1. Manuals
  2. Brands
  3. Komatsu Manuals
  4. Excavators
  5. PC15MRX-1
  6. Operation and maintenance manual

Komatsu PC15MRX-1 Operation And Maintenance Manual

Hydraulic excavator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing this machine. This manual should be kept near
the machine for reference and periodically reviewed
by all personnel who will come into contact with it.
Komatsu has Operation & Maintenance Manuals written in
some other languages. If a foreign language manual is
necessary, contact your local distributor for availability.
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
WARNING
NOTICE
10001
and up
SEAM044900T

Advertisement

Table of Contents
loading

Related Manuals for Komatsu PC15MRX-1

Summary of Contents for Komatsu PC15MRX-1

  • Page 1 NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
  • Page 2 FOREWORD...
  • Page 3 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and speciffications that are necessary for use in your country.
  • Page 4 FOREWORD FOREWORD...
  • Page 5 FOREWORD FOREWORD...

  • Page 6: Foreword

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
  • Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

  • Page 8: Introduction

    FOREWORD INTRODUCTION INTRODUCTION This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following works: Digging work Leveling work Ditching work Loading work Demolition work See the section "RECOMMENDED APPLICATIONS (PAGE 3-54)" for further details. DIRECTIONS OF MACHINE In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when the operator's cab is facing the front and the sprocket is at the rear of the machine.

  • Page 9: Product Information

    FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. MACHINE SERIAL NUMBER PLATE AND ITS LOCATION At the right side of the boom swing mount ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...

  • Page 10: Emission Control Information Label

    FOREWORD PRODUCT INFORMATION EMISSION CONTROL INFORMATION LABEL Inside surface of the left rear leg of the operatar's seat stand. EPA:Environmental Protection Agency,U.S.A. SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No.

  • Page 11: Table Of Contents

    FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD ................................. 1-2 SAFETY INFORMATION............................1-5 INTRODUCTION..............................1-7 DIRECTIONS OF MACHINE ........................1-7 PRODUCT INFORMATION ..........................1-8 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ..............1-8 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ................. 1-8 EMISSION CONTROL INFORMATION LABEL ..................1-9 SERVICE METER LOCATION ........................
  • Page 12 FOREWORD CONTENTS OPERATION GENERAL VIEW ..............................3-2 GENERAL VIEW OF MACHINE ......................... 3-2 GENERAL VIEW CONTROLS AND GAUGES................... 3-3 EXPLANATION OF COMPONENTS........................3-4 MACHINE MONITOR ..........................3-4 SWITCHES ..............................3-9 CONTROL LEVERS, PEDALS ......................... 3-11 VARIABLE BLADE............................ 3-16 ENGINE HOOD ............................3-17 FUSE ................................
  • Page 13 FOREWORD CONTENTS LONG TERM STORAGE ............................ 3-75 BEFORE STORAGE..........................3-75 DURING STORAGE ..........................3-75 AFTER STORAGE............................ 3-76 TROUBLESHOOTING............................3-77 AFTER RUNNING OUT OF FUEL......................3-77 PHENOMENA THAT ARE NOT FAILURES ..................... 3-77 TOWING THE MACHINE ......................... 3-78 PRECAUTIONS ON PARTICULAR JOBSITES ..................3-78 DISCHARGED BATTERY ........................
  • Page 14 FOREWORD CONTENTS SPECIFICATIONS SPECIFICATIONS ..............................5-2 ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS ..........................6-2 PRECAUTIONS RELATED TO SAFETY ....................6-2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ................6-4 HANDLING BUCKET WITH HOOK ........................6-5 CHECKING FOR DAMAGE TO BUCKET WITH HOOK ................6-5 PROHIBITED OPERATIONS ........................

  • Page 15: Safety

    SAFETY WARNING Please read and make sure that you fully understand the precautions discribed in this namual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.

  • Page 16: Safety Information

    SAFETY SAFETY INFORMATION SAFETY INFORMATION POSITION FOR ATTACHING SAFETY LABELS ....................2-4 POSITION FOR ATTACHING SAFETY LABELS .................... 2-5 SAFETY LABELS............................. 2-6 SAFETY INFORMATION ............................ 2-10 SAFETY RULES ............................2-10 IF ABNORMALITIES ARE FOUND ......................2-10 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ..............2-10 FIRE EXTINGUISHER AND FIRST AID KIT ....................
  • Page 17 SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION ........................2-19 STARTING ENGINE ............................2-19 CHECKS BEFORE STARTING ENGINE ....................2-19 SAFETY RULES FOR STARTING ENGINE .................... 2-20 STARTING ENGINE IN COLD WEATHER ....................2-20 OPERATION..............................2-21 CHECKS AFTER STARTING ENGINE ....................2-21 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS ..............

  • Page 18: Position For Attaching Safety Labels

    If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
  • Page 19 SAFETY POSITION FOR ATTACHING SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS...

  • Page 20: Safety Labels

    SAFETY POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and (2) Precautions for operation (22L-98-18160) maintenance (09651-03001) (3) Precautions for leaving the operator's seat (4) Precautions for minimum variable gauge (09654-03001) (21S-98-2A350)
  • Page 21 SAFETY POSITION FOR ATTACHING SAFETY LABELS (5) Precautions for operating pattern (6) Warning for hot oil hazard (09653-03001) Standard machine (09822-03000) (7) Warning for hot water hazard (20M-98-83250) (8) Precautions for handling electric wires (09808-03000)
  • Page 22 SAFETY POSITION FOR ATTACHING SAFETY LABELS (9) The safety lock is operated with the lock lever (10) Precautions for check and adjust track tension (22L-98-18240) (09657-03003) (11) Precautions for opening engine hood (12) Prohibited to enter range of swing (09667-03001) (21R-98-18120, 21R-98-18130)
  • Page 23 SAFETY POSITION FOR ATTACHING SAFETY LABELS (13) Precautions when handling TOPS (09620-30205)

  • Page 24: Safety Information

    SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

  • Page 25: Safety Equipment

    SAFETY SAFETY INFORMATION SAFETY EQUIPMENT Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition. KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation.

