Operation & Maintenance SEAM02080502 Manual: Hydraulic Excavator

Operation & Maintenance SEAM02080502
Manual
HYDRAULIC EXCAVATOR
PC400
pc400Lc
:20001
:2000, and up
SERIAL NUMBERS
FOREWORD
This manual describes procedures for operation, handling, lubrication,
maintenance, checking, and adjustment. It will help the operator or anyone
realize peak performance through effective, economical and safe machine
operation and maintenance.
Please read this manual carefully BEFORE operating the machine.
Please continue studying this manual until proper operation is completely
reinforced into personal habit.
This manual describes the basic techniques. Skill is performed as the
operator or anyone get the correct knowledge and performance of the
machine.
Operation, inspection, and maintenance should be carefully carried out,
and the safety must be given the first priority. Safety precautions are
indicated with A marks and technical precautions with * marks in this
manual. The safety information contained in this manual is intended only
to supplement safety codes, insurance requirements, local laws, rules and
regulations.
Some illustration pictures are different from your machine as technical
improvement is continuously reflected on it. Revision to up-to-date
manual’s content is performed in later editions.
This operation & maintenance manual may contain attachments and
optional equipment that are not available in your area. Please consult
your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
-l-
BREAKING IN YOUR NEW MACHINE
Each machine is carefully adjusted and tested before shipment. However,
a new machine requires careful operation during the first 100 hours to break
in the various parts.
If a machine is subjected to unreasonably hard use at the initial operation
stage, the potential of performance will prematurely deteriorate and the ser-
vice life will be reduced. A new machine must be operated with care, par-
ticularly with regard to the following items.
After starting, let the engine idle for 5 minutes to allow proper engine
warm-up prior to actual operation.
Avoid operation with heavy loads or at high speeds.
Sudden starting or acceleration, unnecessarily abrupt braking and sharp
turning should be avoided.
During the initial 100 hours, the work equipment fixing pins are to be
greased before each operation. Greasing is to be repeated after operation
of the boom, arm and bucket is conducted several times.
If the machine is delivered without any cooling water in the radiator,
flush the cooling system with ample clean water to clean the system,
then fill the radiator with cooling water.
When replacing oil filter elements (cartridges), check their interiors for dirt
and dust. If heavily collected, check for possible cause before starting
operation.
Hours of operation are indicated by the service meter.
-2-
CONTENTS
OPERATION
GENERAL LOCATIONS AND SPECIFICATIONS ............................................ 4
INSTRUMENTS AND CONTROLS ............................................................... 6
METHOD OF USING MODE SELECTOR SWITCHES ..................................... 46
CHECK BEFORE STARTING ....................................................................... 50
OPERATING YOUR MACHINE .................................................................... 56
INVERSION AND REPLACEMENT OF BUCKET ............................................ 80
HANDLING THE CLAMSHELL BUCKET ....................................................... 82
SELECTION OF TRACK SHOES .................................................................. 84
SELECTION OF BUCKET TEETH ................................................................. 86
TRANSPORTATION .................................................................................. 87
INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT ............................ 94
COLD WEATHER OPERATION ................................................................... 96
MAINTENANCE
PERIODIC MAINTENANCE ......................................................................... 105
PRECAUTIONS WHEN DISASSEMBLING MACHINE ................................. 106
BLEEDING AIR FROM CIRCUIT .............................................................. 108
PERIODICAL REPLACEMENT OF SAFETY PARTS .................................... 112
MAINTENANCE TABLE ......................................................................... 116
OIL FILLER AND LEVEL GAUGE POSITIONS ........................................... 120
EVERY 100 HOURS SERVICE ................................................................. 122
EVERY 1000 HOURS SERVICE ............................................................... 140
WHEN REQUIRED ................................................................................. 150
ADJUSTMENT ......................................................................................... 168
TROUBLE SHOOTING GUIDE ..................................................................... 170
SERVICE METER ...................................................................................... 180
MACHINE AND ENGINE SERIAL NUMBERS ................................................ 182
FUEL, COOLANT AND LUBRICANTS .......................................................... 184
LOADING SHOVEL (with bottom dump bucket) . . . . . . . . . . . . . . . .._...................... 187
-3-
GENERAL LOCATIONS AND
SPECIFICATIONS
1. Bucket
2. Bucket cylinder
3. Arm
4. Arm cylinder
5. Boom
6. Boom cylinder
7. Sprocket
8. Track frame
9. Idler
10. Track shoe
MACHINE MODEL PC400 PC400LC
PERFORMANCE Bucket capacity [SAEI 1.8 1.8
(m3) [CECE] 1.6 1.6
Travel speed (km/h) Ta 5.5 5.5

3.1 3.1
Swing speed (rpm) 9.3 9.3
OPERATING WEIGHT (kg) 40700 42300
ENGINE Model Komatsu S6D125-1 W Diesel Engine
Flywheel horsepower (HP) 276.1 276.1

[Rated rpm] [2000] [2000]
NOTE: Specifications are subject to change without notice.
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INSTRUMENTS AND CONTROLS
ELECTRONIC MONITOR & CONTROL CONSOLE
(EMACC)
This monitor system consists of monitor lamp groups (@, @, O), meter
group @ and switch group 0.
@CHECKMONITOR GROUP (Check items before starting)

If there is any abnormality, the appropriate monitor lamp will flash.
Check the location where the monitor is flashing, and carry out the Checks
before starting.
* When the engine is started, these monitor lamps will go off even if there
are abnormalities.
@CAUTION MONITOR GROUP (Caution items)

If any abnormality occurs while the engine is running, the appropriate
monitor lamp will flash to indicate the abnormality.
* Even if any monitor lamp flashes, the machine can operate, but it should
be repaired as soon as possible.
@CAUTION MONITOR GROUP (Emergency caution items)

If any abnormality occurs while the engine is running, the appropriate
monitor lamp will flash and the alarm buzzer will sound intermittently at the
same time.
* If any monitor lamp flashes, stop the engine or run it at a low idling
speed, and repair it immediately.
@METER GROUP
This group consists of engine water temperature gauge, fuel gauge, en-
gine pre-heating monitor lamp and swing lock lamp.
@SWITCH GROUP
This consists of the lamps, car heater, mode selector switches, wiper
switch, alarm buzzer stop switch and travel speed switches.
Functionalcheck of the machine monitor system

To check the monitor system, turn the starting switch to ON before start-
ing the engine. Then all the monitor lamps and the gauges light up and the
alarm buzzer sounds for about 3 seconds. After that all lamps go off and
the buzzer stops. If any monitor lamp does not light up, ask your Komatsu
distributor to inspect that monitor lamp.
* Park the machine on level ground and check the monitor lamps.
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A: CHECK MONITOR GROUP (Check items before starting)
t Do not rely on the “CHECK MONITOR GROUP (Check before starting)”
only for the check before starting. Always make the check by referring to
the section on CHECK BEFORE STARTING.
1. RADIATOR COOLANT LEVEL MONITOR

This warns of any drop in the radiator cooling water level.
If it flashes, check the cooling water level in the radiator and sub-tank,
and add water.
2. ENGINE OIL LEVEL MONITOR

This monitor indicates a low oil level in the engine oil pan.
If the monitor lamp flashes, check the oil level in the engine oil pan and
add oil as required.
3. HYDRAULIC OIL LEVEL MONITOR

This monitor indicates a low oil level in the hydraulic tank. If the monitor
lamp flashes, check the oil level in the hydraulic tank and add oil as
required.
B: CAUTION MONITOR GROUP (Caution items)

t If the warning monitor flashes, carry out the necessary action as soon as
possible.
1. CHARGE MONITOR
This monitor indicates an abnormality in the charging system while the
engine is running.
If the monitor lamp flashes, check the charging circuit.
t This monitor lamp lights when the starting switch is turned to ON imme-
diately after the engine is started. It does not indicate an abnormality.
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2. FUEL LEVEL
This warns that the fuel level is low.
If it flashes, stop the engine, then check the fuel level and add fuel.
C: CAUTION MONITOR GROUP (Emergency caution items)

* If the monitor flashes, stop the engine immediately or run it at low idling,
then take the appropriate action.
1. ENGINE COOLING WATER TEMPERATURE MONITOR

This warns of any rise in the engine cooling water temperature.
If it flashes, the engine overheat prevention system is automatically actu-
ated to run the engine at low idling until the engine water temperature
gauge enters the green range.
2. RADIATOR COOLANT LEVEL MONITOR

This monitor indicates a low radiator coolant level.
Check the coolant level when the alarm buzzer sounds and this monitor
lamp flashes, stop engine and add water as required.
3. ENGINE OIL PRESSURE MONITOR

This monitor indicates a low engine oil pressure.
If the alarm buzzer sounds and this lamp flashes, the engine oil pressure
is below the lower limit. Immediately stop the engine.
* This monitor lamp lights and the alarm buzzer sounds, when the starting
switch is turned to ON immediately after the engine is started. It does
not indicate an abnormality.
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D: METER GROUP
* Confirm that gauges (I), (2) and monitor lamp (3) will light, when the
starting switch is turned to ON before the engine is started. If any gauge
or monitor lamp does not light, ask your Komatsu distributor to inspect
that monitor lamp or gauge.
1. ENGINE COOLING WATER TEMPERATURE GAUGE

This gauge indicates the temperature of the cooling water. If the tempera-
ture is normal during operation, the green range will light. If the red range
lights up during operation, the engine overheat prevention system is actu-
ated.
The engine overheat prevention system acts as follows.
Red range (1) lights up:
The power mode is switched to L mode for each working mode.
Red range (2) lights up:
The engine speed is reduced to low idling.
The engine overheat prevention system is actuated until the temperature
returns to the green ragne.
If red range (2) lights up, after the engine water temperature is lowered,
turn the fuel control dial to low idling (MIN) to cancel the display.
(a): White
(b): Green
(c): Red
-. FUEL GAUGE
This gauge indicates the amount of fuel in the fuel tank. If there is
enough fuel in the tank while the engine is running, the green range lights.
If the red range lights, there is less than 59 liters of fuel in the tank.
When the red range lights, add fuel.
* After the starting switch is turned ON, the correct level may not be dis-
played for a moment, but this does not indicate any abnormality.
(a): Red
(b): Green
3. ENGINE PRE-HEATING MONITOR LAMP

This shows the preheating time when starting the engine at temperatures
below O’C.
It lights up when the starting switch is turned to the HEAT position, and if it
is kept in that position, the lamp flashes after approx. 30 seconds to inform
that preheating is completed. (After flashing for approx. 10 seconds it goes
out.)
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D3
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4. SWING LOCK LAMP
This informs the operator that the swing lock is being actuated.
Actuated: Lights up
* When the swing lock switch is turned ON (ACTUATED), the lamp lights
up.
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GOD013
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E: SWITCHES
1. WORKING MODE SELECTOR SWITCH (BASIC MODE)

This switch is used to set the movement or power for the work equip-
ment to match the content or purpose of the operation.
H.0 (heavy-duty operation mode) lights up:
This is used for heavy-duty work.
G.0 (general operation mode) lights up:
This is used for ordinary work.
F.0 (finishing operation mode) lights up:
This is used for leveling or grading work.
L.0 (lifting operation mode) lights up:
This is used for fine control operations.
f When starting the engine, the general operation mode (S mode) is auto-
matically selected.
2. POWER MODE SWITCH (SELECTED MODE)

This switch is used to set output force for the work equipment to match
the content or soil quality for the operation.
H lights up:
This is used for high productivity loading operations.
S lights up:
This is used for normal operations.
L lights up:
This is used for grading or other light-duty operations.
3. AUTO-DECELERATION SWITCH (SELECTED MODE)

This switch is used to actuate the auto-deceleration system so that the
engine speed is lowered when all the control levers are at neutral.
ON lights up:
Auto-deceleration is actuated
OFF lights up:
Auto-deceleration is canceled
* For the use of switches 1, 2, and 3, see METHOD OF USING MODE
SELECTOR SWITCHES.
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4. TRAVEL SPEED SWITCH
This is used to select the two travel speeds.
Lo lights up:
Low speed travel
Hi lights up:
High speed travel
* When traveling in Hi, the travel speed is automatically switched to low
speed travel (Lo) to match the travel surface on soft ground or when tra-
veling uphill, so there is no need to operate this switch.
t If this switch is operated when the machine is traveling, it may cause
deviation, so always stop the machine before operating the switch.
5. ALARM BUZZER STOP SWITCH

This switch is used to stop the alarm buzzer when it has sounded to
warn of some abnormality while the engine is running.
6. LAMP SWITCH
This lights up the head lamps and panel lamps.
Position 1:
Panel lamps light up
Position 2:
Panel lamps and head lamps light up
OFF: Panel lamps and head lamps are OFF
7. WIPER SWITCH
This operates the wipers for the front window.
Lo lights up:
Intermittent wiper operation
Hi lights up:
continuous wiper operation
OFF: Wipers stopped
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8. CAB HEATER SWITCH
This switch is used to heat the operator’s compartment. The flow rate of
the hot air can be set to two levels.
Lo lights up:
Low wind speed
Hi lights up:
High wind speed
OFF: Cab heater stopped
t The cab is heated by means of warm water from the engine.
Accordingly, heating can not take place while the engine cooling water is
warming up.
METERS
I. SERVICE METER
The service meter indicates the total number of operating hours of the
machine.
While the engine is running, the indicator of the meter will rotate to
indicate that the meter is turning over.
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SWITCHES
1. STARTING SWITCH
OFF
Key insertion-withdrawal position. None of electrical circuits activate.
ON
Charging and lamp circuits activate. Keep key at ON after starting.
START
At this key position, the starting motor will crank the engine. Release key
immediately after starting.
HEAT
Use this position when starting in cold weather.
Release the key to allow it to return automatically to OFF and then, with-
out delay, turn it to START.
t When starting, be sure to use the starting key.
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
* To stop the engine, turn the starting switch to the OFF position.
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2
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3. SWING LOCK SWITCH
This actuates the swing lock.
(a): 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
yi: OFF position (canceled)

The swing lock is actuated only when the work equipment and swing
control levers are at neutral; it is canceled when the work equipment or
swing is operated.
* At the OFF position, the swing lock is actuated approx. 4 seconds after
the work equipment and swing control levers are returned to neutral, and
it locks the upper structure in position.
A When the machine is traveling

is not being operated, always
under its own power, or when the swing
set the switch to the ON (ACTUATED)
position.
(c): Front of machine
4. CIGARETTE LIGHTER
This is used to light cigarettes. To use, push the lighter in. After a few
seconds it will spring back.
At that time, remove the lighter and light your cigarette.
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- 25 -
5. POWER MAX. BUlTON
When the button in the center of the knob of the left work equipment
control lever is being pressed (max.: approx. 8 set), the maximum power is
increased.
6. HORN BUTTON
When this button is pressed, the horn will sound.
7. ROOM LAMP SWITCH

When this switch is moved to ON position, room lamp will light.
(a): Press to switch on.
(b): Press to switch off.
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LEVERS
1. LOCK LEVER
This locks the work equipment, travel, and swing. Lower the lever to
apply the lock.
A When parking the machine or leaving the machine, always lower

bucket to the ground, and apply this lever to lock the control levers.
the
* This lock lever is a hydraulic lock, so even if it is in the lock position, the
work equipment control lever and travel lever will move, but the work
equipment, travel motor, and swing motor will not work.
(a): Free
(b): Lock
2. TRAVEL LEVERS (WITH PEDAL, AUTO-DECELERATION MECHANISM)
(1) FORWARD:
The lever is pushed forward
(The pedal is angled forward)
(2) REVERSE:
The lever is pulled back
(The pedal is angled back)
N (Neutral): The machine stops
t ( ):This indicates operatin of the pedal.
A Do not put your foot on the pedal unless you are using it.
3. LEFT WORK EQUIPMENT LEVER (arm/swing control lever)

(with auto-deceleration device)
(N) Neutral:
When the lever in this position, the upper works and the arm will be
retained in the position in which they stop.
Arm operation
(A)Arm moves out.
(B)Arm moves in.
Swing operation
(C)Upper works swings to the right.
(D)Upper works swings to the left.
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4. RIGHT WORK EQUIPMENT LEVER (boom/bucket control lever)
(with auto-deceleration device)
(N)Neutral:
When the lever in this position, the boom and the bucket will be retained
in the position in which they stop.
Boom operation
(l)Boom raises.
(2)Boom lowers.
Bucket operation
(3)Bucket dumps.
(4)Bucket curls.
t For levers 2, 3, and 4, the engine speed changes as follows because of

the auto-deceleration mechanism.
0 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.
0 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).
A speed
If any lever is operated when in the deceleration range, the engine
will suddenly increase, so be careful when operating the levers.
5. FORWARD ADJUSTMENT BUTTON FOR WORK EQUIPMENT CONTROL

LEVER
If the button at the side of the left and right console boxes is pressed, it
is possible to move the console box forward in two stages.
N: Neutral positin
Fl : Middle position
F2: Deep excavation position
t The left console box only can also be adjusted back from the N position.
Use this position when getting on or off the machine.
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5
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DUST INDICATOR
This device indicates clogging of the air cleaner element. When red pis-
ton (1) appears in the transparent part of this indicator, the element is
clogged. Immediately clean element.
After cleaning, push indicator button (2) to return red piston to original
position.
This is behind the air cleaner inside the engine hood.
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 magnetic
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 magnetic catch.
CEILING WINDOW
Ceiling window is opened by releasing the lock in the direction of the
arrow and pushing the handle.
* When opening or closing the ceiling window, grasp the handle.
Do not push in grasping staydumper (A).
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- 33 -
FRONT WINDSHIELD
It is possible to store (pull up) the front window (top) in the roof of the
operator’s compartment.
When opening
1. Stop the machine on flat ground, lower the work equipment to the
ground, and stop the engine.
2. Lock the left and right work equipment control levers and travel levers.
3. Disconnect the wiring for the wiper motor from socket (B).
4. Pull lock pins (A) at the top left and right sides of the front window to
the inside to release the lock.
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
1. Stop the machine on flat ground, lower the work equipment to the
ground, and stop the engine.
2. Lock the left and right work equipment control levers and travel levers.
3. Release lock pins (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.
5. Lock securely with lock pins (A) at the left and right sides.
6. Connect the wiper motor wiring to socket (B).
Removing front window (bottom)

