PC 21010

Operation & UENAM00902
Maintenance Manual
PC210-10
PC210LC-10
PC210-10 DEMOLITION BASE SPEC .
PC210LC-10 DEMOLITION BASE SPEC.
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
PC210-10 - K60001 and up
PC210LC-10 - K60001 and up
PC210-10 - 450120 and up
PC210LC-10 - 450120 and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read ORIGINAL INSTRUCTIONS
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
FOREWORD
FOREWORD:ALL-0000-001K00A
SAFETY
k WARNING
Komatsu recommends that any service parts used for mainte-
nance, repair or replacement of emission control systems be
genuine new Komatsu or Komatsu approved rebuilt parts or
assemblies or others parts of equivalent quality, and that the
engine be serviced by an authorized Komatsu distributor. Fail-
ure to follow these recommendations could result in ineffective
service, damage to the product or safety risks (including per-
sonal injury or death).
1–1
FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
k WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the fol-
lowing points.
Read this manual thoroughly and understand its contents fully.

q Read the safety messages and safety labels given in this manual carefully so that they should be understood
fully.
q Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all
personnel involved in working on the machine can consult it periodically.
q In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to
obtain a new copy.
q When you sell the machine, make sure that this manual should be provided to the new owner together with the
machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose,
weight units used in the past are also displayed in ().
Storage location for the Operation and Maintenance Manual:

magazine box on the left side of the operator's seat.
1–2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
SAFETY INFORMATION:ALL-1110-010A00A
To enable you to use the machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding
such situations.
Signal Words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
k
Indicates an imminently hazardous situation which, if not avoided, will result in death or
DANGER serious injury.
k
Indicates a potentially hazardous situation which, if not avoided, could result in death or
WARNING serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
k CAUTION moderate injury. This word is used also to alert against unsafe practices that may cause
property damage
Example of safety message using signal word
k WARNING
When standing up from the operator’s seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause serious injury or death.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced
NOTICE
if the precaution is not followed.
REMARKS This word is used for information that is useful to know.
1–3
SAFETY INFORMATION FOREWORD
SAFETY LABELS
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using pictograms” to indicate safety procedures.
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual
Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions
regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in () in the text. (For example: -> (1))
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, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product com-
plies with the applicable standards and regulations of your country, consult Komatsu or your distributor before
operating the machine.
1–4
FOREWORD SAFETY INFORMATION
NOISE (PC210-10, PC210LC-10)

Two labels indicating the machine noise level are affixed on the machine.
q Sound pressure level at the operator’s station, meas-
ured according to ISO 6396 (Dynamic test method, sim-
ulated working cycle).
The maximum value of the standard deviation of the
measured time-averaged A-weighted emission sound
69
pressure level at the operator’s position is 2.5dB, in
accordance with ISO 11201.
q Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 1.0 dB.
1–5
SAFETY INFORMATION FOREWORD
VIBRATION LEVELS
q When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the
operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance
with ISO 7096
q For PC210-10, PC210LC-10
q The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s², the uncertainty for this
value is 0.53 m/s² according to EN12096:1997.
q The actual acceleration value for the body is less than or equal to 0.5 m/s², the uncertainty for this value is
0.28 m/s² according to EN12096:1997.
q These values were determined using a representative machine and measured during the typical operating
condition indicated below according to the measurement procedures that are defined in the standards ISO
2631/1 and ISO 5349.
q Operating condition:
q Excavating (Digging-loading-rotating-unloading-rotating)
q Guide to Reduce Vibration Levels on Machine
q The following guides can help an operator of this machine to reduce the whole body vibration levels:
q Use the correct equipment and attachments.
q Maintain the machine according to this manual
q Tension of crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
q Keep the terrain where the machine is working and travelling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain condi-
tions
q Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustment mechanisms
q Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly
q Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of travelling path as large as possible
q Travel at low speed when travelling around sharp curves
q Minimize vibrations for long work cycle or long distance travelling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
q The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good health.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads
1–6
FOREWORD INTRODUCTION
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
q Digging work
q Levelling work
q Ditching work
q Loading work
q Demolition work
q See the section RECOMMENDED APPLICATIONS (3-198) for further details.
DIRECTIONS OF MACHINE
(A) Front (D) Right

(B) Rear (E) Operator’s seat
(C) Left (F) Sprocket
In this manual, the terms front, rear, left and right refer to the travel direction as seen from the operator’s seat
when the operator’s seat is facing the front and the sprocket is at the rear of the machine.
OPERATOR PROTECTIVE STRUCTURE

This machine is ROPS compliant to ISO12117-2:2008 when a ROPS plate is installed - see Location of safety
labels (2-5) for location of ROPS plate.
VISIBILITY FOR OPERATOR

This machine complies with the visibility standard (ISO 5006).
This machine maintains a close visibility of a height of 1.5 m at a point 1 m away from the outside surface of the
machine and a visibility for a radius of 12m.
1–7
PRODUCT INFORMATION FOREWORD
PRODUCT INFORMATION
PRODUCT INFORMATION:ALL-0000-20EK00A
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN) / MACHINE SERIAL NO. PLATE

PRODUCT IDENTIFICATION NUMBER (PIN)?MACHINE SERIAL NO. PLATE:PC-0000-20RK00A
On the bottom right of the operator's cab

The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE

EPA regulations, engine number plate:PC220-0000-20SK00A
On the top of the engine cylinder head cover.
(The EPA auxiliary nameplate is on the top of the engine cylinder head cover).
EPA: Environmental Protection Agency, U.S.A.
1–8
FOREWORD PRODUCT INFORMATION
SERVICE METER LOCATION

Service meter location:PC-0000-20TK00A
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Your machine serial numbers and distributor:ALL-0000-20EK01A
Machine serial No.
Engine serial No.

Product identification
number (PIN)
Manufacturers name: KOMATSU UK Ltd.
Address: Durham Road
Birtley
Chester-Le-Street
County Durham DH3 2QX
United Kingdom
Distributor name:
Address:
Service Personnel
Phone/Fax
1–9
SERIAL PLATE
B C
D E
F
A MACHINE DESIGNATION TYPE E ENGINE POWER

B SERIAL F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
D WEIGHT
1–10
FOREWORD PRODUCT INFORMATION
DECLARATION OF CONFORMITY
The manufacturer:
KOMATSU UK Ltd
Durham Road
Birtley
Chester-Le-Street
County Durham DH3 2QX
Declares that this machine:

PC210-10, PC210LC-10
Fulfils all the relevant provisions of the following EC Directives.

Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC
1–11
1–12
CONTENTS
CONTENTS
FOREWORD........................................................................................................................................ 1-1
FOREWORD................................................................................................................................... 1-2
SAFETY INFORMATION................................................................................................................ 1-3
NOISE (PC210-10, PC210LC-10) ............................................................................................. 1-5
INTRODUCTION ............................................................................................................................ 1-7
DIRECTIONS OF MACHINE ..................................................................................................... 1-7
OPERATOR PROTECTIVE STRUCTURE ............................................................................... 1-7
VISIBILITY FOR OPERATOR ................................................................................................... 1-7
PRODUCT INFORMATION ............................................................................................................ 1-8
PRODUCT IDENTIFICATION NUMBER (PIN) / MACHINE SERIAL NO. PLATE .................... 1-8
EPA REGULATIONS, ENGINE NUMBER PLATE .................................................................... 1-8
SERVICE METER LOCATION .................................................................................................. 1-9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR .................................................... 1-9
SERIAL PLATE........................................................................................................................ 1-10
CONTENTS .................................................................................................................................. 1-13
SAFETY ............................................................................................................................................... 2-1
SAFETY .......................................................................................................................................... 2-2
SAFETY LABELS ........................................................................................................................... 2-4
LOCATION OF SAFETY LABELS............................................................................................. 2-5
SAFETY LABELS ...................................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................ 2-15
PRECAUTIONS BEFORE STARTING OPERATION.............................................................. 2-15
PREPARATIONS FOR SAFE OPERATION ........................................................................... 2-16
FIRE PREVENTION ................................................................................................................ 2-18
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ................................................... 2-20
DO NOT GET CAUGHT IN WORK EQUIPMENT ................................................................... 2-22
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.............................................. 2-22
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS ........................... 2-23
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES .................................. 2-23
UNAUTHORIZED MODIFICATION ......................................................................................... 2-23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ......................................... 2-24
PRECAUTIONS RELATED TO CAB GLASS.......................................................................... 2-24
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ........................................... 2-24
PRECAUTIONS FOR OPERATION ............................................................................................. 2-25
PRECAUTIONS FOR JOBSITE .............................................................................................. 2-25
SAFETY MACHINE OPERATION ................................................................................................ 2-28
STARTING ENGINE................................................................................................................ 2-28
WHEN OPERATING................................................................................................................ 2-31
TRANSPORTATION................................................................................................................ 2-38
TOWING .................................................................................................................................. 2-39
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) ..... 2-40
SAFETY RULES FOR LIFTING OBJECTS............................................................................. 2-40
PRECAUTIONS FOR MAINTENANCE ........................................................................................ 2-43
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ......................... 2-43
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ................................................... 2-47
OPERATION........................................................................................................................................ 3-1
GENERAL VIEW............................................................................................................................. 3-2
GENERAL VIEW OF MACHINE................................................................................................ 3-2
GENERAL VIEW OF CAB ......................................................................................................... 3-4
GENERAL VIEW OF CONTROLS AND GAUGES ................................................................... 3-6
EXPLANATION OF COMPONENTS .............................................................................................. 3-9
MACHINE MONITOR ................................................................................................................ 3-9
SWITCHES.............................................................................................................................. 3-76
CONTROL LEVERS AND PEDALS ........................................................................................ 3-85
CEILING WINDOW.................................................................................................................. 3-87
OPENING AND CLOSING CAB FRONT WINDOW................................................................ 3-88
EMERGENCY ESCAPE HAMMER ......................................................................................... 3-93
1–13
CONTENTS
DOOR LOCK ........................................................................................................................... 3-94

CAB DOOR HINGE ................................................................................................................. 3-94
OPENING AND CLOSING ENGINE HOOD............................................................................ 3-95
CAPS AND COVERS WITH LOCK ......................................................................................... 3-99
DRINK BOX ........................................................................................................................... 3-102
MAGAZINE BOX ................................................................................................................... 3-102
CUP HOLDER ....................................................................................................................... 3-102
ASHTRAY.............................................................................................................................. 3-103
HANDLING AIR CONDITIONER ........................................................................................... 3-104
HANDLING RADIO................................................................................................................ 3-116
SPACE FOR RADIO CASSETTE.......................................................................................... 3-120
AUXILIARY ELECTRIC POWER........................................................................................... 3-121
FUSE ..................................................................................................................................... 3-122
FUSIBLE LINK....................................................................................................................... 3-124
CONTROLLER ...................................................................................................................... 3-125
TOOL BOX ............................................................................................................................ 3-125
GREASE PUMP HOLDER .................................................................................................... 3-126
FIRE EXTINGUISHER........................................................................................................... 3-126
BATTERY DISCONNECT SWITCH ...................................................................................... 3-127
SYSTEM OPERATING LAMP ............................................................................................... 3-128
HANDLING KDPF.................................................................................................................. 3-129
HANDLING KCCV ................................................................................................................. 3-138
HANDLING MACHINES EQUIPPED WITH KOMTRAX........................................................ 3-139
MACHINE OPERATIONS AND CONTROLS ............................................................................. 3-141
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ............................................ 3-141
STARTING ENGINE.............................................................................................................. 3-163
OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................ 3-166
STOPPING ENGINE ............................................................................................................. 3-177
MACHINE OPERATION ........................................................................................................ 3-178
STEERING MACHINE........................................................................................................... 3-182
SWINGING MACHINE........................................................................................................... 3-184
WORK EQUIPMENT CONTROLS AND OPERATIONS ....................................................... 3-185
WORKING MODE ................................................................................................................. 3-187
PROHIBITED OPERATIONS ................................................................................................ 3-190
RULES FOR OPERATION .................................................................................................... 3-193
TRAVELLING ON SLOPES................................................................................................... 3-195
ESCAPE FROM MUD ........................................................................................................... 3-197
RECOMMENDED APPLICATIONS....................................................................................... 3-198
REPLACING AND INVERTING BUCKET ............................................................................. 3-200
WHEN PARKING MACHINE ................................................................................................. 3-204
AFTER DAILY WORK COMPLETION................................................................................... 3-206
LOCKING............................................................................................................................... 3-206
TRANSPORTATION................................................................................................................... 3-207
TRANSPORTATION PROCEDURE...................................................................................... 3-207
LOADING AND UNLOADING WITH TRAILER ..................................................................... 3-208
LIFTING MACHINE ............................................................................................................... 3-223
COLD WEATHER OPERATION................................................................................................. 3-225
COLD WEATHER OPERATION INFORMATION ................................................................. 3-225
AFTER DAILY WORK COMPLETION................................................................................... 3-226
AFTER COLD WEATHER SEASON ..................................................................................... 3-226
LONG-TERM STORAGE............................................................................................................ 3-227
BEFORE STORAGE ............................................................................................................. 3-227
DURING STORAGE .............................................................................................................. 3-227
AFTER STORAGE ................................................................................................................ 3-228
STARTING MACHINE AFTER LONG-TERM STORAGE ..................................................... 3-228
TROUBLES AND ACTIONS ....................................................................................................... 3-229
RUNNING OUT OF FUEL ..................................................................................................... 3-229
PHENOMENA THAT ARE NOT FAILURES.......................................................................... 3-229
1–14
CONTENTS
TOWING MACHINE .............................................................................................................. 3-230

LIGHTWEIGHT TOWING HOLE ........................................................................................... 3-231
SEVERE JOB CONDITION ................................................................................................... 3-231
DISCHARGED BATTERY ..................................................................................................... 3-232
OTHER TROUBLE ................................................................................................................ 3-236
MAINTENANCE................................................................................................................................... 4-1
RULES FOR MAINTENANCE ........................................................................................................ 4-2
SERVICE METER READING .................................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS....................................................................... 4-2
KOMATSU GENUINE LUBRICANTS........................................................................................ 4-2
ALWAYS USE CLEAN WASHER FLUID .................................................................................. 4-2
FRESH AND CLEAN LUBRICANTS ......................................................................................... 4-2
CHECK DRAINED OIL AND USED FILTER ............................................................................. 4-2
FUEL STRAINER ...................................................................................................................... 4-2
WELDING INSTRUCTIONS ...................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ............................................................................ 4-2
DUSTY WORKSITES ................................................................................................................ 4-3
AVOID MIXING OIL ................................................................................................................... 4-3
LOCKING INSPECTION COVERS ........................................................................................... 4-3
BLEEDING AIR FROM HYDRAULIC CIRCUIT......................................................................... 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ................................................... 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE ............................................................ 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ................................ 4-3
CLOSE ENGINE HOOD SECURELY........................................................................................ 4-3
OUTLINE OF SERVICE.................................................................................................................. 4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................... 4-4
HANDLING ELECTRICAL COMPONENTS .............................................................................. 4-7
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.................................................... 4-8
TIGHTENING TORQUE LIST.................................................................................................... 4-8
MAINTENANCE SCHEDULE ......................................................................................................... 4-9
MAINTENANCE SCHEDULE TABLE........................................................................................ 4-9
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER ................................................... 4-11
MAINTENANCE SCHEDULE TABLE........................................................................................... 4-12
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .................. 4-12
WHEN REQUIRED.................................................................................................................. 4-12
CHECKS BEFORE STARTING............................................................................................... 4-39
EVERY 100 HOURS MAINTENANCE .................................................................................... 4-40
EVERY 1000 HOURS MAINTENANCE .................................................................................. 4-59
END OF SERVICE LIFE ............................................................................................................... 4-81
SPECIFICATIONS ............................................................................................................................... 5-1
SPECIFICATIONS .......................................................................................................................... 5-2
EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC-10
1-PIECE BOOM......................................................................................................................... 5-4
ATTACHMENTS AND OPTIONS ........................................................................................................ 6-1
GENERAL PRECAUTIONS FOR SAFETY .................................................................................... 6-2
PRECAUTIONS WHEN SELECTING ....................................................................................... 6-2
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY ............................ 6-2
PRECAUTIONS WHEN REMOVING OR INSTALLING............................................................ 6-2
PRECAUTIONS WHEN USING ................................................................................................ 6-2
HANDLING QUICK COUPLER....................................................................................................... 6-4
AUTOMATIC GREASE SYSTEM ................................................................................................... 6-7
1–15
CONTENTS
CHECK AUTO-GREASING SYSTEM ..................................................................................... 6-10

BUCKET WITH HOOK.................................................................................................................. 6-13
HOOK CONDITION ................................................................................................................. 6-13
PROHIBITED OPERATIONS .................................................................................................. 6-13
MACHINE READY FOR INSTALLATION OF ATTACHMENT ..................................................... 6-14
EXPLANATION OF COMPONENTS....................................................................................... 6-14
HYDRAULIC CIRCUIT ............................................................................................................ 6-18
REMOVAL AND INSTALLATION OF ATTACHMENT ............................................................ 6-25
ATTACHMENT OPERATIONS................................................................................................ 6-28
LONG-TERM STORAGE......................................................................................................... 6-31
SPECIFICATIONS................................................................................................................... 6-32
ARM/PIN INFORMATION........................................................................................................ 6-32
ATTACHMENTS AND OPTIONS ................................................................................................. 6-33
ATTACHMENT COMBINATIONS ........................................................................................... 6-33
TRACK SHOES SELECTION.................................................................................................. 6-34
BUCKET TEETH SELECTION ................................................................................................ 6-35
HANDLING OF RUBBER PAD SHOE AND ROAD LINER ..................................................... 6-36
HANDLING TRAPEZOIDAL BUCKET..................................................................................... 6-38
HANDLING EXTENSION ARM ............................................................................................... 6-40
HANDLING CLAMSHELL BUCKET ........................................................................................ 6-41
RECOMMENDED ATTACHMENT OPERATIONS....................................................................... 6-42
HYDRAULIC BREAKER.......................................................................................................... 6-42
REPLACEMENT PARTS ..................................................................................................................... 7-1
SAFETY CRITICAL PARTS............................................................................................................ 7-2
SAFETY CRITICAL PARTS LIST.............................................................................................. 7-2
CONSUMABLE PARTS.................................................................................................................. 7-3
CONSUMABLE PARTS LIST .................................................................................................... 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .............................................................. 7-4
LUBRICATION CHART ............................................................................................................. 7-5
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE............ 7-7
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER
THAN KOMATSU GENUINE OIL .............................................................................................. 7-8
INDEX .................................................................................................................................................. 8-1
1–16
SAFETY
SAFETY
SAFETY:ALL-0000-001K01A
SAFETY
k WARNING
Please read and make sure that you fully understand the pre-
cautions described in this manual and the safety labels on the
machine. When operating or servicing the machine, always fol-
low these precautions strictly.
2–1
SAFETY SAFETY
SAFETY
Safety:PC220-1210-002A00A
SAFETY................................................................................................................................................. 2-2
SAFETY LABELS .................................................................................................................................. 2-4
LOCATION OF SAFETY LABELS ................................................................................................... 2-5
SAFETY LABELS............................................................................................................................. 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ................................. 2-15
PRECAUTIONS BEFORE STARTING OPERATION ...................................................................... 2-15
ENSURING SAFE OPERATION ................................................................................................ 2-15
UNDERSTANDING THE MACHINE........................................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION .................................................................................... 2-16
SAFETY-RELATED EQUIPMENT.............................................................................................. 2-16
INSPECTING MACHINE ............................................................................................................ 2-16
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ...................................... 2-16
KEEP MACHINE CLEAN............................................................................................................ 2-16
INSIDE OPERATOR’S COMPARTMENT .................................................................................. 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ............................................................. 2-17
IF ANY PROBLEM IS FOUND.................................................................................................... 2-17
FIRE PREVENTION......................................................................................................................... 2-18
ACTION IF FIRE OCCURS ........................................................................................................ 2-18
PREVENT FIRE.......................................................................................................................... 2-18
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ............................................................ 2-20
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE .............................. 2-20
NO JUMPING ON OR OFF MACHINE ....................................................................................... 2-20
LIFTING OF PERSONNEL PROHIBITED .................................................................................. 2-20
NO PEOPLE ON ATTACHMENTS............................................................................................. 2-20
WHEN STANDING UP FROM OPERATOR’S SEAT ................................................................. 2-21
WHEN LEAVING MACHINE....................................................................................................... 2-21
EMERGENCY EXIT FROM OPERATOR’S CAB ....................................................................... 2-21
ELECTROMAGNETIC INTERFERENCE ................................................................................... 2-21
DO NOT GET CAUGHT IN WORK EQUIPMENT............................................................................ 2-22
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ...................................................... 2-22
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS .................................... 2-23
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES .......................................... 2-23
UNAUTHORIZED MODIFICATION.................................................................................................. 2-23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................. 2-24
PRECAUTIONS RELATED TO CAB GLASS .................................................................................. 2-24
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING .................................................... 2-24
PRECAUTIONS FOR OPERATION ...................................................................................................... 2-25
PRECAUTIONS FOR JOBSITE....................................................................................................... 2-25
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS .......................................................... 2-25
WORK ON LOOSE GROUND .................................................................................................... 2-25
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................................. 2-26
ENSURE GOOD VISIBILITY ...................................................................................................... 2-26
CHECK SIGNS AND SIGNALMAN’S SIGNALS......................................................................... 2-27
BEWARE OF ASBESTOS DUST ............................................................................................... 2-27
SAFETY MACHINE OPERATION ......................................................................................................... 2-28
STARTING ENGINE ........................................................................................................................ 2-28
USE WARNING TAGS ............................................................................................................... 2-28
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ................................................. 2-28
WHEN STARTING ENGINE ....................................................................................................... 2-29
IN COLD AREAS ........................................................................................................................ 2-29
START ENGINE WITH BOOSTER CABLES ............................................................................. 2-30
WHEN OPERATING ........................................................................................................................ 2-31
CHECKS BEFORE OPERATION ............................................................................................... 2-31
WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING....................................... 2-31
WHEN TRAVELLING.................................................................................................................. 2-32
WHEN TRAVELLING ON SLOPES............................................................................................ 2-32
2–2
SAFETY SAFETY
WHEN OPERATING ON SLOPES ............................................................................................. 2-34

PROHIBITED OPERATIONS ..................................................................................................... 2-34
WHEN OPERATING ON SNOW OR FROZEN SURFACES ..................................................... 2-36
WHEN PARKING MACHINE ...................................................................................................... 2-36
TRANSPORTATION ........................................................................................................................ 2-38
SAFETY RULES FOR LOADING AND UNLOADING ................................................................ 2-38
SHIPPING THE MACHINE ......................................................................................................... 2-38
TOWING........................................................................................................................................... 2-39
SAFETY RULES FOR TOWING................................................................................................. 2-39
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) .............. 2-40
SAFETY RULES FOR LIFTING OBJECTS ..................................................................................... 2-40
SAFETY RULES FOR LIFTING OBJECTS ................................................................................ 2-42
PRECAUTIONS FOR MAINTENANCE ................................................................................................. 2-43
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE.................................. 2-43
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ................................ 2-43
KEEP WORKPLACE CLEAN AND TIDY.................................................................................... 2-43
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE ................................... 2-43
ONLY AUTHORIZED PERSONNEL........................................................................................... 2-43
STABILITY .................................................................................................................................. 2-43
GUARDS..................................................................................................................................... 2-43
END OF SERVICE LIFE ............................................................................................................. 2-43
APPOINT LEADER WHEN WORKING WITH OTHERS ............................................................ 2-44
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE .................... 2-44
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ................................... 2-45
INSTALLING, REMOVING, OR STORING ATTACHMENTS..................................................... 2-45
WORK AT HIGH PLACES .......................................................................................................... 2-45
WORK ON MACHINE................................................................................................................. 2-46
WORK UNDER MACHINE OR WORK EQUIPMENT ................................................................ 2-46
PROPER TOOLS........................................................................................................................ 2-46
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ............................................................ 2-47
TURN OFF THE BATTERY DISCONNECT SWITCH ................................................................ 2-47
WELDING INSTRUCTIONS ....................................................................................................... 2-47
BATTERY ................................................................................................................................... 2-47
WHEN USING HAMMER............................................................................................................ 2-48
HIGH-TEMPERATURE COOLANT ............................................................................................ 2-48
HIGH-TEMPERATURE PARTS.................................................................................................. 2-48
HIGH-TEMPERATURE OIL........................................................................................................ 2-48
HIGH-PRESSURE OIL ............................................................................................................... 2-49
HIGH-PRESSURE FUEL............................................................................................................ 2-49
HIGH-PRESSURE HOSES AND PIPING................................................................................... 2-49
HIGH VOLTAGE ......................................................................................................................... 2-49
NOISE......................................................................................................................................... 2-50
HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION ...................................... 2-50
DO NOT DISASSEMBLE RECOIL SPRING .............................................................................. 2-50
ACCUMULATOR AND GAS SPRING ........................................................................................ 2-50
COMPRESSED AIR ................................................................................................................... 2-51
MAINTENANCE OF AIR CONDITIONER................................................................................... 2-51
CHEMICAL HAZARD.................................................................................................................. 2-51
DISPOSE OF WASTE MATERIALS........................................................................................... 2-51
SELECT WINDOW WASHER FLUID ......................................................................................... 2-51
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................................................... 2-52
2–3
SAFETY LABELS SAFETY
SAFETY LABELS
SAFETY LABELS:ALL-Q5L0-043K00A
The following warning signs and safety labels are used on this machine.
q Be sure that you fully understand the correct position and content of labels.
q To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or petrol. These may cause the labels to
peel off.
q There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
q 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.
2–4
SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS

Location of safety labels:PC220_KU-Q5L0-04DK00A
b e c d h
f g
KS000651
a: if equipped
2–5
SAFETY LABELS
SAFETY LABELS:PC220_KU-Q5L1-012K00A
(1) (20Y-00–K2021)
q Warnings for operation, inspection and maintenance.
q Improper operation and maintenance can cause serious
injury or death.
q Read the manual and labels before operation and mainte-
nance.
Follow instructions and warnings in manual and in labels on
machine.
q Warning!
q a. Read the manual before operating, maintenance, disas-

sembly, assembly and transportation.
q b. Before standing up from operator’s seat.
q Lower work equipment to ground and move safety lock

lever (located near seat) to lock position to avoid hitting
unlocked operation levers.
q Sudden and unwanted machine movement can cause seri-

ous injury or death.
2–6
q c. WARNING — No passengers
No passengers allowed to ride on machine while it is
moving.
q d. WARNING — DANGER OF FALLING OBJECTS

Do not operate where a danger of falling objects exists.
Consult your dealer for fitting of FOPS protection.
q e. Caution for going close to electric cables.
q An electrocution hazard if the machine is brought too near

to electric power lines.
q Keep a safe distance from electric power lines.
q f. Control levers operational function diagram.
k WARNING
q In order to prevent an accident resulting in injury or
death caused by error-operation, confirm the machine
motion and indicated operating pattern, when operat-
ing machines. Pay attention to the circumference and
operate slowly when confirming the machine motion.
2–7
q g. Caution when standing in operator cab
q Before standing up from the operator’s seat (such as when

opening or closing the front window or roof window, or when
removing or installing the bottom window, or when adjusting
the operator’s seat), always lower the work equipment com-
pletely to the ground, set lock lever (1) securely to the
LOCK position (L), then stop the engine. If you accidentally
touch the control levers (pedals) when they are not locked,
there is a hazard that the machine may suddenly move and
cause serious injury or property damage.
q (h) Caution when reversing
To prevent SEVERE INJURY or DEATH, do the following

before moving machine or its attachments:
q Sound horn to alert people nearby.
Be sure no one is on or near machine or in swing area.
Rotate cab for full view of travel path if it can be done safely.
Use spotter if view is obstructed.
Follow the above even if machine is equipped with travel alarm,

mirrors and rear view camera.
2–8
k WARNING
To open or close the front or ceiling windows, never stand up from the operator’s seat before throwing
the safety lock lever to the LOCK position.
Inadvertently touching any of the working equipment control levers might cause the machine to start
moving all of a sudden, probably resulting in a serious injury.
(2) Caution when stowing front window (09803-A0481)
q Sign indicates a hazard from falling window.
q After raising window, be sure to lock it in place with lock

pins.
(3) Caution for high-temperature coolant and hydraulic oil

(09653-A0481)
q Never remove the cap when the engine is at operating

(high) temperature. Steam or high temperature oil blowing
up from the radiator or hydraulic tank, will cause personal
injury and/or burns.
q Never remove the radiator cap or hydraulic tank oil filler

when cooling water or hydraulic oil is at high temperature.
(4) Caution for handling accumulator and gas spring

(09659-A057B)
q There is a hazard of explosion causing injury.
q Do not disassemble the accumulator, make holes in it, weld

it, cut it, hit it, roll it or bring it near flame.
2–9
(5) Caution when adjusting track tension (09657-A0881)
q Sign indicates a hazard of flying plug from track adjuster

that could cause injury.
q Read manual regarding adjusting track for safe and proper
handling.
(6) Caution when handling cable (09808-A0881)
q Sign indicates an electric hazard from handling the cable.

q Read manual for safe and proper handling.
(7) Stopping rotation for inspection and maintenance (09667-

A0481)
q Sign indicates a hazard of rotating parts, such as belt.

q Turn off before inspection and maintenance.
(8) Emergency escape (09844-00050)
2–10
(9) Caution against falling (09805-C0481)
q Sign indicates a hazard of falling.
q Do not stand on this place here
(10) Prohibited to enter swing radius (09133-A3281)
q There is a danger of getting caught when upper structure

swings.
q Do not enter range of swing
(11) Keeping out of working range area (09134-A1681)
q Sign indicates a hazard of being hit by the working device of

the machine.
q Keep away from the machine during operation.
2–11
(12) Prohibition of jump start (09842-A0481)
q Start the engine only after sitting down in the operator’s

seat.
Do not attempt to start the engine by short-circuiting the engine
starting circuit. Such an act may cause a serious bodily injury
or fire.
(13) Caution for use of hydraulic quick coupler piping system

(20J-00–11271)
q There is a danger of an exposed person being killed by fall-
ing attachment.
q Read the manual for safe operation.
(14) Caution when swinging or travelling in reverse

(09833-A0881)
k WARNING
q When swinging or backing up excavator, press button
to change display mode on monitor so you can see rear
and side of machine.
Before moving, look around and at mirror and monitor
to confirm that no one is around the machine. Failure to
do so can result in serious injury or death.
(15) Caution when handling batteries (09664-60001)
(a) Never smoke or use any naked flame near the batteries, no
sparks.
2–12
(b) Always wear safety glasses when working with batteries.
(c) Keep children away from batteries.
(d) Caution battery acid.
(e) Read the operator’s manual before working with batteries.
(f) Caution - explosive gases.
(16) Caution when replacing fresh air filter (208-00-71261)
q After replacing fresh air filter remember to remove key from

cover as the key may get damaged when cab door is
opened.
(17) (Where fitted) Warning of an explosion hazard caused by

active radio transmitter at a blast zone (09845-00480)
q Keep machine at a safe distance from blast zone and a det-

onator.
2–13
(18) Caution for high-pressure fuel (6271-81-2980)
(19) Caution for high temperature (09817-A0753)
(20) Caution for machine with ROPS (09620-J2000, 09620-

A3000)
q If any modification is applied to the ROPS, it may affect the

strength and may not comply with the standard.
Consult your Komatsu Distributor before altering.
q ROPS may provide less protection if it has been structurally
damaged or involved in roll-over.
q Always wear seat belt when moving
(21) Overload caution
q Do not exceed the safe working loads.
2–14
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
GENERAL PRECAUTIONS COMMON TO OPERATION AND

MAINTENANCE
General precautions common to operation and maintenance:ALL-1130-010A00A
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying
out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully
and obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION

Precautions before starting operation:ALL-0000-001K07A
ENSURING SAFE OPERATION

Ensuring safe operation:ALL-0000-177K00A
q Only trained and authorized personnel can operate and maintain the machine.
q Follow all safety, precautions, and instructions in this manual when operating or performing inspection or
maintenance on the machine.
q If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely oper-
ate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in
danger.
q When working with another operator or with the person on the worksite traffic duty, discuss the content of the
operation beforehand and use the determined signals when carrying out the operation.
UNDERSTANDING THE MACHINE

Understanding the machine:ALL-0000-178K00A
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
2–15
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY
PREPARATIONS FOR SAFE OPERATION

Preparations for safe operation:ALL-0000-001K08A
SAFETY-RELATED EQUIPMENT
Safety-related equipment:ALL-0000-127K00A
q Be sure that all guards, covers, cameras, and mirrors are in their proper position. Have them repaired immedi-
ately if they are damaged.
q Understand the method of use of safety features and use them properly.
q Never remove any safety features. Always keep them in good operating condition.
INSPECTING MACHINE
Inspecting machine:ALL-0000-128K00A
Check the machine before starting operations. If any abnormality is found, do not operate the machine until
repairs of the problem location have been completed.
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

Wear well-fitting clothes and protective equipment:ALL-0000-129K00A
q Do not wear loose clothes or any accessories. If these

catch on the control levers or protruding parts, there is dan-
ger that it may cause the machine to move unexpectedly.
q Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear protective eyeglasses, mask,
gloves, ear plugs, and safety belt when operating or main-
taining the machine.
q If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
q Check that all protective equipment functions properly
before using it.
KEEP MACHINE CLEAN
Keep machine clean:ALL-0000-12AK00A
q If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or
oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the
machine clean.
q If water gets into the electrical system, there is a hazard
that it will cause malfunctions or misoperation. If there is
any misoperation, there is danger that the machine may
move unexpectedly and cause serious personal injury or
death. When washing the machine with water or steam, do
not allow the water or steam to come into direct contact with
electrical components.
q When washing the machine with high-pressure water, direct
spray onto camera may cause trouble. Defective camera
cannot monitor surrounding area. When cleaning camera,
do not allow the high-pressure water to get into camera
directly, and wipe off any dirt with soft cloth.
q When cleaning camera, if you stand on an unstable place,
or take an unstable posture, you may fall and be injured.
Put proper stepladder or step on the level and firm ground,
and clean the camera in secure posture.
INSIDE OPERATOR’S COMPARTMENT
Inside operator’s compartment:ALL-0000-12BK00A
q When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
q Do not leave tools or a machine parts lying around inside the operator's compartment. If tools or parts get into
the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in seri-
ous personal injury or death.
q Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
q Do not use a cellular phone when driving or operating the machine. This may lead to mistakes in operation,
which could cause serious personal injury or death.
q Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
2–16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Provide fire extinguisher and first aid kit:ALL-Q5G5-012K00A
Always follow the precautions below to prepare for action if any injury or fire should occur.
q Be sure that fire extinguishers have been provided and read
the labels to ensure that you know how to use them in
emergencies.
q Carry out periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
q Provide a first aid kit in the storage point. Carry out periodic
checks and add to the contents if necessary.
IF ANY PROBLEM IS FOUND

If any problem is found:ALL-0000-12CK00A
If you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
2–17
FIRE PREVENTION
Fire prevention:ALL-0000-001K09A
ACTION IF FIRE OCCURS

Action if fire occurs:ALL-0000-17AK00A
q Turn the start switch OFF to stop the engine.

q Use the handrails and steps to get off the machine.
q Do not jump off the machine. There is the danger of falling and suffering serious injury.
PREVENT FIRE
PREVENT FIRE:ALL-0000-17BK00A
q Fire caused by fuel, oil, coolant, or window washer fluid

Do not bring any flame or fire close to flammable substances
such as fuel, oil, coolant, or window washer fluid. There is
danger that they may catch fire. To prevent fire, always
observe the following.
q Do not smoke or use any flame near fuel or other flam-
mable substances.
q Stop the engine before adding fuel.
q Do not leave the machine when adding fuel or oil.
q Tighten all fuel and oil caps securely.
q Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
q After adding fuel or oil, wipe up any spilled fuel or oil.
q Put greasy rags and other flammable materials into a
safe container to maintain safety at the workplace.
q When washing parts with oil, use a non-flammable oil.
Do not use diesel oil or gasoline. There is danger that
they may catch fire.
q Do not weld or use a cutting torch to cut any pipes or
tubes that contain flammable liquids.
q Determine well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the determined place and do not
allow unauthorized persons to enter.
q When carrying out grinding or welding work on the
machine, move any flammable materials to a safe place
before starting.
q Fire caused by accumulation of flammable material
q Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated
or affixed around the engine exhaust manifold, muffler or battery, or inside the undercovers.
q To prevent fires spreading from sparks or burning particles from other fires, remove any flammable materi-
als such as dry leaves, chips, coal dust, or any other flammable materials accumulated around the cooling
system (radiator, oil cooler) or inside the undercover.
q Fire coming from electric wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following.
q Keep all electric wiring connections clean and securely tightened.
q Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
q Fire coming from piping
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or
death.
2–18
q Fire around the machine due to highly heat exhaust gas

This machine is equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust gas. Its exhaust gas discharged during purification process
(regeneration) can be at higher temperature than that from existing models. Do not bring any flammable close
the outlet of the exhaust pipe.
q When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas.
For the setting procedure, see "Handling KDPF (3-129)".
q Explosion caused by lighting equipment
q When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
q When taking electrical power for the lighting from the machine itself, see "Auxiliary electric power (3-121)".
2–19
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

Precautions when getting on or off machine:ALL-0000-001K10A
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE

Use handrails and steps when getting on or off machine:PC-0000-17DK00A
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
q Use the handrails and steps marked by arrows in the dia-
gram on the right when getting on or off the machine.
q Do not climb on the step if it is damaged.
q Damaged steps must be repaired immediately.
Please call your Komatsu distributor and ask for repair or

replacement of the step.
q Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one
foot) with the handrail and steps to ensure that you support
yourself.
q Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on
them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.
q Do not grip the control levers or lock lever when getting on or off the machine.
q Never climb on the engine hood or covers where there are no non-slip pads.
q Do not get on or off the machine while holding tools in your hand.
q The collapsible type side mirror can turn, so do not grab hold of it as a handrail.
NO JUMPING ON OR OFF MACHINE

No jumping on or off machine:ALL-0000-17EK00A
Getting on or off the moving machine can cause serious personal injury. Always observe the following.
q Never jump on or off the machine. Never get on or off a moving machine.
q 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.
LIFTING OF PERSONNEL PROHIBITED

Under no circumstances should this machine be used for the lifting of personnel.
NO PEOPLE ON ATTACHMENTS
No people on attachments:ALL-0000-17FK00A
Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering seri-
ous personal injury or death.
2–20
WHEN STANDING UP FROM OPERATOR’S SEAT

When standing up from operator’s seat:PC-0000-17GK00A
Before standing up from the operator's seat, such as when

opening or closing the front window or ceiling window, when
removing or installing the bottom window, or adjusting the posi-
tion of the seat, always lower the work equipment completely to
the ground, set lock lever (1) to lock position (L), and stop the
engine.
If the control levers are touched by mistake, the machine may
suddenly move and cause serious personal injury or death.
WHEN LEAVING MACHINE

WHEN LEAVING MACHINE:PC-0000-17HK00A
If the proper procedures are not taken when parking the

machine, the machine may suddenly move off by itself, and this
may lead to serious personal injury or death. For this reason,
always observe the following.
q When leaving the machine, always lower the work equip-
ment completely to the ground, set lock lever (1) to lock
position (L), and stop the engine. In addition, lock all parts,
always take the key with you and leave it in the specified
place.
EMERGENCY EXIT FROM OPERATOR’S CAB

Emergency exit from operator’s cab:PC-0000-17JK00A
q If it should be impossible to open the door of the cab, break the window glass with the hammer supplied and
use the window as an emergency escape.
For details, see "Emergency escape hammer (3-93)"in this volume.
q When escaping, remove all the pieces of glass from the window frame first and be careful not to cut yourself
on the glass. Be careful also not to slip on the broken pieces of glass on the ground.
ELECTROMAGNETIC INTERFERENCE
When this machine is operating close to a source of high electromagnetic interference, such as a radar station,
some abnormal phenomena may be observed.
q The display on the monitor panel may behave erratically.
q The warning buzzer may sound.
These effects do not signify a malfunction and the machine will return to normal as soon as the source of interfer-
ence is removed.
2–21
DO NOT GET CAUGHT IN WORK EQUIPMENT

DO NOT GET CAUGHT IN WORK EQUIPMENT:ALL-0000-17KK00A
The clearance in the area around the work equipment changes

according to the movement of the link. If you get caught, you
may suffer serious personal injury or death. Do not allow any-
one to come close to any rotating or extending/retracting por-
tion.
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

Precautions related to protective structures:ALL-K200-170K00A
The operator's compartment is equipped with a structure (such

as ROPS, OPG) to protect the operator by absorbing the
impact energy.
As for the machine equipped with ROPS, if the machine weight
(mass) exceeds the certified value (shown on the ROLL-OVER
PROTECTIVE STRUCTURE (ROPS) CERTIFICATION plate),
ROPS will not be able to fulfil its function. Do not increase
machine weight beyond the certified value by modifying the
machine or by installing attachments to the machine.
Also, if the function of the protective equipment is impeded, the
protective equipment will not be able to protect the operator,
and the operator may suffer injury or death. Always observe
the following.
q If the machine is equipped with a protective structure, do
not remove the protective structure and carry out operations
without it.
q If the protective structure is welded, or holes are drilled in it,
or it is modified in any other way, its strength may drop.
Consult your Komatsu distributor before carrying out any
modifications.
q If the protective structure is damaged or deformed by falling
objects or by rolling over, its strength will be reduced and it
will not be able to fulfil its function properly. In such cases,
always contact your Komatsu distributor for advice on the
method of repair.
q Even if the protective structure is installed, always fasten
your seat belt properly when operating the machine. If you
do not fasten your seat belt properly, it cannot display its
effect.
2–22
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS

Protection against falling, flying, or intruding objects:PC-K200-171K00A
On jobsites where there is a hazard that falling objects, flying

objects, or intruding objects may hit or enter the operator's cab,
consider the operating conditions and install the necessary
guards to protect the operator.
q When operating on jobsites, such as mines or quarries,
where there is a hazard of falling rocks, install FOPS and a
front guard, and always keep all the windows and doors
closed when operating. Additionally use a fully transparent
laminated coating sheet on the front glass. In addition,
always check that there is no one except the operator in the
surrounding area. They may be hit by falling objects or fly-
ing objects.
q When carrying out demolition or breaker operations, install
a front guard and always keep all the windows closed when
operating. In addition, always check that there is no one
except the operator in the surrounding area. They may be
hit by falling objects or flying objects.
Above precautions are developed for the standard worksite.
Depending on the conditions of the given worksite, installation
of additional guards will become necessary.
In such a case, do not operate the machine without an addi-
tional guard. Be sure to consult with your Komatsu distributor
about necessary guards.
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES
Unauthorized modification:ALL-0000-17MK00A
The following components comprise the machine safety structure that can prevent injury to the operator from
falling objects, flying objects and intruding objects as detailed in the previous section.
q Operator cabin
q FOPS (falling object protective structure).
q Front window guard
In the event any of the above parts become broken or damaged such that their function would be impaired, they
must be replaced with genuine Komatsu replacement parts.
No attempt should be made to repair these parts as this may have an adverse effect on component strength or
durability.
If such a repair is undertaken without authorisation from Komatsu there is a danger that a problem might occur
that will lead to serious personal injury.
If in doubt please contact your Komatsu distributor.
Komatsu can not take any responsibility for accidents, failures or damage caused by unauthorized repair to the
above mentioned components.
UNAUTHORIZED MODIFICATION
Unauthorized modification:ALL-0000-17MK00A
q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result-
ing from modifications made without authorization from Komatsu.
q Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
2–23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

Precautions related to attachments and options:ALL-RA17-170K03A
q Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized
attachments or parts will not be the responsibility of Komatsu.
q When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-
fore contact your Komatsu distributor for advice.
q The machine weight will not exceed the ROPS certified value as long as the optional attachments written in
the attachment combination table of this manual are installed. When installing optional attachments other than
written in this manual, their weight may exceed the certified value, so please contact your Komatsu distributor
before installing.
q Depending on type of combination of optional attachments, there is hazard that the work equipment may hit
the cab or other parts of the machine. During operation, an interference of an optional attachment with the
machine may cause a serious personal injury. Before using unfamiliar attachment, check there is hazard of
interference, and operate within not contact.
q When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.
PRECAUTIONS RELATED TO CAB GLASS

PRECAUTIONS RELATED TO CAB GLASS:ALL-K183-012K00A
q If the cab glass is broken during operations, stop operations and repair the cab glass immediately.
q If the cab glass on the work equipment side is broken, there is a hazard that the operator may be directly hit or
caught in the work equipment. If the glass is broken, stop operations immediately and replace the glass.
q The ceiling window is made of plastic, so if it is scratched, the visibility will become poor and there is danger
that it may break. If it is scratched, replace it with the new part as soon as possible. If the window is scratched
and is not replaced, there is danger that any rocks falling on it will cause it to break, leading to injury to the
operator.
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING:ALL-0000-17NK00A
The engine exhaust gas contains substances that may damage

your health or even cause death. Start or operate the engine in
a place where there is good ventilation. If the engine or
machine must be operated inside a building or under ground,
where the ventilation is poor, take steps to ensure that the
engine exhaust gas is removed and that ample fresh air is
brought in.
2–24
SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR OPERATION

Precautions for operation:ALL-1140-001A00A
PRECAUTIONS FOR JOBSITE

Precautions for jobsite:PC-0000-001K08A
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

Investigate and confirm jobsite conditions:ALL-0000-17RK00A
On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm that there is no danger on the jobsite.
q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass,
there is a hazard of fire, so be careful when operating.
q Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not operate where there is a hazard of landslides or falling rocks.
q If water lines, gas lines, or high-voltage electrical lines may
be buried under the worksite, contact each utility and iden-
tify their locations. Be careful not to sever or damage any of
these lines.
q Take necessary measures to prevent any unauthorized per-
son from entering the operating area.
q In particular, if you need to operate on a road, protect
pedestrian and cars by designating a person for worksite
traffic duty or by installing fences around the worksite.
q When travelling or operating in water or on soft ground,
check the water depth, speed of the current, bedrock, and
shape of the ground beforehand and avoid any place that
will obstruct travel.
WORK ON LOOSE GROUND
Work on loose ground:ALL-0000-17SK00A
q Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
q When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
2–25
PRECAUTIONS FOR OPERATION SAFETY
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not go close to high-voltage cables:PC-0000-17TK00A
Do not travel or operate the machine near electric cables.

There is a hazard of electric shock, which may cause serious
personal injury or death. On jobsites where the machine may
go close to electric cables, always do as follows.
q 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.
q Even going close to high-voltage cables can cause electric Voltage of Cables Safety Distance
shock, which may cause serious burns or even death.
100 V – 200 V Over 2 m
Always maintain a safe distance (see the table on the right)
6,600 V Over 2 m
between the machine and the electric cable. Check with the
local power company about safe operating procedure 22,000 V Over 3 m
before starting operations. 66,000 V Over 4 m
q To prepare for any possible emergencies, wear rubber 154,000 V Over 5 m
shoes and gloves. Lay a rubber sheet on top of the seat, 187,000 V Over 6 m
and be careful not to touch the chassis with any exposed 275,000 V Over 7 m
part of your body. 500,000 V Over 11 m
q Use a signalman to give warning if the machine approaches
too close to the electric cables.
q When carrying out operations near high voltage cables, do
not let anyone near the machine.
q If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not
leave the operator's compartment until it has been con-
firmed that the electricity has been shut off. Also, do not let
anyone near the machine.
ENSURE GOOD VISIBILITY

Ensure good visibility:ALL-0000-17UK00A
This machine is equipped with mirrors and cameras to ensure good visibility, but even then there are places that
cannot be seen from the operator's seat, so be careful when operating.
Before travelling or operating the machine, the operator should sound the horn to warn people in the area.
When travelling or carrying out operations in places with poor visibility, it is impossible to check for obstacles in the
area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury
or death. When travelling or carrying out operations in places with poor visibility, always observe the following.
q Position a signalman if there are areas where the visibility is not good.
q Only one signalman should give signals.
q When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
q Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
q When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to ensure
good visibility.
q If the machine is equipped with cameras, clean off any dirt from the lens and make sure that the camera gives
a clear view. If there is any problem with the camera and the rear view cannot be displayed, contact your
Komatsu distributor immediately and ask for repairs to be carried out.
2–26
SAFETY PRECAUTIONS FOR OPERATION
CHECK SIGNS AND SIGNALMAN’S SIGNALS

Check signs and signalman’s signals:ALL-0000-17VK00A
If signals and labels are not clear, serious personal injury can result from downward slip, overturn or accidental
contact with nearby people or obstacles. Always observe the following.
q Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operator should pay careful attention to the signs and follow the instructions from the signalman.
q Only one signalman should give signals.
q Make sure that all workers understand the meaning of all signals and signs before starting work.
BEWARE OF ASBESTOS DUST

Beware of asbestos dust:ALL-0000-17WK00A
Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working
on jobsites handling demolition work or work handling industrial waste. Always observe the following.
q Spray water to keep down the dust.
q Do not use compressed air.
q If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position, and
make sure that all workers operate on the upwind side.
q All workers should use anti-dust masks.
q Do not allow other persons to approach during the opera-
tion.
q 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.
2–27
SAFETY MACHINE OPERATION SAFETY
SAFETY MACHINE OPERATION

STARTING ENGINE
Starting engine:ALL-0000-001K05A
USE WARNING TAGS

USE WARNING TAGS::PC220_KU-0000-17YK00A
If there is any "DANGER! Do NOT operate!" warning tag dis-

played, it means that someone is carrying out inspection and
maintenance of the machine. If the warning sign is ignored and
the machine is operated, there is danger that the person carry-
ing out inspection or maintenance may be caught in the rotat-
ing parts or moving parts and suffer serious personal injury or
death. Do not start the engine or touch the levers.
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

Checks and adjustment before starting engine::PC220_KU-0000-17ZK00A
Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly problems may occur
with the operation of the machine, and there is danger that this may lead to serious personal injury or death.
q Remove all dirt from the surface of the window glass to ensure a good view.
q Carry out the "WALK-AROUND CHECKS (3-141)".
q Remove all dirt from the surface of the lens of the front lamps and working lamps, and check that they light up
correctly.
q Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
q Check that there is no mud or dust accumulated around the movable parts of any pedals, and check that the
pedals work properly.
q Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.
q Check that the gauges work properly, check the angle of the mirror, and check that the control levers are all at
the NEUTRAL position.
2–28
SAFETY SAFETY MACHINE OPERATION
q Before starting the engine, check that lock lever (1) is in

LOCK position (L).
q Adjust the mirrors so that the rear of the machine can be
seen clearly from the operator's seat.
When adjusting, see "Mirrors adjustment (3-154)".
q Adjust the angle of each camera so that the surrounding
area can be seen clearly from the operator's seat.
When adjusting, see "ADJUST REAR VIEW CAMERA
ANGLE (3-157)".
q Adjust the armrest to a position for easier operation, and
then fix it securely. Operation in an improper position can
cause a serious personal injury.
When adjusting, see "SEAT ADJUSTMENT (3-153)".
q Check that there are no persons or obstacles above, below,
or in the area around the machine.
WHEN STARTING ENGINE
WHEN STARTING ENGINE:ALL-0000-181K00A
The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the
following.
q Start the engine only while sitting in the operator's seat.
q When starting the engine, sound the horn as a warning.
q Do not allow anyone apart from the operator to ride on the machine.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious
personal injury or death.
IN COLD AREAS
IN COLD AREAS:ALL-0000-182K00A
q If the warm-up operation is not carried out thoroughly, and the work equipment is operated, the reaction of the
work equipment to the operation of the control levers and pedals will be slow and the movement of it may not
be what the operator intended. Be sure to carry out the warm-up operation. Particularly in cold weather, be
sure to carry out the warm-up operation thoroughly.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
2–29
START ENGINE WITH BOOSTER CABLES

Start engine with booster cables:ALL-AW10-14JK00A
If any mistake is made in the method of connecting the booster

cables, it may cause the battery to explode, so always observe
the following.
q Always wear protective eyeglasses and rubber gloves when
starting the engine with booster cable.
q When connecting a normal machine to a problem machine
with booster cables, always use a normal machine with the
same battery voltage as the problem machine.
q 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).
q When starting from another machine, do not allow the two
machines to touch.
q When connecting the booster cables, turn the starting
switch and the battery disconnect switch of the failed
machine to OFF position.
For detail, see "BATTERY DISCONNECT SWITCH (3-
127)".
There is a hazard that the machine will move when the
power is connected.
q Be sure to connect the positive (+) cable first when install-
ing the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.
q When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch
the machine.
q For details of the starting procedure when using booster
cables, see "Start engine with booster cables (2-30)"in the
OPERATION section.
2–30
WHEN OPERATING
When operating:ALL-0000-001K11A
CHECKS BEFORE OPERATION

CHECKS BEFORE OPERATION:PC-0000-184K00A
If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful
attention to the surrounding area. Do not allow anyone near the machine.
q Always wear the seatbelt. There is danger that you may be
thrown out of the operator's seat and suffer serious injury
when the brakes are applied suddenly.
q Check that the movement of the machine matches the dis-
play on the control pattern card.
If it does not match, replace it immediately with the correct
control pattern card.
q Check the operating condition of the machine, work equip-
ment, and travel and swing systems.
q Check for any problem in the sound of the machine, vibra-
tion, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
q If any problem is found, carry out repairs immediately.
WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING
WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING:PC-0000-185K00A
q When travelling, drive with sprocket (1) at the rear of the

machine. If sprocket (1) is at the front, the operation of the
travel levers will be the opposite of the actual direction of
travel, so there is a hazard that the machine may travel in
an unexpected direction, leading to serious injury or death.
q Always lock all the door and windows of the operator's com-
partment in position (open or closed).
On jobsites where there is a hazard of flying objects or of
objects entering the operator's compartment, check that all
the door and windows are securely closed.
q Do not allow anyone apart from the operator to ride on the
machine.
q If there are any persons in the area around the machine,
there is danger that they may be hit or caught by the
machine, and this may lead to serious personal injury or
death. Before starting travel or swing, be sure to observe
the following items:
q Always operate the machine only when seated.
q Before starting to move, check again that there is no
person or obstacle in the surrounding area.
q Before starting to move, sound the horn to warn people
in the surrounding area.
q Check that the travel alarm and other alarms work prop-
erly.
q If there is an area to the rear of the machine that cannot
be seen, position a signalman. Be extremely careful not
to hit any person or object, and travel or swing slowly.
Always be sure to carry out the above precautions even when
the machine is equipped with mirrors and cameras.
2–31
WHEN TRAVELLING
WHEN TRAVELING:PC-0000-186K00A
Serious personal injury can result from tipping over of the travelling machine or its accidental contact. Always
observe the following.
q When travelling or carrying out operations, always keep a safe distance from people, structures, or other
machines to avoid coming into contact with them.
q When travelling on the level ground, keep the work equip-
ment approximately 40 to 50 cm above the ground. Other-
wise, the work equipment may contact to the ground and
the machine may be turned over.
q If the view to the right side is poor, raise the boom to ensure
better visibility.
q Always turn the auto-deceleration switch OFF when travel-
ling on rough ground or steep slopes. If the machine is
operated with the auto-deceleration system ON, the engine
speed will rise and the machine travel speed may suddenly
become faster.
q Avoid travelling over obstacles when possible. If the
machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
There is more danger of the machine tipping over to the left
or right than tipping over to the front or rear, so do not travel
over obstacles which make the machine tilt strongly to the
left or right sides.
q When travelling on rough ground, travel at low speed and
do not operate the steering suddenly. There is danger that
the machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance,
or may damage the machine or structures in the area.
q When using the machine, to prevent personal injury caused
by damage to the work equipment or by the machine over-
turning due to overloading, do not exceed the permitted
performance of the machine or the maximum permitted load
for the structure of the machine.
q When passing over bridges or structures, check first that the structure is strong enough to support the weight
of the machine.
q When operating in tunnels, under bridges, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the machine body or work equipment hit anything.
WHEN TRAVELLING ON SLOPES

When travelling on slopes:PC-0000-187K00A
To prevent the machine from tipping over or slipping to the side, always do as follows.
q Keep the work equipment approximately 20 to 30 cm
above the ground. In case of emergency, lower the work
equipment to the ground immediately to help stopping the
machine.
q When travel up slopes, set the operator's cab facing uphill,
when travel down slopes, set the operator's cab facing
downhill. Always check the firmness of the ground under
the front of the machine when travelling.
2–32
q When travelling up a steep slope, extend the work equip-

ment to the front to improve the balance, keep the work
equipment approximately 20 to 30 cm above the ground,
and travel at low speed.
q When travelling downhill, lower the engine speed, keep the travel lever close to the NEUTRAL position, and
travel at low speed.
q Always travel straight up or down a slope. Travelling at an
angle or across the slope is extremely dangerous.
q Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again.
q Do not travel on a slope covered with the steel plates. Even with slight slopes there is a hazard that the
machine may slip.
q Travel on grass or fallen leaves with low speed. Even with slight slopes there is a hazard that the machine may
slip.
q If the engine stops when the machine is travelling on a slope, move the control levers immediately to the NEU-
TRAL position, and lock lever to LOCK position and start the engine again.
2–33
WHEN OPERATING ON SLOPES

When operating on slopes:PC-0000-188K01A
q 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.
q Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
q If the machine has to be used on a slope, pile the soil to
make a platform (A) that will keep the machine as horizontal
as possible.
q Do not work on a slope covered with the steel plates. Even
with slight slopes there is a hazard that the machine may
slip.
PROHIBITED OPERATIONS
PROHIBITED OPERATIONS:PC-0000-189K00A
If the machine turns over or falls, or the ground at the working point collapses, or a structure being demolished
collapses, it may lead to serious personal injury or death. Always observe the following.
q Never dig the work face under an overhang. There is a haz-
ard that rocks may fall or that the overhang may collapse
and fall on top of the machine.
q Do not excavate too deeply under the front of the machine.