  • Page 26: Handrails And Steps

    SAFETY SAFETY INFORMATION When leaving the machine, always lower the work equip- ment completely to the ground, set safety lock lever (1) securely to the LOCK position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place.

  • Page 27: Mounting And Dismounting

    SAFETY SAFETY INFORMATION MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.

  • Page 28: Fire Prevention And Explosion Prevention

    SAFETY SAFETY INFORMATION FIRE PREVENTION AND EXPLOSION PREVENTION Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling.

  • Page 29: Action If Fire Occurs

    Always contact your Komatsu distributor for advice. ATTACHMENT INSTALLATION When installing optional parts or attachments, there may be problems with safety or legal restrictions, so please contact your Komatsu distributor for advice.

  • Page 30: Attachment Combinations

    Any modification mode without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications made without authorization from Komatsu. SAFETY AT JOBSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

  • Page 31: Distance To High Voltage Cables

    SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows. Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

  • Page 32: Ventilation For Enclosed Area

    Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-18...

  • Page 33: Safety Machine Operation

    SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.

  • Page 34: Safety Rules For Starting Engine

    SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR STARTING ENGINE When starting the engine, sound the horn as a warning. Start and operate the machine only while seated. Do not allow anyone apart from the operator to ride on the machine. Do not short circuit the starting motor circuit to start the engine.

  • Page 35: Operation

    SAFETY SAFETY MACHINE OPERATION OPERATION CHECKS AFTER STARTING ENGINE When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Check that the movement of the machine matches the display on the control pattern card. If it does not match, replace it immediately with the correct control pattern card.

  • Page 36: Safety Rules For Traveling

    SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply. When traveling on level ground, pull in the work equipment and keep it at a height of 40 to 50cm (16 to 20 in) from the ground.

  • Page 37: Traveling On Slopes

    SAFETY SAFETY MACHINE OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. When traveling on slopes, keep the work equipment approximately 20 to 30cm (8 to 12 in) above the ground. In case of emergency, quickly lower the work equipment to the ground immediately to help stop the machine.

  • Page 38: Operations On Slopes

    SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SLOPES When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.
  • Page 39 SAFETY SAFETY MACHINE OPERATION Do not carry out demolition work under the machine. There is a hazard that the machine may become unstable and tip over. When working on or from the top of buildings or other structures, check the strength and the structure before starting operations.

  • Page 40: Operations On Snow

    SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SNOW Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.

  • Page 41: Transportation

    SAFETY SAFETY MACHINE OPERATION TRANSPORTATION LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.

  • Page 42: Shipping The Machine

    SAFETY SAFETY MACHINE OPERATION SHIPPING THE MACHINE When shipping the machine on a trailer, do as follows. Investigate all state and local laws governing the weight, width, and length of a load. If necessary, disassemble the work equipment. The width, height and weight of the load differ according to the work equipment, so take this into account when determining the shipping route.

  • Page 43: Battery

    SAFETY SAFETY MACHINE OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.

  • Page 44: Starting Engine With Booster Cables

    SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).

  • Page 45: Towing

    SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec- tion or inspection of the wire rope. When towing, always use the method given in TOWING THE MACHINE (PAGE 3-78) in the OPERATION section. Always wear leather gloves when handling wire rope.

  • Page 46: Lifting Objects With Bucket

    SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable. Use wire rope that conforms to the specified standard. Do not exceed the specified lifting load.

  • Page 47: Safety Maintenance Information

    SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if nec- essary.

  • Page 48: Stop Engine Before Carrying Out Maintenance

    SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no danger of falling rocks, landslides, or flooding. Lower the work equipment completely to the ground and stop the engine.

  • Page 49: Two Workers For Maintenance When Engine Is Running

    SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.

  • Page 50: Accumulator

    Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.

  • Page 51: Noise

    SAFETY SAFETY MAINTENANCE INFORMATION NOISE If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov- ers or ear plugs while working.

  • Page 52: Safety First When Using High-Pressure Grease To Adjust Track Tension

    SAFETY SAFETY MAINTENANCE INFORMATION SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment sys- tem under high pressure. If the specified procedure for maintenance is not followed when making adjustment, grease drain plug (1) may fly out and cause serious injury or property damage.

  • Page 53: Safety Handling High-Pressure Hoses

    If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.

  • Page 54: Periodic Replacement Of Safety Critical Parts

    SAFETY SAFETY MAINTENANCE INFORMATION PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service and maintenance at periodic intervals. In order to further increase safety, components with a strong relation- ship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
  • Page 55 OPERATION WARNING Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 56: Operation

    OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Bucket Track shoe Bucket cylinder Sprocket Track frame Arm cylinder (10) Idler Boom (11) Blade cylinder Boom cylinder (12) Front blade...

  • Page 57: General View Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW CONTROLS AND GAUGES Operator's seat (11) Lamp switch Safety lock levers (12) Pedal lock Left work equipment control lever (13) Boom swing control pedal Travel levers (14) Blade control/variable gauge lever Horn switch (15) Traveling accelerator pedal Right work equipment switch (16) Service meter Blade control lever...

  • Page 58: Explanation Of Components

    OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays. MACHINE MONITOR A:Emergency Stop Items B:Meter Display Portion...
  • Page 59 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEMS CAUTION If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point immediately and repair the problem. These are items that should be watched when the engine is running. If any abnormality occurs, the monitor for the problem point lights up and the buzzer sounds.
  • Page 60 OPERATION EXPLANATION OF COMPONENTS CHARGE LEVEL MONITOR This monitor(1) indicates an abnormality in the charging sys- tem while the engine is running. If the monitor lamp flashes, check the V-belt tension. If any abnormality is found, see "OTHER TROUBLE (PAGE 3-83)". REMARK While the starting switch is ON, the lamp will remain lit and will go off once the engine is started.
  • Page 61 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION (1)Service Meter (3)Fuel Gauge (2)Engine Coolant Temperature Gauge (4)Engine Pre-heating Monitor SERVICE METER This meter(1) shows the total operation hours of the machine. Set the periodic maintenance intervals using this display. The service meter advances while the engine is running - even if the machine is not traveling.
  • Page 62 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE This meter (3) shows the amount of fuel remaining in the fuel tank. During normal operations, the indicator should be in the green range. If the indicator goes down to the E position during operation, there is less than 3.5 l remaining, so check and add fuel.