With the front window open, remove lock pin (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.
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OPERATOR’S SEAT
The seat adjustment should be checked at the beginning of each shift
and when operators change.
@ Forward-backward adjustment
Move lever (1) to the right, move the seat to the best position and
release the lever. The seat can be moved forward or backward over 160
mm in nine stages.
@ Backrest adjustment
Pull lever (2) in the direction of arrow, move the back-rest to the desired
position and release the lever.
0 Up-down adjustment of seat

When carrying out the adjustment, stop the engine and lock the left and
right work equipment control levers with the lock lever.
Up-down adjustment range: 110 mm (5 stages)
1. Turn knob (3) to the left to loosen it, then pull up lever (4).
2. Align the pin hole in the mount base with the seat bracket pin hole at
the desired height, then return lever (4) and insert pin (5).
Turn knob (3) to the right to fix the seat in position.
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FUSE BOX
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse
is loose in the fuse holder, replace the fuse.
* Replace a fuse with another of the same capacity.
A Before replacing a fuse, be sure to turn off the starting switch.
Fuse arrangement and circuit

t Spare fuses (two of IOA, one of 15A) are kept in the spare fuse box.
Fuse
No. Circuit Remark
capacity
0 10A Pump controller, solenoid -
0 10A Engine governor controller -
0 10A Monitor, buzzer -
0 15A Heater (air conditioner, cooler) -
0 10A Right head lamp, working lamp -
@ 10A Room lamp, radio -
0 10A Wiper motor, horn (window washer) -
@ IOA Cigarette lighter -
@ 10A Battery relay, electric heater relay, start signal -
@ 10A Spare (swing flasher) -
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I
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FUSIBLE LINK
If the starting motor does not turn even when the starting switch is
turned to START position, a possible cause is a disconnection in the wire-
shaped fusible link (I), so check and replace if necessary.
ELECTRONIC MONITOR AND CONTROL CONSOLE (EMACC)

The angle of the monitor panel can be changed to make it easier to see.
When changing the angle, use both hands, and always stop the monitor
panel at a position where it is held in the notch.
* Range of adjustment: 30’ (3 stages)
CONTROLLERS
PUMP CONTROLLER
This informs of the location of any abnormality in the electronic control
system of the pump.
A 2-digit display (01 - 29) indicates the location of the abnormality.
When the electronic control system is normal, the display in the table is
shown.
* If a display is given to show an abnormality, see Causes of Failures and
Action to Take.
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7
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When normal
No. input mode and condition Display
0 Power source monitor (with starting switch ON Lights up
H mode \_’
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0 Power mode S mode --\
L mode
L
L
Engine speed signal monitor (when engine is running) Flashes
\
Heavy-duty operation mode \
7
General operation mode
C
@ Working mode
-1
Finishing operation mode 3
Lifting operation mode
* The combinations given in the table above are displayed according to the
input mode and machine condition.
* Engine speed signal monitor (3) flashes according to the engine speed.
(At 2000 rpm, it flashes approx. 20 times/l 0 set)
* When switching the input, the following display is given.
When switching input Display
When electric
power is switched t-1
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on (0.5 set)
Switching travel
speed
Auto-deceleration switch n )
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Swing lock switch
Work equipment,
Swing control lever
\7 I I The display is given for 0.5 -

Service control lever .\- .-\ 1.5 set after the input is
n \-
Travel lever .I- .o switched.
\ 11-1
Power max. button .1-c.\-
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- 43 -
ENGINE THROTTLE CONTROLLER
This informs of the location of any abnormality in the control system for
the electrically controlled throttle. Green and red LEDs (Light Emitting
diodes) are installed, and these go out or light up to give a combination
that shows the location of the abnormality.
When the electrically controlled throttle is normal, the display is as given
in the table.
* If the LEDs light up to show an abnormality, see Causes of TROUBLE
SHOOTING GUIDE.
When normal
(a): Red
(b): Green
(c): Red
LED display
Condition of machine
L, L, L,
Red Green Red
OFF ON OFF
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METHOD OF USING MODE SELECTOR
SWITCHES
The mode selector switches can be used to switch the mode to match
the conditions and purpose of work, thereby enabling efficient operations.
Use the following procedures to make effective use of each mode.
PROCEDURE FOR SETTING MODE SELECTOR SWITCH

SETTING BASIC MODES
When the starting switch is turned ON, the working mode is set to gen-
eral operation mode, so normal work can be carried out without any need
to set the mode. The most effective mode for the type of work is set with
the basic mode (1) (working mode switch).
* The table below shows the condition of the power mode and auto-decel-
eration, and the most suitable type of work for each setting.
Basic mode Selected mode

Applicable work
Working mode Power mode dec$$ation
Heavy-duty control Large digging and loading production in

H mode ON
operation mode a short time
General operation Normal digging and loading operations,
S mode ON
mode crushing (breaker) operations
Finishing operation Finishing and leveling operations,
S mode OFF
mode general hauling operations
Lifting operation
L mode OFF Positioning, etc.
mode
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SETTING OF SELECTED MODES
The selected modes are automatically set by setting the basic mode, but
after the basic mode is selected, it is possible to change the selected mode
(2) as desired.
Power mode
Working mode Selection of power mode Effect
Heavy-duty operation mode H-S Reduction in fuel consumption
H-S Increase in speed

General, finishing operation
mode
S--L Reduction in fuel consumption
Lifting operation mode S-L Increase in speed
Auto-deceleration
If the auto-deceleration is always actuated, it improves fuel consumption,
so we recommend that it always be used. However, if the control levers
are operated in small movements, the engine speed changes greatly, so it
is better to carry out such operations with the auto-deceleration canceled.
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CHECK BEFORE STARTING
Pre-operation checks forestall machine trouble. Never neglect them.
a. WALK-AROUND CHECK
Look around the machine and under the machine to check for loose nut
or bolts, collection of dirt, or leakage of oil, fuel, or coolant, and check the
condition of the work equiment and hydraulic system. Check also for loose
wiring, play, and collection of dust at places which reach high temperatures.
1. Check for oil leak at high pressure hose, high pressure hose joints and
hydraulic cylinder seal.
2. Check tightness of idler mounting bolt.
3. Check tightness of battery terminal.
4. Check radiator for water leak.
5. Check around the engine for water and oil leaks.
6. Check final drive case for oil leaks and check tightness of sprocket
mounting bolt.
7. Check tightness of air cleaner mounting bolt.
b. CHECK AND REFILL COOLANT

Open the cover at the rear of the machine and check that the cooling
water is inside the correct range (shown in the diagram on the right) for
sub-tank (1). If the water level is low, add water through water filler (2).
(3): FULL
(4) LOW
* If the volume of coolant added is more than usual, check for possible
water leakage.
A Do not remove the cap while cooling water is hot. Hot water may
spout out.
When removing the cap, release radiator pressure little by little by
loosening the cap slowly, then remove the cap.
C. CHECK OIL LEVEL IN ENGINE OIL PAN

1. Open the cover at the rear of the machine.
2. Use the dipstick (G) to check the oil level.
3. The oil level should be between mark L and H, if necessary, add oil at
the oil filler (F).
* The type of lubricant used depends on the ambient temperature. Select
according to the table “FUEL, COOLANT AND LUBRICANTS”.
* When checking the oil level, park the machine on a level surface, stop
the engine and wait for 15 minutes before checking.
- 50 -
b
- 51 -
d. CHECK FUEL LEVEL
1. Check the fuel level using sight gauge (G) on the side face of the tank.
2. Upon completion of work, pour in additional fuel from filler (F) until the
fuel tank is full.
* If breather hole (1) in the cap is blocked up, fuel flow to the engine may
stop. Accordingly, clean it from time to time.
* Fuel capacity: 550 L
t When adding fuel, never let the fuel overflow. This may cause a fire.
e. CHECK OIL LEVEL IN HYDRAULIC TANK

1. 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. Operate all the control levers (work equipment and travel) in all directions
to the end of their stroke to release the internal pressure.
t Carry out this operation within 15 seconds of stopping the engine.
3. If the level of hydraulic oil is not between top H and bottom L lines of
sight gauge (G), pour in additional engine oil from filler (F).
* Do not pour in additional oil if the level is above the top line H of the
sight gauge.
t The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:
0 When the oil temperature is close to the ambient temperature (10 to
30X), the level will be close to bottom line L on the sight gauge.
0 When the oil temperature is the normal operating temperature (50 to
80X), the level will be close to top line H on the sight gauge.
- 52 -
I
d
f. CHECK DUST INDICATOR
When the air cleaner element is clogged, the red piston of dust indicator
(1) reaches the service level and gets locked.
In that case, clean the element, referring to the section “WHEN
REQUIRED”.
After cleaning the element, push the button to return the red piston.
g. CHECK ELECTRIC WIRINGS

Check for damage of the fuse and any sign of disconnection or short cir-
cuit in the electric wiring. Check also for loose terminals and tighten any
loose parts.
Check the following points carefully.
0 Battery
0 Starting motor
0 Alternator
A tric
If the fuse is damaged or there is any sign of shortcircuiting in the elec-
wiring, always investigate the cause and correct it.
t Please contact your Komatsu distributor for investigation and correction of

the cause.
h. LUBRICATE CLAMSHELL BUCKET

Apply grease to the grease fitting shown by the arrows. (12 points)
i. CHECK FOR SEDIMENT AND WATER IN THE WATER SEPARATOR

The water separator separates water mixed in the fuel. If float (2) is at or
above red line (I), drain the water. For the draining procedure, see section
“WHEN REQUIRED”.
t Even if a water separator is installed, be sure to check the fuel tank to
remove water and sediment in the fuel.
-54-
n
caO708
i
OPERATING YOUR MACHINE
AUTOMATIC WARMING-UP SYSTEM
When the engine is started with the engine coolant temperature below
3O”C, even if the fuel control dial is at the low idling position, the engine
speed is automatically set for the engine to run at a midrange speed to
carry out automatic warming up.
The automatic warming-up is canceled when the engine coolant tempera-
ture is above 30X, or when 10 minutes have passed since starting.
* Canceling automatic warming-up operation.
It is becomes necessary in an emergency to lower the engine speed to
low idling, cancel the automatic warming-up operation as follows.
1. Set the power mode to S mode or H mode.
2. Turn the fuel control dial to the full speed (MAX) position and hold it for
3 seconds.
3. When the fuel control dial is returned to the low idling (MIN) position, the
engine speed will drop.
A: BEFORE STARTING THE ENGINE

1. Carry out an initial inspection. (For details of the inspection, see CHECK
BEFORE STARTING.)
2. Is lock lever (1) in the LOCK position?
(a): Free
(b): Lock
B: TO START THE ENGINE

1. Set fuel control dial (1) at the low idling (MIN) position.
(a): Low idling.
Turn starting key (2) to the START position.
When the engine starts, return the key of starting switch key (2) to the
ON position.
(The key will return automatically when released).
If engine will not start, repeat the starting procedure after about 2
minutes.
Do not leave the key in START for more than 20 seconds.
Do not put the key in OFF position while the engine is running.
To start engine in cold weather, refer to COLD WEATHER OPERATION.
Special starting
When starting after running out of fuel, fill with fuel, then fill the fuel fil-
ter cartridge with fuel and bleed the air from the fuel system before
starting.
* For details of bleeding the air, see the section on replacement of the
FUEL FILTER.
-56-
B
B2
- 57 -
_. ..
Starting machine after long period out of use

When starting the machine after a long period out of use, first cancel the
automatic-up warming function as follows.
1. Turn the starting switch key to the ON position.
2. Turn the fuel control dial from the low idling (MIN) to the full (MAX) posi-
tion, hold it in position for at least 3 seconds, then return it to the low
idling (MIN) position and start the engine.
C: CHECKS AFTER STARTING

After starting, make the following checks.
1. Turn fuel control dial (1) to run the engine at a midrange speed, and run
under no load for approx. 5 minutes.
(a): Midrange speed
2. Push working mode switch (2) on the monitor panel to select H.0 (heavy-
duty operation) mode.
(The H.0 lamp above the working mode switch lights up)
3. Operate bucket control lever (3) and arm control lever (4) slowly to move
the bucket cylinder and arm cylinder to the end of their stroke.
(a): In
(b): Out
(c): Curl
(d): Dump
4. Operate the bucket for 30 seconds and the arm for 30 seconds in turn
fully for 5 minutes.
* When pulling in the work equipment, be careful not to hit the chassis or
ground.
t Turn the swing lock switch ON (ACTUATED) and operate the lever to
make the oil temperature rise more quickly.
5. After the warming-up operation, check that all gauges and caution lamps
are normal.
t Run under light load until the engine water temperature gauge enters the
green range.
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r
I
WORKING MODE
- 59 -
6. Check that there is no abnormal exhaust gas color, noise, or vibration.
Do not suddenly accelerate the engine before the completion of the
warming-up operation.
The most suitable temperature for the hydraulic oil is 50 - 8o’C, but in
order to extend the life of the machine, the temperature must be raised
to at least 20°C before starting work.
Do not suddenly operate the levers when the hydraulic oil temperature is
below 20°C.
Do not run the engine at low idling or high idling for more than 20
minutes.
If it is necessary to run the engine at idling, apply a load or run at a
mid-range speed from time to time.
D: TO MOVE THE MACHINE OFF

1. Turn swing lock switch (1) ON (ACTUATED) and check that swing lock
lamp (2) lights up.
(a): ON (actuated)
(b): OFF (canceled)
(c): Front of machine
2. Turn fuel control dial (3) and increase the engine speed.
(a): Full speed
3. Set lock lever (4) in the FREE position, fold the work equipment, and
raise it 40 - 50 cm from the ground.
(a): Free
(b): Lock
4. Slowly incline left and right traveling and steering levers (5) in the for-
ward (a: forward moving off) or reverse (b: reverse moving off) direction,
and move off.
A Check whether the track frame is facing forward or backward before

operating the traveling and steering levers.
A Avoid abruptly operating the traveling and steering levers with the fuel
control dial fully open, as this will cause the machine to move off sud-
denly.
A side
For machine with auto-deceleration device,
the deceleration range, the engine speed
if the lever is operated
will rise suddenly.
in-
- 60 -
D4
- 61 -
E: STEERING (CHANGING DIRECTION)
Use the travel levers to change direction.
Operate the two travel levers (1) as follows.
t When the sprocket is at the front, the travel levers turn the machine in
the opposite direction, so before operating the travel levers, check the
position of the sprocket.
t Avoid sudden changes of direction as far as possible. In particular, when
carrying out counter-rotation (spin turn), stop the machine first before
turning.
1. Changing direction of machine when stopped

(a): Turning left when traveling forward
(b): Turning left when traveling in reverse
When turning to the left:
Push the right travel lever forward to travel left when traveling forward; and
pull it back to turn left when traveling in reverse.
t When turning to the right, operate the left travel lever in the same way.
2. Steering when traveling (left and right travel levers both operated in
same direction
(a): Turning left when traveling forward
(b): Turning left when traveling in reverse
When turning to the left:
If the left travel lever is returned to the neutral position, the machine will
turn to the left.
+ When turning to the right, operate the right travel lever in the same way.
3. 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.
* When turning to the right using counter-rotation, pull the right travel lever
back and push the left travel lever forward.
- 62 -
El
E3
- 63 -
F: SWINGING
1. Before operating the swing, turn swing lock switch (1) OFF (CANCELED).
t Check that swing lock lamp (2) goes out at the same time.
2. Operate the left work equipment control lever to swing the upper structure.
3. When not operating the siwng, turn the swing lock switch ON (ACTUATED).
-64-
- 65 -
G: OPERATION OF THE WORKING EQUIPMENT
N. Neutral
1. Arm out
2. Arm out and swing right
3. Swing right
4. Arm in and swing right
5. Arm in
6. Arm in and swing left
7. Swing left
6. Arm out and swing left
The work equipment is operated by the left and right work equipment
control levers. The left work equipment control lever operates the arm and
swing, and the right work equipment control lever operates the boom and
bucket.
The movements of the lever and work equipment are as shown in the
diagrams on the right. When the levers are released, they automatically
return to the HOLD position and the work equipment is held in place.
l If the work equipment control lever is returned to HOLD 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.
A speed
* 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
loading the machine on a trailer.
- 66 -
I
- 67 -
N. Neutral
1. Boom lower
2. Boom lower and bucket dump
3. Bucket dump
4. Boom raise and bucket dump
5. Boom raise
6. Boom raise and bucket curl
7. Bucket curl
8. Boom lower and bucket curl
- 68 -
- 69 -
H: TO STOP THE MACHINE
1. Put the left and right traveling and steering levers (1) in the neutral posi-
tion.
(a): Neutral
2. Turn fuel control dial (2) to lower the engine speed.
(a): Low idling
3. Lower the bucket horizontally until its underside touches the ground.
4. Set lock lever (3) in the LOCK position.
(a): Free
(b): Lock
A When stopping
ous places. If
the machine, select fiat hard ground and avoid danger-
it is unavoidably necessary to park the machine on a
slope, insert blocks underneath the track shoes. As an additional safety
measure, thrust the bucket into the ground.
I: TO STOP THE ENGINE

1. Run the engine at low idling speed for about 5 minutes to allow it to
gradually cool down.
2. Return starting key (1) to the OFF posjtion and remove key.
t If the engine is abruptly stopped before it has cooled down, engine life
may be greatly shortened. Consequently, do not abruptly stop the engine
apart from an emergency.
t In particular, if the engine has overheated, do not abruptly stop it but run
it at medium speed to allow it to cool gradually, then stop it.
- 70 -
H 0
Hl
H2 H4
12
GO01 19
J: PRECAUTIONS FOR OPERATION
1. Be careful not to compact the soil or damage earth mounds as a result
of the swinging force.
2. When swinging, do not dig the bucket teeth into the soil.
3. Do not move off and excavate with the bucket leaving dug into the
ground.
4. When working with the machine, do not move the cylinder to the end of
its stroke but leave a small safety margin.
5. Do not use the dropping force of the bucket as a pickaxe, breaker, or
pile driver.
6. Do not use the dropping force of the machine for digging.
7. 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.
8. Note that the following phenomena are not faults:
a) When the arm is pulled back, it will sometimes stop when becomes more
or less vertical.
b) The arm may sometimes stop when the bucket teeth become more or
less horizontal.
c) At the beginning and end of a swinging, a noise may sometimes be emit-
ted from the brake valve.
d) When descending a steep slope at low speed, a noise may sometimes be
emitted from the travel motor.
A machine
If it is necessary to operate the work equipment lever when the
is traveling, stop the machine before operating the work equip-
ment lever.
A the
For machine with autodeceleration
deceleration range, the engine
device, if the lever is operated
speed will rise suddenly.
inside
K: PRECAUTIONS WHEN TRAVELING