The ground under the machine may collapse and cause the
machine to fall.
q To make it easier to escape if there is any problem, set the

tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations.
2–34
q When carrying out demolition work, do not carry out demoli-

tion work under the front of the machine. This makes the
ground unstable, and there is a hazard of the machine fall-
ing.
q When carrying out demolition work, do not carry out demoli-

tion work above your head. There is a hazard of broken
parts falling or of the building collapsing and causing seri-
ous injury or death.
q When carrying out demolition work, do not use the impact

force of the work equipment for breaking work. There is a
hazard of damage to the work equipment and also a hazard
of serious personal injury or death being caused by flying
pieces of broken materials, or of the machine tipping over
due to reaction from the impact.
q Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other
hauling equipment. There is danger that the load may spill or the bucket may hit the dump truck and cause
serious personal injury or death.
q When working on or from the top of buildings or other structures, check the strength and the structure before
starting operations. There is a hazard of the building collapsing and causing serious injury or damage.
q Generally speaking, the machine is more liable to overturn when the work equipment is at the side than when
it is at the front or rear of the machine.
Be extremely careful when swinging the work equipment from the front or rear to the side of machine while it is
applied a load. There is danger that the machine may turn over.
q When using a breaker or other heavy work equipment, there is a hazard of the machine losing its balance and
turning over. When operating on flat ground as well as on slopes, observe the following.
q Do not suddenly lower, swing, or stop the work equipment.
q Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the machine
to turn over.
2–35
q In the operation using the fork or grapple, do not attempt to

pick up an object with their tips.
There is a danger of damage to the machine or personal
injury, as the picked - up object can easily slip off.
WHEN OPERATING ON SNOW OR FROZEN SURFACES

When operating on snow or frozen surfaces:PC-0000-18AK00A
q Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling 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.
q With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to turn over or make it impossible for the machine to escape.
q If the machine enters deep snow, there is a hazard that it may turn over or become buried in the snow. Be
careful not to leave the road shoulder or to get trapped in a snow drift.
q When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine turning over or hitting covered objects, so always carry out opera-
tions carefully.
WHEN PARKING MACHINE

When parking machine:PC-0000-161K00A
Unexpected move of the parked machine can cause serious personal injury. Always observe the following.
q Park the machine on firm, level ground.
q Select a place where there is no hazard of landslides, falling
rocks, or flooding.
q Lower the work equipment completely to the ground.
q When leaving the machine, set lock lever (1) to LOCK posi-
tion (L), then stop the engine.
q Always close the operator's cab door, and use the key to
lock all the equipment in order to prevent any unauthorized
person from moving the machine. Always remove the key,
take it with you, and leave it in the specified place.
2–36
q If it is necessary to park the machine on a slope, always do

as follows.
q Set the work equipment on the downhill side and dig it
into the ground.
q In addition, put blocks under the tracks to prevent the
machine from moving.
2–37
TRANSPORTATION
TRANSPORTATION:ALL-0000-81AK00A
When the machine is transported on a trailer, there is danger of serious personal injury or death during transpor-
tation. Always observe the following.
q Always check the machine dimensions carefully. Depending on the work equipment and optional devices
installed, the machine weight, transportation height, and overall length differ.
q Check beforehand that all bridges and other structures on the transportation route are strong enough to with-
stand the combined weight of the transporter and the machine being transported.
q The machine can be divided into parts for transportation, so when transporting the machine, please contact
your Komatsu distributor to have the work carried out. When transporting the machine, please contact your
Komatsu distributor to have the work carried out.
SAFETY RULES FOR LOADING AND UNLOADING

Safety rules for loading and unloading::PC220_KU-0000-84AK00A
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 observe the following.
q Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
q Never use the work equipment to load or unload the
machine. There is danger that the machine may fall or turn
over.
q Always use ramps of adequate strength. Be sure that the
ramps are wide, long, and thick enough to provide a safe
loading slope. Take suitable steps to prevent the ramps
from moving out of position or coming off. (1) Blocks
q Be sure the ramp surface is clean and free of grease, oil, (2) Ramp
ice and loose materials. Remove dirt from machine-tracks. (3) Centerline of trailer
On a rainy day, in particular, be extremely careful since the (4) Angle of ramps: Max. 15°
ramp surface is slippery.
q For machines equipped with an auto-deceleration device, always turn the auto-deceleration switch OFF. If the
machine is operated with the auto-deceleration system ON, there is danger that the engine speed will sud-
denly rise, the machine will suddenly move off, or the machine travel speed will become faster.
q Run the engine at low idle and drive the machine slowly at low speed.
q When on the ramps, do not operate any lever except for the travel lever.
q Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the
ramps again.
q The centre of gravity of the machine will change suddenly at the joint between the ramps and the track or
trailer, and there is danger of the machine losing its balance. Travel slowly over this point.
q When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
q When swinging the upper structure on the trailer, the trailer is unstable, so pull in the work equipment and
swing slowly.
q Be sure to turn the mirror and lay the radio antenna down.
For the details of folding, see "STOW RADIO ANTENNA (3-212)", "Installation and removal of mirrors (3-213)".
For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door
may suddenly open during transportation.
See "TRANSPORTATION (3-207)".
SHIPPING THE MACHINE

When shipping the machine on a trailer, do as follows.

q The weight, transportation height and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
q When passing over bridges or structures on private land, check first that the structure is strong enough to sup-
port the weight of the machine. When travelling on public roads, check first with the relevant authorities and
follow their instructions.
For details of the shipping procedure, see TRANSPORTATION (3-207) in the OPERATION section.
2–38
TOWING
Towing:ALL-0000-001K15A
SAFETY RULES FOR TOWING

SAFETY RULES FOR TOWING:ALL-0000-147K00A
Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or tow-
ing bar or in the method of towing a disabled machine may lead to serious personal injury or death.
For towing, see "Towing machine (3-230)".
NOTE: Do not use tie down lugs (PAGE 3-212) for towing.
q Always confirm that the wire rope or drawbar used for tow-
ing has ample strength for the weight of the machine being
towed.
q Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope
may break during the towing operation.
q Always wear leather gloves when handling wire rope.
q Never tow a machine on a slope.
q During the towing operation, never stand between the tow-
ing machine and the machine being towed.
q Operate the machine slowly and be careful not to apply any
sudden load to the wire rope.
2–39
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL

EQUIPMENT)
SAFETY RULES FOR LIFTING OBJECTS
q Determine the signals to be used and place a signalman in position.
q To prevent the machine from tipping over or falling, carry out the operation on flat ground.
q To prevent the danger of contact with a raised load or the danger from a falling load, do not allow any worker
inside the area.
q Do not exceed the specified lifting load.
For details of the maximum lifting load permitted for this machine, see the lifting capacity decal and link mark-
ings.
NOTE: RLL (Rated Lifting Load) for the link may not be the same as the lifting capacity of the machine.
Always be sure to lift within the relevant lifting limits.
q The lifting link RLL (Rated Lifting Load) and part number are stamped on the link as shown below.
q All components in the load line (eg.chains, shackles etc.) must be rated correctly for the load to be lifted.
q When swinging or operating the work equipment, check carefully that the surrounding area is clear from
objects, structures or any persons working around the machine.
q During the lifting operation, reduce the engine speed and
carry out the operation in L mode.
q Never travel the machine while lifting the load.
q Do not swing or operate the work equipment suddenly.
There is a danger that this may cause the load to swing and
the machine to become unstable or tip over.
q Do not leave the operator seat when there is a raised load.
q If the load approaches the lifting limit of the machine, a
warning is shown on the monitor panel and an audible
alarm sounds. In this case, lower the load to the ground.
(A) RLL (Rated Lifting Load) number.
(B) Part number
2–40
q Do not use the work equipment or swing to pull the load in

any direction.
There is a danger that the lifting eye may be damaged due
to abnormal loading making it unsafe to lift.
q The operator or person attaching the sling should inspect

the bucket link lifting device and all components in the load
line (e.g. chains, shackles etc) visually for damage or defor-
mation before use to ensure that they are not damaged or
worn.
Any damaged, deformed or worn parts should not be used
and must be replaced.
q Where possible the lifting operation should be carried out

with the bucket curled in order to increase visibility and pre-
vent any obstruction or deflection of the sling or chain away
from the vertical position.
q If the load is to be lifted at a height where this is not possi-
ble, the sling or chain must only be guided by the back wall
of the bucket and not any other part of the machine.
2–41
LIFTING OBJECTS WITH BUCKETS

SAFETY RULES FOR LIFTING OBJECTS
q Determine the signals to be used and place a signalman in position.
q To prevent the machine from tipping over or falling, carry out the operation on flat ground.
q To prevent the danger of contact with a raised load or the danger from a falling load, do not allow any worker
inside the area.
q Do not exceed the specified lifting load.
For details of the maximum lifting load permitted for the machine see the decal and bucket manufacturers RLL
(Rated Lifting Load).
NOTE:RLL (Rated Lifting Load) for the bucket may not be the same as the lifting capacity of the machine.
Always be sure to lift within the relevant lifting limits.
q All components in the load line (eg.chains, shackles etc.) must be rated correctly for the load to be lifted.
q It is dangerous if the raised load hits any person or structure. When swinging or operating the work equipment,
check carefully that the surrounding area is safe.
q Do not swing or operate the work equipment suddenly. There is danger that this may cause the load to sway
and the machine to tip over.
q Do not leave the operator's seat when there is a raised
load.
q Do not use the work equipment or swing to pull the load in
any direction. There is danger that the hook may break and
the load come off, causing the work equipment to move
suddenly and cause personal injury.
q When swinging or operating the work equipment, check
carefully that the surrounding area is clear from objects,
structures or any persons working around the machine.
q During the lifting operation, reduce the engine speed and
carry out the operation in L mode
q Never travel the machine while lifting the load.
q If the load approaches the lifting limit of the machine, a
warning is shown on the monitor panel and an audible
alarm sounds. In this case, lower the load to the ground.
2–42
SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

Precautions for maintenance:ALL-1150-001A00A
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE

Precautions before starting inspection and maintenance:ALL-0000-001K12A
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE

DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE::PC220_KU-0000-2A6K00A
Be sure to put up the warning tag "DANGER! Do NOT oper-

ate!" during inspection and maintenance.
If there is any "DANGER! Do NOT operate!" warning tag dis-
played, it means that someone is carrying out inspection and
maintenance of the machine. If the warning sign is ignored and
the machine is operated, there is danger that the person carry-
ing out inspection or maintenance may be caught in the rotat-
ing parts or moving parts and suffer serious personal injury or
death. Do not start the engine or touch the levers.
q If necessary, put up signs around the machine also.
Warning tag part No. 09963-A1640
When not using this warning tag, keep it in the toolbox. If
there is no toolbox, keep it in the pocket for the Operation
and Maintenance Manual.
KEEP WORKPLACE CLEAN AND TIDY

KEEP WORKPLACE CLEAN AND TIDY:PC-0000-2A7K00A
q Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely. If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over
and injure yourself.
q When cleaning the ceiling window which is made of organic glass (polycarbonate), use tap water and avoid
use of organic solvents for cleaning. An organic solvent like benzene, toluene or methanol can invite a chemi-
cal reaction like dissolution and decomposition on the window glass, deteriorating polycarbonate in use.
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE:ALL-0000-2A8K00A
q Stop the machine on firm, level ground.

q Select a place where there is no hazard of landslides, falling rocks, or flooding.
ONLY AUTHORIZED PERSONNEL

ONLY AUTHORIZED PERSONNEL:ALL-0000-2A9K00A
As long as maintenance of the machine is continued, do not allow unauthorized person comes near the work-
place. They might get unexpected personal injury from, for instance, touching machine. Do not allow anyone
except the workers concerned to enter the workplace. If necessary, employ a guard.
STABILITY
q When dismantling or assembling the machine for the purpose of maintenance, repair or transportation, always
ensure that at each stage of the process, care is taken to ensure that the machine remains stable. Failure to
do this could result in serious injury or death.
GUARDS
q Guards are installed in the area of the engine to protect personnel from moving parts. These guards should
only be removed by a Komatsu service engineer unless specific instructions are given in this manual.
END OF SERVICE LIFE

q For safe dismantling of the machine at end of service life, please contact you Komatsu Distributor.
2–43
PRECAUTIONS FOR MAINTENANCE SAFETY
APPOINT LEADER WHEN WORKING WITH OTHERS

APPOINT LEADER WHEN WORKING WITH OTHERS:ALL-0000-2AAK00A
q When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his instructions during the operation in order to prevent personal injuries caused by being caught or pinched.
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE:PC-0000-2ABK00A
Serious personal injury can result if you are caught or pinched between the work equipment in operation, or
exposed to high-temperature or high-pressure liquids. Always observe the following.
q Lower the work equipment completely to the ground and
stop the engine before performing any inspection and main-
tenance.
q Turn the starting switch to the ON position. Operate the

work equipment control lever back and forth, left and right at
the full stroke 2 to 3 times to eliminate the remaining inter-
nal pressure in the hydraulic circuit. Move lock lever (1) to
LOCK position (L) and turn the starting switch to the OFF
position.
q Check that the battery relay is off and main power is not
conducted. (After turning off the starting switch, wait for
approximately 1 minute and press the horn switch. If the
horn does not sound, power is not conducted.)
q Put blocks under the track to prevent the machine from

moving.
q Allow Komatsu Diesel Particulate Filter to cool.
2–44
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING:PC220-0000-2ACK00A
To prevent personal 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 observe the following.
q One worker must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must main-
tain contact with the other workers.
q When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close.
q Never drop or insert tools or other objects into the fan, fan
belt, or other rotating parts. There is danger that they may
contact the rotating parts and break or be sent flying.
q If the KDPF automatic regeneration starts during mainte-
nance, the temperature around KDPF increases. During
maintenance, stop the KDPF regeneration according to
"Handling KDPF (3-129)".
q Release the residual pressure from the hydraulic system,
and place Lock lever (1) to its LOCK position. For releasing
of the residual oil pressure, see the "METHOD OF
RELEASING PRESSURE IN HYDRAULIC CIRCUIT (4-
69)".
q Do not touch the control levers or pedals. If it is necessary
to operate the control levers or pedals, always give a signal
to your fellow workers and have them move to a safe place.
INSTALLING, REMOVING, OR STORING ATTACHMENTS

INSTALLING, REMOVING, OR STORING ATTACHMENTS:ALL-0000-2ADK00A
q Appoint a leader before starting removal or installation

operations for attachments.
q Place attachments that have been removed from the
machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.
WORK AT HIGH PLACES

WORK AT HIGH PLACES:ALL-0000-2AEK00A
When working at high places, use a step ladder or other stand to ensure that the work can be carried out safely.
There is a danger falling from high place that can lead to serious personal injury.
2–45
WORK ON MACHINE
WORK ON MACHINE:PC-0000-2AWK00A
q When carrying out maintenance work on the machine,

maintain the foothold clean and orderly to prevent falling.
Always observe the followings.
q Avoid spilling of oil and grease.
q Do not litter the tools.
q Watch your step when walking around on the machine.
q Remove mud and greases stuck to the shoe sole.
q Do not try to jump down from the machine. When getting on
or off the machine, use the ladder and handrail, and support
your body at three points using hands and feet (both feet
and a hand or both hand and a foot).
q You must walk along the access aisle for checking being
paved with non-slip pads. Do not try to climb on the engine
hood and cover to prevent personal injuries from falling or
failing over due to losing your footing.
WORK UNDER MACHINE OR WORK EQUIPMENT
WORK UNDER MACHINE OR WORK EQUIPMENT:ALL-0000-2AFK00A
Serious personal injuries can result from a falling machine or work equipment. Always observe the following.
q Make sure the hoists or jacks you use are in good condition
and strong enough to handle the weight of the component.
Never use jacks at places where the machine is damaged,
bent, or twisted. Never use frayed, twisted or pinched wire
rope. Never use bent or distorted hooks.
q It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is sup-
ported only with the work equipment. If any of the control
levers is touched by accident, or there is damage occurring
to the hydraulic piping, the work equipment or the machine
will suddenly drop. This is extremely dangerous. Never
work under the work equipment or the machine.
q If it is necessary to raise the work equipment or the machine and then go under it to carry out inspection or
maintenance, support the work equipment and machine securely with blocks and stands strong enough to
support the weight of the work equipment and machine.
If the work equipment and machine are not supported, there is a hazard that they may come down and that this
may lead to serious personal injury or death.
q Never use concrete blocks for supports. They can collapse under even light loads.
PROPER TOOLS
PROPER TOOLS:ALL-0000-2AGK00A
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, deformed, or low quality tools, or
making improper use of the tools may cause serious personal
injury.
2–46
PRECAUTIONS FOR INSPECTION AND MAINTENANCE

Precautions for inspection and maintenance:ALL-0000-001K06A
TURN OFF THE BATTERY DISCONNECT SWITCH

TURN OFF THE BATTERY DISCONNECT SWITCH:ALL-AW1P-012K00A
In the following cases, set the starting switch to the OFF position and confirm that the system operating lamp is
off.
If the system operating lamp is not confirmed to be off and the battery disconnect switch is set to the OFF posi-
tion, there may occur serious personal injuries like electric shock, etc.
q When the machine is stored for a long time (more than a month)
q When the electrical system is repaired
q When electrical welding is conducted
q When the battery is handled
q When the fuse is replaced
WELDING INSTRUCTIONS
Welding instructions:ALL-0000-629K00A
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
Before starting welding work, turn the starting switch to the OFF position, wait over one minute, then switch off the
battery disconnect switch and take out the battery disconnect switch key.
BATTERY
BATTERY:ALL-AW10-012K00A
Before inspecting or handling the battery, turn the key in the starting switch to the OFF position.
q Danger of battery exploding
When the battery is being charged, flammable hydrogen gas
is generated and may explode. In addition, the battery elec-
trolyte includes dilute sulphuric acid. Any mistake in handling
may cause serious personal injury, explosion, or fire, so
q Do not use or charge the battery if the battery electrolyte
is below the LOWER LEVEL mark. This may cause
explosion. Always carry out periodic inspection of the
battery electrolyte level, and add distilled water (or com-
mercially available battery filler solution) to the UPPER
LEVEL mark.
q Do not smoke or bring any flame close to the battery.
q Hydrogen gas is generated when the battery is being
charged, so remove the battery from the machine, take
it to a well-ventilated place, remove the battery caps,
then carry out the charging.
q After charging, tighten the battery caps securely.
q Danger from dilute sulphuric acid

When the battery is being charged, flammable hydrogen gas
is generated and may explode. In addition, the battery elec-
trolyte includes dilute sulphuric acid. Any mistake in handling
may cause serious personal injury, explosion, or fire, so
q When handling the battery, always wear protective eye-
glasses and rubber gloves.
q If battery electrolyte gets into your eyes, immediately
wash your eyes with large amounts of fresh water. After
that, get medical attention immediately.
q If battery electrolyte gets on your clothes or skin, wash it
off immediately with large amounts of water.
q Danger of sparks
There is hazard that sparks will be generated, so always observe the following.
q Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools
lying around near the battery.
2–47
q When removing the battery cables, turn the starting switch to OFF position and, after checking that the sys-
tem operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing,
connect the positive (+) cable first, then connect the ground.
q Tighten the battery cable terminals securely.
q Secure the battery firmly in the specified position.
WHEN USING HAMMER

WHEN USING HAMMER:ALL-0000-2AKK00A
When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious personal injury or death.
Always observe the following.
q When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
q If hard metal parts such as pins, bucket teeth, cutting
edges, or bearings are hit with a hammer, there is a hazard
that pieces might be scattered and cause serious personal
injury or death. Always wear protective eye glasses and
gloves.
q If the pin is hit with strong force, there is a hazard that it may
fly out and injure people in the surrounding area. Do not
allow anyone to enter the surrounding area.
HIGH-TEMPERATURE COOLANT
HIGH-TEMPERATURE COOLANTALL-B210-012K00A
To prevent burns from boiling water or steam spurting out when

checking or draining the coolant, wait for the coolant to cool
down to a temperature where the radiator cap can be touched
by hand. Then loosen the cap slowly to release the pressure
inside the radiator, and remove the cap.
HIGH-TEMPERATURE PARTS
HIGH-TEMPERATURE PARTS:PC220-0000-2AHK00A
To prevent burns from touching high-temperature parts, when checking or carrying out maintenance after stop-
ping engine, check the parts have been cooled down to touch with bare hand before checking or maintenance.
HIGH-TEMPERATURE OIL
HIGH-TEMPERATURE OIL:ALL-0000-2ALK00A
To prevent burns from hot oil spurting out or from touching

high-temperature parts when checking or draining the oil, wait
for the oil to cool down to a temperature where the cap or plug
can be touched by hand. Then loosen the cap or plug slowly to
release the internal pressure and remove the cap or plug.
2–48
HIGH-PRESSURE OIL
HIGH-PRESSURE OIL:ALL-0000-2AMK00A
The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pressure
when the engine is running and immediately after the engine is stopped. When carrying out inspection or replace-
ment of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not done, it
may lead to serious personal injury or death. Always do as follows.
q Do not carry out inspection or replacement work with the circuit under pressure.
Always release the pressure before starting. For details, see "METHOD OF RELEASING PRESSURE IN
HYDRAULIC CIRCUIT (4-69)".
q If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the
piping and hoses and for swelling in the hoses.
When carry out inspection, wear protective eyeglasses and leather gloves.
q There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause loss of sight if it
contacts your skin or eyes directly. If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes,
wash the place with clean water, and consult a doctor
immediately for medical attention.
HIGH-PRESSURE FUEL
High-pressure fuel:ALL-AD02-2AHK00A
When the engine is running, high-pressure is generated in the engine fuel piping. If you try to disassemble the pip-
ing before the internal pressure is released, serious personal injury can result. When carrying out inspection or
maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal pres-
sure to go down before starting the operation.
HIGH-PRESSURE HOSES AND PIPING

High-pressure hoses and pipings:ALL-0000-2ANK00A
q If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or misoperation, and lead to serious
personal injury, or death. If the hose or piping mounts are loose or oil or fuel is found to be leaking from the
mount, stop operations and tighten to the specified torque.
If any damaged or deformed hoses or piping are found, please consult your Komatsu distributor.
Replace the hose if any of the following problems are found.
q Damaged hose or deformed hydraulic fitting.
q Frayed or cut covering or exposed reinforcement wire layer.
q Covering swollen in places.
q Twisted or crushed movable portion.
q Foreign material embedded in covering.
HIGH VOLTAGE
HIGH VOLTAGE:ALL-0000-2APK00A
When the engine is running and immediately after it is stopped,

high voltage is generated inside the engine controller and the
engine injector, and there is danger of electrocution. Never
touch the inside of the controller or the engine injector portion.
If it is necessary to touch the inside of the controller or the
engine injector portion, please contact your Komatsu distribu-
tor.
2–49
NOISE
NOISE:ALL-0000-2AQK00A
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear
covers or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION

HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION:PC-DTL0-2ARK00A
q Grease is pumped into the track tension adjustment system

under high pressure. If the specified procedure for mainte-
nance is not followed when making adjustment, grease
drain plug (1) may fly out and cause serious injury or prop-
erty damage.
q When loosening grease drain plug (1) to loosen the track
tension, never loosen it more than one turn. Loosen the
grease drain plug slowly.
q Never put your face, hands, feet, or any other part of your
body close to grease drain plug (1).
DO NOT DISASSEMBLE RECOIL SPRING

DO NOT DISASSEMBLE RECOIL SPRING:ALL-DTBP-2AHK00A
Never disassemble the recoil spring assembly.

The recoil spring assembly has a powerful spring that acts to
reduce the impact on the idler. If it is disassembled by mistake,
the spring may shoot out and cause serious personal injury or
death. It is necessary to disassemble the recoil spring assem-
bly, always ask your Komatsu distributor to carry out the opera-
tion.
2–50
ACCUMULATOR AND GAS SPRING

ACCUMULATOR AND GAS SPRING:ALL-0000-2ASK00A
This machine is equipped with an accumulator. Even after the engine stops, the work equipment control levers
can be operated for a short time in the LOWER direction to allow the work equipment to go down under its own
weight.
After stopping the engine, set the lock lever to the LOCK position.
The accumulator and gas spring are charged with high-pressure nitrogen gas. If the accumulator or gas spring is
handled mistakenly, it may cause an explosion that could lead to serious personal injury or death. Always observe
the following.
q Do not disassemble the accumulator or gas spring.
q Do not bring it near flame or dispose of it in fire.
q Do not make holes in it, weld it, or use a cutting torch.
q Do not hit it, roll it, or subject it to any impact.
q When disposing of the accumulator or gas spring, the gas
must be released. Ask your Komatsu distributor to perform
this work.
COMPRESSED AIR
COMPRESSED AIR:ALL-0000-2ATK00A
q When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying
dust or particles.
q When using compressed air to clean the filter element or radiator, wear protective eyeglasses, anti-dust mask,
gloves, and other protective equipment.
MAINTENANCE OF AIR CONDITIONER

MAINTENANCE OF AIR CONDITIONER:ALL-K500-2AHK00A
q If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause
frostbite. Never loosen any parts of the cooling circuit.
q Never touch refrigerant.
CHEMICAL HAZARD
During maintenance or dismantling operations, where there is the risk of contact with hazardous chemical sub-
stances, relevant safety precautions should be taken.
If any doubt exists, contact your Komatsu distributor.
See also
See also "DISPOSE OF WASTE MATERIALS (2-51) and MAINTENANCE OF AIR CONDITIONER (2-51)"
DISPOSE OF WASTE MATERIALS

DISPOSE OF WASTE MATERIALS:ALL-0000-99AK00A
To prevent pollution, pay careful attention to the method of disposing of waste materials.
q Always put oil drained from your machine in containers.
Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
q Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.
q If any doubt exists, contact your Komatsu distributor.
SELECT WINDOW WASHER FLUID

SELECT WINDOW WASHER FLUID:ALL-K7B3-171K00A
Use an ethyl alcohol base washer liquid.

Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
2–51
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS:ALL-0000-2AUK00A
q For using the machine safely for an extended period of time, you must periodically replace the safety critical
parts that have a particularly close relation to safety, such as hoses and the seat belt.
Replacement of important parts: see "SAFETY CRITICAL PARTS (7-2)".
q The material of these components naturally changes over time, and repeated use causes deterioration, wear,
and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or
death. It is difficult to judge the remaining life of these components from external inspection or the feeling when
operating, so always replace them at the specified interval.
q Replace or repair safety-critical parts if any defect is found, even when they have not reached the specified
replacement time.
q The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the
machine.
2–52
OPERATION
OPERATION
OPERATION:ALL-0000-001K02A
OPERATION
k WARNING
Please read and make sure that you understand the safety
volume before reading this section.
3–1
GENERAL VIEW OPERATION
GENERAL VIEW
General view:PC-0000-001K01A
GENERAL VIEW OF MACHINE

GENERAL VIEW OF MACHINE:PC220-0000-04DK00A
(1) Bucket (7) Sprocket

(2) Bucket cylinder (8) Track frame
(3) Arm (9) Track shoe
(4) Arm cylinder (10) Idler
(5) Boom (11) Handrail
(6) Boom cylinder
3–2
OPERATION GENERAL VIEW
(11) KDPF (16) Battery

(12) KCCV ventilator (17) Grease pump holder
(13) Disconnect switch (18) Toolbox
(14) System operating lamp (19) Engine hood
(15) Fusible link
3–3
GENERAL VIEW OF CAB

GENERAL VIEW OF CAB:PC220_KU-K000-04DK00A
(1) Ceiling window (7) Ashtray

(2) Front window (8) Power outlet
(3) Emergency escape hammer (9) Fuse 1
(4) Door unlock lever (10) Fuse 2
(5) Drink box (11) Fire extinguisher (if equipped)
(6) Magazine box, Cup holder
3–4
3–5
GENERAL VIEW OF CONTROLS AND GAUGES

GENERAL VIEW OF CONTROLS AND GAUGES:PC220_KU-K190-04DK00A
3–6
(1) Radio (20) Swing brake cancel switch

(2) Lock lever (21) Engine shutdown secondary switch
(3) L.H. work equipment control lever (22) AUX
(4) One-touch power max. switch (23) Lower wiper switch
(5) Travel pedals (24) Seat heater switch
(6) Travel levers (25) Additional lamps switch (if equipped)
(7) Horn switch (26) 1st attachment proportional control switch
(8) Machine monitor (27) 2nd attachment proportional control switch
(9) Cigarette lighter (if equipped)
(10) R.H. work equipment control lever (28) Breaker switch
(11) Starting switch (29) Spare switch
(12) Fuel control dial (30) Spare switch
(13) Lamp switch (31) Quick coupler switch
(14) Swing lock switch (32) Spare switch
(15) Revolving warning lamp switch (if equipped) (33) Spare switch
(16) Attachment control pedal (if equipped) (34) Quick coupler switch
(17) Attachment control pedal (if equipped) (35) Roof wiper switch (if equipped)
(18) Room lamp switch (36) Automatic grease system monitor (if equipped)
(19) Emergency pump drive switch
3–7
Machine monitor
AA: Standard screen, BB: Check before starting screen, CC: Maintenance interval warning screen
(1) Wiper switch (20) Radiator coolant level monitor
(2) Buzzer cancel switch (21) Message monitor
(3) Auto-deceleration switch (22) Air conditioner monitor
(4) Engine coolant temperature monitor (23) Wiper monitor
(5) Engine coolant temperature gauge (24) Swing lock monitor
(6) Hydraulic oil temperature gauge (25) Engine preheating monitor or One-touch power max.
(7) Service meter, Clock monitor
(8) Hydraulic oil temperature monitor (26) Auto-deceleration monitor
(9) Working mode monitor (27) Engine oil level monitor
(10) Travel speed monitor (28) Air cleaner clogging monitor
(11) Fuel gauge (29) Water separator monitor
(12) ECO gauge (30) Function switches (F1 to F6)
(13) Fuel level monitor (31) Maintenance monitor
(14) Working mode selector switch (32) Seat belt monitor
(15) Travel speed selector switch (33) Engine stop monitor
(16) Window washer switch (34) KDPF regeneration monitor or KDPF regeneration
(17) Air conditioner switch monitor
(18) Engine oil pressure monitor (35) Fuel consumption gauge
(19) Charge level monitor
REMARK
The above drawing needs not show all alarm monitor symbols. For details of the alarm monitor, see "WARNING
DISPLAY (3-15)".
3–8
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS
Explanation of components:ALL-0000-043K00A
The following is an explanation of devices needed for operating the machine.

To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
MACHINE MONITOR
Machine monitor:PC220-Q180-04DK00A
AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen
(1) Warning display (4) Monitor switches portion
(2) Pilot display (5) Guidance icon display
(3) Gauge and Meter display
REMARK
q For the user menus used for various machine setting done from the machine monitor, see "USER MENU
SELECTOR SWITCH (3-49)".
q One of the features of liquid crystal display panels is that there may be black spots (spots that do not light up)
or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this is not a
failure or a defect.
q If ambient temperature of the machine monitor is high, brightness may be automatically reduced to protect the
liquid crystal. It is, however, not an error.
3–9
EXPLANATION OF COMPONENTS OPERATION
BASIC OPERATION OF MACHINE MONITOR

BASIC OPERATION OF MACHINE MONITOR:PC220-Q180-044K00A
STARTING ENGINE WHEN SITUATION IS NORMAL
q When the starting switch is turned to the ON position, the opening screen GG is displayed.
q After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting
screen BB.
q After the check before starting screen BB is displayed for 2 seconds, the screen switches to the working mode/
travel mode display screen HH.
q After the working mode/travel mode display screen HH is displayed for 2 seconds, the screen switches to
standard screen AA.
q If the working mode when the engine is started is B mode, the opening screen GG is displayed for 2 seconds,
and the screen then switches to the breaker mode confirmation screen II.
When starting in B mode, press switch F6. If you do not want to
start B mode, press switch F5. In this case, the system starts
with E mode.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery
condition. If this happens, the machine monitor may restart, but this does not indicate any abnormality.
3–10
STARTING ENGINE WHILE ENGINE STOP SUB-SWITCH IS ON

While engine stop sub-switch (1) is ON (engine stop), when the
starting switch is turned to the ON position, the screen shown
at right is displayed and engine does not start.
If engine stop sub-switch (1) is turned OFF (normal), the
machine monitor switches to the standard screen, and the
engine can be started with usual starting switch key operation.
For the function and operating method of engine stop sub-
switch (1), see "ENGINE SHUTDOWN SECONDARY SWITCH
(3-82)".
STOPPING ENGINE WHEN SITUATION IS NORMAL
q When the starting switch is turned to the OFF position, ending screen JJ or KK is displayed for 5 seconds, then
the display goes out.
Ending Screen with Message
If there is any message from your Komatsu distributor, it is dis-
played on the ending screen.
In this case, turned the starting switch to the ON position to re-
check the message, and if it is the message requesting
response, send back your reply.
For the method of display and reply for KOMTRAX message,
see "MESSAGE DISPLAY (3-73)".
3–11
IF THERE IS ABNORMALITY WHEN STARTING ENGINE
q If there is any abnormality when starting the engine, the check before starting screen BB changes to the main-
tenance time warning screen CC, warning screen FF, or error screen EE.
q After displaying the check before starting screen BB for 2 seconds, the screen changes to the maintenance
time warning screen CC.
q After displaying the maintenance time warning screen CC for 30 seconds, the screen returns to the standard
screen AA.
q After displaying the check before starting screen BB for 2 seconds, the screen changes to the warning screen
FF or error screen EE.
If there is any error existing, "!" is displayed on top of switch F5.
Press switch F5 to check the detail of the error. Existing error
list screen is displayed.
3–12
IF ANY ABNORMALITY OCCURS DURING OPERATION
q If any abnormality occurs during operation, the standard screen AA changes to warning screen FF-(1) or the
error screen EE.
q After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-
(2).
3–13
If there is any error existing, "!" is displayed on top of switch F5.

Press switch F5 to check the detail of the error. Existing error
list screen is displayed.
3–14
WARNING DISPLAY
WARNING DISPLAY:PC-Q1FB-043K00A
NOTICE
Appearance of any of action levels "L01" to "L04" on the machine monitor indicates presence of an
abnormality on the machine.
Take appropriate actions following the list of action level monitor displays and remedies.
The alarm monitor that is lit in red when an action level is displayed urges you to stop the current work
urgently, stop it in the normal procedure or pause it temporarily.
If no action is taken, the machine can be seriously affected. Take necessary actions immediately.
(1) Action level monitor (5) Alarm monitor

(2) Engine coolant temperature monitor (6) Alarm monitor
(3) Hydraulic oil temperature monitor (7) Alarm monitor
(4) Fuel level monitor
REMARK
q Standard screen
If the currently issued alarm is a single type, it is displayed on alarm monitor (5).
If the currently issued alarms are two types, they are displayed on alarm monitors (5) and (6), respectively.
If the currently issued alarms are three types or more, they are displayed on alarm monitors (5) and (6) alter-
nately on a 2-second basis.
q Camera image display screen
The currently issued alarm is displayed by flashing on alarm monitor (7).
When two or more alarms are issued, they are sequentially displayed starting from the leftmost side of the
screen.
ACTION LEVEL MONITOR
ACTION LEVEL MONITOR:PC220_KU-Q1FC-043K00A
This monitor (1) indicates the level of urgency of the abnormal-

ity in the machine by "L01"to "L04".
The larger the number in the table is, the more serious effects
the abnormality has on the machine if it is left unrepaired.
If the machine monitor indicates an action level, check the
message displayed on the monitor panel.
If switch F5 is pressed on the standard screen while this moni-
tor is displayed, the list of the errors currently occurring are dis-
played.
For how to display the errors, see "Occurred error list display
switch".
Take appropriate actions following the message displayed on
the monitor panel.
3–15
List of action level monitor displays and remedies

Urgency Action level Buzzer Alarm monitor Remedy
Stop the machine immediately, and carry out the inspection
Sounds
L04 Lights in red and maintenance.
continuously
Ask your Komatsu distributor for inspection and maintenance.
Stop the work, move the machine to a safe place, and carry
Sounds out the inspection and maintenance.
High L03 Lights in red
intermittently Please ask your Komatsu distributor for inspection and
I
maintenance.
│
Stop work and run engine at medium speed with no load or
│
Sounds stop it.
│ L02 Lights in red
intermittently If the condition is not improved, ask your Komatsu distributor
│
for inspection and maintenance.
O
Low Part of the above functions may be restricted in some cases.
However, it does not affect your work.
Lights in Whenever finished the work, carry out the inspection and
L01 –
yellow maintenance.
As needed, ask your Komatsu distributor for inspection and
maintenance.
ALARM MONITORS LIST

NOTICE
q These monitors do not guarantee the condition of the
machine.
Do not simply rely on the monitor when carrying out checks before starting (start-up inspection).
Always get off the machine and check each item directly.
q When the alarm monitor is displayed in red, if no action is taken, the machine can be seriously
affected.
Take the remedy immediately.
q The engine output or engine speed is limited and the machine operation speed may become slow,
depending on the contents of the alarm.
3–16
The alarm monitors and their colours are as follows.

Display colour/Machine condition (Action level)
Symbol Type of monitor
Red Yellow White Blue
High
Engine coolant temperature Low
temperature – Normal
monitor temperature
(L02)
High
Hydraulic oil temperature Low
temperature – Normal
monitor temperature
(L02)
Fuel level monitor Low level – – Normal
Abnormal Abnormal
System state monitor – –
(L04/L03) (L01)
Hydraulic system state Abnormal Abnormal

– –
monitor (L04/L03) (L01)
Abnormal Abnormal
KDPF system state monitor – –
(L04/L03) (L01)
KDPF soot deposition Abnormal Deposition

– –
monitor (L03) (L01)
Abnormal Abnormal
Engine system state monitor – –
(L04/L03) (L01)
Low oil pressure

Engine oil pressure monitor – – –
(L03)
Low oil level

Engine oil level monitor – – –
(L01)
Low coolant
Radiator coolant level
– level – –
monitor
(L01)
Abnormal
Charge level monitor – – –
(L03)
Water separator monitor Abnormal – – –
3–17
Display colour/Machine condition (Action level)

Symbol Type of monitor
Red Yellow White Blue
Clogged
Air cleaner clogging monitor – – –
(L01)
Air conditioner system state Abnormal

– – –
monitor (L01)
Overload caution monitor Overload – – –
Maintenance monitor Time is over Notice – –
For the meaning of each alarm monitor and the remedy to take for them, see the section of each monitor.
OCCURRED ERROR DISPLAY SWITCH
If there is any error existing, "!"is displayed on the top of switch
F5.
If switch F5 is pressed while "!"is displayed, the screen of the
monitor display section is changed to the occurred error list
screen.
Take appropriate remedies according to the message dis-
played on the monitor panel.
3–18
q On the occurred error list screen, switches F1, F2 and F5

allow the following operations.
F1: Displays next page. When on the last page, it displays the
first page.
F2: Displays the previous page. When on the first page, it dis-
plays the last page.
F5: Returns to the standard screen.
ENGINE COOLANT TEMPERATURE MONITOR

Engine coolant temperature monitor:PC220_KU-BA8D-043K00A
This monitor warns about states caused by engine coolant

temperature.
q When condition is abnormal:
The monitor lights up in red and displays the action level
"L02".
The engine coolant temperature has risen abnormally high.
While this monitor is lighting, the overheat prevention
system is automatically actuated and the engine speed
drops.
Stop operations and run the engine at low idle until the
monitor changes to the normal display colour (blue) at an
appropriate temperature.
q When temperature is low:
The monitor lights up in white.
The engine coolant temperature has fallen low.
The engine needs to be warmed up.
Carry out the warm-up operation for the engine until monitor
changes to the normal display colour (blue) at an appro-
priate temperature.
See "ENGINE WARM-UP OPERATION (3-167)".
q When temperature is correct:
The monitor lights up in blue.
3–19
HYDRAULIC OIL TEMPERATURE MONITOR

Hydraulic oil temperature monitor:PC220_KU-PMT5-043K00A
This monitor warns about states caused by hydraulic oil tem-

perature.
The monitor lights up in red and displays action level "L02".
The hydraulic oil temperature has risen abnormally high.
Stop operations and stop the engine or run it at low idle until
the monitor changes to the normal display colour (blue) at an
appropriate temperature.
q When temperature is low:
The monitor lights up in white.
The hydraulic oil temperature has fallen low.
It is necessary to warm up the hydraulic component.
Carry out the warm-up operation for the hydraulic equipment
until monitor comes to shows the normal display colour
(blue) at an appropriate temperature.
For details, see "HYDRAULIC SYSTEM WARM-UP OPER-
ATION (3-169)".
q When temperature is correct:
The monitor lights up in blue.
FUEL LEVEL MONITOR
FUEL LEVEL MONITOR:PC-AD45-043K00A
This monitor warns about low remaining fuel level.

q When remaining fuel level is low:
The monitor lights up red.
The remaining fuel amount is decreased to approximately 41
litres or below.
Add fuel as soon as possible.
q When condition is normal:
The monitor lights up blue.
SYSTEM OPERATING MONITOR

SYSTEM OPERATING MONITOR:PC-Q1FD-043K00A
This monitor warns about abnormality in the machine system,

including the sensors.
q When action level "L04"is displayed:
The monitor lights up red and the alarm buzzer sounds
continuously.
and maintenance.
Ask your Komatsu distributor for inspection and mainte-
nance.
The monitor lights up red and the alarm buzzer sounds inter-
mittently.
out the inspection and maintenance.
Please ask your Komatsu distributor for inspection and
maintenance.
The monitor lights up yellow.
Part of the above functions may be restricted in some cases.
Whenever finished the work, carry out the inspection and
maintenance.
maintenance.
3–20
HYDRAULIC SYSTEM OPERATING MONITOR

HYDRAULIC SYSTEM OPERATING MONITOR:PC-C051-043K00A
This monitor warns about abnormality in the hydraulic system.

continuously.
and maintenance.
nance.
mittently.
maintenance.
maintenance.
maintenance.
KDPF SYSTEM OPERATING MONITOR
KDPF SYSTEM OPERATING MONITOR:PC-A9HD-043K00A
This monitor warns about abnormality in the KDPF system.

continuously.
and maintenance.
nance.
mittently.
maintenance.
maintenance.
maintenance.
REMARK
For details of KDPF, see "Handling KDPF (3-129)".
3–21
KDPF SOOT ACCUMULATION MONITOR

KDPF SOOT ACCUMULATION MONITOR:PC-A9HE-043K00A
This monitor warns that soot is accumulated in KDPF or the fil-

tering function of KDPF has lowered abnormally.
To cancel the warning, perform the stationary manual regener-
ation of KDPF.
The monitor lights up red and indicates action level "L03".
The alarm buzzer sounds intermittently.
Much soot is accumulated in KDPF or the filtering function of
KDPF has lowered abnormally.
Urgent remedy is required.
Move the machine to a safe place immediately and carry out
the manual stationary regeneration.
q When soot is accumulated:
The monitor lights up yellow and indicates action level "L01".
Much soot is accumulated in KDPF.
The machine can be operated. However, after finishing
work, move the machine to a safe place and carry out the
manual stationary regeneration.
REMARK
For details of the manual stationary regeneration, see "Han-
dling KDPF (3-129)".
ENGINE SYSTEM OPERATING MONITOR
k
ENGINE SYSTEM OPERATING MONITOR:PC-A9HC-043K00A
CAUTION
If the operation is continued while the red monitor is lighting up, accumulation and combustion of the
soot in KDPF are accelerated, and consequently the temperature of KDPF and exhaust gas can increase
high. Stop the engine immediately.
This monitor warns about abnormality in the engine system.

continuously.
and maintenance.
nance.
mittently.
Please contact your Komatsu distributor for inspection and
repair.
maintenance.
maintenance.
3–22
ENGINE OIL PRESSURE MONITOR

ENGINE OIL PRESSURE MONITOR:PC-ABL0-043K00A
This monitor warns about abnormality in the engine lubricating

oil pressure.
q When oil pressure is low:
maintenance.
ENGINE OIL LEVEL MONITOR

ENGINE OIL LEVEL MONITOR:PC-AB4A-043K00A
This monitor warns about drop of engine lubricating oil level.

It displays only while the engine is stopped.
q When oil level is low:
The monitor lights up in yellow and indicates action level
"L01".
The oil level in the engine oil pan is insufficient.
Check the oil level in the oil pan and add oil.
See "CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (3-
150)".
If the oil level drops again in a short time, the engine oil may
be leaking.
maintenance.
RADIATOR COOLANT LEVEL MONITOR
RADIATOR COOLANT LEVEL MONITOR:PC-B255-043K00A
This monitor warns about drop of radiator coolant level.

q When the coolant level dropped:
The monitor lights up in yellow and indicates action level
"L01".
The radiator coolant is insufficient.
Check the coolant level in the sub-tank of the radiator and
add coolant.
See "CHECK COOLANT LEVEL, ADD COOLANT (3-149)".
If the coolant level drops again in a short time, the coolant is
supposed to be leaking from the radiator.
maintenance.
CHARGE LEVEL MONITOR
CHARGE LEVEL MONITOR:PC-AKV5-043K00A
This monitor warns about abnormality in the charging system

while the engine is running.
Charging cannot be made normally while the engine is
running.
Stop the engine and check if the fan belt is damaged, and
then ask your Komatsu distributor for inspection and mainte-
nance.
For details, see "Other trouble (3-236)".
3–23
WATER SEPARATOR MONITOR

WATER SEPARATOR MONITOR:PC-AEBA-043K00A
This monitor warns when water has accumulated inside the

water separator.
Water is accumulated in the water separator.
Stop the engine and drain the water separator.
See "CHECK FOR WATER AND SEDIMENT IN WATER
SEPARATOR, DRAIN WATER (3-146)".
REMARK
The water separator forms one unit with the fuel pre-filter.
The water separator is at the bottom of the fuel pre-filter and
can be removed.
AIR CLEANER CLOGGING MONITOR
AIR CLEANER CLOGGING MONITOR:PC-AEBA-043K00A
This monitor warns about clogging of the air cleaner.

q When clogged:
The air cleaner is clogged.
Stop the engine and check and clean the air cleaner.
See "CHECK, CLEAN AND REPLACE AIR CLEANER
ELEMENT (4-12)".
AIR CONDITIONER SYSTEM OPERATING MONITOR

AIR CONDITIONER SYSTEM OPERATING MONITOR:PC-K5V3-043K00A
This monitor warns about abnormality in the air conditioner

system.
The air conditioner system has abnormality.
maintenance as soon as possible.
MAINTENANCE MONITOR
MAINTENANCE MONITOR:PC-Q1D3-043K00A
This monitor displays notices and alarms concerning mainte-

nance time.
This monitor lights up when the starting switch is turned to the
"ON"position. It goes out after 30 seconds and the display
changes to the standard screen.
q When the time elapsed:
The maintenance time has already passed.
If no action is taken, the machine performance will become
worse and the machine life will be shortened.
Carry out necessary maintenance as soon as possible.
q At notice time:
The maintenance time is approaching.
Prepare parts necessary for the maintenance.
3–24
REMARK
q Please check necessary maintenance items on the mainte-
nance screen by pressing switch F6 on the maintenance
time alarm screen shown in the right drawing or on the
standard screen.
q The lighting time of maintenance time notice (yellow) has
been initially set to 30 hours, but you can change it.
To change the initial setting, contact your Komatsu distribu-
tors.
q For operations on the maintenance screen, see "MAINTE-
NANCE SCREEN SETTING (3-65)".
OVERLOAD CAUTION MONITOR

This monitor warns that machine is close to tipping due to the
load (an audible warning is also given), if the warning is given
lower the load.
Refer the lifting capacity chart for safe load.
3–25
METER DISPLAY
METER DISPLAY:PC220-Q1LA-04DK00A
Pilot display Gauge and Meter

(1) Engine preheating monitor (15) Engine coolant temperature gauge
(2) Swing lock monitor (16) Hydraulic coolant temperature gauge
(3) Wiper monitor (17) Fuel gauge
(4) Auto-deceleration monitor (18) Service meter, Clock
(5) Working mode monitor (19) ECO gauge
(6) Travel speed monitor (20) Fuel consumption gauge
(7) One-touch power max. monitor
(8) Air conditioner monitor
(9) Message monitor
(10) Seat belt monitor
(11) Engine stop monitor
(12) KDPF regeneration monitor
(13) KDPF regeneration stop monitor
(14) ECO guidance
PILOT DISPLAY
Pilot Display:ALL-Q15A-043K00A
q The pilot display at the top of the screen consists of the pilot lamps to confirm the actuation of each function.
q When the starting switch is turned ON, the pilot lamp lights up when the display items are functioning.
ENGINE PREHEATING MONITOR
Engine preheating monitor:ALL-AM4A-043K00A
This monitor (1) is displayed while preheating before starting

the engine in temperatures below 0°C.
When the temperature is low (in cold areas) and the automatic
preheating function is actuated, the preheating monitor lights
up. When the preheating is completed, it goes out.
Automatic preheating is for a maximum of approx. 30 seconds.
3–26
SWING LOCK MONITOR

Swing Lock Monitor::PC220_KU-JC5N-043K00A
This monitor (2) informs that the swing lock is being actuated.
Lighting: The swing lock is being actuated.
When the swing lock switch is turned ON (ACTUATED), the
monitor lights up.
This lamp flashes when the swing brake cancel switch is set to
the FREE position.
q For details of the positions of the swing lock switch and the
swing brake cancel switch, see "GENERAL VIEW OF CON-
TROLS AND GAUGES (3-6)".
REMARK
The swing motor is equipped with a disc brake that mechani-
cally stops the rotation. When the swing lock monitor is lighted
up, the brake remains applied.
WIPER MONITOR
Wiper Monitor::PC220_KU-K73A-043K00A
Monitor (3) indicates operating status of the wiper.