  • Page 63: Switches

    OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting Switch Lamp Switch Horn Switch STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position The key can be inserted or withdrawn. The switches for the electric system are all turned off and the engine is stopped. ON position Electric current flows in the charging and lamp circuits.
  • Page 64 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH When the button(2) at the tip of the right work equipment con- trol lever is pressed, the horn will sound. LAMP SWITCH This switch (3) lights up the head lamps and the panel lamp. ON position : Panel lamp and head lamp lights up.

  • Page 65: Control Levers, Pedals

    OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Safety lock lever Travel levers (for left and right work equipment control levers) Pedal lock (for boom swing control pedal) Left work equipment control levers Boom swing control pedal Right work equipment control levers Traveling accelerator pedal Fuel control lever (10) Variable gauge/blade selector control lever...
  • Page 66 OPERATION EXPLANATION OF COMPONENTS SAFETY LOCK LEVER WARNING When leaving the operator's compartment, set the safety lock lever securely to the LOCK position. If the safety lock lever is not at the LOCK position and the control levers are touched by mistake, it may lead to serious personal injury.
  • Page 67 OPERATION EXPLANATION OF COMPONENTS FUEL CONTROL LEVER This lever (4) is used to control the engine speed and output. (a) Low idling : Push the lever fully. (b) High idling : Pull the lever fully. BLADE CONTROL/VARIABLE GAUGE LEVER NOTICE This lever is not locked even when the safety lock lever is set to the LOCK position, so be careful not to touch the blade control lever if blade operations are not being carried out.
  • Page 68 OPERATION EXPLANATION OF COMPONENTS TRAVEL LEVERS WARNING If the track frame is facing the rear, the direction of travel operations will be reversed. When operating the travel levers, check if the track frame is facing the front or the rear. (If sprocket (A) is at the rear, the track frame is facing the front.) Use this lever (6) to driver the machine.
  • Page 69 OPERATION EXPLANATION OF COMPONENTS BOOM SWING CONTROL PEDAL WARNING If the bucket is wider than the standard bucket, there is danger that the bucket will contact the operator's cab when swinging the boom to the left with the work equipment pulled in. Check the distance between the bucket and the cab during the operation and operate the work equipment slowly.

  • Page 70: Variable Blade

    OPERATION EXPLANATION OF COMPONENTS This lever (10) switches between the variable gauge and blade control. Lever control Direction of operation (a) RAISE Variable gauge (b) LOWER Blade For details of the method of operating the variable gauge and blade, see the section on the "BLADE CONTROL/VARIABLE GAUGE LEVER (PAGE 3-13)".

  • Page 71: Engine Hood

    OPERATION EXPLANATION OF COMPONENTS ENGINE HOOD CAUTION When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine hood open. NOTICE Check the direction of the key slot in the opening knob to check that it is locked.

  • Page 72: Fuse

    OPERATION EXPLANATION OF COMPONENTS FUSE The fuse box is under the seat. NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

  • Page 73: Cover With Lock

    OPERATION EXPLANATION OF COMPONENTS COVER WITH LOCK Locks are installed to the cover on the right side of the machine, the operator's cab, engine hood, and tool box. Use the starting switch key to lock or unlock these places. Opening and Closing Covers with Lock Insert the key as far as it will go to the shoulder.

  • Page 74: Tipping Operator's Seat

    OPERATION EXPLANATION OF COMPONENTS TIPPING OPERATOR'S SEAT When carrying out inspection or maintenance, tip the opera- tor's seat as follows. Move the the operator's seat to the front, then remove butterfly nut (1) under the seat. Tip operator's seat (2) up and over to the front and lock it in position.

  • Page 75: Machine Operations And Controls

    Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your Komatsu distributor. Always check the items in this section before starting the engine each day.
  • Page 76 OPERATION MACHINE OPERATIONS AND CONTROLS CHECKS BEFORE STARTING Always carry out the items of the checks in this section before starting the engine. CHECK COOLANT LEVEL, ADD WATER WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
  • Page 77 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. Open the engine hood on the machine.
  • Page 78 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK FUEL LEVEL, ADD FUEL WARNING Be careful not to let the fuel overflow when adding fuel. This may cause a fire. Wipe up all fuel that is spilled. If there is sand where the fuel is spilled, remove all the sand. Fuel is flam- mable and dangerous.
  • Page 79 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. If the work equipment is not in the condition shown in the diagram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinders, then lower the boom, set the bucket teeth in contact with the...
  • Page 80 If the fuses frequently blowor if there are traces of short circuits on the electrical wiring, locate the cause immediately and carry out repairs, or contact your Komatsu distributor for repairs. If flammable materials (dead leaves, twigs, dry grass, etc.) accumulate around the battery, they will cause fire, so always remove such material immediately.
  • Page 81 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUSTMENT WARNING Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switchis can be operated freely and easily with the oper- ator back against the backrest. SEAT ADJUSTMENT (A) Fore-and-aft adjustment The seat can move forward and backward.
  • Page 82 OPERATION MACHINE OPERATIONS AND CONTROLS FASTENING AND REMOVING Adjust the seat so that the operator still feels that there is sufficient knee room when fully depressing the pedal while seated, with the operator's back against the back- rest. After adjusting the seat poaition, sit in the seat. Grip buckle (1) and tongue (2) in each hand and insert tongue (2) into buckle (1).
  • Page 83 Engine water temperature gauge (4) Fuel gauge (5) If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or discon- nection in the monitor wiring, so contact your Komatsu distributor for repairs. 3-29...
  • Page 84 Press lamp switch(6) to turn on the head lamps. If it does not light up, there is probably a blown bulb or disconnection, so please contact your Komatsu dis- tributor for repairs. Press horn switch (7) to confirm that the horn will sound.