1. When traveling 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 obstacle at the center of the
tracks.
Special tracks
Wide triple shoes (700, 750, 800, 900 mm) are used as special shoes for
soft ground. Therefore, do not use them when traveling over rocky ground,
sandy gravel, rough ground with cobbles, and even on soft ground where
there are boulders or tree roots.
+ When selecting the track, see “SELECTION OF TRACK SHOES”.
- 72 -
Jl 53
54 J5
GO0124
J6
- 73 -
L: PERMISSIBLE WATER
1. Do not immerse the machine in water by more than the permissible
depth (under swing circle (1)). In addition, properly grease parts which
have been immersed in water for a long time, until the old grease comes
out from the bearings (vicinity of bucket pins, swing circle system, etc.).
2. When driving the machine out of water, if the angle of the machine ex-
ceeds 15”, the rear of the upper structure will go under water, and water
will be thrown up by the radiator fan. This may cause the fan to break.
Be extremely careful when driving the machine out of water.
M: PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS

When traveling on a steep downhill grade.
When traveling down a hill, adjust the speed with the travel lever and
fuel control dial.
If the grade exceeds 15”, set the machine in the posture shown in the di-
agram above, and reduce the engine speed.
A chine
Do not travel on slopes
may overturn.
of over 30” as there is danger that the ma-
b. A when traveling, raise the bucket approx. 20 - 30 cm from the

ground.
Do not travel in reverse down slopes.
C.
A When traveling over
equipment close to the
ridges or other obstacles,
ground and travel slowly.
keep the work
d. AN ever change direction on slopes or travel across slopes. To ensure

safe travel, go down to flat ground even if this route is longer.
e. A immediately
If the machine starts to slide or loses
and brake the machine.
stability, lower the bucket
f. Awtien working on slopes, swinging the upper structure and using

the work equipment may cause the machine to lose balance and
turn over, so avoid these operations as far as possible.
If earth-filling operations must be carried out on slopes, keep the
machine as close to horizontal as possible.
- 74 -
Ll
I
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1
Ml
3
F14Ea
Md Mf
- 75 -
2. Braking when traveling downhill
To brake the machine during downhill runs, put the traveling and steering
lever in the neutral position. This will cause the brake to be automatically
applied.
3. If shoes slip
When climbing a hill, if the shoes slip or the travel motor relieves, pre-
venting the machine from climbing by means of the tracks alone, it is
possible to use the force of the arm as an aid.
4. If engine stops
When the engine stops on a slope, move the traveling and steering le-
vers to neutral position and lower the bucket. Thereafter, turn starting key
to START.
N: MATTERS FOR ATTENTION AT SPECIAL WORK SITES

a) If operation is executed in water, if the work equipment fixing pins come
in contact with water, greasing is to be performed after every underwater
operation.
b) Greasing of the work equipment fixing pins is to be performed every time
before heavy digging or deep digging.
t After greasing is done, the boom, arm and bucket are to be operated
several times. This should be followed by re-greasing.
- 76 -
- 77 -
0: PROTECTION OF CONTROLLER
* Always keep cover (1) of the display panel closed unless necessary. If
rain or dust gets in, it may cause a failure in the controller.
P: HOW TO ESCAPE FROM MUD

l 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.
1. When one side is stuck.
When only one side is stuck in mud, use the bucket to raise the track,
then lay boards or logs and drive the machine out. If necessary, put a
board under the bucket also.
* When using the boom or arm to raise the machine, always have the bot-
tom of the bucket in contact with the ground. (Never push with the
teeth.) The angle between the boom and arm should be 90” to 110”.
The same applies when using the inverting bucket.
2. When both sides are stuck.
When the tracks on both sides are stuck in mud and the machine will not
move, lay boards as explained on the left, and dig the bucket into the
ground in front. Then pull in the arm as in normal digging operations and
put the travel levers in the FORWARD position to pull the machine out.
3. Method of towing machine

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 (a) as shown in the diagram on the right.
* Do not use the hole for the towing hook.
- 78 -
P2
- 79 -
INVERSION AND REPLACEMENT OF
BUCKET
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.
1. Select a flat surface and stabilize the bucket.

(a): Bucket cylinder
(b): Link
(c): Arm
2. After removing the stop bolt and nut for each pin, extract pins A and B.
* After removing the pins, make sure that they do not become contami-
nated with sand or mud and that the seals of bushing on both sides do
not become damaged..
3. Reverse the bucket.
* After reversing the bucket, correct the direction and inclination of mount-
ing pin holes (1) and (2) then firmly stabilize the bucket so that it does
not shake about.
4. Couple the arm to hole (l), then connect the link to hole (2).
5. After mounting the stop bolt and nut for each pin, apply grease to each
pin.
* When replacing bucket, adjust bucket clearance.
- 80 -
- 81 -
HANDLING THE CLAMSHELL BUCKET
This bucket is used for digging and loading in side-ditches or the con-
fined spaces.
How to perform excavation

Carry out digging work by lowering the boom keeping the clamshell
opened.
Close the bucket while raising the boom gradually.
When you begin to dig and find the bucket rotating, do as follows.
Extend the bucket cylinder fully and hold, the bucket will soon stop
rotating.
* Make the teeth of the bucket vertical in digging.
* For safety, always avoid abrupt traveling, swing and stopping.
t Do not swing the bucket to crush the rock or to cut through soil.
t Do not use the bucket for hammering or pulling out piles etc.
t Before leaving the machine, open the bucket and lower it to the ground.
t Remove the bucket from the arm when transporting the machine.
- 82 -
- 83 -
SELECTION OF TRACK SHOES
Choose suitable track shoes to match the ground 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 confirm that these shoes are suitable.
* When selecting the shoe width, select the narrowest shoe possible that
will give the required flotation and ground pressure. 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, l On rough ground with large obstacles such as

A
normal soil boulders or fallen trees, travel at low speed.
0 These shoes cannot be used on rough ground

where there are large obstacles such as
boulders or fallen &es.
B Normal soil, soft ground
0 Travel at Hi soeed onlv on flat around. and if it
is impossible’to avoid’going over obstacles,
shift down and travel at half speed in Lo.
0 Use the shoes only in places where the

machine sinks and it is impossible to use A or
B shoes.
0 These shoes cannot be used on rough ground
Extremely soft ground
C where there are large obstacles such as
(swampy ground)
boulders or fallen trees.
0 Travel at Hi speed only on flat ground, and if it
is impossible to avoid going over obstacles,
shift down and travel at half speed in Lo.
- 84 -
Table 2
PC400 PC4OOLC
Specifications Category Specifications Category
600 triple grouser A 700 triple grouser B
700 triple grouser B 600 triple grouser A
750 triple grouser B 750 triple grouser B
800 triple grouser C 800 triple grouser C
900 triple grouser C 900 triple grouser C
- 85 -
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
0 Jobsites where wear life is demanded, such as when loading hard rocks.
l Jobsites where no penetration is needed, such as when working with
crushed rock after blasting or ripping.
0 Jobsites where heavy-duty operations are carried out, such as hitting or
pulling up rocks with the tips of the teeth.
Self-sharpening teeth
0 Jobsites demanding penetration such as digging and loading sandy or
clayey soil.
- 86 -
TRANSPORTATION
When transporting the machine, observe the various road rules, road
transportation vehicle laws and vehicle limit ordinances, etc. It is a good
idea to obtain a special platform for loading and unloading the machine.
When it is unavoidably necessary to use a gangplank, however, at the very
least observe the following for the sake of safety.
Properly apply the brakes on the trailer and insert blocks beneath the
tires to ensure that it does not move. Then fix the gangplank in line with
the centers of the trailer and the machine.
Make sure the gangplank has sufficient width, length and thickness to
enable the machine to be safely loaded and unloaded.
If the gangplank sags appreciably, reinforce it with blocks, etc.
Turn the AUTO-DECEL switch OFF, and set the travel speed switch to the
Lo position.
Determine the direction of the gangplank, then slowly load or unload the
machine.
A slipping
Remove the mud from the undercarriage
to the side on slopes.
to prevent the machine from
* Move the machine backward to get on the trailer.

t Do not on any account change the direction of the machine while it is on
the gangplank. To change the direction of the machine, first take it down
from the gangplank.
4. Correctly load the machine onto the specified part of the trailer.
After loading the machine, fully extend the bucket and arm cylinders,
then slowly lower the boom.
* When transporting the machine, place rectangular timber under one end
of the bucket cylinder to prevent it touching the ground, thereby saving it
from possible damage.
5. 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.
6. Lock all the control levers securely with the lock lever.
* Determine the route for transporting the machine by taking into account
the width, height and weight of the machine.
- 87 -
DIVIDING THE MACHINE
To simplify transportation, the machine cab be divided into the body,
attachments, and counteweight. Before transporting a machine, consult your
Komatsu distributor.
The following points when dividing a machine.
t When disassembling the attachments, take care not to let dust get into
the joints of the piping. After removing the attachment, plug or tape the
joints.
* After packing, check for water leakage and oil leakage. Refill if necessary.
* Fix each section securely to protect cylinders and other parts.
t Reinstall the pins and bolts which were removed for disassembly.
A The lifting hooks on the counterweight

ing the counterweight.
should only be used when rais-
Never use the lifting hooks on the counterweight to raise the machine
itself.
0 Detachment sites:
I-l Boom lamp and associated wiring.
I-2 Cylinders and associated piping.
I-3 Boom cylinder foot
I-4 Boom foot
I-5 Countemeight
II-1 Bucket cylinder piping
II-2 Arm cylinder rod end
II-3 Boom-arm junction
III-1Link-bucket junction
III-2
Arm-bucket junction
- 88 -
II 2 11 3 I 1
- 89 -
(a): weight : 8.0 ton
capacity : 7.53 x 3.74 x 1.57 = 44.2 m3
(b): weight : 24.2 ton (25.8 ton)
capacity : 5.74 x 3.23 x 3.34 = 61.9 m3
(5.90 x 3.23 x 3.44 = 65.6 m3)
(c): weight : 8.5 ton
capacity : 2.96 x 1.18 x 0.76 = 2.8 m3
(d): weight : 3.3 ton
capacity :4.9x1.94x1.57=14.9m3
(e): weight : 3.3 ton
capacity : 6.36x 1.17 x 1.57 = 11.7 m3
(9: weight : 4.7 ton
capacity : 7.29 x 1.62 x 0.78 = 9.2 m3
(g) : weight : 2.0 ton
capacity : 4.62 x 0.91 x 0.57 = 2.4 m3
(h): weight : 1.3 ton
capacity : 2.03 x 1.17 x 1.57 = 3.7 m3
( ): PC4OOLC
- 90 -
I
I
I I
- 91 -
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME
GAUGE
REDUCING TRACK GAUGE
1. Remove center frame mounting bolts (1). (one side, front + rear: 18
bolts).
(a): Center frame
(b): Track frame
2. Swing the upper structure and set at a right angle to the track frame on
side (A) which is to be retracted, then use the work equipment to jack up
the track frame.
3. Fit block (C) (wooden block approx. 20 - 30 cm square) in the outside of
track frame (A), then lower the body a little at a time with the boom
cylinder. The track frame will slide and will stop when it contacts the
stopper.
4. Lower the machine carefully and install bolts (2). (one side, front + rear:
8 bolts out of bolts (1))
t Tightening torque: 175 i 20 kgm
5. Remove steps (3) (front + rear: 2 places) on the side of the track frame.
6. Follow the same procedure to retract the track frame on the other side.
A Never use the machine for operations with the track frame retracted.
INCREASING TRACK GAUGE
1. Remove center frame mounting bolts (2) (one side, front + rear: 8) from
the front and rear of the track frame on the side to be extended.
2. Install steps (3) (front + rear: 2 places) on the side of the track frame.
* Tightening torque: 28.25 2 3.25 kgm
3. Swing the upper structure to the side opposite track frame (A) to be
extended until the upper structure is at a right angle to the tracks.
* Do not raise the track frame higher than 50 mm.
If it is raised too high, the stopper bolt will be twisted and will bend.
4. Pull the machine forward with the arm, and the track frame will slide
sideways.
5. Extend the track frame until it comes into contact with the stopper, then
lower the machine slowly to the ground. install bolts (1) (one side, front
+ rear: 18) and tighten to specified torque:
* Tightening torque 175+20kgm
6. Follow the same procedure to extend the track frame on the other side.
* The track gauge should be changed on level, hard ground.
t When changing the track gauge, it is dangerous to operate any cylinder
suddenly. Always operate the control levers slowly.
- 92 -
5
I
H \
@
- 93 -
INSTALLATION OF OPTIONAL
ELECTRICAL EQUIPMENT
A:Power source when installing optional electrical equipment.
When installing extra electrical equipment, always take the power from
connector No. M26 provided inside the panel (within 15A).
Never take the power from the following terminals.
It will cause the fuse to blow or will have adverse effect on the mecha-
tronics equipment.
0 Fuse No. 9
0 Starting swtich terminal B, BR and ACC
0 Battery relay terminal BR
Use a male connector (4 pin) to connect to the power source pick-up.
B: Connections when adding extra lamps

When adding lamps, use the connection method shown in the diagram.
* When the present lamp relay is turned ON, the standard lamps light up.
At the same time, power flows to the additional relay, so the additional
relay is switched on and the extra lamps light up.
(a): Fuse box

(b): Monitor panel
(c): Lamp switch
(d): Two direct relays cannot be used
(e): Lamp relay
(f): Additional relay
(g): Standard lamps
(h): Additional lamps
----- Dashed line: Additional wiring harness
- 94 -
- 95 -
COLD WEATHER OPERATION
PREPARATION 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 the TABLE OF FUEL, COOLANT
AND LUBRICANTS.
COOLANT
After cleaning inside of the cooling system, add antifreeze to the coolant
to prevent the coolant from freezing when the machine is not being used.
* For details of the antifreeze mixture when changing the coolant, see
WHEN REQUIRED.
Care in using Antifreeze
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibi-
tor, antifoam agent, etc.) meeting the standard requirements as shown
below. With permanent antifreeze, no change of coolant is required for a
year. If it is doubtful that an available antifreeze meets the standard require-
ments, ask the supplier of that antifreeze for information.
Standard requirements for permanent antifreeze
SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1034
FEDERALSTANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..O-A_548D
Never use methanol, ethanol or propanol based antifreeze.
Where no permanent antifreeze is available, an ethylene glycol 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.
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.
A Antifreeze is flammable, so keep it away from any flame.
BATTERY
As ambient temperature drops, battery capacity will drop, and electrolyte
may sometimes freeze if battery charge is low. Maintain battery at a charge
level of approx. 100% and insulate it against cold temperature so that
machine can be readily started the next morning.
- 96 -
t Measure specific gravity of fluid and obtain rate of charge from the fol-
lowing conversion table:
Temo.
of fldid
20°C O’C -1 O’C -2o’c
Rate of
charae
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
* When electrolyte level is low, add distilled water in the morning before
work instead of after the day’s work. This is to prevent fluid from freez-
ing at night.
A To avoid gas explosions, do not bring fire or sparks near the battery.
A If the electrolyte gets on your skin or clothes,

plenty of clean water.
immediately wash with
- 97 -
A: STARTING IN COLD WEATHER
For the pre- and post-starting inspection, refer to the section OPERATING
YOUR MACHINE.
1. Set fuel control dial (1) at the low idling (MIN) position.
(a): Low idling
2. Turn starting key (2) to HEAT, and confirm that engine preheating monitor
lamp (3) comes on. After about 30 seconds, preheating monitor lamp (3)
will flash for about 10 seconds to indicate that preheating is finished.
3. After preheating monitor lamp (3) starts to flash, turn the key (2) to
START and start the engine.
4. When the engine starts, return the key of starting switch (2) to the ON
position.
(The key will return automatically when released.)
* If the engine does not start up under the above procedure, repeat steps
2 and 3 after waiting for about 2 minutes.
A Never use starting aid fluids as they may cause explosions.
- 98 -
Al
1
IA4
- 99 -
B: AUTOMATIC WARMING-UP OPERATION
(STARTING IN COLD AREAS)
After starting the engine in cold areas, carry out automatic warming-up
operation.
1. Set fuel control dial (1) to the low idling (MIN) position.
* After starting the engine, if the engine water temperature is low (below
3O”C),warming-up operation will be carried out automatically.
* The automatic warming-up operation is canceled when the engine water
temperature reaches the specified temperature (30°C) or after warming-up
operation has been continued for 10 minutes, so if the engine water tem-
perature and hydraulic oil temperature are still low after the automatic
warming-up operation, warm up the engine as follows.
2. Leave fuel control dial (1) at the low idling (MIN) position and run for ap-
prox. 5 minutes under no load.
3. Press working mode switch (2) on the monitor panel to set to H.0
(heavy-duty operation) mode.
4. Turn fuel control dial (1) to the mid-range speed position.
(a): Mid-range speed
5. Operate bucket control lever (3) and arm control lever (4) slowly to move
the bucket cylinder and arm cylinder to the end of their stroke.
(a): In (c): Curl
(b): Out (d): Dump
Operate the bucket for 30 seconds and the arm for 30 seconds in turn
fully for 5 minutes.
When pulling in the work equipment, be careful not to hit the chassis or
ground.
Turn the swing lock switch ON (ACTUATED) and operate the lever to
make the oil temperature rise more quickly.
Turn fuel control dial (1) to the full speed (MAX) position and carry out
the operation in Step 6 for 3 - 5 minutes.
(a): Full speed
Repeat the following operation 3 - 5 times and operate slowly.
Boom operation RAISE - LOWER
Arm control operation IN - OUT
Bucket control operation CURL * DUMP
Swing operation LEFT - RIGHT
Travel (Lo) operation FORWARD - REVERSE
If the above operation is not carried out, there may be a delay in re-
sponse when starting or stopping each actuator.
- IOO-
Bl B3
H.0 G.0 F.0 L.0
e;q: 0 0
WORKING MODE
B4 B5
B7
CAUTIONS AFTER COMPLETION OF WORK
1. Mud and water on the machine body should be completely removed.
Park the machine on concrete or hard ground. If this is impossible, park
the machine on wooden boards. This will prevent the accessories from
freezing or the track and undercarriage from freezing to the ground
thereby preventing vehicle movement the next morning. Particular atten-
tion should be given to water drops collected on the surface of the
hydraulic cylinder piston rods. Such droplets must be fully wiped off
because if water is frozen to the rod when the cylinder is utilized, the
cylinder oil seals may be damaged.
2. Drain water collected in fuel system so that such water may be frozen at
night.
3. As battery capacity drops at low ambient temperature, cover the battery
or remove it from the machine to be kept warm at night.
AFTER COLD WEATHER

