions may lead to a serious accident.

PRECAUTIONS FOR MAINTENANCE

BEFORE CARRYING OUT MAINTENANCE

WARNING TAG

● If others start the engine or operate the controls while you are
performing service or lubrication, you could suffer serious
injury or death.

● ALWAYS attach the WARNING TAG to the control lever in the

operator’s cab to alert others that you are working on the
machine. Attach additional warning tags around the machine,
if necessary.

● These tags are available from your Komatsu distributor. (Part

no. 20E-00-K1340)

PROPER TOOLS

● Use only tools suited to the task. Using damaged, low quality,
faulty, or makeshift tools could cause personal injury.

Tools : see “LIST OF NECESSARY TOOLS” on page 185.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

● Replace the following fire-related components periodically:

Fuel system: Fuel hose, spilling hose, and fuel tube cap

Hydraulic system: Pump outlet hose, and front and rear

pump branch hoses

● Replace these components periodically with new ones,

regardless of whether or not they appear to be defective.
These components deteriorate over time.

● Replace or repair any such components if any defect is found,

event though they have not reached the time specified.

Replacement of safety critical components : see “PERI-

ODIC REPLACEMENT OF SAFETY CRITICAL PARTS” on
page 187.

41
PRECAUTIONS FOR MAINTENANCE SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

STOP THE ENGINE BEFORE CARRYING OUT INSPECTION

AND MAINTENANCE

● Always stop the machine on firm flat ground and stop the
engine before carrying out inspection and maintenance.
AT OFF
● If it is necessary to run the engine when carrying out mainte- HE
nance, such as when cleaning the inside of the radiator, place
the safety lock lever at the LOCK position (1) and carry out ON
the operation with two workers.

START
AM089160A

● One worker should sit in the operator’s seat so that he can

stop the engine immediately if necessary. He should also be
extremely careful not to touch any lever by mistake. Touch the
levers only when they have to be operated.

● The worker carrying out the maintenance should be

extremely careful not to touch or get caught in the moving
parts.

AB30576C

RULES TO FOLLOW WHEN ADDING FUEL OR OIL

● Spilt fuel and oil may cause you to slip, so always wipe it up
immediately.

42
SAFETY PRECAUTIONS FOR MAINTENANCE

WARNING: Failure to follow these safety precautions may lead to a serious accident.

● Always tighten the cap of the fuel and oil fillers securely.

● Never use fuel for washing any parts.

● Always add fuel and oil in a well-ventilated place.

RADIATOR WATER LEVEL

● If it is necessary to add water to the radiator, stop the engine

and allow the engine and radiator to cool down before adding
the water.

● Slowly loosen the caps to relieve pressure before removing

the caps.

43
PRECAUTIONS FOR MAINTENANCE SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

USE OF LIGHTING

● When checking fuel, oil, coolant, or battery electrolyte, always

use lighting with anti-explosion specifications.
If such lighting equipment is not used, there is danger of
explosion.

DURING MAINTENANCE

PERSONNEL

● Only authorised personnel can service and repair the

machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.

ATTACHMENTS

● Place attachments that have been removed from the machine

in a safe place so that they do not fall. If they fall on you or
others, serious injury could result.

● Do not let and children or unauthorized personnel into the

place where the attachments are stored.

STABILISE THE WORK EQUIPMENT FIRST

Always lower the work equipment to the ground before carrying

out maintenance.

● If maintenance must be carried out with the work equipment

raised, always support it with safety supports or safety blocks.

● When the boom or arm are repaired, they cannot be sup-

ported by the hydraulic cylinder alone, so always support
them on a stand.

If they are supported only by the hydraulic cylinder, there is

danger that the work equipment will drop if the control lever is
touched by mistake or if there is any damage to the hydraulic
line.

44
SAFETY PRECAUTIONS FOR MAINTENANCE

WARNING: Failure to follow these safety precautions may lead to a serious accident.

WORK UNDER THE MACHINE

● Always lower all movable work equipment to the ground or to

their lowest position before performing service or repairs
under the machine.

● Always block the track shoes of the machine securely.

● Never work under the machine if the machine is poorly sup-

ported.

KEEP THE MACHINE CLEAN

● Spilt oil or grease, or scattered tools or broken pieces are

dangerous because they may cause you to slip or trip.
Always keep your machine clean and tidy.

● If water gets into the electrical system, there is danger that

the machine may not move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors,
or the inside of the operator’s compartment.

PRECAUTIONS WITH BATTERY

● When repairing the electrical system or when carrying out

electrical welding, remove the negative (-) terminal of the bat-
tery to stop the flow of current.

45
PRECAUTIONS FOR MAINTENANCE SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

HANDLING HIGH-PRESSURE HOSES

● Do not bend high-pressure hoses or hit them with hard

objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.

● Always repair any loose or broken fuel hoses or oil hoses. If

fuel or oil leaks, it may cause a fire.

PRECAUTIONS WITH HIGH PRESSURE OIL

● Do not forget that the work equipment circuits are always

under pressure.

● Do not add oil, drain oil, or carry out maintenance or inspec-

tion before completely releasing the internal pressure.

A0055180A

● If oil is leaking under high pressure from small holes, it is dan-

gerous if the jet of high-pressure oil hits your skin or enters
your eyes. Always wear safety glasses and thick gloves, and
use a piece of cardboard or a sheet of wood to check for oil
leakage.

● If you are hit by a jet of high-pressure oil, consult a doctor

immediately for medical attention.
A055190A
BE CAREFUL OF FIRE OR EXPLOSION

● Oil is highly flammable, so do not weld or gas cut any tube or

pipe that contains oil.
Do not carry out any heating or welding close to hydraulic
equipment or piping. When carrying out such work, remove
the oil first and wash the part.

● Always check that part such as clamps used to prevent vibra-

tion, guards used to prevent rubbing against other parts, and
heat proof boards used for heated parts are installed properly.

46
SAFETY PRECAUTIONS FOR MAINTENANCE

WARNING: Failure to follow these safety precautions may lead to a serious accident.

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT

HIGH TEMPERATURE OR HIGH PRESSURE

● Immediately after stopping operations, the engine cooling

water and oil at all parts is at high temperature and under high
pressure.

In this condition, if the cap is removed, or the oil or water are

drained, or the filters are replaced, this may result in burns or
other injury. Wait for the temperature to go down, then carry
out the inspection and maintenance in accordance with the
procedures given in this manual.

Cleaning inside or cooling system: see “INITIAL 250

HOURS SERVICE” on page 194.

Checking cooling water level, hydraulic oil level : see

“CHECK BEFORE STARTING” on page 206.

Checking lubricating oil level, adding oil: see “MAINTE-

NANCE SCHEDULE CHART” on page 190.”

Changing oil, replacing filters: see “MAINTENANCE

SCHEDULE CHART” on page 190.”

PRECAUTIONS FOR REMOVAL AND INSTALLATION OPERA-

TIONS

When removing or installing attachments, obey the following pre-

cautions and take care to ensure safety during the operation.

● Carry out the removal and installation operations on a flat,

firm ground surface.

● When the operation is carried out by two or more workers,

determine signals and follow these during the operation.

● When carrying heavy objects (more than 25 kg), use a crane.

● When removing heavy parts, always support the part before

removing it.

● When lifting such heavy parts with a crane, always pay care-
ful attention to the position of the center of gravity.

● It is dangerous to carry out operations with the load kept sus-

pended. Always set the load on a stand, and check that it is
safe.

● When removing or installing attachments, make sure that

they are in a stable condition and will not fall over.

● Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load should
fall.

47
PRECAUTIONS FOR MAINTENANCE SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

For details of removal and installation operations, please contact

your Komatsu distributor.

PRECAUTIONS 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 mainte-
nance is not followed when making adjustments, the plug or
grease fitting may fly out and cause damage or personal
injury.

● When loosening the grease drain plug, never loosen it more

than one turn.

● Never put your face, hands, feet, or any other part of your
body directly in front of any grease drain plug or valve.

Adjusting track tension: see “WHEN REQUIRED” on

page 194.”

ROTATING FAN AND BELT

● Keep away from rotating parts and be careful not to let any-
thing get caught in them.

● If your body or tools touch the fan blades or fan belt, they may
be cut off or sent flying, so never touch any rotating parts.

WASTE MATERIALS

● Never dump waste oil in a sewer system, rivers, etc.

● Always put oil drained from your machine in containers.

Never drain oil directly on the ground.

● Obey appropriate laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters, bat-
teries, and others.
A0055220A

48
SAFETY POSITION FOR ATTACHING SAFETY LABELS

WARNING: Failure to follow these safety precautions may lead to a serious accident.

POSITION FOR ATTACHING SAFETY LABELS

Always keep these labels clean. If they are lost or damage, attach
them again or replace them with a new label.

There are other labels in addition to the safety labels listed as fol-
lows, so handle them in the same way.

Safety labels are available from your Komatsu distributor.

POSITION FOR ATTACHING SAFETY LABELS

49
POSITION FOR ATTACHING SAFETY LABELS SAFETY

1. Warnings for operation, inspection and maintenance

(20E-00-K1170)

● Improper operation and maintenance can cause serious

injury or death.

● Read the manual and labels before operation and mainte-

nance.
Follow instructions and warnings in manual and in labels on
machine.

● Keep the manual in machine cab near operator.

If this manual is lost, please contact your Komatsu distributor
for a replacement.

● Always apply lock when leaving operator’s seat.

50
SAFETY POSITION FOR ATTACHING SAFETY LABELS

2. Warnings when opening front window (20E-00-K1230)

● When raising window, lock it in place with lock pins on both

sides.

● Falling window can cause injury.

3. 20Y-00-K2220

● Emergency exit

● Read operation manual before operation

4. 20E-00-K1130

● WARNING - No passengers
No passengers allowed to ride on machine while it is moving

● WARNING - DANGER OF FALLING OBJECTS

Do not operate where a danger of falling objects exists.
Consult your dealer for fitting of FOPS protection.

● HAZARDOUS - Voltage hazard

Serious injury or death can occur if machine or attachments
are not kept safe distance away from electric lines.

51
POSITION FOR ATTACHING SAFETY LABELS SAFETY

5. 20E-00-K1280

● Pump Control override switch and swing lock override switch

● Read the operation manual before operation

6. 20E-00-51150

Keeping out of moving area

To prevent SEVERE INJURY or DEATH do the following before

moving machine or its attachments:

● Sound horn to alert people nearby.

● Be sure no one is on or near machine or in the swing area.

● Rotate cab for full view of travel path if it can be done safely.

● Use spotter if view is obstructed.

Always follow the above

7. 20E-00-K1140

Keeping out of working range area.

● Make sure no one is in the work equipment swing area.

52
SAFETY POSITION FOR ATTACHING SAFETY LABELS

8. 20E-00-K1310

● Do not open cover while engine is running.

9. (20E-00-K1210) Warnings for handling the accumulator

Explosion hazard

● Keep away from flame.

● Do not weld or drill.

● Read operation manual before operation.

10. 20E-00-K1190

Warning for high temperature coolant and oil.

Hot water and oil hazard

To prevent hot water and oil from spurting out:

● Turn engine off.

● Allow water to cool.

● Slowly loosen cap to relieve pressure before removing.

Read operation manual before operation.

53
POSITION FOR ATTACHING SAFETY LABELS SAFETY

11. 20E-00-K1110

● Warning for falling from upper-structure.

● Keep away from sides of machine.

● Keep of counterweight.

● Do not ride on machine when it is moving

54
OPERATION

55
GENERAL VIEW OPERATION

GENERAL VIEW

GENERAL VIEW OF MACHINE

If directions are indicated in this section, they refer to the direc-
tions shown by the arrows in the diagram below.

A : FRONT B : REAR C : RIGHT D : LEFT

5 6
C 7

8
2
D
9
A
10
1
11
AM089190A

1. Bucket 7. Boom cylinder

2. Bucket link 8. Sprocket

3. Bucket cylinder 9. Track frame

4. Arm 10. Track shoes

5. Arm cylinder 11. Idler

6. Boom

56
OPERATION GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES

2 7
3 6
8
9
1
21 10
11

12
13
14
15
16
19 17
18
20
AM162500C

1. Safety lock lever 12. Swing lock switch

2. Left work equipment control lever 13. Wiper switch

3. Knob button (Power Max) (lower button) 14. Lamp switch

4. Travel lever 15. Alarm buzzer stop

5. Machine monitor 16. Lower wiper switch (option)

6. Horn button (lower button) 17. Rotating beacon switch (option)

7. Right work equipment control lever 18. Heated operator seat switch (option)

8. Ignition key 19. Heater/air conditioner control switch

9. Fuel control dial 20. 12V power supply

10. Flow control switch (option) 21. Travel pedal

11. Cigarette lighter

57
GENERAL VIEW OPERATION

11
1
12
2
13
3 14

4 15

5 16

6 17
7 18
8
19
9
20

10 21
AD32421C

1. Display (for clock and fault indication 11. Service meter

2. Engine water temperature gauge 12. Fuel gauge

3. Engine water temperature monitor 13. Fuel level monitor

4. Radiator water level monitor 14. Engine oil level monitor

5. Engine oil pressure monitor 15. Hydraulic oil level monitor

6. Air cleaner clogging monitor 16. Charge level monitor

7. Overload caution monitor 17. Engine preheating monitor

8. Working mode selector switch 18. Swing lock monitor

9. Power-max, swift slow-down switch 19. Engine oil replacement monitor

10. Travel speed switch 20. Auto-deceleration switch

21. Active mode switch

58
OPERATION EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for operat-
ing the machine.

To carry out suitable operations correctly and safely, it is important

to understand fully the methods of operating the equipment and
the meanings of the displays.

MACHINE MONITOR

AD324220A

A. BASIC CHECK ITEMS

This displays the basic items that should be checked before start-
ing the engine.

If there is any abnormality, the appropriate monitor lamp will flash.

NOTICE
When carrying out checks before starting, do not simply rely
on the monitor. Always refer to the periodic maintenance
items or “OPERATION” on page 95 to carry out the checks.

59
EXPLANATION OF COMPONENTS OPERATION

B. CAUTION ITEMS

CAUTION
If these monitor items flash, check and repair the appropriate
location as soon as possible.

These are items which need to be observed while the engine is

running. If any abnormality occurs, items which need to be
repaired as soon as possible are displayed.

If there is any abnormality, the appropriate monitor lamp will flash

to indicate the location of the abnormality.

C. EMERGENCY STOP ITEMS

CAUTION
If these monitors items flash, stop operations immediately,
then check and repair the appropriate location.

These are items which need to be observed while the engine is

running. If any abnormality occurs, items which need to be
repaired immediately are displayed.

If there is any abnormality, the appropriate monitor lamp will flash

to indicate the location of the abnormality and the buzzer will
sound.

D. METER DISPLAY PORTION

This portion consists of pre-heating monitor, swing lock monitor,

engine water temperature gauge, fuel gauge and display.

E. SWITCHES

The switches are used for setting clock time and for selecting
working mode and travel speed.

60
OPERATION EXPLANATION OF COMPONENTS

A: BASIC CHECK ITEMS

AD324230

NOTICE
● Do not rely on the “BASIC CHECK ITEMS” only for the
check before starting

● Always refer to the periodic maintenance items or

“OPERATION” on page 95 to carry out the checks.

1. RADIATOR WATER LEVEL

This warns that the radiator cooling water level is too low. If the
monitor lamp flashes, check the cooling water level in the radiator
and reserve tank, and add water.

61
EXPLANATION OF COMPONENTS OPERATION

2. ENGINE OIL LEVEL

This warns that the oil level in the engine oil pan is too low. If the
monitor lamp flashes, check the oil level in the engine oil pan, and
add oil.

3. HYDRAULIC OIL LEVEL

This warns that the hydraulic oil level is to low.

If the monitor lamp flashes, check the hydraulic oil level, and add
oil.

4. REPLACEMENT OF ENGINE OIL (for only set machines)

If the set time (125, 250, 500H) passes after the engine oil is
replaced, this lamp lights up. At this time, replace the engine oil.

B: CAUTION ITEMS

CAUTION
If the caution monitor lamp flashes, repair the problem as
soon as possible.

1. CHARGE LEVEL

This monitor indicates an abnormality in the charging system

while the engine is running. If the monitor lamp flashes, check the
V-belt tension. If any abnormality is found, see “OTHER TROU-
BLE” on page 152.

62
OPERATION EXPLANATION OF COMPONENTS

REMARK
While the starting switch is ON, the lamp will remain lit and
will go off once the engine is started.

2. FUEL LEVEL

If the fuel drops below 25 litres, the lamp will flash. Top up the fuel
before this.

3. AIR CLEANER CLOGGING

This warns that the air cleaner is clogged.

If the monitor lamp flashes, stop the engine then inspect and
clean the air cleaner.

4. OVERLOAD CAUTION (When lifting)

This warns that the machine is close to tipping due to the load (an
audible warning is also given), if the warning is given lower the
load. Refer to the lifting capacity chart for safe load.

C: EMERGENCY STOP ITEMS

CAUTION
If any monitor lamp flashes, stop the engine or run it at low
idling, and take the following action.

1. ENGINE WATER TEMPERATURE

If the temperature of the engine cooling water becomes abnor-

mally high, the monitor lamp flashes, and the overheat prevention
system is automatically actuated to reduce the engine speed.

Stop operations and run the engine at low idling until the engine
water temperature gauge enters the green range.

63
EXPLANATION OF COMPONENTS OPERATION

2. RADIATOR WATER LEVEL

If the radiator water level drops, the monitor lamp flashes. Stop
the engine, check the radiator water level, and add water if neces-
sary.

3. ENGINE OIL PRESSURE

If the engine oil pressure drops below the normal pressure, the
monitor lamp flashes. At this item, stop the engine and inspect it
according to, see “OTHER TROUBLE” on page 152.

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.

D: METER DISPLAY PORTION

AD324240A

PILOT DISPLAY

When the starting switch is ON, the pilot display lights up when
the display items are functioning.

64
OPERATION EXPLANATION OF COMPONENTS

1. ENGINE PRE-HEATING MONITOR

This monitor lamp indicates the pre-heating time required when

starting the engine at an ambient temperature below 0oC.

The monitor lamp lights when the starting switch is turned to

HEAT position and flashes after about 30 seconds to show that
the pre-heating is completed. (The monitor lamp will go off after
about 10 seconds.)

AD313430A

2. SWING LOCK MONITOR

This informs the operator that the swing lock is being actuated.
Actuated: Lights up

When the swing lock switch is turned ON (ACTUATED), the mon-

itor lamp lights up.

When the swing lock override switch is turned on, this monitor
lamp flashes.

REMARK
A disc brake is installed in the swing motor to mechanically
stop motor rotation.

The brake is always applied while the swing lock is actuated.

METERS

3. ENGINE WATER TEMPERATURE GAUGE

This gauge indicates the engine cooling water temperature.

If the temperature is normal during operation, the green range (A)
will light up.
If the red range (C) lights up during operation, the overheat pre-
vention system will be actuated. (A)

The overheat prevention system acts as follows.

C
(B)
When red range (1) lights up:
Output horsepower drops, and water temperature monitor (3)
flashes.
3 AW34991D

When red range (2) lights up:

Engine speed is lowered further to low idling, engine water tem-
perature monitor (3) lights up, and alarm buzzer sounds at the
same time.

The overheat prevention system is actuated until the temperature

enters the green range.

When red range (2) lights, if the engine water temperature is

reduced and the fuel control dial is turned to the low idling posi-
tion, the display will be cancelled.

65
EXPLANATION OF COMPONENTS OPERATION

4. FUEL GAUGE

This gauge indicates the amount of fuel in the fuel tank. If the fuel
level is normal during operation, the green range (2) will light up.

If only the red range (1) lights up during operation, there is less
than 25 litres of fuel remaining in the tank, so check and add fuel. 1 2

Red range a ON/ Fuel gauge monitor lamp (LED) (3) flashes.

After the starting switch is turned ON, the correct level may not be
displayed for a moment, but this does not indicate any abnormal-
AW34992C
ity.

When stopping the engine, turn the starting switch ON and check
that the monitor lamps on items A, B, C and D and the meters
light up.

5. DISPLAY

When the starting switch is ON, the time and service meter read-
ing is displayed if the condition is normal. If the condition is abnor-
mal, the content of the failure is displayed.

When setting the time, the symbol flashes.

Manual setting

1. When the time is displayed, depress clock switch (4) for 2.5
sec or more.

2. The symbol flashes.

3. Pressing H switch (2) increases hours and pressing M switch

(3) increases minutes. If switch (2) or (3) is pressed for 2.5
seconds or more, hours or minutes increase continuously.

AD31347C

4. When the correct time is reached, press clock switch (1). This
completes clock setting.

Synchronising to another clock or time signal

1. When the time is displayed, depress the clock switch for 2.5
sec or more.

2. The symbol flashes.

AD324250A

3. When SET switch v is pressed, the hour is rounded off for 0 to

14 minutes and rounded up for 45 to 59 minutes.

[Examples) 10:14 becomes 10:00 /rounded off)

10:45 becomes 11:00 (rounded up)

66
OPERATION EXPLANATION OF COMPONENTS

4. When the correct time is reached, press clock switch (1). This
completes clock setting.

If the machine has a fault, error information appears while the

starting switch is turned ON. The monitor flashes and displays all
error informations sequentially.

Monitor display Failure mode

E02 PC-EPC system error

E03 Swing brake system error

E05 Governor system error

CALL Continuation of work impossible

If any of these monitors flashes, see “ELECTRONIC CONTROL

SYSTEM” on page 156.

6. SERVICE METER

This meter shows the total operation hours of the machine.

Set the periodic maintenance intervals using this display.

The service meter advances while the engine is running - even if

the machine is not travelling.

The meter will advance by 1 for each hour of operation regardless

of the engine speed.

E: SWITCHES

AD324260A

67
EXPLANATION OF COMPONENTS OPERATION

1. WORKING MODE SELECTOR SWITCH (Basic switch)

This switch is used to set the movement or power for the work
equipment. By selecting the mode to match the working condi-
tions, it is possible to carry out operations more easily.
H/O G/O F/O L/O B/O
H.O. (heavy-duty operation mode) lights up:
This is used for heavy-duty work. H M

G.O. (general operation model lights up:

This is used for ordinary work. AD157770A

F.O. (finishing operation mode) lights up:

This is used for levelling or grading work.

L.O. (lifting operation mode) lights up:

This is used for fine control operations.

B.O. (breaker operation mode) lights up:

This is used for breaker work.

When starting the engine, G.O. (general operation) mode is auto-

matically selected. Each time the switch is pressed, the mode
selection changes.

NOTICE
When the breaker is used, never select the H.O. (heavy-duty
operation) mode.

REMARK
H switch is also used for setting “hours” in the clock and M
switch for setting “minutes”. see “DISPLAY” on page 66.

2. AUTO-DECELERATION SWITCH (Selection switch)

This switch acts to activate the function that automatically lowers

the engine speed and reduces fuel consumption when the control
lever is at neutral.

ON lights up: Auto-deceleration is actuated.

OFF: Auto-deceleration is cancelled.

Each time the switch is pressed, the auto-deceleration is actuated

or cancelled. AD157780A

3. TRAVEL SPEED SWITCH

WARNING
If the Hi-Lo switch is operated when the machine is travel-
ling, the machine may deviate even when travelling in a
straight line. To prevent this, always stop the machine before
operating the travel speed switch.

68
OPERATION EXPLANATION OF COMPONENTS

This is used to select the three travel speeds.

Lo lights up: Low speed travel

Mi lights up: Mid range speed travel
Hi lights up: High speed travel

When the engine is started, the travel speed is automatically set

to Lo.

When travelling in Hi, the travel speed is automatically adjusted to

match the travel surface on soft ground or when travelling uphill, AD157790A
so there is no need to operate this switch. The monitor indication
keeps lamp Hi or Mi lighted.

4. POWER MAX./SWIFT SLOW-DOWN SWITCH

During operations, the digging power can be increased and the

speed reduced by a one-touch operation of the left lower knob
button (single click while pushing).

Power max. (power up) lights up:

When the working mode is heavy-duty and general operation

mode only, the power can be increased while the knob button is
being pressed. Even if the knob button continues to be pressed, AD157800A
the increase in power finishes after approx. 8.5 sec.

Swift slow-down (speed down) lights up:

When the working mode is heavy-duty operation and general

operation mode only, the speed is reduced while the knob button
is being pressed.

When the engine is started, the power max. lamp lights up. Each
time this switch on the monitor panel is pressed, the mode is
switch.

5. ACTIVE MODE SWITCH (SELECTOR SWITCH)

The active mode is effective for quick leveling operations or deep

digging and loading operations.

Lamp lights up: Active mode is actuated.

Lamp goes out: Active mode is cancelled.

The lamp is off when the engine is started.

If it is turned ON (lights up), it is possible to enter the active mode
from any working mode.
AD324270A
Even when it is turned ON (lights up), the working mode display
does not change. When the lamp goes out, the system returns to
the original working mode.

69
EXPLANATION OF COMPONENTS OPERATION

SWITCHES

10 9

1
2

12 4
5
6
7
8
13
11
AM161511A

1. STARTING SWITCH

This switch is used to start or stop the engine.

OFF position HEAT OFF

The key can be inserted or withdrawn. Except for the cab lamp, ON
radio (if fitted) and clock, the switches for the electric system are
all turned off and the engine is stopped.
START
ON position AM089390A

Electric current flows in the charging and lamp circuits.

Keep the starting switch key at the ON position while the engine is
running.

START position

This is the engine-start position. Keep the key at this position dur-
ing cranking. Immediately after starting the engine, release the
key which will automatically return to the ON position.

HEAT (preheat) position

When starting the engine in winter, set the key to this position.
When the key is set to the HEAT position, the pre-heating monitor
lights up. Keep the key at this position until the monitor lamp goes
off. Immediately after the pre-heating monitor goes off, release
the key. The key automatically returns to the OFF position. Then,
start the engine by turning the key to the START position.

70
OPERATION EXPLANATION OF COMPONENTS

2. FUEL CONTROL DIAL

(WITH AUTO-DECELERATION MECHANISM)

This adjusts the engine speed and output.

(1) Low idling (MIN): Turned fully to the left

(2) Full speed (MAX): Turned fully to the right

3. CIGARETTE LIGHTER

This 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.

Nothing may be connected to the cigarette lighter without the prior
permission of an authorised Komatsu distributor.

4. SWING LOCK SWITCH

WARNING
● When the machine is travelling under its own power, or
when the swing is not being operated, always set the
switch to the ON (ACTUATED) position.

● On a slope, the work equipment may swing to the down

side even if the swing lock switch is located at the ON
position. Be careful concerning this point.

This switch is used to lock the upper structure so that it cannot

swing.

ON position (actuated):

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.

OFF position (cancelled):

The swing lock is applied only when the swing control lever is at
neutral; when the swing control lever is operated, it is cancelled.

The swing lock is actuated approx. 4 seconds after the swing

lever is placed in neutral.

71
EXPLANATION OF COMPONENTS OPERATION

5. WIPER SWITCH

This switch actuates the front window wiper.

1. OFF: The wiper stops.

2. ON: The wiper moves continuously

3. Window washer fluid is sprayed out: When the switch is

released, it returns to (2).

4. ON: The wiper moves intermittently.

5. Window washer fluid is sprayed out: When the switch is

released, it returns to (4).

6. LAMP SWITCH

This switch is used to turn on the front light, working light, addi-
tional lights on the cab roof, rear lights, and monitor lighting.
1 2 3
(1) OFF

(2) Standard work lamps

(3) Standard and additional work lamps(if fitted).

7. ALARM BUZZER STOP SWITCH

This is used to stop the alarm buzzer when it has sounded to

warn of some abnormality in the EMERGENCY STOP ITEMS ON
while the engine is running. OFF

AM089440A

8. LOWER WIPER SWITCH (if fitted)

This switch activates the front lower wiper.

OFF : wiper stops

ON : wiper moves continuously
NB. Do not operate with front lower screen removed.

72
OPERATION EXPLANATION OF COMPONENTS

9. HORN BUTTON

When the lower button of the right work equipment control lever is
pressed, the horn will sound.

AM089470A

10. KNOB BUTTON (Power Max)

The lower button of the left work equipment control lever is used
to actuate the power max./swift slow-down functions. Press the
button once (single click) and keep it depressed. In the heavy-
duty and general operation modes, the power max. function actu-
ates for max. 8.5 seconds and the swift slow-down function actu-
ates while the button is depressed.

AM089480A

11. HEATED OPERATOR SEAT SWITCH (If fitted)

This switch is used to switch on the heated seat.

OFF : seat not heated OFF

ON : seat heated

12. BEACON SWITCH (If fitted)

This switch is used to switch on the rotating beacon.

OFF
OFF

ON: beacon lights lights and rotates

73
EXPLANATION OF COMPONENTS OPERATION

13. CAB LAMP SWITCH

This lights up the cab lamp.

ON position(1) : Lights up
1

AM089510A

The cab lamp can be turned on even when the starting switch is
at the OFF position (2), so be careful not to leave it on by mistake.

13

AM166910B

74
OPERATION EXPLANATION OF COMPONENTS

14. PUMP CONTROL OVERRIDE SWITCH

(2) When normal: Switch is down

14 15 AM166920B

(1) When abnormal: When the monitor display shows E02 (PC-
EPC valve system error), it is possible to carry out operation when
this switch is moved up. The pump control override switch is 1
designed to allow operations to be carried out for a short period
when there is an abnormality in the pump control system (PC-
EPC valve system error). The abnormality must be repaired
immediately.

2
AM089520A

15. SWING LOCK OVERRIDE SWITCH

(2) When normal: Switch is down 1

(1) When abnormal: When the monitor display shows E03 (swing
brake system error), the brake is cancelled and it becomes possi-
ble to swing the upper structure when this switch is moved up, so
normal operations can be carried out. However, the swing brake
remains cancelled.
2
AM089520A
The swing lock override switch is designed to allow operations to
be carried out for a short period when there is an abnormality in
the swing brake electrical system (swing brake system error). The
abnormality must be repaired immediately.

16. 12V POWER SUPPLY

The 12V socket provided on the right hand panel may be used
only for electrical accessorIes drawing 1,5 A. maximum. Any
accessories attached to this socket must carry the EC mark.

75
EXPLANATION OF COMPONENTS OPERATION

CONTROL LEVERS, PEDALS

AM161520A

1. SAFETY LOCK LEVER

WARNING
● When leaving the operator’s compartment, set the safety
lock lever securely to the LOCK position. If the control
levers are not locked, and they are touched by mistake,
AM088930A
this may lead to a serious accident.

● If the safety lock lever is not placed securely in the LOCK

position, the control levers may not be properly locked.
Check that the situation is as shown in the diagram.

● When the safety lock lever is raised, take care not to

touch the work equipment control lever. If the safety lock
lever is not properly locked at the upper position, the
work equipment and swing will move, creating a poten-
tially dangerous situation.

● When the safety lock lever is lowered, take care not to

touch the work equipment control lever.

This lever locks the work equipment, swing and attachment con-
trols.

This lock lever is a hydraulic lock, so even if it is in the lock posi-

tion, the work equipment control lever will move, but the work
equipment and swing motor will not work.

AM089540A

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OPERATION EXPLANATION OF COMPONENTS

2. TRAVEL LEVERS (WITH PEDAL, AUTO-DECELERATION

MECHANISM)

WARNING
● Do not put your foot on the pedal unless the machine is
travelling. If you leave your foot on the pedal and press it
by mistake, the machine will move suddenly, and this
may lead to a serious accident.