The monitor display when wiper switch is operated, is as fol-
lows.
When ON lights up: Wiper moves continuously
When INT lights up: Wiper moves intermittently
When nothing lights up: Wiper stops
q For details of the positions of the wiper switch, see "GEN-
ERAL VIEW OF CONTROLS AND GAUGES (3-6)".
AUTO-DECELERATION MONITOR
Auto-deceleration Monitor::PC220_KU-AF6F-043K00A
This monitor (4) shows the setting of the auto-deceleration

either ON or OFF.
The monitor display when auto-deceleration switch is operated,
are as follows.
Auto-deceleration monitor lights up: Auto-deceleration ON
Auto-deceleration monitor goes out: Auto-deceleration OFF
q For details of the position of the auto-deceleration switch,
see "GENERAL VIEW OF CONTROLS AND GAUGES (3-
6)".
WORKING MODE MONITOR

Working mode monitor:PC220_KU-PT0A-043K00A
This monitor (5) displays the setting of the working mode.

The monitor display is as follows according to the operation of
the working mode switch.
P: P mode (for heavy-load operations)
E: E mode (for operations with emphasis on fuel consumption)
L: L mode (for fine control and lifting operations)
B: B mode (for breaker operations)
(machines ready for installation of attachment)
ATT/P: ATT/P mode (for operations of 2-way attachments like
crusher, etc.)
ATT/E: ATT/E mode (for operations of 2-way attachments like
crusher in emphasis of fuel consumption)
q For details of the positions of the working mode switch, see
"GENERAL VIEW OF CONTROLS AND GAUGES (3-6)".
3–27
TRAVEL SPEED MONITOR

Travel Speed Monitor:PC-Q1R9-043K00A
This monitor (6) shows the setting mode for the travel speed.
The monitor display is as follows according to the operation of
the travel speed selector switch.
Lo: Low-speed travel
Mi: Mid-range speed travel
Hi: High-speed travel
q For details of the position of the travel speed selector
switch, see "GENERAL VIEW OF CONTROLS AND
GAUGES (3-6)".
ONE-TOUCH POWER MAX. MONITOR

One-Touch Power Max. Monitor::PC220_KU-PT0B-043K00A
This monitor (7) shows if the one-touch power max. function is

being actuated.
The monitor display when the knob switch on the left control
lever is operated is as follows. (The actual monitor display is
shown at the position of preheating monitor (1).)
Monitor lights up: Digging power increases while the knob
switch is kept pressed (for a maximum of 8.5 seconds).
Monitor goes out: Power max function stopped
q For details of the position of the knob switch, see "GEN-
ERAL VIEW OF CONTROLS AND GAUGES (3-6)".
REMARK
Only when the working mode is P, E, ATT/P, ATT/E mode, the
power is increased while the knob switch is being pressed.
Even if the knob switch continues to be pressed, the power
increase is finished after 8.5 seconds.
AIR CONDITIONER MONITOR
Air Conditioner Monitor:ALL-K5V3-043K00A
This monitor (8) displays the working status of the air condi-
tioner.
Monitor lights up: Air conditioner ON
Monitor goes out: Air conditioner OFF
MESSAGE MONITOR
MESSAGE MONITOR:PC-Q235-043K00A
This monitor (9) lights up when Komatsu send out any informa-
tion.
To read the information, see the paragraph of "MESSAGE DIS-
PLAY (3-73)".
Green lamp (A) lights up: There is any unread information.
Blue lamp (B) lights up: There is any read information to which
no reply is made.
No lamp lights up: There is no information.
3–28
SEAT BELT MONITOR

SEAT BELT MONITOR:PC-K2S5-043K00A
This monitor (10) is displayed when the seat belt is not fas-
tened. It goes out when the seat belt is fastened.
For how to fasten the seat belt, see "SEAT BELT (3-159)".
ENGINE STOP MONITOR

ENGINE STOP MONITOR:PC-AKHK-043K00A
This monitor (11) is displayed while the engine is stopped. It

goes out after the engine is started.
KDPF REGENERATION MONITOR
k
KDPF REGENERATION MONITOR:PC-A9HF-043K00A
CAUTION
q Exhaust gas temperature may increase higher than the current models during KDPF regeneration.
Avoid getting near the exhaust pipe outlet to prevent being scalded. Also, keep flammables away from
the exhaust pipe outlet to prevent a fire.
q When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to
disable the regeneration to prevent fire hazards due to highly heated exhaust gas while regeneration
of KDPF. For details of the setting method, see "Handling KDPF (3-129)".
This monitor (12) lights up while KDPF is being regenerated. It

goes out when the regeneration is completed.
3–29
KDPF REGENERATION STOP MONITOR

KDPF REGENERATION STOP MONITOR:PC-A9HN-043K00A
This monitor (13) lights up when KDPF is set not to be regener-

ated.
REMARK
Even if no regeneration of KDPF is set, when the manual sta-
tionary regeneration is necessary, accumulated soot monitor of
KDPF lights up.If it lights up, cancel no regeneration setting
and carry out manual stationary regeneration.
For the procedures of cancellation of regeneration disable set-
ting, and setting of manual stationary regeneration, see "Han-
dling KDPF (3-129)".
ECO GUIDANCE
ECO GUIDANCE:PC-Q1L3-043K00A
The guidance for energy saving operation to reduce the fuel

consumption may be displayed during operation.
The details of the guidance are as follows:
IDLING STOP GUIDANCE (A)

If no operation is performed for more than five minutes, and the
engine is idling, the idling stop message is displayed on the
monitor. When waiting for work or stopping work for a short
periods, stop the engine to reduce unnecessary fuel consump-
tion.
q The idling stop message goes out if any lever is operated
again or switch F5 is pressed.
3–30
HYDRAULIC RELIEF DETERRENCE GUIDANCE (B)

If the hydraulic oil is kept relieved for more than 3 seconds dur-
ing operation, the hydraulic relief deterrence message is dis-
played on the monitor.
q The hydraulic relief deterrence message goes out 10 sec-
onds after or when switch F5 is pressed.
E MODE RECOMMENDATION GUIDANCE (C)

If light-load work is continued for more than 10 minutes in P or
ATT/P mode, E mode recommendation message is displayed.
When working on light load, set the working mode to E to
reduce unnecessary fuel consumption.
q E mode recommendation message goes out more than 10
seconds after or when switch F5 is pressed.
TRAVEL PARTIAL MODE RECOMMENDATION GUIDANCE (D)

If the machine keeps travelling for more than 2 minutes with the
travel mode Hi and the fuel control dial at the MAX position, the
travel partial mode recommendation message is displayed.
When travelling for a long time, the fuel consumption can be
reduced by lowering the fuel control dial.
q The travel partial mode recommendation message goes out
more than 10 seconds after or when switch F5 is pressed.
LOW FUEL LEVEL GUIDANCE (E)

If the operable time estimated from the current fuel level and
the latest average fuel consumption is shorter than 8 hours, the
low fuel level message is displayed.
q The low fuel level message goes out more than 10 seconds
after or when switch F5 is pressed.
3–31
GAUGES AND METER

Gauges and Meter:ALL-Q1LB-001K00A
ENGINE COOLANT TEMPERATURE GAUGE

Engine coolant temperature gauge:PC220_KU-BA80-043K00A
This meter (15) shows the engine coolant temperature.

During normal operations, the indicator should be in the green
range. If the indicator goes beyond red range (A) during opera-
tions, the overheat prevention system is actuated.
q (A) - (B): Indicates red range
q (A) - (C): Indicates green range
q (C) - (D): Indicates white range
The overheat prevention system is actuated as follows.

Red range (A) position: Engine coolant temperature monitor (E) shows abnormality display
Red range (B) position: Engine speed changes to low idling, engine coolant temperature monitor (E) shows
abnormality display, alarm buzzer sounds at same time
The overheat prevention system continues to work until the indicator enters the green range.
When the engine is started, if the indicator is at position (D), engine coolant temperature monitor (E) shows the
low-temperature display.
If this happens, carry out the warm-up operation. For details, see "ENGINE WARM-UP OPERATION (3-167)".
q Display (G) at low temperatures: Monitor background (K) is
white
q Display (H) at correct temperatures: Monitor background
(K) is blue
q Display (J) when condition is abnormal: Monitor back-
ground (K) is red
HYDRAULIC OIL TEMPERATURE GAUGE

HYDRAULIC OIL TEMPERATURE GAUGE:PC220_KU-PMT6-043K00A
This meter (16) shows the hydraulic oil temperature.

range.
If the indicator enters the red range (A) during operations, the
hydraulic oil temperature is 102°C or more. Run the engine at
low idling or stop it and wait for the hydraulic oil temperature to
go down. Run the engine at low idle or stop it and wait for the
hydraulic oil temperature to go down.
q (C) - (D): Indicates white range
REMARK
When the indicator reaches red range (A), the hydraulic oil temperature is as follows.
Red range (A) position: 102°C or more
Red range (B) position: 105°C or more
When the indicator is in red range (A) - (B), hydraulic oil temperature monitor (E) shows the abnormality display.
When the engine is started, if the indicator is at position (C) and the hydraulic oil temperature is 20°C, hydraulic oil
temperature monitor (E) shows the low-temperature display. If this happens, carry out the warm-up operation. For
details, see "HYDRAULIC SYSTEM WARM-UP OPERATION (3-169)".
3–32
q Display (G) at low temperatures: Monitor background (K) is

white
q Display (H) at correct temperatures: Monitor background
(K) is blue
q Display (J) when condition is abnormal: Monitor back-
ground (K) is red
FUEL GAUGE
FUEL GAUGE:PC-AER3-043K00A
This meter (17) shows the amount of fuel remaining in the fuel
tank.
range.
If the indicator starts to enter red range (A) during operation,
the remaining fuel is less than 60 litres. So carry out inspection
and add fuel.
REMARK
When the indicator reaches red range (B), the remaining fuel is 41 litres.
When the indicator is in red range (B), fuel level monitor (D) lights up red.
The correct fuel level may not be displayed for a short time when the starting switch is turned ON, but this is not
an abnormality.
SERVICE METER OR CLOCK
Service meter or clock:PC-Q1MA-043K00A
This meter (18) shows the total hours of operation of the machine or the present time.
When the engine is running, the service meter advances even if the machine is not moving. The service meter
advances 0.1 every 6 operation minutes, regardless of the engine speed.
q Service meter display
q Clock display (12-hour display)
3–33
q Clock display (24-hour display)
q When the standard screen is being displayed, if function

switch F4 is pressed, it is possible to switch between the
clock display and the service meter display.
REMARK
If the battery is disconnected for a long period for storage
etc., the time information may be lost.
q Clock display (12-hour or 24-hour displays are available)
For details of setting and correction of time, see "CLOCK
ADJUSTMENT (3-68)".
ECO GAUGE
ECO GAUGE:PC-Q1LC-043K00A
This gauge (19) shows the instantaneous fuel consumption.

The instantaneous fuel consumption means the fuel consump-
tion rate at each current moment, which varies with the work
load and engine speed.
When the gauge is in green range A, the instantaneous fuel
consumption is at a good to medium level.
When the gauge is in yellow range B, the instantaneous fuel
consumption is at a bad level.
q When the gauge enters the yellow range, there is no abnor-
mality on the machine, but to protect the environment,
reduce the engine output to a point where there is no
adverse effect on the operation. Generally, carry out
energy-saving operations in the green range. Reducing the
frequency of travel also helps to save energy. Consider the
best way of saving energy.
FUEL CONSUMPTION GAUGE
FUEL CONSUMPTION GAUGE:PC-AD48-043K00A
This monitor (20) indicates average fuel consumption of the

machine.
(A): Displays the average fuel consumption of a day (from 0:00
a.m. of the day to 0:00 a.m. of the next day).
(B): Displays the split fuel consumption under measurement.
(C): Indicates the split fuel consumption measurement is
stopped.
REMARK
Display on the fuel consumption gauge can be switched
between the average fuel consumption per day and the aver-
age fuel consumption during an selected period (split fuel con-
sumption).
For the display change procedure, see "ECO GUIDANCE (3-
51)".
3–34
MONITOR SWITCH PORTION

MONITOR SWITCH PORTION:PC220-Q1C0-04DK00A
(1) Function switches (5) Wiper switch

(2) Working mode selector switch (6) Window washer switch
(3) Auto-deceleration switch (7) Buzzer cancel switch
(4) Travel speed selector switch (8) Air conditioner switch
GUIDANCE ICONS, FUNCTION SWITCHES

GUIDANCE ICONS, FUNCTION SWITCHES:PC-Q1C1-043K00A
q Function switches (1) at the bottom of the monitor display

consist of 6 switches (F1 to F6). The function of each switch
differs according to the content of each screen.
q The function of switches (1) on each screen can be con-
firmed by guidance icons (9) displayed on top of the switch.
q Switch (1) not displayed in guidance icon (9) does not func-
tion even if pressed.
q Even if guidance icon (9) is pressed, it will not function.
Press switch (1) right under the guidance icon display to
operate the function.
When the monitor display shows the standard screen, the kinds of guidance icons and functions of function
switches are as follows:
For the details of each function, see the detailed explanation of each item
3–35
(A) Switch F3: Camera screen selector switch.

(B) Switch F4: Service meter/time display selector switch
(C) Switch F5: Occurred error list display switch

(While the alarm monitor is displayed)
(D) Switch F5: Energy saving (ECO) guidance erase switch

(While Energy saving (ECO) guidance is displayed)
(E) Switch F6: User menu display switch
Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance
icons frequently used and their functions are as follows:
(F) Switch F1 or F3: To move to the left by 1 space. (An icon at
the left end moves to the right end.)
(G) Switch F2 or F4: To move to the right by 1 space. (An icon
at the right end moves to the left end.)
3–36
(H) Switch F3: To move downward (forward) by 1 space. (An

icon at the extreme end moves to the top.)
(I) Switch F4: To move upward (backward) by 1 space. (An icon
at the top moves to the extreme end.)
(J) Switch F5: To cancel any change and return to the previous
screen.
(K) Switch F6: To decide any selection and change contents
and to advance to the next screen.
REMARK
q Even if guidance icons are of the same shape, their display positions and corresponding function switches
may differ according to screens to be displayed.
q The guidance icons and their functions not explained above are shown in the pages where the control meth-
ods of respective screens are explained.
WORKING MODE SELECTOR SWITCH
WORKING MODE SELECTOR SWITCH:PC220-PT5W-043K00A
Use this switch (2) to set the movement or power of the work
equipment.
The operation becomes easier if the mode is selected to match
the content of the operation.
P mode: For heavy-load operations
E mode: For operation with emphasis on fuel consumption
L mode: For fine control and lifting operations
B mode: For breaker operations
ATT/P mode: For operations of 2-way attachments like crusher
(machines ready for installation of attachment)
ATT/E mode: For operations emphasizing fuel consumption out
of those of double-acting attachments, such as crusher (attach-
ment-ready machines)
q When the monitor first appears, it is automatically set to the
mode in use when the starting switch was turned to the
OFF position in the previous time.
q Press switch (2) to display the working mode selection
screen. For each set mode, the pilot monitor at the top right
of the monitor display shows P, E, L, B, ATT/P, ATT/E.
3–37
q For machines ready for attachment, the attachment mode is

added to the display.
For details of the method for handling machines ready for
attachment, see the ATTACHMENTS AND OPTIONS
Section.
q When the monitor starts up, if the working mode setting is B
mode, the confirmation message on the right is displayed
and the buzzer sounds.
q When starting up and staying in B mode, always press func-
tion switch F6 (Yes).
If you press F5 (No), the system starts up in E mode.
q If you want to have automatic setting of the P, E, L, B, ATT/P or ATT/E mode when starting (optional default
setting), please ask your Komatsu distributor to change the setting.
PROCEDURE FOR OPERATION
1. If working mode selector switch (2) is pressed, the Working
Mode screen is displayed on the monitor.
2. Press function switches F3 or F4 at the bottom of the
screen or working mode selector switch (2) to change the
mode selection one at a time.
q If no switch is touched for more than 5 seconds, the
selected working mode is automatically set as the work-
ing mode and the screen changes to the one for Steps 3
and 4.
REMARK
To return to the standard screen without changing the working
mode, press function switch F5.
3. After selecting the desired mode, press function switch F6

and the mode is displayed in the centre of the monitor dis-
play.
(Example: When the power mode is selected: P)
4. After 2 seconds, the pilot monitor display at the top right of
the screen is highlighted in yellow.
3–38
After 2 seconds, the screen returns to the standard screen.

The monitor display highlighted in yellow in Step 4 returns to
blue.
REMARK
When setting the working mode to B mode, to ensure safety,
the buzzer sounds and at the same time, the message in the
illustration on the right is displayed. When setting to the
breaker mode, always press function switch F6.
If function switch F5 is pressed, the breaker mode is not set,
and the screen returns to working mode selection screen.
NOTICE
When using the breaker, set to B mode. If B mode is not
used, there is danger that the breaker may break.
AUTO-DECELERATION SWITCH
AUTO-DECELERATION SWITCH:PC-AF6C-043K00A
If the control levers are at NEUTRAL, this switch (3) automati-

cally lowers the engine speed and turns on the function to
reduce fuel consumption.
Auto-deceleration monitor lights up: Auto-deceleration ON
Auto-deceleration monitor goes out: Auto-deceleration OFF
Each time the switch is pressed, the auto-deceleration is
switched between ON and OFF.
q Function of auto-deceleration
When the auto-deceleration function is ON, if the work
equipment and travel levers are returned to the N position,
the engine speed will drop after 4 seconds from the oper-
ating speed to idle speed.
As a result, fuel consumption can be reduced.
If any lever is operated in this condition, engine speed will
return to the previous operating speed to make it possible to
perform operations.
3–39
1. When auto-deceleration switch (3) is pressed and the auto-

deceleration function is turned ON, the mode is displayed in
the centre of the monitor display, and after two seconds, the
screen returns to the standard screen.
2. On the standard screen, the Auto-deceleration monitor

lights up.
(When the auto-deceleration is OFF, it does not light up.)
3–40
TRAVEL SPEED SELECTOR SWITCH
k
TRAVEL SPEED SELECTOR SWITCH:PC220-C6T7-043K00A
WARNING
q When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch
(4) at the Lo position).
q Never operate travel speed selector switch (4) while loading or unloading. If the travel speed is
switched between Hi and Lo when the machine is travelling, the machine may deviate to one side,
even when travelling in a straight line. Stop the machine before switching the travel speed.
Switch (4) is used to set the travel speed to 3 stages.

Lo lights up : Low-speed travel
Mi lights up : Medium-speed travel
Hi lights up : Hi-speed travel
When the engine is started, the speed is automatically set to
Lo.
Each time that the switch is pressed, the display changes
LooMioHioLo in turn.
Even if the travel speed is set to high-speed (Hi) or a mid-range
speed (Mi), when travelling on soft ground or uphill, and travel
power is needed, the system automatically shifts down to low
speed travel (Lo). There is no need to operate the switch. In
this case, the pilot monitor on the monitor display stays lighted
up at Hi (high-speed) or Mi (mid-range speed).
REMARK
Each time travel speed selector switch (4) is switched, the
mode is displayed on the monitor display, and after two sec-
onds, the screen returns to the standard screen.
3–41
WIPER SWITCH
WIPER SWITCH:PC-K751-043K00A
This switch (5) actuates the front window wiper.

Each time the switch is pressed, it changes ON to INT to Stop
(monitor goes out).
Wiper monitor INT lights up: Wiper operates intermittently
Wiper monitor ON lights up: Wiper operates continuously
Wiper monitor goes out: Wiper stops
REMARK
Each time wiper switch (5) is pressed, the mode is displayed in
the centre of the monitor display, and after two seconds, the
screen returns to the standard screen.
3–42
WINDOW WASHER SWITCH

WINDOW WASHER SWITCH:PC-K7DA-043K00A
This switch (6) is kept continuously pressed, window washer

fluid is sprayed out on the front glass. When the switch is
released, the spray stops.
q If switch (6) is kept pressed when the wiper is stopped, the
window washer fluid will spray, and at the same time, the
wiper will be actuated continuously. When switch (6) is
released, the wiper will continue to operate for 2 cycles,
then stop.
q If the wiper is moving intermittently and switch (6) is kept
pressed continuously, window washer fluid will spray, and at
the same time, the wiper will be actuated continuously.
When switch (6) is released, the wiper will continue to oper-
ate for 2 cycles, then return to intermittent operation.
BUZZER CANCEL SWITCH

BUZZER CANCEL SWITCH:PC-Q576-043K00A
When this switch (7) is pressed, the warning buzzer for the
abnormal warning item stops.
3–43
AIR CONDITIONER SWITCH

AIR CONDITIONER SWITCH:PC-K5FK-04DK00A
The air conditioner switches (8) consist of 9 switches.

For explanation of each switch, see "Handling air conditioner
(3-104)".
3–44
HANDLING FUNCTION SWITCHES

HANDLING FUNCTION SWITCHES:PC-Q1C1-100K00A
The operation of the function switches in the standard screen

CAMERA SCREEN SELECTOR MODE SWITCH
CAMERA SCREEN SELECTOR MODE SWITCH:PC-Q16A-100K03A
On the standard screen, press switch F3 to switch to the cam-

era screen display.
q On machines not equipped with a camera, the guidance
icon on top of switch F3 is not displayed.
Even if switch F3 is pressed, the screen will not switch to the
camera screen display.
q A maximum of three cameras can be installed.
q If you want to install another camera, please consult your
Komatsu distributor.
OPERATION OF ONE CAMERA IMAGE DISPLAY SCREEN

The following explanation describes the method of operation when it is desired to display only one camera screen
on the monitor.
q On the standard screen, if switch F3 is pressed, the image
display screen is displayed.
q Press switch F1 to display all the screens for images from

the No. 1 camera.
the No. 2 camera.

the No. 3 camera.
REMARK
If the machine is not equipped with a No. 2 camera or No. 3
camera, guidance icons (a), (b) and (c) are not displayed.
3–45
q Press switch F5 to return to the standard screen.
OPERATION OF IMAGE DISPLAY SCREEN WHEN TWO CAMERA IMAGES ARE SHOWN SIMULTA-
NEOUSLY
The following explanation describes the method of operation when it is desired to display two camera screens at
the same time on the monitor.
q On the one camera image display screen, if switch F4 is
pressed, No. 1 camera image (d) and No. 2 camera image
(e) are displayed.
q Even if three cameras are installed, only the images from
the No. 1 camera and No. 2 camera can be displayed at the
same time.
q When two screens are displayed at the same time, the dis-
play changes more slowly than when only one screen is dis-
played.
q Press switch F5 to return to the standard screen.
OTHER MODE OPERATIONS WHEN DISPLAYING CAMERA IMAGE

q Even during the camera display, it is possible to operate fol-
lowing modes.
q The air conditioner can be operated.
If the air conditioner switch is operated, the screen switches
to the air conditioner control screen. If the screen switches
to the air conditioner control screen, press switch F6 to
return to the camera image screen. In addition, if no opera-
tion is carried out for five seconds after the screen switches
to the air conditioner control screen, the screen automati-
cally returns to the camera image screen.
For details of the operation of the air conditioner, see
"Handling air conditioner (3-104)".
3–46
q It is possible to change the working mode by pressing the

working mode selector switch.
For details of the method of using the working mode selector
switch, see "WORKING MODE SELECTOR SWITCH (3-
37)".
When the working mode is changed, the screen returns
automatically to the camera image screen. When this
happens, the pilot monitor display at the top right of the
monitor screen is highlighted in yellow for 2 seconds, then
returns to blue.
q It is possible to change the travel speed by pressing the

travel speed selector switch.
For details of the method of using the travel speed selector
switch, see "TRAVEL SPEED SELECTOR SWITCH (3-41)".
When the travel speed is changed, the pilot monitor display
at the top right of the monitor screen is highlighted in yellow
for 2 seconds, then returns to blue.
q Press the auto-deceleration switch to turn the auto-deceler-

ation function ON/OFF.
Even if the auto-deceleration switch is pressed, the camera
image display screen does not switch to another screen or
return to the standard screen display.
q With pressing the buzzer cancel switch, it is possible to stop

the alarm buzzer for the warning item where there is an
abnormality.
Even if the buzzer cancel switch is pressed, the camera
image display screen does not switch to another screen or
return to the standard screen display.
3–47
q Press the wiper switch and washer switch to operate the

wipers and washer.
Even if the wiper switch or washer switch is pressed, the
camera image display screen does not switch to another
screen or return to the standard screen display.
ACTIONS AGAINST WARNING DURING CAMERA DISPLAY

q If an error or alarm occurs while the camera image is being
displayed, the error monitor or alarm monitor is displayed at
the top left of the screen and flashes.
q If the error monitor or alarm monitor is displayed, press

switch F6, return to the standard screen, and check the
content of the error or alarm display.
When the error monitor is flashing, if no lever is operated for
more than 10 seconds, the screen automatically returns to
the standard screen.
When the screen returns to the standard screen, the error
monitor at the top left of the screen goes out and the error or
alarm is displayed in the centre of the screen.
q If an error monitor is displayed, move the machine, set it in
a safe posture, then have inspection carried out immedi-
ately.
q For details of the warning displays, see "WARNING DIS-
PLAY (3-15)" and "Troubles and actions (3-229)".
3–48
USER MENU SELECTOR SWITCH

USER MENU SELECTOR SWITCH:PC220-Q1C3-100K00A
When switch F6 is pressed on the standard screen, the user

menu screen will be displayed on which you can make various
settings for the machine in the monitor display.
3–49
USER MENU
USER MENU:PC220-Q1C3-100K01A
The user menu consists of the following kinds. Press switches

F1 and F2 to move to right and left for selecting menu screens.
(a): ECO guidance
(b): Machine settings
(c): KDPF regeneration
(d): Maintenance
(e): Monitor setting
(f): Mail check
These menus (a) to (f) are for setting and confirming the following items:
For operations in each menu, see the detailed explanation pages of respective items.
(a) ECO guidance (c) KDPF regeneration
q Check of operating record q Setting for regeneration stop
q Check of ECO guidance record q Operation of manual stationary regeneration
q Check and reset of fuel consumption record (d) Maintenance
q Display setting q Check and reset of various maintenance times
(b) Machine settings (e) Monitor setting
q Economy mode adjustment q Screen adjustment
q Breaker setting (if equipped) q Screen adjustment (Camera)
q Attachment setting (if equipped) q Clock adjustment
q Language selection
(f) Mail check
q Check of mail contents and reply to mail
q On the User Menu screen, it is possible to carry out the fol-

lowing operations with switches F1 to F6.
3–50
F1: Moves to the left menu. When on the left-end menu, it

moves to the right-end menu.
F2: Moves to the right menu. When on the right-end menu, it
moves to the left-end menu.
F3: Moves to next item (1 line down). When on the last line, it
moves to the top line on the next page.
F4: Moves to previous item (1 line up). When on the top line, it
moves to the last line on the previous page.

F6: Displays the setting screen for selected item.
q If no switch is operated for 30 seconds on the user menu
screen, the screen automatically returns to the previous
screen.
ECO GUIDANCE
ECO GUIDANCE:PC-Q1L3-100K00A
Each item of this menu (a) is used for displaying and setting the
notification relevant to energy saving.
3–51
OPERATING RECORD
Select operating record (1) from the ECO guidance menu
screen, then press switch F6.
Using the operating record menu, display the operating hours,
average fuel consumption, actual operating hours, fuel con-
sumption in actual operating hours, fuel consumption in the
period, idling hours and E mode time ratio on daily basis or on
a split measurement period basis.
OPERATION ON THE OPERATING RECORD SCREEN

On the operating record screen, it is possible to carry out the
following operations with switches F3 to F5.
F3: Displays the next page. When on the last page, it displays
the first page.
F4: Displays the previous page. When on the first page, it dis-
plays the last page.
F5: Returns to the ECO guidance menu screen.
ENERGY SAVING (ECO) GUIDANCE RECORD

Select energy saving (ECO) guidance record (2) from the ECO
guidance menu screen, then press switch F6.
From the energy saving (ECO) guidance record menu, display
the frequency of display of the energy saving (ECO) guidance
on a daily basis or during the split measurement period.
OPERATIONS ON THE ENERGY SAVING (ECO) GUIDANCE SCREEN

On the energy saving (ECO) guidance record screen, it is pos-
sible to carry out the following operation with switch F3.
3–52
REMARK
Energy saving (ECO) guidance denotes displaying the guid-
ance for energy saving operation. This display may appear on
the standard screen while the machine is in operation.
For details, see "ECO GUIDANCE (3-30)".
FUEL CONSUMPTION RECORD

Select fuel consumption record (3) from the ECO guidance
menu screen, then press switch F6.
Using the fuel consumption record menu, display the graph of
hourly average fuel consumption during the last 12 hours or the
graph of daily fuel consumption during the last one week.
OPERATION ON THE FUEL CONSUMPTION RECORD SCREEN

On the fuel consumption record screen, it is possible to carry
out the following operations with switches F1, F2 and F5.
F1: Clears the graph data.

F2: Switches graphical displays of the average fuel consump-
tion.
REMARK
The displayed value of fuel consumption may differ from the actual value due to the operating conditions of the
customers (fuel, weather or work contents, etc.).
3–53
SWITCHING OF A DISPLAYED GRAPH

On the fuel consumption record screen, it is possible to change
the currently displayed graph to another with switch F2.
REMARK
There are two types of graphs. One shows hourly average fuel
consumption during the last 12 hours and the other is daily
average fuel consumption during the last one week. Switching
between them is available.
DELETING FUEL CONSUMPTION RECORD

1. When the switch F1 (CLEAR) is pressed, the reconfirmation
screen shown in the figure on the right is displayed.
2. When the switch F6 is pressed, graphs of data of the last 12
hours and the last one week are both deleted, and returns
to the fuel consumption record screen.
REMARK
When cancelling data deletion (clear), press switch F5.
3–54
DISPLAY SETTING
Select display setting (4) from the ECO guidance menu screen,
then press switch F6.
From the display setting menu, following operations are availa-
ble.
q Setting the fuel consumption gauge
q Switching Display/Non-display of ECO Gauge
q Setting the Target Fuel Consumption Value Displayed in the
ECO Gauge
q Switching Display/Non-display of Energy Saving (ECO)
Guidance
q Switching display/non-display of guidance when the starting
key is turned off
OPERATIONS ON THE DISPLAY SETTING SCREEN

On the display setting screen, it is possible to carry out the following operations with switches F3 to F6.
F3: Selects the next item (a line down below the current one). When on the last line, it moves to the top line on the
next page.
F4: Moves to previous item (1 line up). When on the top line, it moves to the last line on the previous page.
SETTING THE DISPLAY OF THE FUEL CONSUMPTION GAUGE
Is possible to change the display of fuel consumption gauge (5)
and the setting of Display/Non-display.
1. Select display fuel consumption gauge (6) from the display

setting screen, then press switch F6.
On the display setting screen, it is possible to carry out the fol-
F3: Selects the next item (a line down below the current one).
When on the last line, it moves to the top line on the next page.
F5: Cancels the setting and returns to the display setting
screen.
F6: Changes the setting and returns to the display setting
screen.
3–55
2. The display setting of fuel consumption gauge screen

appears.
q 1 day
Displays the average fuel consumption from 0:00 a.m. of
the day to 0:00 a.m. of the next day.
q Split
Displays the average fuel consumption during the split
measurement period.
Select the split to start the automatic measurement of
fuel consumption.
REMARK
If you select the split measurement, the measurement
stop switch (STOP) is displayed on the operating record
screen and the energy saving (ECO) guidance record
screen.
When you stop the measurement, move from ECO guid-
ance menu (a) screen to the operating record screen or
energy saving (ECO) guidance record screen, then
press the measurement stop switch F1 (STOP).
q No
Does not display the fuel consumption gauge.
SWITCHING DISPLAY/NON-DISPLAY OF ECO GAUGE

Is possible to change the setting of Display/Non-display of
ECO gauge (7).
3–56
1. Select the ECO gauge display (8) from the display setting
2. The ECO gauge display setting screen appears.
q ON: Displays the ECO gauge (7) on the standard
screen.
q OFF: Does not display ECO gauge (7) on the standard
screen.
screen.
screen.
SETTING THE TARGET FUEL CONSUMPTION VALUE DISPLAYED IN THE ECO GAUGE
Is possible to change the target fuel consumption value (the
upper limit value of the green range) of the ECO gauge (7).
1. Select the target fuel consumption value displayed in the
ECO gauge (9) from the display setting screen, then press
switch F6.
2. The target fuel consumption value displayed in ECO gauge
setting screen appears.
On the display setting screen, it is possible to carry out the
following operations with switches F3 to F6.
F3: Decreases the target fuel consumption value by 1 litre /h.
F4: Increases the target fuel consumption value by 1 litre /h.
screen.
screen.
3–57
SWITCHING DISPLAY/NON-DISPLAY OF ENERGY SAVING (ECO) GUIDANCE

It is possible to change the setting of Display/Non-display of energy saving (ECO) guidance (10).
1. Select energy saving (ECO) guidance display (11) from the
display setting screen, then press switch F6.
2. The energy saving (ECO) guidance display setting screen
appears.
q ON: Displays energy saving (ECO) guidance (10) on the
standard screen.
q OFF: Does not display energy saving (ECO) guidance
(10) on the standard screen.
screen.
screen.
3–58
SWITCHING DISPLAY/NON-DISPLAY OF GUIDANCE WHEN THE STARTING KEY IS TURNED OFF

It is possible to change the setting of Display/Non-display of
guidance (12) when the starting key is turned off.
1. Select guidance display when starting key is OFF (13) from

the display setting screen, then press switch F6.
2. The guidance display setting screen for when starting key is
OFF appears.
q ON: Displays energy saving (ECO) guidance (12) on the
exit screen.
q OFF: Does not display energy saving (ECO) guidance
(12) on the exit screen.
screen.
screen.
3–59
MACHINE SETTINGS
Machine settings:PC-Q1C9-100K00A
On this menu (b), it is possible to set items of machine.
ECONOMY MODE ADJUSTMENT

Select economy mode adjustment (1) on the machine setting
menu screen, then press switch F6.
On the economy mode adjustment menu, it is possible to
adjust the engine output in E mode.
In the economy mode, the higher the selection is made from
E0, the lower engine output becomes, however, the fuel con-
sumption becomes better accordingly.
OPERATION ON THE ECONOMY MODE ADJUSTMENT SCREEN

On the economy mode adjustment menu screen, it is possible
to carry out the following operations with switches F3 to F6.
F3: Moves to next item (1 line down). When on the last line, it
moves to the top line on the next page.
F5: Cancels selection and returns to machine setting menu
screen.
F6: Selects an adjustment mode and returns to machine set-
ting menu screen.
3–60
BREAKER SETTING
1. Move to the machine setting menu (b) on the user menu.
2. Select the breaker setting menu (2), then press switch F6.
3. On the breaker setting screen shown on the right, select
breaker and press switch F6.
On the breaker setting screen shown on the right, it is
possible to carry out the following operations with switches
F1 to F6.
F1: Changes the name of the selected breaker setting.
F2: Changes the oil flow of the selected breaker setting.
F3: Moves to next item (1 line down). When on the last line,
it moves to the top line on the next page.
F4: Moves to previous item (1 line up). When on the top line,
it moves to the last line on the previous page.
screen.
F6: Allocates the selected setting to that of B mode.
CHANGING OF THE BREAKER SETTING NAME

It is possible to change the breaker setting name as you like.
Alphabetical letters A to Z, Arabic numerals 0 to 9, symbols #, +, -, and / are available for the name.
1. On the breaker setting screen, select a breaker to change
its name, then press switch F6.
2. The breaker name setting screen is displayed.

On the breaker name setting screen, it is possible to carry
out the following operations with switches F1 to F6.
F1: "CLEAR" Deletes all the letters.
(If some letters are left.)
F1: "DEFAULT" Displays the initial name.
(If all the letters are deleted.)
F2: Moves 1 letter to right.
F3: Moves to the next alphabet, numeral, or symbol.
F4: Moves to the previous alphabet, numeral, or symbol.
F5: Returns to the breaker setting screen without changing
the name.
F6: Accepts change and returns to the breaker setting
screen.
3–61
CHANGING BREAKER OIL FLOW SETTING

1. On the breaker setting screen, select a breaker to change
its oil flow, then press switch F2.
2. The breaker oil flow setting screen is displayed.

On the breaker oil flow setting screen, it is possible to carry
F3: Decrease the flow by 1 scale.
F4: Increase the flow by 1 scale.
F5:Returns to the breaker setting screen without changing
the oil flow.
F6: Accepts the oil flow setting and returns to the breaker
setting screen.
(X): Present oil flow setting
(Y): Min. adjusted oil flow
(Z): Max. adjusted oil flow
ATTACHMENT SETTING
On machines ready for attachment, it is possible on the attachment setting menu to adjust the oil flow in ATT/P
mode and ATT/E mode to match the attachment.
For machines that have no attachment, the attachment setting menu is not displayed.
CHANGING ATTACHMENT SETTING
1. Move to the machine setting menu (b) on the user menu.
2. Select the attachment setting menu (3), then press switch
F6.
3. On the attachment setting screen shown on the right, select
an attachment to adjust and press switch F6.
On the attachment setting screen shown on the right, it is
possible to carry out the following operations with switches
F1 to F6.
F1: Change the name of the selected attachment setting.
F2: Change the oil flow of the selected attachment setting.
F3: Moves to next item (1 line down). When on the last line,
it moves to the top line on the next page.
screen.
F6: Allocates the selected setting to that of ATT/P or ATT/E
mode.
CHANGING ATTACHMENT SETTING NAME

It is possible to change the attachment setting name as you like.
Alphabetical letters A to Z, Arabic numerals 0 to 9, symbols #, +, -, and / are available for the name.
3–62
1. Select an attachment to change its name on the attachment

setting screen, then press switch F6.
2. The attachment name setting screen is displayed.

On the attachment name setting screen, it is possible to
carry out the following operations with switches F1 to F6.
F1: "CLEAR" Deletes all the letters.
(If some letters are left.)
F1: "DEFAULT" Displays the initial name.
(If all the letters are deleted.)
F2: Moves 1 letter to right.
F3: Moves to the next alphabet, numeral, or symbol.
F4: Moves to the previous alphabet, numeral, or symbol.
F5: Returns to the attachment setting screen without
changing the name.
F6: Accepts change and returns to the attachment setting
screen.
q It is not possible to change the name for "No Attach-
ment" setting.
CHANGING ATTACHMENT OIL FLOW SETTING
1. Select an attachment to change its oil flow on the attach-
ment setting screen, then press switch F2.
2. The attachment oil flow setting screen is displayed.

On the attachment oil flow setting screen, it is possible to
F3: Decreases the flow by 1 scale.
F4: Increases the flow by 1 scale.
changing the oil flow.
F6: Accepts the oil flow setting and returns to the attachment
setting screen.
q It is not possible to change the oil flow for "No Attach-
ment" setting.
3–63
ATTACHMENT 2 SETTING
Attachment 2 Setting:PC220_KU-PT5X-100K00A
If installing 2nd attachment line as a field kit ask distributor to change monitor setting to allow 2 attachments (as
shown below).
On machines equipped with 2 attachment lines it is possible on the attachment 2 settings menu to adjust the oil
flow in ATT mode to match the attachment installed.
CHANGING ATTACHMENT OIL FLOW SETTING
1. When attachment 2 is set, the oil flow in ATT mode screen
shows as the drawing on the right.Select the oil flow setting
to be changed and press switch F2.
(a): Oil flow in attachment 1
(b): Oil flow in attachment 2
2. The attachment oil flow setting screen is displayed.

On the attachment oil flow setting screen, it is possible to
F1:Switches the display from attachment 2 oil flow setting
screen to attachment 1 oil flow setting screen.
F2: Switches the display from attachment 1 oil flow setting
screen to attachment 2 oil flow setting screen.
F3: Decreases the flow by 1 scale.
F4: Increases the flow by 1 scale.
changing the oil flow.
F6: Accepts the oil flow setting and returns to the attachment
setting screen.
q The guidance icon "ATT2" (c) is displayed on the attach-
ment 1 oil flow setting screen, and the guidance icon
"ATT1" (d) is displayed on the attachment 2 oil flow set-
ting screen.
q It is not possible to change the oil flow for "No Attach-
ment" setting.
KDPF REGENERATION
KDPF REGENERATION:PC-Q1C8-100K00A
Each item of this menu (c) is to make settings for the KDPF
regeneration.
For details of the KDPF regeneration, see "Handling KDPF (3-
129)".
3–64
MAINTENANCE SCREEN SETTING

MAINTENANCE SCREEN SETTING:PC-Q1C2-100K00A
Each item of this menu (d) is used for displaying and setting the
notification relevant to maintenance.
The items on the maintenance display are as follows.
a b
Air cleaner check and cleaning -
Engine oil change 500 (*1
Engine oil filter change 500 (*1
Fuel main filter change 1000
Fuel pre-filter change 500
Hydraulic oil filter change 1000
Hydraulic tank breather change 500
Damper case service 1000
Final drive oil change 2000
Swing machinery oil change 1000
Hydraulic oil change 5000
KCCV filter change 2000
KDPF filter cleaning 4500
a: Maintenance item
b: Default maintenance interval settings (h)
c: Time remaining until maintenance (h)
*1: When using the engine oil for cold weather area, it is neces-
sary to change the maintenance intervals of the engine oil and
filter cartridge setting. For details of the oil, see "RECOM-
MENDED FUEL, COOLANT, AND LUBRICANT (7-4)".
On the maintenance menu screen, it is possible to carry out the following operations with switches F1 to F6.
F1, F2: Selects the right and left menus.
F3: Selects the next item (a line down below the current one). When on the last line, it moves to the top line on the
next page.
F6: If this switch is kept pressed, the screen changes to the screen for resetting the remaining time to the mainte-
nance for the selected item.
REMARK
When resetting the remaining time, keep switch F6 pressed for at least 1.5 seconds. If this time is short, the
switch operating sound can be heard, but the screen does not switch to the screen for resetting the remaining
time to the maintenance.
q If no switch is operated for 30 seconds on the maintenance menu screen, the screen automatically returns to
the standard screen.
q When the maintenance time monitor lights up on the standard screen, press F6 on the standard screen and
the screen automatically displays the maintenance menu screen.
q On the maintenance menu screen, if the time remaining to the maintenance for any item is less than 30 hours
(initial setting value), the remaining time display (c) is highlighted in yellow. If the time remaining to the mainte-
nance is less than 0 hour, display (c) is highlighted in red.
q If you want to change the setting for the maintenance interval or maintenance interval notice time (initial set-
ting: 30 hours), please consult your Komatsu distributor.
3–65
OPERATIONS ON THE MAINTENANCE INTERVAL RESET SCREEN

On the maintenance menu screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the
maintenance interval reset screen.
Reset the remaining time to the maintenance on this screen.
1. Press switch F6 when the reset screen is in the condition
shown in the drawing on the right. The screen switches to
the reconfirmation screen.
REMARK
q When cancelling the reset, press switch F5. The screen
returns to the maintenance menu screen.
q On the reset screen, if no switch is operated for more than
30 seconds, the screen automatically changes to the main-
tenance menu screen.
2. The reconfirmation screen shown on the right is displayed.

3. If switch F6 is pressed again, the remaining time is reset
and the screen returns to the maintenance menu screen.
REMARK
q When cancelling the reset, press switch F5. The screen
returns to the maintenance menu screen.
q On the reconfirmation screen, if no switch is operated for
more than 30 seconds, the screen automatically returns to
the maintenance menu screen.
3–66
MONITOR SETTING
Monitor setting:PC-Q193-110K00A
Each item of this menu (e) is to make settings for the monitor.
SCREEN ADJUSTMENT
SCREEN ADJUSTMENT:PC-Q19C-100K00A
Use the screen adjustment menu to adjust brightness of the monitor screen.
1. Select screen adjustment (1) on the monitor setting menu
2. Use switches F2 to F6 to adjust brightness the screen.
F2: Resets an adjusted value to initial value
F3: Moves the indicator to the left by one notch
F4: Moves the indicator to the right by one notch
F5: Cancels the change and returns to the monitor setting
menu screen.
F6: Accepts the change and then returns to the monitor
setting menu screen.
REMARK
q If the light switch is at night mode ON, and the screen is
adjusted, it is possible to adjust the brightness of the moni-
tor screen (night mode).
q If the light switch is at day mode ON, and the screen is
adjusted, it is possible to adjust the brightness of the moni-
tor screen (day mode).
q As long as "*" mark is displayed in the upper right corner of
the screen, brightness is automatically restricted by the
machine monitor to protect the liquid crystal. Screen adjust-
ment may not change the screen brightness as long as "*"
mark is displayed. However, it is not an error.
SCREEN ADJUSTMENT (CAMERA)
Use the screen adjustment menu (camera) to adjust brightness of the camera screen.
3–67
1. Select screen adjustment (camera) (2) on the monitor set-

ting menu screen, then press switch F6.
2. Use switches F2 to F6 to adjust brightness the screen.

F2: Resets an adjusted value to initial value
F3: Moves the indicator to the left by one notch
F4: Moves the indicator to the right by one notch
F5: Cancels the change and returns to the monitor setting
menu screen.
F6: Accepts the change and then returns to the monitor
setting menu screen.
REMARK
As long as "*" mark is displayed in the upper right corner of the
screen, brightness is automatically restricted by the machine
monitor to protect the liquid crystal. Screen adjustment may not
change the screen brightness as long as "*" mark is displayed.
However, it is not an error.
CLOCK ADJUSTMENT
CLOCK ADJUSTMENT:PC-Q1MC-100K00A
On the clock adjustment menu, it is possible to change the setting of the clock displayed on the standard screen
of the monitor.
1. Select clock adjustment (3) on the monitor setting menu
screen, then press switch F6. The screen switches to the
selection menu for the clock adjustment.
q The following five items can be changed.
(a): GPS Synchronization
(b): Calendar
(c): Time
(d): 12h/24h Mode
(e): Daylight Saving Time
REMARK
q Since after a long-term storage of a monitor, (b) Calendar
and (c) Time are reset, you must readjust them.
q When the GPS Synchronization is set to ON, the above are
automatically readjusted.
2. Implement the following setup procedure by operating

switches F3 to F6 on the selection menu screen for the
clock adjustment.
3–68
GPS SYNCHRONIZATION
On machines equipped with KOMTRAX, turning the GPS Syn-
chronization menu ON enables automatic setting of the moni-
tor's date and time in accordance with the GPS's clock.
F5: Cancels change and returns to the clock adjustment
screen.
REMARK
q When the machine is in the environment where the radio
waves from GPS cannot be received, such as inside of a
building, the automatic setting function might be disable.
q Turning the GPS Synchronization menu ON disables
selecting the menu for (b) Calendar and (c) Time.
CALENDAR SETTING
Adjust the date of the monitor.
REMARK
As long as the GPS Synchronization menu is turned ON, the Calendar menu is not selectable.
1. Select Calendar (b) on the clock adjustment screen, then
press switch F6.
2. The calendar setting screen is displayed.

When year display (A) is highlighted in yellow, operate the
switches as follows to change year display (A). If it is not
necessary to change the year setting, press switch F6.
F3: Calendar goes back one year
F4: Calendar advances one year
screen.
F6: Proceeds to setting for month
3–69
3. When month display (B) is highlighted in yellow, operate the

switches as follows to change month display (B). If it is not
necessary to change the month, press switch F6.
F3: Calendar goes back one month
F4: Calendar advances one month
F5: Cancels change and returns to the year setting screen.
F6: Proceeds to setting for date.
4. When date display (C) is highlighted in yellow, operate the

switches as follows to change day display (C). If it is not
necessary to change the day, press switch F6.
F3: Calendar goes back one day.
F4: Calendar advances one day.
F5: Cancels change and returns to the month setting screen.
F6: Accepts change and returns to the clock adjustment
screen.
TIME
Adjust the time of the monitor clock.
REMARK
As long as the GPS Synchronization menu is turned ON, the time setting menu is not selectable.
3–70
1. Select Time (c) on the clock adjustment screen, then press

switch F6.
2. The time setting screen is displayed.

When hour display (D) is highlighted in yellow, operate the
switches as follows to change hour display (D). If it is not
necessary to change the hour setting, press switch F6.
F3: Time goes back one hour.
F4: Time advances one hour
screen.
F6: Proceeds to setting for minute.
3. When minute display (E) is highlighted in yellow, operate

the switches as follows to change minute display (E). If it is
not necessary to change the minute, press switch F6.
F3: Time goes back one minute.
F4: Time advances one minute.
F5: Cancels change and returns to the time setting screen.
screen.
3–71
12H/24H MODE
Choose either a 12-hour display (am/pm) or a 24-hour display.
q 24-hour display
q 12-hour display (am/pm)
1. Select 12h/24h Mode (d) on the clock adjustment screen,

then press switch F6.
2. 12h/24h Mode screen appears.

F3: Selects the next item (a line down below the current
one). When on the last line, it moves to the top line on the
next page.
screen.
screen.
DAYLIGHT SAVING TIME

If daylight saving time is turned ON, the clock display becomes 1 hour earlier. If daylight saving time is turned
OFF, the clock display returns to the set time.
1. Select Daylight Saving Time (e) on the clock adjustment
2. The Daylight Saving Time screen is displayed.