When weather becomes warm, perform the following without fail:
0 Replace lubricating oils for various units with the ones specified for
warm-weather use.
0 If for any reason permanent antifreeze connot be used, and an ethyl gly-
col base antifreeze (winter, one season type) is used instead, or if no
antifreeze is used, drain the cooling system completely, then clean out
the inside of the cooling system thoroughly, and fill with fresh water.
PREPARING THE CAB HEATER

If the ambient temperature drops, use the cab heater.
1. When using the cab heater, turn valve (1) on the water manifold coun-
terclockwise to open it.
2. When leaving the cab heater unused for a long time, turn valve (1) clock-
wise to close it.
-102-
-103-
MEMO
-104-
PERIODIC MAINTENANCE
Proper lubrication and maintenance assure trouble-free operation and long
machine life. Time and money spent for scheduled periodic maintenance will
be amply compensated by prolonged machine operation and reduced
operating cost.
All hourly figures given in the following descriptions are based on service
meter readings. In practice, however, it is recommended to rearrange all of
them into units of days, weeks and months to make the maintenance sche-
dule more convenient. Under rough job site or operating conditions, it is
necessary to somewhat shorten the maintenance intervals stated in this
manual.
-105-
PRECAUTIONS WHEN DISASSEMBLING
MACHINE
When disassembling the machine or removing piping for inspection or
maintenance, always release the remaining pressure as follows.
A. RELEASING PRESSURE IN WORK EQUIPMENT CIRCUIT, SWING

CIRCUIT, TRAVEL CIRCUIT
1. Lower the work equipment to the ground on a firm, flat surface as shown
in the diagram, then stop the engine.
* Set the lock lever to the FREE position.
2. Operate all the work equipment levers to the end of their travel within 5
- 6 seconds of stopping the engine.
3. Remove the cap from the hydraulic tank.
4. Start the engine, run for approx. IO seconds, then stop the engine.
* Do not run the engine at above 1000 rpm.
* Place the work equipment levers at neutral.
5. Operate all the work equipment levers to the end of their travel within 5
- 6 seconds of stopping the engine.
* Repeat Steps 4 - 5 three times.
A When removing the oil filler cap from the hydraulic tank, turn it slowly
to release the internal pressure, and remove it carefully.
B. RELEASING PRESSURE FROM ACCUMULATOR CIRCUIT

Pilot circuit
After stopping the engine, place lock lever (1) in the FREE position, oper-
ate all the work equipment levers 3 - 4 times to the end of their travel,
then wait for at least 1 minute for the pressure to be released.
Do not loosen any piping for at least 1 minute after releasing the
pressure.
-106-
Al
-107-
BLEEDING AIR FROM CIRCUIT
When replacing or cleaning the hydraulic oil, filter element, or strainer, or
when replacing or cleaning the line filter element, or when repairing or re-
placing hydraulic equipment, or after removing the hydraulic piping, bleed
the air from the circuit.
PROCEDURE FOR BLEEDING AIR

Air bleeding item Air bleeding procedure
1 2 3 4 5 6
Bleed air Bleed air Bleed air Bleed air
Start
from from from swing from travel opz$&s
Nature of work engine
pump cylinder motor motor
. Change hydraulic oil o-o-o-o-o-o

. Clean strainer
‘1 *1
. Replace return filter 0 CO

element
. Replace, repair pump
. Replace, clean line filter element o-o-o -0
. Remove suction piping
. Replace, repair control valve o-o-o-o-o
. Replace cylinder o-o -0

. Remove cylinder piping
. Replace swing motor 0 -0 -0
. Remove swing motor piping
. Replace travel motor, swivel
. Remove travel motor, 0 -0-o
*1 Bleed the air from the swing motor and travel motor only when the oil inside the motor case
has been drained.
Bleeding air from pump

Loosen the bleeder at portion (A), remove plug (B), then add oil through
filler (B) to fill the pump with oil.
After completion of bleeding the air, install plug (B) first, then tighten the
bleeder.
If the breather is tightened first, oil will spurt out from hole (B).
If the pump is operated without the pump case being filled with hydraulic
oil, abnormal heat will be generated, and this may lead to premature
damage to the pump.
* Tightening torque
Bleeder (A): 0.9 + 0.1 kgm
Plug (B): 7.0 + 1.0 kgm
- 108-
- 109-
b. Start engine
Start the engine (see HANDLING ENGINE) and run at low idling for 10
minutes, before going on to the next operation.
c. Bleeding air from cylinders
1. Run the engine at low idling,and extend and retract each cylinder 4 - 5
times without operating it to the end of its stroke. (Stop 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.
* If, at first, the engine is run 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 or other parts.
d. Bleeding air from swing motor
1. Run the engine at low idling, loosen air bleed plug (I), and when no
more cloudy white oil flows out from air bleed plug (I), tighten the plug.
t Tightening torque: 7.0 k 1.0 kgm
* When doing this, do not operate the swing.
2. Run the engine at low idling, and swing 2 or more times slowly and
uniformly to the left and right.
* If the air is not bled from the swing motor, the ‘bearings of the motor
may be damaged.
e. Bleeding air from travel motor
1. Run the engine at low idling, loosen air bleed plug (l), and when no
more cloudy white oil flows out, tighten the plug.
t Tightening torque: 0.9 k 0.1 kgm
2. Keep the engine running at low idling, and swing the work equipment 90”
to bring it to the side of the track.
3. Jack up the machine until the track is raised slightly from the ground.
Rotate the track under no load for 2 minutes. Repeat this procedure on
both the left and right sides, and rotate the track equally both forward
and in reverse.
f. Start operations
After completion of bleeding the air, stop the engine, and wait for at
least 5 minutes before starting operations. In this way, the air bubbles are
removed from the oil inside the hydraulic tank.
+ Check for any leakage of oil, and wipe off any oil that has been spilled.
-llO-
b
Go0632
- 111 -
PERIODICAL REPLACEMENT OF SAFETY
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 addi-
tion, to furher improve safety, the user should also carry out periodic
replacement of the parts given in the table on the next page. These parts
are particularly closely connected to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear
or deteriorate. However, it is difficult to judge the condition of the parts
simply by periodic maintenance, so they should always be replaced after a
fixed time has passed, regardless of their condition. This is necessary to
ensure that they always maintain their function compeletly.
However, if these parts show any abnormality before the replacement
interval has passed, they should be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking,
replace the clamps at the same as the hoses.
Carry out the following inspection for hydraulic hoses in addition to the
periodic replacement parts listed on the next page. If any abnormality is
found, tighten, replace, or take any other necessary action.
Category of inspection Inspection item
Check before starting Leakage from joints or caulked portion of fuel or hydraulic hoses
Periodic inspection Leakage from joints or caulked portion of fuel or hydraulic hoses
(monthly inspection) Damage (cracks, wear and tear) or fuel or hydraulic hoses
Leakage from joints or caulked portion of fuel or hydraulic hoses

Periodic inspection
Interference, deterioration, twisting, damage (cracks, wear and
(yearly inspection)
tear, crushed parts) of fuel or hydraulic hoses
- IIZ-
-113-
Fuel system parts
No. Safety parts for periodical replacement o’tv Replacement interval
1 Fuel hose (fuel tank - engine) 2
2 Fuel hose (fuel filter - injection pump) 2

Every 2 years or 4000 hours,
whichever comes sooner
3 Spill hose (nozzle - injection pump) 1
4 Spill hose (between nozzles) 5
Hydraulic system parts
No. Safety parts for periodical replacement QW Replacement interval
5 Front pump hose (front pump - line filter) 1
6 Front pump hose (line filter - control valve) 1
Every 2 years or 4000 hours,

7 Rear pump hose (rear pump - line filter) 1
whichever comes sooner
8 Rear pump hose (line filter - control valve) 1
9 Front and rear pump branch hoses 2
* For the part numbers and quantity of the periodic replacement parts, see
the section in the parts book on periodic replacement and safety parts.
* When replacing the hoses, always replace the O-rings, gaskets, and other
such parts at the same time.
- 114-
-115-
MAINTENANCE TABLE
No. ITEM SERVICE PAGE

a Walk-around check 50
b Coolant Check and supply 50
C Engine oil pan Check and supply 50
d Fuel Check and supply 52
e Hydraulic tank Check and supply 52
f Dust indicator Check 54
9 Electric wirings Check 54
h Clamshell bucket Lubricate 12 points 54
i Water separator Inspect float position 54
EVERY 100 HOURS SERVICE

a Swing machinery case Check and supply 122
b Fuel tank Drain water and sediment 122
C Lubricating 124
-1 Boom cylinder foot pin Lubricate 2 points 124
-2 Boom foot pin Lubricate 2 points 124
-3 Boom cylinder rod end Lubricate 2 points 124
-4 Arm cylinder foot pin Lubricate 1 point 124
-5 Arm cylinder rod end Lubricate 1 point 124
-6 Boom-Arm coupling pin Lubricate 1 point 124
-7 Bucket cylinder foot pin Lubricate 1 point 126
-8 Arm-Link coupling pin Lubricate 1 point 126
-9 Arm-Bucket coupling pin Lubricate 1 point 126
-10 Link coupling pin Lubricate 2 points 126
-11 Bucket cylinder rod end Lubricate 1 point 126
- 116-
-12 Bucket-Link coupling pin Lubricate 1 point 126

(The items marked * are carried out after the first 250 hours only for new
machines.)
* Fuel filter Replace cartridge 128
* Engine valve clearance Check and adjust 128
a Final drive case Check and supply 128

(ZZ;;ytil and replace
b Engine oil pan and filter 128
9
C Fan belt Check tension 130
d Hydraulic filter Replace element 130
e Swing circle Lubricate 3 points 132
f Battery electrolyte Check fluid level 132

Drain water and
g Fuel filter 134
sediment
h Hydraulic tank breather Replace element 134

a Swing circle pinion Lubricate with grease 136
b Radiator fins and oil cooler fins Clean 136
C Fuel filter Replace cartridge 138

a Swing machinery case Change oil 140
b Damper case Check and supply 140
C Turbocharger clamping joint Check and retighten 140
-117-
(EVERY 1000 HOURS SERVICE)
d Turbocharger rotor Check play 142
e Corrosion resistor Replace cartridge 142

a Hydraulic tank Change oil 144
b Hydraulic tank strainer Clean 146
C Final drive case Change oil 146
d Engine breather Clean 146
e Turbocharger Clean blower impeller 148
f Alternator and starting motor Check 148
g Vibration damper Check 148
h Engine valve clearance Check and adjust 148

a Water pump Check 149
WHEN REQUIRED
a Cooling system Clean 150
Check, clean or replace
b Air cleaner element 154
when required
C Track Check and adjust tension 158
d Electrical intake air heater Check once a year 160
e Track shoe bolts Check and retighten 160
f Bucket teeth (Vertical pin type) Replace 162
9 Bucket teeth (Horizontal pin type) Replace 164
h Line filter Clean 166
i Water separator Drain water 166
- 118-
MEMO
- c- 11-q-r -
- 119 -
.’
OIL FILLER AND LEVEL GAUGE

POSITIONS
1. Swing machinery case oil filler
2. Hydraulic tank oil filler
3. Hydraulic tank level gauge
4. Final drive case oil filler
5. Final drive case drain plug
6. Hydraulic tank drain plug
7. Engine oil pan level gauge
8. Engine oil pan oil filler
9. Cooling water inlet
IO. Fuel tank oil filler
11. Fuel tank level gauge
12. Fuel tank drain valve
13. Swing machinery case drain plug
14. Cooling water drain valve
15. Engine oil pan drain plug
-120-
-121-
Seethe section on CHECK BEFORE STARTING aforementioned.

a. SWING MACHINERY CASE
Inspect the oil level using dipstick (G), and if insufficient pour in addi-
tional engine oil from gauge hole.
* Before supplying oil, remove air bleeding plug (1). After refilling, tighten
plug (I).
* Insert dipstick (G) fully into the guide when checking the oil level.
b. FUEL TANK
Loosen valve (1) on the bottom of the tank so that the precipitation and
mixed water will be drained in accompaniment with fuel.
-122-
__
-123-
c. LUBRICATING
Apply grease to the grease fittings shown by arrows.
* If any abnormal noise is heard from any greasing point, add grease
regardless of the service interval.
Jr For the first 100 hours of operation of new machines, grease the boom
cylinder foot pin and boom foot pin every 10 hours.
1. Boom cylinder foot pin (2 points)

2. Boom foot pin (2 points)
3. Boom cylinder rod end (2 points)
4. Arm cylinder foot pin (1 point)
5. Arm cylinder rod end (1 point)
6. Boom - Arm coupling pin (1 point)
- 124-
S 5 i 9 lo,1112 1
won0
cl
7
-I
7. Bucket cylinder foot pin (1 point)
8. Arm - Link coupling pin (1 point)
9. Arm - Bucket coupling pin (1 point)
10. Link coupling pin (2 points)
11. Bucket cylinder rod end (1 point)
12. Bucket - Link coupling pin (1 point)
- 126-
-1127-
Carry out the following maintenance only after the first 250 hours.
. FUEL FILTER, REPLACE CARTRIDGE
. ENGINE VALVE CLEARANCE, CHECK AND ADJUST
For details of the method of replacing or maintaining, see the section on
EVERY 500 HOURS AND 2000 HOURS SERVICE.
a. FINAL DRIVE CASE

1. Set with the UP mark at the top, and with the line connecting the UP
mark and plug (P) perpendicular to the ground surface.
2. Remove plug (F), and if the oil is not within IO mm below the bottom of
the plug hole, install plug (F), rotate the sprocket one turn, then check
again. If the oil is still not within 10 mm below the bottom of the plug
hole, add engine oil through the plug hole.
b. ENGINE OIL PAN AND FILTER

1. Remove drain plug (P) under the chassis, drain the oil, then tighten it
again.
2. Using a filter wrench, remove cartridge (1) of the engine oil filter by turn-
ing it counterclockwise.
3. Clean the filter holder, coat the seal surface of the new filter cartridge
with engine oil (or coat it thinly with grease), then install.
t When installing, to prevent overtightening, tighten until the packing sur-
face contacts the seal surface of the filter holder, then tighten up it 3/4
to 1 of a turn.
4. After replacing the cartridge, pour in the specified quantity of engine oil
from oil filler (F).
5. Run the engine at idling for a short time, then stop the engine and check
that the oil level is correct. For details, see CHECK BEFORE STARTING.
* Refill capacity: 32 II
t The type of lubricant used depends on the ambient temperature. Select
* Be sure to fit a genuine Komatsu cartridge.
* Replace once every 6 months, regardless of the number of hours oper-
ated.
* When supplying oil, be careful not to get oil on the alternator.
* If filter cartridge (1) is removed immediately after stopping the engine, oil
will spill. Wait at least IO minutes after stopping the engine before replac-
ing the filter cartridge.
* Use API category CD class oil. If CC class oil must be used, change the
oil and replace the oil filter at half the usual interval (125 hours).
-128-
a
- 129-
c. FAN BELT
1. The belt tension should normally deflect by about 6 - 7 mm (a) when
pressed with the finger at a point midway between the alternator (b) and
the fan pulley (c) (approx. 6 kg).
(d): Crankshaft pulley
2. To adjust the belt tension, loosen bolt and nut (11, (2) and shift alternator
(3) slightly.
3. After adjusting, tighten bolt and nut (l), (2) securely.
* When adjusting the V-belt, do not attempt to push alternator (3) directly
with a bar or the like, but use a wood pad to’ prevent damage to the
core.
* Check each pulley for damage, and V-grooves and V-belt for wear. Parti-
cularly, check whether V-belt is in contact with bottom of V-groove
through wear.
t Replace belt if it has stretched, leaving no allowance for adjustment, or if
there is a cut or crack on belt.
d. HYDRAULIC FILTER
1. Remove the cap from oil filler (F).
2. Remove cover (I), then remove spring (2) and valve (3), and take out
element (4).
3. Clean the parts after taking them out, then install a new element.
A When removing the cap, turn it slowly to relieve inner pressure.
A When removing the cover (I), undo the bolts (4 bolts) gradually to pre-
vent the cover flying off under the force of the spring (2).
* When a hydraulic breaker is installed, the hydraulic oil deteriorates faster

than for the normal bucket excavation work, so always install the extra
filter specified by Komatsu.
t For installation of extra filters, please contact your Komatsu distributor.
t Replace the extra filters on new machines after the first 250 hours, and
following this, replace at the intervals shown in the table below.
(a): Replacement interval (h)

(b): Breaker operation rate (%)
(c): Replacement interval for main filter
(d): Replacement interval for extra filter
- 130-
d
1000
@ 500
250
0 20 40 60 80 100
c3
G&l657
-131-
e. SWING CIRCLE
Lubricate to the 3 grease fittings shown by an arrow.
f. BAlTERY ELECTROLYTE
If the electrolyte level is lower than the prescribed level (10 to 12 mm
above the plate), supply distilled water.
* Should any of the acid be spilt, have it replenished by the nearest battery
shop with acid of the correct specific gravity.
* When inspecting electrolyte level, clean the air hole of the battery cap
(1).
A plenty
If the electrolyte gets on your skin or clothes,
of clean water.
immediately wash with
A To avoid gas explosions, do not bring fire or sparks near the battery.
-132-
e
-133-
g. FUEL FILTER
Loosen the drain plug at the bottom of the fuel filter, and drain the water
and sediment collected at the bottom together with fuel.
* If air has been sucked in by mistake, bleed the air. For details, see
REPLACING FUEL FILTER CARTRIDGE.
h. HYDRAULIC TANK BREATHER
A When replacing
internal pressure
the breather,
first.
turn oil filler (F) slowly to release the
0 Replacement of filter element of breather (I)

1. Remove cap nut (2), nut (3), seal washer (4), and cover (5).
2. Replace filter element (6) with a new element, then install cover (5), seal
washer (4), nut (3), and cap nut (2) in order.
t Install the filter element with the sponge packing at the top.
* Align the notched portions of body (7) and cover (5), then install and lock
in position.
(a): Notch
* Tightening torque
Cap nut (2), nut (3): 1.2 f 0.2 kgm
0 Replacement of element of cap (F)

1. Remove bolt (8) and cover (9).
2. Replace filter element (10) with a new element, then install cover (9) and
bolt (8).
* When installing cover (9). check that the male and female portions inside
are aligned.
* Tightening torque of bolt (8): 0.8 + 0.1 kgm
- 134-
h g------o
- 135-
. .