● With the track frame facing to the rear, the machine will
move in the reverse direction by forward travelling and in
the forward direction by reverse travelling.

● When the travel lever is used, check to see if the track

frame is facing forward or backward. (If the sprocket is
located to the rear, the track frame is facing forward.)

(1) FORWARD ( 2) REVERSE:

The lever is pushed forward The lever is pulled back.

(The pedal is angled forward) (The pedal is angled back)

N (Neutral): The machine stops

( ) This indicates operation of the pedal.

3. LEFT WORK EQUIPMENT CONTROL LEVER

(with auto-deceleration device)

WARNING
If any lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when
operating the levers.

AM089560A
This lever is used to operate the arm and upper structure.

Arm operation Swing operation

(A) Arm OUT (C) Swing to right

(B) Arm IN (D) Swing to left

N (Neutral)

When the lever in this position, the upper structure and the arm
will be retained in the position in which they stop.

77
EXPLANATION OF COMPONENTS OPERATION

4. RIGHT WORK EQUIPMENT CONTROL LEVER

(with auto-deceleration device)

WARNING
If any lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when
operating the levers.

AM089570A
This lever is used to operate the boom and bucket.

Boom operation Bucket operation

(1) RAISE (3) DUMP

(2) LOWER (4) CURL

N (Neutral)

When the lever in this position, the boom and the bucket will be
retained in the position in which they stop.

For levers (2), (3) and (4), the engine speed changes as follows
because of the auto-deceleration mechanism.

● When the travel lever and work equipment control levers are
at neutral, even if the fuel control dial is above the mid-range
position, the engine speed will drop to a mid-range speed. If
any of the levers are operated, the engine speed will rise to
the speed set by the fuel control dial.

● If all control levers are set to neutral, the engine speed will
drop by approx. 100 rpm, and after approx. 4 seconds, the
engine speed will drop to the deceleration speed (approx.
1400 rpm).

78
OPERATION EXPLANATION OF COMPONENTS

5. ATTACHMENT CONTROL PEDAL

AM161521

WARNING
Do not put your foot on the pedal except when operating the
pedal. If you leave your foot resting on the pedal during oper-
ation and it is depressed by accident, the attachment may
move suddenly and cause serious damage or injury.

When breaker is installed

● When the front part of the pedal is depressed, the breaker is

actuated.

● Set the working mode to the breaker (B.O.).

N
When general attachment is installed

● When the pedal (1) is depressed, the attachment is actuated.

● The right hand switch panel has a ten position thumb- AM092130D
wheelswitch (2). This allows nine values of flow for the right
hand foot pedal and no flow at position zero. When selecting
switch positions, the RH foot pedal must be fully released
before beginning work at the new flow setting.

● Please note your preferred switch position against attach-

ment used for your future reference.

Switch position 1 2 3 4 5 6 7 8 9

Approximate maxi- Full

30 50 100 125 150 170 202 280
mum flow (L/min) flow

Attachment

● Adjustment of these range of flows is possible.

Contact your Komatsu dealer if required.

79
EXPLANATION OF COMPONENTS OPERATION

HYDRAULIC OIL FLOW

When the front of the pedal is depressed, the oil flows to the left
piping for the work equipment; when the rear of the pedal is
depressed, the oil flows to the right piping for the work equipment.
(When the breaker is installed, only the front of the pedal is used.)

AM089620A

6. SELECTOR VALVES FOR BREAKER AND GENERAL

ATTACHMENT (CRUSHER, ETC.)

Contact dealer to set left hand boom piping relief pressure.

When using the breaker or general attachment (crusher etc) turn

the rotors the rotor of the 3-way valve (1) to charge over accord-
ing to the following illustrations.

(The marks indicating the port direction are stamped on the 3-way
valve)

Attachments Right 3-way valve (1)

Front

1-way frow (Breaker)

Front

2-Way flow (Crusher)

NOTICE
Perform work only after the engine is stopped and the work
equipment and machine body are in a stable posture on the
ground.

For details, see “MACHINES READY FOR ATTACH-

MENTS” on page 255.

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OPERATION EXPLANATION OF COMPONENTS

CEILING WINDOW

When opening

1. Lock the safety lock lever securely.

2. Check for an ceiling window movement by pulling lock (2)

located on both sides, then push up and open the ceiling win-
dow grasping grip (1).

When closing

Close the ceiling window grasping grip (1) and lock it with lock
(2). If the lock cannot be applied, open and close the ceiling win-
dow again.

81
EXPLANATION OF COMPONENTS OPERATION

FRONT WINDOW

WARNING
When opening the front window, always hold grip firmly with
both hands and pull up. If you use only one hand, your hand
may slip and get caught.

It is possible to store (pull up) the front window (top) in the roof of
the operator’s compartment.

When opening

WARNING
When the front window is open, there is danger that it will
fall, so always lock it with left and right lock pins (A).

1. Place the work equipment on flat ground and stop the engine.

2. Securely lock the safety lock lever.

AM088930A

3. Confirm that the wiper is stored inside the right frame.

4. Pull lock pins (A) at the top left and right sides of the front win-
dow to the inside to release the lock.

(B) Top grip B

(C) Bottom grip
C
A

AM089670A

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OPERATION EXPLANATION OF COMPONENTS

5. From the inside of the operator’s cab, hold the bottom grip
with the left hand and the top grip with the right hand, pull up
the window, and push it in fully until it is locked by catch (C).

6. Lock with lock pins (A) on the left and right sides.

When closing

WARNING
When closing the window, lower it slowly and be careful not
to get your hand caught.

1. Place the work equipment on a flat ground and stop the

engine.

2. Securely lock the safety lock lever.

AM088930A

3. Release the lock pin (A).

4. Hold the grip at the bottom of the front window with your left
hand and the grip at the top with your right hand, release the
lock of catch (C) with your right thumb, then pull the top grip
slowly and lower the front window. When releasing the lock of
catch (C), push release lever (D) in the direction of the arrow
to release the lock.

83
EXPLANATION OF COMPONENTS OPERATION

5. Lock securely with lock pins (A) at the left and right sides

C
A

AM089670A

Removing front window (bottom)

Ensure lower wiper (if fitted) is in correct park position.

With the front window open, remove lock pins (E), and the bottom
part of the front window can be removed.

Store the removed bottom part of the front window at the rear of
the operator’s cab and lock with lock pins (E).
Storage position

NOTICE
Do not operate lower wiper (if fitted) when front window (bot-
tom) is removed.

AM089740A

DOOR LOCK

Use the door lock to fix the door in position after opening it.

1. The door will become fixed in place when it is pressed against

catch (1).

2. To release the lock, press knob (2) down at the left side of the
operator’s seat to release the catch.
When fixing the door, fix it firmly to the catch.

CAP, COVER WITH LOCK

The fuel filler, operator’s cab, engine hood, battery box cover,
right side door and left side door of the machine body are fitted
with locks.

Use the starting switch key to lock or unlock these places.

84
OPERATION EXPLANATION OF COMPONENTS

METHOD OF OPENING AND CLOSING CAP WITH LOCK (For

the fuel tank filler port)

To open the cap

1. Insert the key into the cap.

type A
2. Turn the key clockwise (2), align the match mark on the cap
with the rotor groove, then remove the cap.

2
1 AW34934D

To lock the cap

1. Turn the cap into place. type B

3
2. Turn the key and take the key out.

3. Match mark on the cap 1

2
AW34935D

Insert the key as far as it will go (A) . If the key is turned before it
is inserted all the way, it may break.

METHOD OF OPENING AND CLOSING COVER WITH LOCK

(cover with Iock)

To open the cover (locked cover)

A
1. Insert the key.
AL067870A

2. Turn it counterclockwise and open the cover by pulling the

cover grip.

To lock the cover

1. Close the cover and insert the key.

2. Turn the key clockwise and take the key out.

LUGGAGE TRAY

This tray is located to the rear of the operator’s seat. Always keep
the operation & maintenance manual in this box for easy reading
access.

AM089770A

85
EXPLANATION OF COMPONENTS OPERATION

ASHTRAY

This is on the side of the operator’s seat. Always make sure that
you extinguish the cigarette before closing the lid.

86
OPERATION EXPLANATION OF COMPONENTS

AIR CONDITIONER

GENERAL LOCATIONS ON CONTROL PANEL

The pilot lamp for the switches light up to indicate that the switch
is functioning.

1. VENT SELECTOR SWITCH

This is used to select the vents which match the purpose of use.

Air flow to face and

Air flow to foot space
body

Switch
selection

Air flow

87
EXPLANATION OF COMPONENTS OPERATION

2. FRESH/RECIRC SELECTOR SWITCH

This switch is used to intake fresh air or recirculate the internal air.

Recirculating
Fresh air intake
Use this position to
Use this position
heat or cool the
Function when taking in clean,
operator’s cab
fresh air or when
quickly or when the
demisting.
outside air is dirty.

Switch
selection

3. TEMPERATURE CONTROL SWITCH

This switch is used to adjust the temperature steplessly between

low and high.

Cooling Heating

Switch
selection

Bleu Red
AA30813C

Function The more lamps in the blue range light up, the
lower the temperature becomes; the more lamps in
the red range light up, the higher the temperature
becomes.
The range is divided into 7 levels, and each range
is steplessly further divided.

88
OPERATION EXPLANATION OF COMPONENTS

4. WIND FLOW SELECTOR SWITCH

The wind flow can be adjusted to 3 levels.

Function Low Medium High

Switch
selection

AIR CONDITIONER SWITCH

This is used to switch the air conditioner ON/OFF.

OFF SWITCH

This switch is use to stop the fan.

DEFROSTER SELECTOR LEVER

This is used to clear the mist from the front glass in cold or rainy
conditions.

Selector lever forward: Defroster (2)

1
Selector lever back: Foot (1)

AA30814C

The defroster can be used when the vent selector panel is at the
position.

PRECAUTIONS WHEN USING AIR CONDITIONER

Carry out ventilation from time to time when using the cooler.

● If you smoke when the cooler is on, the smoke may start to
hurt your eyes, so turn the lever to FRESH 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 ventila-
tion and cooling.

89
EXPLANATION OF COMPONENTS OPERATION

Be careful not to make the temperature in the cab too low.

● When the cooler is on, set the temperature so that it feels

slightly cool when entering the cab (5 - 6°C lower than the
outside temperature). This temperature difference is consid-
ered to be the most suitable for your health, so always be
careful to adjust the temperature properly.

CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR

CONDITIONER

When carrying out inspection and maintenance of a machine

equipped with air conditioner, see Maintenance shedule chart.

CAB RADIO
Refer to the separate operation manual for radio cassette.

NOTE: Ensure radio is switched off when leaving the machine

for long periods to prevent draining of battery charge.

Antenna

If the reception is weak or generates noise, extend the antenna. If

the reception is too strong, adjust the sensitivity by retracting the
antenna.

NOTICE
When transporting the machine or parking it in a garage,
always fully retract the antenna to avoid the possibility of
breakage.
AM090050A
PRECAUTION OF USE

● To ensure safe operation, adjust the volume level so that

external noise is still audible.

● Ensure no water is splashed over the speaker case or cab

radio to prevent malfunction.

● Never use solution such as benzine or tinners to clean the

dial or buttons. These should be wiped with a dry, soft cloth.
(Use a cloth dipped alcohol for very dirty surfaces.)

● At battery replacement, all the memory pre-set with the pre-

set buttons will be cleared. Perform pre-setting again.

90
OPERATION EXPLANATION OF COMPONENTS

FUSE

NOTICE
Before replacing a fuse, be sure to turn off the starting
switch.

The fuses protect the electrical equipment and wiring from burn-
ing 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 a
fuse with another of the same capacity.

Fuse capacity and name of circuit

Fuse
No. Circuit
capacity

(1) 10 A Governor and pump controller

(2) 10 A Solenoid valve

(3) 20 A Air conditioner (motor)

Right head lamp, work lamps (Boom LH &

(4) 15 A
RH), engine romm lamp, heated seat

Cigarette lighter, Heater, window washer,

(5) 20 A
left knob button
(6) 10 A Horn

(7) 15 A Wiper controller

(8) 20 A Cab mounted work lamps (X3), Beacon

(9) 20 A Lower wiper, Refueling pump

(10) 10 A Key switch signal

Work lamps
(11) 15 A
(Left hand deck, counterweight)

(12) 10 A Spare

(13) 10 A Alarm buzzer, monitor

(14) 20 A Battery relay, Ribbon heater, start signal

(15) 10 A Room lamp, radio

(16) 10 A Spare fuse

(17) 10 A Spare fuse

(18) 15 A Spare fuse

(19) 20 A Spare fuse

91
EXPLANATION OF COMPONENTS OPERATION

FUSIBLE LINK
If the starting motor will not rotate when the starting switch is
turned ON, a possible cause is disconnection of wire-type fusible
link (1). Open the battery room door on the right side of the
machine body to inspect the fusible link and, if necessary, replace
it.

REMARK
A fusible link refers to the large-sized fuse wiring installed in
the high current flow portion of the circuit to protect electrical com-
ponents and wiring from burning, similar to an ordinary fuse.
AM090100A

CONTROLLERS
A combined pump controller and engine controller are provided.

NOTICE
● Never splash or spill water, mud or drink over the con-
trollers as this may cause a fault.

● If a fault occurs in the controller, do not attempt repair,

but consult your Komatsu distributor.

TOOL BOX
This is used for storage of tools.

92
OPERATION EXPLANATION OF COMPONENTS

REFUELLING PUMP

WARNING
Do not bring fire or sparks near the fuel.

1. When the machine is operated on sites with no fuel container

and pump, the machine may be refuelled using the refuelling
pump (if fitted) from fuel barrels.
The refuelling pump is located next to batteries at the front
right hand side of the machine.

2. Place the fuel hose (2), which is stored in tray (3) into the fuel
barrel placed next to the machine.

3. Switch on refuelling pump using switch (1) on the pump

assembly when adding fuel, never let the fuel overflow. This
may cause a fires.

NOTICE
● This pump is protected by a fuse (5). If pump fails to
function check fuse (10A).

● Ensure strainer on hose end is clean.

93
EXPLANATION OF COMPONENTS OPERATION

HANDLING THE ACCUMULATOR

WARNING
On machines equipped with an accumulator, for a short time
after the engine is stopped, if the work equipment control
lever is moved to the LOWER position, the work equipment
will move down under its own weight.

After stopping the engine, always place the safety lock lever
in the LOCK position and lock the attachment control pedal
with the lock pin.

The accumulator is filled with high-pressure nitrogen gas,

and it is extremely dangerous if it is handled in the wrong
way. Always observe the following precautions.

● Never make any hole in the accumulator or expose it to

flame or fire.

● Do not weld any boss to the accumulator.

● When disposing of the accumulator, it is necessary to

release the gas from the accumulator, so please contact
your Komatsu distributor.

This machine is equipped with the accumulator in the control cir-

cuit. The accumulator is a device to store the pressure in the con-
trol circuit, and when it is installed, the control circuit can be
operated for a short time even after the engine is stopped. There-
fore, if the control lever is moved in the direction to lower the work
equipment, it is possible for the work equipment to move under its
own weight.

The accumulator is installed to the position shown in the diagram

AM090140A
on the right.

METHOD FOR RELEASING PRESSURE IN CON-

TROL CIRCUIT OF MACHINES EQUIPPED WITH
ACCUMULATOR

1. Lower the work equipment to the ground. Close any attach-

ment such as the crusher attachment jaws, etc.

2. Stop the engine.

3. Move the safety lock lever completely in the FREE position.

Move the work equipment control lever and attachment con-
trol pedal full to the back and forth, right and left so as to
release the pressure in the control circuit.

4. Move the safety lock lever to the lock position. Lock the con-
trol lever and attachment control pedal. The pressure, how-
ev e r, wi l l no t b e c o mp l et e ly r e l ea s e d, s o wh e n th e
accumulator is removed in the control circuit, gradually loosen
the screws. Never stand in the oil ejection direction.

94
OPERATION OPERATION

OPERATION

CHECK BEFORE STARTING ENGINE

WALK-AROUND CHECK

WARNING
Dirt, oil or fuel around the parts of the engine which reach
high temperatures may cause fire and damage to the
machine. Check carefully, and if any abnormality is found,
always repair it or contact your Komatsu distributor.

Before starting the engine, look around the machine and under
the machine to check for loose nut or bolts, or leakage of oil, fuel,
or coolant, and check the condition of the work equipment and
hydraulic system. Check also for loose wiring, play, and collection
of dust at places which reach high temperatures.

Always carry out the items in this section before starting the
engine each day.

1 5 6 8 4 3

9 5 6 7 4 2
AM090150B

1. Check for damage, wear, play in work equipment, cylinders,

linkage, hoses
Check that there are no cracks, excessive wear, or play in the
work equipment, cylinders, linkage, or hoses. If any abnor-
mality is found, repair it.

95
OPERATION OPERATION

2. Remove dirt from around engine, radiator

Check that there is no dirt accumulated around the engine or
radiator. If any dirt is found, remove it.

3. Check for leakage of water or oil around engine

Check that there is no leakage of oil from the engine or leak-
age of water from the cooling system. If any abnormality is
found, repair it.

4. Check for oil leakage from hydraulic equipment, hydraulic

tank, hoses, joints
Check that there is no oil leakage. If any abnormality is found,
repair the place where the oil is leaking.

5. Check the undercarriage (track, sprocket, idler, guard) for

damage, wear, loose bolts or leaks of oil from rollers.

6. Check for damage to handrail, loose bolts

Repair any damage and tighten any loose.

7. Check for damage to gauges, monitor, loose bolts.

Check that there is no damage to the gauges and monitor in
the operator’s cab. If any abnormality is found, replace the
parts. Clean off any dirt on the surface.

8. Clean rear view mirror, check for damage

Check that there is no damage to the rear view mirror. If it is
damaged, replace it with a new mirror. Clean the surface of
the mirror and adjust the angle so that the view to the rear
can be seen from the operator’s seat.

9. Check bucket with hook for damage

Check the hook, catcher and hook foot for damage. If dam-
age is found, contact your Komatsu distributor for repair.

CHECK BEFORE STARTING

Always carry out the items in this section before starting the
engine each day.

96
OPERATION OPERATION

CHECK COOLANT LEVEL, ADD WATER

WARNING
Do not open the radiator cap unless necessary. When check-
ing the coolant, always check the radiator reserve tank when
the engine is cold.

1. Open the left rear cover on the machine and check that the
cooling water level is between the FULL and LOW marks on
radiator reserve tank 1 (shown in the picture on the right).
If the water level is low, add water through the water filler of
reserve tank a to the FULL level.

2. After adding water, tighten the caps securely.

3. If the reserve tank becomes empty, first inspect for water

leaks and then fill the radiator and the reserve tank with
water.

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the engine hood on the machine.

2. Remove dipstick (G) and wipe the oil off with a cloth.

3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.

4. The oil level should be between the H and L marks on dipstick

(G).
If the oil level is below the L mark, add engine oil through oil
filler F.

For details of the oil to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

5. If the oil is above the H mark, drain the excess engine oil from
drain valve (P), and check the oil level again.

97
OPERATION OPERATION

6. If the oil level is correct, tighten the oil filler cap securely and
close the engine hood.

REMARK
When checking the oil level after the engine has been oper-
ated, wait for at least 15 minutes after stopping the engine before
checking.
If the machine is at an angle, make it horizontal before checking.

CHECK FUEL LEVEL, ADD FUEL

WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. If spilling fuel, thoroughly clean up any spillage.

1. Use sight gauge (G) on the front face of the fuel tank to check
that the tank is full.

2. If the fuel level is not within the sight gauge, add fuel through
filler port (F) while watching sight gauge (G).

Fuel capacity: 340 l

For details of the fuel to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

3. After adding fuel, tighten the cap securely.

REMARK
If breather holes a on the cap is clogged, the pressure in the
tank will drop and fuel will not flow.
Clean the holes from time to time.

98
OPERATION OPERATION

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
● When removing the oil filler cap, oil may spurt out, so
turn the cap slowly to release the internal pressure
before removing the cap.

● If oil has been added to above the H mark, stop the

engine and wait for the hydraulic oil to cool down, then
drain the excess oil from the drain plug (P).

1. If the work equipment is not in the condition shown in the dia-

gram on the right, start the engine, run the engine at low
speed, retract the arm and bucket cylinders, 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 con-

trol lever (for work equipment and travel) to the full stroke in
all directions to release the internal pressure. AM090210A

3. Check sight gauge (G). The oil level is normal if between the
H and L marks.

NOTICE
Do not add oil if the level is above the H line. This will dam-
age the hydraulic equipment and cause oil to spurt out.

4. If the level is below the L mark, remove the upper cover of the
hydraulic tank and add oil through oil filler (F).

For details of the oil to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

REMARK
The oil level will vary depending upon the oil temperature
Accordingly, use the following as a guide:

● Before operation: around L level

(Oil temperature 10 to 30oC)

● Normal operation: around H level

(Oil temperature 50 to 80oC)

99
OPERATION OPERATION

CHECK AIR CLEANER FOR CLOGGING

1. Confirm that the air cleaner clogging monitor does not flash

2. If it flashes, immediately clean or replace the element.

For details of the method of cleaning the element, see

“CHECK, CLEAN AND REPLACE AIR CLEANER ELE-
MENT” on page 194.

CHECK ELECTRIC WIRINGS

AD313590A

WARNING
● If the fuse blows frequently, or there are traces of short-
circuiting in the electric wiring, always locate and repair
the cause.

● Accumulation of flammable material (dead leaves, twigs,

grass etc.) around the battery may cause fire, so always
check and remove such material.

● 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 clear the breather hole.

Check for damage and wrong capacity of the fuse and any sign of
disconnection or short circuit in the electric wiring. Check also for
loose terminals and tighten any loose parts.
Check the wiring of the “battery”, “starting motor” and “alternator”
carefully in particular.

When carrying out walk-around checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.

Please contact your Komatsu distributor for investigation and cor-

rection of the cause.

CHECK FUNCTION OF HORN

1. Turn the starting switch to the ON position.

2. Confirm that the horn sounds without delay when the horn
button is pressed. If the horn does not sound, ask your
Komatsu distributor for repair.

100
OPERATION OPERATION

CHECK FOR WATER AND SEDIMENT IN WATER

SEPARATOR, DRAIN WATER

A fuel sedimentor is mounted in pump compartement. Entrapped

sediment & water can been seen trough the glass bowl.

1. LOOSE DRAIN PLUG (1) and drain water and sediment until
none visable in bowl.

2. Tighten drain plug

CHECK FOR WATER IN PRIMARY FUEL FILTER,

DRAIN WATER

A primary fuel filter is fitted on the engine.

Drain the water from from the primary seperator by turning cap at
the bottom of the filter.

101
OPERATION OPERATION

ADJUSTMENT BEFORE OPERATION

OPERATOR’S SEAT

WARNING
● Adjust the seat position before starting operations or
after changing the operator.

● Adjust the seat so that the brake pedal can be depressed

fully with the operator’s back against the backrest.

A: Fore-and-aft adjustment of seat

Pull lever (1) up. After the seat is set to the desired position,
release the lever.

NOTE: This operation will not affect relative position of seat and
wrist control levers.

B: Fore-and-aft adjustment of seat

Pull lever (2) up. After the seat is set to the desired position,
release the lever.

NOTE: This operation will affect relative position of seat and wrist
control levers.

C: Adjustment of seat tilting angle

Pull lever (3) up. After the seat back is set to the optimum posi-
tion for easy operation, release the lever. Sit with your back
against the seat back when adjusting. If your back is not touching
the seat back, it may suddenly move forward.

D: Adjustment of armrest height

Turn thumbwheel (4) to adjust armrests to comfortable height.

(Armrest can also be lifted upwards to ease access).

E : Adjustment of tilting seat angle

Push lever (5) down to alter seat angle, release lever when seat is
in required position.

F: Suspension adjustment (standard seat)

When knob (6) is turned clockwise, the suspension becomes

harder and when turned anti-clockwise, softer. Adjust the dial so
that the suspension best matching the operator ’s weight is
selected.

102
OPERATION OPERATION

G: Lumbar adjustment

Turn knob (7) to adjust lumbar supports.

(H) Air suspension adjustment (option).

When button 8 is pressed the air compressor will harden the sus-
pension, and when the button is pulled out, air is released to 8
soften the suspension. Note that the compressor can only be acti-
vated when the ignition is on.

ADJUSTMENT OF MONITOR PANEL ANGLE

Turn the monitor panel so that the operator can view the monitor
with ease. When adjusting the angle, the panel should be set to
the desired position using both hands. The panel is automatically
locked at that position.
Amount of adjustment: 30° (stepless)

USING THE SEAT BELT

WARNING
● Before operating the machine, adjust the seat and fasten
the seat belt.

● Adjust the seat belt to fit snugly and low around the hips
to lessen the chance and severity of injury in the event of
an accident. Never wear the seat belt across the abdo-
men.

● Do not use the seat belt with either half of the belt kinked.

● Do not use bleach, color dye or solvents on the seat belt

webbing which may cause a severe loss of tensile
strength. This could cause the webbing to break result-
ing in personal injury. It is recommended that the belt be
cleaned only with warm water and a mild detergent.

To buckle, insert the tongue portion (A) of the buckle into the lock-
ing portion (B). Fasten the seat belt along your body without kink-
ing it.

To release, press the release button (C) on the locking portion of

the buckle and pull the tongue portion out.

Keep belts flat to avoid twisting and roping when not being used.
Do not place heavy or sharp object on the belts.

103
OPERATION OPERATION

OPERATIONS AND CHECKS BEFORE STARTING

ENGINE
WARNING
If the control lever is touched by accident, the work equip-
ment or the machine may move suddenly. When leaving the
operator’s compartment, always set the safety lock lever
securely to the LOCK position.

AE313600A

1. Check that safety lock lever (1) is at the LOCK position.

2. Check the position of each lever.

Set the control lever to the neutral position.

When starting the engine, never touch the knob button.

3. Insert the key in starting switch (2), turn the key to the ON
position, then carry out the following checks.
AM088930A
The buzzer will sound for approx. 1 sec, and the following moni-
tors and gauges will light up for approx. 3 sec.

● Radiator water level monitor (3)

● Engine oil level monitor (4) HEAT OFF

● Hydraulic oil level monitor (5)

ON
● Charge level monitor (6)
START
● Fuel level monitor (7)
AM090710A
● Engine water temperature monitor (8)

● Engine oil pressure monitor (9)

● Engine water temperature gauge (10)

● Fuel gauge (11)

● Engine pre-heating monitor (12)

● Air cleaner clogging monitor (13)

AD313610A
● Swing lock monitor (14)

● Replacement monitor of engine oil (15)

If the monitors or gauges do not light up or the buzzer does not

sound, there is probably a broken bulb or disconnection in the
monitor wiring, so contact your Komatsu distributor for repairs.

104
OPERATION OPERATION

After approx. 3 sec, the following gauges will remain on and the
other monitors will go out.

● Engine water temperature gauge (10)

● Fuel gauge (11)

(2) Press lamp switch (1) to turn on the head lamps.

If the lamp switch does not light up, there is probably a broken
bulb or disconnection in the wiring, so contact your Komatsu dis- 1
tributor for repairs.

AM090290A

105
OPERATION OPERATION

STARTING ENGINE
NORMAL STARTING

WARNING
Check that there are no persons or obstacles in the sur-
rounding area, then sound the horn and start the engine.

NOTICE
Do not keep the starting motor rotating continuously for
more than 20 seconds.
If the engine will not start, wait for at least 2 minutes before
trying to start the engine again.

1. Set fuel control dial (1) at the low idling (MIN) position.

AM090340A

2. Turn the key in starting switch (2) to the START position. The
engine will start.
T OFF
HEA
ON
START

AM090350A

3. When the engine starts, release the key in starting switch (2).
The key will return automatically to the ON position.
OFF
AT
HE
ON
START

AM090360A

106
OPERATION OPERATION

STARTING IN COLD WEATHER

WARNING
● Check that there are no persons or obstacles in the sur-
rounding area, then sound the horn and start the engine.

● Never use starting aid fluids as they may cause explo-

sions.

NOTICE
Do not keep the starting motor rotating continuously for
more than 20 seconds.
If the engine fails to start, repeat from step 2 and after waiting
for about 2 minutes.

When starting in low temperatures, do as follows.

AD324280A

1. Set fuel control dial (1) at the low idling (MIN) position.

REMARK
There are 10 notches for the dial rotation, and a click can be
felt by hand.

AM090340A

2. Hold the key in starting switch (2) at the HEAT position, and
check that preheating monitor (3) lights up.
After about 30 seconds, preheating monitor lamp (3) will flash
for about 10 seconds to indicate that preheating is finished.
AT OFF
HE
ON
START

AM090380A

107
OPERATION OPERATION

REMARK
The monitor and gauge also light up when the key is at the
HEAT position, but this does not indicate any abnormality.

3. When preheating monitor (3) flashes, turn the key in starting

switch (2) to the START position to start the engine.
T OFF
HEA
ON

START
AM090390A

4. When the engine starts, release the key in starting switch (2).
The key will return automatically to the ON position.
OFF
AT
HE
ON

START
AM090360A

OPERATIONS AND CHECKS AFTER STARTING ENGINE

WARNING
● Emergency stop

● If there has been any abnormal actuation or trouble, turn

the starting switch key to the OFF position.

● If the work equipment is operated without warming the

machine up sufficiently, the response of the work equip-
ment to the movement of the control lever will be slow,
and the work equipment may not move as the operator
desires, so always carry out the warming-up operation.
Particularly in cold areas, be sure to carry out the warm-
ing-up operation fully.

WHEN NORMAL

NOTICE
● When the hydraulic oil is at a low temperature, do not
carry out operations or move the levers suddenly.
Always carry out the warming-up operation. This will
help to extend the machine life. Do not suddenly acceler-
ate the engine before the warming-up operation is com-
pleted.

108
OPERATION OPERATION

● Do not run the engine at low idling or high idling continu-

ously for more than 20 minutes. This will cause leakage
of oil from the turbocharger oil supply piping.
If it is necessary to run the engine at idling, apply a load
from time to time or run the engine at a mid-range speed.

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

AM090400A

1. Turn fuel control dial (1) to the center position between LOW
IDLING (MIN) and HIGH IDLING (MAX) and run the engine at
medium speed for about 5 minutes with no load.

AM090410A

2. While running the engine at medium speed (A), press working

mode switch (2) until the heavy-duty operation mode lamp is
turned on.
H/O G/O F/O L/O B/O

H M

AD157770A

3. Set the safety lock lever to the FREE position, and raise the
bucket from the ground.

AM090430A

4. Operate bucket control lever (5) and arm control lever (4)
slowly to move the bucket cylinder and arm cylinder to the
5 (B) 4
end of the stroke. (D)
(A)
(C)
(A) IN (C) CURL

(B) OUT (D) DUMP

AM090440A

109
OPERATION OPERATION

5. Carry out bucket and arm operation for 5 minutes at full

stroke, alternating between bucket operation and arm opera- 6 Left swing 5
tion at 30 second intervals.
If the swing lock switch (6) is set to the ON (actuated) position
and swing control lever (5) is operated at full stroke, oil tem-
perature rise can be increased earlier.
Right
swing
NOTICE
When the work equipment is retracted, take care that it does
not interfere with the machine body or ground. AM090450B

6. After carrying out the warming-up operation, check that each

gauge and monitor lamp is in the following condition.