F3: Selects the next item (a line down below the current
one). When on the last line, it moves to the top line on the
next page.
screen.
screen.
REMARK
Daylight saving time or summer time means moving the clock
forward an hour to take advantage of the fact that the sun rises
early in summer in our daily life.
3–72
LANGUAGE SELECTION
LANGUAGE SELECTION:PC-Q19B-110K00A
On the language selection menu, it is possible to select the language used on the monitor display.
The languages that can be selected are as follows.
Japanese, English, German, French, Spanish, Portuguese, Italian, Swedish, Dutch, Danish, Norwegian, Finish,
Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Estonian, Latvian, Lithuanian, Bulgarian, Greek, Romanian
and Croat
1. Select Language (4) on the monitor setting menu, then
press switch F6.
2. Select the language to use for the display, then press switch
F6. The screen display changes to the selected language.
q On the language selection screen, it is possible to carry
F3: Moves to item right below.
F4: Moves to item right above.
F5: Cancels change and returns to the monitor setting
screen.
F6: Accepts change and returns to the monitor setting
screen.
MESSAGE DISPLAY
MESSAGE DISPLAY:PC-Q235-100K00A
On machines equipped with KOMTRAX, it is possible to see

the messages from your Komatsu distributor on this menu (f).
When any massage is available, the message monitor at the
left end of the standard screen lights up.
q Lighting statuses of message monitor (1) can be discrimi-
nated as follows:
Lights up green (A): There is any unread information.
Lights up blue (B): There is any read information to which no
reply is made.
No lighting up: There is no information.
REMARK
q When the message monitor lights up blue (B), it means that
no reply has been made yet to any read message to your
Komatsu distributor. Please reply to the message in accord-
ance with the replying method mentioned below:
q If the starting switch is turned OFF when there is any
unread message, the message will be displayed on the
ending screen, and when the monitor is started next time,
the message will change to a read message (the message
monitor: lights up blue (B)).
q The message will be deleted when it becomes out of date
or when a new message reaches.
3–73
MESSAGE CONFIRMING METHOD

1. On the standard screen, press switch F6.
q When there is any message, press switch F6, and the
mail confirmation menu directly opens.
2. Select mail confirmation menu (f), and you can read the
arrived message.
3. In case of a message requesting for reply, the column of

Ten-key input value : [] is displayed in place (2) of the mail
confirmation menu. Make any reply to the message.
REMARK
q (4) is the subject of the received message. When no mes-
sage reached, "There is no message." is displayed in place
(4).
q (5) is the serial number of received messages.
3–74
REPLYING METHOD TO A MESSAGE

1. When replying to a message, input the selected item num-
ber in ten-key input value column (2). The selected item
number is written in place (3) of the message text.
q Input the number by using the monitor panel switch.
Each switch corresponds to the value shown on the right
side below the switch.
q If you input an incorrect number, press switch F5, and
you can clear an input character at a time.
q If switch F5 is pressed when the input column is blank,
the screen returns to the standard screen.
2. After inputting a selected item number, press switch F6.
3. When the message "Will you sent the input value?" is dis-
played in the column (2) of the mail confirmation menu
screen, press switch F6 again. The input value will be sent
out.
q If switch F5 is pressed when the message "Will you
send the input value?" is displayed, the message reply
screen will appear. At this time, the previous input value
will be cleared.
3–75
SWITCHES
SWITCHES:PC220_KU-Q13C-04DK00A
(1) Starting switch (12) Ceiling window wiper switch (if equipped)
(2) Fuel control dial (13) Engine shutdown secondary switch
(3) Cigarette lighter (14) Lower wiper switch (if equipped)
(4) Swing lock switch (15) Seat heater switch
(5) Lamp switch (16) Quick coupler switch
(6) Horn switch (17) Quick coupler switch
(7) One-touch power max. switch (18) 1st attachment proportional control switch
(8) Room lamp switch (19) 2nd attachment proportional control switch
(9) Swing brake cancel switch (if equipped)
(10) Emergency pump drive switch (20) Breaker switch
(11) Revolving warning lamp switch (if equipped) (21) Additional lamps switch (if equipped)
3–76
STARTING SWITCH
Starting Switch:ALL-AKB0-043K00A
Starting switch (1) is used to start or stop the engine.

(A): OFF position The key can be inserted or withdrawn.
Switches for the electrical system (except room lamp), are all
turned off and the engine is stopped.
(B): ON position electric current flows through the charging and
lamp circuits. Keep starting switch key in the ON position while
the engine is running.
(C): START position This is the engine-start position. Keep the key at this position during cranking. Immediately
after starting the engine, release the key.
It will automatically return to the ON position (B).
FUEL CONTROL DIAL

Fuel Control Dial:ALL-AGJ7-043K00A
Dial (2) adjusts the engine speed and output.

(a) Low idling (MIN): Turned fully to the left
(b) Full speed (MAX): Turned fully to the right
CIGARETTE LIGHTER
Cigarette Lighter:ALL-K850-043K00A
This switch (3) is used when lighting cigarettes.

When the cigarette lighter is pushed in, it will return to its origi-
nal position after several seconds, so pull it out to use it.
If the cigarette lighter is removed, the socket can be used as an
85 W (24 V x 3.5 A) power source.
NOTICE
This cigarette lighter is for 24 V. Do not use this as the
power supply for 12 V equipment.
3–77
SWING LOCK SWITCH

k
Swing Lock Switch:PC-JC5P-043K00A
WARNING
q When not using the swing operation, e.g. when travelling, put the swing lock switch to the ON posi-
tion.
q On slopes, even when the swing lock switch is at the ON position, the weight of the work equipment
may cause the upper structure to swing if the swing control lever is operated in the downhill direction,
so always carry out operations carefully.
This switch (4) is used to lock the upper structure so that it can-
not swing.
(a) ON position (actuated): The swing lock is always applied,
and the upper structure will not swing even if the swing is oper-
ated. In this condition, the swing lock lamp lights up.
(b) OFF position (cancelled): The swing lock is released, when
operating the swing control lever, allowing the upper structure
to swing.
LAMP SWITCH
Lamp Switch:ALL-Q6B8-043K00A
This switch (5) is used to light up the working lamp and monitor
illumination.
(a) Night position:
Lamps light up and monitor illumination is set to night mode
(b) Day position:
Lamps light up and monitor illumination is set to day mode
(c) OFF position:
Lamps go out.
(The monitor illumination is set to day mode.)
HORN SWITCH
Horn Switch::PC220_KU-Q544-043K00A
Use this switch (6) to sound the horn.

Press the switch on the right work control lever to sound the
horn.
3–78
ONE-TOUCH POWER MAX. SWITCH

One-Touch Power Max. Switch::PC220_KU-PT5H-043K00A
This switch (7) on the left work equipment control lever is used
to actuate the power max functions.
Press once (single click) and keep the switch pressed. The
one-touch power max. function is actuated for a maximum of
8.5 seconds at P, E, ATT/P, ATT/E mode.
ROOM LAMP SWITCH

Room Lamp Switch:ALL-Q6L3-043K00A
NOTICE
Leaving the room lamp on may cause a dead battery. Do
not forget to turn it off.
Use this switch (8) to light up the room lamp.
(a) ON position: Lamp lights up
(b) OFF position: Lamp goes out
The room lamp lights up even when the starting switch is at the
OFF position.
EMERGENCY PUMP DRIVE SWITCH

EMERGENCY PUMP DRIVE SWITCH:PC-Q5H5-043K00A
NOTICE
q This switch (9) is provided to enable you to carry out operation temporarily, when any problem
occurred on the pump control system. DO NOT use it except in emergencies. Repair the problem as
soon as possible.
q If this switch is moved to the EMERGENCY position by mistake while the machine is operating nor-
mally, "L03" mark is shown in the display.
If "L03" is displayed during operation, press the monitor function switch F5 to check whether the occur-
ring failure code includes any of the hydraulic system errors "DXA9KB", "DXA8KB", "DXA9KA" or
"DXA8KA". Then make sure this switch is set to "Normal" position.
This switch (9) is used to make it possible to carry out opera-
tions temporarily if any problem should occur in the pump con-
trol system.
(a) EMERGENCY: When abnormal (switch is set up)
(b) NORMAL: When normal (switch is set down)
If the occurring failure code includes any of the hydraulic sys-
tem errors "DXA9KB", "DXA8KB", "DXA9KA" or "DXA8KA",
setting this switch to emergency position (a) allows resuming
the operation.
3–79
SWING BRAKE CANCEL SWITCH

SWING BRAKE CANCEL SWITCH:PC220-JA16-043K00A
NOTICE
This switch (10) makes it possible to perform swing operations for a short time even when there is a prob-
lem in the swing holding brake electric system. DO NOT use this switch except in emergencies. Repair
the problem as soon as possible.
This switch (10) is used to make it possible to carry out opera-
tions temporarily when the swing holding brake system is out of
order (when no swing is possible even though "L03" is not
shown on the display).
(a) FREE: When abnormal (move switch up)
(b) NORMAL: When normal (move switch down)
q When no swing is possible even though "L03" is not shown
on the display, the operation may become possible if this
switch set to FREE position (a).
q When the switch is moved to FREE position (a), the swing
lock monitor flashes.
REVOLVING WARNING LAMP SWITCH

Revolving Warning Lamp Switch:ALL-Q5F1-043K00A
(if equipped)
Use this switch (11) to light up the yellow rotating lamp on top
of the cab.
(a) ON: Lamps light up
(b) OFF: Lamps go out
3–80
CEILING WINDOW WIPER SWITCH

CEILING WINDOW WIPER SWITCH:PC220_KU-K77F-043K00A
(if equipped)
This switch (12) is used to actuate the ceiling window wiper
and spray the washing water.
q (a) Wiper position: To actuate the ceiling window wiper
q (b) Washer position:
While depressing the switch, the washing water for the
ceiling window is sprayed and wiper actuates at the same
time.
By finger off the switch, it returns to (a) position, washing
water stops, and only ceiling window wiper actuates.
q (c) Stop position: The ceiling window wiper stops.
(1):nozzle
(2):ceiling window
(3):ceiling window wiper
3–81
ENGINE SHUTDOWN SECONDARY SWITCH

ENGINE SHUTDOWN SECONDARY SWITCH:PC-AKHL-100K00A
NOTICE
q Do not use this switch (13) except in emergencies.
Ask for repair of the problem as soon as possible.
q If this switch is moved to the "STOP ENGINE" position by mistake while the machine is operating nor-
mally, "ENGINE SHUTDOWN SECONDARY SWITCH ON" is displayed on the machine monitor.
If "ENGINE SHUTDOWN SECONDARY SWITCH ON" is displayed on the machine monitor, check that
the switch cover is closed and the switch is in the "NORMAL" position. If not, set it to the "NORMAL"
position.
This switch (13) is used to stop the engine when the starting switch is turned to the OFF position but the engine
does not stop.
1. Raise cover (C) to open it.
2. Set switch (13) in upper position (a), and the engine stops.
(a) STOP ENGINE: When abnormal (switch is set up)
(b) NORMAL: When normal (switch is set down)
q When cover (c) is closed, switch (13) is automatically
returned to normal position (b).
q When the starting switch is turned to the ON position
while this switch is in STOP ENGINE position (a),
"ENGINE SHUTDOWN SECONDARY SWITCH ON" is
displayed on the machine monitor.
If this screen is displayed, return switch (13) to normal
position (b).
3–82
LOWER WIPER SWITCH

LOWER WIPER SWITCH:PC220_KU-K77H-043K00A
(if equipped)
When this switch (14) is pressed, the lower wiper is turned on.
q (a) ON: Lower wiper operates.
q (b) OFF: Lower wiper stops.
SEAT HEATER SWITCH

Seat heater switch:PC220_KU-K313-043K00A
This switch (15) is used to warm the seat.

q (a) OFF
q (b) ON: Seat is warmed.
QUICK COUPLER SWITCHES

QUICK COUPLER SWITCHES:PC220_KU-LGC8-043K00A
To operate the quick coupler circuit switches (16) on the RHS console and (17) on the LH PPC lever must be
operated together.
Refer to "GENERAL PRECAUTIONS FOR SAFETY (6-2)" for an explanation of these switches operation.
1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH

1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH:PC220_KU-PT0R-043K00A
This switch (18) is a roller proportional control switch used to operate the 1st attachment circuit (e.g. crusher,
clamshell open/close).
Refer to “1st-line attachment proportional switch (6-17)”for warnings and explanation of operation.
2ND ATTACHMENT PROPORTIONAL CONTROL SWITCH

2ND ATTACHMENT PROPORTIONAL CONTROL SWITCH:PC220_KU-PT0T-043K00A
This switch (19) is a roller proportional control switch used to operate the 2nd attachment circuit (e.g. clamshell
rotation).
Refer to “2nd-line attachment proportional switch (6-17)”for warnings and explanation of operation.
BREAKER SWITCH
BREAKER SWITCH:PC220_KU-LGGA-043K00A
Switch (20) operates the breaker, Refer to “Breaker mode switch (6-17)”for warnings and explanation of opera-
tion.
3–83
ADDITIONAL LAMPS SWITCH

ADDITIONAL LAMPS SWITCH:PC220_KU-Q6BC-043K00A
(if equipped)
Switch (21) is used to turn on the cab front lamps, cab rear
lamps and extra boom lamps (NB If fitted by customer).
(a) ON: Lamps light up.
(b) OFF: Lamps go out.
3–84
CONTROL LEVERS AND PEDALS

CONTROL LEVERS AND PEDALS:PC220_KU-K191-04DK00A
(1) Lock lever (3) Left work equipment control lever (with auto-
deceleration system)
(2) Travel levers (4) Right work equipment control lever (with pedal
and auto-deceleration system)
LOCK LEVER
k
Lock Lever:PC-Q5J0-043K00A
WARNING
q When leaving the operator's seat, set the lock lever securely to the LOCK position. If the lock lever is
not at the LOCK position and the control levers or control pedals are touched by mistake, it may lead
to serious personal injury.
q Always check that the lock lever is in LOCK position.
q When pulling the lock lever up, or when pushing the lock lever down, be careful not to touch the work
equipment control lever.
q Before raising the lock lever, make sure that all levers and pedals are set to the NEUTRAL position.
This lever (1) is a device to lock the work equipment, swing,

travel, and attachment control levers (if equipped).
(L) LOCK position:
Even when levers or attachment control pedal (if equipped) are
operated, machine does not move
(F) FREE position:
Machine moves according to operation of levers or attachment
control pedal (if equipped).
REMARK
This lock lever is of hydraulic lock type. Accordingly, when it is in the LOCK position (L), the control levers or con-
trol pedals move but the machine does not move.
3–85
TRAVEL LEVERS
k
Travel Levers:PC-C6W1-043K00A
WARNING
q If you carry out operations with your foot on the pedal, the machine may suddenly start if you depress
the pedal by mistake, and this may lead to serious personal injury. Be extremely careful when using
the pedal for travel and steering operations, and do not put your foot on the pedal when it is not neces-
sary.
q When the track frame is facing the rear, the direction of operation of the steering lever is the opposite
to the direction of movement of the machine (forward/reverse, right/left turn).
When operating the travel lever, always check if the track frame is facing the front or the rear. (If the
sprocket is at the rear, the track frame is facing the front).
This lever (2) is used to change the direction of travel between

forward and reverse. () shows the pedal operation.
(a) FORWARD:
The lever is pushed forward
(The pedal is angled forward)
(b) REVERSE:
The lever is pulled back
(The pedal is angled back)
N (NEUTRAL):
The machine stops.
REMARK
If the lever is shifted to the FORWARD or REVERSE position
from the NEUTRAL position, the alarm sounds to warn that the
machine is starting to move.
WORK EQUIPMENT CONTROL LEVER

Work Equipment Control Lever:PC-PK11-043K00A
Left work equipment control lever (3) is used to operate the

arm and upper structure.
Arm control
(a): Arm OUT
(b): Arm IN
Swing control
(c): Right swing
(d): Left swing
N (NEUTRAL):
The upper structure and arm are held in position and do not
move.
3–86
Right work equipment control lever (4) is used to operate the

boom and bucket.
Boom control
(a): Boom RAISE
(b): Boom LOWER
Bucket control
(c): Bucket DUMP
(d): Bucket CURL
N (NEUTRAL):
The boom and bucket are held in position and do not move.
CEILING WINDOW
CEILING WINDOW:PC220_KU-K18H-100K00A
The operator cab is provided with a fixed clear ceiling window

for improved visibility.
An optional guard can be provided for working in areas at risk
from falling objects.
3–87
OPENING AND CLOSING CAB FRONT WINDOW

k
Opening and closing cab front window:PC220-K181-100K00A
WARNING
q When opening or closing the front window, bottom window, or door, always set the lock lever to the
LOCK position.
If the lock lever is at the FREE position and the control lever or control pedal is touched by mistake,
this may lead to a serious personal accident.
q When opening or closing the front window, stop the machine on level ground, lower the work equip-
ment completely to the ground, stop the engine, then carry out the operation.
q When opening the front window, hold the handle securely with both hands, pull up, and do not let go
until the automatic lock catch is locked.
q When closing the front window, the window will move quicker under its own weight. Hold the handles securely
with both hands when closing it.
It is possible to stow the front window (upper side) in the roof of the operator's compartment.
OPENING
1. Stop the machine on level ground, lower the work equip-
ment completely to the ground, then stop the engine.
2. Set lock lever (1) securely to LOCK position (L).
3. Check that the wiper blade is stowed in the right stay.
4. Hold 2 handles (A) on the right and left top sides of the front
window, and pull 2 levers (B) to release the locks at the top
of the front window. The top of the front window will come
out.
3–88
3–89
5. Hold lower handle (C) with your left hand from inside the
operator's cab, and with your right hand, grip top handle
(D), pull it up, and push it against lock catch (E) at the rear
of the cab securely to lock the window.
REMARK
You may not use the two handles (A) on the left and right top
sides of the front window to pull up the front window. Do not
pull down the front window with the handles (A).
6. Check that lever (B) is securely at the LOCK position.

q If the arrow on lock case (F) matches the position of the
arrow on lever (B), the lock is engaged. Check visually.
q If the arrow on lock case (F) does not match the position
of the arrow on lever (B), the lock is not engaged.
Repeat the operation in Step 5 to engage the lock.
3–90
CLOSING
k CAUTION
When closing the window, lower it slowly and be careful not to get your hand caught.

ment completely to the ground, then stop the engine.
2. Set lock lever (1) securely to LOCK position (L).
3. Grip right and left handles (A), and pull down lever (B) to
release the lock.
4. Grip handle (C) at the bottom of the front window with your
left hand and handle (D) at the top with your right hand,
push to the front, then lower slowly.
REMARK
The handles (A) on the right and left top sides of the front win-
dow are not for pulling up and down the window. Do not pull
down the front window with the handles (A).
3–91
5. When the bottom of the window reaches the top of lower

side window, push the top of the window to the front to push
it against right and left lock catches (G) and engage the
lock.
6. Check that lever (B) is securely at the LOCK position.

q If the arrow on lock case (F) matches the position of the
arrow on lever (B), the lock is engaged. Check visually.
q If the arrow on lock case (F) does not match the position
of the arrow on lever (B), the lock is not engaged.
Repeat the operation in Step 5 to engage the lock.
REMOVING LOWER WINDSHIELD (UPPER SIDE)

1. Open the front window (upper side), then hold grip (1), pull
up, and remove the lower side window.
q If sand or dust is collected at the bottom of the front window

(lower side), it will be difficult to remove the window. In addi-
tion, when stowing, the sand and dust stuck to the glass will
be carried inside the cab. To prevent this, clean area (A)
before removing.
2. After removing the lower side window, store it at the right

rear of the operator's cab, and set lever (2) to lock position
(B) to hold it securely in position.
3. When removing it, set lever (2) to release position (C), hold
the glass with both hands, and pull it up.
3–92
EMERGENCY ESCAPE HAMMER

k
Emergency escape hammer:ALL-Q5K1-043K00A
CAUTION
q If it is necessary to break the window glass with the hammer, be extremely careful not to injure your-
self on the flying pieces of broken glass.
q To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through
the window. Be careful also not to slip on the broken pieces of glass.
If it should become impossible to open the cab door for any

reason, and it is necessary to make an emergency escape
from the operator's compartment, use hammer (A) to escape.
To escape from the operator's cab, use hammer (A) to break

the glass and escape through the window.
3–93
E X P L A N A T IO N O F C O M P O N E N T S OPERATION
DOOR LOCK
k
Door lock:PC-K164-043K00A
WARNING
q Before the releasing the door lock, always stop the machine on level ground.
q Never release the door lock on a slope. The door may suddenly close and cause injury.
q When releasing the door lock, do not extend your body or hands outside the machine and do not put
your hands on the door frame. The door may suddenly close and cause injury.
Use the door lock to fix the door in position after opening it.
1. Push the door against catch (1) to lock it in position.
2. When closing the door, push down lever (2) on the left of
the operator's seat to release the catch.
3. When fixing the door in position, lock it firmly to the catch.
CAB DOOR HINGE

Cab door hinge:PC-K166-041K00A
The cab door hinge has two rotation axes with stoppers (S).
REMARK
When opening and closing the cab door, hitting sound of stop-
per (S) is heard, but this is not trouble.
3–94
OPENING AND CLOSING ENGINE HOOD

k
Opening and closing engine hood:PC-H540-100K00A
CAUTION
q When opening or closing the engine hood, stop the machine on level ground, lower the work equip-
ment to the ground, stop the engine, then carry out the operation.
q When opening the engine hood, do not release the handle until the stay is set in the lock position
securely.
q When closing the engine hood, hold the handle securely since the engine hood may moves down
because of its weight.
If the engine hood is not locked, it may close suddenly because of wind etc.
q Just after the engine is stopped, the engine hood and KDPF are hot. Wait until they cool down, and
then open or close the engine hood.
WHEN OPENING (NORMAL CASE: INTERMEDIATE LOCK POSITION)

ment to the ground, then stop the engine.
2. Pull right and left levers (A) to take off rings (B) from hooks
(C).
3. Holding handle (D), pull up the engine hood, and pull stay
(E) in the direction of the arrow and set it securely in LOCK
position (1).
REMARK
The engine hood can be locked at 2 different opening angles.
However, lock it to intermediate LOCK position (1) usually for
inspection etc.
3–95
REMARK
To open the engine hood fully, hold handle (D) and pull up the
engine hood. Stay (E) stops first at branch portion (3) of the
guide groove. Then, while pushing stay (E) in the direction of
the arrow, open the engine hood and set stay (E) in LOCK posi-
tion (2).
3–96
WHEN CLOSING (NORMAL CASE: INTERMEDIATE LOCK POSITION)

1. While holding handle (D) to support the hood, push stay (E)
in the direction of the arrow and take it off from intermediate
LOCK position (1). Check that stay (E) is set in guide
groove (4), and then lower the engine hood.
REMARK
q Do not lower the engine hood forcibly while stay (E) is not
set in guide groove (4). If you do so, stay (E) may be
deformed.
q Do not release handle (D) until the engine hood is lowered
fully.
2. Lower the engine hood, hitch rings (B) of right and left
levers (A) to hooks (C), and pull up levers (A) and lock
them.
REMARK
q To close the engine hood from the full open position, hold
grip (D) to support the engine hood, and pull stay (E) in the
direction of the arrow. Check that stay (E) has come off full
open LOCK position (2) and is set in guide groove (5), and
then lower the engine hood. When the engine hood is low-
ered, it stops at intermediate LOCK position (1). Then,
close and lock the engine hood according to closing Steps 1
and 2 described above.
3–97
q Do not lower the engine hood while stay (E) is not set in
guide grooves (4) and (5). If you do so, stay (E) may be
deformed.
q Do not release handle (D) until the engine hood is lowered
fully.
3–98
CAPS AND COVERS WITH LOCK

Caps and covers with lock:ALL-Q8E0-043K00A
Use the starting switch key to open and close the locks on the caps and covers.
For details of the locations of the caps and covers with locks, see "LOCKING (3-206)".
Insert the key as far as it will go to the shoulder (A). If the key is
turned before it is inserted all the way, it may break.
OPEN AND CLOSE CAPS WITH LOCK

OPEN AND CLOSE CAPS WITH LOCK:ALL-Q8E1-100K00A
OPENING THE CAP

1. Insert the key into the key slot.
2. Turn the key clockwise, align the key groove with mark (1)
on the cap, then open the cap.
Position (A): OPEN
Position (B): LOCK
LOCKING THE CAP

1. Turn the cap until tight, then insert the key into the key slot.
2. Turn the starting switch key to LOCK position (B), then remove the key.
3–99
OPEN AND CLOSE COVERS WITH LOCK

OPEN AND CLOSE COVERS WITH LOCK:PC-Q8E2-100K00A
OPENING THE COVER (LOCKED COVER))

4. Turn the key counterclockwise and open the cover by pull-
ing the cover handle.
Position (A): OPEN
position (B): LOCK
LOCKING THE COVER

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and take the key out.
LOCK AND UNLOCK ENGINE HOOD

LOCK AND UNLOCK ENGINE HOOD:PC-H54B-100K00A
OPENING THE HOOD (LOCKED HOOD)

2. Turn the key counterclockwise (A) and take the key out.
Position (A): OPEN Position (B): CLOSE
3. Pull lever grip (1) and take off ring (2) at the bottom of the
lever from the hook.
4. Similarly, take off the ring from the hook for left lever
according to Step 3.
5. Hold hood handle (3) and pull up to open the hood.
LOCKING THE HOOD

1. Holding hood handle (3), lower the hood.
2. Hitch rings (2) at the bottom of the right and left levers to the hooks and press lever grips (1) inward to close
the hood.
4. Turn the key clockwise (B) and take the key out.
Position (A): OPEN Position (B): CLOSE
3–100
LOCK AND UNLOCK CAB DOOR

LOCK AND UNLOCK CAB DOOR:PC-K164-100K00A
OPENING THE DOOR (LOCKED DOOR)

6. Turn the key clockwise to unlock the key, then open the
door handle.
Position (A): OPEN
Position (B): LOCK
LOCKING THE DOOR

1. Close the door and insert the key into the key slot.
2. Turn the starting switch key to LOCK position (B), then take the key out.
3–101
DRINK BOX
Drink box:ALL-K821-043K00A
This is on the right side at the rear of the operator's seat. It

keeps drinks and other things hot or cold.
Hot or cold air blows into the box according to the setting of the
air conditioner.
MAGAZINE BOX
Magazine box:PC-K820-043K00A
Located on the left side of the operator's seat.

Keep the Operation and Maintenance Manual in this box so
that it can be taken out and read whenever necessary.
CUP HOLDER
Cup holder:PC-K822-043K00A
This is located on the left side of the operator's seat.
3–102
ASHTRAY
Ashtray:ALL-K851-043K00A
This is on top of the console box on the left side of the opera-
tor's seat.
Always put out your cigarette before putting it in the ashtray
and be sure to close the lid.
NOTICE
While removing the ashtray, if it is stuck in the console
cover and hard to remove, open the lid (A) of ashtray, then
hold and twist the ashtray body (B) to remove.
If you hold and twist the lid of ashtray, there is a danger
that the ashtray may break.
3–103
HANDLING AIR CONDITIONER

Handling air conditioner:ALL-K500-001K00A
AIR CONDITIONER CONTROL PANEL

Air Conditioner Control Panel:PC-K5V0-04DK00A
(1) OFF switch (6) FRESH/RECIRC selector switch

(2) Fan switch (7) Display monitor
(3) Temperature control switch (8) Air conditioner switch
(4) Vent selector switch (9) Sunlight sensor
(5) Auto switch
OFF SWITCH
OFF Switch:ALL-K5V4-043K00A
Switch (1) is used to stop the fan and air conditioner.

REMARK
Even if this switch (1) is pressed, the monitor screen does not
switch to the air conditioner adjustment screen.
3–104
FAN SWITCH
Fan Switch:ALL-K5V5-043K00A
Switch (2) is used to adjust the air flow. The air flow can be
adjusted to six levels.
q Press the E switch to increase the air flow; press the R
switch to decrease the air flow.
q During auto operation, the air flow is automatically adjusted.
Monitor display and air flow

A: Monitor display
B: Air flow
a: Air flow "low"
b: Air flow "medium 1"
c: Air flow "medium 2"
d: Air flow "medium 3"
e: Air flow "medium 4"
f: Air flow "high"
TEMPERATURE CONTROL SWITCH

Temperature Control Switch:ALL-K5V6-043K00A
Switch (3) is used to control temperature inside the cab. The

temperature can be set between 18°C and 32°C.
q Press the E switch to raise the set temperature; press the
R switch to lower the set temperature.
q The temperature is generally set at 25°C.
q The temperature can be set in stages of 0.5°C.
Monitor display and the function

Monitor display
Set temperature
(°C)
18.0 Max. cooling
18.5–31.5 Adjusts temperature inside cab to set temperature.
32.0 Max. heating
REMARK
If the mode is set to auto mode and the temperature setting is set to 18.0 °C or 32.0 °C, the air flow from the fan is
always set to HIGH and does not change even when the set temperature is reached.
3–105
VENT SELECTOR SWITCH

VENT SELECTOR SWITCH:PC220-K5V7-043K00A
Switch (4) is used to select the vents.

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

(B1): Face vent (1 place)
(C): Foot vent (1 place)
(D): Front window glass vent (2 places)
(B2): Front window glass vent (1 place)
Liquid crystal Vent

Vent mode Remarks
display (A) (B) (C) (D)
Cannot be selected for

Front vents O
automatic operation
Front and rear vents O O —
Front, rear and foot vents O O O —
Foot vent O —
Foot vents Cannot be selected for

O O
Defroster vent) automatic operation
Cannot be selected for

Defroster vent O
automatic operation
Note1: Air blows out from vents marked O
3–106
AUTO SWITCH
Auto Switch:ALL-K5V8-043K00A
With switch (5), the air flow, vents, and air source (FRESH/
RECIRC) are automatically selected according to the set tem-
perature.
q Press switch (5), then use temperature control switch (3) to
set the temperature, and run the air conditioner under auto-
matic control.
q When switching from automatic operation to manual opera-
tion, it is possible to use the switches to select the air flow,
vents, and air source (FRESH/RECIRC).
REMARK
When Auto Mode is selected, if the set temperature is set to
18.0 °C or 32.0 °C, the air flow is always set to High, but this is
not a problem.
FRESH / RECIRC SELECTOR SWITCH
FRESH?RECIRC Selector Switch:ALL-K5V9-043K00A
Switch (6) is used to switch the air source between recircula-

tion of the air inside the cab and intake of fresh air from the out-
side.
q During automatic operation, the selection of inside air
(RECIRC) and outside air (FRESH) is performed automati-
cally.
Outside air is shut off and only air inside the cab is circulated.
RECIRC
Use this setting to perform rapid cooling of the cab or when outside air is dirty.
Outside air is taten into the cab.
FRESH
Use this setting to take in fresh air when performing demisting.
DISPLAY MONITOR
DISPLAY MONITOR:PC220-K5VA-043K00A
Monitor (7) displays the status of temperature setting (a), air

flow (b), and vents (c).
q When OFF switch (1) is pressed, the display of temperature
setting (a) and air flow (b) goes out, and operation stops.
AIR CONDITIONER SWITCH

Air Conditioner Switch:ALL-K5FK-043K00A
Switch (8) is used to turn the air conditioner (cooling, dehumid-

ifying, heating) ON or OFF.
q Press air conditioner switch (8) when the fan is operating
(when display (b) is shown on the display monitor). The air
conditioner is switched ON and starts to work. Press the
switch again to stop the air conditioner.
q Air conditioner cannot be operated while the fan is off.
3–107
SUNLIGHT SENSOR
Sunlight Sensor:PC-K5FH-043K00A
This sensor (9) automatically adjusts the flow of air from the
vents to match the strength of the sun's rays. In addition, it
automatically detects changes in the temperature inside the
cab caused by changes in the strength of the sun's rays before-
hand and automatically adjusts the temperature.
OPERATION METHOD
Operation method:ALL-K500-100K00A
The air conditioner can be operated automatically or manually. Select the method of operation as desired.
3–108
AUTOMATIC OPERATION
1. Turn auto switch (5) ON.
q The monitors for the set temperature (a) and air flow (b)
are also displayed.
2. Use temperature set switch (3) to set to the desired temper-

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

Press OFF switch (1). Operation stops.
3–109
MANUAL OPERATION
1. Press fan switch (2) and adjust the air flow. When doing
this, check that temperature setting (a) and air flow (b) are
displayed on monitor (7).
2. Turn air conditioner switch (8) ON.
3. Press temperature setting switch (3) and adjust tempera-

ture inside the cab.
4. Press vent selector switch (4) and select the desired vents.
When this is done, the display for vent (c) of the display
monitor changes according to the selection.
3–110
5. Press RECIRC/FRESH selector switch (6) and select recir-

culation of the air inside the cab (RECIRC) or intake of fresh
air from outside (FRESH).
STOP MANUAL OPERATION

Press OFF switch (1). Operation stops.
OPERATION WITH COLD AIR BLOWING TO THE FACE AND WARM AIR BLOWING TO THE FEET
To operate with cold air blowing to the face and warm air blow-
ing to the feet, set as follows.
3–111
2. Press vent selector switch (4) and set the vent display on
the display monitor to the display shown in the diagram on
the right.
3. Turn air conditioner switch (8) ON.
4. Adjust fan switch (2), temperature setting switch (3) and

RECIRC/FRESH selector switch (6) to the desired posi-
tions.
OPERATION TO DEFROST
3–112
2. Press vent selector switch (4) and set vent display on the
display monitor to (f) or (g) as shown in diagram on the
right.
3. Press RECIRC/FRESH selector switch (6) and set it to take

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

on the display (7) monitor to maximum heating (32.0).
3–113
5. Adjust vents (A), (B1), and (B2) so that the air blows onto
the window glass.
(Vents (C) and (D) are fixed and cannot be adjusted.)
When operating in the rainy season or when it is desired to

remove the mist from the window glass or to dehumidify the air,
turn air conditioner switch (8) ON.
3–114
RULES FOR USING AIR CONDITIONER

RULES FOR USING AIR CONDITIONER:ALL-K500-170K00A
NOTICE
q When running the air conditioner, always start with the engine running at low speed. Never start the air
conditioner when the engine is running at high speed. It will cause failure of the air conditioner.
q If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, be careful not
to let water get on these parts. In addition, never bring any flame near these parts.
q For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean
and do not leave anything around the sunlight sensor that may interfere with its sensor function.
VENTILATION
Ventilation:ALL-K500-170K01A
q When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry
out ventilation and cooling.
q If you smoke when the air conditioner is on, the smoke may start to hurt your eyes, so open the window and
turn the lever to FRESH for a while to remove the smoke while continuing the cooling.
TEMPERATURE CONTROL
Temperature Control:ALL-K500-170K02A
When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 or 6 °C lower than
the outside temperature). This temperature difference is considered to be the most suitable for your health, so
always be careful to adjust the temperature properly.
Always be careful to adjust the temperature properly.
CHECKS AND ADJUSTMENT OF AIR CONDITIONER EQUIPPED MACHINE

Checks and adjustment of air conditioner equipped machine:PC-K500-200K00A
q When carrying out inspection and maintenance on machines equipped with an air conditioner, carry out the
inspection and maintenance according to the chart. For details, see "CHECK AND MAINTENANCE AIR CON-
DITIONER (4-31),CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (4-43), and
CLEAN AIR CONDITIONER FRESH / RECIRC FILTERS (4-54)".
q When the air conditioner is not being used every day, to
prevent loss of the film of oil at various parts, run the engine
at low speed from time to time and carry out cooling or
dehumidifying heating for several minutes.
q If the temperature inside the cab is low, the air conditioner
may not work. In this case, warm the inside of the cab with
recirculation air, then turn ON the air conditioner switch to
actuate the air conditioner.
q If any abnormality is detected in any equipment or sensor
used on the air conditioner, the air conditioner system state
monitor lights up on the monitor screen. If the air condi-
tioner system state monitor lights up, please ask your
Komatsu distributor for inspection and repair.
3–115
HANDLING RADIO
Handling radio:PC-K860-001K00A
RULES FOR USING RADIO

Rules for using radio:ALL-K860-170K00A
q To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera-
tion.
q If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
q Do not wipe the display or buttons with solvent such as benzene or thinner. Wipe with a dry soft cloth.
q When the battery disconnect switch is turned to OFF position or the power for the machine is off at the
replacement of the battery, the clock may be initialized. In such a case, set it again.
For details of the operating method of the battery disconnect switch, see "BATTERY DISCONNECT SWITCH
(3-127)".
3–116
EXPLANATION OF COMPONENTS:PC-K860-043K00A
(1) Power button (5) Preset station buttons (1,2,3,4,5,6)

(2) Band selection button (6) Display selection button
(3) Volume control button (7) Sound adjust button
(4) Tuning/time adjust button (8) Display
POWER BUTTON
Press this power button (1) to supply the power to the radio and the frequency is shown on the display (8). Press
the button again to turn the power off.
BAND SELECTION BUTTON
Press this button (2) to select the desired band
Each time the button is pressed, the band changes FM -> AM -> AUX -> FM - - - -
VOLUME CONTROL BUTTON
Use this button (3) to control volume.
Press the E button, and the volume increases. Press the R button, and the volume decreases. The range for the
volume is 0 to 32.
TUNING/TIME ADJUST BUTTON
Use the button (4) to select frequency and step for sound adjustment and to adjust time.
For details of the adjusting method, see "OPERATION METHOD (3-119)".
PRESET STATION BUTTONS
If this button (5) has been used to decide your desired stations in advance, you can select the station by touching
this button once.
It is possible to preset 6 stations each for both AM and FM.
For details of the presetting method, see "OPERATION METHOD (3-119)".
DISPLAY SELECTION BUTTON
Use this button (6) to change frequency and time shown on the display.
Each time you press this button, frequency, time and band are shown on the display in this order.
1.5 seconds elapse when a band is shown, a frequency will be displayed again.
In the AUX state, the AUX display and the time display are changed over alternately.
SOUND ADJUST BUTTON
Press this button (7), and the sound adjustment is ready.
Each time this button is pressed, BAL (Balance), TRE (Treble) and BAS (Bass) will be selected in this order.
If this button (7) is pressed while BAS is displayed, the sound adjustment will be cancelled.
For details of the sound adjusting method, see "OPERATION METHOD (3-119)".
3–117
DISPLAY
(A): Band name, "AUX", frequency, time and other character/
numeric information are displayed.
(B): Frequencies are displayed in step of 50 kHz in certain
areas.
(C): Lights up when a stereo broadcasting is heard while a FM
station is selected.
(D): Lights up at the time of balance adjustment in the sound
adjusting condition.
(E): Lights up at the time of treble adjustment in the sound
(F): Lights up at the time of bass adjustment in the sound
AUX
AUX:PC-K866-043K00A
You can hear the voice through the speaker of the machine when you connect a commercially available portable
audio equipment to the machine.
1. Open cap (a).
2. Connect a portable audio equipment by using an commer-
cially available audio cable.
3. Press band selection button (2) and select AUX.
NOTICE
q A stereo miniature plug can be connected.
Read the instruction manual of the equipment to connect carefully.
q As a power source, use the battery attached to the equipment to connect.
If you use an electric power supply installed to the machine, the noise may occur.
q The noise may occur if you pull out the input plug when AUX is selected, or if you push in or pull out
the plugs of the equipment to connect.
3–118
OPERATION METHOD
Antenna:PC-K861-822K00A
FREQUENCY ADJUSTMENT
1. Press band selection button (2) and select FM or AM.

2. In this condition, press the E button of the tuning/time adjust button (4), and the frequency becomes higher.
Also, press the R button, and the frequency becomes lower.
3. Keep pressing the E button of tuning/time adjust button (4), and the frequency becomes higher continuously.
4. Keep pressing the R button of tuning/time adjust button (4), and the frequency becomes lower continuously.
5. Keep pressing the E button and release it, and the frequency becomes higher continuously. Keep pressing
the R button and release it, and the frequency becomes lower continuously as an auto seek.
When a proper frequency is picked up, the tuning automatically stops.
FREQUENCY ADJUSTMENT (AUTO PRESETTING)

2. In this condition, keep pressing sound adjust button (7), and the auto presetting starts, i.e., a well-receiving fre-
quency is detected and is automatically registered in the preset memory 1 to 6.
PRESET CALL

2. In this condition, press any of buttons 1 to 6 of preset button (5), and the frequency registered to the preset
number is called to start receiving.
Example:
While a frequency is displayed, press button 1 of preset station button (5), and the preset number "P-1" appears
on the display.
The preset number is shown for 0.5 seconds, and then the frequency is displayed.
PRESET MEMORY
While the radio is receiving a station, keep pressing any of buttons 1 to 6 of preset button (5), and the frequency
being received now is memorized to the corresponding preset number.
Example:
While a frequency is displayed, keep pressing button 1 of preset station button (5), and the preset number "P-1"
appears on the display.
After the preset number flashes 3 times, the frequency is displayed and then memorized to the preset number "1".
SOUND ADJUSTMENT (BALANCE)
1. Press the sound adjust button (7) to turn on BAL on the display for starting sound adjustment (Balance).
2. In this condition, press the E button of the tuning/time adjust button (4), and the speaker output increases by
1 from R output. (R1 to R7)
3. Also, press the R button of the tuning/time adjust button (4), and the speaker output increases by 1 from L
output. (L1 to L7)
SOUND ADJUSTMENT (TREBLE)
1. Press the sound adjust button (7) to turn on TRE on the display for starting sound adjustment (Treble).
2. In this condition, press the E button of the tuning/time adjust button (4), and the treble level increases by 1.
(Maximum + 7)
3. Also, press the R button of the tuning/time adjust button (4), and the treble level decreases by 1. (Minimum -
7)
SOUND ADJUSTMENT (BASS)
1. Press the sound adjust button (7) to turn on BAS on the display for starting sound adjustment (Bass).
2. In this condition, press the E button of the tuning/time adjust button (4), and the bass level increases by 1.
(Maximum + 7)
3. Also, press the R button of the tuning/time adjust button (4), and the bass level decreases by 1. (Minimum - 7)
TIME ADJUSTMENT
1. Press display selection button (6) to display the time.

2. In this condition, keep pressing display selection button (6) for starting time adjustment.
3. For the time adjustment, press display selection button (6), and the adjustment target changes from "Hour" to
"Minute".
At this time, the adjustment target flashes.
3–119
4. Flash the item to be adjusted, and press the tuning/time adjust button (4) and start the adjustment.
5. If display selection button (6) is pressed during the minute adjustment, the time adjustment will be released
and the time display will resume.
ANTENNA
Before transporting the machine putting it inside a building, stored the antenna to prevent any interference. Stow
the antenna as follows.
Loosen antenna mounting bolt (1) and store the antenna at
position (A).
After storing the antenna, tighten bolt (1).
USE RADIO WITH CARE

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

SPACE FOR RADIO CASSETTE:PC220_KU-K831-041K00A
The radio cassette is not factory fitted. If fitment is required

then remove front cover (1) and connect speaker wires and
aerial to radio cassette.
Please contact your distributor for a fitting instruction.
If radio is fitted in this location, do not operate radio in LH con-
sole.
3–120
AUXILIARY ELECTRIC POWER

Auxiliary electric power:ALL-K890-001K00A
24V POWER SOURCE

24V Power Source:PC-K891-043K00A
NOTICE
Do not use this as the power supply for 12 V equipment.
It will cause failure of the equipment.
If the cigarette lighter is removed, the socket can be used as a
power source.
Maximum usable electric power is 85 W (24 V x 3.5 A).
REMARK
Use this power source while engine is running.
12V POWER SOURCE

12V Power Source:PC-K892-043K00A
This power source can be used up to a capacity of 144 W (12 V

x 12 A).
When it is used at one place: 144 W (12 V x 12 A)
When it is used at two places: 144 W in total
REMARK
Use this power source while engine is running.
3–121
FUSE
Fuse::PC220_KU-Q6G0-043K00A
NOTICE
Before replacing a fuse, be sure to turn the starting switch to the OFF position, then turn the battery dis-
connect switch to the OFF position.
q The fuse holders are installed for fuse 1 (a) at the rear right
and for fuse 2 (b) at the rear left of the operator's seat,
q It protects the electrical equipment and wiring from burning
out.
q If a fuse is corroded and coated with white powder, or there
is any play between the fuse and fuse holder, replace the
fuse.
q Replace the fuse with a new one of the same capacity.
3–122
FUSE CAPACITIES AND CIRCUIT NAMES

Fuse 1
No. Fuse Name of circuit

(1) 10 A Lamp relay, emergency switch
(2) 30 A Solenoid valve
(3) 5A PPC hydraulic lock solenoid
(4) 10 A Window washer, Cigarette lighter
(5) 10 A Horn
(6) 5A Auto pre-heater relay
(7) 10 A Revolving warning lamp
Radio, Speaker, Left knob switch, Right
(8) 10 A
knob switch
(9) 10 A Deck light
(10) 20 A Air conditioner unit
(11) 20 A Working lamp (Boom, Rear)
(12) 10 A Optional power source (1)
Optional power source (2), 12 V power
(13) 30 A
source, Air suspension seat with heater
(14) 5A Air conditioner ECU power source
(15) 5A Key ACC signal
Radio backup, Room lamp , System
(16) 10 A
operation
(17) 20 A Monitor, Pump controller
(18) 30 A Engine controller
(19) 5A Air conditioner ECU backup
Optional power source (continuous power
(20) 10 A
supply)
Fuse 2
No. Fuse Name of circuit

(1) 10 A Head light 1
(2) 10 A Cab rear light
(3) 10 A Lower wiper
(4) 10 A Quick coupler
(5) 10 A Refuel pump
(6) 10 A Head light 2
(7) 10 A Option light
(8) 20 A Auto grease
(9) 30 A Option heater
(10) 10 A Spare
3–123
REMARK
q Spare fuses are installed in the back of the fuse holder lid
(A) at the rear right of the operator's seat.
q After using spare fuses, replenish them immediately.
q One spare fuse is installed for each 5 A, 10 A, 20 A, 25 A,
and 30 A.
FUSIBLE LINK
Fusible link:PC-AKD9-043K00A
NOTICE
Before replacing a fusible link, be sure to turn the starting switch to the OFF position, then turn the bat-
tery disconnect switch to the OFF position.
Fusible links are located inside the cab rear cover on the L.H.
side of the machine.
If the following phenomena occur, fusible links are suspected of
disconnection.
q If the engine starting motor does not operate even when the
engine starting switch is turned to the START position, fusi-
ble links (1) and (2) are suspected of disconnection.
q Fusible link (3) is suspected of disconnection if it is hard to
start the engine even when the starting switch is at HEAT
(pre-heating) position when temperature is low.
In such case, perform inspection and replacement of fusible
links after removing upper cover (4) and inside cover (5) at the
rear of cab.
REMARK
A fusible link refers to the large-sized fuse wiring installed in
the high current flow portion of the circuit. It protects electrical
components and wiring from burning, in the same way as an
ordinary fuse.
Connector
No. Capacity Name of Circuit Part No.
No.
Continuous
(1) 65A F04 22U-06-11270
power supply
Continuous
(2) 30A F05 20Y-06-31660
power supply
(3) 80A Preheating F12 421-06-22820
3–124
CONTROLLER
Controller installed.
NOTICE
q Be careful not to get water, mud or juice on the controller .
This will cause failures.
q If any problem occurs in the controller, do not disassemble it
yourself. Contact your Komatsu distributor for repairs.
TOOL BOX
Tool box:PC-Q8G1-043K00A
Store the tools in this box.
3–125
GREASE PUMP HOLDER

Grease pump holder::PC220_KU-Q8A6-043K00A
This is installed in the door at rear left of the machine. Keep the
grease pump hooked on this holder while it is not used.
FIRE EXTINGUISHER
Fire extinguisher:PC-Q5G1-043K00A
(if equipped)
A fire extinguisher is prepared at the rear part inside the opera-
tor's cab.
The directions are described on the nameplate affixed to it.
Just in case, carefully read and grasp them beforehand.
3–126
BATTERY DISCONNECT SWITCH

k
BATTERY DISCONNECT SWITCH:PC-AW1P-043K00A
CAUTION
If you have turned the battery disconnect switch to the OFF position, be sure to pull out the switch key.
If someone turns the key to the ON position carelessly, this is extremely dangerous.
NOTICE
q Keep this switch in the ON position, except the following cases.
q When the machine is stored for a long time (more than a month)
q When the electrical system is repaired
q When an electrical welding is conducted
q When the battery is handled
q When the fuse is replaced
q Do not turn this switch to the OFF position while the system operating lamp is lighting up. The electri-
cal system may have trouble or abnormality.
q If this switch is turned to the OFF position, all the electrical system is cut out and the functions of
KOMTRAX stop. In addition, the time information of the clock and the radio station select information
may be lost. In this case, see "CLOCK ADJUSTMENT (3-68)"and "OPERATION METHOD (3-119)"and
set again.
Use switch (1) to cut out the electricity from the battery.
This switch is installed inside the cover on the left side of the
machine.
Raise rubber cover (2), and the switch is seen.
REMARK
Operate this switch while system operating lamp (3) is OFF.
(O): OFF position

Switch key (1) can be pulled out (and inserted) and the current
from the battery is cut out.
(I): ON position
The electricity of the battery flows into the circuit.
Before starting the machine, be sure to set the switch to this
position.
3–127
SYSTEM OPERATING LAMP

System operating lamp:PC-AW1Q-043K00A
This lamp (1) indicates that the controller mounted on the

machine is turned ON.
Lamp (1) lights up in green when the controller is turned ON
and goes out in 1 to 2 minutes after the power for the machine
is turned OFF.
Before operating the battery disconnect switch, check that
lamp (1) is turned OFF.
NOTICE
If the battery disconnect switch is turned OFF while this lamp is lighting, the data in the controller may be
lost.
If the data are lost, when the engine is tried to be started next time, "L04" is displayed on the monitor
panel and the engine may not start.
Ask your Komatsu distributor to carry out inspection and repair.
REMARK
Even if the starting switch is in the OFF position, the controller may operate. The lamp lights up at this point, but it
is not a failure.
After the starting switch has been turned OFF, the system operating lamp may remain turned on for a long time.
In such cases, please contact your Komatsu distributor.
3–128
HANDLING KDPF
k
Handling KDPF:PC-A9H0-251K00A
CAUTION
q Exhaust gas temperature may increase higher than the current models during KDPF regeneration and
may not decrease just after regeneration.
Avoid getting near the exhaust pipe outlet to prevent being burnt.
Also, keep flammables away from the exhaust pipe outlet to prevent a fire.
q When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to
disable the regeneration to prevent fire hazards due to highly heated exhaust gas while regeneration
of KDPF.
For the setting procedure, see "KDPF regeneration disable procedure".
KDPF (Komatsu Diesel Particulate Filter) is a device to capture

soot in the exhaust gas to purify the exhaust gas.
If soot is accumulated to a certain level in the filter, a purifica-
tion process to burn the soot is performed automatically to
keep the filtering performance of KDPF high.
This purification process is called the "regeneration".
If operations which lower the purification function of KDPF con-
tinues for long hours, the regeneration is performed to protect
the KDPF system, regardless of the quantity of the accumu-
lated soot.
During the KDPF regeneration, KDPF regeneration monitor (1)

keeps lighting in the monitor panel.
REMARK
Even if KDPF regeneration monitor (1) lights up, the machine
does not need to be stopped and the work can be continued,
unless the alarm monitor is displayed at the centre of the moni-
tor panel.
The KDPF regeneration is performed automatically. However,

the accumulated soot may not be burnt sufficiently and the
purification function may not be improved under certain operat-
ing conditions.
In that case, KDPF soot accumulation monitor (2) lights up. If
this monitor lights up, stop the machine in a safe place and per-
form the manual stationary regeneration.
For the performance procedure, see "Operation procedure of
stationary manual regeneration".
Two types of monitor display require the manual stationary regeneration, depending on the level of urgency.
NOTICE
If the work is continued with red KDPF soot accumulation monitor (2) displayed, KDPF or the engine can
have trouble.
If KDPF soot accumulation monitor (2) is displayed, be sure to perform the manual stationary regenera-
tion.
3–129
1. When level of urgency is low

q If KDPF soot accumulation monitor (2) lights up yellow
(Action level monitor (3): L01), screen (A) is displayed
first.
q The action level monitor goes out 2 seconds after and
the screen changes to standard screen (B).
q If the lock lever is set to the LOCK position or all the
work equipment control levers are set in NEUTRAL, the
screen changes to KDPF regeneration screen (C) after
3 seconds only the first time. If the manual stationary
regeneration is not performed, the screen returns to
standard screen (B) after 30 seconds.
Then, if the accumulated soot does not decrease, the
KDPF regeneration screen (C) is displayed for 30
seconds every 2 hours.
q If KDPF soot accumulation monitor (2) lights up yellow,
stop the machine in a safe place after finishing the work
and perform the manual stationary regeneration.
2. When level of urgency is high

q If KDPF soot accumulation monitor (2) lights up red
(Action level monitor (3): L03), screen (D) is displayed.
q If the lock lever is set to the LOCK position or all the
work equipment control levers are set in NEUTRAL, the
screen changes to KDPF regeneration screen (C) after
3 seconds. Then, the KDPF regeneration screen (C)
and standard screen (D) are automatically displayed
alternately according to the lever operation, until the
manual stationary regeneration is performed.
q If KDPF soot accumulation monitor (2) lights up red,
immediately stop the machine in a safe place and per-
form the manual stationary regeneration.
REMARK
q If the lock lever is in the LOCK position, the manual station-
ary regeneration may start automatically to protect the
KDPF.
q If KDPF soot accumulation monitor (2) lights up red, the
maximum engine output and maximum engine speed are
limited to protect the engine and KDPF system.
3–130
NOTICE
If the work is continued without performing the stationary
manual regeneration and the quantity of soot exceeds the
allowable limit, action level monitor "L04" lights up. In this
case, the machine needs to be repaired by your Komatsu
distributor. Also, the maximum engine output and maxi-
mum engine speed are limited to protect the engine and
KDPF system.
REMARK
q Soot accumulation level (4) can be checked with the KDPF
regeneration screen. Press switch F6 on the standard
screen to display the KDPF regeneration screen of the user
menu.
q Since the soot in the filter of KDPF can be burnt by the high-
performance catalyst and high-temperature exhaust heat,
the soot accumulation quantity may decrease even if the
regeneration is not performed, depending on the operating
condition.
q Even when the soot accumulation level is low, the auto-
matic regeneration may be performed and the manual sta-
tionary regeneration may be requested to protect the
system. In particular, if engine is kept running with no load,
the regeneration frequency may increase, but this is not
trouble.
q Even just after the regeneration is completed, the soot
accumulation level may not be "0". This is caused by the
accumulated noncombustible material in the exhaust gas
and is not trouble.
q Since noncombustible matter which cannot be burnt by the
regeneration is accumulated in the filter of KDPF, the filter
needs to be cleaned or replaced at regular intervals. See
"EVERY 4500 HOURS MAINTENANCE (4-10)".
q The engine speed or engine sound may change during or
after the regeneration. This is caused by the control for bet-
ter regeneration and is not trouble.
q The smell of the exhaust gas is different from that of the
conventional diesel engine because of the exhaust gas
purification function.
q White smoke may be discharged for a short time just after
the engine is started or during the regeneration in the cold
season, but this is not trouble.
q Always use Komatsu genuine engine oil for KDPF. If the
engine oil other than Komatsu genuine oil for KDPF is used,
it may shorten cleaning interval of KDPF filters, adversely
affect the engine such as lubricating function reduction by
deteriorated oil, and it may cause failure. In addition, the
regeneration interval may be shortened and the fuel con-
sumption may increase. For details of the genuine oil, see
"RECOMMENDED BRANDS AND QUALITY FOR PROD-
UCTS OTHER THAN KOMATSU GENUINE OIL (7-8)".
3–131
OPERATION PROCEDURE OF MANUAL STATIONARY REGENERATION
k CAUTION
Exhaust gas temperature may increase higher than the
current models during KDPF regeneration. Avoid getting
near the exhaust pipe outlet to prevent being burnt. Also,
keep flammables away from the exhaust pipe outlet to pre-
vent a fire.
The manual stationary regeneration can be performed while

KDPF soot accumulation monitor (1) is lighting.
1. Move the machine to a safe place and stop it with engine

running.
2. Check that there is no person or combustible matter around
the machine (particularly in the direction of the exhaust gas
flow).
3. Set the lock lever to LOCK position (L).
4. Set the fuel control dial to low idle (MIN) position.
5. Press switch F6 to display the KDPF regeneration screen.