* Maintenance for every 100 and 250 hours should be carried out at the
same time.
a. SWING CIRCLE PINION

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 25 mm. Add more grease
if necessary.
If the grease is particularly milky due to ingress of water, etc., then
remove cover (3) from the bottom of the track frame and remove the
grease. Replace all of the grease with new grease.
The total amount of grease is 35 II [31.5 kg].
When changing the grease, contact your Komatsu distributor.
b. RADIATOR FINS AND OIL COOLER FINS

Clean the radiator fins and oil cooler fins clogged with mud, dust and
leaves with compressed air. Steam or water may be used instead of com-
pressed air.
The rubber hose should be checked at the same time. If the hose is
found to have cracks or to be hardened by ageing, such hose should be
replaced by new one. Further, loosened hose clamp should also be
checked.
When cleaning, clean the net at the front of the oil cooler also.
On dusty jobsites, carry out this inspection every day regardless of the
maintenance interval.
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a
\
\
A , i J
5x723
-137-
c. FUEL FILTER
1. Using a filter wrench, remove cartridge (1) by turning it counterclockwise.
2. Fill the new cartridge with fuel and refit it after applying a dab of oil to
the gasket face.
* To refit the cartridge, place the gasket face in contact with the seal face
of the filter stand, then screw up the cartridge l/2 to 3/4 of a turn (be
careful not to tighten it up excessively).
3. After replacing filter cartridge (l), loosen air bleed plug (2).
4. Loosen the knob of feed pump (3), then pump it up and down, and con-
tinue until no more bubbles come out with the fuel from air bleed plug
(2).
5. Tighten air bleed plug (2).
t Always use genuine Komatsu filter cartridges.
* After replacing the filter cartridge, start the engine, and check that there
is no leakage of oil from the filter seal surface.
When starting the engine after it has run out of fuel, if the engine mis-
fires, or black smoke comes out, bleed the air from the line as follows.
6. Loosen the connection of the fuel discharge port of the injection pump,
and bleed the air in the same way as for the fuel filter.
7. After bleeding the air, tighten the fuel discharge port, then push in the
knob of the feed pump and tighten it.
- 138-
- 139-
* Maintenance for every 100, 250 and 500 hours should be carried out at
the same time.
SWING MACHINERY CASE

Drain off oil from drain valve (P) at the bottom of the machine.
After draining, tighten the drain valve (P).
Pour in the specified amount of engine oil from gauge hole (G).
(Refer to EVERY 100 HOURS SERVICE.)
Before supplying oil, remove air bleeding plug (1). After refilling, tighten
plug (I).
The type of lubricant used depends on the ambient temperature. Select
Refill capacity: 22 L
b. DAMPER CASE
Remove plug (G) and check that the oil is near the bottom edge of the
plug hole. If the oil level is low, add engine oil through oil filler (F).
The type of lubricant used depends on the ambient temperature. Select
TURBOCHARGER CLAMPING JOINT

Contact your Komatsu distributor for checking, or proceed as follows:
Periodically inspect all joints for looseness. Tighten when necessary.
Tightening torque for V band on turbine housing side: 1.28 - 1.50 kgm
Tightening torque for turbocharger mounting bolts: 6.0 - 7.5 kgm
Tightening torque for turbocharger oil pipe (inlet): 2.8 - 3.5 kgm
Tightening torque for turbocharger oil pipe (outlet): 2.8 - 3.5 kgm
Tightening torque for clamp bolts on blower housing side: 0.92 - 1 .I 5 kgm
- 140-
r
a i
-141-
TURBOCHARGER ROTOR PLAY
Contact your Komatsu distributor for checking, or proceed as follows:
Remove air intake and exhaust pipes from turbocharger.
1. Axial play
Check axial play by moving rotor in axial direction.
Play:
Standard 0.025 to 0.076 mm
2. Radial play
Measure radial play by moving rotor holding both ends by hands in radial
direction in parallel.
Play:
Standard 0.12 to 0.17 mm
* If the play is over the limit, consult your Komatsu distributor.
* If the rotor is excessively soiled with dust or carbon or if any oil leakage
caused by turbocharger trouble is noted, have the turbocharger repaired
by your Komatsu distributor.
e. CORROSION RESISTOR
1. Screw in valve (1) at the top of the corrosion resistor.
2. Using a filter wrench, turn cartridge (2) to the left and remove it.
3. Coat the seal surface of the new cartridge with engine oil.
* To prevent overtightening, bring the packing surface into contact with the
seal surface of the filter holder, then tighten about 2/3 of a turn.
4. Open valve (1).
* Use a genuine Komatsu cartridge.
5. Start the engine and check that there is no leakage of water from the
seal surface.
- 142-
-143-
* Maintenance for every
100, 250, 500 and 1000 hours should be carried
out at the same time.
a. HYDRAULIC TANK
1. Retract the arm and bucket cylinder to the stroke end, then lower the
boom and put the tip of the arm in contact with the ground.
2. Remove cover and cap (F).
3. Remove drain plug (P) to drain off the oil. After draining off the oil,
tighten up drain plug (P).
4. Pour in the specified amount of engine oil from oil filler (F).
5. After adding oil, check that the oil is at the specified level. For details,
see CHECK BEFORE STARTING.
* Refill capacity: 255 !2
* When changing the oil in the hydraulic tank or replacing the main pump,
or when removing the pump suction piping, bleed the air from the circuit
before starting the engine. For details, see BLEEDING AIR FROM CIRCUIT.
* 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.
* When a hydraulic breaker is installed, the hydraulic oil deteriorates much
more rapidly than when carrying out ordinary digging operations with a
bucket. Therefore, change the oil according to the table.
(a): Change interval (Hours)
(b): (When not using breaker)
(c): Breaker operation rate (%)
(d): (Using only breaker)
(e): Hydraulic oil change interval
-144-
a a
ia a
2000
1500
63
Go0729
1ooc
500
0
@
. GcolW
-145-
b. HYDRAULIC TANK STRAINER
1. Open the cover and remove cap (F).
2. Remove cover (1) and lift up the top of rod (3) from above to take out
spring (2) and strainer (4).
3. Wash the strainer with fuel oil. If strainer (4) is damaged, replace it with
a new one.
4. Refit strainer (4) by inserting it into tank projecting part (5).
A the
When removing cover (1). undo the bolts (4 bolts)
cover flying off under the force of spring (2).
gradually to prevent
c. FINAL DRIVE CASE

1. Set with the UP mark at the top, and with the line connecting the UP
mark and plug (P) perpendicular to the ground surface.
2. Drain the oil from drain plugs (P) on both sides of the machine. After
draining, tighten the drain plugs.
3. Then, supply new engine oil through oil filler (F) respectively to the speci-
fied level. (Refer to EVERY 250 HOURS SERVICE.)
+ The type of lubricant used depends on the ambient temperature. Select
+ Refill capacity: 11 II (each)
d. ENGINE BREATHER
1. Loosen the clamp, and remove the hose, then remove breather (1) from
the cylinder block.
2. Wash the breather unit in diesel oil or flushing oil, dry with compressed
air, then install it again.
3. Check the breather hose, and if any deteriorated oil (sludge) is stuck to
the inside, replace it with a new hose.
* Before removing the breather, remove alC the dust from around the
breather.
* Replace the breather o-ring with a new part, coat with engine oil, then
install.
- 146-
C
-147-
e. TURBOCHARGER
Excessive carbon or oil sludge adhering to the turbocharger blower impel-
ler may deteriorate normal performance of the turbocharger and may some-
times damage it.
Contact your Komatsu distributor.
1. Remove the turbocharger oil supply tube and the drain tube. Then,
remove the connection area of the intake manifold and the blower hous-
ing so that the blower impeller can be seen.
2. Using light oil, wash the impeller to eliminate carbon adhered on the sur-
face.
* Do not use wire brushes or the like to prevent damage to the impeller
surface.
3. Pour light oil through the turbocharger oil filer. Turn the blower impeller
several turns so that foreign materials such as sludge can be washed
away.
4. Using your fingers, turn the impeller vigorously for one revolution or
more. If there is no sigh of interference or catching, the impeller is nor-
mal.
* If the impeller seems to turn heavily, contact your Komatsu distributor to
ask for repair or replacement.
5. If the impeller is found normal after this check, supply engine oil to the
turbocharger.
f. ALTERNATOR AND STARTING MOTOR

Around this time, the brush will become worn and the bearing will run
out of grease, so please ask your Komatsu distributor to carry out inspec-
tion and repair.
* If the engine is started frequently, carry out inspection every 1000 hours.
g. VIBRATION DAMPER
Check the vibration damper for cracks or separation on rubber surface.
If there are cracks or separation, contact your Komatsu distributor for
replacement.
h. ENGINE VALVE CLEARANCE

Ask Komatsu distributor to check engine valve clearance because special
tools should be used.
- 148-
t Maintenance for every 100, 250, 500, 1000 and 2000 hours should be
carried out at the same time.
a. WATER PUMP
inspect the water pump for play in the pulley, grease leakage and water
leakage.
If any fault is detected, ask Komatsu distributor to disassemble and repair
or replace.
- 149-
WHEN REQUIRED
a. CLEAN INSIDE OF COOLING SYSTEM
Clean the inside of the cooling system, change the coolant, and replace
the corrosion resistor cartridge, according to the table.
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.
Be sure to replace the corrosion resistor cartridge.
Use city water for the cooling water.
If river water, well water or other such water supply must be used, con-
tact your Komatsu distributor.
A Antifreeze is flammable, so keep it away from any flame.
Cleaning inside of
Replacing corrosion
Kind of coolant cooling system and
resistor
changing coolant
Every year (autumn) or

Permanent type antifreeze
every 2000 hours whichever
(All season type)
comes first
Non permanent type Every 6 months (spring, Every 1000 hours and when
antifreeze containing autumn) cleaning the inside of the
ethylene glycol (Drain antifreeze in spring, cooling system and when
(Winter, one season type) add antifreeze in autumn) changing coolant
Every 6 months or
When not using antifreeze every 1000 hours whichever
comes first
J
- 150-
0 Add antifreeze in the cooling water
When deciding the ratio of antifreeze to water, check the lowest tempera-
ture 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.
Mixing rate of water and antifreeze
Min.
atmospheric
temperature -5 -10 -15 -20 -25 -30
Amount of
antifreeze 7.8 10.2 12.2 13.9 15.7 17.0
(Q)
amount of
water 26.2 23.8 21.8 20.1 18.3 17.0
(Q)
* We recommend use of an antifreeze density gauge to control the mixing

proportions.
-151-
1. Stop the engine, close corrosion resistor valves (1).
2. Turn cap (2) slowly until it comes off.
(2): Water filler
A This
If the water temperature is high, do not remove the cap.
is because of the possibility of scalding water spurting
out.
When removing the cap, turn the cap slowly to allow pressure to be re-
lieved.
3. Open drain valve (3) at the bottom of the radiator and plug (4) on the
side of cylinder block to drain off the cooling water.
(3): Drain valve (bottom of radiator)
(4): Drain plug (cylinder block)
4. After draining the cooling water, close up drain valve (3), plug (4), and
pour in soft water (ex; city water) up to the vicinity of the water filler.
5. When the water reaches the vivinity of the water filler, put the engine at
low idling, open drain valve (3), plug (4). then pass water for IO minutes
through the cooling system until clean water comes out from drain
valve (3), plug (4).
* When doing this, adjust the speed of filling and draining the water so
that the radiator is always full.
6. When the water becomes completely clean, stop the engine, draining off
the cooling water, and close drain valve (3), plug (4).
7. After draining the water, clean with a cleaning agent.
* We recommend use of a Komatsu genuine cleaning agent. For details of
the cleaning method, see the instructions given with the cleanig agent.
8. After cleaning, drain all the cooling water, then close the drain valve (3),
plug (4) and fill slowly with clean water.
9. When the cooling water comes up to near the radiator water filler port,
start the engine, and run at low idling. Add clean water, open drain
valve (3), plug (4) and continue to run water until clean colorless water
comes out from the drain valve (3) and plug (4).
* When doing this, adjust the speed of filling and draining the water so
that the radiator is always full.
IO. When the water is completely clean, stop the engine and close drain
valve (3), plug (4).
11. Replace the corrosion resistor cartridge and open valves (1).
* For details of replacement of the corrosion resistor, see EVERY 1000
HOURS SERVICE.
12. Add cooling water until it overflows from the water filler.
- 152-
-153-
13. To remove the air in the cooling water, run for five minutes at low id-
ling, then for another five minutes at high idling.
When doing this, leave radiator cap (2) off.
14. After draining off the cooling water of sub-tank (5), clean sub-tank and
refill the water between H and L level.
(5): Sub-tank
15. Stop the engine, wait for about three minutes, add cooling water to the
specified level, then tighten cap (2).
b. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

Checking
Whenever the red piston in dust indicator (1) appears, clean the air
cleaner outer element. Stop the engine when cleaning the element.
Cleaning or replacing outer element

1. Remove wing nut- (2), then remove cover (3), and take out the outer ele-
ment.
2. Clean the air cleaner body interior and the removed cover.
3. Clean and inspect the element. (See the item “Cleaning outer element”
for cleaning procedure.)
4. Install the cleaned element.
5. Push the dust indicator reset button to return the red piston to the orig-
inal positon.
* Replace the outer element which has been cleaned 6 times repeatedly or
used throughout a year.
Replace the inner element at the same time.
* Replace both inner and outer element when the dust indicator red piston
appears soon after installing the cleaned element even though it has not
been cleaned 6 times.
* Remove one seal from the outer element. The number of times the outer
element has been cleaned can be seen by the number of removed seals.
* Check inner element mounting nuts for looseness and, if necessary,
retighten.
* Replace seal washer (4) or wing nut (2) if they are broken.
* When inspecting or cleaning the air cleaner, remove evacuator valve (5)
and clean with compressed air.
- 154-
I
b
Replacing inner element
1. Remove the outer element, and then remove the inner element.
2. Cover the air connector with a clean cloth or tape.
3. Clean inside the body, then remove the cover fitted in Step 2.
4. Install the new inner element.
5. After installing the new outer element, return the red piston in the dust
indicator to its original position.
* Do not attempt to reinstall a cleaned inner element.
A Do not clean or replace the air cleaner element with the engine running.
Cleaning the outer element
With compressed air

Direct dry compressed air (less than 7 kg/cm*) to the element from inside
along its folds, then direct it from outside along its folds and again from
inside, and check the element.
A When using compressed

required to maintain safety.
air, wear safety glasses and other things
The following methods require spare parts.

With water
Dash city water (less than 3 kg/cm*) on the element from inside along
folds, then from outside and again from inside. Dry and check it.
With cleaning agent

For removing oils and fats as well as carbon, etc., attached on the ele-
ment, the element may be cleaned in lukewarm solution of mild detergent,
then rinsed in clean water and left to drip dry.
t Drying can be speeded up by blowing dried compressed air (less than 7
kg/cm*) from the inside to the outside of the element.
Never attempt to heat the element.
Using warm water (about 40°C) instead of soapy water may also be effec-
tive.
If small holes or thinner parts are found on the element when it is
checked with an electric bulb after cleaning and drying, replace the ele-
ment.
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.
-156-
b
-157-
_..
c. CHECK TRACK TENSION

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 standard tension on it.
If the track tension is not at the standard value, adjust it in the follow-
ing manner:
Inspection
1. Raise the chassis with the boom and arm.
2. The standard clearance between the bottom of the track frame and the
top surface of the track shoe is 358 k 20 mm.
(a): Track frame
(b): Track shoe
* Places to measure
PC400: 4th track roller from sprocket
PC400LC: Between 4th and 5th track roller from sprocket
Adjustment
If the tension is not the standard value, adjust as follows.
1. To increase the tension, pump in grease through grease fitting (1); to
reduce the tension, loosen plug (2) a little at a time, and release the
grease.
A soPlugdo (2)notisloosen
under high pressure from the
it more than one turn.
grease inside, and may fly out,
When doing this, do not loosen any part other than plug (2). If the
grease does not come out properly, move the machine backwards and
forwards slightly.
2. When pumping in the grease, make S 0 mm. If the tension is still loose,
it means that there is excessive wear of the pin and bushing, so it is
necessary to turn or replace the pin and bushing. Please contact your
Komatsu distributor for repairs.
- 158-
C c
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GO0645
- 159-
d. CHECK ELECTRICAL INTAKE AIR HEATER
Check electrical intake air heater (1) once a year before commencing
work in the cold season.
Remove electrical intake air heater (1) from the engine intake connection,
and check it for possible open-circuits and dirt.
When inspecting and replacing electrical intake air heater (I), replace the
gasket with new one.
e. TRACK SHOE BOLTS

If the machine is used with track shoe bolts (1) loose, they will break, so
tighten any loose bolts immediately.
Method of tightening
1. Tighten first to a tightening torque of 40 + 4 kgm, then check that the
nut and shoe are in close contact with the link mating surface.
2. After checking, tighten a further 120’ _+ IO”.
Order for tightening

Tighten the bolts in the order shown in the diagram. After tightening,
check that the nut and shoe are in close contact with the link mating
surface.
-160-
e
-161-
f. REPLACE BUCKET TEETH (VERTICAL PIN TYPE)
Replace the point before the adapter starts to wear.
* Set the bucket so that its bottom is horizontal.
1. Use a hammer and drift to drive out lock pin (2), which is fixing point (1)
to the bucket. (If the drift is struck while facing rubber pin lock (3), the
rubber pin lock may break. Direct the drift to the back of the pin.)
2. Check lock pin (2) and rubber pin lock (3) which were removed.
* If the lock pins and rubber pin locks with the following defects are used,
the point may come off the bucket. Replace them with new ones.
1) A lock pin (a) which is too short. (When aligning with bottom face (c),
clearance (b) becomes more than 1/3A.)
2) A rubber pin lock, the rubber (d) of which is broken and whose steel
balls come out easily.
3) A rubber pin lock, the steel balls (e) of which can be buried by being
pressed with a finger.
3. Clean the surface of adapter (4) and remove, the soil from it with a knife.
4. Use your hand or a hammer to drive rubber pin lock (3) into the hole of
the adapter. Take care that the rubber pin lock does not project out of
the adapter.
5. Clean the inside of point (1) and install it to adapter (4). If it is stained
with soil or has projections (f), it will not fit to the adapter.
6. Fit point (1) to adapter (4), and confirm that when the pointer is pressed
strongly, the rear face of the hole for the pin of the point is at the same
level as the rear face of the hole for the pin of the adapter.
* If the rear face of the hole for the pin of point (1) is projecting from that
of adapter (4), do not drive in the pin. Instead, find out what substance is
preventing point (1) from fitting to adapter (4), and remove it. Then fit
point (1) to adapter (4) and drive in lock pin (2).
7. Insert lock pin (2) in the hole of the point and hit it until its top is the
same level as the surface of point (1).
8. After replacing a bucket tooth, confirm that it is installed securely by
doing the following:
1) Confirm that the surface of the lock pin is secured against the point.
2) Lightly hit lock pin (2) in the reverse direction from which it was hit in.
3) Lightly hit the tip of the point from above and below, and hit its sides
from right and left.
4) Confirm that rubber pin lock (3) and lock pin (2) are set as shown in the
figure.
-162-
f
if2
f4
-163-
+ The life of the point can be lengthened and the frequency of its replace-
ment can be reduced by turning it upside down so that it will wear
evenly.
* When replacing the point, replace the rubber pin and lock pin with new
ones. This will prevent the point from falling.
g. REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)