● Engine water temperature gauge (7): Inside green range

● Fuel gauge (8): Inside green range

● Engine water temperature monitor (9): OUT

● Radiator water level monitor (10): OUT

● Engine oil pressure monitor (11): OUT

● Charge level monitor (12): OUT

● Fuel level monitor (13): OUT

● Air cleaner clogging monitor (14): OUT

● Engine pre-heating lamp (15): OUT

● Engine oil level monitor (16): OUT

● Hydraulic oil level monitor (17): OUT AD324290A

● Replacement monitor of engine oil (18): OUT

7. Check that there is no abnormal exhaust gas colour, noise, or

vibration. If any abnormality is found, repair it.

8. Press mode switch (2) until required operation mode lamp is H/O G/O F/O L/O B/O
turned on.
H M

IN COLD AREAS (AUTOMATIC WARMING-UP

OPERATION)
AD157770A

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 30oC), the warming-up operation is carried out automati-
cally.

The automatic warming-up operation is cancelled if the engine

water temperature reaches the specified temperature (30oC) or if
the warming-up operation is continued for 10 minutes. If the
engine water temperature or hydraulic oil temperature are low
after the automatic warming-up operation, warm the engine up
further as follows.

110
OPERATION OPERATION

NOTICE
● When the hydraulic oil is at a low temperature, do not
carry out operations or move the levers suddenly.
Always carry out the warming-up operation. This will
help to extend the machine life.

● Do not suddenly accelerate the engine before the warm-

ing-up operation is completed.

● Do not run the engine at low idling or high idling continu-

ously for more than 20 minutes. This will cause leakage
of oil from the turbocharger oil supply piping. If it is nec-
essary to run the engine at idling, apply a load from time
to time or run the engine at a mid-range speed.

1. Set fuel control dial (1) at the low idling (MIN) position and run
the engine for about 5 minutes without load.

AM090340A

111
OPERATION OPERATION

2. Press working mode switch (2) on the monitor panel until H.O
(heavy duty operation) mode lamp lights up.

H/O G/O F/O L/O B/O

H M

AD157770A

3. Turn fuel control dial (1) to the mid-range (A) speed position.

AM090410A

4. Set safety lock lever (4) to the FREE position and raise the
bucket from the ground.

AM090430A

5. Operate bucket control lever (5) and arm control lever (4)
slowly to move the bucket cylinder and arm cylinder to the
end of their stroke. 5 (B) 4
(D)
(A)
(C)
(A) IN (C) CURL

(B) OUT (D) DUMP

6. Operate the bucket for 30 seconds and the arm for 30 sec- AM090440A
onds in turn fully for 5 minutes.
REMARK
Turn swing lock switch (1) ON (ACTUATED) and operate the
lever to make the oil temperature rise more quickly.
1
NOTICE
When the work equipment is retraced, take care that it does
not interfere with the machine body or ground.

AM090290A

112
OPERATION OPERATION

7. Turn fuel control dial (1) to the full speed (MAX) position and
carry out the operation is Step 6 for 3 -5 minutes.

8. Repeat the following operation 3 - 5 times and operate slowly.

● Boom operation RAISE ↔ LOWER

● Arm operation IN ↔ OUT

● Bucket operation CURL ↔ DUMP

● Swing operation LEFT ↔ RIGHT

AN113990A
● Travel (Lo) operation FORWARD ↔ REVERSE

REMARK
In the above operation is not carried out, there may be a
delay in response when starting or stopping each actuator, so
continue the operation until it becomes normal.

9. Use working mode switch (2) on the monitor panel to select

the working mode to be used.
H/O G/O F/O L/O B/O
NOTICE
Cancelling automatic warming-up operation
H M
If it becomes necessary in an emergency to lower the engine
speed to low idling, cancel the automatic warming-up opera-
tion as follows.
AD157770A

1. Turn fuel control dial (1) to the full speed (MAX) position and
hold it for 3 seconds.

AM090500A

2. When fuel control dial (1) is returned to the low idling (MIN)
position, the engine speed will drop.

MIN
Low idling AN113900A

113
OPERATION OPERATION

MOVING MACHINE OFF

MOVING MACHINE FORWARD

WARNING
● Before operating the travel levers, check the direction of
the track frame. If the sprocket is at front, the operation
of the track levers is reversed.

● When moving off, check that the area around the

machine is safe, and sound the horn before moving.

● Clear all personnel from the machine and the area.

● Clear all obstacles from the path of the machine.

● If the lever is moved inside the deceleration range,

engine speed will rise suddenly. Operate the levers care-
fully.

1. Set swing lock switch (1) to the ON (actuated) position and

confirm that swing lock monitor lamp (2) lights up.
1

2 AD324300A

2. Turn fuel control dial (3) towards the full speed position to
increase the engine speed.

AM090500A

3. Set safety lock lever (4) in the FREE position, fold the work
equipment, and raise it 40 - 50 cm from the ground.

AM090540A

114
OPERATION OPERATION

4. Operate right and left travel levers (5) or right and left travel
pedals (6) as follows.

● When the sprocket is at the rear of the machine.

Push levers (6) forward slowly or depress the front part of
pedals f slowly to move the machine off.

Sprocket
AN114030A

● When the sprocket is at the front of the machine.

Pull levers e backward slowly or depress the rear part of ped-
als (6) slowly to move the machine off.

REMARK
Each time the travel levers are operated on machines
equipped with the travel alarm, the alarm sounds to warn people
in the machine vicinity.
Sprocket
AN114040A
MOVING MACHINE BACKWARD

WARNING
● Before operating the travel levers, check the direction of
the track frame. If the sprocket is at front, the operation
of the track levers is reversed.

● When moving off, check that the area around the

machine is safe, and sound the horn before moving.

● Clear all personnel from the machine and the area.

● Clear all obstacles from the path of the machine.

● Use extreme care when reversing the machine. Note

there is a blind spot behind the machine.

● If the lever is moved inside the deceleration range,

engine speed will rise suddenly. Operate the levers care-
fully.

115
OPERATION OPERATION

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 (MAX) position
to increase the engine speed.

AM090500A

3. Set safety lock lever (4) in the FREE position, fold the work
equipment, and raise it 40 - 50 cm from the ground.

4. Operate right and left travel levers (5) or right and left travel
pedals (6) as follows.

AM090540A

● When the sprocket is at the rear of the machine

Pull levers (5) backward slowly or depress the rear part of
pedals (6) slowly to move the machine off.

Sprocket
AN114050A

● When the sprocket is at the front of the machine

Push levers (5) forward slowly or depress the front part of
pedals (6) slowly to move the machine off.

Sprocket
AN114060A

116
OPERATION OPERATION

STEERING MACHINE
STEERING (changing direction)

WARNING
Before operating the travel levels, check the position of the
sprocket. If the sprocket is at the front, the operation of the
travel levels is reversed.

Use the travel levers to change direction.

Avoid sudden changes of direction as far as possible. In particu-

lar, when carrying out counter-rotation (spin turn), stop the
machine first before turning.

Operate two travel levers (1) as follows.

Changing direction of machine when stopped

When turning to the left: Forward

Push the right travel lever forward to travel left when travelling for- left turn
ward; and pull it back to turn left when travelling in reverse.
Reverse
left turn
REMARK
When turning to the right, operate the left travel lever in the
same way.

AN114080A

Steering when travelling (left and right travel levers both

operated in same direction) Forward
left turn
When turning to the left:
If the left travel lever is returned to the neutral position, the Reverse
machine will turn to the left. left turn

AN114090A

117
OPERATION OPERATION

REMARK
When turning to the right, operate the right travel lever in the
same way.

When making counter-rotation turn (spin turn)

When turning left using counter-rotation, pull the left travel lever
back and push the right travel lever forward.

REMARK
When turning to the right using counter-rotation, pull the right
travel lever back and push the left travel lever forward.

AN114100A

118
OPERATION OPERATION

STOPPING MACHINE

WARNING
● Avoid stopping suddenly. Give yourself ample room
when stopping.

● When stopping the machine, select flat hard ground and

avoid dangerous places. If it is unavoidably necessary to
park the machine on a slope, block the tracks. As an
additional safety measure, thrust the bucket into the
ground.
120

Block

Thrust the bucket AM089100A

● If the control lever is touched by accident, the work

equipment or the machine may move suddenly, and this
may lead to a serious accident. Before leaving the opera-
tor’s compartment, always set the safety lock lever
securely to the LOCK position.

AM088930A

1. Put the left and right travelling and steering levers (1) in the
neutral position, then stop the machine.

119
OPERATION OPERATION

SWINGING
WARNING
When operating the swing, check that the area around the
machine is safe.

1. Before operating the swing, turn swing lock switch (1) OFF
(CANCELLED).

NOTICE
Check that swing lock lamp (2) goes out at the same time. (1 )

( 2 ) AW349440B

2. Operate the left work equipment control lever (3) to swing the
upper structure. A

(A) Left swing B

(B) Right swing

AM090650A

3. When not operating the swing, turn the swing lock switch (1)
ON (ACTUATED).

120
OPERATION OPERATION

OPERATION OF WORK EQUIPMENT

WARNING
If any lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when
operating the levers.

The work equipment is operated by the left and right work equip-
ment control levers. The left work equipment control lever oper-
ates the arm and swing, and the right work equipment control
lever operates the boom and bucket.

AM090660A

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 equip-
ment is held in place.

AM090670A

● If the work equipment control lever is 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.

AM090680A

REMARK
If the levers are operated within 15 seconds after stopping the
engine, it is possible to lower the work equipment to the ground.
In addition, the levers can also be operated to release any
remaining pressure inside the hydraulic cylinder circuit and to
lower the boom after the machine on a trailer.

AM090690A

121
OPERATION OPERATION

HANDLING ACTIVE MODE

Make full use of the active mode to match the purpose and condi-
tions of the operation in order to carry out operations effectively
and efficiently.

The active mode selector switch can be turned ON (lights up) in

order to provide quick leveling operations and effective deep dig-
ging and loading operations.

ON lights up: Active mode ON

AD324270A
ON goes out: Active mode cancelled

The ON lamp is off when the engine is started.

If it is turned ON (lights up), it is possible to enter the active mode

from any working mode.

Even when it is turned ON (lights up), the working mode display

does not change. When the lamp goes out, the system returnes
to the original working mode.

Mode Effective operations Advantages for operations

By increasing the boom lowering

speed and engine speed and the
Digging and loading boom down safety valve pres-
sure, the cycle time for deep dig-
Active mode ging operations is reduced.

By increasing the arm IN speed

and the pump response, the
Levelling
speed of rough levelling (light
loads) is increased.

REMARK
Use the active mode with the fuel control dial turned to the
MAX position. If it is not at the MAX position, it will be impossible
to achieve a suitable increase in the work equipment speed.

1. Turn on the active mode selector switch (lights up)

2. While in this condition, press and hold the knob switch on the
lefthand work equipment lever once (single click).

3. Since the machine returns to the normal active mode in 8.5

sec. after the switch is pressed, use the active power-max
function effectively for heavy and quick work.

Function Suitable work Advantages in work

Since digging forces of arm and

Actice power-max Digging and loading (heavy load)
bucket are increased, working
function Rock raising (Heavy load)
speed is increased.

The load sensing function is installed to the active mode. If the

machine is set to active power-max, however, the load sensing
function is turned off and the engine speed returns to full speed to
increase the speed of the work equipment.

122
OPERATION OPERATION

WORKING MODE SELECTION

WORKING MODE

The mode selector switches can be used to switch the mode to

match the conditions and purpose of work, thereby enabling effi-
cient operation.

Use the following procedures to make the most effective use of

each mode.

When the starting switch is turned ON, the working mode is set to
general operation mode (G.O.), so normal work can be carried out
without needing to set the mode.
H/O G/O F/O L/O B/O
Set the most effective mode according to the type of work using
working mode selector switch. H M

AD157770A

Swift slow-down (Speed

Power max. (power up)
down)
Working mode Applicable work
Set Set
Power Speed
pressure pressure

Heavy-duty
Large amount of digging
operation mode 5 % up 9 % up 40 % down 9 % up
and loading in a short time
(H.O)

General opera- Normal digging and load-

23 % up 9 % up 30 % down 9 % up
tion mode (G.O.) ing operation

Finishing opera- Finishing, leverlling and

-
tion mode (F.O.) general hauling operation

Lifting operation
Positioning, etc. -
mode (L.O.)

Breaker opera-
tion mode Breaker operation -
(B.O.)

NOTICE
Never carry out breaker operation in heavy-duty operation
mode (H.O.) as this may result in breakage of hydraulic
equipment.

123
OPERATION OPERATION

POWER MAX./ SWIFT SLOW-DOWN

During operation the power max. and swift slow-down for the
work equipment can be carried out at a touch during operations.
This can be used effectively in combination with the working HEAT OFF
mode when necessary.
ON

START

AM090710A

1. When the starting switch is turned ON, the power max. lamp
lights up. Each time the set switch is pressed, the system
switches between power max. and swift slow-down.

AD157800A

2. If the left lower knob switch is kept pressed, the function is

actuated as long as the switch is pressed. However, for the
power max. function, the function is automatically finished
after 8.5 seconds.

AM089480A

124
OPERATION OPERATION

PROHIBITIONS FOR OPERATION

WARNING
If it is necessary to operate the work equipment control lever
when the machine is travelling, stop the machine before
operating the work equipment control lever.

● If the lever is moved inside the deceleration range,

engine speed will suddenly rise. Operate the levers care-
fully.

● Never operate the machine on a rock bed (hard or soft

rock).

Prohibited operations using swing force

INCORRECT
Do not use the swing force to compact soil or break earth mounds
or walls.

When swinging, do not dig the bucket teeth into the soil. These
operations will damage the work equipment.

AM090730A

Prohibited operations using travel force

INCORRECT
Do not leave the bucket dug into the ground and use the travel
force to excavate. This will bring excessive force to bear on the
rear of the machine.

AM090740A

Precautions when operating hydraulic cylinders to end of

stroke INCORRECT
(1)
If the cylinder is operated to the end of its stroke during opera-
tions, force will be brought to bear on the stopper inside the cylin-
der, and this will reduce the life of the machine. To prevent this,
always leave a small safety margin (1) when operating the cylin-
ders.

AM090750A

125
OPERATION OPERATION

Prohibited operations using dropping force of bucket

Do not use the dropping force of the bucket as a pickaxe, breaker, INCORRECT
or pile driver. This will bring excessive force to bear on the work
equipment, and will not only damage the machine, but is also
dangerous.

AM090760A

Prohibited operations using dropping force of machine.

INCORRECT
Do not use the dropping force of the machine for digging.

Digging rocky ground

It is better to excavate hard rocky ground after breaking it up by

some other means. This will not only reduce damage to the
machine but make for better economy.
AM090770A
INCORRECT

AM090780A

Sudden lever shifting during HI-speed travel prohibited

INCORRECT
(1) Never carry out sudden lever shifting as this may cause sud-
den starting. Forward

(2) Avoid sudden lever shifting from forward to reverse (or vice
versa) Neutral
Reverse
(3) Avoid sudden lever shifting change such as sudden stopping
from near top speed (lever release operation).

AM090800A

126
OPERATION OPERATION

PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN TRAVELLING

When travelling over obstacles such as boulders or tree stumps,

the machine (in particular, the undercarriage) is subjected to a
large shock, so reduce the travel speed and travel over the obsta-
cle at the center of the tracks. As far as possible, remove such
obstacles or avoid travelling over them.

AM090810A

PRECAUTIONS AT Hi-SPEED TRAVEL

On uneven roadbeds such as rock beds or uneven roads with

large rocks, travel at Mi or Lo speed. When Hi-speed travelling,
set the idler in the forward direction.

PERMISSIBLE WATER DEPTH

AD145900A

NOTICE
When driving the machine out of water, if the angle of the
machine exceeds 15 o , the rear of upper structure will go
under water, and water will be thrown up by the radiator fan.
This may cause the fan to break.
Be extremely careful when driving the machine out of water.

Do not immerse the machine in water by more than the permissi-

ble depth (under center of carrier roller (1)).
AM090830A

In addition, for parts that have been immersed in water for a long
time, pump in grease until the old grease comes out from the
bearings. (Around the bucket pins)

AM090840A

127
OPERATION OPERATION

PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS

WARNING
● When travelling, raise the bucket approx. 20 - 30 cm from
the ground.
Do not travel downhill in reverse.

● When travelling over ridges or other obstacles, keep the

work equipment close to the ground and travel slowly. INCORRECT
● It is dangerous to turn on slopes or to travel across
slopes. Always go down to a flat place to perform these
operations. It may be longer, but it will ensure safety.

● If the machine starts to slide or loses stability, lower the

bucket immediately and brake the machine. CORRECT
AM090850A

● Turning or operating the work equipment when working

on slopes may cause the machine to lose its balance and INCORRECT CORRECT
turn over, so avoid such operations. It is particularly dan-
gerous to swing downhill when the bucket is loaded.
If such operations have to be carried out, pile soil to Platform
make platform on the slope so that the machine can be
kept horizontal when operating.

● Do not travel on slopes of over 30o as there is danger

that the machine may overturn. AM090860A

1. When travelling down steep hills, use the travel lever and fuel
control lever to keep the travel speed low. Down hill
When travelling down slopes of more than 15o, set the work
equipment in the posture shown in the figure on the right, and
lower the engine speed.

Sprocket
AW35085C

2. When travelling up a steep hill of more than 15o, set the work
equipment in the posture shown in the diagram on the right. Up hill
Sprocket
Braking when travelling downhill

To brake the machine during downhill runs, put the travelling and
steering lever in the neutral position. This will cause the brake to
be automatically applied.
AW35086C
If shoes slip

When travelling uphill, if the shoes slip or it is impossible to travel

uphill using the force of the track only, it is possible to use pulling
force of the arm to help the machine travel uphill.

128
OPERATION OPERATION

If engine stops

If the engine stops when travelling uphill, move the travel levers to
the neutral position, lower the bucket to the ground, stop the
machine, then start the engine again.

Precautions on slopes

● If the engine stops when the machine is on a slope, never use

the left work equipment control lever to carry out swing opera-
tions. The upper structure will swing under its own weight.

● Do not open or close the door on the cab if the machine is on

a slope. This may cause a sudden change in the operating
force. Always keep the door locked.

HOW TO ESCAPE FROM MUD

Always operate carefully to avoid getting stuck in mud. If the
machine does get stuck in mud, use the following procedures to
get the machine out.

WHEN ONE SIDE IS STUCK

CORRECT
When only one side is stuck in mud, use the bucket force to raise
the track, then lay boards or logs and drive the machine out. If
necessary, put a board under the bucket also.

NOTICE
When using the boom or arm to raise the machine, always
have the bottom of the bucket in contact with the ground. AM090870

(Never push with the teeth). The angle between the boom and
arm should be 90° to 110°. The same applies when using the
inverting bucket.

WHEN BOTH SIDES ARE STUCK

CORRECT
When both tracks are stuck in mud and the machine will not
move, lay boards as explained above, and dig the bucket into the
ground in front. Then pull in the arm as in normal digging opera-
tions and put the travel levers in the FORWARD position to pull
the machine out.

AM090880

WORK POSSIBLE USING HYDRAULIC EXCAVATOR

In addition to the following, it is possible to further increase the
range of applications by using various attachments.

129
OPERATION OPERATION

BACKHOE WORK

When condition of the machine is as shown in the diagram at

right, each cylinders maximum pushing excavation force is
obtained when the bucket cylinder and link, arm cylinder and arm
are at 90o.
90
When excavating, use this angle effectively to optimise your work 90
efficiency.

AM090900A

The range for excavating with the arm is from a 45o angle away
from the machine to a 30o toward the machine.
30 45
There may be some differences depending on the excavation
depth, but try to use within the above range rather than going all
the way to the extreme end of the cylinder stroke.

AM090910A

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.

AM090920A

DITCHING WORK

Ditching work can be performed efficiently by attaching a bucket

to match the width of the ditch and then setting the tracks parallel
to the line of the ditch to be excavated.

To excavate a wide ditch, first dig out both sides and then finally
remove the center portion.

AM090930A

LOADING WORK

In places where the swing angle is small, work efficiency can be

enhanced by locating the dump truck in a place easily visible to
the operator.

Loading is easier and capacity greater if you begin from the front
of the dump truck body than if loading is done from the side.

AM090940A

130
OPERATION OPERATION

REPLACEMENT AND INVERSION OF BUCKET

WARNING
● When knocking the pin in with a hammer, metal particles
may fly and cause serious injury, particularly if they get
into your eyes. When carrying out this operation, always
wear goggles, helmet, gloves, and other protective
equipment.

● When the bucket is removed, place it in a stable condi-

tion.

Stop the machine on a firm, flat surface. When performing joint

work, make clear signals to each other and work carefully for
safety’s sake.

REPLACEMENT

1. Place the bucket in contact with a flat surface.

Bucket Arm
REMARK cylinder
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 Link
be increased and it will be difficult to remove the pins.

AM090950A

2. Remove the stopper bolts and nuts, then remove pins (A) and
(B) and remove the bucket.

NOTICE
After removing the pins, make sure that they do not become
contaminated with sand or mud and that the seals of bushing
on both sides do not become damaged.

3. Align the arm with holes (1) and the link with holes (2), then
coat with grease and install pins (A) and (B).

REMARK .
When installing the bucket, the O-rings are easily damaged,
so fit the O-rings on the boss of the arm end as shown in the
drawing.
When knocking the pin, move the O-ring down to the regular
groove.

4. Install the stopper bolts and nuts for each pin, then grease the
pin.

Bucket O-ring Arm AM090970A

131
OPERATION OPERATION

INVERSION

The rock bucket interferes with the arm, so it cannot be turned

and used for shovel operations.
Bucket Arm
1. Place the bucket in contact with a flat surface. cylinder

Link

AM090950A

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.

2. Remove the stopper bolts and nuts, then remove pins (A) and
(B), and remove the bucket.

NOTICE
After removing the pins, make sure that they do not become AM090980A
contaminated with sand or mud and that the seals of bushing
on both sides do not become damaged.

3. Install the bucket inversely.

After the bucket is inversed, correct the inclination and direc-
tion of the retaining pin holes a and b and stabilise the bucket
securely.

4. Align the arm with holes a and the link with holes b, then coat
with grease and install pins (A) and (B).

REMARK
Install the O-ring into retaining hole (1) of the arm and the AM090990A
bucket.
When installing the bucket, the O-rings are easily damaged, so fit
the O-rings on the boss of the arm end as shown in the drawing.

When knocking the pin, move the O-ring down to the regular
groove.

5. Install the stopper bolts and nuts for each pin, then grease the
pin.

132
OPERATION OPERATION

PARKING THE 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, block the tracks. As an
additional safety measure, thrust the bucket into the
ground.
120

Block
Thrust the bucket AM089100A

● If the control lever is touched by accident, the work

equipment or the machine may move suddenly, and this
may lead to a serious accident. Before leaving the opera-
tor’s compartment, always set the safety lock lever
securely to LOCK position.

AM088930A

1. Put left and right travel levers (1) in the neutral position.
The machine stops.

133
OPERATION OPERATION

2. Turn fuel control dial (2) to lower the engine speed to low
idling.

AM090340A

3. Lower the bucket horizontally until the bottom touches the

ground.

4. Stop the engine.

AM091020A

5. Set safety lock lever (3) in the LOCK position.

AM088930A

CHECK AFTER FINISHING WORK

Check the engine water temperature, engine oil pressure and fuel
level on the monitor.

STOPPING ENGINE

NOTICE
If the engine is abruptly stopped before it has cooled down,
engine Iife may be greatly shortened. Consequently, do not
abruptly stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly
stop it but run it at medium speed to allow it to cool gradu-
ally, then stop it.

134
OPERATION OPERATION

1. Run the engine at low idling speed for about 5 minutes to

allow it to gradually cool down.

2. Turn the key in starting switch (1) to the OFF position and
stop the engine.
AT OFF
3. Remove the key from starting switch (1). HE
ON

START
AM089160A

CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment,
paintwork, and undercarriage, and check also for leakage of
oil or water. If any abnormalities are found, repair them.

2. Fill the fuel tank.

3. Check the engine compartment for paper and debris. Clean

out any paper and debris to avoid a fire hazard.

4. Remove any mud stuck to the undercarriage.

135
OPERATION OPERATION

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) Battery box cover

AM091051A
(5) Left side door of the machine

(6) Right side door of the machine

(7) Tool box

(8) Hydraulic tank filler port

REMARK
Use the starting switch key to open and close all these
AM091061A
places.

OVERLOAD WARNING DEVICE

Excavators are provided with this device to warn the operator

about tipping over while lifting loads. A buzzer will sound when
the machine is in LO mode and the machine nears its lifting
capacity.

NOTE: Only conduct lifting operations in LO mode as the over-

load warning device is only active in this mode.

NOTE: Ensure "ACTIVE" mode is not selected when in LO mode

as this will cancel the overload warning system

136
OPERATION TRANSPORTATION

TRANSPORTATION
When transporting the machine, observe all related laws and reg-
ulations, and be careful to assure safety.

LOADING, UNLOADING WORK

WARNING
● Loading or unloading the machine can be a dangerous
operation, so be particularly careful.
When loading or unloading the machine, run the engine
at low idling and travel at low speed.

● Make sure the ramp has sufficient width, length and tick-
ness to enable the machine to be safely loaded and
unloaded. If the ramp sags appreciably, reinforce it with
blocks, etc.

● When loading and unloading the machine, park the trailer

on a flat firm roadbed. Keep a fairly long distance
between the road shoulder and the machine.

● Remove the mud from the undercarriage to prevent the 9JM00251

machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil,
ice and loose materials.

● Never change the direction of travel when on the ramps.

If it is necessary to change direction, drive off the ramps CORRECT
and correct the direction, then drive on to the ramps
again.

● When turning the machine on the trailer, the machine’s

footing is unstable, so carry out the operation slowly.

● Always check that the door on the cab is locked, regard-

less of whether it is open or closed. AW34968C
Do not open or close the door on ramps or on a platform.
This may cause a sudden change in the operating force.

● When loading or unloading the machine with the auto-

matic warming-up operation mode, if the automatic mode
is released, the speed may change suddenly. Avoid load-
ing or unloading during automatic warming-up operation.

137
TRANSPORTATION OPERATION

When loading or unloading, always use ramps or a platform and

carry out the operations as follows.

1. Properly apply the brakes on the trailer and insert blocks (2)
beneath the tyres to ensure that it does not move. Then fix
the ramps in line with the centers of the trailer and the
machine. Be sure that the two sides are at the same level as (3)
one another.
(1)
o
Make the angle of the ramps (3) a maximum of 15 .
Set the distance between the ramps (A) to match the center
of the tracks. (2)
(A)
AD052900A

2. Set the travel speed switch to the Lo position.

AD157790A

3. Turn the auto-deceleration switch OFF, and return the fuel

control dial to reduce the engine speed.

AD157780A

4. Turn the swing lock switch ON to apply the swing lock.

5. Set in the direction of the ramps, lower the work equipment as

far as possible without letting it hit the trailer, then travel
slowly to load or unload the machine. When on the ramps, do
not operate any lever other than the travel lever.

6. Load the machine correctly in the specified position on the

trailer.

REMARK
When the work equipment is installed, load the machine from
the front; when the work equipment is not installed, load the
machine from the rear.

138
OPERATION TRANSPORTATION

PRECAUTIONS FOR LOADING

WARNING
When loading the machine, park the trailer on a flat firm road-
bed. Keep a fairly long distance between the road shoulder
and the machine.

After loading to the specified position, secure the machine as fol-

lows.

1. Fully extend the bucket and arm cylinders, then slowly lower
the boom.

2. Stop the engine and remove the key from the starting switch.

AM091070A

3. Lock all the control levers securely with the safety lock lever.

AM088930A

4. When transporting the machine, place rectangular timber

underneath the front and rear track shoes to prevent the
machine from moving about. Also, hold it down with chains or
rope. Be particularly careful to ensure that the machine does
not slip sideways.

NOTICE
When transporting the machine, place rectangular timber
under one end of the bucket cylinder to prevent it touching
AM091080A
the ground, thereby saving it from possible damage.

PRECAUTIONS FOR TRANSPORTATION

WARNING
● Determine the route for transporting the machine by tak-
ing into account the width, height and weight of the
machine.

● Always check that the door on the cab is closed and

locked before transporting the machine.

139
TRANSPORTATION OPERATION

NOTICE
Always retract the car radio antenna.

Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.

METHOD OF LIFTING MACHINE

How to lift a machine

Personnel who perform lifting using a crane must be qualified.

CAUTION
Contact your distributor to get an instruction of lifting a
machine. Some parts are required and available as optional
parts.

WARNING
● Do not lift a machine with personnel in it.

● The rope used for lifting must have sufficient strength to

withstand the weight of this machine.

● The machine must not be in a position other than that

shown in the following procedure when lifting a vehicle.
Otherwise there is danger that the machine may lose its
balance.

● Never lift the machine with the upperstructure swing to

the side.

● When lifting, be careful of the center of gravity and be

sure to maintain the balance.

NOTICE
The lifting procedure given below applies to machines with
standard specifications.
The method of lifting differs according to the attachments
and options actually installed. In such cases, please contact
your Komatsu distributor.

For details of the weight, see “SPECIFICATIONS” on

page 233.

140
OPERATION TRANSPORTATION

Before lifting the machine, place the machine on a flat hori-

zontal surface and follow the procedure shown below.

1. Set the machine to the position shown in the figure on the

right by fully extending all cylinders (Boom at its highest point,
arm and bucket fully retracted). Direct the top revolving
super-structure straight forward (idler side)

2. Set the safety lock lever in the lock position.

Lifting points
3. Switch the engine off and confirm any loose objects are
placed in the storage compartment behind the operator’s
seat. Get off the machine, make sure the cab door, windshield Sprocket
all doors and engine hood is closed and securely locked.

4. Mount a shackles the the lifting hooks on the boom and the
counter weight. Hang the wire rope.

5. The length of the wire rope and the lifting angle must be as
shown in the figure at the right.

6. When lifting, make sure that there is no change in position

due to posible leakage in the hydraulic circuit on the boom 1.1 m or more
cylinder head side. 3 m or more

33° or less
7. When the machine leaves the ground, stop the machine and
make sure sufficiently that the machine is balanced, then lift 20° or less
the machine slowly.

141
COLD WEATHER OPERATION OPERATION

COLD WEATHER OPERATION

PRECAUTIONS FOR LOW TEMPERATURE

If the temperature becomes low, it becomes difficult to start the
engine, and the coolant may freeze, so do as follows.

FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components.

For details of the specified viscosity, see “USE OF FUEL,

COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURE” on page 181.

COOLANT

WARNING
Keep antifreeze fluid away from an open flame. Never smoke
when using antifreeze.

NOTICE
● Never use methanol, ethanol or propanol based anti-
freeze.

● Absolutely avoid using any water leak preventing agent

irrespective of whether it is used independently or mixed
with an antifreeze.

● Do not mix one antifreeze with a different brand.

For antifreeze mixture requirements, see “USE OF FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURE” on page 181.

Use a Permanent Antifreeze (ethylene glycol mixed with corro-

sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available anti-
freeze 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
Where no permanent antifreeze is available, an ethylene gly-
col antifreeze without corrosion inhibitor may be used only for the
cold season. In this case, clean the cooling system twice a year
(in spring and autumn). When refilling the cooling system, add
antifreeze in autumn, but do not add any in spring.