  • Page 85: Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE NORMAL STARTING WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Exhaust gas is toxic. When starting the engine in con- fined spaces, be particularly careful to ensure good ventilation.
  • Page 86 OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE IN COLD WEATHER WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explo- sions.
  • Page 87 OPERATION MACHINE OPERATIONS AND CONTROLS When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position. Continue idling for 15 seconds after the engine starts. During this time, do not operate the control levers or fuel control dial.

  • Page 88: After Starting Engine

    BREAKING-IN THE NEW MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.
  • Page 89 OPERATION MACHINE OPERATIONS AND CONTROLS WARMING-UP OPERATION NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the levers suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warming-up operation is completed.
  • Page 90 OPERATION MACHINE OPERATIONS AND CONTROLS After carrying out the warming-up operation, check that each gauge and monitor lamp is in the following condi- tion. If there is any abnormality, carry out maintenance and repair. Engine water temperature gauge (4): Inside green range Fuel gauge (5): Inside green range Engine oil pressure monitor (6): OFF Charging monitor (7): OFF...

  • Page 91: Stopping The Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at mediumspeed to allow it to cool gradu- ally, then stop it.

  • Page 92: Machine Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION PREPARATIONS FOR MOVING THE MACHINE OFF WARNING Before operating the steering levers, check the direc- tion of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed. When moving off, check that the area around the machine is safe, and sound the horn before moving.
  • Page 93 OPERATION MACHINE OPERATIONS AND CONTROLS MOVING MACHINE FORWARD Set safety lock lever (4) in the FREE position, fold the work equipment, and raise it 40 to 50 cm (16 to 20 in) from the ground. Operate right and left travel levers (3) as follows. When the sprocket (A) is at the rear of the machine Push levers (3) forward slowly to move the machine off.
  • Page 94 OPERATION MACHINE OPERATIONS AND CONTROLS MOVING MACHINE BACKWARD Set safety lock lever (2) in the FREE position, fold the work equipment, and raise it 40 to 50 cm (16 to 20 in) from the ground. Operate right and left travel levers (5) as follows. When the sprocket (A) is at the rear of the machine Pull levers (3) backward slowly to move the machine off.
  • Page 95 OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Put the left and right travel levers (1) in the neutral posi- tion, then stop the machine. 3-41...

  • Page 96: Steering The Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE STEERING WARNING Before operating the travel levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levers is reversed. Use the travel levers to change direction. Avoid sudden changes of direction as far as possible.
  • Page 97 OPERATION MACHINE OPERATIONS AND CONTROLS CHANGING DIRECTION OF THE MACHINE When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. REMARK When turning to the right, operate the right travel lever in the same way.

  • Page 98: Swinging

    OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING The rear of the machine extends outside the track width. Check that the surrounding area is safe before swinging be upper structure. Check that swing lock monitor is not lighted up. If the swing control lever is operated quickly, the upper structure will move quickly;...

  • Page 99: Work Equipment Controls And Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING If the work equipment control lever is operated quickly, the work equipment will move quickly; and if it is operated slowly, the work equipment will move slowly. Use the control levers to operate the work equipment. Note that when the levers are released, they return to the HOLD position and the work equipment is held in that position.
  • Page 100 OPERATION MACHINE OPERATIONS AND CONTROLS Bucket control Move the right work equipment control lever to the left or right to operate the bucket. Boom swing operation The boom swing operation can be carried out with the boom swing control pedal. Blade control Move the lever on the right side of the operator’s seat to the front or rear to operate the blade.

  • Page 101: Prohibited Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the travel and operate the control lever. OPERATIONS USING SWING FORCE Do not use the swing force to compact soil or break objects. This is not only dangerous, but will also markedly reduce the life of the machine.
  • Page 102 OPERATION MACHINE OPERATIONS AND CONTROLS OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. OPERATIONS USING MACHINE DROPPING FORCE Do not use the dropping force of the machine for digging.
  • Page 103 OPERATION MACHINE OPERATIONS AND CONTROLS SUPPORT BLADE ON BOTH SIDES When using the blade as an outrigger, never suport the machine with only one end of the blade. BLADE DURING BACKHOE OPERATIONS When carrying out deep digging operations with the blade at the front, be careful not to the boom cylinder hit the blade.

  • Page 104: General Operation Information

    OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION TRAVELING When traveling over obstacles such as boulders or tree stumps, the machine (in particular, the undercarriage) is sub- jected to a large shock, so reduce the travel speed and travel over the obstacle at the center of the tracks. As far as possible, remove such obstacles or avoid traveling over them.

  • Page 105: Traveling On Slopes

    OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING When traveling, raise the bucket approx. 20 to 30cm (8 to 12 in) from the ground. Do not travel downhill in reverse. When traveling over ridges or other obstacles, keep the work equipment close to the ground and travel slowly.
  • Page 106 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK Travel down fills with the sprocket (1) side down. If the machine travels down with the sprocket (1) side up, the track tends to become loose, and that can cause skipping pitches. When traveling up a steep hill of more than 15º, set the work equipment to the posture shown in the diagram on the right.

  • Page 107: Escape From Mud

    OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get the machine out. STUCK ONE SIDE OF TRACK NOTICE When using the boom or arm to raise the machine, always havethe bottom of the bucket in contact with the ground.

  • Page 108: Recommended Applications

    OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attachments. BACKHOE WORK A backhoe is suitable for excavating at a position lower than the machine. When the condition of the machine is as shown in the diagram at right, each cylinder's maximum pushing excavation force is obtained when the bucket cylinder and link, arm cylinder and...
  • Page 109 OPERATION MACHINE OPERATIONS AND CONTROLS SMOOTHING WORK When refilling after excavation and when smoothing the ground surface, use the blade. SIDE DITCHING WORK The machine can be used for side ditching in a confined work- site by combining the swing and boom swing operations. 3-55...