Replace the teeth before the wear reaches the adapter.
1. Remove pin (2) mounting the bucket, then remove tooth (1).
* When removing pin (2), use a bar that ,is slightly thinner than the pin,
then tap and remove from the opposite side.
2. Fit new tooth (1) in adapter (3), push in pin (2) partially by hand, then
knock in with a hammer.
-164-
!
-165-
h. LINE FILTER
If there is any abnormality in the pump or other hydraulic equipment,
remove the dirt from inside the line filter as follows.
* Before removing the line filter, release the pressure inside the hydraulic
circuit. For details, see PRECAUTIONS WHEN DISASSEMBLING MACHINE.
1. Remove air suction plug (1) corresponding to the line filter to be
removed.
* Some of the oil inside the piping will come out, so prepare a container to
catch it.
Remove plug (2), and drain the oil from inside the piping.
Remove case (3), then remove element (4) and clean it.
Remove the dirt stuck inside the case.
Install element (4), then screw in case (3) to install it.
Replace o-ring (5) and backup ring (6) as a set when reassembling.
Tightening torque
Case (3): 4.5 f 0.5 kgm
5. Replace o-ring (7), then tighten plug (2).
* Tightening torque
Plug (2): 2.5 + 0.5 kgm
6. Tighten air suction plug (1).
* After reassembling the line filter, bleed the air from the circuit. For
details, see BLEEDING AIR FROM CIRCUIT.
i. WATER SEPARATOR
When float (2) is at or above red line (l), drain the water according to
the following procedure:
1. Loosen drain plug (3) and drain the accumulated water until the float
reaches the bottom.
2. Tighten drain plug (3).
3. If the air is sucked into the fuel line when draining the water, be sure to
bleed the air in the same manner as for the fuel filter.
(See Fuel Filter Cartridge in EVERY 500 HOURS SERVICE section.)
-166-
h
-167-
. .
ADJUSTMENT
ADJUSTMENT OF BUCKET CLEARANCE
If there is excessive free play on the coupling section of the bucket and
arm, adjust the bucket clearance in the following manner.
* Set the work equipment in the posture as above.
1. Loosen 4 bolts (2), bolt (3) and plate (1).
2. Take out shims (4) equivalent in size to free play “a”.
* The thickness of shim (4) is 0.5 mm or 1 mm each.
* When free play “a” is less than 0.5 mm, do not compress the shims by
tightening bolt (2).
3. Tighten 4 bolts (2) and bolt (3).
Then, clearance “b” becomes larger and free play “a” is removed.
+ When adjusting, set the work equipment in the posture shown in the dia-
gram below.
(5): Bucket
(6): Bush
(7): Arm
- 168-
\ \
- 169-
TROUBLE SHOOTING GUIDE
This guide is not intended to cover every conditions, however many of the
more common possibilities are listed.
ELECTRICAL SYSTEM
Lamp does not glow brightly even when engine runs at high speed.
Lamp flickers while engine runs.
0 Check for loose terminals and open-circuit wiring.
0 Adjust belt tension.
Charge monitor does not go out even when engine runs at high speed.
0 Replace the alternator.
0 Inspect and repair wiring.
Unusual noise is emitted from the alternator.

a Replace the alternator.
Starting motor does not turn when starting switch is turned on.
0 Inspect and repair the wiring.
0 Charge the battery.
0 Replace the starting motor.
0 Replace the safety relay.
The pinion of the starting motor keeps going in and out.

0 Charge the battery.
0 Replace the safety relay.
Starting motor turns the engine sluggishly.

a Charge the battery.
0 Replace the starting motor.
The starting motor disengages before the engine starts up.

0 Check and repair the wiring.
l Charge the battery.
The engine pre-heating monitor does not flash.

a Check and repair wiring.
0 Replace the monitor.
The engine oil pressure monitor does not light up when engine is station-
ary (when the starting switch is in ON position.)
l Replace the monitor switch.
- 170-
Charge monitor does not light up when the engine is stationary. (When the
starting switch is in ON position.)
0 Inspect and repair the wiring.
Outside the electrical intake air heater is not warm when touched with
the hand.
0 Check and repair wiring.
0 Replace the electrical intake air heater.
0 Check and repair the heater switch.
ENGINE
The engine oil pressure monitor flashes when engine speed is raised after
completion of warm-up.
0 Add the oil to the specified level.
l Replace the oil element.
0 Check oil leakage from the pipe or the joint.
Steam is emitted from the top part of the radiator (the pressure valve).
The radiator cooling water level monitor flashes.
Supply the cooling water and check leakage.
Adjust fan belt tension.
Wash out inside of cooling system.
Clean or repair the radiator fin.
Replace the thermostat.
Tighten the radiator cap firmly or replace the gasket of it.
Replace the monitor.
The engine does not start when the starting motor is turned over.
0 Add fuel.
l Repair where air is leaking into fuel system.
0 Replace the injection pump or the nozzle.
0 Check the valve clearance.
0 Check engine compression pressure.
0 Refer to the section of electrical system.
Exhaust gas is white or blue.

l Adjust to specified oil quantity.
0 Replace with specified fuel.
-171-
Exhaust gas occasionaly turns black.
0 Clean or replace the air cleaner element.
0 .Replace the nozzle.
0 Check engine compression pressure.
0 Clean or replace the turbocharger.
Combustion noise occasionally changes to breathing sound.

0 Replace the nozzle.
Unusual combustion noise or mechanical noise.

0 Replace with specified fuel.
0 Check over-heating.
0 Replace the muffler.
0 Adjust valve clearance.
CHASSIS
Slow speed of travel, swing, boom, arm and bucket

l Add oil to specified level.
Unusual noise emitted from pump

0 Clean the hydraulic tank strainer.
Excessive oil temperature rise of hydraulic oil

l Clean the oil cooler.
l Add oil to specified level.
Track slip out of place

Excessive wear of the sprocket
l Adjust tension of track.
Bucket either rises slowly or not at all

0 Add oil to specified level.
- 172-
-173-
__
MECHATRONICS RELATED PARTS

1. PUMP CONTROLLER
When normal
No. Input mode and condition Display
0 Power source monitor (with starting switch ON) Lights up
U
H mode II
\-
0 Power mode S mode 3
I
L mode L
0 Engine speed signal monitor (when engine is running) Flashes
I
Heavy-duty operation mode \
General operation mode 7

i
0 Workingmode
-1
Finishing operation mode
3
II
Liftingoperationmode -1
* The combinations given in the table above are displayed according to the
input mode and machine condition.
t Engine speed signal monitor (3) flashes according to the engine speed.
(At 2000 rpm, it flashes approx. 20 times/l 0 set)
* When switching the input, the following display is given.
When switching input Display
When electric power is \-I

switched on (0.5 set) . \
Hi
Switching travel
speed
Lo
Auto-deceleration switch
Swing lock switch !a !=I
Work equipment \2 -\
Swing control lever .l .C
Service control lever
n I- a The display is given for 0.5 -

Travel lever .\- .a
\ \ \-\ 1.5 set after the imput is

Power max. button .u .I’ switched.
- 174-
-175-
When abnormal
Display condition of machine
Abnormality in
electrical system
Only power source Abnormality in

monitor lights up electrical system
Abnormality in
All lamps OFF
electrical system
t If any abnormality occurs, lower the work equipment to the ground,

check the display on the controller, then contact your Komatsu distributor
for repairs.
* If it is thought that there is any abnormality or cause not listed above,
please contact your Komatsu distributor for repairs.
* If there is more than one failure, the abnormality display shows each
abnormality in turn, so check all of the abnoramlity codes.
t When any abnormality occurs, always check the abnormality display of
the controller before turning the starting switch to the OFF position.
2. ENGINE THROlTLE CONTROLLER

When normal
(a): Red
(b): Green
(c): Red
LED display
L, L, L,
Red Green Red
OFF ON OFF -
- 176-
QU Q-o
77-J
1-o Qi
-177-
When abnormal
LED display
L3 b L,
Red Green Red
OFF OFF OFF
OFF OFF ON
ON OFF OFF
Abnormality in
OFF ON ON
electrical system.
ON OFF ON
ON ON OFF
ON ON ON
If any abnormality occurs, lower the work equipment to the ground,

check the display on the controller, then contact your Komatsu distributor
for repairs.
If it is thought that there is any abnormality or cause not listed above,
please contact your Komatsu distributor for repairs.
When any abnormality occurs, always check the abnormality display of
the controller before turning the starting switch to the OFF position.
- 178-
L:, L? L,
Go0232
- 179-
SERVICE METER
This meter indicates the integrated work hours. So, use it according to
the following instructions.
Record the readings at the start and the end of work, this is the work
record of the machine.
This record will indicate, when periodical maintenance is due.
It also indicates the integrated working hours when machine problems are
encountered.
How the meter progresses
The service meter progresses by 1 when the engine is operated for one
hour, regardless of the engine speed.
Consequently, if the engine is running, the service meter will advance
even if the machine does not move.
- 180-
- 181 -
MACHINE AND ENGINE SERIAL
NUMBERS
When calling for a service of mechanic or when making replacement-
parts order, be sure to give Komatsu distributor the machine and engine
serial numbers as well as the service meter reading before mentioned.
These numbers are founds on the plates shown in the figure.
A. Location of the machine serial number mark.

This is seen on the bottom right of the cab.
B. Location of the engine serial number mark.

This is seen on the upper side of the cylinder head cover.
- 182-
A
Go0693
-183-
FUEL, COOLANT AND LUBRICANTS
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE
RESERVOIR
Engine oil pan
Swing machinery cake

Final drive case (each)
Damper case
Fuel tank
I I
Cooling system water Add antifreeze 34
3% ASTM D975 No.1
-184-
NOTE:
(1)When fuel sulphur content is less than 0.5%, change oil in the oil pan
every periodic maintenance hours described in this manual.
Change oil according to the following table if fuel sulphur content is
above 0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0 % I l/2 of regular interval
Above 1 .O % I l/4 of regular interval
(2)When starting the engine in an atmospheric temperature of lower than

O”C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAEl5W-40,
even though an atmospheric temperature goes up to 10°C more or less in
the day time.
(3)Use API classification CD as engine oil and if API classification CC, reduce
the engine oil change interval to half.
(4)There is no problem if shingle grade oil is mixed with multigrade oil
(SAEIOW-30, 15W-40), but be sure to add single grade oil that matches
the temperature in the table on the left.
(5)We recommend Komatsu genuine oil which has been specifically formu-
lated and approved for use in engine and hydraulic work equipment
applications.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil
in piping.
Refill capacity: Amount of oil needed to refill system during normal inspec-
tion and maintenance.
- 185-
LOADING SHOVEL (with bottom dump bucket)
This section applies when a loading shovel is installed.
Only the portions which differ from the back hoe type are noted.
- 187-
.’
4 I
(-5-J
-189-
5. BOTTOM DUMP SWITCHES
The knobs on the operating levers contain buttons which control the front
bucket.
(a): Pressing the one on the left closes the bucket.
(b): Pressing the one on the right opens it.
6. HORN BUlTON
The right foot rest contains a foot switch which, when pressed, sounds
the horn.
7. ROOM LAMP SWITCH

When this switch is moved to ON position, room lamp will light.
(a): Press to switch on.
(b): Press to switch off.
(-26-)
- 190-
i
(-27-j
-191-
G:OPERATION OF THE WORKING EQUIPMENT
N. Neutral
1. Arm out
2. Arm out and swing right
3. Swing right
4. Arm in and swing right
5. Arm in
6. Arm in and swing left
7. Swing left
8. Arm out and swing left
9. Bottom dump close (with bottom dump bucket)
The work equipment is operated by left and right control levers, and the
bottom dump switches.
The LEFT work equipment control lever controls SWING, ARM and bottom
dump closing.
The RIGHT work equipment control lever controls BOOM, BUCKET and
bottom dump opening.
The levers and switches, and movement of the work equipment are as
shown in the diagram. If the levers and switches are released, they will re-
turn to the NEUTRAL position, and the work equipment will be held in
position.
0 If the work equipment control lever is returned to HOLD when the ma-
chine is stopped, even if the fuel control dial is set to FULL, the autode-
celeration mechanism will act to reduce the engine speed to a midrange
speed.
A speed
* 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
loading the machine on a trailer.
(-66-_)
- 192-
(-67-)
-193-
N. Neutral
1. Boom lower
2. Boom lower and bucket dump
3. Bucket dump
4. Boom raise and bucket dump
5. Boom raise
6. Boom raise and bucket curl
7. Bucket curl
8. Boom lower and bucket curl
9. Bottom dump open (with bottom dump bucket)
(-68-j
-194-
\
\ i
a
9
-07 N
i5
(-69-)
- 195-
J: PRECAUTIONS FOR OPERATION
1. Be careful not to compact the soil or damage earth mounds as a result
of the swinging force.
2. When swinging, do not dig the bucket teeth into the soil.
3. Do not move off and excavate with the bucket leaving dug into the
ground.
4. When working with the machine, do not move the cylinder to the end
of its stroke but leave a small safety margin..
5. Do not use the dropping force of the bucket as a pickaxe, breaker, or
pile driver.
6. The distribution of the machines weight shifts while swinging.
Do not let a load topple the machine.
7. Do not attempt to excavate by pulling the bucket in fully, then digging
teeth perpendicularly into the ground and operating the tilt.
8. A bottom dump bucket, as the name suggests, is designed only for
dumping; not for grabbing. Do not use it to pick up objects!
9. Leveling the earth with the rear bucket does not hurt the bucket, but
the resultant shocks may damage the work equipment.
(-72-)
- 196-
J3
54
I
J9
(- 72-l - )
-197-
10. When the bucket is full and the boom is raised to its maximum height,
there is danger that the load will spill out the back of the bucket.
11. Do not excavate when the upper structure is at an angle to the track
frame, as the work equipment may hit the undercarriage, damaging the
track links.
12. When performing side digging work, do not excavate when the boom is
lowered to its minimum height as the arm cylinder, boom cylinder hose
may hit the undercarriage, damaging the track links.
13. Be careful not to hit the wristlink on the FOPS, when the boom is raised
to its maximum height and the arm is pulled.
14. Note that the following phenomena are not faults:
a) When the arm is pulled back, it will sometimes stop when becomes
more or less vertical.
b) The arm may sometimes stop when the bucket teeth become more or
less horizontal.
c) At the beginning and end of a swinging, a noise may sometimes be
emitted from the brake valve.
d) When descending a steep slope at low speed, a noise may sometimes
be emitted from the travel motor.
A chine
If it is necessary
is traveling,
to operate the work equipment lever when the ma-
stop the machine before operating the work equip-
ment lever.
A the
For machine with autodeceleration
deceleration range, the engine
device, if the lever is operated
speed will rise suddenly.
inside
K: PRECAUTIONS WHEN TRAVELING

1. When traveling over obstacles such as boulders or tree stumps, the ma-
chine (in particular, the undercarriage) is subjected to a large shock, so
reduce the travel speed and travel over the obstacle at the center of the
tracks.
Special tracks
Wide triple shoes (700, 750, 800, 900 mm) are used as special shoes for
soft ground. Therefore, do not use them when traveling over rocky ground,
sandy gravel, rough ground with cobbles, and even on soft ground where
there are boulders or tree roots.
* When selecting the track, see “SELECTION OF TRACK SHOES”.
( - 72-2 - )
- 198-
lJl0 Jll
mm
513
(-73-j
-199-
TRANSPORTATION
DIVIDING THE MACHINE
To simplify transportation, the machine can be divided into the body, at-
tachments, and counterweight. Before transporting a machine, consult your
The following points when dividing a machine.
t When disassembling the attachments, take care not to let dust get into
the joints of the piping. After removing the attachments, plug or tape the
joints.
* After packing, check for water leakage and oil leakage. Refill if necessary.
t Fix each section securely to protect cylinders and other parts.
* Reinstall the pins and bolts which were removed for disassembly.
A The lifting hooks on the

ing the counterweight.
counterweight should only be used when rais-
Never use the lifting hooks on the counterweight to raise the machine
itself.
PARTS FOR TRANSPORT

The dimensions in the diagrams are given in millimeters.
(a): Weight: 24.2 ton (25.8 ton)
(b): Weight: 9.3 ton
(c): Weight: 8.5 ton
(d): Weight: 0.48 ton x 2
( ): PC4OOLC
(- 88,90 - )
- 200 -
-
:
i
3230 c
2195
c
(- 89,91 - )
- 201 -
c. LUBRICATING
Apply grease to the grease fittings shown by arrows.
1. Boom foot pin (2 points)
2. Boom cylinder rod end (2 points)
3. Boom cylinder foot pin (2 points)
4. Arm cylinder foot pin (1 point)
5. Arm cylinder rod end (1 point)
6. Bucket cylinder foot pin (1 point)
7. Boom-arm coupling pin (2 points)
8. Arm-link coupling pin (2 points)
9. Arm-bucket coupling pin (2 points)
10. Link coupling pin (4 points)
11. Bucket cylinder rod end pin (2 points)
12. Bucket link coupling pin (2 points)
13. Bottom dump cylinder bottom pin (2 points)
14. Bottom dump cylinder rod end pin (2 points)
15. Bucket hinge pin (2 points)
* If any abnormal noise is heard from any greasing point, add grease re-
gardless of the service interval.
t For the first 100 hours of operation of new machines, grease the boom
cylinder foot pin and boom foot pin every 10 hours.
(-124-)
- 202 -
7
14
15
(-125-j
- 203-
EXCAVATOR‘S WORK
A. SHOVEL WORK
This is suitable for digging a place which is higher than the machine’s
position. It is most efficient if the arm’s digging angle is from vertical to 60”
forward, and the arm cylinder is used effectively.
B. LOADING WORK
About half the time taken for digging and loading operations is used for
swinging.
The most efficient method of operation is to keep the swing angle as
small as possible but conforming to topography.
Loading is easier if the excavator is placed beside the dump truck for
loading. This way means more earth can be loaded more effectively than by
a loader working behind the truck.
(page 38 on SAFETY AND OPERATION at end of manual)
- 204 -
B
(page 39 on SAFETY AND OPERATION at end of manual).
- 205 -
SAFETY AND OPERATION
CONTENTS
SAFETY HINTS ... A ...................................................................................... 2