142
OPERATION COLD WEATHER OPERATION

BATTERY

WARNING
● To avoid gas explosions, do not bring fire or sparks near
the battery.

● Battery electrolyte is dangerous. If it gets in your eyes or

on your skin, wash it off with large amounts of water, and
consult a doctor.

When the ambient temperature drops, the capacity of the battery

will also drop. If the battery charge ratio is low, the battery electro-
lyte may freeze. Maintain the battery charge as close as possible
to 100%, and insulate it against cold temperature so that the
machine can be started easily the next morning.

REMARK
Measure the specific gravity and calculate the rate of charge
from the following conversion table.

Temp. of fluid
20°C 0°C -10°C -20°C
Rate of
charge

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

PRECAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and
making it impossible for the machine to move the following morn-
ing, always observe the following precautions.

● Mud and water on the machine body should be completely

removed. This is to prevent damage to the seal caused by
mud or dirt getting inside the seal with frozen drops of water.

● Park the machine on hard, dry ground. If this is impossible,

park the machine on wooden boards. The boards help protect
the tracks from being frozen in soil and the machine can start
next morning.

● Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing.

● As the battery capacity drops markedly in low temperatures,

cover the battery or remove it from the machine, keep it in a
warm place, and install it again the next morning.

143
COLD WEATHER OPERATION OPERATION

● If electrolyte level is found low, add distilled water in the morn-

ing before beginning work. Do not add the water after the
day’s work so as to prevent fluid in the battery from freezing in
the night.

AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as

follows.

● Replace the fuel and oil for all parts with oil of the viscosity
specified.

For details, see “USE OF FUEL, COOLANT AND LUBRI-

CANTS ACCORDING TO AMBIENT TEMPERATURE” on
page 181.

● If for any reason permanent antifreeze cannot be used, and

an ethyl glycol base antifreeze (winter, one season type) is
used instead, or if no antifreeze is used, drain the cooling sys-
tem completely, then clean out the inside of the cooling sys-
tem thoroughly, and fill with fresh water.

144
OPERATION LONG-TERM STORAGE

LONG-TERM STORAGE

BEFORE STORAGE

NOTICE
To protect the cylinder rod when the machine is not being
used, set the work equipment in the posture shown in the
diagram.(This prevents rusting of the cylinder rod)

When putting the machine in storage for a long time, do as fol-

lows.

● After every part is washed and dried, the machine shall be

housed in a dry building. Never leave it outdoors. In case it is
indispensable to leave it outdoors, park the machine on the
well-drained concrete and cover it with canvas etc.

● Completely fill the fuel tank, lubricate and change the oil AM091090A
before storage.

● Apply a thin coat of grease to metal surface of the hydraulic

piston rods.

● Disconnect the negative terminals of the battery and cover it,

or remove it from the machine and store it separately.

● If the ambient temperature is expected to drop below 0oC,

always add antifreeze to the cooling water.

● 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 to the “When not use” position on

machines ready for attachments.

DURING STORAGE

WARNING
If it is unavoidably necessary to carry out the rustpreventive
operation while the machine is indoors, open the doors and
windows to improve ventilation and prevent gas poisoning.

Operate the engine and move the machine for a short distance
once a month so that a new film of oil will be coated over movable
parts and component surfaces. At the same time, also charge the
battery.

Also carry out cooler operation in the case of machines equipped

with an air conditioner.

145
LONG-TERM STORAGE OPERATION

AFTER STORAGE
If the machine is stored without carrying out the monthly rust pre-
vention operation, request your Komatsu distributor for service.

Carry out the following procedure when taking the machine out of
long-term storage.

● Wipe off the grease from the hydraulic cylinder rods.

● Add oil and grease to all places.

STARTING MACHINE AFTER LONG-TERM STORAGE

When starting the machine after a long-term storage, first cancel
the automatic warming-up function as follows.

1. Turn the starting switch key to the ON position.

2. Turn the fuel control dial from the low idling (MIN) position to
the full (MAX) position, hold it there for 3 seconds, then return
it to the low idling (MIN) position and start the engine.

146
OPERATION TROUBLESHOOTING

TROUBLESHOOTING

PHENOMENA THAT ARE NOT FAILURES

Note that the following phenomena are not failures:

1. When the arm is pulled in, the speed of movement will drop
momentarily when the arm is more or less vertical.

2. The arm speed will drop momentarily when the bucket teeth
are more or less horizontal.

3. When starting or stopping the swing, noise will be emitted

from the brake valve.

4. When going down a steep slope at low speed, a noise will be

emitted from the travel motor.

METHOD OF TOWING MACHINE

WARNING
When towing the machine, use a wire rope that has ample
strength for the weight of the machine that is being towed.

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 pre-
vent damage to ropes and body. At this time, never use the tow-
ing hole which is intended only for light-weight towing.

147
TROUBLESHOOTING OPERATION

USING METHOD FOR LIGHT-WEIGHT 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.

The track frame has been equipped with a towing hole to pass the
shackle through for towing light objects.
AM091130A
In this case, the traction load must be 130 KN or less.

PRECAUTIONS ON PARTICULAR JOBSITES

1. When carrying out digging operations in water, if the work
equipment mounting pin goes into the water, carry out greas-
ing every time the operation is carried out.

2. For heavy-duty operations and deep digging, carry out greas-

ing of the work equipment mounting pins every time before
operation.

After greasing, operate the boom, arm and bucket several times,
then grease again.

148
OPERATION TROUBLESHOOTING

IF BATTERY IS DISCHARGED

WARNING
● When checking or handling the battery, stop the engine
and turn the starting switch key to the OFF position
before starting.

● The battery generates hydrogen gas, so there is danger

of explosion. Do not bring lighted cigarettes near the bat-
tery, or do anything that will cause sparks. When removing
disconnect the
● Battery electrolyte is dilute sulphuric acid, and it will cable from the
attack your clothes and skin. If it gets on your clothes or ground terminal
first
on your skin, wash it off immediately with large amounts
of water. If it gets in your eyes, wash it out with fresh
water, and consult a doctor.

● When handling battery, always wear protective goggles.

● When removing the battery, first disconnect the cable

from the ground (normally, from the negative - terminal).
When installing,
When installing, install the positive + terminal first. If a
connect the cable to
tool touches the cable connecting the positive terminal the positive (+)
and the chassis, there is danger that it will cause sparks. terminal first.
● If the terminals are loose, there is danger that the defec-
tive contact may generate sparks that will cause an
explosion. When installing the terminals, install them
tightly.

● When removing or installing, check which is the positive

AD052940A
+ terminal and negative - terminal.

149
TROUBLESHOOTING OPERATION

STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:

INCORRECT
Precautions when connecting and disconnecting booster
cable

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 hydro-
gen gas given off by the battery. If hydrogen gas
explodes, it could cause serious injury.

● Make sure that there is no mistake in the booster cable

connections. The final connection is to the revolving
frame, but sparks will be generated when this is done, so
connect to a place as far as possible from the battery.
(However, avoid connecting the cable to the work equip-
ment, as conduction is poor.)

● Use care when removing the cables from the machine

that has been started. Do not allow the cable ends to con-
tact each other or the machine, to avoid hydrogen explo-
sion.

NOTICE
● The size of the booster cable and clip should be suitable
for the battery size.

● The battery of the normal machine must be the same

capacity as that of the engine to be started.

● Check the cables and clips for damage or corrosion.

● Make sure that the cables and clips are firmly connected.

Connecting the booster cables

Keep the starting switch at the OFF position.

Connect the booster cable as follows, in the order of the numbers
marked in the diagram.

1. Make sure that the starting switches of the normal machine

and problem machine are both at the OFF position.

2. Connect one clip of booster cable (A) to the positive + termi-

nal of the problem machine.

3. Connect the other clip of booster cable (A) to the positive +

AD052980A
terminal of the normal machine.

150
OPERATION TROUBLESHOOTING

4. Connect one clip of booster cable (B) to the negative - termi-

nal of the normal machine.

5. Connect the other clip of booster cable (B) to the engine block
of the problem machine.

Starting the engine

1. Make sure the clips are firmly connected to the battery termi-
nals.

2. Start the engine of the normal machine and keep it to run at

high idling speed.

3. Turn the starting switch of the problem machine to the START

position and start the engine. If the engine doesn’t start at
first, try again after 2 minutes or so.

Disconnecting the booster cables

After the engine has started, disconnect the booster cables in the
reverse of the order in which they were connected.

1. Remove one clip of booster cable (B) from the engine block of
the problem machine.

2. Remove the other clip of booster cable (B) from the negative
terminal of the normal machine.

3. Remove one clip of booster cable (A) from the positive + ter-
minal of the normal machine.

4. Remove the other clip of booster cable (A) from the positive + AD052981A
terminal of the problem machine.

151
TROUBLESHOOTING OPERATION

OTHER TROUBLE

ELECTRICAL SYSTEM

● ( ): Always contact your Komatsu distributor when dealing

with these items.

● In cases of abnormalities or causes which are not listed

below, please contact your Komatsu distributor for repairs.

Problem Main causes Remedy

Lamp does not glow brightly even (● Check, repair loose termi-
● Defective wiring
when the engine runs at high speed nals,disconnections)
● Adjust V belt tension For details,
● Defective adjustment of fan belt
Lamp flickers while engine is running see “EVERY 250 HOURS SER-
tension
VICE” on page 214.

Charge level monitor does not go out ● Defective alternator (● Replace)

even when engine is running ● Defective wiring (● Check, repair)

Abnormal noise is generated from

● Defective alternator (● Replace)
alternator

● Defective wiring (● Check, repair)

Starting motor does not turn when
● Insufficient battery charge ● Charge
starting switch is turned to ON
● Defective starting motor (● Replace)

Pinion of starting motor keeps going in ● Insufficient battery charge ● Charge

and out ● Defective safety relay (● Replace)

● Insufficient battery charge ● Charge

Starting motor turns engine sluggishly
● Defective starting motor (● Replace)

Starting motor disengages before ● Defective wiring (● Check, repair)

engine starts ● Insufficient battery charge ● Charge

● Defective wiring ● Charge

Pre-heating monitor does not light ● Defective heater relay (●Replace)
● Defective monitor (● Replace)

Oil pressure monitor does not light up

● Defective monitor (● Replace)
when engine is stopped
● Defective caution lamp switch (● Replace)
(starting switch at ON position)

● Defective wiring (● Check, repair)

Outside of electrical heater is not
● Disconnection in electric heater (●Replace)
warm when touched by hand.
● Defective operation of heater switch (●Replace)

152
OPERATION TROUBLESHOOTING

CHASSIS

● ( ): Always contact your Komatsu distributor when dealing

with these items.

● In cases of abnormalities or causes which are not listed

below, please contact your Komatsu distributor for repairs.

Problem Main causes Remedy

● Add oil to specified level, see

Speed of travel, swing, boom, arm,
● Lack of hydraulic oil “CHECK BEFORE STARTING” on
bucket is slow
page 206.

● Clogged element in hydraulic tank ● Clean, see “EVERY 2000 HOURS

Pump generates abnormal noise
strainer SERVICE” on page 227.

● Loose fan belt ● Check fan belt tension, see EVERY

250 HOURS SERVICE
● Dirty oil cooler ● Clean, see “EVERY 500 HOURS
Excessive rise in hydraulic oil tempera-
SERVICE” on page 218.
ture
● Lack of hydraulic oil ● Add oil to specified level, see
“CHECK BEFORE STARTING” on
page 206.

Track comes off ● Adjust track tension, see “WHEN

● Track too loose
Abnormal wear of sprocket REQUIRED” on page 194.

● Add oil to specified level, see

Bucket rises slowly, does not rise ● Lack of hydraulic oil “CHECK BEFORE STARTING” on
page 206.

153
TROUBLESHOOTING OPERATION

ENGINE

● ( ): Always contact your Komatsu distributor when dealing

with these items.

● In cases of abnormalities or causes which are not listed

below, please contact your Komatsu distributor for repairs.

Problem Main causes Remedy

● Engine oil pan oil level is low (suck- ● Add oil to specified level, see
ing in air) “CHECK BEFORE STARTING” on
page 206.
● Clogged oil filter cartridge ● Replace cartridge, see "EVERY 500
Engine oil pressure monitor HOURS SERVICE"
lights up (●Check, repair)
● Defective tightening of oil pipe joint,
oil leakage from damaged part
● Defective engine oil pressure sen- (●Replace sensor)
sor

● Add cooling water, repair, "CHECK

● Cooling water level low, water leak-
BEFORE STARTING"
age
● Check fan belt tension, see
● Loosen fan belt
Steam is emitted from top part of radia- "CHECK BEFORE STARTING"
tor (pressure valve) ● Change cooling water, clean inside
● Dirt or scale accumulated in cooling
of cooling system, see "WHEN
system
REQUIRED"

● Clean or repair, see "EVERY 500

● Clogged radiator fin or damaged fin
HOURS SERVICE"
● Defective thermostat
(●Replace thermostat)
Radiator water level monitor lights up ● Loose radiator filler cap (high alti-
● Tighten cap or replace packing
tude operation)
● Defective water level sensor
(●Replace sensor)

● Lack of fuel
● Add fuel, see "CHECK BEFORE
● Air in fuel system STARTING"
● Repair place where air is sucked in,
see "EVERY 500 HOURS SER-
VICE"
(●Replace pump or nozzle)
● Defective fuel injection pump or
nozzle
Engine does not start when
● Starting motor cranks engine slug- see "ELECTRICAL SYSTEM"
starting motor is turned
gishly
● Preheating monitor does not light
up
● Defective compression ● (Adjust valve clearance)
● Defective valve clearance ● Drain & clean fuel system
● Contaminated fuel ● Check/replace pump
● Lift pump not working ● change filters
● fuel filter clogged ● check/ blow out lines
● fuel lines blocked

154
OPERATION TROUBLESHOOTING

ENGINE (cont’d)

Problem Main causes Remedy

● Too much oil in oil pan ● Add oil to specified level, see
Exhaust gas is white or blue "CHECK BEFORE STARTING"
● Improper fuel ● Change to specified fuel

● Clogged air cleaner element

● Clean or replace,
● Defective nozzle (●Replace nozzle)
Exhaust gas occasionally turns
● Defective compression (●See defective compression
black
above)
● Defective turbocharger ● Clean or replace turbocharger

Combustion noise occasionally

● Defective nozzle (●Replace nozzle)
makes breathing sound
● Change to specified fuel
● Low grade fuel being used
● Refer to "Radiator water level
Abnormal noise generated ● Overheating
monitor lights up" as above
(combustion or mechanical) ● Damage inside muffler
(●Replace muffler)
● Excessive valve clearance
(●Adjust valve clearance)

155
TROUBLESHOOTING OPERATION

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 monitor failure display

Monitor display Failure mode Remedy

If the pump override switch is set to the ON position, opera-

PC-EPC valve system
E02 tion can be carried out, however, have the PC-EPC valve
error
system inspected by your Komatsu distributor. (✽)

Set the swing override switch to the On position to release

Swing brake system the brake. If applying swing brake, manually operate swing
E03
error lock switch. In this case, have the swing brake system
inspection immediately by your Komatsu distributor. (✽)

The governor cannot carry out control. Operate the gover-

nor lever manually. To secure at the full position, there is a
E05 Governor system error mounting hole for the lock bolts in the bracket. In this case,
carry out inspection immediately by your Komatsu distribu-
tor.

Operation cannot be Place the machine to a safe posture, and carry out inspec-
CALL
continued tion immediately by your Komatsu distributor.

IN case where the monitor will not display no

Carry out inspection immediately.
error code and work equipment or swing opera-
tion cannot be carried out.

(✽) For detail of operating the pump override switch and

the swing override switch, see “SWITCHES” on page 70.

156
OPERATION OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6

OPERATION INSTRUCTIONS FOR HIGH REACH WORK

EQUIPMENT FOR PC240-6
This section covers only the operation of the HIGH
REACH WORK EQUIPMENT derivative of the PC240
excavator.

PRECAUTIONS WHEN OPERATING

● The high reach demolition machine should be operated only
by an experienced operator.

● Before operating the high reach demolition machine, make

sure that the operator has read all the relevant manuals and
is completely familiar with the controls and limits of the
machine.

● Make sure that the operator reviews and reads the relevant
manuals from time to time to ensure continuing familiarity with
the machine.

● Check that the ground inside the operating range is flat and
firm.

● Never operate the boom outside the specified working range.

There is danger that the machine may overturn.
As far as possible, always carry out operations to the front or
rear of the tracks; do not carry out work to the left or right of
the tracks.

Max. working radius to front and rear: 8.17 m

WARNING
If work is carried out outside the specified operating range
(to the front or rear of the track), the warning buzzer (continu-
ous sound) will sound. If this happens, return the boom to a
safe working range.

157
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 OPERATION

PROHIBITON OF WORK IN THE OVER SIDES

DIRECTION

● Do not work in the over sides direction, since the machine

becomes unstable and may fall over.

PROHIBITON OF WORK OUTSIDE THE WORKING

RANGE OF THE MACHINE

● Never work outside the specified working range. If you do, the Maximum
Working
machine may fall over. Range

WARNING
To ensure long life of the work equipment, and to carry out
work safely, avoid the following kinds of operation.

● Do not travel at high speed on rough ground.

INCORRECT

● Do not operate the control levers suddenly.

INCORRECT

158
OPERATION OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6

● Do not or stop the swing suddenly.

INCORRECT

● Do not use hitting force for demolition work.

INCORRECT

● Do not use the swing force for hitting operations.

INCORRECT

● Do not use the dropping force of the machine for operations.

INCORRECT

159
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 OPERATION

● Do not use the travel force of the machine for operations.

INCORRECT

● Do not use the jaw on one side only.

INCORRECT

● Do not grip and crush at one blow.

INCORRECT

● Do not pick up objects and raise or lower them.

INCORRECT

160
OPERATION OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6

PROHIBITION OF WORK AT THE STROKE END OF

A CYLINDER

If the machine is operated with the bucket cylinder at the extract-

ing end, piston (1) strikes cylinder head (2). As a result, cylinder
head mounting bolt (3) may become loose and the cylinder piston
may come out at last.

Confirmation and inspection before and after work.

Check the bolts of the bucket cylinder head for looseness. If any Matching of piston
bolts loosened, tighten them to the specified torque. If any bolts and cylinder head
have been removed, notify your Komatsu distributors.

Cylinder stroke end

PROHIBITION OF WORK WITH HYDRAULIC

BREAKER

Do not install a hydraulic breaker to the long demolition arm for

breaking work. If you do, the work equipment will be damaged.

Do not use the attachment with the cylinder extended or retracted

all the way to its stroke end.
INCORRECT
Leave some allowance at the stroke end when extending or
retracting the cylinder.

161
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 OPERATION

WARNING
If there is external force bearing on the attachment (when hit-
ting against an object), the cylinder may come out and break,
so be extremely careful when operating.

When gripping objects, do not use cylinder to shake them.

Do not pull in the crusher with the arm pulled in.

The crusher will contact the boom and this may result in damage
to the machine.

162
OPERATION OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6

CHECK BEFORE STARTING

Always carry out the following inspection and maintenance before
starting work each day.

● Greasing

Supply grease to the greasing points shown in the diagram below.

Straight Boom machine

High Reach machine

1. Boom cylinder bottom pins and

2. Boom cylinder top pins 3. Arm cylinder bottom pin
boom foot pin

4. Bucket cylinder bottom pin 5. Arm cylinder top pin 6. Bucket cylinder bottom pin

7. Bucket cylinder top pin 8. Bucket links 9. Bucket pivot pins

● Check for cracks, furrows in the base metal.

163
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 OPERATION

OPERATION

Attachment control

1. Control pedal for attachment open/close 2. Left pedal control (crusher rotation)

WARNING
● If any lever is operated when in the deceleration range,
the engine speed will suddenly increase, so be careful
when operating the levers.

● Do not put your foot on the pedal when operating it. If

you rest your foot on the pedal during operations, and
you depress the pedal by mistake, the attachment may
move suddenly and cause serious damage or injury.

The crusher is operated by the right pedal, the left pedal controls
the attachment rotation. The operation of the controls and move- The direction of rotation
ment of the machine are as shown in the diagram below. depends on the crusher

● Operation to rotate crusher.

Left pedal

● Operation to open or close crusher

Right pedal

Open
Close

164
OPERATION OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6

RAISING WORK EQUIPMENT

Operate the work equipment slowly. In particular, operate the
work equipment as slowly as possible during lowering operations.

The boom and arm are operated in the same way as the standard
machine.

WORKING RANGE AND USING RANGE OF BOOM

WARNING
● Make sure, when operating the machine, that the work
equipment does not move outside the acceptable operat-
ing range.

● Always operate in the front-rear direction of the track-

frame, never over the side.

Green Range

Red Range

Boom working
inclination area
gauge

1. Use the boom between the angles of 79o and 90o. The maxi-
mum working radius is 8.17m (at the tip of the arm).

2. When raising and lowering the crusher, do not allow it to go

beyond the maximum horizontal reach.

3. Use the angle indicator on the boom to ensure that the

crusher remains in the correct range at all times.

165
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 OPERATION

WORKING RANGE AND RANGE OF USE OF BOOM

WARNING
Carry out operations at the front or rear of the track.
Do not carry out operations at the left or right side so that the
machine does not lose balance.

Always use the boom within the specified range. If the boom goes
below the minimum operating boom angle, the alarm buzzer will
sound. If the alarm buzzer sounds, return the boom to a position
where the buzzer stops.

If the alarm buzzer does not sound when the boom is below the
specified angle (inclination gauge in red range), adjust as follows.

Boom

Proximity
switch

Red range Green range

Proximity Clearance
switch

Plate

Plate

1. Loosen bolt (A) and adjust so that clearance between the

proximity switch and plate (1) is 5 - 8 mm.

2. Raise the boom to the maximum height, then gradually lower

it and stop the boom at the position where the indicator of the
inclination gauge is on line (P) between the green range and
red range.

3. Loosen bolt (B) and move plate (2) to the left or right to fix
dimension (L) so that the buzzer sounds at this position.

166
OPERATION OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6

REMARK
Set clearance so that there is no contact even when the boom
is moved.

WARNING
This adjustment should only be performed by Komatsu Certi-
fied Mechanics. Failure to adjust properly may result in an
unsafe operating condition.

TRANSPORTATION (HIGH REACH DEMOLITION)

Dimension Label PC240 High Reach

Overall Length (mm) A 12830

Boom height (mm) B 2950

Cab height (with FOPS) (mm) C 3240

Cab height (without FOPS) (mm) C 2905

Distance from centre to counterweight (mm) D 2850

Maximum tool weight (kg) 2450

Operating weight (700 mm shoes) (kg) 26940

Operating weight (800 mm shoes) (kg) 27240

Operating weight (900 mm shoes) (kg) 27250

When transporting the high reach demolition machine, make sure

that you comply with all relevant national standards for road trans-
port, including weights and dimensions.

167
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6 OPERATION

168
 MAINTENANCE

WARNING
Before carrying out maintenance, always attach the
WARNING TAG to the control lever in the operator’s cab.

169
GUIDES TO MAINTENANCE MAINTENANCE

GUIDES TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is
not given in this manual.
Perform maintenance work on hard, flat ground.

Check service meter:

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

Komatsu genuine replacement parts:

Use Komatsu genuine parts specified in the Parts Book as

replacement parts.

Komatsu genuine oils:

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

Always use clean washer fluid:

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

Always use clean oil and grease:

Use clean oil and grease. Also, keep containers of the oil and
grease clean. Keep foreign materials away from oil and grease.

Keeping the machine clean:

Always keep the machine clean. This makes is easier to find parts
causing problems. Keep in particular grease fittings, breathers
and oil level gauges clean and avoid foreign matters from getting
in them.

Be careful of hot water and oil:

Draining hot oils and coolants and removing their filters immedi-
ately after the engine stops are hazardous. Allow the engine to
cool.

If the oil has to be drained when it is cold, warm up the oil to a

suitable temperature (approx. 20 - 40°C) before draining it.

Checking foreign materials in drained oil and on filter:

After oil is changed or filters are replaced, check the oil and filters
for metallic particles and foreign materials. If large quantities of
metallic particles or foreign materials are found, contact your
Komatsu distributor.

170
MAINTENANCE GUIDES TO MAINTENANCE

Fuel strainer:

If your machine is equipped with a fuel strainer, do not remove it

while fueling.

Oil change:

Check or change oils in the places where dust is scarce to keep

foreign materials away from oils.

Warning tag:

Attach the warning tag to the starting switch or other appropriate

control lever to avoid someone who is not aware of the circum-
stances from starting the engine.

Obey precautions:

During the operation, always obey the precautions on the safety

label attached to the machine.

Welding instructions:

● Turn off the engine starting switch.

● Do not apply more than 200 V continuously.

● Connect grounding the cable within 1 m from the area to be

welded.

● Avoid seals or bearings from being between the area to be

welded and the position of grounding point.

● Do not use the area around the work equipment pins or the
hydraulic cylinders as the grounding point.

Fire prevention:

Use nonflammable cleaner or light oil for cleaning parts. Keep

flame or cigarette light away from light oil.

Clamp faces:

When O-rings or gaskets are removed, clean the clamp faces and
replace the O-rings and gaskets with new ones. Be sure to fit O-
rings and gaskets when assembling.

Objects in your pockets:

Keep your pockets free of loose objects which can fall out and
drop into the machinery; especially when you work on the
machinery while bending over it.

Checking undercarriage:

When working in rocky areas, check for damage to the undercar-

riage and for looseness, flaws, wear and damage in bolts and
nuts. Loosen the track tension a little when working in such areas.

171
GUIDES TO MAINTENANCE MAINTENANCE

Precautions when washing machine:

● Never spray steam or water directly on the connectors and

mechatronics parts.

● Do not allow water to get on the monitors and controllers

inside the operator’s cab.

● Never spray steam or water directly at the radiator or oil

cooler portions.

Pre-and post-work checks:

Before starting work in mud, rain, snow or at seashore, check

plugs and valves for tightness.

Wash the machine immediately after the work to protect compo-

nents from rusting.

Lubricate components more frequently than usual. Be sure to

lubricate work equipment pins daily if they are submerged in
water.

Dusty worksites:

When working at dusty worksites, do as follows:

● Inspect the air cleaner clogging monitor to see whether the air
cleaner is blocked up.

● 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.

Avoid mixing oils:

Never mix oils of different brands. If you have only oil which is a
different brand from the one that is used in the machine, do not
add it but replace all the oil.

172
MAINTENANCE OUTLINES OF SERVICE

OUTLINES OF SERVICE
● Use Komatsu genuine parts for replacement.

● When changing or adding oil, do not use a different type of oil.

● Unless otherwise specified, the oil and coolant used at the

time of shipment from the factory are as shown in the table
below.

Item Kind of fluid

SAE 10W-30
Engine oil pan
API classification CE or CF-4

Swing machinery case

SAE 30
Final drive case
API classification CD
Damper case

SAE 10W
Hydraulic tank
API classification CD

ASTM D975 No. 2

(However, ASTM D975 No. 1 is
Fuel tank
used for the winter season (Octo-
ber to March)

Komatsu Super Coolant

Radiator
(AF-ACL) 50% added to water

OUTLINE OF OIL, FUEL, COOLANT

OIL

● Oil is used in the engine and work equipment under extremely

severe conditions (high temperature, high pressure), and it
deteriorates with use.
Always use oil that matches the grade and temperature for
use given in the Operation and Maintenenance Manual. Even
if the oil is not dirty, always replace the oil after the specified
interval.

NOTICE
When using biodegradable oil, preferably use synthetic
esters (Hees type).
For this type of oil the maximum hydraulic oil interval is at
2500 hours.
Please contact your Komatsu dealer for more information.

● Oil corresponds to blood in the human body, so always be

careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the
entry of such impurities.
Take particular care not to let any impurities get in when stor-
ing or adding oil.

173
OUTLINES OF SERVICE MAINTENANCE

● 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 prob-
lems.

● If the oil in the work equipment is not clear, there is probably

water or air getting into the circuit. In such cases, please con-
tact your Komatsu distributor.

● When changing the oil, always replace the related filters at

the same time.

● We recommend you to have an analysis made of the oil peri-

odically to check the condition of the machine. For those who
wish to use this service, please contact your Komatsu distrib-
utor.

FUEL

● The fuel pump is a precision instrument, and if fuel containing

water or dirt is used, it is causes of problems.

● Be extremely careful not to let impurities get in when storing

or adding fuel.

● Always use the fuel specified in the Operation and Mainte-

nance Manual.
Fuel may congeal depending on the temperature when it is
used (particularly in low temperature below-15°C), so it is
necessary to change to a fuel that matches the temperature.

● To prevent the moisture in the air from condensing and form-

ing 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, it is necessary to bleed the air

from the circuit.

COOLANT

● River water contains large amounts of calcium and other

impurities, so if it is used, scale will stick to the engine and
radiator, and this will cause defective heat exchange and
overheating.
Do not use water that is not suitable for drinking.

● When using anti-freeze, always observe the precautions

given in the Operation and Maintenance Manual.

174
MAINTENANCE OUTLINES OF SERVICE

● Komatsu machines are supplied with Komatsu original anti-

freeze in the coolant when the machine is shipped.
This anti-freeze is effective in preventing corrosion of the
cooling system.
The anti-freeze can be used continuously for two years or
4000 hours. Therefore, it can be used as it is even in hot
areas.

● Anti-freeze is inflammable, so be extremely careful not to

expose it to flame or fire.

● The proportion of anti-freeze to water differs according to the

ambient temperature.

For details of the mixing proportions, see “CLEAN

INSIDE OF COOLING SYSTEM” on page 196.

● If the engine overheats, wait for the engine to cool before

adding coolant.

● If the coolant level is low, it will cause overheating and will

also cause problems with corrosion from the air in the cool-
ant.

GREASE

● Grease is used to prevent twisting and noise at the joints.

● The nipples not included in the maintenance section are nip-

ples for overhaul, so they do not need grease.
If any part becomes stiff after being used for long time, add
grease.

● 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.

STORING OIL AND FUEL

● Keep indoors to prevent any water, dirt, or other impurities

from getting in.

● When keeping drum cans for a long period, put the drum on
its side so that the filler port of the drum can is at the side. (To
prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a
waterproof sheet or take other measures to protect them.

● To prevent any change in quality during long-term storage, be

sure to use in the order of first in - first out (use the oldest oil
or fuel first).

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

175
OUTLINES OF SERVICE MAINTENANCE

and Maintenance Manual.

However, when working in severe conditions, it is necessary
to consider replacing 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

stuck to the old filter. If any metal particles are found, please
contact your Komatsu distributor.

● Do not open packs of spare filters until just before they are to
be used.

● Always use Komatsu genuine filters.