6. Select manual stationary regeneration, check again that
there is no person or combustible matter around the
machine, then press switch F6.
If the machine needs to be moved again to secure safety,
move it to a safe place and repeat the procedure from Step
1.
3–132
REMARK
After switch F6 is pressed in Step 6, the screen shown at right
may be displayed. This indicates that the operations in Steps 1
- 4 were not performed correctly or there is trouble other than
KDPF soot accumulation abnormality. Check that the engine is
running normal, the lock lever is in LOCK position (L), and the
fuel control dial is in low idle position (MIN), then repeat the
procedure from Step 6.
If the manual stationary regeneration still cannot be performed,
return to the standard screen, press switch F5 to check the
contents of other occurring troubles, stop the operation and
carry out inspection and maintenance.
REMARK
q The explanation of the manual stationary regeneration is
displayed in 3 parts on the monitor panel. If switch F6 is
pressed, the regeneration can be started immediately,
regardless of which part is displayed. If switch F5 is
pressed, the screen returns to the standard screen.
q If no monitor switch is operated for 30 seconds, the expla-
nation of the manual stationary regeneration disappears
and the screen returns to the standard screen. At this time,
to display the explanation of the manual stationary regener-
ation again, press switch F6 on the standard screen to dis-
play the KDPF regeneration screen.
3–133
7. This screen is displayed during the manual stationary

regeneration. It may take more than 40 minutes to complete
the manual stationary regeneration. Do not switch any
screen or operate fuel control dial until the regeneration is
complete and the standard screen appears again.
REMARK
q The progress of the manual stationary regeneration per-
formed when soot is accumulated can be checked by the
number of lighting lamps of soot accumulation level (4). The
manual stationary regeneration starts at soot accumulation
level "4" or higher and finishes when all the level lamps go
out.
q The time required for the manual stationary regeneration
depends on the soot accumulation level or the ambient tem-
perature when it is started. If the regeneration starts at soot
accumulation level "6" or higher, it may take approximately
two hours to finish.
q The manual stationary regeneration for protection of the
system may start even when the soot accumulation level is
"0" to "3". In this case, the soot accumulation level may not
decrease, but this is not trouble. The progress is not dis-
played on the monitor during this regeneration. It is com-
pleted in about 10 minutes.
q If the lock lever or fuel control dial is operated during the
manual stationary regeneration, the regeneration is stopped
automatically. Return the lock lever to LOCK position (L)
and return the fuel control dial to low idle position (MIN),
then repeat the procedure from Step 6.
q If the machine needs to be moved during the manual sta-
tionary regeneration, stop the regeneration temporarily and
move the machine, referring to the KDPF regeneration disa-
ble and cancel procedures described below.
When restarting the manual stationary regeneration, secure
the safety of the machine and around it, then cancel the
regeneration disable.
8. After the manual stationary regeneration, the screen auto-
matically returns to the standard screen.
KDPF REGENERATION DISABLE PROCEDURE
If there is combustible material around the machine and the
forced regeneration that increases the exhaust temperature
must not be performed, the automatic KDPF regeneration can
be disabled. Also, the regeneration in progress can be
stopped.
NOTICE
Even if the regeneration is disabled, KDPF soot accumula-
tion monitor (1) lights up if soot is accumulated and the
manual stationary regeneration is required. If it lights up,
move the machine to a safe place and carry out manual
stationary regeneration.
If the work is continued without carrying out the manual
stationary regeneration, KDPF or the engine can have
trouble.
3–134
WHILE REGENERATION IS NOT BEING PERFORMED: SETTING FOR REGENERATION DISABLE

(When KDPF regeneration monitor is not lighting on standard
screen)
1. On the standard screen, press switch F6.
2. Operate switches F1 and F2 to select KDPF regeneration

menu (C) and display the KDPF regeneration screen.
3. Select regeneration disable and press switch F6, and the

regeneration function is disabled and the regeneration can-
not be performed.
REMARK
q If the regeneration is disabled, KDPF regeneration disable
monitor (2) on the standard screen is hatched.
q The regeneration disable setting is cancelled if starting
switch is turned to the OFF position. If the automatic regen-
eration needs to be kept disabled, perform the above proce-
dure each time you start the engine.
q Even if the regeneration disable is set, if the regeneration is
performed to protect the system, the regeneration lamp
may light up, but this is not trouble. In addition, if the regen-
eration is performed to protect the system, the regeneration
disable can not be operated.
q When the regeneration is performed to protect the system,
the exhaust temperature is lower than that of when the
regeneration is performed to burn soot, and is about the
normal exhaust gas temperature.
3–135
WHILE REGENERATION IS BEING PERFORMED: STOPPING REGENERATION

(When KDPF regeneration monitor (3) is lighting on standard
screen)
1. If switch F6 is pressed on the standard screen, the KDPF
regeneration screen is displayed.
2. Select regeneration disable and then press switch F6, and

the regeneration stops.
REMARK
The regeneration performed to protect the system may not be
stopped, but this is not trouble.
3–136
KDPF REGENERATION DISABLE CANCEL PROCEDURE
k CAUTION
When cancelling the regeneration disable, move the
machine to a safe place and check that there is no person
or combustible matter around. And start the cancel opera-
tion.
1. If switch F6 is pressed on the standard screen, the KDPF

regeneration screen is displayed.
(If the KDPF regeneration screen is not displayed, display it
by operating switches F1 and F2.)
2. Select cancel of regeneration disable and press switch F6,
and the regeneration disable is cancelled.
If soot accumulation level (4) lights up 3 or more, the regen-
eration is started automatically.
REMARK
q When cancelling the manual stationary regeneration disa-
ble, set the lock lever to LOCK position and set the fuel con-
trol dial to low idle position, then cancel the regeneration
disable.
q The regeneration disable setting is also cancelled by turn-
ing the starting switch to the OFF position to stop the
engine.
3–137
HANDLING KCCV
Handling KCCV:PC-A185-043K00A
The KCCV (Komatsu Closed Crankcase Ventilation) filter

means the filter that cleans the gas discharged from the engine
crankcase and return it to the engine air intake system.
NOTICE
q The KCCV filter element needs to be replaced every
2000 hours. For details of the replacement procedure,
see "REPLACE KCCV FILTER ELEMENT (4-71)".
q If the engine is operated without the KCCV filter ele-
ment or if a filter element other than the Komatsu genu-
ine one is used, the engine sucks oil and foreign matter
which can cause a trouble. Always use Komatsu genu-
ine KCCV filter element.
q The filter element cannot be cleaned. Never reuse the
filter element since it can cause an engine trouble, even
if it is cleaned.
3–138
HANDLING MACHINES EQUIPPED WITH KOMTRAX

Handling machines equipped with KOMTRAX:ALL-Q210-043K00A
KOMTRAX equipment may not be mounted on machines for some countries or regions.
OUTLINE OF KOMTRAX
q KOMTRAX is a system used for remote management of machines mounted with KOMTRAX equipment by
using satellite communication or cellular wireless communication.
q The customer can obtain various machine information (including machine position) by viewing the web screen
on a personal computer.
q Machine information that can be viewed with KOMTRAX includes the following:
Machine position, service meter, operating hours and fuel consumption.
Komatsu, Komatsu associated companies and Komatsu distributors will use this machine information to provide
better service to customers and improve products and services etc.
If you are interested in using KOMTRAX, consult your Komatsu distributor for registration of using KOMTRAX.
k WARNING
q Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This
may cause failure or fire on the KOMTRAX equipment or the machine itself. (Your Komatsu distributor
will carry out removal and installation of KOMTRAX.)
q For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm away
from the pacemaker. The radio waves may have an adverse effect on the operation of the pacemaker.
q Near the blasting jobsite, there may be a danger of unexpected explosion due to use of interactive
wireless communication device of KOMTRAX and resulting serious personal injury. Make sure to oper-
ate the machine away from the blasting jobsite.
If you have to operate the machine within 12 m from the blasting jobsite or a remote-controlled blasting
device, the power supply cable of KOMTRAX must be disconnected in advance. If you want to do this,
ask your Komatsu distributor for disconnecting power supply cable of KOMTRAX.
Also, if there are requirements or regulations concerning the operation of this machine in your area or
country, be sure to observe them in priority to this warning.
When checking for compliance with regulations, refer to the following KOMTRAX equipment satellite
communication specifications.
Transmit power: 5 - 10 W
Transmit frequency: 148 - 150 MHz
PRECAUTIONS
q Even when the starting switch is at the OFF position, a small amount of electric power is consumed by KOMT-
RAX system.
It is recommended to run the engine periodically to charge the battery. When storing the machine for a long
period, see LONG-TERM STORAGE (3-227)
q When using the battery disconnect switch, turn the starting switch to the OFF position and turn the battery dis-
connect switch to the OFF position. Then, pull out the key.
When the battery disconnect switch is turned to the OFF position, it is possible to prevent power consumption
of the battery, but the functions of KOMTRAX stop at the same time.
For details of the operation of the battery disconnect device, see BATTERY DISCONNECT SWITCH (3-127).
q Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
REMARK
q The KOMTRAX equipment uses wireless communications, so it cannot be used inside tunnels, underground,
inside buildings, or in mountain areas where radio waves cannot be received. Even when the machine is out-
doors, KOMTRAX cannot be used in areas where the radio signal is weak or in areas outside the wireless
communication service area.
q There is absolutely no need of inspection or maintenance of the KOMTRAX communications terminal, but if
any abnormality is found, consult your Komatsu distributor.
3–139
OBSERVANCE OF THE APPLICABLE LAWS AND REGULATIONS, EXEMPTIONS
The KOMTRAX equipment is a wireless device using radio waves, so it is necessary to obtain authorisation and
to conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used.
Observe the applicable laws and regulations of the country or region in which the machine is used.
Always contact your Komatsu distributor before exporting this machine equipped with KOMTRAX or using it in a
foreign country.
The KOMTRAX may already have been registered and used if the machine is purchased second-hand. For the
registration and usage records of KOMTRAX, consult your Komatsu distributor.
If the machine has been lent out by the customer, the borrower or another third party may have been using the
KOMTRAX. Ask the borrower about the usage of KOMATRAX.
Komatsu may suspend KOMTRAX communication in the following cases.
q When Komatsu judges that KOMTRAX is used by an unregistered user.
q When Komatsu judges that KOMTRAX is used in a country or region not allowing the use of KOMTRAX.
q In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX
communication.
If you do not obey the above precautions, neither Komatsu nor your Komatsu distributor can take any responsibil-
ity for any problem that is caused or for any loss that results.
3–140
OPERATION MACHINE OPERATIONS AND CONTROLS
MACHINE OPERATIONS AND CONTROLS

Machine operations and controls:ALL-0000-001K13A
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

Checks and adjustment before starting engine:ALL-3310-001A00A
WALK-AROUND CHECKS
WALK-AROUND CHECKS:PC220_KU-0000-289K00A
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual like
loose bolts and nuts, leakage of fuel, oil and coolant. Also check the condition of the work equipment and the
hydraulic system.
Check also for loose wiring, play, and accumulation of dust in places that get very hot and are exposed to
extremely high temperatures.
k WARNING
Any flammable materials from around the battery, KDPF, turbocharger, or other high temperature engine
parts, and leakage of fuel or oil will cause the machine to catch fire.
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check for cracks, excessive wear, play in work equipment, cylinders, linkage, and hoses. If any problem is
found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator
Check for dirt accumulated around the engine and radiator. Also check for flammable materials (dry leaves,
twigs, etc.) around the battery, KDPF, turbocharger, or other high temperature engine parts. If any dirt or flam-
mable materials are found, remove them.
For the method of removing dirt from the radiator, see "CLEAN AND INSPECT RADIATOR FINS, OIL COOLER
FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (4-52)".
3. Check for coolant and oil leakage around the engine
Check for oil leakage from the engine and coolant leaks from the cooling system. If any problem is found, repair
it.
4. Check for leakage from fuel line
Check that there is no leakage of fuel or damage to the hoses and tubes. If any problem is found, repair it.
5. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, and joints
Check for oil leakage. If any problem is found, repair the area where oil is leaking.
6. Check the undercarriage (track shoe, sprocket, idler and guard) for abnormality, wear, loose bolts, leakage of
oil from rollers. If any trouble is found, repair it.
7. Check for problems in handrails, steps, loose bolts
If any problem is found, repair it. Tighten any loose bolts.
8. Check for problem in gauges, monitor
Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts.
Clean off any dirt from the surface.
REMARK
When cleaning the stains deposited on the monitor surface such as dusts, brush them off using a clean, dry and
soft rag.
When removing tough stains such as oil, clean them using commercially offered household detergents (mild acid-
ity to mildly alkaline without abrasive agent), then wipe the surface using a dry, clean and soft rag.
9. Check, clean rear view mirror
Check that there is no damage to the rear view mirror. If it is damaged, repair it. Clean the surface of the mirror
and adjust the angle so that the area at the rear can be seen from the operator's seat.
10. Seat belt and mounting clamps
Check the seat belt and mounting clamps for any abnormality. If any damage is found, ask your Komatsu distrib-
utor to replace it with new one.
11. Check bucket with hook (if equipped) for damage
Check for damage to the hook, guide, and hook mount. If any problem is found, ask your Komatsu distributor
for repair.
12. Check, clean camera
Check the camera for any abnormality. If any problem is found, ask your Komatsu distributor for repair.
13. Removing dusts around KDPF
3–141
MACHINE OPERATIONS AND CONTROLS OPERATION
Check the space around KDPF for accumulated dirt and flammable materials (dry leaves and twigs). If any dirt
or flammable materials are found, remove them.
14. Checking gas leakage in the space around KDPF
Check the pipe connecting KDPF to turbocharger and also KDPF connection for leakage of gas (and deposition
of soot). If any problem is found, ask your Komatsu distributor for repair.
3–142
CHECKS BEFORE STARTING

Checks Before Starting:ALL-3340-015A00A
Always check the items in this section before starting the engine each day.
REFUELLING PUMP
k
REFUELLING PUMP:PC220_KU-AD5G-100K00A
WARNING
Only for use with diesel fuel.
Do not use for, or with petrol (gasoline) and solvents with flashpoint <55° C.
When adding fuel, never spill the fuel or let it overflow. It will cause a fire.
If any fuel has spilled, wipe it up completely. If the fuel has spilled over soil or sand, remove that soil or
sand.
Fuel is highly flammable and dangerous. Never bring flames near fuel.
k CAUTION
Ensure that the machine is parked on level ground during refuelling operation.
Do not leave machine unattended during refuelling and monitor.
Following any over filling or spillage of fuel, inspect machine to ensure no fuel remains near electrical or
high temperature components.
Do not run refuel pump dry. Monitor fuel level in barrel during refuelling to prevent pump running dry.
The fuel pump is protected by an in-line blade fuse (15A). If the pump fails to function — check fuse.
Ensure the strainer on the hose end is clean.
When not in use, fully close the hose strainer valve cap (H) to prevent leakage or spillage.
If there is any malfunction of the refuel automatic shut-off system, consult your Komatsu Distributor and
do not use the system until the problem is rectified.
3–143
1. When the machine is operated on sites with no fuel con-

tainer and pump, the machine may be refuelling pump from
fuel barrels.
The refuelling pump is located in the right hand rear pump
compartment of the machine.
2. Remove the refuel hose which is stored in tool case (3)
from the machine. Unscrew the strainer valve cap (H) to the
open position (J).
Place the fuel hose (2) into the fuel barrel placed next to the
machine. Remove the fuel cap (F).
-5
3. Refuel switch box (7) is located on the right hand side pump
compartment.
Switch ON the master switch of the refuel system (4) on the
refuel switch box.
To start refuelling press switch (5) once.
Refuelling will continue automatically until the tank has
reached capacity (float switch (6) will reach its limit and the
pump will stop).
It is important to ensure the machine is parked on level
ground and monitor refuelling to avoid fuel overfill or
spillage.
Refuelling can be stopped at any time by turning off the
master switch (4).
If more fuel is needed in the fuel tank after the float switch
has stopped the pump, press and hold switch (5).
When switch (5) is pressed and held, the refuel pump will fill
tank.
Releasing switch (5) will stop the refuel pump in this override
condition.
When using this override, the level of the tank must be moni-
tored to prevent overfilling and fuel spillage.
If fuel is allowed to overflow stop refuelling immediately by
turning off the master switch.
After finishing refuelling make sure the master switch (4) is
returned to the OFF position.
3–144
4. After refuelling is complete:

5. Push float gauge (G) straight down with fuel filler cap (F),
be careful not to get the float gauge (G) caught in the tab of
the fuel filler cap (F) and tighten fuel filler cap (F) securely.
6. Tighten strainer valve cap (H) to the closed position (K) to
prevent leakage of fuel left in the hose.
7. Replace the fuel hose in tool case (3).
DRAIN WATER AND SEDIMENT FROM FUEL TANK

DRAIN WATER AND SEDIMENT FROM FUEL TANK:PC220-AD10-220K00A
1. Open the door at the right of the machine.

2. Set a container under drain hose (1) to catch the drained
fuel.
3. Turn drain valve (2) to the OPEN (O) position and drain all
the sediment and water accumulated at the bottom together
with the fuel.
4. When clean fuel comes out, turn drain valve (2) to the
CLOSE (S) position.
5. Close the door.
3–145
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER

CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER:PC220-AEB0-220K00A
1. Open the pump room door on the right side of the machine.
2. It is possible to judge the water level and amount of sedi-
ment by looking through transparent cap (2). If there is any
water or sediment collected at the bottom, set a container to
catch the drain water under drain hose (3).
3. Loosen drain valve (4) and drain the water.
4. When fuel starts to drain from drain hose (3), tighten drain
valve (4) immediately.
On this machine, a sensor is installed to detect if water is
accumulated in transparent cap (2).
When the water separator monitor (5) lights up red on the
machine monitor, it indicates that water is accumulated in
transparent cap (2).
In this case also, use the procedure above to drain the
water.
REMARK
When only the water separator monitor lights up, it lights up in
the position shown in the diagram on the right. If other monitors
also light up the same time, the water separator monitor lights
up at a different position.
NOTICE
q If the water accumulated in transparent cap (2) freezes, the water separator monitor may not light up.
After the engine is started, as the temperature around fuel pre-filter (1) increases, the frozen water will
melt and the water separator monitor may suddenly light up. In cold areas, even if the water separator
monitor does not light up, drain the water frequently.
q If the water inside transparent cap (2) freezes, check that the frozen water has melted completely, then
use the procedure above to drain the water.
REMARK
q If transparent cap (2) is dirty and it is difficult to see the inside, clean transparent cap (2) when replacing fuel
pre-filter cartridge (1).
q When drain valve (4) has been removed during the cleaning operation, coat the O-ring with grease and tighten
until it contacts the bottom.
3–146
ADJUSTING DRAIN VALVE

Adjusting drain valve:PC220-AEB4-270K00A
If drain valve (4) is stiff, coat the O-ring portion of the drain valve with grease to make the movement smooth.
1. Turn the valve (6) at the bottom of the fuel tank to the
CLOSE position (S).
2. Set the container to catch the fuel under the pre-filter car-
tridge.
3. Loosen drain valve (4), then drain all the water and sedi-
ment in the transparent cap (2) and also the fuel accumu-
lated in filter cartridge (1).
4. Check that nothing more comes out from drain hose (3),
then remove drain valve (4).
5. Coat O-ring portion (7) with a suitable amount of

grease.When doing this, be careful not to let the grease get
stuck to the drain valve water drain port (8) or drain valve
thread (9).
6. Tighten drain valve (4) by hand until it contacts the bottom
of transparent cap (2).
7. Remove the fuel container.
8. Turn the valve (6) at the bottom of the fuel tank to the OPEN
position (O).
REMARK
For details of bleeding air, see "REPLACE FUEL PRE-FILTER CARTRIDGE (4-49)" or "REPLACE FUEL MAIN
FILTER CARTRIDGE (4-62)".
3–147
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
k
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL:PC220-PM30-212K00A
WARNING
q 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 work.
q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Set the work equipment in the posture shown in the dia-

gram on the right, then check the oil level and add oil if nec-
essary.
2. If the work equipment is not in the condition shown in the
diagram on the right, start the engine, run the engine at low
speed, retract the arm and bucket cylinder rods fully, then
lower the boom, set the bucket teeth in contact with the
ground, and stop the engine.
3. Within 15 seconds after stopping the engine, move each
control lever (for work equipment and travel) to the full
stroke in all directions to release the internal pressure.
4. Open the door at the right of the machine, then check sight
gauge (G). The oil level should be between the H and L
lines.
NOTICE
Do not add oil above the H line. This will damage the
hydraulic circuit or cause the oil to spurt out. If oil is added
above the H level, stop the engine, wait for the oil tempera-
ture to cool down, discharge excessive oil from drain plug
(P) under the suction tube in a container for waste oil.
5. If the oil level is below the L line, add oil through oil filler (F)
at the top of the hydraulic tank.
REMARK
The oil level will vary depending upon the oil temperature.
Accordingly, use the followings as a guide:
q Before starting operation: Between H and L levels
(Oil temperature: 10 - 30°C)
q Normal operation: Around H Level
(Oil temperature: 50 - 80°C)
3–148
CHECK COOLANT LEVEL, ADD COOLANT
k
CHECK COOLANT LEVEL, ADD COOLANT:PC220-B000-216K00A
WARNING
q 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.
q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure. If the cap is removed to check the coolant level in this condition, there is a haz-
ard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure and
remove it carefully.
1. Open the door at the rear left of the machine, and check if
the coolant in sub-tank (1) (shown in the diagram on the
right) is between the FULL and LOW marks. If the coolant
level is low, add coolant to the FULL level through the filler
port of sub-tank (1).
2. After adding coolant, tighten the cap securely.
3. If the sub-tank becomes empty, there is probably coolant
leakage. After checking, repair any abnormality immedi-
ately. If no abnormality is found, check the level of the cool-
ant in the radiator. If it is low, add Non-Amine Engine
Coolant (AF-NAC) of the same density in the radiator to the
Non-Amine Engine Coolant (AF-NAC) density table in
"CLEAN INSIDE OF COOLING SYSTEM (4-17)", then add
Non-Amine Engine Coolant (AF-NAC) to the sub-tank.
4. When the inside of sub-tank (1) is dirty and the coolant level
cannot be checked, see "CLEAN INSIDE OF COOLING
SYSTEM (4-17)".
3–149
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
k
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL:PC-AB20-212K00A
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait
for the temperature to go down before starting the work.
1. Open the engine hood.

2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe, then remove it.
4. The oil level should be between the H and L marks on dip-

stick (G).
If the oil level is below the L mark, add oil through oil filler
port (F).
5. If the oil is above the H line, drain the excess oil from drain
valve (P) at the bottom of the engine oil pan, then check the
oil level again.
6. If oil level is correct, securely tighten the oil filler cap and
close the engine hood.
REMARK
q When checking the oil level after the engine has been oper-
ated, wait for at least 15 minutes after stopping the engine
before checking.
If the machine is at an angle, make it to a horizontal position
before checking.
q When the ambient temperature is low, water or emulsified
matter may stick to the dipstick, fuel filler cap, etc. or the
drained oil may be milky white because of water vapour in
the blow-by gas. However, if the coolant level is normal, it is
not a problem.
CHECK ELECTRIC WIRING
k
Check Electric Wiring:ALL-AK51-280K00A
CAUTION
q If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly
ask your Komatsu distributor to locate the cause and make the repair.
q Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap to clear the breather hole.
Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no discon-
nection or trace of short-circuiting in the electric wiring and no damage to the coating. Check also that there is no
loosened terminals. If any, tighten them.
Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and alter-
nator.
3–150
Be sure to check that there is no inflammable material accumulated around the battery. If any is found, remove
immediately.
CHECK FUEL LEVEL, ADD FUEL
k
CHECK FUEL LEVEL, ADD FUEL:PC220-AD10-211K00A
WARNING
When adding fuel, never spill the fuel or let it overflow. It will cause fire.
If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
Fuel is highly flammable and dangerous. Never bring flames near fuel.
1. Turn the engine starting switch to the ON position and

check the fuel level gauge (1) on the monitor panel for fuel
level.
After checking, turn the switch back to the OFF position.
2. If fuel is found to be low, unscrew fuel filler cap (F) on the

fuel tank and add fuel through the filler port until float gauge
(G) comes up to the highest point.
q Fuel tank capacity: 400 litres
Position of tip (a) of float gauge (G) when fuel tank is full:
Approx. 50 mm.
3. After adding fuel, push float gauge (G) straight down with
fuel filler cap (F). Be careful not to get float gauge (G)
caught in the tab (2) of fuel filler cap (F), and tighten fuel
filler cap (F) securely.
REMARK
If breather hole (3) on the cap is clogged, the pressure in the
tank will drop and fuel will not flow. Clean the hole from time to
time.
3–151
CHECK WORKING LAMP SWITCH

Check Working Lamp Switch:ALL-Q6B1-280K00A
Check that the working lamps and lamps inside the instruments light up properly. Check also that there is no dirt
or damage.
If any lamp does not light up, the bulb is probably blown up or there is a disconnection, so ask your Komatsu dis-
tributor for repair.
1. Turn the starting switch to the ON position.
2. Turn the lamp switch ON (night mode (a), and day mode
(b)) and check that the working lamp lights up.
CHECK HORN FUNCTION

CHECK HORN FUNCTION:PC-Q544-280K00A
1. Confirm that the horn sounds immediately when the horn

button is pressed.
If the horn does not sound, ask your Komatsu distributor for
repair.
3–152
ADJUSTMENT
Adjustment:ALL-K000-001K01A
SEAT ADJUSTMENT
k
SEAT ADJUSTMENT:PC220_KU-K2Q0-270K00A
WARNING
When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to pre-
vent any accidental contact with the control levers.
q Always adjust the operator's seat before starting each operation or when the operators change shift.
q Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's
back against the backrest.
(A) Fore-and-aft adjustment
Pull up lever (1), set the seat to the desired position, then
release the lever.
Fore-and-aft adjustment: 160mm (16 stages)
(B) Adjusting reclining
REMARK
The seat can be reclined more when the seat is pushed to the
front. The amount of reclining decreases as the seat is pushed
back, so when moving the seat back, return the seat back to
the upright position.
Pull up lever (2) and set the backrest to a position that is com-
fortable for operation, then release the lever.
Sit with your back against the seat backrest when adjusting. If
your back is not against the backrest, the backrest may sud-
denly move forward.
(C) Adjusting seat tilt

Pull up lever (3) to adjust angle of the front of seat. (3 stages)
q To raise the angle at front of the seat, keep the lever pulled up and apply your weight to the rear of seat.
q To lower the angle at front of the seat, keep the lever pulled up and apply your weight to the front of seat.
Amount of tilt: Up 5°, down 5°
Adjusting seat height
Pull up lever (1) to move the seat back, then turn handle (4) to adjust the height.
Height adjustment: 75 mm.
(D) Adjusting armrest height
The height of armrest (5) can be adjusted up or down by
changing the position of adjustment bolt (6) at the rear of the
armrest.
Armrest height adjustment: 43 mm.
3–153
Adjusting armrest angle

Angle of armrest (7) can be adjusted vertically by turning
adjustment dial (8) at the bottom of the armrest.
Armrest angle adjustment: 9° in lower direction and, 4° in upper
direction
(E) Lumber adjustment

Rotate knob (9) in direction shown to increase the amount of
lumber support. (5 stages)
Further rotation in the same direction causes the lumber sup-
port to return to the original position.
MIRRORS ADJUSTMENT
k
Mirrors adjustment:PC220_KA-K810-270K00A
WARNING
Be sure to adjust the mirrors before starting work. If mir-
rors are not adjusted properly, you cannot secure the visi-
bility and may be injured or may injure someone seriously.
MIRROR (A)
Adjust the mirror by hand so that it is possible to see people at
the rear left of the machine.
q Adjust the mirror so that the side of the machine is reflected
on the mirror as shown in the drawing on the right.
3–154
The specified positions of the mirror and the stay are as fol-
lows:
q Stay (1)
Mounting position (2): 77mm
Mounting angle (3): 89deg.
Mounting angle (4): 107 deg.
Tightening torque of mounting bolt (5): 15.0 to 19.6 Nm {1.52
to 2 kgm}
q Mirror (6)
to 0.71 kgm}
Mounting position (8): 89mm
NOTICE
q Tighten the right and left bolts of each bracket alter-
nately so that their right and left clearances (R) and (L)
become equal.
q If the mirror and stay mounting bolts are tightened
excessively, the bracket may be damaged. Be sure to
tighten bolts with the specified torque.
MIRROR (B)
Adjust the mirror by hand so that it is possible to see people at
the rear right of the machine.
q Adjust the mirror so that the side of the machine is reflected
on the mirror as shown in the drawing on the right.
3–155
The specified positions of the mirror and the stay are as fol-
lows:
q Stay (9)
Mounting position (10): 590 mm
Tightening torque of mounting bolt (13): 15.0 to 19.6 Nm
{1.52 to 2 kgm}
q Mirror (14)
to 0.71 kgm}
NOTICE
q Tighten the right and left bolts of each bracket alter-
nately so that their right and left clearances (R) and (L)
become equal.
q If the mirror and stay mounting bolts are tightened
excessively, the bracket may be damaged. Be sure to
tighten bolts with the specified torque.
MIRROR (C)
Adjust the side view mirrors so that people within 1 m away
from around the machine can be seen from the operator's seat.
(W): 1 m
The specified position of the mirror is as follows:

q Mirror (18)
to 0.71 kgm}
3–156
ADJUST REAR VIEW CAMERA ANGLE
k
ADJUST REAR VIEW CAMERA ANGLE:PC220-Q162-270K00A
WARNING
q Be sure to adjust the camera before starting work. If it
is not adjusted properly, you cannot secure the visibil-
ity and may be injured or may injure someone seri-
ously.
q When adjusting the angle of the rear view camera, pre-
pare a scaffold first in order to provide a safe working
platform.
If you try to make such an adjustment, standing on the
counterweight, there is always the danger of serious
injury due to falling off from the machine.
Adjust the angle of the rear view camera so that people within 1
m away from the machine's rear part (W) appears in the
machine monitor at the operator's seat.
3–157
If the image on the monitor is not aligned correctly, adjust

mounting angle (A) of the rear view camera in the following
procedure.
Angle (A) can be adjusted within the range from 32 to 53
degrees.
1. Insert a flat-head screwdriver or the like into hole (3) of

cover (2) and push inside tooth (B) to remove the cover.
2. Remove bolts (4) from 2 places.
3. Remove cover (1).
REMARK
q Shims (6) may be installed to adjust the clearance on cover
outer periphery portion. When removing cover (1), take a
note of position and numbers of the shims to restore them,
q Shims (6) comes off together with cover (1). Remove them
carefully.
4. Loosen camera mounting bolts (5) (at 3 places) and adjust

camera mounting angle (A) so that corner (D) of mounting
bracket (C) is aligned with horizontal line (E)
REMARK
Part of the machine is shown on the monitor screen.
5. After adjusting, tighten bolt (5).
Tightening torque: 11.8 to 14.7 Nm (1.2 to 1.5 kgm)
3–158
SEAT BELT
k
SEAT BELT:PC-K2Q3-100K00A
WARNING
q Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt.
If it is worn or damaged, replace it.
q Even if no problem can be seen in the belt, replace the seat belt every 3 years from starting usage or 5
years after manufacture whichever comes sooner. The date of manufacture of the belt is shown on the
back of the belt.
q Always wear the seat belt during operations.
q Fit the seat belt so that it is not twisted.
REMARK
The date attached to the seat belt is the manufactured date. It is the start of the 5-year period. It is not the start of
the 3-year period of actual usage.
FASTENING AND REMOVING OF SEAT BELT
This seat belt has a wind-in device, so it is not necessary to adjust the length.
HOW TO FASTEN SEAT BELT
Hold grip (2) and pull the belt out from wind-in device (1), check
that the belt is not twisted, then insert tongue (3) into buckle (4)
securely.
When doing this, pull the belt lightly to check that it is properly
locked.
HOW TO REMOVE SEAT BELT

Press button (5) in buckle (4), and remove tongue (3) from buckle (4).
The belt is automatically wound in, hold grip (2) and return the belt slowly to wind-in device (1).
3–159
REMARK
If the tongue is not inserted in the buckle, the seat belt monitor
is displayed at the left top of the monitor panel. If it is displayed,
fasten the seal belt.
OPERATIONS AND CHECKS BEFORE STARTING ENGINE

k
OPERATIONS AND CHECKS BEFORE STARTING ENGINE:PC220_KU-0000-12DK00A
WARNING
When starting the engine, check that the lock lever is securely at the LOCK position.
If the lock lever is not locked securely and the control levers or control pedals are touched when the
engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
k CAUTION
Proportional Control Neutral Detection
When turning the key in the starting switch (2) to ON position (B) DO NOT touch the left (D) or right (E)
proportional control slide switches, otherwise the Neutral Detection System will recognise the wrong
position as Neutral and this may result in unexpected movement of the Attachment.
3–160
1. Check that battery disconnect switch (S) is in ON position

(I).
2. Check that lock lever (1) is at LOCK position (L).

3. Check that all control levers and control pedals are at the
NEUTRAL position.
If the control levers and control pedals are not being
touched, they will be at the NEUTRAL position.
4. Insert the key in starting switch (2), turn the key to the ON
position (B) – DO NOT touch the left (D) or right (E) propor-
tional control slide switches, otherwise the Neutral Detec-
tion System will recognise the wrong position as Neutral
and this may result in unexpected movement of the Attach-
ment.
Next carry out the following checks :
3–161
q If a password has been set, the input display screen will

be displayed on the monitor screen.
q After inputting the password, press enter switch F6 (3).
REMARK
Contact your Komatsu distributor for details of the method of
setting, changing, or cancelling the password.
1) The buzzer sounds for approximately 2 seconds, then

the monitor or meter lights up for approximately 2 sec-
onds.
q Radiator coolant level monitor (4)
q Charge level monitor (5)
q Engine oil pressure monitor (6)
q Engine oil level monitor (7)
q Air cleaner clogging monitor (8)
q Water separator monitor (9)
q Engine coolant temperature gauge (10)
If any monitor does not light up or the buzzer does not
sound, there is probably a failure in the monitor, so
please ask your Komatsu distributor for repair.
2) After approximately 2 seconds, the screen will change to
the working mode/travel speed display monitor. Next, it
will switch to the standard screen.
q Engine coolant temperature gauge (10)
q Engine coolant temperature monitor (11)
q Fuel gauge (12)
q Fuel level monitor (13)
q Hydraulic oil temperature gauge (14)
q Hydraulic oil temperature monitor (15)
3) If the hydraulic oil temperature gauge goes out or alarm

monitor (16) stays lighted up red, immediately check the
item that lights up red.
For details of the alarm monitor, see "WARNING
DISPLAY (3-15)".
4) If the maintenance time has passed, maintenance time

monitor (17) lights up in red for 30 seconds. Press user
menu display switch (18), check the item, and carry out
maintenance immediately.
For details of the method of checking the maintenance
time, see "MAINTENANCE SCREEN SETTING (3-65)"
in the explanation for each component.
3–162
AUTOMATIC GREASE SYSTEM

Check Automatic Grease System is normal, see section Maintenance - AUTOMATIC GREASE SYSTEM (6-7)
STARTING ENGINE
k
STARTING ENGINE:PC220_KU-0000-132K00A
WARNING
q Start the engine only while sitting in the operator's seat.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may
cause a serious personal injury or fire.
q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start
the engine.
q Never use starting aid fluids as they may cause explosions.
q Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.
NOTICE
q Before starting the engine, check that fuel control dial
(2) is at the low idle (MIN) position. If the fuel control
dial is at the full speed (MAX) position, the engine will
accelerate suddenly and cause damage to the engine
parts.
q Do not keep the key in starting switch (3) at the START
position continuously for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes,
then start again from the beginning.
q After the engine starts, wait for the engine oil pressure
monitor to go out. Do not touch the control levers or
control pedal while the engine oil pressure monitor is
lighted up.
This machine is equipped with an engine automatic preheating device that functions to start the engine preheating
automatically.
If the ambient temperature is low, the preheating monitor will light up when the key in starting switch (3) is turned
to the ON position to inform the operator that preheating has been started automatically.
1. Check lock lever (1) is in LOCK position (L). If lock lever (1)
is in FREE position (F), the engine does not start.
2. Set fuel control dial (2) to the low idle (MIN) position.
3–163
3. Turn the key in starting switch (3) to ON position (B).

If the ambient temperature is low, the preheating monitor
lights up and automatic preheating is carried out. Keep the
key in starting switch (3) at ON position (B) until the
preheating monitor goes out.
The time that the preheating monitor stays lighted up
depends on the ambient temperature as shown in the table.
Ambient temperature Lighting time
-4°C to -15°C 5 seconds to 30 seconds
-15°C or less 30 seconds
4. If the preheating monitor does not light up, or it lights up and
then goes out to inform that the engine preheating has been
completed, turn the key in starting switch (3) to START posi-
tion (C) and start the engine.
REMARK
If the ambient temperature is low, the engine may not start
even when the key in starting switch (3) is kept at the START
position for 20 seconds. If this happens, wait for at least 2 min-
utes, then start again from the beginning.
5. After the engine starts, release the key in starting switch (3).
The key will automatically return to ON position (B).
REMARK
When the engine is started, the battery voltage may suddenly
drop depending on the temperature and the battery condition. If
this happens, the display on the machine monitor may momen-
tarily go out, but this does not indicate any abnormality.
6. Even if the engine starts, wait for the engine oil pressure
monitor to go out. Do not touch the control levers or control
pedal while the engine oil pressure monitor is lighted up.
NOTICE
If the engine oil pressure monitor does not go out even
after 4 to 5 seconds have passed, stop the engine immedi-
ately. Check the oil level, check for leakage of oil, and take
the necessary action.
3–164
REMARK
Regardless of the ambient temperature, it is possible to start
the engine preheating manually.
1. Turn the key in starting switch (3) to the left from OFF posi-
tion (A). The preheating monitor lights up and engine preheat-
ing starts.
(Preheating continues while the key in starting switch (3) is
held at the left position.)
2. The preheating monitor starts lighting about 30 seconds after
preheating starts and then goes out in about 10 seconds.
3. After the preheating monitor goes out, turn the key in starting
switch (3) to START position (C). The engine will start.
If the engine cannot be started with the above procedure, wait
for at least two minutes, then start again from Step 1.
If a password has been set, the input display screen will be dis-
played on the monitor screen, but the preheating monitor oper-
ates as in the standard screen.
TURBO PROTECT FUNCTION

The turbo protect function is a function to protect the turbocharger by keeping the engine speed at less than
approx. 1,000 rpm immediately after the engine is started.
q When the turbo protect function is actuated, the engine speed is held at less than approx. 1,000 rpm, regard-
less of the position of the fuel control dial.
q When the turbo protect function is actuated, the engine speed is held at less than approx. 1,000 rpm, even if
the fuel control dial is operated.
q When the turbo protect function is cancelled, the engine speed is set to the speed for the position of the fuel
control dial.
q The actuation time of the turbo protect function is limited to 20 seconds.
REMARK
White smoke may be discharged for a short time just after the engine is started or during the KDPF regeneration
in the cold season, but this is not trouble.
AMBIENT TEMPERATURE RANGE FOR OPERATION AND STORAGE

q The recommended ambient temperature range for operation and storage is -20° C to +45° C.
When operating in ambients below O° C, refer to COLD WEATHER OPERATION (3-225) for details of precau-
tions.
3–165
OPERATIONS AND CHECKS AFTER STARTING ENGINE

k
OPERATIONS AND CHECKS AFTER STARTING ENGINE:PC220-0000-133K00A
WARNING
q To stop the engine in emergencies or when the actua-
tion of the engine is abnormal or there is any other
trouble, turn the key in the starting switch to the OFF
position.
q Do not carry out operations nor operate the levers or
pedal suddenly while the hydraulic oil is at low temper-
ature. Always carry out the warm-up operation for the
hydraulic equipment until the hydraulic oil temperature
monitor displays the proper temperature.
(When the hydraulic oil temperature is low, the low
temperature display shown in the figure on the right is
given.
q (A) Display when temperature is proper: Monitor
background (C) is blue
q (B) Display when temperature is low: Monitor back-
ground (C) is white
q If the warm-up operation for the hydraulic equipment is
not carried out thoroughly, and the machine is moved,
the reaction of the machine to the operation of the con-
trol levers and pedals will be slow and the movement of
the machine may not be what the operator intended.
Always warm up the hydraulic equipment. In particular,
in cold environment, always warm up the hydraulic
equipment thoroughly.
q While the engine is running or just after stopping the
engine, keep away from the exhaust pipe. Keep com-
bustible materials away from the exhaust pipe outlet.
There are two types of warm-up operation: warm-up of the engine and warm-up of the hydraulic equipment. In
addition, depending on the environment, the method of carrying out the warm-up operation may differ, so carry
out the warm-up operation according to the descriptions given in the appropriate section.
(When only the engine is warmed up, the hydraulic equipment is not warmed up, so always carry out the warm-up
operation for the hydraulic equipment separately from the warm-up operation for the engine. Warm-up of the
hydraulic equipment thoroughly ensures that the hydraulic oil is warmed up and that warm hydraulic oil circulating
in all the control circuits.)
CHECK ENGINE STARTABILITY AND ABNORMAL NOISE

Check engine startability and abnormal noise:PC-0000-134K00A
When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and
smoothly.
Check also that there is no abnormal noise when the engine is idling or when the engine speed rises slightly.
q When there is an abnormal noise at the engine startup and if that condition continues, the engine may be dam-
aged. In that case, ask your Komatsu distributor to check the engine as soon as possible.
CHECK ENGINE ACCELERATION AND DECELERATION

CHECK ENGINE ACCELERATION AND DECELERATION:PC220-0000-137K00A
When stopping the machine during normal operation, check that there is no irregular engine revolution or that the
engine does not stop suddenly.
Check also that the engine speed increases smoothly when the fuel control dial is turned to the full (Max).
q Carry out these checks in a safe place, watching out for danger in the surroundings.
q When the engine performs very badly at low idling and in the acceleration and if that condition continues, the
engine may be damaged or confuse the operator's sense of driving or lower the braking efficiency, and as a
result an unexpected accident may result. In that case, ask your Komatsu distributor to check the engine as
soon as possible.
3–166
REMARK
q The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas purification function.
q White smoke may be discharged for a short time just after the engine is started or during the KDPF regenera-
tion in the cold season, but this is not trouble.
BREAKING-IN THE NEW MACHINE

BREAK-IN THE NEW MACHINE:PC-0000-138K00A
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking in the machine may adversely affect the per-
formance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the descriptions in this manual, and pay attention to the following points when
breaking in the machine.
q Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
q Warm up the engine for five minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction of the machine.
ENGINE WARM-UP OPERATION

ENGINE WARM-UP OPERATION:PC220_KU-0000-139K00A
NOTICE
q Do not accelerate the engine suddenly until the warm-
up operation is completed.
q Do not run the engine at low idling or high idling under
no load for more than 20 minutes. This will have an
adverse effect on the environment, and will also have
an adverse effect on the internal structure of the
engine. If it is necessary to run the engine at idling for
more than 20 minutes, apply a load from time to time or
run at a mid-range speed.
After the engine starts, do not start operating the machine immediately. First, carry out the following operations
and checks.
3–167
1. This machine is equipped with an automatic engine warm-

up system, so if the engine coolant temperature is below
30°C after the engine is started, the engine warm-up opera-
tion starts automatically. When the engine automatic warm-
up operation starts, the engine speed is maintained at a
speed higher than the normal low idling speed.
If the engine coolant temperature goes above 30°C or if the
warm-up operation is continued for more than 10 minutes,
the automatic warm-up operation is cancelled and the
engine speed drops to the normal low idling speed.
2. Check that engine coolant temperature monitor (1) displays
the proper temperature.
If it displays low temperature, use the procedure in Step 3 to
carry out additional warm-up of the engine until the monitor
displays the proper temperature.
q Display (A) when temperature is proper: Monitor back-
ground (C) is blue
q Display (B) when temperature is low: Monitor back-
ground (C) is white
3. Turn fuel control dial (2) to a point midway between low
idling (MIN) and full speed (MAX), run the engine under no
load at a mid-range speed until engine coolant temperature
monitor (1) displays the proper temperature.
If the engine coolant temperature monitor displays the proper temperature, the engine warm-up operation is com-
pleted.
After checking that the engine coolant temperature monitor displays the proper temperature, carry out the warm-
up operation for the hydraulic equipment.
NOTICE
Cancelling automatic warm-up operation
If it becomes necessary in an emergency to cancel the automatic warm-up operation or to lower the
engine speed to low idle, do as follows.
3–168
1. Turn fuel control dial (2) to the full speed (MAX) position
and hold it for three seconds.
2. When fuel control dial (2) is returned to the low idle (MIN)
position, the engine speed will drop.
HYDRAULIC SYSTEM WARM-UP OPERATION

k
HYDRAULIC SYSTEM WARM-UP OPERATION:PC220_KU-0000-13EK00A
WARNING
q Before carrying out the warm-up operation for the
hydraulic equipment, turn the swing lock switch ON,
check on the monitor that the swing lock is actuated,
then start the warm-up operation.
q When warming up the hydraulic equipment, check that
there is no person or obstacle in the surrounding area,
then sound the horn and start the operation.
q Carry out the warm-up operation for the hydraulic
equipment until the hydraulic oil temperature monitor
displays the proper temperature. (When the hydraulic
oil temperature is low, the low temperature display
shown in the figure on the right is given.
Display (A) when temperature is proper: Monitor back-
ground (C) is blue
Display (B) when temperature is low: Monitor back-
ground (C) is white)
q The warm-up operation for the hydraulic equipment is
necessary not only for the circuit between the pump
and cylinders and between the pump and motor, but
also for the control circuits. Do not carry out the opera-
tion just for one cylinder or motor, or the operation just
in one direction. Carry out the operation in all direc-
tions for all the work equipment (boom, arm and
bucket), swing, travel, and attachment (if equipped).
q Before operating the travel lever, check the direction of
the track frame.
3–169

ground (C) is blue
ground (C) is white
If it displays low temperature, carry out additional warm up
of the engine until engine coolant temperature monitor (1)
2. Turn swing lock switch (2) to the ON position and check that
the swing lock monitor lights up.
3. To complete the warm-up operation of the hydraulic equip-

ment more quickly, set the working mode to P mode (heavy-
duty mode).
For details of the procedure for setting the working mode,
see "WORKING MODE SELECTOR SWITCH (3-37)".
4. Move lock lever (3) slowly to FREE position (F), then raise
the bucket from the ground.
3–170
5. Turn fuel control dial (4) to a 2/3 position between low idle
(MIN) and full speed (MAX).
NOTICE
q When the work equipment is operated, take care
that it does not interfere with the machine body or
ground.
6. Move right work equipment control lever (5) slowly in the direction to pull in bucket (D). Operate the lever to the
end of its travel and hold it in position for 30 seconds.
7. Move right work equipment control lever (5) slowly in the direction to push out bucket (C). Operate the lever to
the end of its travel and hold it in position for 30 seconds.
8. Next, move left work equipment control lever (6) slowly in the direction to pull in arm (B). Operate the lever to
the end of its travel and hold it in position for 30 seconds.
9. Move left work equipment control lever (6) slowly in the direction to push out arm (A). Operate the lever to the
10. Repeat the operation in Steps 6 to 9 for five minutes.
11. Check that hydraulic oil temperature monitor (7) displays
If the hydraulic oil temperature monitor is not displaying the
correct temperature (it is displaying low temperature), repeat
Steps 6 to 10 until the display is the correct temperature.
ground (C) is blue
ground (C) is white

ground (C) is blue
ground (C) is white
If it displays low temperature, carry out additional warm up
of the engine until engine coolant temperature monitor (1)
3–171
13. Check that the hydraulic oil temperature monitor and engine
coolant temperature monitor are displaying the proper tem-
perature, then check that all the gauges and caution moni-
tors on the machine monitor are in the following conditions.
q Radiator coolant level monitor (8): OFF
q Charge level monitor (9): OFF
q Engine oil pressure monitor (10): OFF
q Engine oil level monitor (11): OFF
q Air cleaner clogging monitor (12): OFF
q Water separator monitor (13): OFF
q Engine preheating monitor (14): OFF
q Engine coolant temperature gauge (15): Indicator in
green range
q Engine coolant temperature monitor (1): Displays proper
temperature
q Hydraulic oil temperature gauge (16): Indicator in green
range
q Hydraulic oil temperature monitor (7): Displays proper
temperature
q Fuel gauge (17): Indicator in green range
q Fuel level monitor (18): Displays appropriate level
14. Check for abnormal exhaust gas colour, noise, or vibration.
If any problem is found, contact your Komatsu distributor.
In cold temperatures [ambient temperature below 0°C], even
when the hydraulic oil temperature monitor displays the
proper temperature, carry out additional Step 15 to warm up
all the hydraulic equipment.
15. Turn fuel control dial (4) to the full speed (MAX) position,
repeat Steps 6 to 9 for 3 to 5 minutes, then check again that
the hydraulic oil temperature monitor is displaying the cor-
rect temperature.
If it is not displaying the correct temperature, repeat Steps 6
to 9 for 3 to 5 minutes until hydraulic oil temperature monitor
(7) displays the correct temperature.
ground (C) is blue
ground (C) is white
For both normal weather and cold weather, carry out the follow-
ing operation.
3–172
16. Before starting the work, check that fuel control dial (4) is at
a 2/3 position between low idling (MIN) and full speed
(MAX).
If it is not at a 2/3 position, set it to the midway position and
run the engine at 2/3 speed between MIN and MAX before
operating.
17. Before starting operations, repeat the following operations

slowly 3 to 5 times to circulate warm oil through the all con-
trol circuits.
q Boom operation: RAISE (E)ioLOWER (F)
q Arm operation: IN (B)ioOUT (A)
q Bucket operation: CURL (D)ioDUMP (C)
When carrying out swing operations, release swing lock
switch (2), check that swing lock monitor (19) goes out, then
operate the swing.
q Swing operation: Left (G)ioRight (H)
q Travel (Lo) operation: FORWARD (A)ioREVERSE (B)
18. For attachment operations (if equipped), change the work-

ing mode to the attachment mode.
3–173
q Attachment operation: One way (A)ioOther way (B)

If the hydraulic oil temperature monitor is not displaying the
correct temperature (it is displaying low temperature), repeat
Steps 6 to 10 until the display is the correct temperature.
ground (C) is blue
ground (C) is white
If the hydraulic oil temperature monitor displays the proper
temperature, the hydraulic equipment warm-up operation is
completed.
After checking that the hydraulic oil temperature monitor
displays the proper temperature, carry out the following
procedure.
OPERATION AFTER COMPLETION OF WARM-UP OPERATION
OPERATION AFTER COMPLETION OF WARM-UP OPERATION:PC220-0000-13FK00A

the correct temperature.
q (A) Display when temperature is correct: Monitor back-
ground (C) is blue
q (B) Display when temperature is low: Monitor back-
ground (C) is white
2. Push working mode selector switch (20) of the machine

monitor to select the working mode to be used.
For details of the procedure for switching the working mode,
q Working mode monitor display
3–174
1) P mode
For heavy-duty operations
2) E mode
For operations with emphasis on fuel economy
3) L mode
For operations requiring fine control
4) B mode
For breaker operations
3–175
5) ATT/P mode
For operations with crusher or other double-acting action
attachment
6) ATT/E mode
For operations with crusher or other double-acting action
attachment
(operations with emphasis on fuel consumption)
3–176
STOPPING ENGINE
k
STOPPING ENGINE:PC220-0000-13GK00A
WARNING
Keep away from the exhaust pipe just after stopping the engine.
NOTICE
If the engine is stopped abruptly, the service lives of com-
ponent parts of the engine may be considerably reduced.
Do not stop the engine abruptly except the case in an
emergency. If the engine is overheated, do not try to stop it
abruptly but run it at medium speed to allow it to cool
down gradually, and then stop it.
1. Run the engine at low idle for about five minutes to cool
down gradually.
2. Turn the key in starting switch (1) to the OFF position (A)
and stop the engine.
3. Remove the key from starting switch (1).
3–177
MACHINE OPERATION
k
MACHINE OPERATION::PC220_KU-0000-13HK00A
WARNING
q Before operating the travel levers or travel pedals, check the direction of the track frame.
If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite
direction to the direction of the operation of the travel levers or travel pedals (front and rear travel are
reversed, left and right steering are reversed).
q Before starting the machine, check that the area around the machine is safe, and sound the horn.
q Do not allow anyone to enter the area around the machine.
q Clear any obstacles from the travel path.
q There is a blind spot at the rear of the machine, so be particularly careful when travelling in reverse.
q If the travel levers or travel pedals are operated when the auto deceleration is being actuated, the
engine speed will suddenly increase, so be careful when operating.
q When travelling, check that the alarm sounds normally.
PREPARATIONS FOR MOVING MACHINE

PREPARATIONS FOR MOVING MACHINE:PC220-0000-13HK01A
1. Set swing lock switch (1) to the ON (actuated) position and

check that swing lock monitor lamp (2) lights up.
(a): ON position
(b): OFF position
2. Turn fuel control dial (3) towards the full speed (MAX) posi-
tion to increase the engine speed.
3–178
MOVE MACHINE FORWARD

Move Machine Forward:PC-0000-13HK02A
1. Set lock lever (4) in the FREE position (F), fold the work
equipment, and raise it 40 to 50 cm from the ground.
q If the work equipment blocks the view and it is difficult to
travel safely, raise the work equipment further.
2. Operate the right and left travel levers (5), or the right and
left travel pedals (6) as follows:
q When sprocket (A) is situated at the rear of the machine;

Start the machine either by pushing lever (5) forward slowly
or by depressing the front part of pedal (6) slowly.
q When sprocket (A) is situated at the front of the machine;

Start the machine either by pulling lever (5) backwards
slowly or by depressing the rear part of pedal (6) slowly.
3. Check that the travel alarm sounds properly. If the travel alarm does not sound, contact your Komatsu distrib-
utor for repair.
REMARK
In low temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation.
In addition, if the undercarriage is packed with mud and the machine travel speed is not normal, remove the soil
and mud from the undercarriage.
3–179
MOVE MACHINE BACKWARD

Move Machine Backward:PC-0000-13HK03A
1. Set lock lever (4) in the FREE position (F), fold the work
equipment, and raise it 40 to 50 cm.) from the ground.
q If the work equipment blocks the view and it is difficult to
travel safely, raise the work equipment further.
2. Operate the right and left travel levers (5), or the right and
left travel pedals (6) as follows:
q When sprocket (A) is situated at the rear of the machine;

Start the machine either by pulling lever (5) backwards
slowly or by depressing the rear part of pedal (6) slowly.
q When sprocket (A) is situated at the front of the machine;

Start the machine either by pushing lever (5) forward slowly
or by depressing the front part of pedal (6) slowly.
3. Check that the travel alarm sounds properly. If the travel alarm does not sound, contact your Komatsu distrib-
utor for repair.
REMARK
In low temperatures, if the machine travel speed is not normal, thoroughly perform the warming-up operation.
In addition, if the undercarriage is packed with mud and the machine travel speed is not normal, remove the soil
and mud from the undercarriage.
STOP THE MACHINE

Stop the machine::PC220_KU-0000-13HK04A
Avoid stopping suddenly. Stop the machine gradually.