  • Page 110: Replacement And Inversion Of Bucket

    OPERATION MACHINE OPERATIONS AND CONTROLS REPLACEMENT AND INVERSION OF BUCKET WARNING When the pin is knocked in with a hammer, pieces of metal may fly into your eyes and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equip- ment.
  • Page 111 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket, the O-rings are easily damaged, so fit the O-rings on the boss of the arm end as shown in the dia- gram. When knocking in the pins, move the O-ring down to the regular groove.

  • Page 112: Parking Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably nec- essary to park the machine on a slope, insert blocks underneath the track shoes.

  • Page 113: Check After Finishing Work

    OPERATION MACHINE OPERATIONS AND CONTROLS Lower the bucket horizontally until the bottom touches the ground. Lower the blade to the ground. Set safety lock lever (3) in the LOCK position. CHECK AFTER FINISHING WORK Check the engine water temperature(1), engine oil pressure(2), and fuel level(3) on the machine monitor.

  • Page 114: Rubber Shoes

    OPERATION MACHINE OPERATIONS AND CONTROLS RUBBER SHOES RUBBER SHOES INFORMATION Rubber shoes have excellent properties that are not found in steel shoes. However, if they are used in the same way as steel shoes, full use cannot be made of their advantages. Be sure to operate without straining the rubber shoes in a way that matches the condition of the jobsite and the nature of the work.
  • Page 115 OPERATION MACHINE OPERATIONS AND CONTROLS USING RUBBER SHOES Prohibited works Do not carry out the following types of work. Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near the edges of steel plates will cause damage to the rubber shoes. In places such as river beds where there are large numbers of large and small boulders, the stones may get caught and damage the rubber shoes or make the shoes come off.
  • Page 116 OPERATION MACHINE OPERATIONS AND CONTROLS When traveling in reverse up a slope, do not turn when moving from flat ground onto the slope. If it is necessary to turn on slopes, be sure to turn gradu- ally. Avoid traveling along the edge of slopes or on rough ground with the track on one side raised (with the machine tilting at an angle of more than approx.
  • Page 117 OPERATION MACHINE OPERATIONS AND CONTROLS When turning in a condition where the rubber shoe cannot move to the side because of the object it is passing over, or because of some other object. When the rubber shoe has moved out of alignment and the idler or track roller are not aligned with the core.

  • Page 118: Transportation

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

  • Page 119: Loading And Unloading With Trailer

    OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING When loading or unloading on to a trailer, set to low speed, and do not operate the travel speed selector switch during the operation. Run the engine at low idling, set to low speed, and operate the machine slowly when loading or unload- ing.
  • Page 120 OPERATION TRANSPORTATION LOADING Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
  • Page 121 OPERATION TRANSPORTATION Stop the machine at the specified place, then swing the upper structure slowly 180°. Stop the machine at the specified position on the trailer. 3-67...
  • Page 122 OPERATION TRANSPORTATION SECURING MACHINE WARNING Load the machine on a level and hard place. Secure a sufficient distance between the road shoulder and the machine. NOTICE To prevent damage to the bucket cylinder during transportation, fit a wooden block at one end of the bucket cylinder to prevent it from touching the floor.

  • Page 123: Lifting Machine

    The lifting procedure applies to machines with standard specifications. The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your Komatsu distributor for information. When lifting the machine, carry out the operation on flat ground as follows.
  • Page 124 OPERATION TRANSPORTATION Install shackles to the lifting holes B (2 places) on both ends of the blade, then install the wire ropes. Install shackles to the lifting holes A of the boom, then install the wire ropes. NOTICE Be sure to use the three brackets. Do not lift the machine with the boom or the upper structure swung.

  • Page 125: Cold Weather Operation

    Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing anti- freeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to the ground surface.
  • Page 126 OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.

  • Page 127: After Daily Work Completion

    OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, so stay well away from the tracks. After completion of operations, fill the fuel tank to prevent the formation of water caused by conden- sation of moisture in the empty space in the tank when the temperature goes down.

  • Page 128: After Cold Weather Season

    OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER SEASON When season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE (PAGE 4-11)".

  • Page 129: Long Term Storage

    Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it sepa- rately. Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water, so there is no need to change the density for temperatures above -10°C (14ºF).

  • Page 130: After Storage

    NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. Wipe off all the grease coating the hydraulic cylinder rods.

  • Page 131: Troubleshooting

    OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see "REPLACE FUEL FILTER ELEMENT (PAGE 4-48)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm is pulled in, the speed of movement will drop...

  • Page 132: Towing The Machine

    OPERATION TROUBLESHOOTING TOWING THE MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope. If the machine sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram on the right.

  • Page 133: Discharged Battery

    OPERATION TROUBLESHOOTING DISCHARGED BATTERY WARNING It is dangerous to charge the battery while it is still mounted on the machine. Always remove the battery before charging it. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
  • Page 134 OPERATION TROUBLESHOOTING REMOVAL AND INSTALLATION OF BATTERY NOTICE After securing the battery, check that it does not move. If it moves, tighten it again securely. Before removing the battery, remove the ground cable (normally connected to the negative(-) terminal). If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated. When installing the battery, connected the ground cable last.
  • Page 135 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLES When starting the engine with a booster cable, do as follows: CONNECTING AND DISCONNECTING BOOSTER CABLES WARNING When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
  • Page 136 OPERATION TROUBLESHOOTING BOOSTER CABLE CONNECTION Keep the starting switch of the nornal machine and problem amchine are both at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. Make sure that the starting switches of the normal machine and problem machine are both at the OFF posi- tion.