EXPLANATION OF LUBRICATION CHART DECAL

Interval of service Change filter

Lubrication by greasing (G) Amount of oil required at change (liters)

Check oil level/change (EO)

176
MAINTENANCE OUTLINES OF SERVICE

Key to lubrication points

Item Part Action refer to page

Check level 207

1 Engine oil
Change oil 220

Check level 208

2 Hydraulic oil
Change oil 229

Check level 213

3 Swing machinery oil
Change oil 224

4 Boom cylinder foot pin Grease 211

5 Boom foot pin Grease 212

6 Boom cylinder rod end pin Grease 212

7 Arm cylinder foot pin Grease 212

8 Boom arm coupling pin Grease 212

9 Arm cilinder rod end Grease 212

10 Bucket cylinder foot pin Grease 212

11 Bucket cylinder rod end Grease 212

12 Bucket-link coupling pin Grease 212

13 Arm-bucket coupling pin Grease 212

14 Arm link coupling pin Grease 212

15 Link coupling pin Grease 211

Check level 214

16 Final drive oil
Change oil 227

Engine oil filter & fuel water

17 Change filter 218
seperator

18 Hydraulic filter element Change filter 222

19 Swing circle Lubricate 216

20 Engine oil filter Change filter 220

21 Swing pinion Lubricate 220

22 Damper case Check level 225

177
OUTLINES OF SERVICE MAINTENANCE

OUTLINE OF ELECTRICAL SYSTEM

● If the wiring gets wet or the insulation is damaged, the electric
system leaks and this could result in hazardous malfunction
of the machine.

● Services relating to the electric system are (1) check of fan

blet tension, (2) check of damage or wear in the fan belt and
(3) check of battery fluid level.

● Never remove or disassemble any electric components

installed in the machine.

● Never install any electric components other than these speci-

fied by Komatsu.

● Be careful to keep the electric system free of water when

washing the machine or when it rains.

● Since the controller for the control system may cause mal-
function due to external wave interference, before installing a
radio receiver and a walkie-talkie or citizen band, consult your
Komatsu distributor.

● When working on the seashore, carefully clean the electric

system to prevent corrosion.

● When installing a car cooler or any other electrical equipment,

connect it to an independent power source connector. The
optional power source must never be connected to the fuse,
starting switch, or battery relay.

OUTLINE OF HYDRAULIC SYSTEM

● During operation and immediately after operation is ended,
the temperature of the hydraulic system still remains high.
In addition, high hydraulic pressure is applied to the system.
Take care when inspecting and maintaining the hydraulic sys-
tem.

❍ Stop the machine on level ground, lower the bucket to the

ground, then set so that there is no pressure applied to
the cylinder circuit.

❍ Always stop the engine.

❍ Immediately after operations, the hydraulic oil and lubri-

cating oil are at high temperature and high pressure, so
wait for the oil temperature to go down before starting
maintenance.
Even when the temperature goes down, the circuit may
still be under internal pressure, so when loosening the
plug or screw, or the hose joint, do not stand in front of
the part. Loosen it slowly to release the internal pressure
before removing it.

❍ When carrying out inspection or maintenance of the

hydraulic circuit, always bleed the air form the hydraulic
tank to remove the internal pressure.

178
MAINTENANCE OUTLINES OF SERVICE

● Periodic maintenance includes the inspection of the hydraulic

oil level, replacement of the filter and refilling of hydraulic oil.

● When the high pressure hose, etc. is removed, check the O-

ring for damage. If necessary, replace it.

● After the hydraulic filter element and strainer are cleaned or

replaced, or after the hydraulic system is repaired or replaced
or the hydraulic piping is removed, bleed air from the hydrau-
lic circuit.

The accumulator is charged with high-pressure nitrogen gas.

Incorrect handling may be dangerous.

For the handling procedure, see “HANDLING THE ACCU-

MULATOR” on page 94.

179
WEAR PARTS LIST MAINTENANCE

WEAR PARTS LIST

Wear parts such as the filter element, bucket tooth, etc., are to be
replaced at the time of periodic maintenance or before their abra-
sion limits.
The wear parts should be changed correctly in order to use the
machine economically.
For part change, Komatsu genuine parts should be used.
When ordering parts, please check the part number in the parts
book.

The parts in parentheses are to be replaced at the same time.

Item Part No. Part Name Q’ty Replacement frequency

07063-51210 Element 1
Hydraulic oil filter Every 500 hours service
(07000-05180) (O-ring) (1)

Engine oil filter 6736-51-5140 Cartridge 1 Every 500 hours service

Primary fuel filter 6732-71-6110 Cartridge 1 Every 500 hours service

Secondary fuel filter 6732-71-6120 Cartridge 1 Every 500 hours service

Hydraulic tank
20Y-60-21470 Cartridge 1 Every 500 hours service
breather

205-01-73570 Outer element 1

Air cleaner -
205-01-K1480 Inner element 1

180
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND

LUBRICANTS

AMBIENT
Capacity
TEMPERATURE °C
RESERVOIR KIND OF FLUID Type of oil
Min Temp Max Temp Specified Refil

0° C 30° C SAE 30
-20° C 10° C SAE 10W 26.3
Engine oil pan 24 liters
-20° C 40° C SAE 10W-30 liters
-15° C 50° C SAE 15W-40

Swing machin- 0° C 50° C SAE 50

6.8 liters 6.8 liters
ery case -20° C 30° C SAE 20
Final drive case 0° C 50° C SAE 50
4.4 liters 4.2 liters
(each) Engine oil -20° C 30° C SAE 30

Damper case -20° C 40° C SAE 30 0.75 liter -

-20° C 40° C SAE 10W

-20° C 40° C SAE 10W-30 (PC210)
Hydraulic sys- -15° C 50° C SAE 15W-40 239 liters
166 liters
tem -25° C 40° C Bio degradable (PC240)
hyd. oil (Hees) 246 liters
ISO 46
ASTM D975 N° 2
- 6° C
Fuel tank Engine oil ASTM N° 1 340 Liters -
-20° C
for winter

(PC210)
22.9 liters
Cooling system Water -30° C Add antifreeze -
(PC240)
23.2 liters

✽ ASTM D975 No. 1

REMARK
When fuel sulphur content is less than 0.5%, change oil in the
oil pan at every periodic maintenance interval given in this man-
ual.
Change oil according to the following table if fuel sulphur content
is above 0.5%.

181
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

Change interval of oil in engine

Fuel sulphur content
oil pan

0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval

● When starting the engine in an atmospheric temperature of

under 0°C, be sure to use engine oil of SAE10W, SAE10W-30
and SAE15W-40, even though atmospheric temperature
goes up to 10°C more or less in the day time.

● Use API classification CE or CF-4 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 multi-

grade oil (SAE10W-30, 15W-40), but be sure to add single
grade oil that matches the temperature in the table.

● We recommend Komatsu genuine oil which has been specifi-

cally formulated and approved for use in engine and hydraulic
work equipment applications. SPECTRUM XXX
KOMATSU GENUINE LUBRICANTS

Specified capacity: Total amount of oil including oil for compo-

nents and oil in piping.

Refill capacity: Amount of oil needed to refill system during nor- TYPE CLASS VISCOSITY REF.NO
mal inspection and maintenance. Engine oil CF - 4 SAE15W - 40 EO - 1540
CF - 4 SAE10W - 30 EO - 1030
TRANSMISSION OIL CD SAE10W TO - 10
ASTM: American Society of Testing and Material & GEAR BOX OIL CD SAE10W STO - 10
HEAVY DUTY
CD SAE30 TO - 30
SAE: Society of Automotive Engineers CD SAE50 TO - 50
HYDRAULIC OIL CD SAE10W HO - 10
API: American Petroleum Institute BIO HYDRAULIC OIL SAE10W BO - 10
GREASE LG - N2
BIO GREASE BIO - R2
If an engine is operated in ambient temperatures consistently ANTI FREEZE AF - 03
BIO ANTI FREEZE BIO - AF - 0
below -23°C and there are no provisions to keep the engine warm
when it is not in operation use a synthetic API performance classi-
fication CE or CF-4 engine oil with adequate low temperature
properties such as SAE SW-20 or 5W-30.

The oil supplier must be responsible for meeting the performatic

service specifications.

NOTICE
The use of a synthetic base oil does not justify extended oil
change intervals. Extended oil chance intervals can
decrease engine life doe to factors such as corrosion depos-
its and wear.

182
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

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 diselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo

Multi-purposegear RYKON premium

3 AMOCO *Amoco 300 -
oil grease

Litholine HEP 2
4 ARCO *Arcofleet S3 plus Arco HD gear oil -
Arco EP moly D

Gear oil EP Energrease LS-

5 BP Vanellus C3 Antifreeze
Hypogear EP EP2

Universal thuban Marfak all purpose

*RPM delo 400
6 CALTEX Universal thuban 2 AF engine coolant
RPM delo 450
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
Tranself EP
10 ELF 3C - Glacelf
Tranself EP type 2
Performance 3C

Essolube D3
*Essolube XD-3
EXXON *Essolube XD-3 Gear oil GP
11 Beacon EP2 All season coolant
(ESSO) Extra Gear oil GX
*Esso heavy duty
Exxon heavy duty

Super duty motor Gulfcrown EP2

Multi-purpose gear Antifreeze and
12 GULF oil Gulfcrown EP spe-
lubricant coolant
*Super duty plus cial
Mobilux EP2
Delvac 1300
Mobilube GX Mobilgrease 77
13 MOBIL *Delvac super -
Mobilube HD Mobilgrease spe-
10W-30, 15W-40
cial

183
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 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
*Supreme duty Multi-purpose 4092 white grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White - bear- summer coolant
ing grease

FINA potonic N
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
FINA potonic NE
Spirax EP
16 SHELL Rimula X Albania EP grease -
Spirax heavy duty

Sunoco ultra pres-

Sunoco antifreeze
Sunoco GL5 tige
17 SUN - and summer cool-
gear oil 2EP
ant
Sun prestige 742

*Ursa super plus Multifak EP2 Code 2055 startex

18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total transmission Multis EP2 Antigel/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

184
MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

STANDARD TIGHTENING TORQUES FOR BOLTS AND

NUTS

LIST OF NECESSARY TOOLS

The following tools are needed when carrying out maintenance.

No. Name of tool Part No. Remarks

Applicable width across flats (S1-S2)

8 mm - 10 mm
09002-00810
12 mm- 14 mm
09002-01214
13 mm - 17mm
09002-01317
1 Wrench 19mm - 22mm
09002-01922
24 mm - 27 mm
09002-02427
30 mm - 32 mm
09002-03032

2 Wrench 09002-03641 Applicable width across flats 36 mm - 41 mm

3 Screwdriver 09033-00190 Interchangeable flat-head and cross-head type

Applicable width across flats

4 Socket wrench set 09020-10282 12 mm, 14 mm, 17 mm, 19 mm, 24 mm, 36 mm
Extension, Handle, Joint, Bar

5 Pliers 09036-00150

6 Filter wrench 09019-08035

7 Grease pump 07950-10450 For greasing work

8 Nozzle 07951-11400

9 Grease cartridge 07950-90403 (Lithium base grease, 400 g)

10 Hammer 09039-00150

11 Pinch bar 09055-10520

12 Gauge 09054-00009

If any of the above tools are broken, please order them from your
Komatsu distributor.

185
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE

TORQUE LIST
Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.

The tightening torque is determined by the width across the flats

(b) of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu

genuine part of the same size as the part that was replaced.

Nm (newton meter): 1Nm 0.1 kgm

Thread diameter Width across

of bolt (mm) flats (mm)
(a) (b)

Nm kgm

6 10 13.2 ± 1.4 1.35 ± 0.15

8 13 31.4 ± 2.9 3.2 ± 0.3
10 16/17 65.7 ± 6.8 6.7 ± 0.7
12 18/19 112 ± 9.8 11.5 ± 1.0
14 21/22 177 ± 19 18.0 ± 2.0
16 24 279 ± 29 28.5 ± 3
18 27 383 ± 39 39 ± 3
20 30 549 ± 58 56 ± 6
22 32/34 745 ± 78 76 ± 8
24 36 927 ± 98 94.5 ± 10

27 41 1320 ± 140 135 ± 15

30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3280 ± 340 335 ± 35

NOTICE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tight-
ening torque: doing so will damage the plastic parts.

186
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the
machine, the user of the machine must always carry out periodic
maintenance. In addition, to further improve safety, the user
should also carry out periodic replacement of the parts given in
the table. These parts are particularly closely connected to safety
and fire prevention.

With these parts, the material changes as time passes, or they

easily wear or deteriorate. However, it is difficult to judge the con-
dition of the parts simply by periodic maintenance, so they should
always be replaced after a fixed time has passed, regardless of
their condition. This is necessary to ensure that they always main-
tain their function completely.

However, if these parts show any abnormality before the replace-

ment interval has passed, they should be repaired or replaced
immediately.

If the hose clamps show any deterioration, such as deformation or

cracking, replace the clamps at the same time as the hoses.

When replacing the hoses, always replace the O-rings, gaskets,

and other such parts at the same time.

Ask your Komatsu distributor to replace safety critical parts.

187
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE

SAFETY CRITICAL PARTS

No. Safety critical parts for periodic replacement Q’ty Replacement interval

1 Fuel hose (fuel tank - Sedimenter) 2

2 Fuel hose (sedimenter - fift pump) 1

3 Spill hose (engine - tank) 5

Every 2 Years or 4000
4 Pump outlet hose (Pump to control valve) 2 hours, whichever comes
sooner
5 Turbocharger librication hose 1

6 Work equipment hose (arm cylinder line - Boom foot sec’n 2

7 Work equipment hose (Arm cylinder inlet) 2

8 Seat belt 1 Every 3 years

188
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

189
MAINTENANCE SCHEDULE CHART MAINTENANCE

MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

INITIAL 250 HOURS SERVICE (only after the first 250 hours)

REPLACE FUEL FILTER CARTRIDGE 194

WHEN REQUIRED

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 194

CLEAN INSIDE OF COOLING SYSTEM 196

CHECK AND TIGHTEN TRACK SHOE BOLTS 199

CHECK and adjust TRACK TENSION 200

CHECK ELECTRICAL INTAKE AIR HEATER 202

REPLACE BUCKET SIDE CUTTERS 202

REPLACE BUCKET TEETH 203

ADJUST BUCKET CLEARANCE 203

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 204

CHECK, MAINTAIN AIR CONDITIONER 205

CHECK BEFORE STARTING

CHECK COOLANT LEVEL, ADD COOLANT 206

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 207

CHECK FUEL LEVEL, ADD FUEL 207

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 208

CHECK AIR CLEANER FOR CLOGGING 209

CHECK ELECTRIC WIRINGS 209

190
MAINTENANCE MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE

(CHECK BEFORE STARTING)

CHECK FUNCTION OF HORN 210

CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR, DRAIN WATER AND SEDIMENT 210

CHECK EVERY 100 HOURS SERVICE

LUBRICATING 211

1. Boom cylinder foot pin (2 points) 211

2. Boom foot pin (2 points) 212

3. Boom cylinder rod pin (2 points) 212

4. Arm cylinder foot pin (1 point) 212

5. Boom-Arm coupling pin (1 point) 212

6. Arm cylinder rod end (1 point) 212

7. Bucket cylinder foot pin (1 point) 212

8. Arm-link coupling pin (1 point) 212

9. Arm-bucket coupling pin (1 point) 212

10. Link coupling pin (2 points) 212

11. Bucket cylinder rod end (1 point) 212

12. Bucket-Link coupling pin (1 point) 212

CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL 213

DRAIN WATER AND SEDIMENT FROM FUEL TANK 213

CLEAN FRESH AIR INTAKE FILTER 214

EVERY 250 HOURS SERVICE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 214

CHECK LEVEL OF BATTERY ELECTROLYTE 215

LUBRICATE SWING CIRCLE (2 POINTS) 216

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION ADJUST. 216

EVERY 500 HOURS SERVICE

REPLACE FUEL FILTER CARTRIDGE 218

CHECK SWING PINION GREASE LEVEL, ADD GREASE 220

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 220

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY
221
FOR MACHINES EQUIPPED WITH AIR CONDITIONER)

191
MAINTENANCE SCHEDULE CHART MAINTENANCE

SERVICE ITEM PAGE

REPLACE HYDRAULIC TANK BREATHER ELEMENT 222

REPLACE HYDRAULIC FILTER ELEMENT 222

EVERY 1000 HOURS SERVICE

CHANGE OIL IN SWING MACHINERY CASE 224

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 225

CHECK ALL TIGHTENING PARTS OF TURBOCHARGER 225

CHECK PLAY OF TURBOCHARGER ROTOR 225

CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB. 226

CHECK FAN BELT TENSION 226

EVERY 2000 HOURS SERVICE

CHANGE OIL IN FINAL DRIVE CASE 227

CLEAN HYDRAULIC TANK STRAINER 228

CLEAN, CHECK TURBOCHARGER 228

CHECK ALTERNATOR, STARTING MOTOR 228

CHECK ENGINE VALVE CLEARANCE, ADJUST 228

CHECK VIBRATION DAMPER 228

CHANGE ANTI FREEZE 228

CHECK AND ADJUST VALVE CLEARANCE 229

EVERY 4000 HOURS SERVICE

CHECK WATER PUMP 229

EVERY 5000 HOURS SERVICE

CHANGE OIL IN HYDRAULIC TANK 229

192
MAINTENANCE MAINTENANCE SCHEDULE CHART

MAINTENANCE WHEN USING HYDRAULIC BREAKER

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

● Replacing hydraulic filter element

Replacement interval (H)

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.
Replacement interval
● Changing oil in hydraulic tank for hydraulic oil
Change the oil according to the table on the right.

(When not
Breaker operation
using breaker)
(ratio %)
Hydraulic AD31373D
Filler element
(When using
breaker only

193
SERVICE PROCEDURE MAINTENANCE

SERVICE PROCEDURE

INITIAL 250 HOURS SERVICE

Carry out the following maintenance only after the first 250 hours.

● REPLACE FUEL FILTER CARTRIDGE

For details of the method of replacing or maintaining, see

the section on EVERY 500 HOURS and 2000 HOURS SER-
VICE.

WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER
ELEMENT

WARNING
● Never clean or replace the air cleaner element with the
engine running.

● When using pressure air to clean the element wear safety AD313740A
glasses or goggles to protect the eyes.

Checking

If air cleaner clogging monitor (1) flashes, clean the air cleaner
element.

Cleaning the outer element

1. Open the front door on the left side of the machine, remove
wing nut (2), then take out element (3).
To prevent entry of dirt or dust, cover the air connector side of
the rear end of the air cleaner body with a clean cloth and
adhesive tape.

2. Clean interior of the air cleaner body interior and the cover.

3. Direct dry compressed air (less than 700 kPa (7 kg/cm²), to

element (3) from inside along its folds, then direct it from out-
side along its folds and again from inside.

❍ Replace the outer element if it has been cleaned 6 times

repeatedly or used throughout a year. Replace the inner
element at the same time.

❍ Replace both inner and outer elements when the monitor

lamp (1) start flashing soon after installing the cleaned

194
MAINTENANCE SERVICE PROCEDURE

outer element even though it may not have been cleaned

6 times.

❍ Check inner element mounting nuts for looseness and , if

necessary, retighten.

4. If small holes or thinner parts are found on the element when

it is checked with an electric bulb after cleaning, replace the
element

NOTICE
● Do not use an element whose folds or gasket or seal are
damaged.

● When cleaning the element, do not hit it or beat it against

something.

5. Remove the cloth and tape used for cover in Step 1.

6. Install the cleaned element and fix it with the wing nut.

7. Replace the seal washer (4) or the wing nut (2) with new parts
if they are broken.

8. Remove the evacuator valve (5) and clean it with compressed

air. After cleaning, install it.

Replacing the inner element

1. Firsts remove the cover and the outer element, and then
remove the inner element.

2. To prevent dust from getting in, use a clean cloth or tape to

cover the air connector (outlet side).

3. Clean the air cleaner body interior, then remove the cover
installed in Step 2.

4. Fit a new inner element to the connector and tighten it with

the nuts. Do not clean and reinstall a inner element.

5. Install the outer element and fix it with the wing nut

195
SERVICE PROCEDURE MAINTENANCE

CLEAN INSIDE OF COOLING SYSTEM

WARNING
● Soon after the engine has been stopped, the coolant is
hot and can cause personal injury. Allow the engine to
cool before draining the coolant.

● Since cleaning is performed while the engine is running,

it is very dangerous to enter the rear side of the machine
as the machine may suddenly start moving. If the under
cover is left removed, it may interfere with the fan. While
the engine is running, never enter the rearside of the
machine.

● Never remove the radiator cap when the engine is at

operating temperature. At operating temperature, the
coolant is under pressure. Steam blowing up from the
radiator could cause personal injury. Allow the engine to
cool until the radiator filler cap is cool enough to touch
with your hand. Remove the filler cap slowly to allow
pressure to be relieved.

● Clean the inside of the cooling system change the coolant

and replace the corrosion resistor according to the table
below.

Cleaning inside of cooling system

Kind of coolant
and changing coolant

Permanent type antifreeze Every year (autumn) or every 2000

(All season type) hours whichever comes first

Non permanent type antifreeze Every 6 months (spring, autumn)

containing ethylene glycol (Drain antifreeze in spring, add anti-
(winter, one season type) freeze in autumn)

Every 6 months or every 1000 hours

When not using antifreeze
whichever comes first

● Stop the machine on level ground when cleaning or changing

the coolant.

● Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type
antifreeze, use an antifreeze containing ethylene glycol.

● Super Coolant (AF-ACL) has an anti-corrosion effect as well as an

antifreeze effect.
The ratio of antifreeze to water depends on the ambient tem-
perature, but to obtain the corrosion resistance effect, a mini-
mum ratio of 30% by volume is necessary.

When deciding the ratio of antifreeze to water, check the lowest ;

temperature in the past, and decide from the mixing rate table
given below.

It is actually better to estimate a temperature about 10°C lower

when deciding the mixing rate.

196
MAINTENANCE SERVICE PROCEDURE

Mixing rate of water and antifreeze

PC210 series

Min.
atmospheric °C -5 -10 -15 -20 -25 -30
temperature

Amount of
liters 5.1 6.7 8.0 9.1 10.2 11.1
antifreeze

Amount of
liters 17.1 15.5 14.2 13.1 12.0 11.1
water

PC240 series

Min.
atmospheric °C -5 -10 -15 -20 -25 -30
temperature

Amount of
liters 5.4 7.0 8.4 9.6 10.7 11.65
antifreeze

Amount of
liters 17.4 16.3 14.4 13.7 12.6 11.65
water

WARNING
Antifreeze is flammable, so keep it away from any flame.

● Use city water for the cooling water.

If river water, well water or other such water supply must be
used, contact your Komatsu distributor.

● We recommend use of an antifreeze density gauge to control

the mixing proportions.

197
SERVICE PROCEDURE MAINTENANCE

WARNING
When removing drain plug, avoid pouring coolant on your-
self.

WARNING
Hot, scalding coolant can spray out if the radiator cap is
removed suddenly. Relieve system pressure by slowly turn-
ing the cap to the first notch or lifting the safety lever (if
equipped). Remove the cap only after the pressure is
relieved.

● Prepare a container to catch drained coolant: Min 23.3 l

capacity.

1. Turn radiator cap (2) slowly to release the internal pressure.

2. Pushing radiator cap (2), turn it slowly to remove it.

3. Remove the bolted cover beneath the radiator, then set a

container to catch the coolant under drain valve (2) and drain
plug (3). Open drain valve (2) at the bottom of the radiator to
drain the water. Remove drain plug (3) in the cylinder block
when draining the water.

4. After draining the water, close drain valve (2) and drain plug
(3) and fill with city water.

5. Open drain valve (3) and drain plug (3) run the engine at low
idling, and flush water through the system for 10 minutes.

When doing this, adjust the speed of filling and draining the water
so that the radiator is always full.
While flushing water through the system, watch carefully that the
water inlet hose does not come out of the radiator water filler.

6. After flushing, stop the engine, open drain valve (2) and drain
plug (3), then close it again after all the water has drained out.

7. After draining the water, clean with a flushing agent. We rec-

ommend use of a Komatsu genuine cleaning agent. For
details of the cleaning method, see the instructions given with
the cleaning agent.

8. After cleaning, open drain valve (2) and drain plug (3) to drain
all the cooling water, then close them and fill slowly with clean
water.

9. When the water comes up to near the water filler port, open
drain valve (2) and drain plug (3), run the engine at low idling,
and continue to run water through the system until clean col-
orless water comes out.

When doing this, adjust the speed of filling and draining the water
so that the radiator is always full.

198
MAINTENANCE SERVICE PROCEDURE

10. When the water is completely clean, stop the engine, close
drain valve (2), wrap the drain plug with seal tape, then close
drain plug (3).

11. Install the undercover.

12. Add cooling water until it overflows from the water filler.

13. To remove the air in the cooling water, run for five minutes at
low idling, then for another five minutes at high idling. When
doing this, leave radiator cap (1) off.

14. After draining off the cooling water of reserve tank (4), clean
the inside of the reserve tank and refill the water between
FULL and LOW level.

15. Stop the engine, wait for about three minutes, add cooling
water, up to near the radiator water filler port, then tighten cap
(1).

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.

Method for tightening

1. Tighten first to a tightening torque of 390 ± 40 Nm (40 ± 4

kgm), then check that the nut and shoe are in close contact
with the link mating surface.

AM091210A

2. After checking, tighten a further 120o ± 10o.

Order for tightening

Tighten the bolts in the order shown in the diagram. After tighten-
ing, check that the nut and shoe are in close contact with the link
mating surface.

AD053090A

199
SERVICE PROCEDURE MAINTENANCE

CHECK AND ADJUST TRACK TENSION

WARNING
Carry out this operation with two workers. The operator must
move the machine in accordance with the signals from the
other worker. The track tension is checked with the chassis
raised, so it extremely dangerous if the machine is lowered
by mistake during the inspection. Never move the machine
while anyone is carrying out measurements.

The wear of pins and bushings on the undercarriage will vary with
the working conditions and soil properties. It is thus necessary to
continually inspect the track tension so as to maintain the stan-
dard tension.

Carry out the check and adjustment under the same conditions as
when operating (on jobsites where the track becomes clogged
with mud, measure with the track clogged with mud).

Inspection

1. Raise the chassis with the boom and arm.

When doing this, operate the levers slowly.

2. Measure the clearance between the bottom of the track frame

and the top of the track shoe at a position that is safe even if
the chassis should come down

AM091220A

Standard clearance: 303 ± 20 mm.

● Places to measure Track frame

303 – 20 mm

❍ PC210: 4th track roller from sprocket.

❍ PC210LC, PC240NLC: 5th track roller from sprocket.

❍ PC240: Midway between 4th and 5th track rollers from

AM091231B
sprocket. Track shoe

❍ PC240LC: Midway between 5th and 6th track rollers from

sprocket.

If the track tension is not the standard value, adjust in the follow-
ing manner.

200
MAINTENANCE SERVICE PROCEDURE

Adjustment

WARNING
● Grease inside the adjusting mechanism is under high
pressure.

● Grease coming from plug a under pressure can penetrate

the body causing injury or death. For this reason, do not
loosen any part other than the plug a more than one turn.
Do not bring your face in front of the plug (1). If the track
tension is not relieved by this procedure, please contact
your Komatsu distributor.

AM091240A

When increasing tension

Prepare a grease gun.

1. Pump in grease through grease fitting (2) with a grease gun.

2. To check that the correct tension has been achieved, move

the machine backwards and forwards.

3. Check the track tension again, and if the tension is not cor- AM091250A
rect, adjust it again.

4. Continue to pump in grease until S becomes 0 mm. If the ten-

sion is still loose, the pin and bushing are excessively worn.
so they must be either turned or replaced. Please contact
your Komatsu distributor

S AM091260A

When loosening tension.

WARNING
It is extremely dangerous to release the grease by any
method except the procedure given below. If the track ten-
sion is not relieved by this procedure, please contact your
komatsu distributor.
AM091240A

1. Loosen plug (1) gradually to release the grease.

2. Turn plug (1) a maximum of one turn.

3. If the grease does not come out smoothly, move the machine
backwards and forwards a short distance.

4. Tighten plug (1)

201
SERVICE PROCEDURE MAINTENANCE

5. To check that the correct tension has been achieved, move

the machine backwards and forwards.

6. Check the track tension again, and if the tension is not cor-
rect, 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
repaired or checked for dirt or disconnections.

REPLACE BUCKET SIDE CUTTERS

WARNING
It is dangerous if the work equipment moves by mistake
when the teeth are being replaced. Set the work equipment in
a stable condition, then stop the engine and apply the locks
securely to the levers.

1. Untighten nuts (5) and bolts (3) and remove side cutters (1)
and (2).

AM088930A

2. Clean cutter mounting face on bucket side plate.

3. Check nuts and bolts and replace if damaged.

4. Fit new side cutters.

5. Tighten bolts to 110 ± 10 kgm.

NOTICE
Please confirm with your bucket supplier for the correct pro-
cedure to replace bucket teeth and side cutters.

NOTICE
When side cutters are not being used, shrouds should be fit-
ted to prevent wear of the bucket side plate.

202
MAINTENANCE SERVICE PROCEDURE

REPLACE BUCKET TEETH

Replace the point before the adapter starts to wear.

WARNING
It is dangerous if the work equipment moves by mistake
when the teeth are being replaced. Set the work equipment in
a stable condition, then stop the engine and apply the locks
securely to the levers.

AM088930A
NOTICE
Please confirm with your bucket supplier for the correct pro-
cedure to replace bucket teeth and side cutters.

ADJUST BUCKET CLEARANCE

It is dangerous if the work equipment moves by mistake when the

clearance is being adjusted.

WARNING
● Set the work equipment in a stable condition, then stop
the engine and lock the lever securely.

● When knocking the pin in with a hammer, metal particles

may fly and cause serious injury, particulary if they get
into your eyes. When carrying out this operation, always AM088930A
wear goggles, helmet, gloves, and other protective
equipment.

● When the bucket is removed, place it in a stable condi-

tion.

1. Set the work equipment to the position shown in the diagram

at right, stop the engine and set the safety lock lever to the
lock position.

203
SERVICE PROCEDURE MAINTENANCE

2. Measure the amount of play (a).

Measurement is easier of you move the bucket to one side or
the other so all the play can be measured in one place. (In the
diagram this is on the left-hand side)
Use a gap (clearance) gauge for easy and accurate measure-
ment.

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.

3. Remove the stopper bolt (2) and nut and remove the pin half
way.

4. Fit shims (3) according tot the amount of free play A mea-
Arm
sured above. Bucket

(EXAMPLE)

If the play is 3 mm, fit two 1.0 mm shims and one 0,5 mm shim
and the play will become 0,5 mm.

When the play (a) is smaller than 0,5 mm. Do not carry out any
maintenance.
Bucket
5. Refit pin and stopper bolt.
Arm

CHECK WINDOW WASHER FLUID LEVEL, ADD

FLUID

If air is ejected with the window washer fluid, check the fluid level
in window washer tank a. If showing under the level, fill with auto-
mobile window washer fluid.

When adding fluid, be careful not to let dirt or dust get in.

● Mixture ratio of pure washer fluid and water

Since the ratio should be varied depending on atmospheric
temperature, replenish washer fluid at the following mixture
ratio, taking temperature into account.

Operation area and Freezing

Mixture ratio
season temperature

Pure washer fluid

Normal - 10°C
1/3: water 2/3

Pure washer fluid

Winter in cold region - 20°C
1/2: water 1/2

Winter in extremely
Pure washer fluid - 30°C
cold region

204
MAINTENANCE SERVICE PROCEDURE

Pure washer fluid comes in two types: for -10°C (for general use)
and for -30°C (cold regions).

Use pure washer fluid according to operation area and season.

CHECK, MAINTAIN AIR CONDITIONER

CHECK LEVEL OF REFRIGERANT (GAS)

WARNING
If the refrigerant used in the cooler gets into your eyes or on
your hands, it may cause loss of sight or frostbite, so never
loosen any part of the refrigerant circuit.