1. Put right and left travel levers (1) in the NEUTRAL position.
The machine stops.
3–180
3–181
STEERING MACHINE
Steering machine:PC-0000-001K12A
STEERING
k
Pivot turn:PC-0000-13PK01A
WARNING
Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the
position of the sprocket).
When the sprocket is at the front, the directions of operations of the travel levers or control pedals are the
opposite to the direction of movement of the machine.
Use the travel levers to change direction.

Avoid sudden changes of direction to travel as much as possi-
ble.
Especially when performing counter-rotation (spin turn), stop
the machine before turning.
Operate two travel levers (1) as follows.
PIVOT TURN
Pivot turn:PC-0000-13PK01A
When turning to the left: Push the right travel lever forward to
turn to the left when travelling forward; and pull it back to turn
left when travelling in reverse.
(A): Forward left turn
(B): Reverse left turn
REMARK
When turning to the right, operate the left travel lever in the
same way.
3–182
CHANGE DIRECTION OF THE MACHINE

Change Direction of the Machine:PC-0000-13PK02A
When turning to the left: If the left travel lever is returned to the
NEUTRAL position, the machine will turn to the left.
(A): Forward left turn
(B): Reverse left turn
REMARK
When turning to the right, operate the right travel lever in the
same way.
COUNTER-ROTATION TURN (SPIN TURN)

Counter-rotation Turn (Spin Turn):PC-0000-13PK03A
When using counter-rotation (spin turn) to turn left, pull the left
travel lever backward and push the right travel lever forward.
REMARK
When using counter-rotation to turn right, pull the right travel
lever backward and push the left travel lever forward.
3–183
SWINGING MACHINE
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SWINGING MACHINE:PC220_KU-0000-13TK00A
WARNING
q The tail of the machine extends outside the tracks. Before operating the swing, check that the area
around the machine is safe.
q If the lever is operated when the engine speed is decreased by the auto-deceleration function, the
engine speed will suddenly increase. Operate the levers carefully.
1. Before starting the swing operation, turn swing lock switch

(1) OFF and check that swing lock monitor (2) goes out.
(a): ON position
(b): OFF position
2. Operate left work equipment control lever (3) to swing the

upper structure.
(A): Left swing
(B): Right swing
3. When not using the swing, turn swing lock switch (1) ON.
Check that swing lock monitor (2) lights up.
(a): ON position
(b): OFF position
3–184
WORK EQUIPMENT CONTROLS AND OPERATIONS

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WORK EQUIPMENT CONTROLS AND OPERATIONS:PC-0000-13UK00A
WARNING
If the lever is operated when the engine speed is decreased by the auto-deceleration function, the engine
speed will suddenly increase. Operate the levers carefully.
Use the control levers to operate the work equipment.

Note that when the levers are released, they return to the HOLD position and the work equipment is held in that
position.
q Arm control
Move the left work equipment control lever back and forth to
operate the arm.
q Swing control
Move the left work equipment control lever to the right or left
to swing the upper structure.
q Boom control
Move the right work equipment control lever back and forth
to operate the boom.
q Bucket control
Move the right work equipment control lever to the right or
left to operate the bucket.
3–185
If the work equipment control levers are returned to the NEUTRAL position when the machine is stopped, even if
the fuel control dial is set to FULL, the auto-deceleration mechanism works to reduce the engine speed to a low-
range speed.
REMARK
The control circuit on this machine is equipped with an accumulator. Even if the engine is stopped, if the starting
switch key is turned to the ON position within 15 seconds after stopping the engine, and the lock lever is set to the
FREE position, it is possible to use the lever operation to lower the work equipment to the ground.
This procedure can also be used for releasing the remaining pressure in the hydraulic cylinder circuits or for low-
ering the boom after loading the machine onto a trailer.
3–186
WORKING MODE
WORKING MODE:PC-0000-100K00A
WORKING MODE
WORKING MODE:PC220-PT5W-100K00A
Use working mode selector switch (1) to select the working mode that matches the operating conditions or pur-
pose. This will make it possible to carry out operations efficiently.
Use the following procedure to select the most efficient working mode.
When the starting switch is turned ON, the working mode is set to the mode that was in operation when the start-
ing switch was last turned OFF.
Use the working mode switch to set the mode to the most effi-
cient mode to match the type of work.
Working
Applicable operations
mode
Normal digging or loading operations
P mode
(production conscious operation)
Normal digging or loading operations
E mode
(fuel consumption conscious operation)
Aligning position (fine control operations)
L mode
Lifting operations
B mode Breaker operations
Operations of double-acting attachment on
ATT/P mode crusher
(production conscious operation)
Operations of double-acting attachment on
ATT/E mode crusher
(fuel consumption conscious operation)
NOTICE
q If breaker operations are carried out in a mode other than the breaker mode, there is danger of breakage of
the hydraulic equipment. Do not carry out breaker operations in any mode except the breaker mode.
q Lifting operations must be carried out in L mode in order to activate the overload warning system.
3–187
1. When working mode selector switch (1) is pressed, the

screen switches to the working mode selection screen.
2. Press the working mode selector switch or, switches F3 or

F4 to select the appropriate mode.
3. After selecting the desired mode, press switch F6 to accept

the change. The screen returns to the standard screen.
If switch F5 is pressed, the screen returns to the standard
screen without changing the mode.
q If a working mode is selected, and nothing is done for
five seconds, the selected working mode is automati-
cally accepted and the screen returns to the standard
screen.
q If a working mode is selected and working mode switch
(1) is kept pressed, the selected mode is accepted and
the screen returns to the standard screen.
q If the breaker mode is selected, "Really Set Breaker
Mode?" is displayed on the screen.
To set to the breaker mode, press switch F6.
If switch F5 is pressed, the screen returns to the working
mode selection screen.
3–188
ONE-TOUCH POWER MAX. SWITCH

Operations Using Travel Force:PC-0000-189K02A
The one-touch power max. switch can be used during operations to increase the power. Make effective use of this
function whenever necessary in combination with the working mode.
q Press the left knob switch and keep it pressed. The power
is increased as long as the switch is being pressed. How-
ever, the increased power is automatically cancelled after
8.5 seconds.
q This function does not work when the working mode is set
to L mode or B mode, ATT/P mode or ATT/E mode.
3–189
k
Prohibited operations:PC-0000-001K15A
WARNING
q Do not operate the work equipment control lever when the machine is travelling.
q If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly
increase, so be careful when operating.
OPERATIONS USING SWING FORCE

Operations Using Swing Force:PC-0000-189K01A
Do not use the swing force to compact soil or break objects.

This is not only dangerous, but also drastically reduces the life
of the machine.
OPERATIONS USING TRAVEL FORCE

Operations Using Travel Force:PC-0000-189K02A
Do not use the travel force to carry out excavation by digging

the bucket into the ground. This damages the machine or work
equipment.
PROHIBITION OF OPERATIONS USING HYDRAULIC CYLINDERS TO STROKE

ENDS
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends:PC-0000-189K03A
If the work equipment is used with the cylinder rod operated to

its stroke end, and given impact by some external force, the
hydraulic cylinders may be damaged, causing personal injury.
Avoid operations with the hydraulic cylinder fully retracted or
fully extended.
3–190
OPERATIONS USING BUCKET DROPPING FORCE

Operations Using Bucket Dropping Force:PC-0000-189K04A
Do not use the dropping force of the machine for digging, nor
use the dropping force of the bucket as a pickaxe, breaker, or
pile driver. This will drastically reduce the life of the machine.
OPERATIONS USING MACHINE DROPPING FORCE

Operations Using Machine Dropping Force:PC-0000-189K05A
Do not use the dropping force of the machine for digging.
DIGGING HARD ROCKY GROUND

Digging Hard Rocky Ground:PC-0000-189K06A
Do not attempt to directly excavate hard rocky ground with the work equipment. It is better to excavate it after
breaking up by some other means. This will not only save the machine from damage but will make for better econ-
omy.
SUDDEN LEVER OR PEDAL SHIFTING HIGH SPEED TRAVEL

Sudden Lever or Pedal Shifting High Speed Travel:PC-0000-189K07A
(1) Do not operate the levers and pedals suddenly nor take any
other action to move the machine quickly.
(2) Do not operate the levers or pedals suddenly from FOR-
WARD (A) to REVERSE (B) (or from REVERSE (B) to FOR-
WARD (A)).
(3) Do not operate the levers or pedals suddenly (do not
release them suddenly) to stop the machine when travelling at
high speed.
3–191
LONG-TIME CONTINUOUS TRAVEL OPERATIONS

Long-Time Continuous Travel Operations:PC-0000-189K08A
Do not travel continuously at high speed for one and a half

hours or more. The lubricating oil inside the track rollers and
final drive will rise to a high temperature. And there is a danger
that this will cause damage to the oil seal or leakage of oil.
When travelling continuously for a long time, stop the machine
for 30 minutes every one and a half hours to allow the lubricat-
ing oil inside the track rollers and final drive to cool down.
3–192
RULES FOR OPERATION

RULES FOR OPERATION:PC-0000-001K13A
TRAVELLING
Traveling:PC-0000-186K01A
Travelling over boulders, tree stumps, or other obstacles will

cause a big shock to the machine (and in particular to the
undercarriage), and this will cause damage to the machine. For
this reason, always remove any obstacles or travel around
them, or take other steps to avoid travelling over such obsta-
cles as far as possible.
If there is no way to avoid travelling over an obstacle, reduce
the travel speed, keep the work equipment close to the ground,
and try to travel so that the centre of the track shoe passes
over the obstacle.
HIGH SPEED TRAVEL

HIGH SPEED TRAVEL:PC220-0000-186K00A
On uneven roadbeds such as rock beds or uneven roads with

large rocks, travel at Lo speed. When travelling at high speed,
set the idler in the forward direction.
q Press travel speed selector switch (1) to switch the travel
speed. The travel speed (Lo, Mi, Hi) is displayed on the
travel speed monitor (2).
3–193
PERMISSIBLE WATER DEPTH

Permissible Water Depth:PC-0000-18NK00A
NOTICE
When driving the machine out of water, if the angle of the
machine exceeds 15°, the rear of the upper structure will
go under water, and water will be thrown up by the cooling
fan. This may cause the fan to break. Be extremely careful
when driving the machine out of water.
Do not drive the machine in water deeper than the centre of

carrier roller (1).
After the job, be sure to supply grease to the parts which have
been under water for a long time until the used grease is pro-
jected. (around the bucket pin, in particular)
3–194
TRAVELLING ON SLOPES
k
Travelling on slopes:PC-0000-187K01A
WARNING
q Turning or operating the work equipment when working
on slopes may cause the machine to lose its balance
and turn over, so avoid such operations.
It is particularly dangerous to swing downhill when the
bucket is loaded.
If such operations have to be performed, pile soil to
make a platform (A) on the slope so the machine is kept
horizontal during operation.
q Do not work on a slope covered with the steel plates.
Even with slight slopes there is a hazard that the
machine may slip.
q Do not travel up or down steep slopes. There is a dan-
ger that the machine may turn over.
q When travelling, raise the bucket approximately 20 to
30 cm from the ground.
Do not travel downhill in reverse.
q Never turn on slopes or travel across slopes.
Always go down to a flat place to perform these opera-
tions. It may be longer, but it will ensure safety.
q Always operate or travel in such a way that it is possi-
ble to stop safely at any time if the machine slips or
becomes unstable.
q When travelling uphill, if the shoes slip or it is impossi-
ble to travel uphill using only the force of the tracks, do
not use the pulling force of the arm to help the machine
travel uphill. There is danger that the machine may tip
over.
q If the engine stops when the machine is on a slope,
never use the left work equipment control lever to carry
out swing operations. The upper structure will swing
under its own weight.
q Do not open or close the door when the machine is on a
slope. The operating effort may suddenly change.
Always keep the door locked in position when it is open
and when it is closed.
3–195
1. When travelling down steep hills, use the travel lever and
fuel control dial to keep the travel speed low.
When travelling down a steep hill of more than 15°, set the
work equipment to the posture shown in the figure on the
right, and lower the engine speed.
2. When travelling up a steep hill of more than 15°, set the

work equipment to the posture shown in the figure on the
right.
q When travelling up a steep slope, extend the work equip-

ment to the front to improve the balance, keep the work
equipment approximately 20 to 30 cm above the ground,
and travel at low speed.
BRAKING ON DOWNHILL SLOPE

BRAKING ON DOWNHILL SLOPE:PC-0000-18QK00A
Put the travel lever in the neutral position. This will cause the brake to be automatically applied.
IF ENGINE STOPS ON SLOPE

IF ENGINE STOPS ON SLOPE:PC-0000-18RK00A
If the engine stops when travelling uphill, move the travel levers to the neutral position, lower the bucket to the
ground, stop the machine, then start the engine again.
CAB DOORS ON SLOPE

q If the engine stops when the machine is on a slope, never use the left work equipment control lever to carry out
swing operations. The upper structure will swing under its own weight.
q Do not open or close the door when the machine is on a slope. The operating effort may suddenly change.
Always keep the door locked in position when it is open and when it is closed.
3–196
O P E R A T IO N MACHINE OPERATIONS AND CONTROLS
ESCAPE FROM MUD

ESCAPE FROM MUD:PC-0000-14CK00A
Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get
the machine out.
TRACK ON ONE SIDE STUCK

Track on One Side Stuck:PC-0000-14CK01A
NOTICE
When using the boom or arm to raise the machine, always
have the bottom of the bucket in contact with the ground.
The angle between the boom and arm should be 90° to
110°.
The same applies when using the bucket installed in the
reverse direction.
When only one side is stuck in mud, use the bucket to raise the
track, then lay boards or logs and drive the machine out.
TRACKS ON BOTH SIDES STUCK

Tracks on Both Sides Stuck:PC-0000-14CK02A
When the tracks on both sides are stuck in mud and they slip,
making it impossible for the machine to move, lay boards or
logs as explained above, and dig the bucket into the ground in
front. Then pull in the arm as in normal digging operations and
put the travel levers in the FORWARD position to pull the
machine out.
3–197
RECOMMENDED APPLICATIONS
RECOMMENDED APPLICATIONS:PC-0000-13VK00A
In addition to the following, it is possible to further increase the range of applications by using various attach-
ments.
BACKHOE WORK
Backhoe Work:PC-0000-13WK00A
A backhoe is suitable for excavating areas that are lower than

the machine.
When the condition of the machine is as shown in the figure on
the right (angle between [bucket cylinder and link] and [arm cyl-
inder and arm] is 90°), the maximum excavation force is
obtained from the pushing force of each cylinder.
When excavating, use this angle effectively to optimize your
working efficiency.
The range for excavating with the arm is from a 45° angle away
from the machine to a 30° angle towards the machine.
There may be some differences depending on the excavation
depth, but try to stay within the above range rather than operat-
ing the cylinder to the end of its stroke.
SHOVEL WORK
Shovel Work:PC-0000-13XK00A
A shovel is suitable for excavating at a position higher than the

machine.
Shovel work is performed by attaching the bucket in the
reverse direction.
DITCHING WORK
Ditching Work:PC-0000-13YK00A
Ditching work can be performed efficiently by attaching a

bucket which matches the digging operation and then setting
the tracks parallel to the line of the ditch to be excavated.
To excavate a wide ditch, first dig both sides and then finally
remove the centre portion.
3–198
LOADING WORK
Loading Work:PC-0000-13ZK00A
In places where the swing angle is narrow, work efficiency can

be enhanced by locating the dump truck in a place easily visi-
ble to the operator.
When loading the soil into dump truck body, it is easier to load
from the rear of the dump body than to load from the side of the
dump body, and more soil can be loaded as well.
3–199
REPLACING AND INVERTING BUCKET

k
REPLACING AND INVERTING BUCKET:PC-LBK0-928K00A
WARNING
q When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury.
When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equip-
ment.
q When the bucket is removed, place it in a stable condition.
q If pins are hit with a strong force, there is a hazard that the pin may fly out and injure people in the sur-
rounding area. Make sure that there is no one in the surrounding area before starting the operation.
q When removing the pins, do not stand behind the bucket. In addition, be extremely careful not to put
your foot under the bucket while standing on the side for the work.
q When removing or inserting pins, be extremely careful not to get your fingers caught.
q Never insert your fingers into the pin holes when aligning the holes.
Stop the machine on a firm and flat surface and do the work. When performing joint work, appoint a leader and fol-
low that person's instructions and signals.
REPLACE
Replace:PC-LBK0-923K00A
1. Place the bucket in contact with a flat surface of the ground.

REMARK
When removing the pins, place the bucket so that it is in light contact with the ground.
If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the
pins.
NOTICE
After removing the pins, make sure that mud or sand does not get on them. Dust seals are fitted at both
ends of the bushings, be careful not to damage them.
2. Remove the double nuts on the stopper bolt for arm pin (A)
and link pin (B), remove the bolt, pull out arm pin (A) and
link pin (B), and then remove the bucket.
3. Align the pin hole of arm (5) with replacement bucket hole
(1), then align the pin hole of link (6) with hole (2), coat pins
(A) and (B) with grease, and install.
3–200
REMARK
When installing the bucket, for arm pin portion (A), fit O-ring (3)
to bucket (4) in the position shown in the figure on the right.
After inserting the pin, fit it in the regular groove. For link pin
portion (B), install the bucket with O-ring (3) fitted in the regular
groove.
4. Install the stopper bolts and nuts for each pin, then grease the pins.
REMARK
q Lubricate with grease thoroughly until the grease comes out from the end faces.
q When replacing the bucket, replace the dust seal with a new one if it is damaged. If a damaged seal is used
without being replaced, sand and dirt may enter the pin portion and cause abnormal wear of the pin.
INVERT
INVERT:PC-LBK0-6D5K00A
1. Place the bucket in contact with a flat surface of the ground.

REMARK
When removing the pins, place the bucket so that it is in light
contact with the ground.
If the bucket is lowered strongly to the ground, the resistance
will be increased and it will be difficult to remove the pins.
NOTICE
After removing the pins, make sure that mud or sand does
not get on them. Dust seals are fitted at both ends of the
bushings, be careful not to damage them.
2. Remove the double nut on the stopper bolt for arm pin (A)
and link pin (B), remove the bolt, pull out arm pin (A) and
link pin (B), and then remove the bucket.
3–201
3. After removing the bucket, reverse it.

4. Align the pin hole of arm (5) with replacement bucket hole
(1), then align the pin hole of link (6) with hole (2), coat pins
(A) and (B) with grease, and install.
REMARK
When inverting, do not install O-rings. Keep the O-rings in a
safe place until using them next.
5. Install the stopper bolts and nuts for each pin, then grease
the pins.
REMARK
q Lubricate with grease thoroughly until the grease comes out
from the end faces.
q When replacing the bucket, replace the dust seal with a
new one if it is damaged. If a damaged seal is used without
being replaced, sand and dirt may enter the pin portion and
cause abnormal wear of the pin.
3–202
REMARK
q Machines with Automatic Grease System require one time
lubrication each time the bucket is changed.
Lubricate at the bucket linkage and at the grease metering
valve as indicated until grease comes out from the end
faces. It will be necessary to replace the plug at the grease
metering valve with a grease nipple during lubrication. The
plug must be replaced after lubrication.
Grease metering valve for standard machines
Grease metering valve for Super Long Front machines
3–203
WHEN PARKING MACHINE

k
When parking machine:PC220_KU-0000-160K00A
WARNING
q Avoid stopping suddenly. Stop the machine gradually.
q Park the machine on flat hard ground.
Avoid to park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, put blocks to the track shoes. As an additional
safety measure, thrust the bucket into the ground.
q If the control lever is touched by accident, the machine
may move suddenly, and this may lead to a serious per-
sonal accident. Before leaving the operator's compart-
ment, always set the lock lever securely to LOCK
position.
1. Set left and right travel levers (1) in the neutral position.The
machine stops.
2. Turn fuel control dial (2) to low idling position (MIN) and
lower the engine speed.
3–204
3. Lower the bucket horizontally until the bottom touches the

ground.
4. Set lock lever (3) in the LOCK position (L).
5. Check the engine coolant temperature and engine oil pres-

sure with the machine monitor.
q If the coolant temperature gauge is in the red range,
allow it to cool until the indicator enters the green range,
then stop the engine. Perform the inspection and action
to take according to "Troubles and actions (3-229)".
q If the engine oil pressure monitor lights up, stop the
engine immediately. Perform the inspection and action
to take according to "Troubles and actions (3-229)".
6. Stop the engine.For details on the procedure for stopping
the engine, see "STOPPING ENGINE (3-177)".
3–205
AFTER DAILY WORK COMPLETION

After daily work completion:ALL-3330-200A00A
1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for
any leakage of oil or coolant. If any problems are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud stuck to the undercarriage.
LOCKING
LOCKING:PC220-Q8E0-100K00A
Always lock the following places.

(1) Operator's cab door
Always close the window.
(2) Fuel tank filler port
(3) Engine hood
(4) Tool case cover
(5) Left side door of the machine
(6) Right side door of the machine
(7) Hydraulic tank filler port
(8) Air conditioner FRESH air filter intake port
REMARK
Use the starting switch key to lock and unlock all these places.
3–206
OPERATION TRANSPORTATION
TRANSPORTATION
TRANSPORTATION:ALL-0000-810K00A
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
TRANSPORTATION PROCEDURE:PC-0000-813K00A
q Select the method of transportation to match the weight and dimensions given in "SPECIFICATIONS (5-2)".
Note that the weight and dimension given in SPECIFICATIONS (weight and dimension) may differ according
to the type of shoe or arm, or other attachments.
q Consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard
installed for the operator's cab.
q Please consult your Komatsu distributor for information about handling of handrail.
3–207
TRANSPORTATION OPERATION
LOADING AND UNLOADING WITH TRAILER

k
LOADING AND UNLOADING WITH TRAILER:PC-0000-830K00A
WARNING
Always observe the following when loading or unloading
the machine from a trailer.
q Select firm, level ground when loading or unloading the
machine.
Maintain a safe distance from the edge of a road.
q Always turn the auto-deceleration switch OFF (cancel).
If the auto-deceleration switch is left ON, the machine
may suddenly start moving.
q Always set the travel speed switch to low speed (Lo),
run the engine at low idling, and operate the machine
slowly when loading or unloading.
q In cold areas, carry out the warming-up operation thor-
oughly and make sure that the engine speed is stable
before carrying out the loading or unloading operation.
q Never correct your steering on the ramps. There is dan-
ger that the machine may tip over.
If necessary, drive off the ramps or back on to the trailer
and correct the direction.
q It is dangerous to use the work equipment for loading
and unloading operations. Always use ramps.
q On the ramps, do not operate any lever except the
travel lever.
q The centre of gravity of the machine will change sud-
denly at the joint between the ramps and the trailer, and
there is danger of the machine losing its balance.
Travel slowly over this point.
q If it is necessary to swing the work equipment on the
trailer platform, the footing is unstable, so be extremely
careful that the machine does not tip over.
If the work equipment is installed to the machine, pull
the work equipment in, and operate slowly to prevent
the machine from losing its balance.
q Position a flagman to give guidance to prevent the
machine from coming off the ramps and to ensure
safety in the operation.
Always observe the following regarding the ramps and
trailer platform.
q Use ramps with ample width, length, thickness, and
strength and install them with a maximum slope of 15°.
When using piled soil, compact the piled soil fully to
prevent the slope face from collapsing.
q Clean the machine tracks and ramps before starting in
order to prevent the machine from slipping on the
ramps.
There is danger of the machine slipping if there is water,
snow, grease, oil, or ice on the ramp surface.
When loading or unloading, always use ramps or a platform. Proceed as follows.
3–208
LOADING
Loading:PC220-0000-831K00A
1. Load and unload on firm level ground only.

2. Apply the trailer brakes securely, then put blocks (1) under
the tires to prevent the trailer from moving.
q Set left and right ramps (2) parallel to each other and
equally spaced to the left and right of centre (3) of the
trailer. Make angle of installation (4) a maximum of 15°.
If the ramps bend a large amount under the weight of
the machine, put blocks under the ramps to prevent
them from bending.
3. Turn the travel speed selector switch to low speed travel

(Lo lamp lights up).
q Press travel speed selector switch (5) to switch the
travel speed. The travel speed (Lo, Mi, Hi) is displayed
on the travel speed monitor (6).
4. Turn auto-deceleration switch (7) OFF and operate the fuel
control dial to set the engine speed to low idling.
q Each time auto-deceleration switch (7) is pressed, it
switches OFF—ON—OFF in turn.
q When auto-deceleration switch (7) is turned OFF, the
auto-deceleration monitor (8) goes out.
5. Turn the swing lock switch ON to apply the swing lock.

q When the swing lock switch is turned to the ON position,
pilot monitor display (9) lights up.
(a): ON position
(b): OFF position
6. If the machine is equipped with work equipment, set the

work equipment at the front, and travel forward to load it; if it
has no work equipment, travel in reverse to load it.
Follow instructions and signals of a conductor particularly
when travelling in reverse.
7. Before moving onto the ramps, make sure that the machine
is positioned in a straight line with the ramps and that the
centre line of the machine matches that of the trailer.
Align the direction of travel with the ramps and travel slowly.
Lower the work equipment as far as possible without
causing interference.
When on the ramps, operate only the travel lever. Do not
operate any other lever.
3–209
8. When loading or unloading a machine with the work equip-

ment installed, at the point where the tracks are on both the
ramps and the ground surface, turn the swing lock switch
OFF, then swing the upper structure slowly 180°.
After doing that, drive slowly in reverse and load the
machine onto the trailer.
9. Turn the swing lock switch ON to apply the swing lock.

q When the swing lock switch is turned to the ON position,
pilot monitor display (9) lights up.
(a): ON position
(b): OFF position
10. When the machine travels over the rear wheels of the
trailer, it becomes unstable, drive slowly and carefully.
(Never operate the steering.)
11. At the moment the machine passes the rear wheels, it tilts
forward, be careful not to let the work equipment hit the
trailer body. Drive the machine forward to the specified
position, then stop the machine.
12. Lower the work equipment on top of wooden blocks.
3–210
SECURE MACHINE
SECURE MACHINE:PC220-0000-821K00A
NOTICE
q Stow the radio antenna. Reassemble the mirrors so that they are within the width of the machine.
q To prevent damage to the bucket cylinder during transportation, put a wooden block under the tip of
the bucket link to prevent the bucket cylinder from touching the floor.
q The use of rubber matting between the tracks and the trailer bed is highly recommended.
q Tying down equipment (e.g. chains, shackles etc.) must be in good condition and protected where
crossing or in contact with sharp corners.
q Check that the engine hood catcher is locked. Hold the handle of the engine hood and raise it slightly.
If it does not open, the catcher is locked.
If the engine hood catcher is not locked, there is a danger that the engine hood may open during trans-
portation.
After loading the machine onto a trailer, secure the machine as follows:
1. Extend the bucket and arm cylinders fully, then lower the
boom slowly.
2. Set the lock lever securely to LOCK position (L).

3. Stop the engine, then remove the key from the starting
switch.
4. Close all of the doors, windows, and covers.
Lock the doors, covers, and caps fitted with locks.
5. Check machine mass on the machine model plate and use
the appropriate rated equipment for tying down the machine
to the trailer.
Select the way of secure the machine according to the transportation form of each territory from the following.
3–211
q Securing the machine when using tie-down point

Tie one end of each chain or wire rope of appropriate strength
to the tie-down holes on the track frame.
X : 50 mm minimum up to 100 mm.
(chain clearance to track)
NOTE: Do not use tie down lugs for towing.
q Securing the machine when not using tie-down point

Place blocks under both ends of the tracks to prevent the
machine from moving during transportation, and secure the
machine with chains or wire rope of suitable strength. Be par-
ticularly careful to secure the machine in position so it does not
slip to the side.
STOW RADIO ANTENNA

STOW RADIO ANTENNA:PC-K861-822K01A
q Loosen bolt (2) of radio antenna (1) at the rear of the cab,
turn the antenna to the lower side, then tighten bolt (2)
again to secure radio antenna (1) in position.
q When unloading the machine from the trailer to operate, fol-
low the reverse procedure to the procedure for stowing to
set radio antenna (1) vertical, then secure it in position with
bolt (2).
3–212
INSTALLATION AND REMOVAL OF MIRRORS

Installation and removal of mirrors:PC220_KA-K810-924K00A
The mirrors are at the positions shown in the diagram on the

right.
If they are damaged, or are to be removed for shipment, or are
to be installed again, use the following procedure.
q After installing the mirrors, be sure to adjust them, referring
toMirrors adjustment (3-154).
REMOVAL
q Mirrors (A), (B)
1. Loosen mounting bolt (2), then remove mirror (1) from sup-
port (3).
2. Loosen bolt (4) and remove support (3) and clamp (5) from
the handrail.
q Mirror (C)
3. Loosen mounting bolt (2), then remove mirror (1) from sup-
port (3).
3–213
INSTALLATION
q Mirrors (A), (B)
1. Install support (3) and clamp (5) to the handrail, then tighten
with bolt (4).
2. Install mirror (1) to support (3), then tighten lock bolt (2).
q Mirror (C)
3. Install mirror (1) to support (3), then tighten lock bolt (2).
REMOVE AND INSTALL HANDRAIL

Remove and install handrail:PC220-H5H0-924K00A
Depending on the height of the trailer platform, the handrail part might exceed the high limit. Accordingly, contact
your Komatsu distributor for handling of the handrail transportation.
k WARNING
q After transporting the machine, be sure to install the handrails before inspection and maintenance.
q Use the crane etc. for carrying the handrails.
Tumbling from the machine may cause serious personal injuries. Check the scaffolding and ensure
your safety before starting the work.
q Improper order for removal and installation of the handrails may cause tumbling from the machine
during the work.
As for the order of removal and installation, see following procedures.
ORDER FOR REMOVAL AND INSTALLATION OF HANDRAILS

q Remove handrails in the order of (A)o(B).
q Install handrails in the order of (B)o(A).
3–214
REMOVAL OF HANDRAILS
1. Remove bolts (1), then remove handrail (A).
2. Remove bolts (2), then remove handrail (B) and cover (3).
INSTALLATION OF HANDRAILS
1. Install handrail (B) and cover (3), then tighten them with bolt (2).
2. Install handrail (A) then tighten them with bolt (1).
Tightening torque: 98 to 123Nm (10.0 to 12.5 kgm)
3–215
REMOVE AND INSTALL REVOLVING WARNING LAMP

REMOVE AND INSTALL REVOLVING WARNING LAMP:PC-Q5D0-822K00A
REMOVAL OF REVOLVING WARNING LAMP

1. Remove connector (A) of the revolving warning lamp.
When removing the connector, pull it out while pressing the
claw in the centre of the connector.
2. Place the connector for wiring (B) in a clean vinyl bag or the
like to protect it from water, etc. during transportation and fix
it to the operator's cab with sealing tape or the like.
3. Release lock (D) of bracket (C) of the revolving warning
lamp to remove it by shifting from claw (F) of mounting por-
tion (E).
REMARK
When removing and installing the revolving warning lamp, be
sure to hold grip (G) instead of lamp itself to prevent damage.
3–216
INSTALLATION OF REVOLVING WARNING LAMP

1. Insert bracket (C) of the revolving warning lamp to claw (F)
of mounting portion (E) and fix it with lock (D).
REMARK
If the reaction force of lock (D) is large, try it again by shifting
bracket (C).
2. Insert connector (A).

Be sure to insert the connector firmly until a click sound can
be heard.
REMOVAL AND INSTALLATION OF CAB PARTS

Removal and installation of cab parts:PC-K16F-822K00A
HOW TO REMOVE CAB PARTS BEFORE TRANSPORTATION

NOTICE
If the door is opened completely while door stoppers are removed, there is a danger that the door may be
damaged by hitting the cab.
Do not open the door completely while door stopper is removed.
1. Removal of stoppers
Loosen adapter (4) to remove stoppers (1) and (2).
q Do not loosen nut (5) (silver) of stopper (1) and nut (6)
(black) of stopper (2). There is a danger that the door
may be damaged.
3–217
2. Removal of striker
1) Remove cap (7) from inside the door by picking the pro-
trusion (a) of cap (7) with fingers.
2) Loosen the inside nuts (8) (2 pieces) to remove striker
(3).
q Keep the removed parts and the removal procedure
manual in the magazine box.
3–218
3. Covering stoppers and striker

Cover the mounting holes of stoppers and striker with tape
(b) etc. to prevent dust from entering the holes.
HOW TO INSTALL CAB PARTS AFTER TRANSPORTATION

1. Removal of covering of stoppers and striker
Completely remove the covering tapes (b) for mounting
holes of stoppers and striker.
2. Installation of stoppers
Tighten adapter (4) to install stoppers (1) and (2).
Tightening torque for adapter (4): 59 to 98 Nm {6.0 to 10.0
kgm}
3–219
3. Installation of striker
1) Tighten nuts (8) (2 pieces) to install striker (3).
2) Install cap (7) to inside the door by picking protrusion (a)
of cap (7) with fingers.
q Be careful to install cap (7) so that the part which has
one claw (c) comes upside.
3–220
UNLOADING
UNLOADING:PC220-0000-841K00A
1. Load and unload on firm level ground only.

2. Apply the trailer brakes securely, then put blocks (1) under
the tires to prevent the trailer from moving.
q Set left and right ramps (2) parallel to each other and
equally spaced to the left and right of centre (3) of the
trailer. Make angle of installation (4) a maximum of 15°.
If the ramps bend a large amount under the weight of
the machine, put blocks under the ramps to prevent
them from bending.
3. Remove the chains and wire ropes fastening the machine.

4. Start the engine.
Warm the engine up fully.
5. Set the lock lever to FREE position (F).
6. Turn the travel speed selector switch to low speed travel

(Lo lamp lights up).
q Press travel speed selector switch (5) to switch the
travel speed. The travel speed (Lo, Mi, Hi) is displayed
on the travel speed monitor (6).
7. Turn auto-deceleration switch (7) OFF and operate the fuel
control dial to set the engine speed to low idling.
q Each time auto-deceleration switch (7) is pressed, it
switches OFFoONoOFF in turn.
q When auto-deceleration switch (7) is turned OFF, the
auto-deceleration monitor (8) goes out.
8. Raise the work equipment, pull in the arm under the boom,
then move the machine slowly.
9. When the machine is horizontal on top of the rear wheels of
the trailer, stop the machine.
3–221
NOTICE
q When unloading the machine, always keep the arm and
boom at an angle of 90° - 110°.
If the machine is unloaded with the arm pulled in, it will
cause damage to the machine.
q When moving onto the ramps, do not thrust the bucket
into the ground. This will cause damage to the hydrau-
lic cylinders.
10. When moving from the rear of the trailer on to the ramps,
set the angle of the arm and boom to 90° to 110°, lower the
bucket to the ground, then move the machine slowly.
11. When moving down the ramps, operate the boom and arm
slowly to lower the machine carefully until it is completely off
the ramps.
3–222
LIFTING MACHINE
k
Lifting machine:PC-0000-815K00A
WARNING
q The operator carrying out the lifting operation using a crane must be a properly qualified crane opera-
tor.
q Never raise the machine with any worker on it.
q Always make sure that the wire rope is of ample strength for the weight of this machine.
q When lifting, keep the machine horizontal.
q When carrying out lifting operations, set the lock lever to the LOCK position to prevent the machine
from moving unexpectedly.
q Never enter the area under or around a raised machine.
Never try to lift the machine in any posture other than the posture given in the procedure below or using
lifting equipment other than in the procedure below.
There is a hazard that the machine may lose its balance.
NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs according to the attachments and options installed.
For details of the procedure for machines that are not the standard specification, please consult your
For weight, see "SPECIFICATIONS (5-2)".
When lifting the machine, carry out the operation on flat ground as follows.
3–223
STANDARD SPECIFICATION MACHINES

STANDARD SPECIFICATION MACHINES:PC220-0000-816K00A
1. Start the engine, then the swing the upper structure so that
the work equipment is on the side of sprocket (1).
2. Extend the bucket cylinder and arm cylinder fully, then
lower the work equipment to the ground as shown in the fig-
ure on the right using the boom cylinder.
3. Set the lock lever securely to the LOCK position (L).

4. Stop the engine, check that there is nothing around the
operator's compartment, then get off the machine.
Close the cab door and front window securely.
5. Pass wire ropes between the 1st and 2nd track rollers from
the front and between the 1st and 2nd track rollers from the
rear.
However, for machines equipped with full roller guards for
the track rollers, pass the wire ropes under the tracks.
When friction occurs between the wire rope and the
machine, put wooden block or backing metal between them.
6. Set the lifting angle (A) of the wire rope to 30° to 40°, then
lift the machine slowly.
7. After the machine comes off the ground, check the hook
condition and the lifting posture, and then lift the machine
slowly.
3–224
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION

COLD WEATHER OPERATION:ALL-0000-265K00A
COLD WEATHER OPERATION INFORMATION

COLD WEATHER OPERATION INFORMATION:ALL-0000-265K01A
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol-
lows.
FUEL AND LUBRICANTS

Fuel and Lubricants:ALL-RA19-265K00A
Change to fuel and oil with low viscosity for all components.
For the details of specified viscosity, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)".
COOLANT
k
COOLANT:ALL-B210-265K00A
WARNING
q Coolant is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or
on your skin, wash it off with large amount of fresh water and see a doctor immediately.
q When changing the coolant or draining the coolant from the radiator during repairs, ask a qualified
person to handle any coolant containing antifreeze, or contact your Komatsu distributor. Coolant is
toxic, so never pour it into ditches or drain it onto the ground surface.
NOTICE
Komatsu recommends using Non-Amine Engine Coolant (AF-NAC) for the coolant.
The Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For details of the density of the Non-Amine Engine Coolant (AF-NAC) and the interval for changing the coolant,
see "CLEAN INSIDE OF COOLING SYSTEM (4-17)".
If the ambient temperature is expected to drop below 0° C, change fuel and oil to low viscosity type for all compo-
nents. For detail see RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4).
BATTERY
k
Battery:ALL-AW10-265K00A
WARNING
q The battery generates flammable gas. Do not bring fire or sparks near the battery.
q Battery electrolyte is dangerous.If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
q Battery electrolyte dissolves paint.If it gets on the bodywork, wash it off immediately with water.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source.There is a danger that the battery may explode.
q Battery electrolyte is toxic. Do not let it flow into ditches or spray it on to the ground surface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low,
the battery electrolyte may freeze. Maintain the battery charge ratio as close as possible to 100%. Insulate it
against cold temperature to ensure the machine can be started easily on the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
fluid temperature (°C)
20 0 –10 –20
battery charge ratio (%)
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
q As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine,
store the battery in a warm place, and install it again the next morning.
q If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after
the day's work to prevent diluted electrolyte in the battery from freezing during the night.
3–225
COLD WEATHER OPERATION OPERATION
AFTER DAILY WORK COMPLETION

k
AFTER DAILY WORK COMPLETION:PC-0000-15AK00A
WARNING
Performing idle-running of the tracks is dangerous, stay well away from the tracks.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
q Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to
prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
q Park the machine on hard, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next
morning.
q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
q Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.
q After operation in water or mud, remove water from undercarriage as described below to extend undercarriage
service life.
1. Swing 90° with engine at low idle and bring the work equip-
ment to the side of the track.
2. Jack up the machine until the track is raised slightly from
the ground. Rotate the track under no load. Repeat this pro-
cedure on both the left and right sides.
AFTER COLD WEATHER SEASON

AFTER COLD WEATHER SEASON:ALL-0000-266K00A
When the season changes and the weather becomes warmer, do as follows.
q Replace the fuel and oil for all equipment with the ones of the viscosity specified. For details, see
"RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)".
3–226
OPERATION LONG-TERM STORAGE
LONG-TERM STORAGE
LONG-TERM STORAGEALL-0000-870K00A
BEFORE STORAGE
Before storage:PC220-0000-870K01A
NOTICE
When storing the machine (one month or more), set the
machine in the posture shown in the figure on the right to
protect the cylinder rods.
(To prevent rusting of the cylinder rods)
When putting the machine in storage for a long time (more than one month), do as follows.
q Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select
level ground and cover the machine with canvas.
q Completely fill the fuel tank. This prevents moisture from collecting.
q Lubricate and change the oil before storage.
q Coat the exposed portions of the hydraulic cylinder piston rods with grease.
q Turn OFF the starting switch, turn the battery disconnect switch key to the OFF position and pull it out, then
store the battery after placing a cover on it.
For details of the operating method of the battery disconnect switch, see "BATTERY DISCONNECT SWITCH
(3-127)".
q Set the attachment control pedal to the lock position on the machines ready for attachments.
q Set the stop valve to the LOCK position on the machines ready for attachments. Install the blind plugs to the
elbows.
For details of the explanation of LOCK and FREE of the stop valve, see "REMOVAL AND INSTALLATION OF
ATTACHMENT (6-25)".
q To prevent rust, fill the cooling circuit with Non-Amine Engine Coolant (AF-NAC) to give a density of at least
30% for the engine coolant.
DURING STORAGE
k
During storage:ALL-0000-870K02A
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors
and windows to improve ventilation and prevent gas poisoning.
q During storage, operate and move the machine for a short distance once a month so that a new film of oil will
coat moving parts. At the same time, also charge the battery.
q When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
q If the machine is equipped with an air conditioner, operate the air conditioner for three to five minutes once a
month to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing
this. In addition, check the refrigerant level twice a year.
3–227
LONG-TERM STORAGE OPERATION
AFTER STORAGE
After storage:PC-0000-870K03A
NOTICE
If the machine is stored without carrying out the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine after long-term storage, do as follows before using it.
q Wipe off the grease from the hydraulic cylinder rods.
q Add oil and grease at all lubrication points.
q When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and
after starting the engine. If there is water in the oil, change all the oil.
q Insert the battery disconnect switch key and turn it to the ON position.
For details of the operating method, see "BATTERY DISCONNECT SWITCH (3-127)".
q If the machine is stored with the battery cable taken off or the battery disconnect switch is turned OFF for a
long time, the clock time information and radio station selecting information may be lost. In this case, see
"CLOCK ADJUSTMENT (3-68)",Handling radio (3-116)" and set again.
STARTING MACHINE AFTER LONG-TERM STORAGE

Starting machine after long-term storage::PC220_KU-0000-870K04A
When starting the engine after long-term storage, carry out the warming-up operation thoroughly. For details, see
"ENGINE WARM-UP OPERATION (3-167)".
3–228
OPERATION TROUBLES AND ACTIONS
TROUBLES AND ACTIONS

Troubles and actions:ALL-0000-001K14A
RUNNING OUT OF FUEL

RUNNING OUT OF FUEL:ALL-0000-14GK00A
When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before stating.
When bleeding air, see "REPLACE FUEL PRE-FILTER CARTRIDGE (4-49)"or "REPLACE FUEL MAIN FILTER
CARTRIDGE (4-62)".
PHENOMENA THAT ARE NOT FAILURES

Phenomena that are not failures:PC-0000-14HK00A
Note that the following phenomena are not failures:

q When the arm control lever is operated to the IN position
and the work equipment is lowered under no load from a
high position, the arm speed drops momentarily when the
arm is more or less at the vertical position.
q When the bucket control lever is operated to the CURL

position and the work equipment is lowered under no load
from a high position, the bucket speed drops momentarily
when the bucket teeth are more or less at the horizontal
position.
q The bucket or arm wobbles by itself during heavy-duty dig-
ging operations.
q When starting or stopping the swing, noise will be emitted from the brake valve.
q When going down a steep slope at low speed, a noise is emitted from the travel motor brake valve.
3–229
TROUBLES AND ACTIONS OPERATION
TOWING MACHINE
k
Towing machine:PC-0000-146K00A
WARNING
Any mistake in the selection of the wire rope or towing bar
or in the method of towing, may lead to serious personal
injury or death.
q Always check that the wire rope used for towing has
ample strength for the weight of the machine being
towed.
q Never use the wire rope which has cut strands (A),
reduced diameter (B), or kinks (C). There is a danger
that the rope may break during the towing operation.
q Always wear leather gloves when handling the wire
rope.
q Never tow a machine on a slope.
q During the towing operation, never stand between the
towing machine and the machine being towed.
q Operate the machine slowly and be careful not to apply
any sudden load to the wire rope.
q Do not use the holes for towing light objects or tie-
down holes when towing the machine.
NOTICE
The maximum towing capacity for this machine is 158,000 N (16,100 kg).
Always carry out towing operations within the maximum towing capacity.
q If the machine sinks in mud and cannot get out under its
own power, or if the machine tows a heavy object, use a
wire rope as shown in the figure on the right.
q Place pieces of wood between the wire ropes and the
machine to prevent damage to the ropes and the machine.
q Hold the wire rope level and set it straight to the track
frame.
q When towing a machine, travel at a speed of less than 1
km/h for a distance of only a few meters to a place that is
suitable for carrying out repairs.
This is for use only in emergencies.
3–230
LIGHTWEIGHT TOWING HOLE

k
Lightweight towing hole:PC220-0000-148K00A
WARNING
q If tools such as a wire rope are selected inappropriately or working approaches such as towing
method are executed inappropriately, serous personal injury can result. Select the appropriate tools
and methods.
q The shackle must always be used.
q Hold the wire rope level and set it straight to the track frame.
q Move the machine slowly and be careful not to apply any sudden load to the wire rope.
q Do not use the tie-down holes when towing the machine.
There is a hole in the track frame to fit the shackle when towing
light objects.
Permissible towing load: Max. 58,800 N (6,000 kgf)
NOTE: Do not use tie down lugs (PAGE 3-212) for towing.
SEVERE JOB CONDITION

Severe job condition::PC220_KU-0000-20FK00A
q When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry
out greasing every time the operation is carried out.
q For heavy-duty operations and deep digging, carry out greasing of the work equipment mounting pins every
time before operation.
After greasing, operate the boom, arm and bucket several times, then grease again.
q For machines with Automatic Greasing System, consider if the heavy duty mode should be selected (if ena-
bled).
3–231
DISCHARGED BATTERY
k
DISCHARGED BATTERY:PC-AW10-2A1K00A
WARNING
q It is dangerous to charge a battery when installed on a
machine. Make sure that it is removed before charging.
q When checking or handling the battery, stop the engine
and turn the starting switch and battery disconnect
switch keys to the OFF positions.
q The battery generates hydrogen gas, so there is a haz-
ard of explosion. Do not bring lighted cigarettes near
the battery, or do anything that will cause sparks.
q Battery electrolyte is dilute sulphuric acid, and it will
attack your clothes and skin. If it gets on your clothes
or on your skin, immediately wash it off with a large
amount of water.
If it gets into your eyes, wash them immediately with
fresh water, then consult a doctor for treatment.
q When handling batteries, always wear protective eye
glasses and rubber gloves.
q When removing the battery, first disconnect the cable
from the ground (normally the negative (-) terminal).
When installing, first connect the cable to the positive
(+) terminal.
If a tool touches the positive terminal and the chassis,
there is a danger that it will cause a spark, so be
extremely careful.
q If the terminals are loose, there is a danger that the
defective contact may generate sparks that will cause
an explosion.
Install the cable terminals securely.
q When removing or installing the cable terminals, check
which is the positive (+) terminal and which is the nega-
tive (-) terminal.
3–232
REMOVE AND INSTALL BATTERY

Remove and install battery:PC-AW10-924K00A
q When removing the battery, remove the ground cable (nor-

mally connected to the negative (-) terminal) first.
If any tool touches the positive terminal of the battery and the
chassis, there is a hazard of sparks being generated.
q When installing the battery, connect the ground cable last.
Tightening torque of battery terminal fixing nut (A): 9.8 to
11.8 Nm (1.0 to 1.2 kgm)
q When replacing the battery, secure it with the battery hold-
down fittings.
Allowable tightening torque of mounting bolt (B):
(Lower side) 1.47 to 1.96 Nm (0.15 to 0.2 kgm)
(Upper side) 11.8 to 19.6 Nm (1.2 to 2.0 kgm)
BATTERY CHARGES
k
Battery Charges:ALL-AW10-2A3K00A
WARNING
When charging the battery, if the battery is not handled
correctly, there is a hazard that the battery may explode.
Always follow the instructions of "DISCHARGED BAT-
TERY (3-232)" and the instruction manual accompanying
the charger, and do as follows.
q Set the voltage of the charger to match the voltage of
the battery to be charged. If the correct voltage is not
selected, the charger may overheat and cause an ,&
explosion.
q Connect the positive (+) charger clip of the charger to
the positive (+) terminal of the battery, then connect the
negative (-) charger clip of the charger to the negative (-
) terminal of the battery. Be sure to attach the clips
securely.
q Set the charging current to 1/10 of the value of the rated
battery capacity; when carrying out rapid charging, set
it to less than the rated battery capacity.
If the charger current is too large, the electrolyte will
leak or dry up, and this may cause the battery to catch
fire and explode.
q If the battery electrolyte is frozen, do not charge the
battery or start the engine with a different power
source. There is a danger that this will ignite the battery
electrolyte and cause the battery to explode.
q Do not use or charge the battery if the battery electro-
lyte level is below the LOWER LEVEL line. This may
cause an explosion. Check the battery electrolyte level
periodically and add purified water to bring the electro-
lyte level to the UPPER LEVEL line.
3–233
START ENGINE WITH BOOSTER CABLES

Start Engine with Booster Cables:ALL-AW10-14BK00A
When starting the engine with a booster cable, do as follows.