RADIO .................................................................................................................... 18
LOCKING CAP ....................................................................................................... 22
OPERATING THE CAR COOLER ........................................................................... 24
OPERATING THE AIR CONDITIONER ................................................................... 28
EXCAVATOR’S WORK .......................................................................................... 38
HANDLING OF BAITERY ...................................................................................... 40
PRECAUTIONS FOR MAINTENANCE ................................................................... 46
STORAGE .............................................................................................................. 52
COOLANT AND LUBRICANTS .............................................................................. 54
-l-
SAFETY HINTS . l l A
OPERATION
GENERAL
1. Wear well-fitting helmet, safety shoes and working clothes. If the nature
of the work requires safety, wear protective goggles or mask, thick
gloves, ear plugs or other protection.
2. Accidents or injuries are liable to occur when the operator is careless or
slack. It is most important to bear safe operation in mind at all times.
3. Take care of your health. Do not operate when tired, or after drinking.
4. Learn the prohibitions, cautions and rules about work procedures in the
work site.
When there is a leader, fix standard signals and always follow these sig-
nals when operating.
5. If there should be an accident or fire or ,any other such unexpected mis-
hap, deal with it quickly, using the nearest apparatus.
Learn beforehand the locations of the first aid boxes and fire extinguish-
ers and how to use them. It is also important to know the emergency
contact system.
6. Learn about the safety devices on your own machine and about how to
use them. Confirm that they are correctly attached in the prescribed
position. Such safety devices include:
* Protective-Devices
t Seat Belts
7. Exhaust gas is dangerous. When running the engine for long periods in
a poorly ventilated area, there is a danger of gas poisoning, so open
the windows or doors to ensure a good supply of fresh air.
a. Read the Operation and Maintenance Manual carefully. Learn how to use
the control devices, gauges and warning devices. Be sure you under-
stand the meaning of the caution plates. Remember the check points
and checking method for engine oil, fuel, cooling water and hydraulic oil
levels.
9. When operating inside a building always be sure of the clearance of the
ceiling, entrances, aisles, etc. and the load limit of the floor.
10. Never allow other person than the’operator to ride on the machine dur-
ing operation.
-2-
7
-3-
BEFORE STARTING OPERATION
1. Examine the lay of the land and the kind of soil at the work site to
determine the dangerous points and the best method of operation.
Proceed with the work only after making safety arrangements about the
dangerous points.
2. Inspect leakages from the fuel, lubricating and hydraulic systems. Check
that the shoe bolts are not loose, and that no other parts are damaged
or missing. Machines having such failures should not be operated.
When getting on or off the machine, use the handrail provided. Do not
jump up or down from the machine.
Do not leave parts or tools lying around in the vicinity of or on the floor
of the operator’s cab. Keep everything in its proper place.
Wipe off thoroughly any grease, oil or mud on the handrail, floor or
control levers. Failure to do this may cause you to slip.
Check the level of the fuel, lubricants and cooling water. Extinguish ciga-
rettes before checking or replenishing. Check that the radiator cap and
each oil filler caps or plugs are firmly tightened.
7. Adjust the operator’s seat until it is in the most comfortable position for
operating. Always sit in the seat while operating. Do not operate the
machine from any other position.
8. To ensure the safety of workers near the machine, always sound the
horn to warn them before starting the engine and moving the machine.
Be particularly careful to check that the rear is clear before backing the
machine.
9. Inspect the inside of the engine room and remove any dead leaves or
papers. Dead leaves or papers are highly inflammable and can cause
fires.
IO. Before starting the engine, confirm that all control levers are in NEU-
TRAL.
-4-
4
Go0242
IO
-5-
AFTER STARTING THE ENGINE
1. Confirm that all gauges and warning devices are functioning correctly,
and that the gauge readings are within the prescribed range.
2. Check the play and travel of each lever.
3. Operate the work equipment to confirm that they are functioning nor-
mally.
4. Before operating the traveling and steering levers, check whether the
track frame is forward or backwards. If the track frame is facing back-
wards, operate the traveling and steering levers in the reverse manner to
that when the track frame is facing forward.
5. Move the machine slowly and listen carefully to the engine or gears to
confirm that they are not making any unusual noises.
6. Choosing a safe place, turn the machine to the left and right to confirm
that the traveling and steering levers are functioning normally.
7. If these tests reveal anything wrong, however slight is may be, contact
the man in charge of the machine and operate the machine only after
obtaining his permission.
-6-
6
c-
-
-7-
DURING OPERATION
1. Maintain the bucket at a height of 40 to 50 cm above the ground so
that it can be quickly lowered to the ground and the machine stopped
in an emergency.
2. As far as possible, operate the machine so that it does not tilt. (Do not
tilt it by more than 35” in either the forward, rear, left or right direc-
tions, even under static conditions.)
3. Always operate slowly in crowded places. On haul roads or in narrow
places, give way to loaded vehicles.
4. Do not allow unauthorized persons into the work area.
5. Before reversing or turning, ensure that there is nobody in the vicinity.
Also, be careful of obstacles.
6. When operating on slopes, as far as possible, avoid turning the machine
on a slope. It may cause the machine to roll over or slip sideways.
7. When operating the machine along a road, retract the work equipment
to improve machine stability. As far as possible proceed along a flat
road.
8. The machine should always be operated at a speed where it can be
correctly controlled. Never do the following:
1) Speeding
2) Sudden starting, sudden braking, sudden turning.
3) Snaking
4) Coasting
9. When operating on uneven ground or in places where there are obsta-
cles, remember the following points:
Operate at as low a speed as possible and avoid sudden changes in
direction.
Wherever possible, avoid traveling over large rocks, fallen trees, tree
stumps and other such obstacles. Either use the work equipment to
remove them, or travel round them.
When it is impossible to avoid traveling over them, reduce speed and
mount over the obstacle. Just before the front of the machine tips
down, reduce speed even more to make the shock of hitting ground
as small as possible.
Never mount over an obstacle at an angle; never disengage one tra-
veling and steering lever to travel over an obstacle.
10. The machine condition can be judged from many factors. Changes in
the gauges, sound, vibration, exhaust gas color or response of the con-
trol levers can indicate the occurrence of some disorder. If any disorder
occurs, park the machine immediately in a safe place and take appropri-
ate action. Be especially careful in the case of a fuel leak as there is
danger of fire.
11. The work area should be made as flat as possible. If the work area is
flat, operation is made much easier and this reduces operator fatigue.
-8-
.:
WO25( ,
7
GO0252
I cm25a
GO0255 GO0256
-9-
12. Always concentrate. It is extremely dangerous to allow yourself to be
distracted or to think of other things when operating a machine. In
. . ..
dangerous places, or where there is restricted vrsrbrlrty, it is important to
get down from the machine and confirm whether it is safe before con-
tinuing work.
13. Be careful of those around you, and always confirm that there is no
person or obstacle in the way before moving or turning the machine.
14. When using the work equipment, be sure to keep your eyes on it all the
time. Failure to do this may result in an accident.
15. When passing through a narrow space, be careful of the side and over-
head clearances. Take special care not to touch any obstacles on either
side or overhead. If necessary, have someone outside the machine call
out instructions.
16. Be careful not to operate the machine into a bog. In the event that the
machine goes into a bog, extract it in the following manner;
1) If only one track of the machine is in the bog, push the bucket down
against the ground on the side of the machine which is stuck so as
to float the track. Then place logs or timber underneath the track and
free the machine.
t When raising the undercarriage by means of the boom or arm, push
the bottom of the bucket against the ground (on no account use the
teeth) until the angle between the boom and the arm is SO”to 110”.
2) If both tracks of the machine are in the bog and slip, preventing the
machine from getting in, place logs or timber under the tracks in the
manner described in l), then thrust the bucket into the soil in front of
the machine and drag it out by bending the arm in the same manner
as when excavating and putting the traveling and steering lever into
the forward position.
17. After earthquakes, confirm that the ground is still firm; after blasting,
confirm that there are no unexploded charges remaining.
18. When working on river embankments or other places made of piled soil,
there is the danger that the weight of vibration of the machine may
cause the machine to sink into the piled soil, so be extremely careful
when operating in such places.
19. When continuing operations after rain, remember that conditions will
have changed from those before the rain started, so proceed with cau-
tion.
Be particularly careful when approaching the shoulder of the road of
cliffs, as they may have been loosened by the rain.
20. Check the load limits of bridges before crossing.
21. When working in water or marshy ground, be careful of the following:
* When working on soft ground, place thick boards on the ground to
prevent the machine sinking. Place the boards horizontally and
arrange them as neatly as possible.
-lO-
GW261
20 21
-ll-
22. When operating in water or when crossing shallows, first check the bed
soil condition and the depth and flow speed of water, then proceed, tak-
ing care not to go beyond the permitted depth.
t First check the water depth, the firmness of the ground and the
strength of the current. Do not enter if the water exceeds the permis-
sible depth (up to the bottom of the swing circle).
23. When operating in fog, mist or smoke, where visibility is bad, be espe-
cially careful to confirm first whether operation is safe.
When visibility drops below safety level, stop work and wait for the
. . ._
vrsrbrlrty to improve.
24. When operating at night, remember the following points:
t Be sure to arrange an adequate lighting system.
* At night it is very easy to make mistakes in assuming the distance
and height of objects and land.
25. Be very careful not to touch electric wires, always bearing in mind that
there is a possibility of receiving an electric shock.
t Wear rubber or leather soled shoes.
t Position a full-time watcher at the site to ensure that operator is not
exposed to the risk of electric shock.
* Depending upon the supply voltage it is conceivable that an electric
shock may be received by merely coming into the vicinity of an electric
feeder wire. Accordingly, observe the minimum distances given in the
table below, taking into account the inertia of the boom when in motion.
* Become familiar with the necessary measures to be taken in the event

that a operator receives an electric shock.
26. Do not perform excavation at the bottom of a precipice as it is danger-
ous practice.
27. If it is unavoidably necessary to operate the work equipment lever when
traveling the machine in the vicinity of a precipice, road shoulders, on
sloping ground or through a confined space, stop the machine momen-
tarily before operating the work equipment lever in order to minimize
danger.
28. When working on loose, crumbly soil, do not dig deeply and back the
machine off smartly. If the ground crumbles, preventing the machine
from getting away in time, do not panic and raise the work equipment.
It is often better in the interests of stability to leave it down.
- 12-
22 23
C,
: _--..
24
P
f.-_-
r
f
-13-
29. Do not undercut the machine, unless absolutely necessary.
If-necessary, always take care to prevent the machine falling.
30. When operating at the edge of a cliff or on the shoulder of a road,
remember the following points:
f When operating in a place where there is danger of the machine falling
over the side, be doubly careful. Do not approach the edge of the cliff
or road shoulder by mistake.
31. If you suspect that there are buried facilities (water or gas pipes, etc.) at
the work site, check with the companies responsible for looking after
such facilities and also try a different method of excavation. Then, after
confirming the existence and location of such facilities, carefully carry
out excavation work.
32. Take care not to swing the bucket against the sides of trenches or
dump trucks. Load the truck from the rear.
-14-
31
32
- 15-
PARKING
1. When parking the machine, park it in a safe place outside the working
area, or in the specified place. The following factors should be considered
when choosing a parking place: it should be on flat, firm ground where
there is no danger of rockfalls, landslides or floods. If the machine has to
be parked on a slope, it should be parked facing directly up or down the
slope, and chocks should be placed under the tracks. When the machine
is facing downhill, lower the bucket so that it cuts slightly into the ground
to further increase the safety.
If it is absolutely necessary to park the machine on a slope, park it facing
downhill and put chocks against the tracks. If the ground is soft enough,
dig the bucket into the ground for added safety.
When parking the machine, return the work equipment levers to neutral,
apply the brake lock, lower the bucket to the ground, and put all safety
levers in the lock position. Switch off the engine and remove the key.
Before leaving the machine, carry out the following:
* Apply the swing lock.
t Lower the bucket to the ground.
* Put the work equipment lever in neutral and lock it.
t Stop the engine and remove the key to prevent other people using the
machine.
t Lock the cab.
- 16-
.’
Go0275
-17-
RADIO
A: TUNING KNOB
Turn this knob in to the desired station.
Turn right in to the station. If the tuning is off center, the sound quality
will be unnatural and sensitivity will be reduced.
B: TONE CONTROL
Use this konb to adjust the tone as desired.
When it is turned to the right the high tones will be emphasized, and
when it turned to the left the high tones will be cut, resulting in a mellow
tone.
c: POWER SWITCH/VOLUME CONTROL

Press the knob to turn on (or off) the radio. When it is turned to the
right, the sound level will increase, and vice-versa.
D: STATION SELECTOR BUTTONS (5 buttons)

By pressing these buttons it is possible to tune in to preset stations.
E: POINTER
- 18-
A
I- E
ml276
-19-
How to set station selector buttons
Set the station selector buttons to the desired stations as shown in the
following figure.
1. Pull back the button corresponding to the station to be preselected.

2. Turn the station selector knob until the pointer is in front of the desired
station. (Carefully tune in so that noise disappears and the broadcast is
heard plainly.)
3. Carefully push back the button with the fingertip until it clicks into place.
* When setting the turning selector to a strong station, shorten the antenna
to reduce the input as far as possible before carrying out alignment.
Precautions when using radio

To prevent possible breakdown, keep water well away from the speaker
case and interior of the radio. In particular, close the window during rain
or when washing the machine.
Do not wipe the dial plate or knobs with benzine or paint thinners, etc.
Always use a dry, soft cloth (if the radio is particularly dirty, soak the
cloth in alcohol).
Do not disassemble the radio.
Trouble shooting guide
No sound
0 Turn the SWIVOL knob to the right and press it two or three times.
Sound quality is poor.

Reception is noisy.
0 Return using the station selector knob. If the problem disappears, reset
the tuning button.
l Try lengthening the antenna to its fullest extent.
- 20 -
;
Go0277
-2l-
LOCKING CAP
Locks are installed to the fuel tank filler cap, hydraulic tank filler cap,
operator’s cab, left side door (rear), and engine hood.
* Use the starting key to open and close the cap.
A. METHOD OF OPENING AND CLOSING FUEL TANK FILLER CAP

0 To open the cap
1. Insert the key into the cap.
(a): OPEN
(b): LOCK
2. Turn the key clockwise, align the match mark on the cap with the rotor
groove, then remove the cap.
l To lock the cap

1. Turn the cap into place.
2. Turn the key counterclockwise and take the key out.
* Insert the key as far as it will go. If the key is turned before it is inserted
all the way, it may break.
(c): Shoulder
B. METHOD OF OPENING AND CLOSING HYDRAULIC TANK FILLER CAP

1. Insert hexagon wrench (1) (4 mm) into the hole at the side of the side
block.
2. With the wrench turned to the outside, turn the cap counterclockwise
approx. 30”. Stop here to release the pressure, then turn fully and
remove the cap.
3. When closing the cap, align the cap with protrusion (2) on the case, then
screw in the cap clockwise until it locks.
A When removing the cap,

lock before opening it.
always use a hexagon wrench to release the
- 22 -
A
- 23 -
OPERATING THE CAR COOLER
CONTROL PANEL
0 Air flow control knob

Turn from LO to MED or HI to increase the air flow.
0 Temperature control knob
Turn the knob clockwise to give a lower room temperature.
For efficient use

If the inside of the operator’s cab is hot after the machine has been
parked for a long time in the sun, open the windows and doors fully to
cool the operator’s cab before switching on the cooler.
When using the cooler, make sure that the windows and doors are prop-
erly shut.
If there is dirt or mud on the condenser, the cooler will not cool properly.
When washing or checking the machine, always remove all dirt and mud
from the condenser, to ensure a good flow of air.
For reasons of health, the temperature inside the cab should not be
adjusted too low. As a general rule, the temperature should be kept at a
maximum of 5 to 6°C below the outside temperature, enough to feel cool
when entering the cab.
- 24 -
- 25 -
CHECKING AND MAINTAINING CAR COOLER
a. Checking coolant level

if the cooling effect is poor, check the side glass (liquid eye) of the
receiver drier. If there are many bubbles, the coolant level is too low. Check
whether there is any coolant, and have the cooler serviced.
b. Clogging of condenser
If there is any dirt or mud stuck to the condenser, there will be a big
reduction in the cooling efficiency of the condenser. That will mean a reduc-
tion in the cooling capacity, so clean the dirt and mud off and correct any
bent fins with a screw-driver.
c. Checking and adjusting V-belt tension

The slack should be 14 to 16 mm when pushed with a finger force of
about 6 kg midway between the compressor pulley (1) and the crankshaft
pulley (2).
1. Loosen bolts (3) and (4), and move compressor (5) to adjust.
2. After adjusting, tighten 2 bolts (3) and bolt (4) securely.
* When adjusting the V-belt, do not attempt to push compressor (5) directly
with a bar or the like, but use a wood pad to prevent damage to the
core.
- 26 -
C
14-16mm
- 27 -
OPERATING THE AIR CONDITIONER
CONTROL PANEL
0 Outlet change-over knob

l Switches over air outlets
Konb
Air outlet Purpose
position
FOOT
Heating
Floor
%A Dehumidity
FACE
Rear Cooling
ZQ
0 Heater temperature knob

Controls heating temperature
The nearer to WARM MAX. the knob goes, the higher heater outlet air
temperature will be.
At OFF position, water valve will be closed and heating function will stop.
Blower switch
Used for both controlling the air flow in cooling and heating and as the
main switch.
Changeable at three steps; low, medium and high.
Placing knob in OFF cuts off the power supply and stops the air condi-
tioner.
@ Cooler temperature knob