If the level of the refrigerant (gas) is low, the cooling effect will be
reduced. Run the engine at high idling, and check the flow of the
refrigerant gas (freon 134a) in the refrigerant circuit through the
sight glass of the receiver 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 A

❍ (C) Colorless, transparent: No refrigerant B

REMARK C
When there are bubbles, the refrigerant gas level is low, so AD053280A
contact your refrigerant dealer to have refrigerant added. If the air
conditioner is run with the refrigerant gas level low, it will cause
damage to the compressor.

INSPECTION DURING OFF-SEASON

Even during the off-season, run the compressor at low speed for
3 - 5 minutes once a month to prevent the loss of the oil film at the
lubricated Parts of the compressor.

Inspection and maintenance items list for cooler

Check, Guideline for

Content of check,
maintenance maintenance
maintenance
items interval

Twice a year (spring,

Refrigerant (gas) Charge amount
autumn)

Condenser Clogged fins Every 500 hours

Compressor Operating condition Every 4000 hours

V-belt Damage, tension Every 250 hours

205
SERVICE PROCEDURE MAINTENANCE

Check, Guideline for

Content of check,
maintenance maintenance
maintenance
items interval

Operating condition
Blower motor, fan (does it make abnormal When required
noise?)

Operating condition
Control mecha-
(does it function nor- When required
nism
mally?)

Mounting condition,
looseness at tightening
Piping mounts When required
or connecting portions,
leakage of gas, damage

CHECK BEFORE STARTING

CHECK COOLANT LEVEL, ADD COOLANT

WARNING
Do not open the radiator cap unless necessary. When check-
ing the coolant, always check the radiator reserve tank when
the engine is cold.

1. Open the rear door on the right side of the machine and
check that the coolant level is between the FULL and LOW
marks on radiator reserve tank (shown in the drawing on the
right). If the coolant level is low, add coolant through the filler
of reserve tank (1) to the FULL level.

2. After adding coolant, tighten the cap securely.

3. If the reserve becomes empty, first inspect for coolant leaks

and then fill the radiator and the reserve tank with coolant.
FULL

LOW
AM090180B

206
MAINTENANCE SERVICE PROCEDURE

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

WARNING
The turbocharger (with safety cover) exhaust manifold is
near dipstick (G), so be careful not to touch it.

1. Open the engine hood on the machine.

2. Remove dipstick (G) and wipe the oil off with a cloth.

3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.

4. The oil level should be between the (H) and (L) marks on dip-
stick (G). If the oil level is below the (L) mark, add engine oil
through oil filler (F).

For details of the oil to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM- AD052340A

PERATURE” on page 181.

5. If the oil is above the (H) mark, drain the excess engine oil
using drain valve in the bottom of oil pan, (P) and check the
oil level again.

6. If the oil level is correct, tighten the oil filler cap securely and
close the engine hood.

REMARK
When checking the oil level after the engine has been oper-
ated wait for at least 15 minutes after stopping the engine before
checking. If the machine is at an angle, make it horizontal before
checking.

CHECK FUEL LEVEL, ADD FUEL

WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. If spilling fuel, thoroughly clean up any spillage.

1. Use sight gauge (G) on the rear face of the fuel tank to check
that the tank is full.

2. If the fuel level is not within the sight gauge, add fuel through
filler port (F), while watching sight gauge (G).

Fuel capacity: 310 liter.

For details of the fuel to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

207
SERVICE PROCEDURE MAINTENANCE

3. After adding fuel, tighten the cap securely.

NOTE: To prevent moisture due to condensation, the fuel tank

must be filled at the end of each day’s operation.

REMARK
If breather holes (1) on the cap is clogged, the pressure in the
tank will drop and fuel will not flow.
Clean the holes from time to time.

If required, the contents of the fuel tank may be drained from the
tank by loossening the drain valve (2) located on the bottom of the 2
tank.

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.

● If oil has been added to above the H mark, stop the AM090210A

engine and wait for the hydraulic oil to cool down, then
drain the excess oil from drain plug (P).

1. If the work equipment is not in the condition shown in the dia-

gram on the right, start the engine run the engine at low
speed, retract the arm and bucket cylinders, 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 con-

trol lever (work equipment and travel) to full stroke in all direc-
tions to release the internal pressure.

3. Open the door on the left side of the machine. Check sight
gauge (G). The oil level is normal if between the H and L
marks.

208
MAINTENANCE SERVICE PROCEDURE

NOTICE
Do not add oil if the level is above the H line. This will dam-
age the hydraulic equipment and cause the oil to spurt out.

4. If the level is below the L mark, remove the upper cover of the
hydraulic tank and add oil through oil filler (F). H
For details of the oil to use, see “USE OF FUEL, COOL- L
ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.
AM090230A
REMARK
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:

❍ Before operation: around L level

(Oil temperature 10 to 30oC)

❍ Normal operation: around H level

(Oil temperature 50 to 80oC)

CHECK AIR CLEANER FOR CLOGGING

1. Confirm that the air cleaner clogging monitor does not flash.

2. If it flashes, immediately clean or replace the element.

For details of the method of cleaning the element, see

“CHECK, CLEAN AND REPLACE AIR CLEANER ELE-
MENT” on page 194.

CHECK ELECTRIC WIRINGS AD313590A

WARNING
● If the fuses are frequently blown or if there are traces of
short circuit on the electrical wiring, locate the cause and
carry out repair.

● Accumulation of flammable material (dead leaves, twigs,

grass, etc.) around the battery may cause fire, so always
check and remove such material.

● 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 for damage and wrong capacity of the fuse and any sign of
disconnection or short circuit in the electric wiring. Check also for
loose terminals and tighten any loose parts.

Check the wiring of the “battery”, “starting motor” and “afternator”

carefully in particular.

When carrying out walk-around checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.

209
SERVICE PROCEDURE MAINTENANCE

Please contact your Komatsu distributor for investigation and cor-

rection of the cause.

CHECK FUNCTION OF HORN

1. Turn the starting switch to the ON position.

2. Confirm that the horn sounds without delay when the horn
button is pressed. If the horn does not sound, ask your
Komatsu distributor for repair.

CHECK FOR WATER AND SEDIMENT IN SEDIMEN-

TOR, DRAIN WATER AND SEDIMENT

A fuel sedimentor is mounting in the pump compartment and is

accessed by the door on the right hand side of the machine.
Entrapped sediment and water can be seen through the glass
bowl.

1. Loosen drain plug (1) and drain water and sediment until
none is visible in bowl.

2. Tighten drain plug.

A : Fuel A
B : Water/sediment
B

CHECK FOR WATER IN PRIMARY FUEL FILTER,

drain water

A primary fuel filter is fitted on the engine. Drain the water from
the primary fuel filter by turning cap at the bottom of the filter.

210
MAINTENANCE SERVICE PROCEDURE

EVERY 100 HOURS SERVICE

LUBRICATING

The minimum greasing intervall is 100 hours.

However, more frequent greasing will be required depending on

conditions/environment

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 fit-

tings shown by arrows.

3. After greasing, wipe off any old grease that was pushed out.

2,3,4 1

6 AM091440

7 8 9 10,11 12

1. Boom cylinder foot pin (2 points)

1
1
AM091450A

211
SERVICE PROCEDURE MAINTENANCE

2. Boom foot pin (2 points)

AM091460A

3. Boom cylinder rod pin (2 points)

4. Arm cylinder foot pin (1 point)

2

AM091510A

5. Boom-Arm coupling pin (1 point)

6. Arm cylinder rod end (1 point)

7. Bucket cylinder foot pin (1 point)

4

5 6 AM091520A

8. Arm-link coupling pin (1 point)

9. Arm-bucket coupling pin (1 point)

4
3
AM091470A

10. Link coupling pin (2 points)

11. Bucket cylinder rod end (1 point)

12. Bucket-Link coupling pin (1 point)

7
5
6 5 AM091480A

212
MAINTENANCE SERVICE PROCEDURE

CHECK OIL LEVEL IN SWING MACHINERY CASE,

ADD OIL

WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carry-
ing out this check.

1. Remove dipstick (G) and wipe the oil from the dipstick with a
cloth.

2. Insert dipstick (G) fully in the guide.

3. When dipstick (G) is pulled out, if the oil level is between the
H and L marks of the gauge, oil level is correct.

4. If the oil does not reach the L mark (F) on dipstick (G), add
engine oil through dipstick insertion hole (F).
AM096230A
When refilling, remove bleeding plug (1).

For details of the oil to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

5. If the oil level exceeds the H mark on the dipstick, loosen

drain plug (P) to drain the excess oil.

6. After checking oil level or adding oil, insert the dipstick into
the hole and install air bleeding plug (1).

DRAIN WATER AND SEDIMENT FROM FUEL TANK

1. Carry out this procedure before operating the machine.

2. Prepare a container to catch the fuel that is drained.

3. Open valve (1) at the bottom of the tank and drain the sedi-
ment and water that has accumulated at the bottom together
with fuel.
When doing this, be careful not to get fuel on yourself.

4. When only clean fuel comes out, close drain valve (1).

NOTICE
Never use trichlene for washing the inside of the tank.

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SERVICE PROCEDURE MAINTENANCE

CLEAN FRESH AIR INTAKE FILTER

NOTICE
The normal cleaning interval is 100 hours, however if the
machine is used at a dusty side, shorten this interval.

Clean recirculation air filter (air conditioner option only.)

1. Remove 4 bolts on the upper side of the luggage tray and

remove bracket (1).

2. Remove 4 bolts on the lower side and lift away luggage

tray(2). If radio is fitted, disconnect radio connector first by
removing radio (using special tools provided).

3. Pull filter elements (3) out of air conditioner housing.

4. Clean as fresh air intake filter (note recirculation air filter is

homogenous and can be fitted in either direction).

5. Re-install.

EVERY 250 HOURS SERVICE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD

OIL

WARNING
● The oil is at high temperature immediately after the
machine has been operated. Wait for the oil to cool down
before 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.

214
MAINTENANCE SERVICE PROCEDURE

● Prepare a handle.

1. Set the TOP mark at the top, with the TOP 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 below the bottom of the plug hole, the correct
amount of oil has been added.

3. If the oil level is to 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; is still low, add engine oil through the hole in plug (F)
until the oil overflows.

For details of the oils to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

5. After checking, install plug (F).

CHECK LEVEL OF BATTERY ELECTROLYTE

WARNING
● To avoid gas explosions, do not bring fire or sparks near
the battery.

● Battery electrolyte is dangerous. If it gets in your eyes or

on your skin, wash it off with large amounts of water, and
consult a doctor.

Carry out this check before operating the machine.

1. Open the battery box cover on the right side of the machine.

2. Remove caps (1), and check that the electrolyte is at the

specified level (10 to 12 mm) above the plates). If the electro-
lyte level is low, add distilled water to the specified level.
If the battery electrolyte is spilled, have dilute sulphuric acid
added.

3. Clean the air hole in the battery caps, then tighten the caps
securely.

When adding distilled water in cold weather, add it before starting

operations in the morning to prevent the electrolyte from freezing.

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SERVICE PROCEDURE MAINTENANCE

LUBRICATE SWING CIRCLE (2 POINTS)

1. Lower the work equipment to the ground.

2. Using a grease gun, pump in grease through the grease fit-

tings shown by arrows.

3. After greasing, wipe off all the old grease that was pushed
out.

CHECK AIR CONDITIONER COMPRESSOR BELT

TENSION ADJUST.

CHECKING

1. Remove belt guard (1)

2. Press compressor drive belt midway between fan pulley and

compressor pulley. The belt should normally deflect by about
15 - 18 mm when pressed with the finger (with a force of
approx. 6 kg

ADJUSTING

1. Loosen two nuts and bolts (1)

2. Carefully lever compressor housing as shown to tighten belt

to within tightness criteria. Tighten lower bolt to hold in posi-
tion.

3. Tighten upper bolt.

216
MAINTENANCE SERVICE PROCEDURE

4. Check each pulley for damage, wear of the v-groove and

wear of the v-bolt. In particular, be sure to check the v-belt is
not touching the bottom of the v-groove.

5. Replace belt if it has stretched, leaving no allowance for

adjustment, or if there is a cut or crack on belt.

6. Refit belt guard.

7. When the new belt is set, readjust it after operating for one
hour.

217
SERVICE PROCEDURE MAINTENANCE

EVERY 500 HOURS SERVICE

Maintenance for every 50, 100 and 250 hours service should be
carried out at the same time.

REPLACE FUEL FILTER CARTRIDGE

WARNING
● Engine is at high temperature immediately after the
machine has been operated. Wait for engine to cool down
before replacing the filter.

● Do not bring fire or sparks near the fuel.

● When craking the engine, confirm the safety around the

engine, as the engine may start.

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 primary fuel filter cartridge (1)

counterclockwise to remove it. Repeat for secondary fuel
folter cartridge (2)

3. Clean the filter holder, fill a new filter cartridge with clean fuel,
coat the packing surface with engine oil, then install it to the
filter holder.

4. When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up 1/2 of a 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 car-
tridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
After replacing the fuel filter cartridge, bleed the air from the
system.

5. After replacing filter cartridge, bleed the air

bleed the air according to the following procedures.

BLEEDING THE FUEL SYSTEM

Controlled venting is provided at the injection pump through the

fuel drain manifold. Small amounts of air introduced by changing
the filters or injection pump supply line will be vented automati-
cally, if the fuel filter is changed in accordance with the instruc-
tions.
However, manual bleeding will be required if :

● The fuel filter is not filled prior to installation.

● Injection pump is replaced.

● High pressure fuel lines are replaced.

218
MAINTENANCE SERVICE PROCEDURE

VENTING THE LOW PRESSURE LINES AND FUEL FILTER

1. Open the bleed screw. (wrench size: 10 mm.)

2. Operate the hand lever until the fuel flowing from the fitting is
free of air.
Tighten the bleed screw to 9 N.m.

3. Air/fuel can be pumped from this location with the hand lever
on the lift pump if the fuel solenoid valve is energised.

4. Air can be vented from both pumps through the fuel drain
manifold line by operating the starting motor.
When using the starting motor to vent the system, do not
engage it for more than 30 seconds at a time: wait two (2)
minutes between engagements.

WARNING
It is necessary to put the engine in the “RUN” position.
Because the engine may start, be sure to follow all the safety
precautions. Use the normal starting procedure.

VENTING THE HIGH PRESSURE LINES

Loosen the fittings at the injectors, and crank the engine to allow
entrapped air to bleed from the lines. Tighten the fittings to 30
N.m. (wrench size: 17 mm.)

CAUTION
High pressure could cause penetration of the skin.

WARNING
Do not bleed a hot engine as this could cause fuel to spill
onto a hot exhaust manifold creating a danger of fire.
Start the engine and vent one line at a time until the engine
runs smoothly.

219
SERVICE PROCEDURE MAINTENANCE

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 28
mm. Add more grease if necessary.

3. Check if the grease is milky white. If it is milky white, it is nec- AM091710A

essary to change the grease. Please contact your Komatsu
distributor.

❍ The total amount of grease is 21 l

4. Install cover (2) with bolts (1).

CHANGE OIL IN ENGINE OIL PAN, REPLACE

ENGINE OIL FILTER CARTRIDGE

WARNING
The oil is at high temperature after the engine has been oper-
ated, so never change the oil immediately after finishing
operations. Wait for the oil to cool down before changing it.

Prepare the following

● Container to catch drained oil: Min 24 l capacity

● Refill capacity: 24 l

● Filter wrench

1. Place a drain container under drain tap (P) located on the bot-
tom of the machine.

2. Loosen drain tap (P) slowly to avoid getting oil on yourself,

and drain the oil.

3. Check the drained oil, and if there are excessive metal parti-
cles or foreign material, please contact your Komatsu distrib-
utor.

4. Install drain tap (P)

5. Open the engine hood. Using the filter wrench from the upper
side of the engine, turn filter cartridge (2) counterclockwise to
remove it.
Lever
Portion P
In particular, if this operation is carried out immediately after stop-
ping the engine, a large amount of oil will come out, so wait for 10
minutes before starting the operation.

6. Clean the filter holder, coat the packing surface of a new filter
cartridge with engine oil, and fill the filters with clean lubricat-

220
MAINTENANCE SERVICE PROCEDURE

ing oil (or coat it thinly with grease), then install it to the filter
holder.

REMARK
Confirm that no remnants of old packing still adhere to the fil-
ter holder as this may result in oil leakage.

7. When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up further 3/4 of
a turn.

8. After replacing the filter cartridge, add engine oil through oil
filler (F) until the oil level is between the H and L marks on
dipstick (G).

For details of the oil to use, “USE OF FUEL, COOLANT

AND LUBRICANTS ACCORDING TO AMBIENT TEMPER-
ATURE” on page 181

9. Run the engine at idling 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 BEFORE STARTING” on

page 206

NOTICE
Replace once every 6 months, regardless of the number of
hours operated.

CLEAN AND INSPECT RADIATOR FINS, OIL

COOLER FINS AND CONDENSER FINS (ONLY FOR
MACHINES EQUIPPED WITH AIR CONDITIONER)

WARNING
If compressed air, steam, or water hit your body directly,
there is danger of injury. Always wear protective glasses,
mask, and safety shoes.

1. Open the engine hood and rear door on the left side of the
machine. Loosen bolts (1) and remove the radiator front
cover.

2. Blow off mud, dust or leaves clogging the radiator fins and oil
cooler fins using compressed air.
At the same time, clean the net in front of the oil cooler. Clean
the condenser fins on machines equipped with the air condi-
tioner. The condenser is mounted on the front of the cooling
package. AM096320A

Steam or water may be used instead of compressed air. After

cleaning, fix the cover with bolts (1)

3. Check the rubber hose. Replace with a new one if the hose is
found to have cracks or to be hardened by ageing.
Further, check hose clamps for looseness.

221
SERVICE PROCEDURE MAINTENANCE

NOTICE
To prevent damage to the fins, apply compressed air from an
appropriate distance. Damaged fins may cause water leak-
age or overheating. In a dusty site, check the fins daily, irre-
spective of the maintenance interval.

REPLACE HYDRAULIC TANK BREATHER ELE-

MENT
WARNING
Replace the element when the oil is cold.
When removing the oil filler cap, turn it slowly to release the
internal pressure before removing it.

1. Remove the cap of oil filter (F) at the top of the hydraulic tank.

2. Replace element (1) inside the cap with a new one.

AM091770A

REPLACE HYDRAULIC FILTER ELEMENT

WARNING
When removing the oil filler cap, turn it slowly to release the
internal pressure before removing it.

1. Remove the cap from oil filler (F), and release the internal
pressure.

2. Loosen 4 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.

3. After removing spring (2) and valve (3) take out element (4).

4. Clean the removed parts in diesel oil.

222
MAINTENANCE SERVICE PROCEDURE

5. Install a new element in the place where old element (4) was
installed.

6. Set valve (3) and spring (2) on top of the element.

7. Set cover (1) in position, push it down by hand, and install the
cover with the mounting bolts.

8. Screw in the oil filler cap and install the cover.

To bleed the air, start the engine according to “STARTING

ENGINE” on page 106 and run the engine at low idling for
10 minutes.

Replacement interval (H)

9. Stop the engine.

REMARK
Operate the machine after halting for more than 5 minutes to Replacement interval
eliminate bubbles in the oil inside the tank. for hydraulic oil

10. Check for oil leakage and wipe off any spilled oil.

When the hydraulic breaker is installed, the hydraulic oil deterio-

rates earlier than in normal bucket digging work.

The first element replacement should be at 100 to 150 hours for

new machines. Thereafter, replace the element according to the
table on the right. Breaker operating (When using
ratio(%) breaker only)
Hydraulic filter
element AD31373D

223
SERVICE PROCEDURE MAINTENANCE

EVERY 1000 HOURS SERVICE

Maintenance for every 50, 100, 250 and 500 hours should be car-
ried out at the same time.

CHANGE OIL IN SWING MACHINERY CASE

WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carry-
ing out maintenance.

● Container to catch drained oil: Min. 6.8 l capacity.

● Refill capacity: 6.8 l

1. Set an oil container under drain plug (P) under the machine
body.

2. Loosen drain valve (P) under the body, drain the oil, then
tighten the drain valve again.

3. Remove dipstick (G) and bleeding plug (1).

Add the specified amount of engine oil through gauge hole
(F).
AM091780A
For details of the oil to use, see “USE OF FUEL, COOL-
ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

4. After refilling, install bleeding plug (1).

5. Wipe off oil on the dipstick with a cloth.

6. Insert dipstick (G) into the gauge pipe thoroughly and then
pull it out again.

7. When the oil level is between the H and L marks, on dipstick

(G), it is normal. If the oil does not reach the L mark, add
more oil through oil filler (F).

8. If the oil level exceeds the (H) mark, drain the excess engine
oil from drain plug (P), and check the oil level again.

224
MAINTENANCE SERVICE PROCEDURE

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before carry-
ing out maintenance.

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 door on the left side of the machine.

2. Remove plug (G) and check the oil level. If the oil is up to
near the bottom of the plug hole, it is normal.
If insufficient, remove the plug (F) and add oil through the
hole of plug F up to the bottom of the plug hole (G).

For details of the oil to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

NOTICE
If excess oil is supplied, drain it to the specified amount to
avoid overheating.

3. Install plug (G) and (F)

4. Close the door.

CHECK ALL TIGHTENING PARTS OF TURBO-

CHARGER

Contact your Komatsu distributor to have the tightening portions

checked.

CHECK PLAY OF TURBOCHARGER ROTOR

Ask Komatsu distributor to check the play of the turbocharger

rotor.

225
SERVICE PROCEDURE MAINTENANCE

CHECK FAN BELT TENSIONER BEARING BELT

AND FAN HUB.

Check fan belt

Remove the drive belt by lifting tensioner using a 3/8 inch square
drive wrench to release the tension.

Inspect the belt for damage.

Replace belt if any damage is found.

● Check tensioner bearing

With the fan belt removed rotate fan hub.
The tensioner pulley should spin freely with no rough spots
defected under hand pressure.

● Check the tensioner bearing.

● Replace bearing if damaged.

● Check fan hub. With the drive belt removed, rotate fan hub.

The fan hub should spin freely without excessive end play.

● Check the fan hub bearing.

● Replace bearing if damaged.

CHECK FAN BELT TENSION

Measure the belt deflection at the longest span of the belt.

Maximum deflection: 9.5-12,7 mm

If tension is low (deflection is outside range): (see 24.7.6.

“Check fan belt tensioner bearing, belt and fan hub.”)

● Check belt & replace if damaged

● Check tensioner & replace if damaged

226
MAINTENANCE SERVICE PROCEDURE

EVERY 2000 HOURS SERVICE

Maintenance for every 50, 100, 250, 500 and 1000 hours should
be carried out at the same time.

CHANGE OIL IN FINAL DRIVE CASE

WARNING
● The oil is at high temperature immediately after the
machine has been operated. Wait for the oil to cool down
before carrying out maintenance.

● 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 the following.

● Container to catch drained oil: Min. 4.2 l capacity

● Refill capacity: 4.2 l

● 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 plug (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. Screw in plug (P).

5. Add engine oil through the hole of plug (F).

For details of the oil to use, see “USE OF FUEL, COOL- AM091540A
ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.

6. When the oil overflows from the hole of plug (F), install plug
(F). Tightening torque of plugs P and F: 70 ± 10Nm.

227
SERVICE PROCEDURE MAINTENANCE

CLEAN HYDRAULIC TANK STRAINER

WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
changing the oil. When removing the oil filler cap, turn it
slowly to release the internal pressure, then remove it care-
fully.

1. Remove 4 bolts, then remove cover (1). When doing this,

cover (1) may fly off because of the force of spring (2), so
keep the cover pushed 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 in clean die-
sel oil or flushing oil. If strainer (4) is broken, replace it with a
new part.

4. When installing, insert strainer (4) into protruding part (5) of

the tank, and assemble.

5. Tighten the bolts to install cover (1).

CLEAN, CHECK TURBOCHARGER

Contact your Komatsu distributor for cleaning or inspection.

CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn, or the bearing may have run out of
grease, so contact your Komatsu distributor for inspection or
repair. If the engine is started frequently, carry out inspection
every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts,

you shall request Komatsu distributor for service.

CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of

the rubber (1).

If any cracks or peeling are found, contact your Komatsu distribu-

tor to have the parts replaced.

CHANGE ANTI FREEZE

Follow the procedure of “CLEAN INSIDE OF COOLING AN180870A

SYSTEM” on page 196 for draining and refilling the cool-
ing system.

228
MAINTENANCE SERVICE PROCEDURE

CHECK AND ADJUST VALVE CLEARANCE

Follow the procedure of " check and adjust valve clear-

ance"

EVERY 4000 HOURS SERVICE

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

CHECK WATER PUMP

Check that there is oil leakage, or clogging of the drain hole. If

any abnormality is found, contact your Komatsu distributor for dis-
assembly and repair or replacement.

EVERY 5000 HOURS SERVICE

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

CHANGE OIL IN HYDRAULIC TANK

WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
changing the oil. When removing the oil filler cap, turn it
slowly to release the internal pressure, then remove it care-
fully.

Prepare the following

● Container to catch drained oil: min. 166 capacity

● Refill, capacity: 166 l

● Prepare a handle for the socket wrench set.

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 to the end of the stroke,
then lower the boom and put the teeth in contact with the
ground.

AM091810A

229
SERVICE PROCEDURE MAINTENANCE

3. Set the safety 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 immediately under the drain plug under the

machine body to catch the oil that is drained. Using the han-
dle, remove drain plug (P) and drain the oil. Check the O-ring
installed to plug (P), and if it is damaged, replace the O-ring.
After draining the oil, tighten drain plug (P).
Tightening torque: 69 ± 10 Nm (7 ± 1 kgm).

Take care not to get oil on yourself when remove drain plug (P).

6. Add the specified amount of engine oil through oil filler port
(F). Check that the oil level is between H and L on the sight
gauge.

For details of the oil to use, see “USE OF FUEL, COOL-

ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM-
PERATURE” on page 181.
NOTICE
When the hydraulic breaker is installed, the hydraulic oil
deteriorates earlier than in normal bucket digging work.
Therefore, replace the hydraulic oil according to the chart at
the right.
Replacement interval (H)

7. After replacing hydraulic oil and cleaning or replacing filter

element and strainer, bleed air from the circuit according to
the following procedure. Replacement interval
for hydraulic oil
Procedure for bleeding air

Bleed the air from the various components in the order below (1-
7).

Breaker operating (When using

ratio(%) breaker only)
Hydraulic filter
element AD31373D

Bleeding air from pump

1. Loosen air bleeding plug (1), and check that oil oozes out
from the air bleed plug.

2. If no oil oozes out, remove the drain hose from the pump
case, and add hydraulic oil through drain port (2) to fill the
pump case. Oil will come out when the drain hose is
removed, so secure the hose mouthpiece at a position higher
than the level of the oil in the hydraulic tank.

3. After completing the air bleed operation, tighten air bleeding

plug (1), then install the drain hose.

230
MAINTENANCE SERVICE PROCEDURE

NOTICE
● If the drain hose is installed first, oil will spurt out from
the hole of plug (1).

● If the pump is operated without filling the pump case with

hydraulic oil, abnormal heat will be generated and this
may lead to premature damage of the pump.

Starting engine

Start the engine according to “STARTING ENGINE” on page 106

Keep running the engine at low idling for 10 minutes, and carry
out the following procedure.

Bleeding air from cylinders

1. Run the engine at low idling, and extend and retract each cyl-
inder 4-5 times. Do not operate the cylinder to the end of its
stroke. Stop at a point approx. 100 mm before the end of the
stroke.

2. Next, operate each cylinder to the end of its stroke 3-4 times.

3. After this, operate each cylinder 4-5 times to the end of its
stroke to completely bleed the air.

NOTICE
If the engine is run immediately at high speed or the cylinder
is operated to the end of its stroke, the air inside the cylinder
may cause damage to the piston packing.

Bleeding air from swing motor

1. Run the engine idle at a low speed for about five minutes,
then loosen drain port plug (1) and confirm that oil flows out.

NOTICE
When doing this, do not operate the swing.

2. If oil does not flow out, stop the engine and fill the motor case
with hydraulic oil through drain port plug (1).

3. After completion of the air bleed operation, tighten drain port

plug (1).

4. Run the engine at low idling, and swing the upper structure at
least 2 times uniformly to the left and right.

NOTICE
If the air is not bled from the swing motor, the bearings of the
motor may be damaged.

231
SERVICE PROCEDURE MAINTENANCE

Bleeding air from travel motor.

(Carry out this operation only when the oil in the travel motor case
has been drained.)

1. Run the engine at low idling, loosen air bleed plug (1) and if
oil flows out, tighten the air bleed plug.

2. Keep the engine running at low idling, and swing the upper
structure 90o to bring the work equipment to the side of the
track.

3. Use the work equipment to jack up the chassis so that the

track comes slightly off the ground, then run the track under
no load for 2 minutes. Carry out this operation on the left and
right sides.

Bleeding air from attachment (hydraulic breaker, etc.)

If a hydraulic breaker or any other attachment has been newly

installed, run the engine at low idling and operate the equipment
repeatedly (approx. 10 times) until the air has been bled from the AM091220A

attachment and circuit.

NOTICE
If the method of bleeding the air from the attachment itself is
specified by the manufacturer, bleed the air according to
those specifications.

Operation

1. After completing the air bleed, stop the engine, and wait for at
least 5 minutes before starting operations. This will allow the
bubbles in the oil inside the tank to escape.

2. Check that there is no leakage of oil, and wipe up any oil that
has been spilled.

232
SPECIFICATIONS

233
SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS

PC210-6K, PC210LC-6K

PC210-6K PC210LC-6K

WEIGHT

● Operation weight (without operator) 20,000 kg 21,200 kg

PERFORMANCE

Low speed 3.0 km/h

● Travel speed Middle speed 4.1 km/h

High speed 5.5 km/h

● Swing speed 12.4 rpm

TRACK SHOE

● Triple grouser shoe (standard) 600 mm width 700 mm width

ENGINE

● Model KOMATSU S6D102E Diesel engine

Net 99 kW (133 HP)/2000 RPM

● Flyweel horsepower
gross 104 kW(140 HP)/2000 RPM

● Starting motor 24V 5.5 kW

● Alternator 24V 55 A

STD 12 V 95 Ah x 2 pieces
● Battery
Large capacity (Option) 12V 140 Ah x 2 pieces

234
SPECIFICATIONS SPECIFICATIONS

PC210-6K, PC210LC-6K

The values given are the values for PC210-6K

[ ]: Values for PC210LC-6K.

In cases where are no values given in [ ], the values are the

same as for PC210-6K.