CONNECT AND DISCONNECT BOOSTER CABLES
k
CONNECT AND DISCONNECT BOOSTER CABLES:PC220-AW10-14BK00A
WARNING
q When connecting the cables, never contact the positive
(+) and negative (-) terminals.
q When starting the engine with a booster cable, always
wear protective eyeglasses and rubber gloves.
q Be careful not to let the normal machine and failed
machine contact each other.
The sparks caused near the battery could ignite the
hydrogen gas generated from the battery, so be careful
not to let it happen.
q Be careful not to make a mistake when connecting a
booster cable. In the last connection (to the upper
structure frame), a spark will be caused, connect the
cable to a spot as far away from the battery as possible.
(Avoid the work equipment, however, because it is not
a good conductor)
q When removing the booster cable, exercise good care
so that the booster cable clips may not contact each
other, or they contact the chassis.
NOTICE
q The starting system for this machine uses 24 V. For the normal machine, also use a 24 V battery.
q The size of the booster cable and clip should be suitable for the battery size.
q The battery of the normal machine must have the same capacity as that of the failed machine (engine
to be started).
q Check the cables and clips for damage or corrosion.
q Make sure that the cables and clips are firmly connected.
q Check that the lock levers and parking brake levers (if equipped) of both machine are in the LOCK position.
q Check that each lever is in the NEUTRAL position.
q To prevent electric equipment of a failed machine from being damaged, turn off the starting switch of
the failed machine before connecting the booster cables, and then set the battery disconnect switch
key to the OFF position. For the operating method of the battery disconnect switch, see "BATTERY
DISCONNECT SWITCH (3-127)".
REMARK
When the battery disconnect switch is turned off, the radio station select information may be lost. In that case, see
the paragraph of "Handling radio (3-116)"and set again.
3–234
CONNECTION OF BOOSTER CABLES

Set the starting switch and the battery disconnect switch of the failed machine, and the starting switch of the nor-
mal machine to the OFF positions, and connect the booster cables as follows in the order of the numbers marked
in the figure:
1. Connect the clip of booster cable (A) to the positive (+) ter-
minal of battery (C) on the failed machine.
2. Connect the clip at the other end of booster cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of booster cable (B) to the negative (-) ter-
minal of battery (D) on the normal machine.
4. Turn battery disconnect switch (S) of the failed machine to
the ON position.
5. Connect the other clip of booster cable (B) to the revolving
frame (E) of the failed machine.
STARTING OF ENGINE
k WARNING
Check both of normal machine and failed machine that the lock lever is set to the LOCK position. Check
also that all the control levers are in the NEUTRAL position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and run it at high idle (max. speed).
3. Turn the starting switch of the failed machine to the START position and start the engine.
If the engine doesn't start, try it again after two minutes or so.
DISCONNECTION OF BOOSTER CABLES
After the engine has started, disconnect the booster cables in the reverse of the order in which they were con-
nected.
1. Remove the clip of booster cable (B) from the revolving
frame (E) of the failed machine.
2. Remove the clip of booster cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (C) on the failed machine.
3–235
OTHER TROUBLE
Other trouble:ALL-5110-001A00A
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM:PC-AK50-400K00A
q As for the corrective actions indicated with (*) in the remedy column, be sure to contact your Komatsu distribu-
tor.
q In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Defective wiring, deterioration of Inspection and repair of loosening
battery terminal and breakage of wire
Lamp does not glow brightly even harness, and replacement of battery
when the engine runs at high speed (*)
Loosening and damage of fan belt Check of fan belt tension and its
replacement (*)
Defective wiring, deterioration of Inspection and repair of loosening
battery terminal and breakage of wire
Lamp flickers while engine is harness, and replacement of battery
running (*)
Loosening and damage of fan belt Check of fan belt tension and its
replacement (*)
Defective alternator Replace (*)
Charge level monitor does not go Defective wiring Check, repair (*)
out even when engine is running Loose fan belt Check of fan belt tension and its
replacement (*)
Unusual noise is generated from Defective alternator Replace (*)
alternator
Starting motor does not turn when Defective wiring Check, repair (*)
starting switch is turned to ON Defective starting motor Replace (*)
position Insufficient battery charge Charge
Battery disconnect switch is turned Turn ON
OFF
Engine shutdown secondary switch Set it to "Normal"position
is at "Engine stop"position Apply the cover
Pinion of starting motor repeats Insufficient battery charge Charge
engaging and going out Defective safety relay Replace (*)
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor Replace (*)
Starting motor disengages before Defective wiring, defective ring gear Check, repair (*)
engine starts and pinion
Insufficient battery charge Charge
Preheating monitor does not light up Defective wiring Check, repair (*)
Defective heater relay Replace (*)
Defective monitor Replace (*)
Oil pressure monitor does not light Defective monitor Replace (*)
up when engine is stopped (starting Defective caution lamp switch Replace (*)
switch at ON position)
When startability at a low Defective wiring Check, repair (*)
temperature is bad, outside of the Wire breakage in electric heater Replace (*)
electric heater after pre-heating is Defective operation of heater relay Replace (*)
not felt warn when touched by hand. Fuse of the heater is blown Replace (*)
Engine does not start Data in the controller is damaged Check, repair (*)
( "04"lights up on the monitor) Other system troubles Check, repair (*)
3–236
CHASSIS
CHASSIS:PC220-RA15-400K00A
tor.
q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Speed of travel, swing, boom, arm, Lack of hydraulic oil Set oil to specified level, see
bucket is slow CHECK BEFORE STARTING
Pump generates abnormal noise Clogged element in hydraulic tank Clean, see EVERY 2000 HOURS
(sucking in air) strainer, lack of oil SERVICE
Excessive rise in hydraulic oil Loose fan belt Check of fan belt tension and its
temperature replacement (*)
Dirty oil cooler Clean, see EVERY 500 HOURS
SERVICE
Lack of hydraulic oil Set oil to specified level, see
CHECK BEFORE STARTING
Adjust track tension, see WHEN
Track comes off Track too loose
REQUIRED
Adjust track tension, see WHEN
Abnormal wear of sprocket Track too loose
REQUIRED
Boom rises slowly or does not rise Lack of hydraulic oil Set oil to specified level, see
CHECK BEFORE STARTING
Does not swing Swing lock switch still applied Turn swing lock switch OFF
Swing brake system error Inspection and adjustment (*)
When move of machine to safe
place is required, turn the swing
brake cancel switch to ON position
temporarily.
3–237
ENGINE
ENGINE:PC-A000-400K00A
tor.
q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Engine oil pressure monitor lights up Engine oil pan oil level is low Set oil to specified level, see Check
(sucking in air) before starting.
Improper oil is used (viscosity is Referring to section of how to use
improper) lubricants according to ambient
temperature and Komatsu genuine
oil, replace oil
Clogged oil filter cartridge Replace cartridge, see Every 500
Hours service.
Oil leakage due to improper Check, repair (*)
connection or breakage of oil pipe or
pipe joint.
Defective engine oil pressure sensor Replace sensor (*)
Defective monitor Replace monitor (*)
Steam spurts out from top of radiator Coolant level low, leakage of coolant Check, add coolant, repair, see
(pressure valve) Check before starting.
Loose fan belt Check fan belt tension, replace (*)
Dirt or scale accumulated in cooling Change coolant, flush inside of
system cooling system, see When required.
Clogged radiator fins or damaged fin Clean or repair, see Every 500 hours
service.
Defective thermostat Replace thermostat (*)
Loose radiator filler cap (in high- Tighten cap or replace packing
altitude operation)
Defective thermostat Replace sensor
Defective monitor Replace monitor
Radiator coolant level monitor lights Coolant level low, leakage of Check, add coolant, repair, see
up Check before starting.
Loose fan belt Check fan belt tension, replace (*)
Dirt or scale accumulated in cooling Change coolant, flush inside of
system cooling system, see When required.
Clogged radiator fins or damaged Clean or repair, see Every 500 hours
fins service
Defective thermostat Replace thermostat (*)
Loose radiator filler cap (in high- Tighten cap or replace packing
altitude operation)
Defective coolant level sensor Replace sensor
Defective monitor Replace monitor
Engine does not start when starting Lack of fuel Add fuel, see Check before starting
motor is turned Repair place where air is sucked in,
Air in fuel system
see Every 500 hours service.
Defective fuel injection pump or Replace pump or nozzle (*)
defective nozzle
Starting motor turns engine Service, see electrical system
sluggishly
Preheating monitor does not light up Service, see Electrical System
Improper compression Adjust valve clearance (*)
(Defective valve clearance)
3–238

Exhaust gas is white or blue Water entry in KDPF Check, repair (*)
Broken KDPF Replace KDPF (*)
Too much oil in oil pan Set oil to specified level, see Check
before staring.
Improper fuel Change to specified fuel
Exhaust gas occasionally turns Broken KDPF Replace KDPF (*)
black
Combustion noise occasionally
Defective nozzle Replace nozzle (*)
makes breathing sound
Abnormal noise generated Low-grade fuel being used Change to specified fuel
(combustion or mechanical) Overheating Refer to "Radiator coolant level
monitor lights up" as above
KDPF broken internally Replace KDPF (*)
Excessive valve clearance Adjust valve clearance (*)
3–239
ELECTRONIC CONTROL SYSTEM

ELECTRONIC CONTROL SYSTEM:PC220-Q180-400K00A
When the action level monitor (1) or alarm monitor (2) is shown
on the display of the machine monitor, press switch F5 to dis-
play the occurring failure and check the details and remedy.
For details of action level and alarm monitor, see "WARNING
DISPLAY (3-15)".
q When "DXA8KA", "DXA8KB", "DXA9KA", or "DXA9KB" is
on the occurring failure code screen, you can make it possi-
ble to perform operations temporarily by turning emergency
pump drive switch to upper (emergency) position.
After that, ask your Komatsu distributor for inspection and
repair.
q If a display of "CA2249" or "CA559" appears on the occur-
ring failure code screen and yet the machine has not run
out of fuel, replace both fuel main filter element and fuel
pre-filter element immediately.
If the display of "CA2249" or "CA559" does not disappear
even after the replacement, ask your Komatsu distributor for
an inspection immediately, even though normal operation of
the machine is still possible.
TELEPHONE NUMBER FOR THE POINT OF CONTACT IF AN ERROR OCCURS:

When an error screen is displayed on the monitor, press the
switch F5 to display the occurring failure code and telephone
number (3) for the point of contact is displayed in the message
column at the bottom of the screen.
REMARK
If no point of contact telephone number has been registered,
no telephone number is displayed.
If it is necessary to register the telephone number, ask your
Komatsu distributor to carry out the registration.
3–240
MAINTENANCE
MAINTENANCE
MAINTENANCE:ALL-0000-001K03A
MAINTENANCE
k WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.
4–1
RULES FOR MAINTENANCE MAINTENANCE
RULES FOR MAINTENANCE

Rules for maintenance:ALL-0000-2A4K00A
Do not perform any inspection and maintenance operation that are not found in this manual.
During maintenance ensure that the machine and its attachments are stable enough to avoid overturning, falling
or uncontrolled movements.
When dismantling or assembling the machine for the purposes of maintenance, repair or transportation, always
ensure that at each stage of the process, care is taken to ensure that the machine remains stable. Failure to do
this could result in serious injury or death.
Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only
be removed by a Komatsu service engineer unless specific instructions are given in this manual.
SERVICE METER READING

Service Meter Reading:ALL-Q1M0-280K00A
Check the service meter reading every day to see if the time has come for any necessary maintenance to be per-
formed.
KOMATSU GENUINE REPLACEMENT PARTS

Komatsu Genuine Replacement Parts:ALL-0000-203K00A
Komatsu recommends using Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE LUBRICANTS

Komatsu Genuine Lubricants:ALL-0000-201K00A
For lubrication of the machine, Komatsu recommends using the Komatsu genuine lubricants. Moreover use oil of
the specified viscosity according to the ambient temperature.
ALWAYS USE CLEAN WASHER FLUID

Always use clean washer fluid:ALL-K7B3-200K00A
Use ethyl alcohol window washer fluid, and be careful not to let any dirt get into it.
FRESH AND CLEAN LUBRICANTS

Fresh and Clean Lubricants:ALL-RA1A-2A4K00A
Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
CHECK DRAINED OIL AND USED FILTER

Check drained oil and used filter:ALL-C940-2A4P01A
After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantity of metal particles or foreign materials are found, always report to the person in charge, and carry
out suitable action.
FUEL STRAINER
Fuel strainer:ALL-0000-21EK00A
If your machine is equipped with a strainer, do not remove it while filling oil or fuel.
WELDING INSTRUCTIONS
Welding instructions:PC-0000-628K00A
q When conducting weld repair, turn the starting switch to OFF position and, after confirming that the system
operating lamp is turned off, set the battery disconnect switch key to OFF position and pull it out.
q Do not apply more than 200 V continuously.
q Connect grounding cable within 1 m of the area to be welded. If grounding cable is connected near instru-
ments, connectors, etc., the instruments may malfunction. If grounding cable is connected near instruments,
connectors, etc., the instruments may malfunction.
q Prevent seals, bearings or bushings from entering the space between the weld zone and grounding point.
Seals and the like can cause damage to the nearby parts by catching fire from sparks.
q Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
Sparks generated there can damage the plated portion.
DO NOT DROP THINGS INSIDE MACHINE

Do not drop things inside machine:ALL-0000-20GK00A
q When opening the inspection windows or the oil filler port of the tank to carry out inspection, be careful not to
drop nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and
will lead to failure. If you drop anything inside the machine, always remove it immediately.
q Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4–2
MAINTENANCE RULES FOR MAINTENANCE
DUSTY WORKSITES
Dusty worksites:ALL-0000-20HK00A
When working at dusty worksites, do as follows:

q Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to
let the fins become clogged.
q Replace the fuel filter more frequently.
q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
q When checking and replacing the oil or filters, move the machine to a place where there is no dust and take
care to prevent dust from entering the system.
AVOID MIXING OIL

Avoid mixing oil:ALL-C940-2A4P02A
Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and
replace all the oil with the new brand or grade of oil.
LOCKING INSPECTION COVERS

Locking inspection covers:ALL-M190-2AHP00A
Lock inspection cover securely into position with the lock bar etc. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly shut by the wind and cause
injury to the worker.
BLEEDING AIR FROM HYDRAULIC CIRCUIT

BLEEDING AIR FROM HYDRAULIC CIRCUIT:PC-C000-231P01A
When hydraulic equipment is repaired or replaced, or the hydraulic piping is removed and installed again, the air
must be bled from the circuit. When bleeding air, see "BLEED AIR FROM HYDRAULIC CIRCUIT (4-36)".
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES

Precautions when installing hydraulic hoses:ALL-CE00-72BP00A
q When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace them with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
q When installing the hoses, do not twist them or bend them sharply.
If they are installed so, their service life will be shortened extremely and they may be damaged.
CHECKS AFTER INSPECTION AND MAINTENANCE

Checks after inspection and maintenance:PC-0000-20JK00A
If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious personal injury. Always do the following:
q Checks after operation (with engine stopped)
q Have any inspection and maintenance points been forgotten?
q Have all inspection and maintenance items been performed correctly?
q Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
q Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
q Checks when engine running
q For details of the checks when the engine running, see "TWO WORKERS FOR MAINTENANCE WHEN
ENGINE IS RUNNING (2-45)" and pay attention to safety.
q Do not run the engine for long hours with the engine hood open. The engine hood may be damaged by
heat of exhaust gas.
q Is there any leakage of fuel or oil when the engine speed is increased?
q Are the inspected and maintained parts working properly?
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE

Fuel and lubricants to match the ambient temperature:ALL-RA19-05AK02A
It is necessary to select fuel or lubricant according to the temperature.

For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)".
CLOSE ENGINE HOOD SECURELY
Close engine hood securely:PC-H540-2AHK00A
When closing the engine hood after inspection or maintenance, make sure that the catch is securely locked.
If the engine hood catch is not locked, there is a danger that the engine hood may open.
4–3
OUTLINE OF SERVICE MAINTENANCE
OUTLINE OF SERVICE
Outline of service:PC220-RA1B-2A4K00A
q Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil.
q When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all
the old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem
if the small amount of oil remaining in the piping mixes with the new oil.)
q Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40-LA (Komatsu genuine)
Damper case
Swing machinery case Power train oil TO30 (Komatsu genuine)
Final drive case
Hydraulic system Hydraulic oil HO56-HE (Komatsu genuine)
Non-Amine Engine Coolant (AF-NAC) (Komatsu genuine)
Radiator
(density: 30% or more)
Window washer tank Ethyl alcohol
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

Handling oil, fuel, coolant, and performing oil clinic:PC-RA1B-001K00A
OIL
OIL:PC-C940-2A4P00A
q Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil at the specified interval.
q Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of failures with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
q Never mix oils of different grades or brands.
q Always add the specified amount of oil.
Having too much oil or too little oil are both causes of failures.
q If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
contact your Komatsu distributor.
q When changing the oil, always replace the related filters at the same time.
q We recommend you have an oil analysis periodically to check the condition of the machine. For those who
wish to use this service, contact your Komatsu distributor.
q When using commercially available oil, it may be necessary to reduce the oil change interval.We recommend
that you use the Komatsu oil clinic to check the characteristics of the oil in detail.
NOTICE
Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu gen-
uine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine
such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of the
machine life, lowering of performance and increase of fuel consumption.
4–4
MAINTENANCE OUTLINE OF SERVICE
FUEL
FUEL:PC-AD02-2A4K00A
q To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank after completing the day's work.
q The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
q Be extremely careful not to let impurities get in when storing or adding fuel.
q Always use the fuel specified for the temperature in the Operation and Maintenance Manual.
q Fuel has a characteristics of condensing when used at a temperatures lower than the specified operating
temperature (particularly when used at temperatures below -15°C.
q If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and this
may result in problems such as a drop in output.
q Before starting the engine, or after ten minutes of adding fuel, drain the sediment and water from the fuel
tank.
q If the engine runs out of fuel, or if the filters are replaced, it is necessary to bleed the air from the circuit.
q If any foreign material gets in the fuel tank, wash the tank and fuel system.
NOTICE
The fuel used must be ultra low-sulfur diesel oil (≤10ppm).
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device and emission gas
control system (KDPF). Since the high-pressure fuel injection device requires high precision parts and
lubrication, if low viscosity fuel with low lubricating ability is used, its durability may drop remarkably.
Using fuel with high sulfur content can deteriorate the engine parts and KDPF catalyzer, inducing failures,
decrease of the life and degradation in performance.
GREASE
GREASE:ALL-Q811-2A4K00A
q Grease is used to prevent seizure and noises at the joints.

q This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom-
mended grease and follow the change intervals and recommended ambient temperatures given in this Opera-
tion and Maintenance Manual.
q Grease fittings not included in the maintenance section are the grease fittings for overhaul, so they do not
need grease.
If any part becomes stiff after being used for long time, add grease.
q Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.
COOLANT AND WATER FOR DILUTION

COOLANT AND WATER FOR DILUTION:PC-B210-2A4K00A
q Coolant has the important function of anticorrosion as well as antifreeze.

Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years
or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may
cause serious problems, such as corrosion of the engine and aluminium parts of the cooling system.
q When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
q The Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, thus it is not flammable.
q The coolant concentration needs to be changed according to the ambient temperature.
For details of the coolant concentration, see "CLEAN INSIDE OF COOLING SYSTEM (4-17)".
Even in areas where it is not considered necessary to prevent freezing, always use Non-Amine Engine Coolant
(AF-NAC) of 30% concentration or higher in order to prevent corrosion of the cooling system.
Coolant is diluted with distilled water that does not contain any ions or water-hardening substances. Never dilute
the Non-Amine Engine Coolant (AF-NAC) with ordinary water.
q If the engine overheats, wait for the engine to cool before adding coolant.
q If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air
entering the coolant.
4–5
OUTLINE OF SERVICE MAINTENANCE
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)

CARRYING OUT KOWA (Komatsu Oil Wear Analysis):ALL-0000-371K00A
KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other problems.
Thanks to long term experience and ample data accumulated, we can grasp condition of your machine accurately
and provide proper recommendation.
We strongly recommend you to use this service. The oil analysis is carried out at actual cost, so the cost is low,
and results of the analysis and recommendations are reported promptly.
KOWA ANALYSIS ITEMS
KOWA ANALYSIS ITEMS:ALL-0000-371K01A
q Measurement of metallic powder concentration

An ICP (Inductively Coupled Plasma) analyzer is used for
measuring the concentration of iron, copper, and other metal
powder in the oil.
q Measurement of quantity of iron particles

A PQI (Particle Quantifier Index) measuring instrument is
used for measuring the quantity of iron particles of 5mm or
more, enabling early detection of failures.
q Others
Measurements are made of items such as the ratio of water in the oil, concentration of the coolant, ratio of fuel
in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's condition.
OIL SAMPLING
OIL SAMPLING:ALL-0000-371K02A
q Sampling interval
250 hours: Engine
500 hours: Other components
q Precautions when sampling
q Make sure that the oil is well mixed before sampling.
q Perform sampling at regular fixed intervals.
q Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
STORING OIL AND FUEL

STORING OIL AND FUEL:ALL-RA19-876K00A
q Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
q When keeping drum cans for a long period, lay the drums so that the filler ports of the drums are located in the
lower part of the side to prevent moisture from being sucked in. If drums have to be stored outside, cover them
with a waterproof sheet or take other measures to protect them.
q To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).
4–6
MAINTENANCE OUTLINE OF SERVICE
FILTERS
FILTERS:ALL-C950-2A4P00A
q Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems. Replace all filters periodically. For details, see the Operation and
Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulphur content) being used.
q Never try to clean and use again the filters (cartridge type). Always replace them with new filters.
q When replacing oil filters, check if any metal particles are attached to the old filters.
If any metal particles are found, contact your Komatsu distributor.
q Do not open packs of spare filters until just before they are to be used.
q Komatsu recommends using Komatsu genuine filters.
HANDLING ELECTRICAL COMPONENTS

k
HANDLING ELECTRICAL COMPONENTS:ALL-AK50-2A4K00A
WARNING
q When the battery disconnecting switch key is turned to OFF position for the maintenance work,
always pull out the key and keep it with you. If the key is left in the switch, someone may turn ON the
power by mistake, and it is dangerous.
For the operation of the battery disconnect switch, see "BATTERY DISCONNECT SWITCH (3-127)".
q It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is dam-
aged. This will cause an electrical short circuit and may lead to malfunction of the machine. Do not
wash the inside of the operator's cab with water. When washing the machine, be careful not to let
water get into the electrical components.
q When removing the connectors of electrical components after washing the machine or in the rain, wipe off the
water drop stuck around connectors before removing the connectors and keep the water drop away from
inside of the connectors.
q Service relating to the electric system includes checking fan belt tension, checking damage or wear of the fan
belt and checking battery fluid level.
q Komatsu recommends installing electric components specified by Komatsu.
q External radio wave barrier may cause malfunction of the control system controller. Before installing a radio
receiver or other wireless equipment, contact your Komatsu distributor.
q When working at the seashore, carefully clean the electric system to prevent corrosion.
q When installing electrical equipment, connect it to the special power source connector.
Do not connect the optional power source to the fuse, starting switch, or battery relay.
4–7
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUE FOR BOLTS AND

NUTS
Standard tightening torque for bolts and nuts:ALL-M140-03BP00A
TIGHTENING TORQUE LIST

k
Tightening torque list:ALL-M140-03BP02A
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation. Always be care-
ful when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that is
removed.
Thread Width Tightening torque

diameter across
of bolt a flats b Target value Allowable range
(mm) (mm)
6 10 13.2{1.35} 11.8–14.7{1.2–1.5}
8 13 31{3.2} 27–34{2.8–3.5}
10 17 66{6.7} 59–74{6.0–7.5}
12 19 113{11.5} 98–123{10.0–12.5}
14 22 172{17.5} 153–190{15.5–19.5}
16 24 260{26.5} 235–285{23.5–29.5}
18 27 360{37.0} 320–400{33.0–41.0}
20 30 510{52.3} 455–565{46.5–58.0}
22 32 688{70.3} 610–765{62.5–78.0}
24 36 883{90.0} 785–980{80.0–100.0}
27 41 1295{132.5} 1150–1440{118.0–147.0}
30 46 1720{175.0} 1520–1910{155.0–195.0}
33 50 2210{225.0} 1960–2450{200.0–250.0}
36 55 2750{280.0} 2450–3040{250.0–310.0}
39 60 3280{335.0} 2890–3630{295.0–370.0}
q Apply the following table for hydraulic hose.
Hose Width Tightening torque

nominal across flat
Target value Allowable range
number a (mm)
02 19 44{4.5} 35–54{3.5–5.5}
22 74{7.5} 54–93{5.5–9.5}
03
24 78{8.0} 59–98{6.0–10.0}
04 27 103{10.5} 84–132{8.5–13.5}
05 32 157{16.0} 128–186{13.0–19.0}
06 36 216{22.0} 177–245{18.0–25.0}
4–8
MAINTENANCE MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Maintenance schedule:PC-3110-015A00A
q If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts are different.
For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (4-11)" to check the correct main-
tenance schedule when carrying out maintenance.
q When using the engine oil for cold weather area, the maintenance intervals of the engine oil and filter cartridge
are changed to for every 250 hours. For detail, see the oil part number and notes in "RECOMMENDED FUEL,
COOLANT, AND LUBRICANT (7-4)".
q Contact your Komatsu distributor for changing the maintenance interval of the machine monitor.
MAINTENANCE SCHEDULE TABLE

Maintenance schedule table:ALL-3130-001A00A
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................................ 4-12
WHEN REQUIRED
WHEN REQUIRED:PC220_KU-3370-002A00A
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ........................................................................... 4-12

CLEAN INSIDE OF COOLING SYSTEM........................................................................................................... 4-17
CHECK AND TIGHTEN TRACK SHOE BOLTS ................................................................................................ 4-23
CHECK AND ADJUST TRACK TENSION......................................................................................................... 4-23
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)........................................................................................ 4-25
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) .................................................................................. 4-28
ADJUST BUCKET CLEARANCE....................................................................................................................... 4-29
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ................................................................................ 4-30
CHECK AND MAINTENANCE AIR CONDITIONER.......................................................................................... 4-31
WASH WASHABLE FLOOR .............................................................................................................................. 4-32
CHECK GAS SPRING ....................................................................................................................................... 4-36
BLEED AIR FROM HYDRAULIC CIRCUIT ....................................................................................................... 4-36

CHECKS BEFORE STARTING:ALL-3340-001A00A
EVERY 100 HOURS MAINTENANCE

EVERY 100 HOURS MAINTENANCE::PC220_KU-33A0-002A00A
LUBRICATING ................................................................................................................................................... 4-40

EVERY 250 HOURS MAINTENANCE:PC-33B0-002A00A
CHECK LEVEL OF BATTERY ELECTROLYTE................................................................................................ 4-41

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ....................................................... 4-43

EVERY 500 HOURS MAINTENANCE:PC220_KU-33C0-002A00A
LUBRICATING ................................................................................................................................................... 4-45

LUBRICATE SWING CIRCLE............................................................................................................................ 4-46
BUCKET CYLINDER GUARD LUBRICATION (IF EQUIPPED) ........................................................................ 4-46
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ...................................... 4-47
REPLACE FUEL PRE-FILTER CARTRIDGE .................................................................................................... 4-49
CHECK SWING PINION GREASE LEVEL, ADD GREASE .............................................................................. 4-51
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS,
AND AIR CONDITIONER CONDENSER FINS ................................................................................................. 4-52
CLEAN AIR CONDITIONER FRESH / RECIRC FILTERS ................................................................................ 4-54
CLEAN FRESH AIR FILTER.............................................................................................................................. 4-55
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK............................................................................... 4-56
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL ........................................................................ 4-57
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..................................................................................... 4-58

EVERY 1000 HOURS MAINTENANCE:PC220_KU-33D0-002A01A
REPLACE HYDRAULIC OIL FILTER ELEMENT .............................................................................................. 4-59

CHANGE OIL IN SWING MACHINERY CASE.................................................................................................. 4-60
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ........................................................................................... 4-61
REPLACE FUEL MAIN FILTER CARTRIDGE................................................................................................... 4-62
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS.................................................. 4-64
CHECK FAN BELT TENSION AND REPLACE FAN BELT............................................................................... 4-64
4–9
MAINTENANCE SCHEDULE MAINTENANCE
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER) .............................. 4-64

EVERY 2000 HOURS MAINTENANCE:PC-33E0-002A00A
CHANGE OIL IN FINAL DRIVE CASE .............................................................................................................. 4-65

CLEAN HYDRAULIC TANK STRAINER............................................................................................................ 4-66
CHECK CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) ........ 4-67
CHECK ALTERNATOR ..................................................................................................................................... 4-70
CHECK ENGINE VALVE CLEARANCE, ADJUST ............................................................................................ 4-70
REPLACE KCCV FILTER ELEMENT ................................................................................................................ 4-71

EVERY 4000 HOURS MAINTENANCE:PC-33F0-002A00A
CHECK WATER PUMP ..................................................................................................................................... 4-74

CHECK VIBRATION DAMPER.......................................................................................................................... 4-74
CHECK STARTING MOTOR ............................................................................................................................. 4-74
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) ................................................................................ 4-75
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER.................. 4-76
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER ................................ 4-76
CHECK OPERATING CONDITION OF COMPRESSOR .................................................................................. 4-77

EVERY 4500 HOURS MAINTENANCE:PC-33M0-002A00A
REPLACE KCCV HOSE .................................................................................................................................... 4-78

CLEAN KDPF..................................................................................................................................................... 4-78

EVERY 5000 HOURS MAINTENANCE:PC-33G0-002A00A
CHANGE OIL IN HYDRAULIC TANK ................................................................................................................ 4-79

EVERY 8000 HOURS MAINTENANCE:PC-33H0-002A00A
REPLACE FUEL SPRAY PREVENTION CAP .................................................................................................. 4-80

REPLACE HIGH-PRESSURE PIPING CLAMP................................................................................................. 4-80
END OF SERVICE LIFE

END OF SERVICE LIFE ....................................................................................................................................4-81

RECOMMENDED GREASE ................................................................................................................................6-7
DIAGRAM OF GREASING POINTS ....................................................................................................................6-8
SYSTEM PERFORMANCE .................................................................................................................................6-8
CHANGING THE GREASE INTERVAL WITH THE IN-CAB DISPLAY ...............................................................6-8
INDICATION ON THE IN-CAB DISPLAY ............................................................................................................6-9
REFILLING GREASE.........................................................................................................................................6-11
GREASING PROCEDURE ................................................................................................................................6-11
SYSTEM TEST ..................................................................................................................................................6-11
4–10
MAINTENANCE MAINTENANCE SCHEDULE
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER:PC220_KU-LG10-20CK00A
On the machine equipped with a hydraulic breaker, the hydraulic oil and grease deteriorate faster than in normal
bucket digging operations, so set the maintenance intervals as follows.
q Replace hydraulic filter element
On a new machine, replace the element after the first 100 to
150 hours of operation, then carry out further replacement of
the element according to the chart on the right.
q Change oil in hydraulic tank
Change the oil according to the table on the right.
q Replace additional filter element for breaker (if
equipped)
Replace pilot filter element (if equipped)
Use a guideline of 250 hours for use of the breaker (oper-
ating ratio of the breaker: 50% or more), and replace the
element according to the chart on the right.
X: Breaker operating ratio (%)
Y: Replacement interval (H)
(A): Hydraulic tank element
Pilot filter element
(B): Hydraulic oil
(C): Additional filter element
REMARK
Breaker operating ratio 100% means that only the breaker is
used
Breaker operating ratio 0% means that the breaker is not used
q Lubrication
When the hydraulic breaker is equipped, lubricate the
machine on 100-hour intervals. For detail, see "LUBRI-
CATING (4-40)".
4–11
MAINTENANCE SCHEDULE TABLE MAINTENANCE
MAINTENANCE SCHEDULE TABLE

Carry out the following maintenance only after the first 250 hours of operation on new machines.
q Lubrication
For details of the method of maintaining, see "LUBRICATING (4-40)".
WHEN REQUIRED
WHEN REQUIRED:ALL-3370-001A00A
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

k
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT:PC-A910-929K00A
WARNING
q When using compressed air, there is a danger of dirt flying and causing personal injury.
Always wear protective eyeglasses, work gloves, dust mask, or other protective equipment.
q When removing the outer element from the air cleaner body, it is dangerous to pull it out by force.
When working in high places or where the foothold is poor, be careful not to fall because of the reac-
tion when pulling out the outer element.
NOTICE
q Do not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel light
up. If the element is cleaned frequently before the air cleaner clogging monitor light up, the air cleaner
will not be able to display its performance fully, and the cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner
element.
q If the dirt enters the engine, it may cause damage to the engine. Before performing inspection, clean-
ing or maintenance of the air cleaner, be sure to stop the engine. Do not perform inspection, cleaning
or maintenance of the air cleaner in the strong wind, or dusty place.
Be particularly careful when replacing the inner element.
CHECK
CHECK:PC220-A910-280K00A
If air cleaner clogging monitor (1) of the monitor panel lights up,
clean the air cleaner element.
Replacing
q Replace element, O-ring
If the element has been used for one year, or air cleaner
clogging monitor (1) on the monitor panel lights up after the
element has been cleaned, replace outer element (5), inner
element (6), and O-ring (8).
q Replacing evacuator valve (4)
Replace evacuator valve (4) if it is damaged or if the rubber
is markedly deformed.
4–12
MAINTENANCE MAINTENANCE SCHEDULE TABLE
CLEAN OUTER ELEMENT

CLEAN OUTER ELEMENT:PC220-A92G-250K00A
NOTICE
Before and after cleaning the element, do not leave or keep it under direct sunlight.
1. Open the rear door on the left side of the machine, remove
hooks (2) (four places), then remove cover (3).
NOTICE
q Never remove the inner element (6). It will allow dirt to
enter and cause failures of the engine.
q Do not use a screwdriver or other tool.
2. Hold the outer element (5), rock it lightly up and down and
to the right and left, and rotate the element to the right and
left to pull it out.
3. When the outer element (5) is removed, check that the
inner element does not come out of position and is not at an
angle. If it is at an angle, push it straight to the bottom by
your hand.
4. After removing outer element (5), cover the inner element
(6) with a clean cloth or tape to prevent dirt or dust from
entering.
5. Wipe off or brush off the dirt stuck to cover (3) and the
inside of the air cleaner body (7).
6. Remove any dirt or dust that is accumulated on evacuator
valve (4) installed to cover (3).
NOTICE
When cleaning the element, do not hit or beat it against
anything.
7. Blow dry compressed air (less than 0.2 MPa {2.1 kg/cm2})
to the outer element from inside along its folds. Then blow it
from outside along its folds and again from inside.
1) Replace the outer element if it is cleaned six times
repeatedly or used throughout a year. Replace the inner
element as well at the same time.
2) Replace both inner and outer elements when the air
cleaner clogging monitor (1) lights up soon after install-
ing the cleaned outer element even though it has not
been cleaned six times.
4–13
3) Remove one numbered tab from the decal whenever

the element is cleaned.
8. If small holes or thinner parts are found on the element

when it is checked by lightening inside the element it after
cleaning, replace the element.
9. Remove the cloth or tape covering inner element (6).

NOTICE
q Do not use an element whose folds or gasket or seal
are damaged.
q If the element and O-ring are cleaned and used again
after they are used for more than one year, it will cause
problems. Do not use them again.
10. Check that there is no dirt or oil stuck to the sealing portion
of the new element or cleaned element. Wipe any dirt or oil
off.
11. Push the outer element straight into the air cleaner body
with your hand when installing.If the outer element is held
and rocked up and down lightly and to the right and left
while pushing it in, the outer element can be inserted easily.
NOTICE
Be sure to install the air cleaner element facing in the cor-
rect direction. Install so that the bottom of the air cleaner
element (face where no hole is drilled) (B), (C) comes to
cover (3) end. If it is installed in wrong direction, it may
cause breakage of the air cleaner element or serious dam-
age to the engine.
4–14
NOTICE
When inserting the element into the body, if the rubber at
the tip is swollen or the outer element is not pushed in
straight, and cover (3) is installed by force with hook (2),
there is a danger that the hook and air cleaner body may
be damaged, so be careful when installing.
12. Install cover (3) as follows.

1) Check that O-ring (8) is fitted to cover (3).
2) Mate cover (3) to the element.
13. Hook the tip of hook (2) to the fitting part of the air cleaner
body and lock it in position.
1) Lock hooks (2) diagonally, (top and bottom, right and
left) in the same way as when tightening bolts.
2) Always install cover (3) so that evacuator (4) faces the
ground (A).
3) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too
large. If it is too large, repeat the installation.
REPLACE ELEMENT
REPLACE ELEMENT:PC220-A921-923K00A
1. Open the rear door on the left side of the machine, remove
four hooks (2), then remove cover (3).
2. Hold the outer element (5), rock it up and down lightly and
to the right and left, and rotate the element to the right and
left to pull it out.
Do not remove inner element (6) when doing this.
3. When the outer element (5) is removed, check that the
inner element is not out of position and is not at an angle. If
it is at an angle, push it straight to the bottom with your
hand.
4. Wipe off or brush off the dirt stuck to cover (3) and the
inside of the air cleaner body (7).
5. Remove any dirt or dust that is accumulated on evacuator
valve (4) installed to cover (3).
4–15
NOTICE
q The inner element must not be cleaned and used again.
When replacing the outer element, replace the inner
element at the same time.
q If the inner element is not installed properly and the
outer element and cover are installed, there is a danger
that the outer element is damaged.
q The sealing portion of the imitation part lacks preci-
sion, and allows the entry of dust, which leads to dam-
age of the engine. Do not use such imitation part.
6. Remove inner element (6), then quickly install the new inner
element.
Install the inner element securely so that it does not move.
7. Push new outer element (5) in straight with your hand into
the air cleaner body.
If the element is held and rocked up and down lightly and to
the right and left while pushing it in, the element can be
inserted easily.
NOTICE
Be sure to install the air cleaner element facing in the cor-
rect direction. Install so that the bottom of the air cleaner
element (face where no hole is drilled) (B), (C) comes to
cover (3) end. If it is installed in wrong direction, it may
cause breakage of the air cleaner element or serious dam-
age to the engine.
8. Replace O-ring (8) of cover (3) with a new one.
4–16
NOTICE
When inserting the element into the body, if the rubber at
the tip is swollen or the outer element is not pushed in
straight, and cover (3) is installed by force with hook (2),
there is a danger that the hook and air cleaner body may
be damaged, so be careful when installing.
9. Install cover (3) as follows.
1) Mate cover (3) to the element.
2) Hook the tip of hook (2) to the fitting part of the air
cleaner body and lock it in position.
3) Lock hooks (2) diagonally, (top and bottom, right and
left) in the same way as when tightening bolts.
4) Always install cover (3) so that evacuator (4) faces the
ground (A).
5) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too
large. If it is too large, repeat the installation.
10. Replace decal (9) on the cover (3) with a new decal.
CLEAN INSIDE OF COOLING SYSTEM

k
CLEAN INSIDE OF COOLING SYSTEM:PC220_KU-B000-255K00A
WARNING
q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure. If the cap is removed under this condition, there is a hazard of burns. Wait for
the temperature to go down, then turn the cap slowly to release the pressure before removing it.
q When starting the engine while cleaning the machine, set the lock lever in the lock position to prevent
the machine from moving.
q For details of starting the engine, see "Checks and adjustment before starting engine (3-141)" and
"STARTING ENGINE (3-163)" in OPERATION section.
q There is a danger of touching the fan if the undercover is left removed.
Never enter in the rear part of the machine when the engine is running.
Stop the machine on level ground and clean the inside of the cooling system or change the coolant.
Clean the inside of the cooling system or change the coolant according to the table below.
4–17
Interval for cleaning inside of cooling

Coolant system and changing antifreeze
coolant
Every two years
Non-Amine Engine Coolant
or every 4000 hours
(AF-NAC)
whichever comes first
The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or
4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause
serious problems, such as corrosion of the engine and aluminium parts of the cooling system.
To maintain the anticorrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of
Non-Amine Engine Coolant (AF-NAC) between 30% and 64%.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water. When using coolant, investigate the
lowest temperatures in the past and decide the density for the coolant from the coolant density table below.
When actually deciding the density for the coolant, set it for a temperature 10°C below the actual temperature.
The coolant density varies according to the ambient temperature, but it must always be a minimum of 30%.
Coolant density table
Above
Minimum Temp °C -15 -20 -25 -30 -35 -40 -45 -50
-10
Concentration (%) 30 36 41 46 50 54 58 61 64
k WARNING
q Coolant is toxic. When open the drain valve, be careful not to get coolant on you. If it gets in your eyes,
flush your eyes with large amount of fresh water and see a doctor immediately.
q When changing the coolant or when handling the cooling water containing coolant that has been
drained during repair of radiator, please contact your Komatsu distributor or request a specialist com-
pany to carry out the operation. Coolant is toxic. Do not let it flow into drainage ditches or spray it onto
the ground surface.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable. (For the details
of the diluting water, see "COOLANT AND WATER FOR DILUTION (4-5)".) Check the density with a coolant
tester.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to use when filling with coolant.
4–18
1. Stop the machine on level ground, then stop the engine.

2. Open engine hood (1).
3. Check that the coolant temperature is low enough to make

it possible to touch the radiator cap surface by hand, then
turn radiator cap (2) slowly until it contacts the stopper to
release the pressure.
4. Following this, push radiator cap (2), turn it until it contacts
the stopper, then remove it.
5. Remove the undercover, then set the container under drain

valve (3) to catch the coolant.
Open drain valve (3) at the bottom of the radiator and drain
the coolant.
6. After draining the coolant, close drain valve (3), and fill the
radiator with city water. When the radiator gets full, start the
engine and run at low idling to raise the temperature to at
lowest 90°C, then continue to run for approx. 10 minutes.
7. Turn swing lock switch (2) ON and check that the swing lock
monitor lights up.
8. To hasten the warm-up operation of the hydraulic equip-

ment, set the working mode to P mode (heavy-duty mode).
For details of the procedure for setting the working mode,
4–19
9. Move the lock lever slowly and steadily to FREE position

(F), then raise the bucket from the ground.
10. Turn the fuel control dial to a 2/3 position between low idling
(MIN) and full speed (MAX).
NOTICE
When the work equipment is operated, take care that it
does not interfere with the machine body or ground.
11. Move the right work equipment control lever slowly in the
direction to pull in bucket (D). Operate the lever to the end
of its travel and hold it in position for 30 seconds.
12. Move the right work equipment control lever slowly in the
direction to push out bucket (C). Operate the lever to the
13. Next, move the left work equipment control lever slowly in
the direction to pull in arm (B). Operate the lever to the end
14. Move the left work equipment control lever slowly in the
direction to push out arm (A). Operate the lever to the end
15. When the operations of Steps 11 to 14 are repeated, the
pointer of engine coolant temperature monitor (4) rises. The
pointer of the coolant temperature monitor falls once near
the centre of the graduations (A). Then, continue the opera-
tion for about 10 minutes.
4–20
16. Stop the engine and open drain valve (3) to drain the water.
17. Drain the coolant in sub-tank (5).
18. After draining the water, clean the radiator with detergent.
For the cleaning method, follow the instruction for the deter-
gent.
19. If the sub-tank is extremely dirty and it is difficult to clean,
replace it with a new one.
20. Close drain valve (3).
21. Install the undercover.
22. Fill with Non-Amine Engine Coolant (AF-NAC) through the

water filler port up to the mouth of the port of radiator (1).
Fill sub-tank (5) with NON-Amine Engine Coolant (AF-NAC)
to the middle between the FULL and LOW marks.
For density of the Non-Amine Engine Coolant (AF-NAC),
see the COOLANT DENSITY TABLE.
23. Run the engine at low idle for 5 minutes to remove the air
from the water, then run at high idle for a further five min-
utes. (Remove radiator cap (2) when performing the above
operation.)
24. Stop the engine, wait for approximately 3 minutes, then add
Non-Amine Engine Coolant (AF/NAC) up to the bottom of
the water filler port, and tighten the radiator cap (2).
25. Check the coolant level in sub-tank.
If the coolant level is between the FULL and LOW marks, it
is correct.
If it is insufficient, fill with Non-Amine Engine Coolant (AF-
NAC) to the middle between FULL and LOW marks.
4–21
26. Close engine hood (1).
4–22
CHECK AND TIGHTEN TRACK SHOE BOLTS

CHECK AND TIGHTEN TRACK SHOE BOLTS:PC-DTP4-92BK00A
If the machine is used with track shoe bolts (1) loose, they will
break, so tighten any loose bolts immediately.
RE TIGHTENING
Retightening:PC-DTP4-71AK00A
Triple grouser shoe, swamp shoe, flat shoe, rubber pad shoe
1. First tighten the bolts to a tightening torque of 490 ± 49 Nm (50 ± 5 kgm) then check that the nut and shoe are
in tight contact with the link mating surfaces.
2. After checking, tighten a further 120° ± 10°.
TIGHTENING ORDER
TIGHTENING ORDER:PC-DTP4-711K00A
Tighten the bolts in the order shown in the figure on the right.
After tightening, check that the nut and shoe are in tight contact
with the link mating surfaces.
CHECK AND ADJUST TRACK TENSION

CHECK AND ADJUST TRACK TENSION:PC-DTL0-92CK00A
Wear on pins and bushings of the undercarriage vary with working conditions and type of soil, so inspect the track
tension at any time convenient in order to maintain the standard tension.
For carrying out the inspection and adjustment of the track shoes, park the machine on the flat and solid ground.
CHECK
CHECK:PC-DTL0-285K00A
1. Run the engine at low idle, then move the machine forward
for a distance equal to the track length on ground, and
slowly stop the machine.
2. Put on the track shoe straight wooden bar (3) which
stretches from idler (1) to upper carrier roller (2).
3. Measure the maximum deflection between the bottom sur-
face of the wooden bar and top surface of the track shoe.
q Standard deflection:
Deflection "a" should be 10 to 30 mm.
If the track tension is not at the standard value, adjust it in the following manner.
4–23
ADJUSTMENT
k
Adjustment:PC-DTL0-27CK00A
WARNING
There is a danger of plug (1) flying out under the high
internal pressure of the grease.
Never loosen plug (1) more than one turn.
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 procedure
given here, contact your Komatsu distributor.
INCREASE TRACK TENSION

Increase track tension:PC-DTL0-27CK01A
Prepare a grease pump.

1. Pump in grease through grease fitting (2) with a grease
pump. (Grease fitting (2) forms one part with plug (1).)
2. To check if the tension is correct, run the engine at low idle,
move the machine slowly forward (by an amount equal to
the length of track on the ground), then stop the machine.
3. Check the track tension again, and if the tension is not cor-
rect, adjust it again.
4. Grease can be pumped in until dimension (S) becomes

zero (0). Please ask your Komatsu distributor for repair.
LOOSEN TRACK TENSION
k
Loosen track tension:PC-DTL0-27CK02A
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If the track tension is not relieved by this procedure, contact your Komatsu distributor for repairs.
1. Loosen plug (1) gradually to release the grease.

2. When loosening plug (1), turn it a maximum of one turn.
3. If the grease does not come out smoothly, move the
machine forwards and backwards a short distance.
4. Tighten plug (1).
5. To check if the tension is correct, run the engine at low idle,
move the machine slowly forward (by an amount equal to
the length of track on the ground), then stop the machine.
6. Check the track tension again, and if the tension is not cor-
rect, adjust it again.
4–24
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)

REPLACE BUCKET TEETH (VERTICAL PIN TYPE):PC-LBM1-923K00A
Replace the bucket teeth before the adapter starts to wear.
k WARNING
q It is dangerous if the work equipment moves by mistake when the teeth are being replaced.
Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to
the LOCK position.
q The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.
Check that there is no one in the surrounding area.
q There is a hazard that fragments will fly during the replacement work, so always wear protective equip-
ment like protective eyeglasses and gloves.
1. To make it possible to knock out a pin of tooth (1), put block

(5) under the bottom of the bucket, and level the bottom of
the bucket.
2. Check that the work equipment is in a stable condition, then

set the lock lever to LOCK position (L).
3. Use a hammer and drift to knock out lock pin (2). (If the drift
is set against rubber pin lock (3) when it is hit, the rubber
pin lock may break. Set it against the back of the pin.)
4. After removing lock pin (2) and rubber pin lock (3), check
them.
If lock pin (2) and rubber pin lock (3) are used in the condition
below, it will cause tooth (1) to come off during operation.
Replace them with new parts.
4–25
q Lock pin (2) is too short.

Dimension (B) is 1/3 or more of dimension (A) when lock pin
(2) is aligned with bottom face (C).
q Rubber (6) of the rubber pin lock is cut and the steel ball is
about to come out.
q Steel ball (7) sinks in when it is pushed by hand.
5. Remove the soil stuck to adapter (4) by using a knife.

6. Use your hand or a hammer to push rubber pin lock (3) into
the hole of adapter (4).
When doing this, be careful that rubber pin lock (3) does not
fly out from the adapter surface.
7. Clean the inside of teeth (1), then install it to adapter (4). If

there is mud affixed to it or if there are protrusions, the teeth
(1) will not enter adapter (4) properly, and there will not be
proper contact at the mating portion.
8. Fit tooth (1) to adapter (4), and check that when tooth (1) is
pressed strongly, the rear face of the hole for the pin of
teeth (1) is at the same level as the rear face of the hole for
the pin of adapter (4).
If the rear face of the pin hole of tooth (1) protrudes in front
of the rear face of the pin hole of adapter (4), do not knock
the pin in.
4–26
If this happens, there is something (C) affixed preventing the

tooth (1) from fitting completely in adapter (4). Locate the
problem and remove the obstruction. When tooth (1) fits
completely in adapter (4), knock in lock pin (2).
9. Insert lock pin (2) in the pin hole in tooth (1), and knock it in
so that the top surface of lock pin (2) is the same height as
the surface of tooth (1).
10. After replacing a bucket tooth, always check the following.