  • Page 137: Other Trouble

    OPERATION TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy...
  • Page 138 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
  • Page 139 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights...
  • Page 140 OPERATION TROUBLESHOOTING Problem Main causes Remedy Exhaust gas occasionally turns Clogged air cleaner element Clean or replace, see WHEN black REQUIRED Defective nozzle Replace nozzle) Defective compression See defective compression above) Combustion noise occasionally Defective nozzle Replace nozzle) make breathing sound Abnormal noise generated (com- Low-grade fuel being used Change to specified fuel...
  • Page 141 MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.

  • Page 142: Maintenance Information

    KOMATSU GENUINE REPLACEMENT PARTS Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. WINDSHIELD WASHER FLUID Use automobile windshield washer fluid, and be sure not to let any dirt get into it.
  • Page 143 MAINTENANCE MAINTENANCE INFORMATION DO NOT DROP THINGS INSIDE MACHINE When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead to failure.
  • Page 144 MAINTENANCE MAINTENANCE INFORMATION CHECKS AFTER INSPECTION AND MAINTENANCE WORKS If you forget to carry out the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injuly or property damage. Always do as follows. Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been carried out correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...

  • Page 145: Lubricants, Coolant And Filters

    When changing the oil, always replace the related filters at the same time. We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor. FUEL The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
  • Page 146 Do not use water that is not suitable for drinking. When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu specified anti-freeze in the coolant. This anti-freeze is effective in preventing corrosion of the cooling system.
  • Page 147 Carry out sampling regularly at fixed intervals. Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. GREASE Grease is used to prevent twisting and noise at the joints.

  • Page 148: Electric System Maintenance

    Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and check of battery fluid level. Never install any electric components other than there specified by Komatsu. External electrical interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor.
  • Page 149 MAINTENANCE LUBRICANTS, COOLANT AND FILTERS When carrying out inspection or maintenance of the hydraulic circuits, always bleed the air to release the inter- nal pressure. Inspection or maintenance consists of checking the hydraulic oil level, replacing the filters, and changing the hydraulic oil.

  • Page 150: Wear Parts List

    The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.

  • Page 151: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature

    MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY KIND OF RESERVOIR FLUID Refill Specified 4 liters 3 liters 1.06 US gal 0.79 US gal 0.33 liters...
  • Page 152 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
  • Page 153 SAE80, 90, 140 NLGI No.2 (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super AGIP dieselmulti- grade Rotra MP GR MU/EP...
  • Page 154 MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil [CD or CE] Anti-freeze Coolant Gear Oil Grease SAE10W, 30, 40 [Ethylene Glycol Supplier [GL-4 or GL-5] [Lithium-Base] 10W30, 15W40 Base] SAE80, 90, 140 NLGI No.2 (The 15W40 oil Permanent Type marked * is CE.) FINA potonic N...

  • Page 155: Tightening Torque Specifications

    The tightening torque is determined by the width across the flats of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

  • Page 156: Periodic Replacement Of Safety Critical Parts

    If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. SAFETY CRITICAL PARTS Safety critical parts for periodic replacement...

  • Page 157: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-19)" to confirm the correct main- tenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART Initial 250 Hours Maintenance (Only after the first 250 hours) CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........
  • Page 158 MAINTENANCE MAINTENANCE SCHEDULE Every 500 Hours Maintenance LUBRICATING ..............................4-47 REPLACE FUEL FILTER ELEMENT ........................4-48 CLEAN AND INSPECT RADIATOR FINS......................4-50 REPLACE FUEL FEED PUMP PRE-FILTER...................... 4-51 Every 1000 Hours Maintenance CHANGE OIL IN FINAL DRIVE CASE ....................... 4-52 Every 2000 Hours Maintenance CHANGE AND CLEAN HYDRAULIC OIL AND STRAINER ................

  • Page 159: Maintenance Interval For Hydraulic Breaker

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging operations, so set the maintenance intervals as follows. REPLACING HYDRAULIC ELEMENT On new machines, replace the element after the first 100 to 150 hours, then carry out further replacement of the ele- ment according to the table on the right.

  • Page 160: Maintenance Procedure

    Replace fuel filter element Inspect engine valve clearances Special tools are needed for inspection and maintenance, so contact your Komatsu distributor. For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS and 2000 HOURS SERVICE.

  • Page 161: When Required

    MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and the engine will suffer damage. Always stop the engine before carrying out these opera- tions.
  • Page 162 MAINTENANCE MAINTENANCE PROCEDURE If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit it or beat it against something.

  • Page 163: Clean Inside Of Cooling System

    30% by volume is necessary. In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corro- sion resistor agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liters (0.065 oz/US gal).
  • Page 164 I If it gets in your eyes, flush your eyes with large quantities of fresh water and see a doctor at once. Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
  • Page 165 MAINTENANCE MAINTENANCE PROCEDURE Open the hood (3) at the rear of the machine. Set container to catch the coolant under drain valve (4). Open drain valve (4) to drain the water. Remove drain plug to drain the water. After drain the water, close drain valve (4) and drain plug, and add water.

  • Page 166: Check Battery Electrolyte Level

    MAINTENANCE MAINTENANCE PROCEDURE 13. Drain the cooling water inside sub-tank (5), clean the inside of the sub-tank, then fill again with cooling water to a point midway betwee the FULL and LOW marks. 14. Stop the engine. About 3 minutes later, supply city water up to the water filler, then close radiator cap.
  • Page 167 If distilled water is added to above the U.L line, use a pipette to lower the level to the U.L line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4-27...
  • Page 168 If distilled water is added to above the bottom of the sleeve, use a pipette to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When It is Possible to Use Indicator to Check Electrolyte Level If it is possible to use and indicator to check the electrolyte level, follow the instructions given.

  • Page 169: Clean Fuel Filter

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN FUEL FILTER (With water separator) Prepare a filter wrench for fuel filter. Prepare a container to catch drain fuel. Open the engine hood, and set handle to the LOCK posi- tion. See "ENGINE HOOD (PAGE 3-17)". Using a filter wrench, loosen ring (2), remove case (3), then throw out the water inside.