50
27

2800
1260 1450 9425
6685 2740
2970
2905

2255
2020
1085
26
440

600 3270 [3640]

2180 [2380] [700]

2780 [3060] 4080 [4450]

AMPC2106K

235
SPECIFICATIONS SPECIFICATIONS

PC210-6K, PC210LC-6K

1. The mark * indicates the dimensions for shovel operation.

2. Never allow other person than the operator to enter the swing
range (Max. swing range, Max. digging radius).

3630

7570
9590
9305
6475
6335

9700
6780
6620

5980

9840

9875
10015 AWPC2106K

236
SPECIFICATIONS SPECIFICATIONS

PC210LC-6K straight boom

11

5
J

-1
D

E
-3

-5

9 7 5 3 1

Working ranges Arms 1800 2400 2930

A Max. digging height mm 11270 11780 12230

B Max. dumping height mm 8320 8840 9290

C Max. digging depth mm 3810 4420 4930

D Max. vertical wall digging depth mm 2430 2890 3230

E Max. digging depth of cut for 2440 mm level mm 3570 4220 4760
F Max.digging reach mm 9710 10280 10790

G Max.digging reach at ground mm 9530 10110 10620

H Min. swing radius mm 2420 3000 2890

I Max. height of min. swing mm 9270 9120 9100

J Max. pin height mm 9800 10300 10750

Operating weight with 700 mm shoes kg 20760 20800 20886

Operating weight with 800 mm shoes kg 21060 21100 21186

Operating weight with 900 mm shoes kg 21360 21400 21486

237
SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS

PC240LC-6K, PC240NLC-6K

PC240LC-6K PC240NLC-6K

WEIGHT

● Operation weight (without operator) 24.100 kg 23.700 kg

PERFORMANCE

Low speed 3.0 km/h

● Travel speed Middel speed 4.1 km/h

High speed 5.5 km/h

● Swing speed 12.5 rpm

TRACK SHOE

● Tripple grouser shoe (standard) 700 mm width 600 mm width

ENGINE

● Model KOMATSU S6D102E Diesel engine

Net 118 kW (158 HP)/2000 RPM

● Flyweel horsepower
gross 124 kW(166 HP)/2000 RPM

● Starting motor 24V 5.5 kW

● Alternator 24V 55 A

STD 12 V 95 Ah x 2 pieces
● Battery
Large capacity (Option) 12V 140 Ahx 2 pieces

238
SPECIFICATIONS SPECIFICATIONS

PC240NLC-6K, PC240LC-6K

The values given are the values for PC240NLC-6K

[ ]: Values for PC240LC-6K.

In cases where are no values given in [ ], the values are the

same as for PC240NLC-6K.

60
28

2800
1260 1450 9780
6930 2850
3160
2905

2314 [2255]
2020
1085
26
440

600 3640 [3830]

2380 [2580] [700]

2980 [3280] 4450 [4640]

AMPC2406K

239
SPECIFICATIONS SPECIFICATIONS

PC240NLC-6K, PC240LC-6K

1. The mark * indicates the dimensions for shovel operation.

2. Never allow other person than the operator to enter the swing
range (Max. swing range, Max. digging radius).

3860

7760
9755
9305
6515
6380

10000
7085
6920

6010

10175

10180
10345 AWPC2406K

240
SPECIFICATIONS SPECIFICATIONS

EXPLANATION OF LIFTING CAPACITY CHART

PC210-6K, PC210LC-6

LEGEND
A : Reach from swing centre
B : Bucket hook height

OF : Lifting capacity (rating overfront)

OS : Lifting capacity (rating overside)

LEGEND

(1) Position of lifting point

(2) Arm length:
(3) Boom length
(4) Hydraulic pressure: Nom 36.2 MPa WORKING
Max. 37.2 MPa HOLDING CIRCUIT

WORKING CONDITIONS:

❍ WITH BUCKET (0.9m3 CECE).(680 kg)°

❍ IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL

INSTALLED, THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE
DEDUCTED FROM THE VALUES OF THIS TABLE.

❍ WITH FULLY EXTENDED BUCKET CYLINDER.

❍ ON A COMPACT HORIZONTAL LEVEL GROUND.

❍ WITH 600 mm WIDTH SHOE.

Loads do not exceed 87% of hydraulic capacity or 75% of tipping

capacity (* load limited by hydraulic capacity rather than tipping).

Nom 36.2 MPa

5 7 0 0 Max 37.2 MPa

AW40000

241
SPECIFICATIONS SPECIFICATIONS

Height

max 7.5 m 6.0 m 4.5 m 3.0 m 1.5 m

Model
Arm

OF OS OF OS OF OS OF OS OF OS OF OS
6.0 * 2450 * 2450 * 3300 2750
4.5 * 2450 2150 * 4000 2700 * 4150 4100
3.0 * 2600 1900 4100 2600 * 5050 3850 * 6400 6150 * 10000 * 10000
2,9 m

1.5 * 2800 1850 3950 2450 5700 3600 * 8250 5550 * 5600 * 5600
0.0 3100 1850 3850 2350 5450 3350 8650 5200 * 6500 * 6500
-1.5 3350 2050 3800 2300 5300 3250 8450 5050 * 9550 * 9550 * 5700 * 5700
-3.0 3950 2450 5350 3250 8500 5050 * 14050 9900 * 9200 * 9200
-4.5 5500 3400 5500 3400 8700 5250 * 13050 10300
6.0 * 3850 2950 * 4100 * 4100
PC210 Mono boom

4.5 3800 2400 4150 2700 * 4650 4050

3.0 3450 2150 4050 2600 * 5500 3800 * 7150 5950
2,4 m

1.5 3350 2050 3950 2500 5650 3550 * 8900 5450

0.0 3400 2100 3850 2400 5450 3400 8600 5150
-1.5 3750 2350 3850 2350 5350 3300 8550 5100 * 10150 9900 * 6100 * 6100
-3.0 4600 2850 5450 3350 8600 5150 * 14300 10100 * 10900 * 10900
-4.5 * 6700 4300 * 8250 5400 * 11900 10550
6.0 * 4200 3350 * 4650 4050
4.5 4200 2700 * 5150 3900 * 6100 * 6100
3.0 3800 2400 4000 2500 5800 3700 * 7950 5750
1,8m

1.5 3650 2300 3900 2450 5550 3500 8750 5300

0.0 3800 2350 3850 2400 5400 3350 8550 5100
-1.5 4300 2650 5400 3350 8550 5100 * 10950 * 10000
-3.0 5450 3400 5550 3450 8700 5250 * 13200 10300
-4.5
6.0 * 2450 * 2450 *3300 3200
4.5 * 2450 * 2450 * 4000 3150 * 4150 * 4150
3.0 * 2600 2300 * 4450 3050 * 5050 4450 * 6400 * 6400 * 10000 * 10000
2,9m

1.5 * 2800 2200 4850 2900 * 6050 4200 * 8250 6500 * 5600 * 5600
0.0 * 3200 2250 4700 2800 6750 3950 * 9550 6100 * 6500 * 6500
-1.5 * 3850 2450 4650 2750 6550 3850 * 10150 5950 * 9550 * 9550 * 5700 * 5700
-3.0 4900 2900 6600 3850 * 10000 6000 * 14050 11900 * 9200 * 9200
-4.5 * 6200 4000 * 6250 4000 * 8900 6200 * 13050 12300
PC210LC Mono boom

6.0 * 3850 3400 * 4100 * 4100

4.5 * 3850 2800 * 4400 3100 * 4650 4650
3.0 * 4000 2550 * 4800 3050 * 5500 4400 * 7150 6900
2,4 m

1.5 4100 2450 4850 2900 * 8450 4150 * 8900 6400

0.0 4200 2500 4750 2850 6750 4000 * 9950 6100
-1.5 4650 2750 4700 2800 6650 3900 * 10250 6000 * 10150 * 10150 * 6100 * 6100
-3.0 5650 3350 6700 3950 * 9800 6100 * 14300 12150 * 10900 * 10900
-4.5 * 6700 5000 * 8250 6350 * 11900
6.0 * 4200 3900 * 4650 4650
4.5 * 4200 3150 * 5150 4500 * 6100 * 6100
3.0 * 4400 2800 4900 2950 * 5950 4300 * 7950 6700
1,8m

1.5 4500 2700 4800 2650 * 6800 4100 * 9450 6250

0.0 4700 2800 4750 2800 6650 3900 * 10150 6050
-1.5 5750 3150 6650 3900 * 10150 6050 * 10950 * 10950
-3.0 * 6600 4000 * 6700 4050 * 9350 6200 * 13200 123500
-4.5

242
SPECIFICATIONS SPECIFICATIONS

Height MAX 10.5 m 9m 7.5 m 6.0 m 4.5 m

Model

Arm

OS OF OS OF OS OF OS OF OS OF OS OF

10.5

9.0 *5750 5750 *7400 6700

7.5

6.0 3900 2550 4000 2600 6050 4050 7700 6600

1800 mm

4.5

3.0 3050 1950 3850 2500 5500 3550

1.5

0.0 3100 1950 3700 2850 5150 3250

-1.5

-3.0 *4650 3300

10.5

9.0 *4850 4250 *6500 *6500

PC210LC straight boom

7.5

6.0 3400 2200 4100 2700 *5850 4150 *6100 *6100

2400 mm

4.5

3.0 2750 1700 3900 2500 5600 3650

1.5

0.0 2750 1700 3700 2300 5200 3250

-1.5

-3.0 3750 2400 5250 3300 *6850 5150

10.5 *6500 *6500

9.0 *4400 *4400 *6350 *6350

7.5 *3750 *3400 *6050 4900 *5800 *5800

6.0 *9500 2750 5100 3350 *6250 4800 *6050 *6050

2930 mm

4.5 *3400 2400 5000 3250 *6750 4600 *8600 7150

3.0 *3400 2250 3600 2350 4850 3150 6850 4350 *9950 6550

1.5 3450 2250 3600 2300 4750 3000 6600 4100 *8800 6150

0.0 3550 2250 3600 2300 4650 2950 6450 4000 *9100 6000

-1.5 3850 2450 4650 2900 6450 3950 *9150 6050

-3.0 3550 2250 *4950 3000 *8000 4050 *7500 8510

243
SPECIFICATIONS SPECIFICATIONS

PC240LC-6K, PC240NLC-6K

LEGEND

A : Reach from swing centre

B : Bucket hook height

OF : Lifting capacity (rating over front)

OS : Lifting capacity (rating over side)

LEGEND

(1) Position of lifting point

(2) Arm length:
(3) Boom length
(4) Hydraulic pressure: Nom 36.2 MPa WORKING
Max. 37.2 MPa HOLDING CIRCUIT

WORKING CONDITIONS:

❍ WITH BUCKET (1.1 m3 CECE) ( 750 kg).

❍ IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL

INSTALLED, THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE
DEDUCTED FROM THE VALUES OF THIS TABLE.

❍ WITH FULLY EXTENDED BUCKET CYLINDER.

❍ ON A COMPACT HORIZONTAL LEVEL GROUND.

❍ WITH 700 mm WIDTH SHOE.

Loads do not exceed 87% of hydraulic capacity or 75% of tipping

capacity (* load limited by hydraulic capacity rather than tipping).

Nom 36.2 MPa

5 8 5 0 Max 37.2 MPa

AW40000

244
SPECIFICATIONS SPECIFICATIONS

Height
max 7.5 m 6.0 m 4.5 m 3.0 m 1.5 m
Model

Arm
OF OS OF OS OF OS OF OS OF OS OF OS
6.0 * 2400 * 2400 * 4050 * 4050
4.5 * 2400 * 2400 * 4450 4300
3.0 * 2550 * 2550 * 5150 4150 * 5700 * 5700 * 6900 * 6900
3,5m

1.5 * 2750 2650 * 5950 3950 * 7100 5650 * 9550 8800 * 8750 * 8750
0.0 * 3100 2700 6050 3800 * 8350 5350 * 11600 8250 * 7800 * 7800
-1.5 * 3650 2850 5900 3700 8350 5100 * 12750 7950 * 10150 * 10150 * 6000 * 6000
-3.0 * 4650 3300 5900 3650 8300 5100 * 13050 7950 * 14050 * 14050 * 9250 * 9250
-4.5 6800 4250 8450 5200 * 12500 8050 * 18550 16450 * 13250 * 13250
6.0 * 2850 * 2850 * 4400 4350
4.5 * 2850 * 2850 * 4900 4250 * 5000 * 5000
3.0 * 3000 2950 * 5550 4100 * 6250 5950 * 7850 * 7850 *12400 * 12400
3,0m

1.5 * 3250 2850 6200 3950 * 7600 5600 * 10350 8650

0.0 * 3700 2900 6050 3800 8600 5350 * 12150 8200 * 7050 * 7050
-1.5 * 4400 3150 5950 3700 8350 5150 * 13050 8000 * 10450 * 10450 * 6350 * 6350
-3.0 * 5750 3700 5950 3750 8400 5150 * 13100 8050 * 15300 * 15300 * 10250 * 10250
PC240LC

-4.5 7850 4900 8600 5300 * 12150 8520 * 17800 16750 * 15100 * 15100
6.0 * 4500 4300 * 4850 * 4850
4.5 * 4500 3650 * 5400 4200 * 5650 * 5650 * 5650
3.0 * 4750 3300 * 6000 4050 * 6850 5850 * 8850 * 8850
2,5m

1.5 5050 3200 6150 3900 6150 5500 * 11200 8500

0.0 5150 3250 6050 3800 8550 5300 * 12650 8150
-1.5 5650 3550 6000 3750 8400 5150 * 13200 8050 * 11300 * 11300
-3.0 6800 4250 8500 5250 * 12900 8100 * 18200 16500 * 12250 * 12250
-4.5 * 8900 6100 * 11450 8400 * 16500 * 16500
6.0 * 4550 * 4550 * 5400 * 5400
4.5 * 4550 3900 * 5750 4050 * 6150 6000 * 7200 * 7200
3.0 * 4750 3500 6200 3950 * 7300 5700 * 9700 8900
2,0m

1.5 * 5200 3400 6100 3850 * 8450 5450 * 11850 8300

0.0 5550 3500 6000 3750 8450 5200 * 12950 8050
-1.5 6200 3850 8400 5150 * 13200 8050 * 11600 * 11600
-3.0 7650 4800 8550 5300 * 12550 8200 * 18050 16700
-4.5 * 9250 7450 * 10350 8500

245
SPECIFICATIONS SPECIFICATIONS

Height
max 7.5 m 6.0 m 4.5 m 3.0 m 1.5 m
Model

Arm

OF OS OF OS OF OS OF OS OF OS OF OS
6.0 * 2400 * 2400 * 4050 4000
4.5 * 2400 * 2400 * 4450 3900
3.0 * 2550 2450 * 5150 3700 * 5700 5400 * 6900 * 6900
3,5m

1.5 * 2750 2350 5700 3550 * 7100 5050 * 9550 7850 * 8750 * 8750
0.0 * 3100 2350 5500 3350 7850 4750 * 11600 7300 * 7800 * 7800
-1.5 * 3650 2550 5400 3250 7600 4550 12300 7050 * 10150 * 10150 * 6000 * 6000
-3.0 * 4650 2900 5400 3250 7550 4500 12250 7000 * 14050 13850 * 9250 * 9250
-4.5 6200 3750 7700 4600 12450 * 7100 * 18550 14200 * 13250 * 13250
6.0 * 2850 * 2850 * 4400 3900
4.5 * 2850 * 2850 * 4900 3850 * 5000 * 5000
3.0 * 3000 2650 * 5550 3700 * 6250 5350 * 7850 * 7850 * 12400 * 12400
3,0m

1.5 * 3250 2550 5650 3500 * 7600 5000 * 10350 7700

0.0 * 3700 2600 5500 3350 7650 4750 * 12150 7250 * 7100 * 7100
-1.5 * 4400 2800 5450 3300 7600 4550 12350 7100 * 10450 * 6350 * 6350
PC240NLC

-3.0 5350 3250 5450 3300 7650 4600 12400 7100 * 15300 * 14100 * 10250 * 10250
-4.5 7200 4350 7800 4750 * 12150 7300 * 17800 14500 * 15100 * 15100
6.0 * 4500 3900 * 4850 * 4850
4.5 * 4500 3250 * 5400 3750 * 5650 5550
3.0 * 4750 2950 5800 3650 * 6850 5250 * 8850 8200
2,5m

1.5 4600 2850 5650 3500 8050 4950 * 11200 7550

0.0 47000 2900 5500 3350 7800 4700 12500 7200
-1.5 5150 3150 5450 3350 7650 4600 12400 7100 * 11300 * 11300
-3.0 6200 3800 7750 4650 12500 7200 * 18200 14250 * 12250 * 12250
-4.5 * 8900 5450 * 11450 7450 * 16500 14750
6.0 * 4550 4250 * 5400 * 5400
4.5 * 4550 3500 * 5750 3650 * 6150 5400 * 7200 * 7200
3.0 * 4750 3150 5700 3550 * 7300 5100 * 9700 7950
2,0m

1.5 4900 3000 5550 3400 7950 4850 * 11850 7350

0.0 5100 3100 5500 3350 7700 4600 12400 7100
-1.5 5650 3450 7650 4600 12400 7100 * 11600 * 11600
-3.0 7000 4250 7800 4700 12550 7250 * 18050 * 14450
-4.5 * 9250 6650 * 10350 7500

246
SPECIFICATIONS SPECIFICATIONS

PC210, PC210LC 2-PC BOOM

Model

max 7.5 m 6.0 m 4.5 m 3.0 m 1.5 m

Height
Arm

OF OS OF OS OF OS OF OS OF OS OF OS

6.0 * 2200 * 2200 * 2800 2800 * 3000 * 3000

4.5 * 2200 * 2200 * 3600 2750 * 3550 * 3550
3.0 * 2250 2000 * 4050 2650 * 4450 3950 * 5500 * 5500 * 8450 * 8450
2,9 m

1.5 * 2450 1900 3900 2550 * 5500 3700 * 7500 5750 * 6850 * 6850
0.0 * 2800 1950 3800 2400 5400 3450 8600 5350 * 7200 * 7200
-1.5 3350 2100 3750 2350 5300 3350 8450 5200 * 10250 10100 * 6800 * 6800
-3.0 4000 2550 5300 3350 8450 5200 * 15000 10250
6.0 * 3600 3200 * 3550 * 3550
PC210 2 PC boom

4.5 * 3600 2600 * 4050 2700 * 4100 * 4100 * 4500 * 4500

3.0 3550 2300 4050 2650 * 5000 3900 * 6300 6200
2,4 m

1.5 3450 2250 3900 2550 5650 3650 * 8200 5650

0.0 3550 2250 3850 2450 5450 3500 8600 5350 * 7200 * 7200
-1.5 3900 2500 5350 3400 8500 5250 * 11800 10250
-3.0 4850 3100 5400 3450 8550 5350
6.0 * 3900 3700 * 4250 4150
4.5 * 3900 2950 * 4650 4050 * 5300 * 5300 * 7300 * 7300
3.0 4000 2600 4000 2600 *5500 3800 *7150 5950
1,8m

1.5 3850 2450 3900 2500 5550 3600 8750 5500

0.0 3950 2550 5400 3450 8500 5250
-1.5 4450 2850 5400 3450 8500 5250 * 13000 10250
-3.0
6.0 * 2200 * 2200 * 2800 * 2800 * 3000 * 3000
4.5 * 2200 * 2200 * 3600 2800 * 3550 * 3550
3.0 * 2250 2050 * 4050 2700 * 4450 4000 * 5500 * 8450 * 8450
2,9m

1.5 * 2450 1950 * 4650 2600 * 5500 3750 * 7500 5850 * 6850 * 6850
0.0 * 2800 2000 4550 2450 * 6450 3550 * 9050 5450 * 7200 * 7200
-1.5 * 3350 2150 4500 2400 6350 3400 * 10000 5300 * 10250 * 10250 * 6800 * 6800
-3.0 * 4500 2600 6350 3400 * 10300 5300 * 15000 10450
6.0 * 3600 3250 * 3550 * 3550
PC210LC 2 pc boom

4.5 * 3600 2650 * 4050 2800 * 4100 * 4100 * 4500 * 4500

3.0 * 3800 2350 * 4450 2700 * 5000 4000 * 6300 6300
2,4m

1.5 4100 2250 4650 2500 6500 3550 * 9550 5450 * 7200 * 7200
0.0 4200 2300 4550 2500 6500 3550 * 9550 5450 * 7200 * 7200
-1.5 4700 2550 6450 3500 * 10250 5350 * 11800 10450
-3.0 5800 3150 6450 3500 * 10350 5450
6.0 * 3900 3750 * 4250 4200
4.5 * 3900 3000 * 4650 4100 * 5300 * 5300 * 7300 * 7300
3.0 * 4150 2650 * 4200 2650 * 5500 3900 * 71500 6050
1,8m

1.5 4550 2500 4650 2550 * 6400 3700 * 8850 5600

0.0 4700 2600 6500 3550 * 9950 5350
-1.5 5350 2950 6450 3500 * 10400 5350 * 13000 10450
-3.0

247
SPECIFICATIONS SPECIFICATIONS

PC240LC, PC240 NLC 2 pc Boom

Height
max 7.5 m 6.0 m 4.5 m 3.0 m 1.5 m
Model

Arm

OF OS OF OS OF OS OF OS OF OS OF OS
6.0 * 2350 * 2350 * 3500 * 3500

4.5 * 2350 * 2350 * 3900 * 3900 * 3850 * 3850

3.0 * 2450 * 2450 * 4600 4150 * 5050 * 5050 * 6150 * 6150 * 9050 * 9050
3.5 m

1.5 * 2650 2650 * 5450 4000 * 6450 5700 * 8750 * 8750 * 8100 * 8100

0.0 * 2950 2650 6100 3800 * 7750 5400 * 10900 8350 * 7350 * 7350

-1.5 * 3500 2850 6000 3700 8550 5200 * 12300 8100 * 9750 * 9750 * 6450 * 6450

-3.0 * 4400 3300 6000 3700 8500 5150 * 13050 8050 * 13650 * 13650 * 9950 * 9950

6.0 * 2800 * 2800 * 4050 * 4050

4.5 * 2800 * 2800 * 4400 4300 * 4400 * 4400

3.0 * 2900 * 2900 * 5050 4150 * 5650 * 5650 * 7050 * 7050 * 11200 * 11200
3.0 m
PC240LC 2 pc Boom

1.5 * 3150 2850 * 5800 4000 * 7000 5650 * 9600 8800

0.0 * 3550 2900 6150 3850 * 8250 5400 * 11550 8350 * 6600 * 6600

-1.5 * 4200 3150 6050 3750 8600 5250 * 12750 8150 * 10000 * 10000 * 6750 * 6750

-3.0 * 5450 3700 6100 3800 8600 5250 * 13250 8200 * 14950 * 14950
6.0 * 4400 4250 * 4250 * 4250

4.5 * 4400 3600 * 4900 4200 * 5000 * 5000 * 5600 * 5600

3.0 * 4600 3300 * 5500 4100 * 6200 5900 * 8050 * 8050

2.5 m

1.5 * 5000 3150 * 6200 3950 * 7500 5600 * 10500 8650

0.0 5200 3250 6150 3850 * 8650 5400 * 12200 8300

-1.5 5700 3550 6100 3800 8650 5300 * 13100 8200 * 10650 * 10650

-3.0 6850 4250 8650 5350 * 13250 8300

6.0 * 4450 * 4450 * 4800 * 4800

4.5 * 4400 3850 * 5350 4100 * 5500 * 5500 * 6400 * 6400 * 9150 * 9150

3.0 * 4600 3500 * 5850 4000 * 6650 5750 * 8850 * 8850

2.0 m

1.5 * 5000 3350 6150 3850 * 7900 5500 * 11150 8450

0.0 5600 3450 6100 3800 8650 5300 * 12600 8200

-1.5 6200 3850 8600 5250 * 13200 8150 * 10900 * 10900

-3.0 7700 4800 8700 5350 * 13050 8300

248
SPECIFICATIONS SPECIFICATIONS

Height
Model

Arm max 7.5 m 6.0 m 4.5 m 3.0 m 1.5 m

OF OS OF OS OF OS OF OS OF OS OF OS
6.0 * 2350 * 2350 * 3500 * 3500

4.5 * 2350 * 2350 * 3900 * 3900 * 3850 * 3850

3.0 * 2450 2400 * 4600 3750 * 5050 * 5050 * 6150 * 6150 * 9050 * 9050
3.5 m

1.5 * 2650 2300 * 5450 3550 * 6450 5100 * 8750 7900 * 8100 * 8100

0.0 * 2950 2350 5600 3350 * 7750 4800 * 10900 7350 * 7350 * 7350

-1.5 * 3500 2500 5450 3250 7750 4600 * 12300 7100 * 9750 * 9750 * 6450 * 6450

-3.0 * 4400 2900 5450 3250 7700 4550 12500 7050 * 13650 * 13650 * 9950 * 9950

6.0 * 2800 * 2800 * 4050 3950

4.5 * 2800 * 2800 * 4400 3850 * 4400 * 4400

3.0 * 2900 2600 * 5050 3700 * 5650 5400 * 7050 * 7050 * 11200 * 11200
PC240NLC 2 pc Boom
3.0 m

1.5 * 3150 2550 5750 3550 * 7000 5050 * 9600 7800

0.0 * 3550 2550 5600 3400 7950 4800 * 11550 7350 * 6600 * 6600

-1.5 * 4200 2800 5500 3750 7800 4650 12650 7200 * 10000 * 10000 * 6750 * 6750

-3.0 5400 3250 5550 3350 7800 4650 12650 7200 * 14950 14350

6.0 * 4400 3850 * 4250 * 4250

4.5 * 4400 3200 * 4900 3750 * 5000 * 5000 * 5600 * 5600

3.0 * 4600 2900 * 5500 3650 * 6200 5300 * 8050 * 8050

2.5 m

1.5 4600 2800 5700 3500 * 7500 5000 * 10500 7650

0.0 4750 2850 5600 3400 7950 4800 * 12200 7300

-1.5 5200 3150 5550 3350 7850 4700 12650 7250 * 10650 * 10650

-3.0 6250 3800 7900 4700 12750 7300

6.0 * 4450 4150 * 4800 * 4800

4.5 * 4400 3450 * 5350 3650 * 5500 5450 * 6400 * 6400 * 9150 * 9150

3.0 * 4600 3100 5750 3550 * 6650 5150 * 8850 8000

2.0 m

1.5 4900 3000 5650 3450 * 7900 4900 * 11150 7450

0.0 5100 3050 5550 3350 7850 4700 * 12600 7200

-1.5 5650 3400 7800 4650 12650 7200 * 10900 * 10900

-3.0 7000 4250 7900 4750 12800 7350

249
SPECIFICATIONS SPECIFICATIONS

250
OPTIONS, ATTACHMENTS

251
PRECAUTIONS RELATED TO SAFETY OPTIONS, ATTACHMENTS

PRECAUTIONS RELATED TO SAFETY

If attachments or options other than those authorised by Komatsu
are installed, this will not only affect the life of the machine, but
will also cause problems with safety.

When installing attachments not listed in this Operation and Main-

tenance Manual, please contact your Komatsu distributor first.

If you do not contact Komatsu, we cannot accept any responsibil-

ity for any accident or failure.

WARNING
Precautions for removal and installation operations
When removing or installing attachments, obey the following
precautions and take care to ensure safety during the opera-
tion.

● Carry out the removal and installation operations on a

flat, firm ground surface.

● When the operation is carried out by two or more work-

ers, determine signals and follow these during the opera-
tion.

● When carrying heavy objects (more than 25 kg), use a

crane.

● When removing heavy parts, always support the part

before removing it.
When lifting such heavy parts with a crane, always pay
careful attention to the position of the centre of gravity.

● It is dangerous to carry out operations with the load kept

suspended. Always set the load on a stand, and check
that it is safe.

● When removing or installing attachments, make sure that

they are in a stable condition and will not fall over.

● Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load
should fall.

NOTICE
Qualifications are required to operate a crane. Never allow
the crane to be operated by unqualified person.
For details of the removal and installation operations, please
contact your Komatsu distributor.

252
OPTIONS, ATTACHMENTS PRECAUTIONS RELATED TO SAFETY

PRECAUTIONS WHEN INSTALLING ATTACHMENTS

WARNING
Long work equipment reduces the stability of the chassis, so
if the swing is operated on a slope, or when going down a
steep hill, the machine may lose its balance and overturn.
The following operations are particularly dangerous, so
never operate the machine in these ways.

● If heavy work equipment is installed, the overrun of the

swing becomes greater (the distance from the point
where the operator operates the control levers to stop
the swing to the point where the upper structure stops
completely), so there is danger of mistaking the distance
and hitting something.
Always operate so that there is an ample margin to the
stopping point.
Furthermore, the hydraulic drift also becomes larger
when the work equipment is stopped in mid air, it will AD338730A
gradually move down under its own weight).

● Always follow the correct procedure when installing the

boom and arm. If the correct procedure is not followed,
this may lead to serious damage or injury, so please con-
sult your Komatsu distributor before carrying out instal-
lation.

AM090850A

● If long work equipment is installed, the working range

will suddenly become larger, so there is danger of mis-
taking the distance and hitting something.
Always operate the work equipment so that there is
ample space from any obstacles in the area. Platform

AM090860A

253
HANDLING BUCKET WITH HOOK OPTIONS, ATTACHMENTS

HANDLING BUCKET WITH HOOK

CHECKING FOR DAMAGE TO BUCKET WITH HOOK

Check that there is no damage to the hook, stopper, or hook
mount. If any abnormality is found, please contact your Komatsu
distributor.

AM091840A

PROHIBITED OPERATIONS
The standard work equipment must not be used for lifting loads. If
this machine is to be used for lifting loads, it is necessary to install
the special bucket with hook.

PRECAUTIONS DURING OPERATIONS

● When carrying out lifting operations, reduce the engine speed
and use the lifting operation mode. CORRECT
● Depending on the posture of the work equipment, there is
danger that the wire or load may slip off the hook. Always be
careful to maintain the correct hook angle to prevent this from
happening.

● Never steer the machine while lifting a load.

AL069260A
● If the bucket with hook is turned and used for operations, it
will hit the arm during dumping operations, so be careful
when using it.

● The loads must never exceed those specified in the lifting

capacity chart when carrying out lifting operations. INCORRECT
● If you wish to install a hook in the future, please contact your
Komatsu distributor.

AL069270A

254
OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS

MACHINES READY FOR ATTACHMENTS

EXPLANATION OF COMPONENTS

AM092000A

1. STOP VALVE

This valve stops the flow of the hydraulic oi

2
1

l(1) FLOW : Hydraulic oil flows

(2) STOP : Hydraulic oil stops.

Set this valve to the STOP position when removing or installing
attachments.

255
MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS

2. SELECTOR VALVE

This switches the flow of the hydraulic oil.

For details of the attachment to install and the direction

of right 3-way valve, see “5. HYDRAULIC CIRCUIT” on
page 257.

3. CONTROL PEDAL FOR ATTACHMENT

1
This is used to operate the attachment.

The pedal can be depressed to the front, neutral, and rear to N

operate the attachment as follows.
2

Hydraulic breaker AM092130D

Pedal front (1) actuated

Pedal neutral (N) stopped

Pedal rear (2) stopped

● When the breaker is used, select the breaker operation mode

(B.O) in the monitor panel.

For other attachments, confirm with the manufacturer regarding

the relation between pedal operation and attachment movement
when the attachment is mounted. Use the attachment only after
confirming the above.

● Flow from the left hand second attachment pedal can be

modified by adjusting the stroke limiting bolts (1) located 1
under the pedal. 1

4. ACCUMULATOR
PC21056

WARNING
The accumulator is filled with high-pressure nitrogen gas,
and it is extremely dangerous if it is handled in the wrong
way.

For handling procedure, see "HANDLING ACCUMULA-

TOR".

The accumulator is provided to release the pressure remaining in AM090140A

the attachment circuit after stopping the engine. Normally, never
touch it.

256
OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS

5. HYDRAULIC CIRCUIT

Change-over hydraulic circuit

Contact dealer to set left hand boom piping relief pressure.