0 The temperature is controlled with this knob for cooling.
It is also the cooler switch.
0 Move the knob towards LOW to decrease the output air temperature.
0 When the knob is moved to OFF, the cooler switch is turned off and the
cooling stops.
- 28 -
- 29 -
OPERATION
A. Cooling
Set the knobs to the following positions and a cool breeze will be flowed
in from the rear vents.
0 Outlet change-over knob (1): FACE
0 Heater temperature knob (2): OFF
0 Blower switch (3): See table below.
0 Cooler temperature knob (4): See table below.
Cooler temp.
Blower switch (3)
knob (4)
Puroose
Quick cooling HIGH HIGH
Normal cooling MEDIUM-LOW MEDIUM
Gradual cooling LOW LOW
B: Heating
Set the knobs to the following positions, then warm breeze will be flowed
in to the feet.
0 Outlet change-over knob (1): FOOT
0 Heater temperature knob (2): See table below.
l Blower switch (3): See table below.
0 Cooler temperature knob (4): OFF
Control knob
Heater temp.
Blower switch (3)
knob (2)
Purpose
Quick heating HIGH HIGH
Normal heating MEDIUM MEDIUM or LOW
Mild heating LOW LOW
- 30 -
- 31 -
C. Dehumidity and heating
Set the knobs to the following positions and a dry, fresh, warm breeze
will be flowed from the vents at operator’s feet.
0 Outlet change-over knob (1): FOOT
0 Heater temperature knob (2): See table below.
0 Blower switch (3): See table below.
0 Cooler temperature knob (4): HIGH
Control knob
Heater temp.
Blower switch (3)
knob (2)
Purpose
L
j.a Winter HIGH HIGH
$ 2
._
EZ Spring and MEDIUM MEDIUM
2” Autumn or LOW or LOW
UFPP
If very damp air is used for heating, only hot, humid air will be sent to
the cab, producing an unpleasant atmosphere. This air conditioner first
cools the air to dehumidify it, and then reheats it to produce the opti-
mum heating conditions. In addition, there is no problem with the win-
dows misting up. This setting is particularly useful in spring, autumn or
on rainy days when the air is very damp.
When the outside temperature is from 2’C to 6.!X, a low pressure cut
switch functions to automatically and switch the compressor off.
In this situation it is impossible to use the combination of dehumidifying
and heating.
- 32 -
C
- 33 -
Precautions for using air coditioner
When cooling, change the air occasionally.
Smoking in the air-conditioned cab will cause your eyes to get sore.
While smoking, open the window to let the smoke out of the cab.
While using the air conditioner, open the window once every hour.
When using the cooler, make sure the hot water circuit is completely
stopped.
If hot water is circulating in the heater, it is like having a hot heater, it is
like having a hot water bottle in the cab. Always make sure the heater
temperature knob is at the OFF position.
When not using the heater for a long period, fully close the hot water
outlet and inlet valves under the engine water manifold and radiator.
Be careful not to overcool the cab.
The cab should feel cool when entering there from outside (5°C or SC
lower than the outside temperature). It is unhealthy to have the tempera-
ture in the cab too low. Always give careful consideration to temperature
regulation.
INSPECTION AND MAINTENANCE

A. Clean air filter
If the air filter inlets is clogged, the heating or cooling capacity will drop.
Clean the air filter with compressed air once a week.
B. Check tension of compressor belt.

If the belt is loose, it will slip and the air conditioner will not be able to
cool properly.
Periodically press the mid-point of the belt with the finger and check that
the deflection is 15 to 17 mm.
When the belt is new, it is particularly liable to stretch, so always adjust
it after 2 to 3 days.
(a): Compressor pulley
(b): Drive pulley
C. Check volume of refrigerant (gas)

If there is a lack of refrigerant, the cooling performance will be poor.
When operating the cooler at high speed, there should be no bubbles in
the sight glass (inspection window) mounted on the condenser unit receiver.
If there are any bubbles, there is a lack of gas, so have to add refriger-
ant at a shop.
(a): Sight glass
(b): No refrigerant
(c): Lack of refrigerant
id): Correct amount of refrigerant
-34-
B
15-17 mm
GO3741
cmm /
- 35 -
A The refrigerant
harmless when
used in the cooler is colorless and odorless, and is
released into the atmosphere. However if it gets in the
eyes or on the hands, it will be cause of burn or loss of sight, so never
loosen any part of the refrigerant circuit.
D: Check during off-season

When the air conditioner is not being used, run the compressor at low
speed for a few minutes every week to avoid loss of oil. (Run the engine at
low speed with the cooler temperature regulator knob at LOW COOL.)
* In cold weather, do not run the compressor suddenly at high speed. This
may cause failure in the compressor. When the temperature is below 2 to
6.X, the low pressure cut-off switch functions to stop the compressor
from running even when the air conditioner switch is pressed.
- 36 -
.’
- 37 -
.
EXCAVATOR’S WORK
In addition to the following, it is possible to further increase the range of
applications by using various attachments.
A. BACK HOE WORK

A back hoe is suitable for excavation at a position lower than the ma-
chine. It is possible to effectively move the arm through 30” in the direction
towards the machine and 45’ in the direction away from the machine, mak-
ing for efficient work.
B. 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.
C. LOADING WORK
About half of the time spent during excavating and loading work is taken
up swinging. Maximum work efficiency can be attained by carrying out work
in such a way that the swinging angle is kept as small as possible in ac-
cordance with the terrain.
When loading, it is better to fit the machine in the longitudinal direction
of the dump truck and to load from the front of the dump truck body. This
both faciliates loading and also enables a greater amount of material to be
loaded as compared with loading from the side of the truck.
D. DITCH DIGGING WORK

Ditch digging 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.
- 38 -
4 B
f I
FM421
‘i1
Fc44z2
- 39 -
HANDLING OF BATTERY
A. PRECAUTIONS FOR CHARGING BATTERY
1. Before charging, disconnect the cable from the negative (-) terminal of
the battery. Otherwise, an unusually high voltage will damage the alterna-
tor.
2. While charging the battery, remove all battery plugs for satisfactory venti-
lation.
To avoid gas explosions, do not bring fire or sparks near the battery.
3. If the electrolyte temperature exceeds 45X, stop charging for a while.
4. Turn off the charger as soon as the battery is charged.
Overcharging the battery may cause followings:
1) Overheating the battery
2) Decreasing the quantity of electrolyte
3) Damaging the electrode plate
If the electrolyte gets on your skin or clothes, immediately wash with
plenty of clean water.
Do not mix up cables (positive (-I) to negative (-) or negative (-) to
positive (+)), as it will damage the alternator.
When inspecting or servicing a battery, be sure to stop the engine and
turn the starting switch key to “OFF” position.
When performing any service to battery besides checking the electrolyte
level or measuring the specific gravity, disconnect cables from the bat-
tery.
B. REMOVAL AND INSTALLATION OF BAlTERY

When removing the battery, first disconnect the cable from the ground
(normally, from the negative (-_) terminal). If a tool touches a cable con-
necting the positive terminal and the chassis, there is danger of sparks
being emitted.
When installing the battery, the ground cable should be connected to the
ground terminal as the last step.
- 40 -
C. STARTING ENGINE WITH A BOOSTER CABLE
When starting the engine with a booster cable, do as follows:
1. Before connectinn the booster cable
1) Size of booste;cable and clip should be suitable for the battery size.
2) Check cables and clips for breaks, corroded surfaces, etc.
3) Make sure cables and clips are firmly secured.
4) Keep the starting switch in the “OFF” position.
5) The battery of the running engine must be the same capacity as that
of the engine to be started.
2. Connect the booster cables in the following manner.

1) Connect one clip of booster cable (A) to the positive (+) terminal of
the engine to be started.
2) Connect the other clip to the positive (+) terminal of the engine which
is running.
3) Connect one clip of booster cable (B) to the negative (--) terminal of
the engine which is running.
4) Connect the other clip to the engine block to be started.
* Make sure the clips are firmly connected to battery terminals. Then, start
the engine.
(C): Battery for running engine
(D): Battery for engine to be started
(E): Engine block to be started
A When connecting
(-) terminals.
the cables, never contact the positive (+) and negative
A Make sure that the booster cable connections are correct. Connect
booster cable to the engine block as far as possible from the battery.
the
3. Starting engine
1) Turn the starting switch to START position and start up the engine.
2) If the engine doesn’t start at first, try again after 2 minutes or so.
- 42 -
c2
-0 + 3
- 43 -
D. After the engine has started, the booster cables should be disconnected
in the reverse order in which they were connected.
1. Disconnecting the booster cables
1) Disconnect the clip of booster cable (B) from the engine block which
was started.
2) Disconnect the other clip from the negative (-) terminal of the running
engine.
3) Disconnect the clip of booster cable (A) from the positive (-I-) terminal
of the running engine.
4) Disconnect the other clip from the positive (+) terminal of the engine
which was started.
(C): Battery for running engine
(D): Battery for engine which was started
(E): Engine block which was started
-44-
D
- 45 -
PRECAUTIONS FOR MAINTENANCE
1. Wear well-fitting helmet, safety shoes and working clothes. When drill-
ing, grinding or hammering, always wear protective goggles.
2. Fuel or oil are dangerous substances.
Never handle fuel, oil, grease or oily clothes in places where there is
any fire or flame.
As preparation in case of fire, always know the location and directions
for use of fire extinguishers and other fire-fighting equipment.
3. Do not handle electrical equipment while wearing wet gloves, or in wet
places, as this can cause electric shock.
4. During maintenance do not allow any unauthorized person to stand near
the machine.
5. Exhaust gas is dangerous. When working inside, be particularly careful
to have good ventilation.
6. Unless you have special instructions to the contrary, maintenance should
always be carried out with the engine stopped. Apply the swing lock
and also all of the safety levers. If maintenance is carried out with the
engine running, there must be two men present: one sitting in the oper-
ator’s seat and the other one performing the maintenance. In such a
case, never touch any moving part.
7. When working underneath the machine, place a sign to that effect on
the operator’s seat and, if necessary, put a similar signs in the vicinity
as well.
8. Do not go underneath the machine after raising it up using the boom
and the arm.
9. When working with others, choose a group leader and work according
to his instructions. Do not perform any maintenance beyond the agreed
work.
10. When maintenance has to be carried out with the work equipment
raised, they must be securely supported by blocks.
11. Always remember that the hydraulic oil circuit is under pressure. When
feeding or draining the oil or carrying out inspection and maintenance,
release the pressure first.
Method of relieving oressure
Lower the w&k equipment to the ground and stop the engine after id-
ling it for two or three minutes. Then operate the various operation le-
vers. (work equipment, traveling and steering lever through their full
stroke in each direction)
When removing air instruments or pipings, open the drain valve under
the air reservoir to relieve air pressure.
Gradually unscrew the cap of the hydraulic tank and leave it for a few
minutes.
- 46 -
1 2
Go0296
5 6
7 3
11
12. Flames should never be used instead of lamps. Never use a naked
flame to check leaks or the level of oil, fuel, antifreeze or electrolyte.
13. Immediately remove any oil or grease on the floor of the operator’s
compartment, or on the handrail. It is very dangerous if someone slips
while on the machine.
14. Be particularly careful when removing the radiator cap. if this is done
immediately after using the machine, there is a danger that boiling
water may spurt out.
15. Do not check the fan belt tension while the engine is running. Be sure
to turn off the engine before inspecting other rotating parts and the
vicinity thereof.
16. Do not allow anybody other than the necessary workers to go near the
machine while it is being inspected or maintained. Also, be careful of
people in the vicinity. It is necessary to exercise particular care when
performing grinding or welding, or when swinging a large hammer.
17. Use the tool which is suitable for the maintenance work.
18. Remove the minus terminal from the battery in maintaining the electrical
system.
19. When the tracks are removed, never put your fingers between the
shoes.
20. When carrying out other difficult maintenance works, carrying them out
carelessly can cause unexpected accidents. If you consider the mainten-
ance is too difficult, always request Komatsu distributor to carry out it.
-48-
1 1
18
- 49 -
0 When installing car radio and a walkie-talkie or citizen band, contact your
0 Do not direct the steam jet directly at any mechatronic parts or connec-
tors.
0 Do not get any water on the controllers or monitors inside the operator’s
cab.
0 Do not direct a high-pressure jet directly at the radiator.
0 After disconnecting the connector, cover it with a vinyl bag to prevent oil
or dust from sticking to its contact section.
0 When welding, be careful of the following:
1) Turn OFF the power (starting switch).
2) Do not continuously apply more than 200 V.
3) Install the ground cable at least 1 m from the range to be welded.
4) Do not insert any seal or bearing between the weld and ground.
5) When repairing the controller mount, remove the controller connectors
and carry out the welding.
Precautions when power source for options

When installing electrical components such as a car cooler, connect to
the special power source connector.
The power source for options must never be connected to the fuse, stat-t-
ing switch, or battery relay.
- 51 -
STORAGE
BEFORE STORAGE
To place the machine in storage for an extended period of time, the fol-
lowing measures must be taken to insure that it can be returned to oper-
ation with minimum of service.
After every part is washed and dried, the machine should be housed in a
dry building. Never leave it outdoors.
In case it is unavoidable to leave it outdoors, lay wood plates on the
ground, and park the machine on the wood plates and cover it with can-
vas, etc.
Completely fill the fuel tank, lubricate and change the oil before storage.
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)
Apply a thin coat of grease to metal surfaces (hydraulic piston rods and
front idler adjusting rods).
As for the batteries, remove the terminals and cover them, or remove
them from the machine and store separately.
When the ambient temperature is anticipated to drop below OX, always
add antifreeze in the cooling water.
Lock all the control levers securely with the lock lever.
DURING STORAGE
l 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.
0 Before operating the working equipment, wipe off the grease on the hy-
draulic piston rod.
A while
If it is unavoidably
the machine
necessary to carry out the rust-preventive operation
is indoors, open the doors and windows to improve
vetilation and prevent gas poisoning.
AFTER STORAGE
Carry out the following procedure when taking the machine out of long-
term storage.
0 Wipe off the grease on the hydraulic piston rod.
l Completely fill fuel tank, lubricate and add oil.
* If the machine is stored without carrying out the monthly rust prevention
operation, request your Komatsu distributor for service.
- 52 -
- 53 -
COOLANT AND LUBRICANTS
SAEl OW, 30,40

[Lithium-Base]
1 OW30,l SW40
(The 15W40 oil
marked * is CE.)
*Arcofleet S3 plus
All season coolant
- 54 -
I I I Enaine Oil I I Anti-freeze
[Co or CE]
Grease Coolant
SAElOW, 30,40
No. Supplier [Lithium-Base] [Ethylene Glycol
1 0w30.15w40
NLGI No. 2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
1 16 1 SHELL 1Rimula X Alvania EP grease

I
Sunoco ultra prestige 2EP Sunoco antifreeze and summer
17 SUN
Sun prestige 742 coolant
,S TEXACO Lilrsa super plus Multifak EP2 Code 2055 startex antifreeze
Ursa premium Starplex 2 coolant
Rubia S
19 TOTAL Multis EP2 Antigellantifreeze
*Rubia X
20 UNION ‘Guardol Unoba EP
Antifreeze
- 55 -
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-6112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 9704186
FOR INTERNAL USE ONLY - No. PMR
B NAME OF COMPANY: LOCATION:
: PHONE NO:
; DEPARTMENT: DATE:
i NAME:
AANUAL NAME:
AANUAL NO:
AACHINE MODEL:
i/N IF APPLICABLE:
‘AGE NO:
‘ROBLEM:
ittach photo or sketch.

f more space is needed, use another sheet.
FOR INTERNAL USE ONLY

:ORRECTIVE ACTION:
PFMRI 081696

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Operation & Maintenance SEAM02080502

LOADING SHOVEL (with bottom dump bucket) . . . . . . . . . . . . . . . .._...................... 187

MACHINE MODEL PC400 PC400LC

PERFORMANCE Bucket capacity [SAEI 1.8 1.8

(m3) [CECE] 1.6 1.6

Travel speed (km/h) Ta 5.5 5.5

Swing speed (rpm) 9.3 9.3

OPERATING WEIGHT (kg) 40700 42300

ENGINE Model Komatsu S6D125-1 W Diesel Engine

Flywheel horsepower (HP) 276.1 276.1

NOTE: Specifications are subject to change without notice.

@CHECKMONITOR GROUP (Check items before starting)

@CAUTION MONITOR GROUP (Caution items)

@CAUTION MONITOR GROUP (Emergency caution items)

Functionalcheck of the machine monitor system

1. RADIATOR COOLANT LEVEL MONITOR

2. ENGINE OIL LEVEL MONITOR

3. HYDRAULIC OIL LEVEL MONITOR

B: CAUTION MONITOR GROUP (Caution items)

C: CAUTION MONITOR GROUP (Emergency caution items)

1. ENGINE COOLING WATER TEMPERATURE MONITOR

2. RADIATOR COOLANT LEVEL MONITOR

3. ENGINE OIL PRESSURE MONITOR

1. ENGINE COOLING WATER TEMPERATURE GAUGE

3. ENGINE PRE-HEATING MONITOR LAMP

1. WORKING MODE SELECTOR SWITCH (BASIC MODE)

2. POWER MODE SWITCH (SELECTED MODE)

3. AUTO-DECELERATION SWITCH (SELECTED MODE)

WORKING MODE f-2

5. ALARM BUZZER STOP SWITCH

2. FUEL CONTROL DIAL (WITH AUTO-DECELERATION MECHANISM)

yi: OFF position (canceled)

A When the machine is traveling

7. ROOM LAMP SWITCH

A When parking the machine or leaving the machine, always lower

2. TRAVEL LEVERS (WITH PEDAL, AUTO-DECELERATION MECHANISM)

3. LEFT WORK EQUIPMENT LEVER (arm/swing control lever)

t For levers 2, 3, and 4, the engine speed changes as follows because of

5. FORWARD ADJUSTMENT BUTTON FOR WORK EQUIPMENT CONTROL

Removing front window (bottom)

0 Up-down adjustment of seat

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

Fuse arrangement and circuit

0 10A Pump controller, solenoid -

0 10A Engine governor controller -

0 10A Monitor, buzzer -

0 15A Heater (air conditioner, cooler) -

0 10A Right head lamp, working lamp -

@ 10A Room lamp, radio -

0 10A Wiper motor, horn (window washer) -

@ IOA Cigarette lighter -

@ 10A Battery relay, electric heater relay, start signal -

@ 10A Spare (swing flasher) -

ELECTRONIC MONITOR AND CONTROL CONSOLE (EMACC)

No. input mode and condition Display

0 Power source monitor (with starting switch ON Lights up

Engine speed signal monitor (when engine is running) Flashes

Lifting operation mode

When switching input Display