  • Page 170: Check And Adjust Track Tension

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION WARNING The track tension is checked with the machine raised, so it is extremely dangerous if the machine comes down by mistake during the inspection. Stop the engine and set the safety lock lever to the LOCK position to prevent the machine from moving.
  • Page 171 Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the proce- dure given here, please contact your Komatsu distributor. When increasing tension Prepare a grease gun.

  • Page 172: Check Rubber Shoes

    It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Loosen plug (1) gradually to release the grease.
  • Page 173 If the length is less than 30mm (1.18 in) or the depth of the crack is less than 10mm (0.39 in), there is no particular need to carry out repairs. When making judgement whether to replace, repair, or con- tinue using rubber shoe and load liner, please contact your Komatsu distributor. 4-33...

  • Page 174: Check And Adjust Track Tension

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND ADJUST TRACK TENSION (Machine equipped with rubber shoe) WARNING The track tension is checked with the machine raised, so it is extremely dangerous if the machine comes down by mistake during the inspection. Stop the engine and set the safety lock lever to the LOCK position to prevent the machine from moving.
  • Page 175 Check the track tension again, and if the tension is not correct, adjust it again. If the track tension is still loose after grease is pumped in, it is necessary to replace the rubber shoe or replace the seal inside the cylinder. Please contact your Komatsu distributor for replacement. Loosening Track Tension...

  • Page 176: Replace Rubber Shoes

    NOTICE It is possible to replace rubber shoes with steel shoes, but this makes it necessary to remove and adjust the idler cushion, so please contact your Komatsu distributor. Prepare a grease gun Prepare a steel pipe...
  • Page 177 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please con- tact your Komatsu distributor. Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.
  • Page 178 MAINTENANCE MAINTENANCE PROCEDURE Mesh the rubber shoe with the sprocket and fit it over the idler. Rotate the sprocket in reverse, then push in the rubber shoe and stop the rotation. Fit a steel pipe in the rubber shoe, then rotate the sprocket again and fit the rubber shoe securely on the idler.

  • Page 179: Replace Bucket Teeth

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH Replace the teeth before the wear reaches the adapter. WARNING It is dangerous if the work equipment moves by mis- take when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the levers.

  • Page 180: Drain Water And Sediment From Fuel Tank

    MAINTENANCE MAINTENANCE PROCEDURE DRAIN WATER AND SEDIMENT FROM FUEL TANK NOTICE Never use trichlene for washing the inside of the tank. Use diesel fuel only. Carry out this procedure before operating the machine as a daily maintenance. Carry out this procedure before operating the machine. Prepare a container to catch the fuel that is drained.

  • Page 181: Check Before Starting

    MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECKS BEFORE STARTING (PAGE 3-22)" in the OPERATION section. Check coolant level, add water Check oil level in engine oil pan, add oil Check fuel level, add fuel Check oil level in hydraulic tank, add oil Check electric wirings Check function of horn...

  • Page 182: Every 100 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 100 HOURS MAINTENANCE LUBRICATING NOTICE For the first 100 hours on new machines where the parts are settling in, carry out greasing every 10 hours. After digging operations under water, be sure to grease the pins which were submerged. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop the engine.

  • Page 183: Every 250 Hours Maintenance

    Remove drain plug (P) slowly to avoid getting oil on your- self, and drain the oil. Check the drained oil, and if there are excessive metal particles or foreign material, contact your Komatsu dis- tributor. Install drain plug (P). Using a filter wrench, turn filter cartridge (1) counterclock- wise to remove it.

  • Page 184: Check Oil Level In Final Drive Case, Add Oil

    MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out.
  • Page 185 MAINTENANCE MAINTENANCE PROCEDURE Remove the cap from oil filler (F), and release the internal pressure. Loosen the clamp of hose (1), then loosen 4 bolts. Take out element assembly (2). Using a filter wrench, turn filter cartridge (3) to the left to remove it.

  • Page 186: Inspect And Adjust Cooling Fan Belt Tension

    V-belt. In particular, be sure to check that the V-belt is not touching the bottom the V-groove. If the belt is stretched, leaving no allowance for adjust- ment, or if it is cut or cracked, contact your Komatsu dis- tributor for replacement. 4-46...

  • Page 187: Every 500 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE Maintenance for every 100 and 250 hours service should be carried out at the same time. LUBRICATING Set the machine to the greasing posture shown on the right, lower the work equipment to the ground, then stop the engine.

  • Page 188: Replace Fuel Filter Element

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL FILTER ELEMENT (With water separator) WARNING The engine is at a high temperature immediately after the engine is stopped. Wait for all parts to cool down before replacing the filter. Do not bring fire or spark near the fuel. Prepare a filter wrench for fuel filter element.
  • Page 189 MAINTENANCE MAINTENANCE PROCEDURE Air Bleeding Fill the fuel tank with fuel (until fuel gauge (G) indicates Turn and keep the starting key to the ON position for 10 to 20 seconds. Air is automatically bled by the automatic air bleeding device.

  • Page 190: Clean And Inspect Radiator Fins

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS WARNING If compressed air, high-pressure water, or steamhit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment.

  • Page 191: Replace Fuel Feed Pump Pre-Filter

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL FEED PUMP PRE-FILTER WARNING Do not replace the pre-filter just after stopping the engine, since each part is still hot. Wait until each part has cooled down. After replacing the pre-filter, connect the fuel hoses securely ao that fuel will not leak. Do not bring fire or spark near the pre-filter.

  • Page 192: Every 1000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 100, 250 and 500 hours service should be carried out at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.

  • Page 193: Every 2000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE AND CLEAN HYDRAULIC OIL AND STRAINER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before changine the oil in the hydraulic tank.

  • Page 194: Inspect Alternator And Starting Motor

    3 minutes, then start the normal work. INSPECT ALTERNATOR AND STARTING MOTOR The brush may be worn or the bearing may have run out of grease. Contact your Komatsu distributor for inspec- tion or repair. If the engine is started frequently, carry out inspection every 1000 hours.