When using the breaker and the general attachment (Crusher

etc.), turn the rotor of the 3 way valve a to change over according
to the following illustration.

(The marks indicating the port direction are stamped on the 3-way
valve).

Attachments Right 3-way valve (1)

Front

1-way frow (Breaker)

Front

2-Way flow (Crusher)

NOTICE
Perform work only after the engine is stopped and the work
equipment and machine body are in a stable posture on the
ground.

257
MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS

CONNECTING HYDRAULIC CIRCUIT

When connecting the attachment, connect the circuit as follows.

1. Remove blind plugs (1) located on the end of the stop valve
piping (2 places, left and right).
Take care not to lose or damage the removed parts.

2. Connect attachment tubes (2) supplied by the attachment

manufacturer to the end from which the plug was removed in
step (1).

Path of Oil

The direction of operation of the pedal and the path of the oil are
as shown in the diagram below.

AM092080A

258
OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS

ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE

Dismounting procedure

1. Curl the arm in then lower the boom to the ground. Set the
attachment valves on the arm to the stop position as shown.

2. Place the attachment on the ground and stop the engine.

3. Operate levers and attachment pedals to full stroke 2 to 3

times to release hydraulic system pressure. Ensure oil tem-
perature is low.

4. Remove the hoses on the attachment side. Install the blind

plugs to the two outlets (1).
Install blind plugs to the attachment hoses to prevent entry of FLOW STOP
dirt during dismounting and storage.

5. Dismount the attachment by removing the retaining pins (2

pins). Then, mount the bucket.

For the bucket mounting procedure, see “REPLACE-

MENT AND INVERSION OF BUCKET” on page 131.

6. After the bucket is mounted, check the hydraulic oil level.

fMOUNTING PROCEDURE

1. Remove the bucket.

For bucket dismounting procedure, see “REPLACEMENT

AND INVERSION OF BUCKET” on page 133.

2. Place the attachment on a flat place, install pins (A) and (B) to
the arm in that order.

3. After mounting the attachment, stop the engine. Operate

each work equipment control lever and the attachment control
pedal to full stroke back and forth, right and left to eliminate
the internal pressure in the hydraulic circuit.

4. After confirming low oil temperature, remove the blind plug

from the outlet and inlet port respectively.

Take care that no dust, mud, etc. adheres to the hose mouthpiece
portions.
If O-ring is damaged, replace it with a new one.

259
MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS

5. Turn the rotor of the stop valve connected to the inlet and out-
let piping on the arm side face to the free position.

6. Confirm that oil level in the hydraulic oil tank is correct, after
mounting the attachment.

FLOW STOP

OPERATION

WARNING
● Be careful when operating the pedal in the deceleration
range. The engine speed will rise suddenly.

● Do not put your foot on the pedal except when operating

the pedal. If rest your foot on the pedal during opera-
tions, 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

Set the stop valve to the FLOW position, and depress the front of
the pedal to operate the breaker.
N
Select the working mode for breaker (B.O).

Precautions when using

● Check that the stop valve is in the FLOW position. AM092130D

● Check that the selector valve is in the position for using the
breaker.

For details of the path followed by the oil, see “5.

HYDRAULIC CIRCUIT” on page 257.

● For details of other precautions when handling the breaker,

read and use correctly the instruction manual provided by the
breaker manufacturer.

● When using the breaker, the hydraulic oil deteriorates more

rapidly than for normal operations, so change the hydraulic oil
and replace the element at a shorter interval.

For details, see “MAINTENANCE WHEN USING HYDRAU-

LIC BREAKER” on page 212.

260
OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS

When using general attachment such as crusher

When the pedal is depressed at the front to rear portitions, the

attachment is actuated.

Precautions when using

N

AM092130D

● Check that the stop valve is at the flow position.

● Confirm that the selector valve is set tot the position for gen-
eral attachments such ast the crusher.

For details of the oil path, see “5. HYDRAULIC CIRCUIT”

on page 257.

● For other precautions when using the attachment, see the

instruction manual provided by the attachment manufacturer.

FLOW STOP
LONG TERM STORAGE

If the machine is not to be used for a long period, do as follows.

● Set the stop valve to the STOP position.

● Install the blind plugs and O-rings to the valves.

If the pedal is operated when there is no breaker or general

attachment installed, it will cause overheating and other prob-
lems.

SPECIFICATIONS

Attachments Right 3-way valve (1)

Front

1-way frow (Breaker)

Front

2-Way flow (Crusher)

261
MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS

Hydraulic specifications

● Max. flow when flow is joined: 191 x 2 liter/min

● Safety valve relief set pressure of service valve: 27500 kPa

(280 kg/cm²)

● Safety valve cracking set pressure of service valve: 24500

kPa (250 kg/cm²)

● Left hand boom piping flow and right hand flow can have dif-
ferent pressures.
Consult your dealer for various pressures available.

FIRST ATTACHMENT WITH CLAM-SHELL OPTION

Machines fitted with a single attachment circuit can also be sup-

plied with clam-shell grab piping or can have such piping fitted at
a later time.

The clam-shell open/close function uses the bucket cylinder cir-

cuit with the bucket cylinder disable by the two arm mounted stop
valves (Left hand side example shown below).

The first attachment circuit (right hand cab pedal) can be used to
rotate grabs with a rotary function with the revo-frame mounted 3-
way valve set to 2-way flow.

Fine control of rotation can be achieved by adjusting the maxi-

mum output of the first attachment using the righthand panel
mounted 10 position switch.

Normal flow to bucket cylinder Flow to clam shell

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OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS

FIRST AND SECOND ATTACHMENT

This option can only be fitted to machines that have the main
valve converted to or supplied with 2 attachment spool additions
(8 spools in total)

The arm end valves are set to the flow or stop position as shown
in the figure below.

The second attachment when fitted, is permanently set in two way

flow with full flow (2-pump) output and full system pressure.

Attachment pressures can be modified by your local dealer on

request and can have different pressures for left hand and right-
hand piping by modifying the relief valves in the main control
valve portions.

When handling attachments please follow the same procedure

and precautions as applied to the first attachment circuit (attach-
ment mounting/dismounting).

FLOW

STOP

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INTRODUCTION OF ATTACHMENTS OPTIONS, ATTACHMENTS

INTRODUCTION OF ATTACHMENTS

SPECIFICATION, USE

PC210-6K, PC210 LC-6K

NAME Specification, use

Capacity SAE/CECE 0.45 m³/0.41 m³

Narrow bucket
Outside width 650 mm

Capacity SAE/CECE 0.60 m³/0.55 m³

Narrow bucket
Outside width 800 mm

Capacity SAE/CECE 0.71 m³/0.65 m³

Narrow bucket
Outside width 900 mm

Capacity SAE/CECE 0.87 m³/0.78 m³

General use bucket
Outside width 1050 mm

Capacity SAE/CECE 1.08 m³/0.96 m³

Light duty bucket
Outside width 1250 mm

Capacity SAE/CECE 1.19 m³/1.06 m³

Light duty bucket
Outside width 1350 mm

NAME Specification, use

Track shoes Triple grouser shoe width 700 mm

(PC210) Triple grouser shoe width 800 mm

Triple grouser shoe width 600 mm

Track shoes
Triple grouser shoe width 800 mm
(PC210LC)
Triple grouser shoe width 900 mm

Arm length 2,400 mm

Short arm
Max. digging depth 6,095 mm

Arm length 2,800 mm

Short arm
Max. digging depth 5,485 mm

In place where there is danger of falling rocks, always

Head guard
install the head guard to protect the operator.

FOPS Level 1/ level 2 (see section 6)

Level 1/ level 2 (see section 6)

FRONT GUARD

Optional Equipment

● Large capacity batteries (2 x 140 Ah)

● Additional work lamps
❍ - cab mounted (x 3)
❍ - RH boom
❍ - counterweight mounted

● Rotating beacon lamp

264
OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS

● Heated operators seat

● Arm hose burst valve
● Lower windscreen wiper
● Radio/cassette
● Additional hydraulic circuit piping
● Air suspention heated seat
● Work levers with 4 bottoms

PC240NLC-6K, PC240 LC-6K

NAME Specification, use

Capacity SAE/CECE 0.49 m³/0.45 m³

Narrow bucket
Outside width 650 mm

Capacity SAE/CECE 0.77 m³/0.71 m³

Narrow bucket
Outside width 900 mm

Capacity SAE/CECE 0.95 m³/0.86 m³

General use bucket
Outside width 1050 mm

Capacity SAE/CECE 1.19 m³/1.07 m³

Light duty bucket
Outside width 1250 mm

Capacity SAE/CECE 1.30 m³/1.12 m³

Light duty bucket
Outside width 1450 mm

NAME Specification, use

Triple grouser shoe width 600 mm

Track shoes
Triple grouser shoe width 800 mm
(PC240LC)
Triple grouser shoe width 900 mm

Track shoes Triple grouser shoe width 700 mm

(PC240NLC) Triple grouser shoe width 800 mm

Arm length 2,500 mm

Short arm
Max. digging depth 6,370 mm

Arm length 2,000 mm

Short arm
Max. digging depth 5,870 mm

Arm length 3,500 mm

Long arm
Max. digging depth 7,350 mm

In place where there is danger of falling rocks, always

Head guard
install the head guard to protect the operator.

FOPS Level 1/ level 2 (see section 6)

FRONT GUARD Level 1/ level 2 (see section 6)

Optional Equipment

● Large capacity batteries (2 x 140 Ah)

● Additional work lamps
❍ - cab mounted (x 3)
❍ - RH boom

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INTRODUCTION OF ATTACHMENTS OPTIONS, ATTACHMENTS

❍ - counterweight mounted
● Rotating beacon lamp
● Heated operators seat
● Arm hose burst valve
● Lower windscreen wiper
● Radio/cassette
● Additional hydraulic circuit piping
● Air suspention heated seat
● Work levers with 4 bottom

ATTACHMENT INSTALLATION COMBINATION TABLE

PC210-6K, PC210LC-6K

This table lists the combination of attachments which can be

installed to the different arms.

❍ Can be used. (max weight up to 1.8 t/m³)

❏ Can be used . (max. weight up to 1.5 t/m³)

▲ Can be used only for light duty work

(max. weight up to 1.2 t/m³)

✕ 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.

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OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS

For loading work : loading dry, loose earth and sand

● For digging or loading hard soil or soft rock, it is recom-

mended that the strengthened bucket with high durability and
wear resistance be used

NOTICE
● When the extension arm is equipped, if the bucket is
drawn tot 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..

Bucket capacity heaped (m³) Weight Arm

Outside
(with side No. of
without side
cutters) teeth
SAE, PCSA CECE cutters (mm) 1.8 m 2.4 m 2.93 m
(kg)

0.45 0.41 650 486 3 ❍ ❍ ❍

0.60 0.55 800 552 3 ❍ ❍ ❍

0.71 0.65 900 583 5 ❍ ❍ ❍

0.87 0.78 1050 631 5 ▲ ▲ ▲

1.08 0.96 1250 713 6 ▲ ▲ ▲

1.19 1.06 1350 745 6 ❍ ❍ ✕

These charts are based on over-side stability with fully loaded

bucket at maximum reach.

A wide variety of buckets & attachments is available. Contact your

local dealer for more information.

PC240NLC-6K, PC240LC-6K

This table lists the combination of attachments which can be

installed to the different arms.

❍ Can be used. (max weight up to 1.8 t/m³)

❏ Can be used . (max. weight up to 1.5 t/m³)

▲ Can be used only for light duty work

(max. weight up to 1.2 t/m³)

✕ 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.

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INTRODUCTION OF ATTACHMENTS OPTIONS, ATTACHMENTS

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 recom-

mended that the strengthened bucket with high durability and
wear resistance be used

NOTICE
● When the extension arm is equipped, if the bucket is
drawn tot 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.

Bucket capacity heaped (m³) Weight Arm

Outside
(with side No. of
without side
cutters) teeth
SAE, PCSA CECE cutters (mm) 2.0 m 2.5 m 3.05 m 3.5 m
(kg)

0.49 0.45 650 513 3 ❍ ❍ ❍ ❍

0.77 0.71 968 616 3 ❍ ❍ ❍ ❏

0.95 0.86 1050 666 4 ❍ ❍ ❍ ▲

1.19 1.07 1250 752 5 ❏ ❏ ▲ ✕

1.30 1.12 1450 800 5 ▲ ▲ ▲ ✕

These charts are based on over-side stability with fully loaded

bucket at maximum reach.

A wide variety of buckets & attachments is available. Contact your

local dealer for more information.

SELECTION OF TRACK SHOES

Select suitable track shoes to match the operating conditions.

METHOD OF SELECTING SHOES

Confirm the category from the list of uses in Table 1, then use
Table 2 to select the shoe.

● Categories B and C are wide shoes, so there are limitations

on their use. When using these shoes, check the precautions,
then investigate and study fully the conditions of use to con-
firm that these shoes are suitable.

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OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS

● When selecting the shoe width, select the narrowest shoe

possible that will give the required flotation and ground pres-
sure. If a wider shoe than necessary is used, the load on the
track will increase, and this will cause the shoes to bend, links
to crack, pins to break, shoe bolts to come loose, and various
other problems

Table 1: .

Category Use Precautions when using

Rocky ground, riverbeds, normal ● On rough ground with large obstacles such as boulders
A
soil or fallen trees, travel at low speed.

● These shoes cannot be used on rough ground where

there are large obstacles such as boulders or fallen
trees.
B Normal soil, soft ground
● Travel at Hi speed only on flat ground, and if it is impos-
sible to avoid going over obstacles, shift down and travel
at half speed in Lo.

● Use the shoes only in places where the machine sinks

and it is impossible to use A or B shoes.
● These shoes cannot be used on rough ground where
Extremely soft ground (swampy there are large obstacles such as boulders or fallen
C
ground) trees.
● Travel at Hi speed only on flat ground, and if it is possi-
ble to avoid going over obstacles, shift down and travel
at half speed in Lo.

Table 2:

PC210-6K PC210LC-6K PC240NLC-6K PC240LC-6K

Specifications Category Specifications Category Specifications Category Specifications Category

600 triple
600 triple grouser A 600 triple grouser A 600 triple grouser A A
grouser

700 triple
700 triple grouser B 700 triple grouser B 700 triple grouser B B
grouser

800 triple
800 triple grouser C 800 triple grouser C 800 triple grouser C C
grouser

900 triple
900 triple grouser C C
grouser

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INTRODUCTION OF ATTACHMENTS OPTIONS, ATTACHMENTS

SELECTION OF BUCKET TEETH

Select suitable bucket teeth to match the operating conditions.

METHOD OF SELECTING TEETH

The standard teeth can be used over a wide range, but according
to the operating conditions, we recommend the following teeth.

Long-life teeth

● Jobsites where wear life is demanded, such as when loading

hard rocks.

● Jobsites where no penetration is needed, such as when work-

ing with crushed rock 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 teeth

● Jobsites demanding penetration such as digging and loading

sandy or clayey soil.

HANDLING TRAPEZOIDAL BUCKET

This bucket is used to dig trapezoidal ditches on paddy fields,
farmland ect. and can dig 3 types of ditch gradients ( 45o, 40o and
38o) when a movable plate is attached.

● The mounting position of the movable plate varies depending

on whether the ditch gradient is 45o, 40o or 38o.

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OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS

How to perform excavation

Operate the boom, the arm and the bucket to make the line (A) of
the side-plate of the bucket vertical. 45°, 40°, 38°
45° ditch hole
ditch hole
The guide plate (B) to check this position is installed beside the
40° ditch hole
bucket pins. Accordingly, hold this plate horizontal when digging.

38° ditch hole

38°, 40° ditch hole

Ditch gradient of 45o

Attached the bucket only or the movable plate by selecting the

related ditch holes. Perform digging by the above method.

Ditch gradient of 40o or 38o

Attached the bucket only or the movable plate by selecting the

related ditch holes. Perform digging by the above method.

Even if the trapezoidal bucket is provided with the movable plate,

always perform digging with the bucket side face perpendicular to
the ground.

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INTRODUCTION OF ATTACHMENTS OPTIONS, ATTACHMENTS

USING THE EXTENSION ARM

When the extension arm is installed, be careful when retracting
the arm because the bucket hits the foot of the boom cylinder or
the lower frame of the swing circle. be careful at operation and
transportation.

(A): Prohibited zone to be operated

● When the extension arm is equipped, use the narrow bucket

(bucket width: 750 mm and 560 mm without the side-cutter.
Since the standard bucket causes body instability and the
bucket interferes with the operator’s cab when retracting the
arm, do not mount the standard bucket.

● Work in hard soil or rocky terrain will shorten the life of the
extension arm, the boom and the arm.
It is better not to use the extension arm in such conditions.

HANDLING THE CLAMSHELL BUCKET

This bucket is used for digging and loading in side-ditches or in
confined spaces.

How to perform excavation

This clamshell digs by pushing the boom against the ground.

However, when performing bucket operations, perform digging

while gradually raising the boom.

If the clamshell bucket rotates, relieve the bucket cylinder pres-

sure then set the lever to the neutral position. This can temporally
stop the rotation.

PRECAUTIONS WHEN USING.

● For safety, always avoid abrupt travelling, swing and stop-

ping.

● Make the teeth of the bucket vertical in digging.

● Do not swing the bucket to crush the rock or to cut through

soil.

● Do not use the bucket for hammering or pulling out piles etc.

● Before leaving the machine, open the bucket and lower it to

the ground.

Remove the bucket from the arm when transporting the machine.

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

EXTENDING MACHINE SERVICE LIFE

This section describes the necessary precautions to be observed
when operating a hydraulic excavator equipped with an attach-
ment.

NOTICE
Select the attachment most suited to the machine body.

● The machine models to which attachments can be mounted

vary. For selection of attachment and machine model, consult
your Komatsu distributor.

HYDRAULIC BREAKER
MAIN FIELDS OF APPLICATION

❍ Crushed rock

❍ Demolition work

❍ Road construction

This attachment can be used for a wide range of work including

demolition of buildings, breaking up of road surfaces, tunnel work,
breaking up slag, rock crushing, and breaking operations in quar-
ries.

AL069750A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

Keep the chisel pushed perpendicularly against the impact sur-

face when carrying out breaking operations.

90

90
AL069760A

When applying impact, push the chisel against the impact surface
and operate so that the chassis rises approx. 5 cm off the ground.
Do not let the machine come further off the ground than neces-
sary.

5cm AL069770A

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 opera-
tions closer to the edge.

AL069780A

The direction of penetration of the chisel and the direction of the

breaker body will gradually move out of line with each other, so
always adjust the bucket cylinder to keep them aligned.

AL069790A

Always keep the chisel pressed against the impact surface prop-
erly to prevent using the impact force when there is no resistance.

AL069800A

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

MISTAKEN METHODS OF USE

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 the cylinder to the end of its stroke. Always

leave approx. 5 cm to spare.

Using the mount to gather in pieces of rock

AL069810A

Operations using the swing force

AL069820A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

Moving the chisel while carrying out impacting operations

AL069830A

Holding the chisel horizontal or pointed up when carrying out

impacting operations

AL069840A

Twisting the chisel when it has penetrated the rock

AL069850A

Pecking operations

AL069860A

Extending the bucket cylinder fully and thrusting to raise the

machine off the ground

AL069870A

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

POWER RIPPER

MAIN FIELDS OF APPLICATIONS

● Road repair work

● Demolition work

This attachment can be used for a wide range of work including

peeling off and crushing pavement roads, demolishing wooden
houses and buildings, and crushing foundation and roadbeds.

MISTAKEN METHODS OF USE

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. AM092190A

● Do not operate the cylinder to the end of its stroke. Always

leave approx. 5 cm to spare.

Impact operations using attachment

AM092200A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

Impact operations using swing force

AM092210A

Overloading work equipment during lifting and loading operations

AM092220A

Operations using attachment to grip at an angle

AM092230A

FORK GRAB
MAIN FIELDS OF APPLICATION

❍ Disposing of industrial waste

❍ Disposing of demolition waste

This can be used for a wide range of work including collecting or

loading demolition waste materials and debris, timber, grass.

MISTAKEN METHODS OF USE

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 the cylinder to the end of its stroke. AM092240A

Always leave approx. 5 cm to spare.

278
OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

Operations using the swing force

AM092250A

Operations using one side of work equipment

AM092260A

Pushing fork into ground surface to jack up and change direction

of machine

AM092270A

Impact operation with no load

AM092280A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

GRAPPLE BUCKET

MAIN FIELDS OF APPLICATION

❍ Demolition

❍ Disposing of industrial waste

❍ Forestry

This bucket is widely used for demolition including breaking-up

work, grading and digging, clean-up work after natural disasters,
dumping industrial waste, and forestry work, etc.

MISTAKEN METHODS OF USE

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.
AM092290A

Do not operate the cylinder to the end of its stroke. Always leave
approx. 5 cm to spare.

Operations using the swing force

AM092300A

Grabbing an object using buckets on only one side

AM092310A

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

Closing the sub-bucket with the boom and arm fully extended.

AM092320A

Impact operation with no load

AM092330A

SCRAP GRAPPLE

MAIN FIELDS OF APPLICATION

❍ Disposal of rock or debris

This attachment is mounted to the arm end and used to grasp

rock, debris etc. by opening and closing the claws (3 to 5) corre-
sponding to the extension and retraction of the hydraulic cylinder.

MISTAKEN METHODS OF USE

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 the cylinder to the end of its stroke.

Always leave approx. 5 cm to spare.

AM092340A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

Operations using the swing force

AM092350A

Operations using one side of work equipment

AM092360A

Catching and dragging with claw end

AM092370A

Gouging

AM092380A

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

CRUSHER & SMASHER

MAIN FIELDS OF APPLICATION

❍ Demolition

❍ Road repair work

This is the optimum attachment for demolition of steel frame rein-

forced structures, and for crushing of concrete blocks and rock,
etc. The unique blade shape provides heavy crushing power.

MISTAKEN METHODS OF USE

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 the cylinder to the end of its stroke. Always

leave approx. 5 cm to spare.
AM092390A

Operations using cutting tip on one side only

AM092400A

Impact operation with no load

AM092410A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

Twisting operations at end of cylinder stroke

AM092420A

Sudden gripping and breaking operations

AM092430A

HYDRAULIC PILE DRIVER

MAIN FIELDS OF APPLICATION

❍ Foundation work

❍ River work

❍ Water supply and sewerage

This is a piling machine employing the hydraulic power source of

the excavator. The machine features a long arm and a chuck unit.
This facilitates operations such as driving and removing long
piles, driving in piles at corners, etc.

MISTAKEN METHODS OF USE

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 AM092440A
any of the following ways.

❍ Do not operate the cylinder to the end of its stroke.

Always leave approx. 5 cm to spare.

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

Forward or swing motion while grasping a pile

AM092450A

Lifting more than two piles at the same time

AM092460A

Work other than standard works

AM092470A

Loading or unloading a machine equipped with hydraulic pile

driver

AM092480A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE

MAIN FIELDS OF APPLICATION

❍ Site preparation

❍ Water supply and sewerage

❍ River work

❍ Agricultural, civil engineering work

Crane operation can be carried out without removing the bucket.

This machine is used for laying U section gutters and pipes for
water supply and sewerage as well as river and canal work, agri-
cultural, civil engineering work and site preparation.

AM092490A
MISTAKEN METHODS OF USE

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 the cylinder to the end of its stroke. Always

leave approx. 5 cm to spare.

Abrupt lever operation

AM092500A

Travelling with a suspended load

AM092510A

286
OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

Operating other work equipment during crane operation

AM092520A

Excessive lengthening of wire rope

AM092530A

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

2-PC BOOM

FEATURES OF 2-PIECE BOOM & ARM

This sketch shows format of two piece boom machine, including

location of grease points (For 1st and 2nd booms only).

For starting procedure, refer to “OPERATION” on page 55

1
2
3

Side of arm.
1.
1 grease point located here for joint D

2. Second boom

3. First boom raise cilinder

4. First boom

Top of boom foot

5.
5 grease points located here for joints A, B and C
6 Second boom adjust cylinder

OPERATION

Explanation of Devices

Dual Purpose Control Pedal.

The additional pedal to the right of the travel levers controls two
functions on a 2-Piece Boom machine:

288
OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

In normal operation the pedal controls the operation of the second

boom adjust cylinder. Pressing down on the front of the pedal
pushes the second boom away from the cab, pressing down on
the rear of the pedal pulls the second boom towards the cab.

The foot pedal is also used to operate the HCU circuit. To select
HCU operation, operate the additional switch on the RH. stand
console. Once HCU operation has been selected, it is controlled
by the foot pedal in the same way as the mono-boom machine. 1
The second boom adjust cylinder will not operate if HCU circuit
A
operation is selected at this switch.

1 Dual purpose control pedal

A Extend 2nd boom raise cylinder B

B Retract 2 nd boom raise cilinder

A Press the rear of the pedal B

B Press the front of the pedal

A Five blank additional switches

"HCU Operation" Select switch.

B
Colour : bleu

A B

289
EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

BEFORE STORAGE POSTURE WHEN LEAVING

MACHINE

When leaving the operator’s compartment, put the machine in the

following posture for reasons of safety.

1. When leaving the machine for a long time see ,“LONG-TERM

STORAGE” on page 145 for instructions on correct preparation
of machine for long term storage.

2. When leaving the machine for a short time.

TESTING AND ADJUSTING

INSPECTION AND MAINTENANCE

To use the machine safely, and to prevent failures before they

occur, always carry out checks before starting and periodic main-
tenance.

The locations for periodic inspection are as shown in the diagram

below.

290
OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

A Cracks at end of weld (checks before starting).

PR Play, wear of pins (every 1000 Hours).

B Furrows in base metal (checks before starting).

NOTICE
If any abnormality is found during inspection, please contact
your Komatsu distributor.

For details of inspection and maintenance items for the chassis

other than those listed above, “MAINTENANCE” on page 169

PERODIC MAINTENANCE

● Changing the hydraulic oil

When changing the hydraulic oil, set the work equipment in the
posture shown below.

● Hydraulic oil capacity for the 2-piece boom machine is 187

litres.

● Periodic maintenance required is the same as mono-boom

machine.

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

TRANSPORTATION

PROCEDURE FOR LOADING ON TO TRAILER

● Loading and unloading procedure.

Refer to “TRANSPORTATION” on page 137 for correct procedure

for loading and unloading of machine.

(2-piece boom machine is same as mono-boom machine)

For information on loading and unloading machine for transporta-

tion “LOADING, UNLOADING WORK” on page 137

For transportation dimensions, refer to the below mentioned

table.

Arm 1800 mm 2400 mm 2930 mm

A 9440 mm 9380 mm 9315 mm

B 6215 mm 5415 mm 4875 mm
PC210-6
C 3085 mm 3155 mm 3190 mm

D 2960 mm 3181 mm 3057 mm

A 9440 mm 9380 mm 9315 mm

B 6405 mm 5605 mm 5065 mm

PC210LC-6
C 3085 mm 3095 mm 3100 mm
D 2960 mm 3181 mm 3057 mm

Arm 2000 mm 2500 mm 3000 mm

A 9689 mm 9716 mm 9717 mm

B 6692 mm 6258 mm 5487 mm

PC240LC-6
C 3267 mm 3467 mm 3396 mm

D 3032 mm 3178 mm 3122 mm

292
OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

Arm 2000 mm 2500 mm 3000 mm

A 9689 mm 9716 mm 9717 mm

B 6597 mm 6163 mm 5392 mm

PC240NLC-6
C 3267 mm 3467 mm 3396 mm

D 3032 mm 3178 mm 3122 mm

6.4 M STRAIGHT BOOM

BEFORE STORAGE POSTURE WHEN LEAVING

MACHINE

When leaving the operator’s compartment, put the machine in the

following posture for reasons of safety.

1. When leaving the machine for a long time see ,“LONG-TERM

STORAGE” on page 145 for instructions on correct preparation
of machine for long term storage.

2. When leaving the machine for a short time.

If maintenance must be carried out with the work equipment

raised, lower it on to a stand and check that it is in a stable condi-
tion before starting the maintenance.

If any load is suspended from work equipment, never leave the

operator’s seat or go close to the load.

Always make sure that the load is in stable condition.

Never sit or climb on the work equipment.

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

PREVENTION OF DAMAGE TO WORK EQUIPMENT

To ensure long life on the work equipment, and to carry out work
safely, avoid the following kinds of operation.

Do not travel at high speed on rough ground.

INCORRECT

Do not operate the control levers suddenly.

INCORRECT

Do not start or stop the swing suddenly.

INCORRECT

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

Do not use hitting force for demolition work.

INCORRECT

Do not use the swing force for hitting operations.

INCORRECT

Do not use the dropping force of the machine for operations.

INCORRECT

Do not use the travel force of the machine for operations.

INCORRECT

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EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS

Do not pick up objects and raise or lower them.

INCORRECT

Do not use the jaw on one side only.

INCORRECT

Do not use grip and crush at one blow.

INCORRECT

Do not travel with the work equipment raised.

INCORRECT

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OPTIONS, ATTACHMENTS EXTENDING MACHINE SERVICE LIFE

TRANSPORTATION

PROCEDURE FOR LOADING ON TO TRAILER

● Loading and unloading procedure.

Refer to “TRANSPORTATION” on page 137 for correct procedure

for loading and unloading of machine.

PC210LC-6K straight boom

Dimensions
Arm mm

1,8 m 2691
A Shipping height 2,4 m 2768
2,9 m 2743

1,8 m 10222
B Shipping lenght 2,4 m 10101
2,9 m 10094

1,8 m 8080
G Transport lenght 2,4 m 7222
2,9 m 6511

C Track lenght - 4445

D Track lenght on ground - 3640

E Tail swing radius - 2780

Overall track width with 700 mm - 3080

F Overall track width with 800 mm - 3180
Overall track width with 900 mm - 3280

H Machine tail height - 2005

I Overall height of cab - 2905

J Overall width of upper structure - 3080

K Overall width of machine body - 2905

L Track gauge - 2380

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FRONT DOZER BLADE

BLADE OPERATIONS

BLADE CONTROL LEVER

CAUTION
This lever is not locked even if the safety lock lever is in the
lock position, so do not touch this lever when not operating
the blade.

The lever operates the blade.

1 - blade down.

2 - blade up.

PROHIBITED OPERATIONS

● Do not hit the blade against rock etc. or blade, cylinder and
other parts will be damaged early.

● Take care of interference between the bucket and the blade,

in travel posture with the working equipment folded.

● When using the blade as an outrigger, do not support the

machine by one side only.

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● Take care of interference with the blade and the boom cylin-
der when deep digging over the blade. Use this machine with
the blade at the rear whenever possible.

WEAR PARTS LIST

No. Item Part No. Part name Qty Replacement Frequency

1 Blade Edge 12F 70 31261 Cutting Edge 1 -

2 Blade Edge 12F 70 31281 Cutting Edge 1 -

3 Blade Edge 20Y 71 K1020 End bit 2 -

4 Blade Edge 112 946 1510 End bit (weld) 2 -

MAINTENANCE

● Every 100 hours Service:

Stop the engine after putting the blade down to the ground

Using a grease pump, pump in grease through the grease

fittings shown by arrows.

After greasing, wipe off any old grease that was pushed
out.

1. Blade cylinder foot pin (2 points)

2. Blade cylinder rod end pin (2 points)

3. Blade foot pin (2 points)

If the safety lock lever is not placed securely in the LOCK

position, the control levers may not be properly locked.
Check that the situation is as shown in the diagram.

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