  • Page 195: Inspect Engine Valve Clearances

    MAINTENANCE MAINTENANCE PROCEDURE INSPECT ENGINE VALVE CLEARANCES As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for service. 4-55...

  • Page 196: Specifications

    SPECIFICATIONS...
  • Page 197 Unit PC15MRx-1 Operating weight kg (lb) 1,590 (3,506) Bucket capacity 0.044 (0.05) (cu.yd) Name of engine KOMATSU 3D68EK-3K diesel engine Engine horsepower kW (HP)/rpm 11.20 (15) / 2,600 Overall length mm (ft in) 3,570 (11'9") Overall height mm (ft in) 2,430 (7'12")
  • Page 198 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC15MRx-1 Max. digging reach mm (ft in) 3,880 (12'9") Max. digging depth mm (ft in) 2,150 (7'1") Max. digging height mm (ft in) 3,540 (11'7") Max. vertical wall depth mm (ft in) 1,760 (5'9") Max. dumping height mm (ft in) 2,550 (8'4")

  • Page 199: Attachments And Options

    ATTACHMENTS OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.

  • Page 200: General Precautions

    GENERAL PRECAUTIONS PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu- tor first.
  • Page 201 Stay in a safe place where there is no danger if the load should fall. NOTICE Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per- son. For details of removal and installation operations, contact your Komatsu distributor.

  • Page 202: Precautions When Installing Attachments

    Always follow the correct procedure when installing the boom and arm. If the correct procedure is not followed, this may lead to serious damage or injury, so consult your Komatsu distributor before carrying out installation. If long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting something.

  • Page 203: Handling Bucket With Hook

    Never steer the machine while lifting a load. If the bucket with hook is turned and used for operations, it will hit the arm during dumping operations, so be careful when using it. If you are planning to install a hook, contact your Komatsu distributor.

  • Page 204: Attachment Guide

    When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing. Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment.

  • Page 205: Machines Ready For Attachments

    ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS MACHINES READY FOR ATTACHMENTS EXPLANATION OF COMPONENTS Stop valve Selector valve Attachment control pedal STOP VALVE This valve (1) stops the flow of the hydraulic oil. (a) FREE: Hydraulic oil flows (b) LOCK: Hydraulic oil stops Set this valve to the LOCK position when removing or installing attachments.
  • Page 206 ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS SELECTOR VALVE This valve (2) selector the flow of the hydraulic oil. Position (1): When breaker is used Position (2): When general attachment is used (crusher, etc.) ATTACHMENT CONTROL PEDAL This pedal (3) is used to operate the attachment. REMARK When depressing the rear of the pedal (mainly when operating the breaker), put the tip of your foot on plate (1) at the bottom...

  • Page 207: Hydraulic Circuit

    ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT CONNECTION When connecting the attachment, connect the hydraulic circuit as follows. Check that the stop valve is at the LOCK position, then remove the plug. Be careful not to lose or damage any part that is removed.

  • Page 208: Operation

    ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS OPERATION WARNING Do not put your foot on the pedal except when operating thepedal. If rest your foot on the pedal during operations, and it is depressed by accident, the attachment may move suddenly and cause serious dam- age or injury.
  • Page 209 ATTACHMENTS AND OPTIONS MACHINES READY FOR ATTACHMENTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER Depress the bottom of the pedal to operate the breaker. Precautions when using Check that the stopper valve is in the FREE position. Check that the selector valve is in the position for 2-WAY (for crusher and other general attachment).

  • Page 210: Recommended Attachment Operations

    NOTICE Select the attachment most suited to the machine body. The machine models to which attachments can be mounted vary. For selection of attachment and machine model, consult your Komatsu distributor. HYDRAULIC BREAKER MAIN APPLICATIONS Crushed rock...
  • Page 211 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS When applying impact, push the chisel against the impact sur- face and operate so that the chassis rises approx. 5 cm (2 in) off the ground. Do not let the machine come further off the ground than this amount.
  • Page 212 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS PROHIBITED WORKS To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. Do not operate all cylinders to the end of their strokes. Always leave approx. 5 cm (2 in) to spare. Using the mount to gather in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations...
  • Page 213 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 6-15...
  • Page 214 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS GREASING POSITION FOR HYDRAULIC BREAKER Supply grease in the correct position. NOTICE If grease is supplied in an incorrect position, the breaker is filled with more grease than necessary. As a result, soil and sand will enter the hydraulic circuit and can damage the hydraulic devices while the breaker is used.
  • Page 215 INDEX INDEX AFTER COLD WEATHER SEASON ....3-74 GENERAL OPERATION INFORMATION ..3-50 AFTER DAILY WORK COMPLETION ....3-73 GENERAL PRECAUTIONS ........6-2 AFTER RUNNING OUT OF FUEL ...... 3-77 GENERAL VIEW ..........3-2 AFTER STARTING ENGINE ......3-34 GENERAL VIEW CONTROLS AND GAUGES ..3-3 AFTER STORAGE ..........
  • Page 216 INDEX PARKING MACHINE ..........3-58 WEAR PARTS LIST ........... 4-10 PERIODIC REPLACEMENT OF SAFETY WHEN REQUIRED ..........4-21 CRITICAL PARTS ..........4-16 WORK EQUIPMENT CONTROLS AND PHENOMENA THAT ARE NOT FAILURES ..3-77 OPERATIONS ..........3-45 POSITION FOR ATTACHING SAFETY LABELS .............2-4, 2-5 PRECAUTIONS ON PARTICULAR JOBSITES ..3-78 YOUR MACHINE SERIAL NUMBERS AND PRECAUTIONS RELATED TO SAFETY ....6-2...
  • Page 217 PC15MRx-1 HYDRAULIC EXCAVATOR Form No. SEAM044900T ©2001 All Rights Reserved Printed in Japan 09-01...

Table of Contents