1) After lock pin (2) is knocked in completely, check that it
is secured by teeth (1) and surface.
2) Lightly hit lock pin (2) in the reverse direction from which
it was hit in.
3) Lightly hit the tip of teeth (1) from above and below, and
hit its sides from right and left.
4) Confirm that rubber pin lock (6) and lock pin (2) are set
as shown in the right figure.
REMARK
If the tooth is turned, the wear will become uniform. This will extend the service life of the tooth and reduce the fre-
quency of replacement.
When replacing the tooth, replace the rubber pin lock and lock pin with new parts at the same time. This will pre-
vent the tooth from falling out.
4–27
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)

REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE):PC-LBM2-923K00A
Replace the bucket teeth before the adapter starts to wear.
k WARNING
q It is dangerous if the work equipment moves by mistake when the teeth are being replaced.
Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to
the LOCK position.
q The pins can be knocked out only with strong force, so there is a hazard that the pin may fly out.
Check that there is no one in the surrounding area.
q There is a hazard that fragments will fly during the replacement work, so always wear protective equip-
ment like protective eyeglasses and gloves.
1. To make it possible to knock out pin (1) of tooth (2), put

block (5) under the bottom of the bucket, and level the bot-
tom of the bucket.
2. Check that the work equipment is in a stable condition, then

set the lock lever to the LOCK position (L).
3. Place a bar on the head of pin (1), hit the bar with a hammer
to knock out the pin, then remove tooth (2).
REMARK
If the bucket teeth cannot be safely removed by this method,
ask your Komatsu distributor for replacement of the bucket
teeth.
4. Clean the mounting face. Fit a new tooth (2) in the adapter,
push in pin (1) partially by hand, then lock it with a hammer
to install the tooth to the bucket.
4–28
ADJUST BUCKET CLEARANCE

k
ADJUST BUCKET CLEARANCE:PC-LBK0-27DK00A
WARNING
It is dangerous if the work equipment moves by mistake
when the bucket clearance is being adjusted.Set the work
equipment in a stable condition, then stop the engine and
set the lock lever securely to the LOCK position (L).
1. Set the work equipment in the position shown in the figure

on the right, then stop the engine and set the lock lever to
the LOCK position (L).
2. Shift O-ring (1) and measure the amount of play "a".
Measurement is easier if you move the bucket to one side so
that all the play can be measured at one place (the right side
in the figure).
Use a clearance gauge for easy and accurate measurement.
3. Loosen four plate mounting bolts (2), and loosen plate (3).
The shim is a split type, so the work can be carried out
without removing the bolts.
4. Remove shim (4) corresponding to the amount of play "a"
measured above.
[Example] In the case of play of 3 mm, remove two 1.0 mm
shims and one 0.5 mm shim. Play becomes 0.5 mm.
For shim (4), two types of 1.0 mm and 0.5 mm are used.
When play "a" is smaller than one shim, do not carry out any
maintenance.
5. Tighten four bolts (2).
If bolts (2) are too stiff to tighten, pull out pin stopper bolt (5)
for easier tightening.
(6) Arm
(7) Bucket
4–29
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID:PC220-K7B0-217K00A
If there is air in the window washer fluid, check the level of the
fluid in window washer fluid tank (1). Add Ethyl Alcohol window
washer fluid if necessary.
When adding fluid, be careful not to let any dust get in.
MIXTURE RATIO OF PURE WASHER FLUID AND WATER
Mixture Ratio of Pure Washer Fluid and Water:PC-K7B0-217K01A
The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following
proportions before adding.
Area, season
Proportions Freezing temperature
Normal Washer fluid 1/3: water 2/3 -10°C
Winter in cold area Washer fluid 1/2 : water 1/2 -20°C
Winter in extremely cold area Pure washer fluid -30°C
There are two types depending on the freezing temperature:
-10°C (general use) and -30°C (cold area use), select according to the area and season.
4–30
CHECK AND MAINTENANCE AIR CONDITIONER

CHECK AND MAINTENANCE AIR CONDITIONER:ALL-K500-001K01A
CHECK LEVEL OF REFRIGERANT (GAS)
k
CHECK LEVEL OF REFRIGERANT (GAS):PC220-K512-21DK00A
WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of
sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is leaking.
If there is a lack of refrigerant (Freon 134a), the cooling perfor-

mance will be poor. When the engine is running at full throttle
and the cooler is running at high speed, look at the sight glass
(1) (inspection window) in the refrigerant hose fitting to check
the condition of the refrigerant gas (Freon 134a) flowing in the
refrigerant circuit.?
(A) No bubbles in refrigerant flow: Suitable
(B) Some bubbles in flow (bubbles pass continuously):
Lack of refrigerant
(C) Colourless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant gas level is low, so
contact your Komatsu distributor to have refrigerant added. If
the air conditioner is run with the refrigerant gas level low, it will
cause damage to the compressor.
INSPECTION DURING OFF SEASON

Inspection During Off Season:ALL-K500-20DK00A
Even during the off-season, operate the air conditioner for three to five minutes once a month to maintain the oil
film at all parts of the compressor.
INSPECTION AND MAINTENANCE ITEMS
Inspection and Maintenance Items:ALL-K500-208K00A
Guideline for maintenance

Check, maintenance items Content of check, maintenance
interval
Refrigerant (gas) Charge amount Twice a year (spring, autumn)
Air conditioner condenser Clogged fins Every 500 hours
Compressor Operating condition Every 4000 hours
V-belt Damage, tension Every 250 hours
Operating condition(does it make abnormal
Blower motor, fan When required
noise?)
Control mechanism Operating condition (does it function normally?) When required
Mounting condition, looseness at tightening or
Piping mounts When required
connecting portions, leakage of gas, damage
4–31
WASH WASHABLE FLOOR

k
WASH WASHABLE FLOOR:PC-K150-255K00A
WARNING
q When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely
careful when carrying out the work.
q If the control levers are touched by mistake, the machine may suddenly move, and this may lead to a
serious accident. Always set the lock lever securely to the LOCK position before leaving the opera-
tor's seat.
NOTICE
q When carrying out this work, be careful not to water the
monitor and connectors inside the operator's cab.
q Never water the things above the pedestal of the opera-
tor's seat (4).
q If any water splashes on the surrounding equipment,
be sure to wipe it off.
On the washable cab floor, it is possible to flush out the dirt directly with water.
WASH WASHABLE FLOOR MAT
WASH WASHABLE FLOOR MAT:PC-K840-255K00A
Stop the machine on level ground, lower the bucket to the ground, and then stop the engine.
When washing the floor mat, use a brush to remove the dust, or directly water the mat to wash it with a brush.
4–32
WASH CAB FLOOR

WASH CAB FLOOR:PC220-K151-255K00A
1. Set the machine at an angle. For details, see "SET

MACHINE AT ANGLE (4-35)".
2. Swing the upper structure slowly so that water drain holes
(3) in the cab floor are at a low position.
3. Lower the work equipment to the ground and set the

machine in a stable condition.
4–33
4. Set lock lever (1) to LOCK position (L) and stop the engine.
5. Pull out six projections (2) on the back of the floor mat and
remove the floor mat.
6. Remove the cap from water drain hole (3).
7. Flush out the dirt on the floor directly with water through
water drain hole (3).
8. After completing the washing work, install the cap in water
drain hole (3).
9. Fit the floor mat and secure it by inserting projections (2) on
its back into the holes.
4–34
SET MACHINE AT ANGLE

SET MACHINE AT ANGLE:PC-K151-255K01A
USE SLOPE
k
USE SLOPE:PC-K151-255K02A
WARNING
Select a solid and smooth slope.Always put blocks under the track to prevent the machine from moving,
and dig the work equipment into the ground.
Stop the machine so that the work equipment is on the downhill

side.
Put blocks under the track and dig the work equipment into the
ground.
USE BLOCK
k
USE BLOCK:PC-K151-255K03A
WARNING
Select a firm flat place.Put strong blocks under the undercarriage to stabilize the machine and be
extremely careful when carrying out the operation.
Raise the chassis with the boom and arm.When doing this,
operate the levers slowly.
Insert block (5) under the raised track to make the machine sta-
ble.
Raise the boom slowly and lower the machine.When doing

this, check that the machine is always stable.
4–35
CHECK GAS SPRING

k
CHECK GAS SPRING:PC220_KU-M180-280P00A
WARNING
The gas spring is charged with high-pressure nitrogen gas, so wrong handling may cause an explosion,
which will lead to serious injury or damage. When handling, always do as follows.
q Do not disassemble.
q Do not bring it near flame nor dispose of it in fire.
q Do not make holes in it nor weld it.
q Do not hit it, roll it, nor give it any impact.
q When disposing, the gas must be released. Ask your Komatsu distributor for this work.
The gas springs are located at the engine hood (right, left: two places).
In the following cases, ask your Komatsu distributor for inspec-
tion, repair, and replacement.
q When the engine hood cannot be opened with light effort.
q When the engine hood do not stay open.
q When oil or gas is found to be leaking from the gas spring.
BLEED AIR FROM HYDRAULIC CIRCUIT

BLEED AIR FROM HYDRAULIC CIRCUIT:PC220_KU-C000-231P00A
See "STARTING ENGINE (3-163)". If necessary, see the paragraphs for starting the engine, and moving/steering/
stopping the machine in OPERATION section.
1. Bleeding air from pump
1) Loosen air bleeder (1) and check that oil oozes out from
the air bleeder.
2) If the oil does not ooze out, remove drain hose (2) from
the hydraulic pump case and fill the pump case com-
pletely with hydraulic oil through drain port.
Oil will come out when the drain hose is removed, so
secure the hose fitting at a position higher than the level
of the oil in the hydraulic tank.
3) After completing the air bleed operation, tighten air
bleeder (1) and install the drain hose.
4–36
NOTICE
If the drain hose is installed first, oil will spurt out from
bleeder hole (1).
If the pump is operated without filling the pump case with
hydraulic oil, abnormal heat will be generated and this
may cause a premature damage to the pump.
2. Starting of engine
Start the engine, referring to "STARTING ENGINE (3-163)". Run the engine at low idle for 10 minutes after
starting, then start operations.
3. Bleeding air from hydraulic cylinders
1) Run the engine at low idle, and extend and retract each cylinder 4 or 5 times, taking care that a cylinder is
not moved to the end of its stroke. (Stop the cylinder approximately 100 mm ahead of its stroke end.)
2) Next, operate each cylinder 3 or 4 times to the end of its stroke.
3) Finally, operate each cylinder 4 or 5 times to the end of its stroke to completely bleed the air.
NOTICE
If the engine is run at high speed immediately after startup or a cylinder rod is pushed up to its stroke
end, air taken inside the cylinder may cause damage to the piston packing.
4. Bleeding air from swing motor
1) Run the engine at low idle, loosen hose (3) at port S,
and check that oil oozes out from port S hose (3).
NOTICE
At this time, do not operate the swing.
2) If oil does not ooze out, stop the engine, remove port S
hose (3), and fill the motor case with hydraulic oil.
3) After completely bleeding the air from the swing motor,
tighten port S hose (3).
4) Run the engine at low idle and slowly swing at least two
times uniformly to the right and left.
This will automatically bleed the air from the swing circuit.
NOTICE
q If the air is not bled from the swing motor, the motor
bearings may be damaged.
q When replacing the travel motor safety valve, ask your
Komatsu distributor for the replacement and the air bleed-
ing.
5. Bleeding air from travel motor
(Bleed air only when the oil inside the travel motor case is drained.)
1) Run the engine at low idle, loosen air bleeder (4), and
tighten it when oil flows out.
4–37
2) Run the engine at low idle and swing the upper structure
90° to bring the work equipment to the side of the track.
3) Push up the machine until the track is raised slightly
from the ground. Rotate the track under no load for two
minutes. Repeat this procedure on both the right and left
sides.
When rotating the track under no load, rotate equally
both forward and in reverse.
6. Bleeding air from attachment (when installed)

If a breaker or other attachment is installed, run the engine at low idle and operate the attachment pedal repeat-
edly (approximately 10 times) until the air is completely bled from the attachment circuit.
NOTICE
q If the method of air bleeding from the attachment is specified by the manufacturer, bleed the air
according to the specified procedure.
q After completing the air bleeding operation, stop the engine, and leave the machine for five minutes
before starting operations. This will remove the air bubbles in the oil inside the hydraulic tank.
q Check that there is no leakage of oil and wipe off any oil that is spilled.
q After completing the air bleeding operation, check the oil level, and if the oil level is low, add oil.
4–38

CHECKS BEFORE STARTING:ALL-3340-208A00A
For details of the following items, see "Checks Before Starting (3-143)"in the OPERATION section.
q Drain of water and sediment from fuel tank
q Check of water separator, drain of water and sediment
q Check of oil level in hydraulic tank, addition of oil
q Check of coolant level, addition of coolant
q Check of oil level in engine oil pan, addition of oil
q Check of electric wiring
q Check of fuel level, addition of fuel
q Check of working lamp switch
q Check of function of horn
4–39

EVERY 100 HOURS MAINTENANCE:ALL-33A0-001A00A
LUBRICATING
LUBRICATING:PC220_KU-L410-242K01A
(When greasing is carried out by using grease pump instead of using automatic greasing system.)
NOTICE
q If any abnormal noise is generated from any greasing point, carry out greasing regardless of the
greasing interval.
q Carry out greasing every 10 hours for the first 50 hours operation on a new machine.
q After the machine is subjected to digging work in the water, be sure to grease the wet pins.
1. Set the machine to the greasing posture shown on the right,
lower the work equipment to the ground, then stop the
engine.
2. Using a grease pump, pump in grease through the grease
fittings shown by arrows.
3. After greasing, wipe off any old grease that is pushed out.
(1) Arm-Link connection pin (1 place)

(2) Arm and Bucket connection pin (1 place)
(3) Link connection pin (2 places)

(4) Bucket cylinder rod pin (1 place)
(5) Bucket and Link connection pin (1 place)
4–40

EVERY 250 HOURS MAINTENANCE:ALL-33B0-001A00A
Maintenance for every 100 hours should be carried out at the same time.
CHECK LEVEL OF BATTERY ELECTROLYTE

CHECK LEVEL OF BATTERY ELECTROLYTE:PC220-AW10-217K00A
Carry out this procedure before operating the machine.
k WARNING
q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler-
ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may cause an explosion.
q The battery generates flammable gas and there is a danger of explosion. Do not bring fire or sparks
near the battery.
q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
NOTICE
q When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.
q When adding purified water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.
Inspect the battery electrolyte level at least once a month according to the standard given below.
Open cover (1) on the rear left side of the machine. The batter-
ies are installed at (A) part.
Remove nuts (2) at the two places on the battery top surface,
and remove covers (3) (two places).
REMARK
The thread portion of nut (2) is made of resin, and the thread
face returns to the original condition even if the nut is tightened
repeatedly. The tightening force remains unchanged all the
time and does not become light. This is not an abnormal condi-
tion.
4–41
WHEN THE ELECTROLYTE LEVEL IS CHECKED FROM A SIDE OF THE BATTERY

If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Use a wet cloth to clean the area around the electrolyte
level lines and check that the electrolyte level is between
the (a) UPPER LEVEL (U.L.) and (b) LOWER LEVEL (L.L.)
lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.
C
D
-5
2. If the electrolyte level is below the midway point between

the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines,
remove cap (4) and add purified water (e.g. commercially
available replenishment water for a battery) to the U.L. line.
3. After adding the purified water, tighten cap (4) securely.
REMARK
If purified water is added to above the UPPER LEVEL (U.L.)
line, use a syringe to lower the level to the UPPER LEVEL
(U.L.) line. Neutralize the removed electrolyte with sodium
bicarbonate, then flush it away with a large amount of water. Or
consult your Komatsu distributor or battery maker.
WHEN THE ELECTROLYTE LEVEL CANNOT BE CHECKED FROM A SIDE OF THE BATTERY
If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Remove cap (4) at the top of the battery, look through the
water filler port (5), and check the electrolyte surface. If the
electrolyte does not reach the sleeve (6), add purified water
(e.g. commercially available replenishment water for a bat-
tery) so that the level reaches the bottom of the sleeve
(UPPER LEVEL line) without fail.
q (A) Suitable level: Electrolyte level reaches the bottom
of sleeve, so surface tension causes electrolyte surface
to bulge and pole plates appear bent.
q (B) Low level: Electrolyte level does not reach the bot-
tom of sleeve, so pole plates appear straight and not
bent.
2. After adding, tighten cap (4) securely.
REMARK
If water is added beyond the bottom tip of the sleeve, use a
syringe to remove electrolyte. Neutralize the removed electro-
lyte with sodium bicarbonate, then flush it away with a large
amount of water. If necessary, contact your Komatsu distributor
or your battery maker.
WHEN THE ELECTROLYTE LEVEL CAN BE CHECKED WITH AN INDICATOR, ETC.

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
4–42
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST:ALL-K5A0-92CK00A
CHECK
CHECK:ALL-K5A0-285K00A
Press the belt with a finger force of approx. 60 N (6.2 kg) at a

point midway between drive pulley (1) and compressor pulley
(2). Deflection (A) should be 6.3 to 8.7 mm.
ADJUSTMENT
ADJUSTMENT:PC220-K5A0-27CK00A
1. Remove the two bolts (2), then remove guard (1).

(Use an 8mm hexagonal wrench for the machines with
captive bolts).
2. Loosen three bolts (3).

There is no need to remove bolt (3). Do not loosen too far.
4–43
3. Loosen nut (4) in direction (A).

Nut (4) is provided to prevent loosening of jack bolt (5).
4. Tightening the jack bolt (5) slide compressor (6) in direction
(A), thereby the compressor belt is tensioned.
See items “CHECK (4-43)” for the tension of the belt.
5. When the belt tension becomes appropriate, tighten three

bolts (3) to fix the pulley.
Tightening torque: 59 to 74 Nm {6.0 to 7.5 kgm}.
6. After tightening nut (4) until it touches the boss (7), then
tighten it further in direction (B) to prevent it loosening.
Tightening torque: 108 to 132 Nm {11.0 to 13.5 kgm}.
7. After fixing pulley, check that the belt tension is appropriate
again. Adjust it again If the tension is not within the correct
range.
NOTICE
q Check each pulley for damage, wear of the V-groove, and wear of the V-belt.
In particular, be sure to check that the V-belt is not touching the bottom of the V-groove.
q In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts
with new ones. The fan belt has elongated, leaving little allowance for adjustment. A cut or crack is
found on the belt. Slipping or creaking sound is heard coming from the belt.
When the new V-belt is set, readjust it after one hour of operation.
4–44

EVERY 500 HOURS MAINTENANCE:ALL-33C0-015A00A
Maintenance for every 100 and 250 hours should be carried out at the same time.
LUBRICATING
LUBRICATING:PC220_KU-L410-242K00A
(When greasing is carried out by using grease pump instead of using automatic greasing system.)
NOTICE
q If any abnormal noise is generated from any greasing point, carry out greasing regardless of the
greasing interval.
q Carry out greasing every 10 hours for the first 50 hours on a new machine. Carry out the greasing also
at 250 hours and 500 hours on a new machine.
q After the machine was subjected to jobs in the water, be sure to grease the wet pins.
q When carrying out heavy-duty operations, such as hydraulic breaker operations, carry out the greas-
ing every 100 hours.
1. Set the machine to the greasing posture shown on the right,
lower the work equipment to the ground, then stop the
engine.
fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.
(1) Boom cylinder foot pin (2 places)
4–45
(2) Boom foot pin (2 places)

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

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

LUBRICATE SWING CIRCLE:PC-J110-242K00A
1. Lower the work equipment to the ground.

fittings shown by arrows. (2 places)
3. After greasing, wipe off any old grease that is pushed out.
BUCKET CYLINDER GUARD LUBRICATION (IF EQUIPPED)

LUBRICATE SWING CIRCLE:PC-J110-242K00A
(1) Cylinder guard pivot (1 place)

(2) Cylinder guard slider (6 places)
4–46
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
k
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE:PC-AB02-923K00A
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause burns.Wait
q Refill capacity of oil pan: 23.1 litres

q Prepare a filter wrench
1. Remove the undercover directly under the engine at the
bottom of the machine, then set a container in position to
catch the drained oil.
2. To prevent getting oil on yourself, lower the lever of drain
valve (P) slowly, drain the oil, then raise the lever to close
the valve.
3. Open the cover at the rear right, then use a filter wrench to
turn filter cartridge (1) to the left to remove it.
4. Clean filter holder (2), fill the new filter cartridge with clean
engine oil, coat the thread and packing surface of the new
filter cartridge with clean engine oil (or coat it lightly with
grease), then install it to the filter holder.
REMARK
Check that there is no old packing stuck to filter holder (2). If
there is any old packing stuck to the filter, it will cause leakage
of oil.
5. When installing, tighten until the packing surface contacts
the seal surface of filter holder (2), then tighten it a further 3/
4 to 1 turn.
6. After replacing the filter cartridge, open the engine hood
and add engine oil through oil filler port (F) to the midpoint
between the H and L marks on dipstick (G).
7. Run the engine at idle for a short time, then stop the engine,
and check that the oil level is between the H and L marks
on the dipstick. For details, see "CHECK OIL LEVEL IN
ENGINE OIL PAN, ADD OIL (3-150)".
8. Install the undercover.
4–47
REMARK
When the ambient temperature is low, water or emulsified mat-
ter may stick to the oil level gauge oil filler cap, etc. or the
drained oil may be milky white because of water vapour in the
blow-by gas. However, if the coolant level is normal, it is not a
problem.
There is no problem even if the emulsified matter can not be
removed completely after changing oil.
4–48
REPLACE FUEL PRE-FILTER CARTRIDGE

k
REPLACE FUEL PRE-FILTER CARTRIDGE:PC220-AEA0-923K00A
WARNING
q Immediately after the engine is stopped, all parts are still hot, so do not replace the filter. Wait until all
parts have cooled down before starting the work.
q High pressure is generated inside the engine fuel piping when the engine is running.
Wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
q Do not bring any fire or flame close.
NOTICE
q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering perfor-
mance. When replacing the filter cartridge, Komatsu recommends using a genuine Komatsu part.
q The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzles. If any cartridge other than the genuine Komatsu filter car-
tridge is used, foreign material may get in and cause problems with the injection system. Always avoid
using substitute parts.
q When carrying out inspection or maintenance of the fuel system, pay more attention than normal to
the entry of foreign material. If dirt etc. should stick to the parts in the fuel system, clean them thor-
oughly by using fuel.
q Prepare a container to catch drain oil.
1. Turn the valve (1) at the bottom of the fuel tank to CLOSE
position (S).
2. Open the cover on the right side of the machine.

3. Place the container to catch the fuel under the pre-filter car-
tridge.
4. Loosen drain valve (2), then drain all the water and sedi-
ment in transparent cap (3) and also the fuel accumulated
in filter cartridge (4).
5. Remove connector (5). To prevent water from getting on the
connector, wrap it in a vinyl bag to avoid contamination and
keep it in a safe place until it is installed again. If the con-
nector is dirty the sensor may not operate normally and
engine may fail.
6. Using a filter wrench, turn transparent cap (3) counterclock-
wise to remove it. (This cap is used again.)
7. Using a filter wrench, turn filter cartridge (4) counterclock-
wise to remove it.
8. Install transparent cap (3), which has been removed in the
above step, to the bottom of the new filter cartridge.(When
doing this, always replace O-ring (6) with a new one.)
4–49
9. When installing, apply oil lightly to the packing surface and

bring the packing surface into contact with the seal surface
of filter cartridge (4) and then tighten it further by 1/4 to 1/2
turns.
If the transparent cap is tightened too much, the O-ring will
be damaged and this will cause leakage of fuel; if it is not
tightened enough, fuel will leak through the gap at the O-
ring. To prevent these problems, always tighten securely to
the fixed tightening angle.
10. Clean the filter holder, fill the new filter cartridge with clean
fuel, coat the packing surface lightly with oil, then install the
filter cartridge to the filter holder.
NOTICE
q When adding fuel, do not remove centre cap (B).
Always add fuel through the eight small holes (A) on
the dirty side.
q After adding fuel, remove centre cap (B) and install the
fuel filter.
q Always fill the filter cartridge with clean fuel. Be careful
not to let any dirt or dust get into the fuel. In particular,
the centre portion is the clean side, so do not remove
cap (B) when adding fuel. Be careful not to let dirt or
dust get into the centre portion on the clean side.
11. When installing, tighten it until the packing surface contacts the seal surface of the filter holder, then tighten it
3/4 of a turn.
If the filter cartridge is tightened too much, the packing will be damaged which will cause leakage of fuel. If the
filter cartridge is not tightened enough, fuel will also leak from the packing, so always keep the tightening angle
specified.
q When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
12. Check that drain valve (2) is closed securely.
13. Remove the vinyl bag covering connector (5), then connect connector (5).
REMARK
q If water gets on the connector (5), the sensor may malfunc-
tion and the water separator monitor may light up. When
removing connector (5), be extremely careful not to let
water attach the connector.
q If water attach connector (5), dry it completely before con-
necting it.
14. Turn valve (1) at the bottom of the fuel tank to OPEN position (O).
15. After completing the replacement of filter cartridge (4), bleed the air.
16. Fill the fuel tank with fuel (to the level where the float is at the highest position).
17. Loosen the knob of feed pump (7), pull it out, then pump it in and out until the movement becomes heavy.
REMARK
q It is not necessary to remove the fuel pre-filter head and the plug at the fuel main filter head.
q When the engine runs out of fuel, use the same procedure to operate feed pump (7) and bleed the air.
18. After finishing to bleed air, push in the knob of feed pump (7) and tighten it.
19. After replacing the filter cartridge, start the engine and run it at low idle for 10 minutes.
Check for leakage of oil from the filter seal surface and transparent cap mounting face. If any oil is leaking,
check the tightening of the filter cartridge. If there is still oil leakage, repeat Steps 1 to 7 to remove the filter
cartridge, and if any damage or embedded foreign material on the packing surface is found, replace it with a
new cartridge and repeat Steps 8 to 19 to install it.
4–50
REMARK
Sometimes some air is still left inside water separator (3) after air bleeding, but the engine can be started by oper-
ating feed pump (7) until its motion gets hard. The remaining air is naturally bled when the water separator is left
as it is for a while after the engine stops.
CHECK SWING PINION GREASE LEVEL, ADD GREASE

CHECK SWING PINION GREASE LEVEL, ADD GREASE:PC-J136-218K00A
Prepare a scale.
1. Remove bolts (1) (2 pieces) on the top of the revolving
frame and remove cover (2).
2. Insert scale (3) into the grease through inspection and

adjustment hole (A). Check that the height of grease (S) in
the area where the pinion passes is at least 9 mm. Add
grease if the level is low.
3. Check if the grease is milky white. If it is milky white, it is
necessary to change the grease. Contact your Komatsu
distributor.
The total amount of grease: 14.6 litres.
4. Install cover (2) with bolts (1).
4–51
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER

FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS
k
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS:PC220-RA16-92DK00A
WARNING
If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the com-
pressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear protective
eyeglasses, dust mask, and other protective equipment.
NOTICE
When using compressed air for cleaning, blow it keeping some distance to avoid damaging the fins. Dam-
age on the fins can cause water leakage and overheating. In a dusty job site, check the fins every day,
regardless of the maintenance interval.
1. Open engine hood (1).
2. Remove screws (3) at two places and pull up net (2).

3. After pulling up net (2), clean it.
(Reinstall it in Step 7.)
4. Check the front and rear surfaces of oil cooler fins (4), radi-
ator fins (5), aftercooler fins (6), air conditioner condenser
fins (7), and fuel cooler fins (8). If there is any mud, dirt, or
leaves stuck to the fins, blow it off with compressed air.
Steam or water may be used instead of the compressed air.
However, when carrying out powerful steam cleaning (high-
pressure machine wash) of the heat exchange equipment
(radiator, oil cooler, aftercooler, fuel cooler, air conditioner
condenser), maintain sufficient distance from the machine
when carrying out the work. If steam cleaning (high-pressure
machine wash) is carried out at close distance, there is a
danger that the internal fins of the heat exchange equipment
may be deformed, and this will cause early clogging and
breakage of the fins.
5. Visually check the rubber hose connected to the heat
exchanger. If it is cracked or become fragile, ask your
Komatsu distributor for replacement.
Also, check the hose clamp for looseness.
6. Remove undercover (9) and blow the mud, dirt, and leaves
out to the outside.
7. Push in cleaned net (2) back to the original place and
secure it with screw (3).
4–52
OPENING AND CLOSING CONDENSER

1. Open the rear door on the left side of the machine and
remove bolts (A) (at 2 places) on the right end of the con-
denser.
2. Pull the condenser forward to open it.
3. After cleaning the condenser, close and install it with bolts
(A) (at 2 places).
Tightening torque: 59 - 74 Nm {6.0 - 7.5 kgm}
4–53
CLEAN AIR CONDITIONER FRESH / RECIRC FILTERS

k
CLEAN AIR CONDITIONER FRESH?RECIRC FILTERS:ALL-K520-250K00A
WARNING
When using compressed air, there is a danger of dirt scattering and causing personal injury. Always wear
protective eye glasses, dust mask, and other protective equipment.
NOTICE
As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more
frequently.
Always use genuine Komatsu filters to ensure safe working conditions are maintained for the operator.
Contact your Komatsu distributor for the correct filter information.
Always follow the correct maintenance procedure.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air condi-
tioner unit.
CLEAN RECIRCULATED AIR FILTER
CLEAN RECIRCULATED AIR FILTER:PC220-K521-250K00A
1. Remove wing bolts (1) from the inspection window at the

bottom rear left inside the operator's cab, then take out the
recirculation air filter.
2. Clean the filter with compressed air. If there is oil on the fil-
ter, or if the filter is extremely dirty, wash it in a neutral
detergent. After rinsing it in water, dry it thoroughly before
using it again.
Replace the filter with a new part every year. If the clogging
of the filter cannot be removed by blowing with air or
washing in water, replace the filter immediately.
REMARK
q The recirculation air filter must be installed in the correct
direction.
q Install the filter so that the protrusion of filter (2) matches
the groove of folder (3).
4–54
CLEAN FRESH AIR FILTER

CLEAN FRESH AIR FILTER:PC220-K522-250K00A
1. Use the starting switch key to open cover (4) at the rear left
of the operator's cab, then open cover (4) by hand and
remove filter (5) inside the cover while holding the cover.
2. Clean the filter with compressed air. If there is oil on the fil-
ter, or if the filter is extremely dirty, wash it in a neutral
detergent. After rinsing it in water, dry it thoroughly before
using it again.
Replace the filter with a new part every year. If the clogging
of the filter cannot be removed by blowing with air or
washing in water, replace the filter immediately.
3. After cleaning, return filter (5) to its original position and
close the cover. When doing this, lock it with the starting
key. After locking it, do not forget to remove the starting key.
REMARK
q The fresh air filter must be installed facing it in the correct
direction.
q When removing, insert your finger into dent (D) of duct and
pull it forward.
If you grasp the filter with excessive force, it may be
deformed or damaged.
q When installing, insert long end (L) of filter (5) into duct (6)
first. If short end (S) is inserted first, filter (5) will get stuck
with protrusion (B) of the sheet metal
q Keep the filter away from protrusion (B) of the sheet metal
and insert it from the top first.
If the insertion is not enough or the filter is forcibly inserted
from bottom, it may be deformed or damaged.
After inserted it, pull it to the inside of protrusion (C) of dust
(6).
q Spray compressed air at the pressure less than 0.49 MPa
{5 kg/cm2} in the arrow direction.
q If the filter is damaged or deformed, replace it with new one.
4–55
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK

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REPLACE BREATHER ELEMENT IN HYDRAULIC TANK:PC220_KU-PM39-923K00A
WARNING
q 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 cleaning the engine breather.
q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Remove the cap of oil filler (F) at the top of the hydraulic
tank.
2. Replace element (1) inside the cap.
4–56
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL

k
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL:PC220-J135-212K00A
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious
burns. Wait for the temperature to go down before cleaning the engine breather.
1. Remove dipstick (G) and wipe the oil on the dipstick with a
cloth.
2. Fully insert dipstick (G) into the filler pipe.
3. Pull out dipstick (G) and check that the oil level is between
the (H) and (L) marks on the dipstick.
4. If the oil does not reach the (L) mark on dipstick (G), add oil
through oil filler (F).
5. If the oil level is above the (H) mark on dipstick (G), loosen
drain valve (P) and drain the excess oil.
q Set a container to catch the oil under drain valve (P)
before draining the oil.
6. After checking oil level or adding oil, insert the cap of dip-
stick (G) into the hole.
KS000622
4–57
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

k
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL:PC-DF30-212K00A
WARNING
q The parts and oil are at high temperature immediately after the engine is stopped, and may cause
burns. Wait for the temperature to go down before starting the work.
q If there is remaining pressure inside the case, the oil or plug may fly out. Loosen the plug slowly to
release the pressure.
q Do not stand in front of the plug when you loosen it.
q Prepare a sliding T-handle (with 1/2” square drive).

1. Set the TOP mark at the top, with the line running on TOP
mark and plug (P) perpendicular to the ground surface.
2. Remove plug (F) by using the handle. When the oil level
reaches a point 10 mm below the bottom of the plug hole,
the correct amount of oil is added.
3. If the oil level is too low, install plug (F), operate the travel
levers, and travel forward or in reverse to rotate the
sprocket one turn. Then repeat Step 2 to check again.
4. If the oil level is low, add oil through the hole of plug (F).
Add oil until oil overflows from the hole of plug (F).
5. After checking, install plug (F).
Tightening torque for plugs (F): 68.6 ± 9.8 Nm (7 ± 1 kgm)
REMARK
There are two plugs (F). Add oil through the one easier to sup-
ply oil and through which no internal gears are seen.
-5
4–58

EVERY 1000 HOURS MAINTENANCE:ALL-33D0-015A00A
Carry out the periodic maintenance work of every 100, 250 and 500 hours of operation at the same time.
REPLACE HYDRAULIC OIL FILTER ELEMENT

k
REPLACE HYDRAULIC OIL FILTER ELEMENT:PC220_KU-PM35-923K00A
WARNING
q 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 work.
q When removing the oil filler cap, oil may spout out. Turn it slowly to release the internal pressure, then remove
it.
NOTICE
If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than in
normal bucket operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (4-
11)" when carrying out maintenance.
1. Set the work equipment on the hard and flat ground in the
maintenance posture as shown in the figure, then lower it to
the ground and stop the engine.
2. Remove the cap of oil filler (F), and release the internal
pressure.
3. Loosen six bolts, then remove cover (1). When doing this,
the cover may jump out under the force of spring (2), so
hold the cover down when removing the bolts.
4. After removing spring (2), valve (3) and strainer (4), take out
element (5).
q Inspect the bottom of the filter case for dirt, and remove
it, if any. Take good care that the dirt does not fall into
the hydraulic tank.
5. Clean the removed parts in flushing oil.
6. Install the new element in the place where old element (5)
was installed.
7. Set valve (3), strainer (4) and spring (2) on the top of the
element.
8. Set cover (1) in position, press it down by hand, and install
the cover with the mounting bolts.
9. Install the oil filler cap.
10. To bleed the air, start the engine according to "STARTING
ENGINE (3-163)" and run the engine at low idle for 10 min-
utes.
11. Stop the engine.
4–59
CHANGE OIL IN SWING MACHINERY CASE

k
CHANGE OIL IN SWING MACHINERY CASE:PC220-J135-292K00A
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait
q Refill capacity: 6.5 litres

1. Remove cover (A) of the inspection hole.
2. Place a container under drain valve (P) under the machine

body to catch the oil.
3. Loosen drain valve (P) under the machine body, drain the
oil, then tighten the drain valve again.
REMARK
q If the oil becomes thin thread condition, there is no problem
in stopping the draining operation.
q In low temperatures, swing the upper structure to raise the
oil temperature slightly before starting the operation to drain
the oil. However, never swing the upper structure during the
draining operation. This will cause breakage of the swing
machinery.
4. Remove the cap of oil filler port (F), then add the replace-
ment amount of oil through oil filler port (F).
5. “Check the oil level. For details, see "CHECK OIL LEVEL IN
SWING MACHINERY CASE, ADD OIL (4-57)".
4–60
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

k
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL:PC220-CB10-212K00A
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious
NOTICE
Park the machine on flat ground and stop the engine. When more than 30 minutes elapse after stopping
the engine, check the oil level.
2. Remove plug (G) and check the oil level. If the oil level is
near the bottom of the plug hole, the oil amount is at a
proper level. If the oil amount is short, remove plug (F) and
replenish oil through plug (F) filler port up to the bottom of
plug (G) hole.
NOTICE
If excess oil is supplied, drain it to the specified amount. It
will cause overheat.
3. Install plugs (G) and (F).
4. Close the door.
4–61
REPLACE FUEL MAIN FILTER CARTRIDGE

k
REPLACE FUEL MAIN FILTER CARTRIDGE:PC220-AED0-923K00A
WARNING
q When the engine is stopped, all parts are at high temperature, so do not replace the filter immediately.
Wait for all parts to cool down before starting the work.
q High pressure is generated inside the engine fuel piping system when the engine is running.
Wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
q Do not bring any fire or flame close.
NOTICE
q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing the filter cartridge, Komatsu recommends using a genuine Komatsu part.
q The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzles. If any part other than the genuine Komatsu filter cartridge is
used, dust or dirt may get in and cause problems with the injection system. Always avoid using sub-
stitute parts.
q When carrying out inspection or maintenance of the fuel system, pay more attention than normal to
the entry of dirt.
q Prepare a container to catch drain oil.
1. Turn the valve (1) at the bottom of the fuel tank to the
CLOSE position (S).

3. Set the container to catch the fuel under the filter cartridge.
4. Using a filter wrench, turn filter cartridge (2) counterclock-
wise to remove it.
q After removing the filter cartridge, fuel drops fall down
from the filter head.
In order to prevent flow out of the fuel, be sure not to
leave the machine without the filter cartridge.
5. Clean the filter holder, coat the packing surface of the new
filter cartridge lightly with oil, then install the filter cartridge
to the filter holder.
Replace inner seal (3) with a new part.
4–62
NOTICE
q Do not fill the new filter cartridge with fuel.
q Remove cap (B) and install the filter cartridge.
6. When installing, tighten it until the packing surface contacts

the seal surface of the filter holder, then tighten it 3/4 of a
turn.
If the filter cartridge is tightened too far, the packing will be
damaged which will cause leakage of fuel. If the filter
cartridge is tightened too loose, fuel will also leak from the
packing, so always keep the tightening angle specified.
7. Turn the valve (1) at the bottom of the fuel tank to the OPEN
position (O).
8. After completing the replacement of filter cartridge (2),

bleed the air.
4–63
9. Fill the fuel tank with fuel (to the level where the float is at the highest position).
10. Loosen the knob of feed pump (4), pull it out, then pump it
in and out until the movement becomes heavy.
REMARK
q It is not necessary to remove the fuel pre-filter head and the
plug at the fuel main filter head.
q When the engine runs out of fuel, use the same procedure
to operate feed pump (4) and bleed the air.
11. Push in the knob of feed pump (4) and tighten it.
12. After replacing the filter cartridge, start the engine and run it
at low idle for 10 minutes.
Check for leakage of oil from the filter seal surface. If any oil
is leaking, check the tightening of the filter cartridge. If there
is still oil leakage, repeat Steps 1 to 4 to remove the filter
cartridge, and if any damage or embedded foreign material
on the packing surface is found, replace it with a new
cartridge and repeat Steps 5 to 12 to install it.
REMARK
Sometimes some air is still left inside the water separator after
air bleeding, but the engine can be started by operating feed
pump (4) until its motion gets hard. The remaining air is naturally
bled when the water separator is left as it is for some time after
the engine comes to a stop.
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS:ALL-A980-286K00A
Ask your Komatsu distributor to check the tightening of the clamps between the air cleaner and turbocharger and
aftercooler and engine.
CHECK FAN BELT TENSION AND REPLACE FAN BELT

CHECK FAN BELT TENSION AND REPLACE FAN BELT:ALL-B430-92EK00A
Special tools are required for inspection and replacement of the fan belt. Contact your Komatsu distributors for
inspection and replacement.
REMARK
As the auto fan belt tensioner is installed, no belt tension adjustment is required.
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR

BREAKER)
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker):PC-LG25-362K00A
(if equipped)
A special tool is needed for inspecting and charging of nitrogen gas.
Contact your Komatsu distributor.
4–64

EVERY 2000 HOURS MAINTENANCE:ALL-33E0-015A00A
Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time.
CHANGE OIL IN FINAL DRIVE CASE

k
CHANGE OIL IN FINAL DRIVE CASE:PC220-DF30-292K00A
WARNING
q Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for
the temperature to go down before starting the work.
q If there is remaining pressure inside the case, the oil or plug may jump out. Loosen the plug slowly to release
the pressure.
q Do not stand in front of the plug when you loosen the plug.
q Refill capacity for both right and left: 5.0 litres.

q Prepare a sliding T-handle (with 1/2” square drive).
1. Set the TOP mark at the top, with the line running on the
TOP mark and plug (P) perpendicular to the ground sur-
face.
2. Place a container under plug (P) to catch the oil.
3. Remove plugs (P) and (F) with the handle and drain the oil.
REMARK
Check the O-rings attached to the plugs for damage. If neces-
sary, replace them with new ones.
4. Tighten plug (P).
5. Add oil through the hole for plug (F).
6. When oil begins to overflow from the hole for plug (F),
install plug (F).Tightening torque of plugs (P) and (F): 68.6 ±
9.8 Nm (7 ± 1 kgm)
REMARK
There are two plugs (F). Add oil through the one of plugs (F)
with which it is easier to add oil and through which no internal
gears are seen.
-5
4–65
CLEAN HYDRAULIC TANK STRAINER

k
CLEAN HYDRAULIC TANK STRAINER:PC-PM3E-255K00A
WARNING
q The parts and oil are at high temperature immediately after the engine is stopped, and may cause
q When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pressure,
then remove it.
1. Remove the cap for oil filler (F), and release the internal
pressure.
2. Remove six bolts, then remove cover (1). When doing this,
cover (1) may jump out under the force of spring (2), so
press the cover down while removing the bolts.
3. Hold the top of rod (3) and pull it up to remove spring (2)
and strainer (4).
4. Remove all the dirt stuck to strainer (4), then wash it in
flushing oil. If strainer (4) is damaged, replace it with a new
part.
5. To install, insert strainer (4) into protruding part (5) of the
tank.
6. Install cover (1) so that the protruding part at the bottom of
cover (1) holds spring (2), then fasten the cover with the
bolts.
4–66
CHECK CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CON-

TROL CIRCUIT)
k
CHECK CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT):ALL-PL40-362K00A
WARNING
The accumulator is charged with high-pressure nitrogen gas, so wrong handling may cause an explosion,
which will lead to serious personal injury or damage. When handling the accumulator, always observe the
followings.
q The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction in which the oil spurts out when carrying out the work. In
addition, loosen the bolts slowly when carrying out the work.
q Do not disassemble the accumulator.
q Do not make holes in it or weld it.
q When disposing of the accumulator, the gas must be released. Ask your Komatsu distributor for the
work.
NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become
impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the
machine.
FUNCTION OF ACCUMULATOR
FUNCTION OF ACCUMULATOR:PC-PL40-042K00A
The accumulator stores the pressure in the control circuit. Even

after the engine is stopped, the control circuit can be operated,
so the following operations can be made.
q If the control lever is operated in the direction to lower the
work equipment, it is possible for the work equipment to go
down under its own weight.
q The pressure in the hydraulic circuit can be released.
The accumulator is installed to the position shown in the figure
on the right.
4–67
CHECK FUNCTION OF ACCUMULATOR
k
Check function of accumulator:PC-PL40-360K00A
CAUTION
When carrying out the inspection, check first that there is no person or obstacle in the surrounding area.
Check the nitrogen gas charge pressure as follows.

1. Stop the machine on firm and level ground.
2. Hold the work equipment in the maximum reach posture
(arm fully out, bucket fully dumped) at height (A) 1.5 m from
the ground.
Carry out Steps 3 to 5 within 15 seconds.

When the engine is stopped, the pressure in the accumulator
gradually goes down. For this reason, the check can only be
carried out immediately after the engine is stopped.
3. Keep the work equipment at the maximum reach, turn the
starting switch to the OFF position (A), and stop the engine.
4. Turn the starting switch to the ON position (B).
5. With the lock lever at the FREE position (F), operate the
work equipment control levers fully in the LOWER direction
and check that the work equipment is lowered to the
ground.
4–68
6. If the work equipment goes down under its weight and con-
tacts the ground, the accumulator is normal.
If the work equipment does not go down or stops in midway,
the charged pressure of the gas in the accumulator for the
hydraulic circuit has probably dropped.
Ask your Komatsu distributor for inspection.
7. This completes the inspection. After completion of the

inspection, set the lock lever to the LOCK position and turn
the starting switch to the OFF position.
METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT

METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT:PC-C000-22AP00A
1. Lower the work equipment to the ground. Close the crusher

attachment jaws, etc.
2. Move the work equipment lock lever to the LOCK position.
3. Insert the lock pin for the attachment control pedal in posi-
tion (c) where it is possible to operate the pedal.
(if equipped)
Carry out Steps 4 to 6 within 15 seconds.

When the engine is stopped, the pressure in the accumulator
gradually goes down. For this reason, the release can only be
carried out immediately after the engine is stopped.
4. Stop the engine.
5. Turn the starting switch to the ON position (B).
4–69
6. Set lock lever to FREE position (F), then operate the work
equipment control levers and the attachment control pedal
(if equipped) fully to the front, rear, left, and right to release
the pressure in the control circuit.
7. Set the lock lever to the LOCK position, then turn the start-
ing switch to the OFF position.
8. Insert the lock pin in position (a) so that the attachment con-
trol pedal cannot be operated.
(if equipped)
CHECK ALTERNATOR
CHECK ALTERNATOR:ALL-AKK0-360K00A
Contact your Komatsu distributor to have the alternator checked.

If the engine is started frequently, have this inspection carried out every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST

CHECK ENGINE VALVE CLEARANCE, ADJUST:ALL-A700-27DK00A
Special tools are needed for inspection and maintenance. Contact your Komatsu distributor.
4–70
REPLACE KCCV FILTER ELEMENT

k
CLEAN HYDRAULIC TANK STRAINER:PC-PM3E-255K00A
WARNING
After the engine is operated, all parts are at high temperature, so do not replace the filter element immedi-
ately. Wait for all parts to cool down before starting the work.
NOTICE
q If the engine is operated without the filter element, the turbocharger and aftercooler will become dirty
and their performance will lower and that can cause engine problems such as overrun caused by suc-
tion of oil. Therefore, do not start the engine without the filter element.
q The filter element cannot be cleaned. If the filter element is cleaned, the filter performance lowers. As a
result, the turbocharger and aftercooler become dirty and the crankcase pressure increases. Never
reuse the filter element since it can cause an engine problem.
q After the filter element is replaced, if KCCV is not assembled correctly, oil or blow-by gas may leak.
Replace the filter element in the correct procedure.
Prepare the special wrench for KCCV and a container to catch the oil.
The KCCV ventilator is located at the positions shown in the
figure on the right.
For how to use the special wrench, see the figure on the right.
1. Using the special wrench, loosen ring (3) of KCCV ventila-

tor (1).
4–71
2. After ring (3) comes off, remove case (4) from body (2) and
remove element (5).
Oil may be accumulated or sticking in the case and element.
When replacing the element, take care that the oil will not
spill out.
REMARK
When the ambient temperature is low, water or emulsified mat-
ter may stick to the inside of KCCV because of condensation of
water vapour in the blow-by gas. However, if the coolant level
is normal, it is not a problem.
3. Remove used O-ring (6) sticking to case (4) and install a

new O-ring contained in the service kit.
Apply engine oil to the new O-ring before installing.
4. While matching diamond marks (7) of the new element with

diamond mark (8) of the body label, insert the element
firmly into the end of the body.
The element can be installed only when its claws (9) are
correctly inserted in grooves (10) of the body. Bases (11)
and (12) are oval. Take extreme care so that those bases is
matched with each other.
5. While matching diamond mark (13) of the case with dia-

mond mark (8) of the body label, install the case to the
body.
The case can be installed only when its claws (14) are
correctly inserted in grooves (10) of the body. When
inserting, take extreme care so that protrusion (15) in the
case is matched with rubber lip (16).
4–72
6. Fit ring (3) to the threaded part of the body and tighten it
with the hand firmly until it stops.
7. Using the special wrench, further tighten the ring 1/15 to 2/

15 turns (1 to 2 ridges of the ring). If the engine is operated
with the ring tightened insufficiently, oil and blow-by gas
may leak.
8. Check the KCCV hose for leakage, crack, and loose clamp,
and replace it if necessary.
4–73

EVERY 4000 HOURS MAINTENANCE:ALL-33F0-015A00A
Carry out the periodic maintenance work of every 100, 250, 500, 1000 and 2000 hours of operation at the same
time.
CHECK WATER PUMP

CHECK WATER PUMP:ALL-BA10-360K00A
Check for leakage of water and oil around the water pump. If
any problem is found, ask your Komatsu distributor to carry out
disassembly, repair, or replacement.
CHECK VIBRATION DAMPER

CHECK VIBRATION DAMPER:ALL-A5E0-360K00A
For the check and replacement of the vibration damper, special

tools are required. Ask Komatsu Ltd. or your Komatsu distribu-
tor for the replacement. It has to be replaced with a new one in
the following cases.
Mating mark (1) is stamped both on the damper hub and on the
inertia member of the vibration damper to show any misalign-
ment between the two.
If this misalignment exceeds 1.6 mm, or if there is any dent (2)
found on the damper metal surface deeper than 3.2 mm, then
the vibration damper must be replaced.
CHECK STARTING MOTOR

CHECK STARTING MOTOR:ALL-AK70-360K00A
Contact your Komatsu distributor to have the starting motor checked.

If the engine is started frequently, have this inspection carried out every 1000 hours.
4–74
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)

REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT):PC-PL40-923K00A
Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner.
k WARNING
followings.
q When disposing of the accumulator, the gas must be released. Ask your Komatsu distributor for the
work.
If operations are continued after the performance of the accu-

mulator drops, it will be impossible to release the remaining
pressure in the hydraulic circuit if there should be a failure on
the machine.
Ask your Komatsu distributor to replace the accumulator.
The accumulator is installed to the position shown in the figure
on the right.
4–75
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF

RUBBER
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER:PC-AEF2-287K00A
Check visually and touch by hand to check that there is no hardening of the rubber and no loose bolts of the
mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail. If there
are any problems, the parts must be replaced. In this case, ask your Komatsu distributor for replacement.
Replacement of the high-pressure piping must be made as an assembly.
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUB-

BER
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER:PC-AEFU-288K00A
The fuel spray prevention caps (14 places) on the fuel injection piping and both ends of the high-pressure piping
act to prevent the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the
fuel should leak or spray out. Check visually and touch by hand to check that there are no missing caps, loose
bolts or hardening of the rubber. If there are any problems, the parts must be replaced. In this case, ask your
Komatsu distributor for replacement.
4–76
CHECK OPERATING CONDITION OF COMPRESSOR

CHECK OPERATING CONDITION OF COMPRESSOR:ALL-K590-280K00A
Check the following two items.

1. When the air conditioner switch is turned ON-OFF, do the compressor and magnet clutch also turn ON-OFF?
2. Is any abnormal noise generated by the clutch or compressor unit?
If any problem is found, contact your Komatsu distributor to have the parts disassembled, repaired, or replaced.
4–77

EVERY 4500 HOURS MAINTENANCE:ALL-33M0-015A00A
Carry out the periodic maintenance work of every 100, 250 and 500 hours of operation at the same time.
CLEAN KDPF
CLEAN KDPF:PC-A9H0-923K00A
Komatsu recommends contacting your Komatsu distributor for cleaning of the KDPF.
REPLACE KCCV HOSE

REPLACE KCCV HOSE:PC-A18D-923K00A
Have your Komatsu distributor replace the KCCV hose.
4–78

EVERY 5000 HOURS MAINTENANCE:ALL-33G0-015A00A
Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time.
CHANGE OIL IN HYDRAULIC TANK

k
CHANGE OIL IN HYDRAULIC TANK:PC220-PM30-292K00A
WARNING
q The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri-
ous burns. Wait for the temperature to go down before carrying out the work.
q When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pressure, then
remove it.
NOTICE
If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than in
the normal bucket operations. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
(4-11)" when carrying out maintenance.
q Refill capacity: 132 litres
q Prepare a handle (for the socket wrench).
1. Swing the upper structure so that the drain plug on the

lower side of the suction tube comes to the middle of the
right and left tracks.
2. Retract the arm and bucket cylinder rods, then lower the
boom and put the teeth in contact with the ground.
3. Set the lock lever to the LOCK position and stop the engine.
4. Remove the cap of oil filler port (F) at the top of the hydrau-
lic tank.
5. Place the oil container under the drain plug below the suc-
tion tube. Using the handle, remove drain plug (P) and drain
the oil. Check the O-ring installed to plug (P) for damage.
Replace the O-ring with a new one if necessary. After drain-
ing the oil, tighten drain plug (P).
q The specified tightening torque is 68.6 ± 9.81 Nm (7 ± 1
kgm).
q When removing drain plug (P), be careful not to get oil
on yourself.
6. Add the replacement amount of oil through oil filler (F).
Check that the oil level is between the H and L lines on the
sight gauge.
q For details of appropriate oils, see "RECOMMENDED
FUEL, COOLANT, AND LUBRICANT (7-4)".
q For details of oil level inspection method, see "CHECK
OIL LEVEL IN HYDRAULIC TANK, ADD OIL (3-148)".
7. Bleed the air from the hydraulic circuit.
For details of the method of bleeding the air from the
hydraulic circuit, see "BLEED AIR FROM HYDRAULIC
CIRCUIT (4-36)".
4–79

EVERY 8000 HOURS MAINTENANCE:ALL-33H0-015A00A
Carry out the periodic maintenance work of every 100, 250, 500, 1000, 2000 and 4000 hours of operation at the
same time.
REPLACE FUEL SPRAY PREVENTION CAP

REPLACE FUEL SPRAY PREVENTION CAP:ALL-AEFU-923K00A
Contact your Komatsu distributor to have the fuel spray prevention cap replaced.
REPLACE HIGH-PRESSURE PIPING CLAMP

When replacing the engine high-pressure piping clamps, always ask your Komatsu distributor to carry out the
replacement.
4–80
MAINTENANCE END OF SERVICE LIFE
END OF SERVICE LIFE

For safe dismantling of the machine at end of service life, please contact your local Komatsu Distributor.
4–81
END OF SERVICE LIFE MAINTENANCE
4–82
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS:ALL-0000-001K04A
SPECIFICATIONS
5–1
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS:PC220-2110-930A01A
Item Unit PC210-10 PC210LC-10

Operating weight kg 21,440 22,310
Bucket capacity m3 0.8
Name of engine - KOMATSU SAA6D107E-2 diesel engine
118/2,000 (ISO 9249)
Engine Power kW /rpm
123/2,000 (ISO14396)
A Overall length mm 9,625
B Overall height mm 2,970
C Overall width mm 2,800 3,080
D Track width mm 600 700
E Height of cab mm 3,045
F Tail swing radius mm 2,940
G Length of track mm 4,070 4,450
H Length of track on ground mm 3,275 3,655
I Height of handrail mm 3,135
J Min. ground clearance mm 440
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Swing speed rpm 12.4
KS000711
Dimensions shown are with 2,900 mm arm.
5–2
Working ranges Unit PC210-10, PC210LC-10

A Max. digging reach mm 9,875
B Max. digging depth mm 6,620
C Max. digging height mm 10,000
D Max. vertical wall depth mm 5,980
E Max. dumping height mm 7,110
F Min. dumping height mm 2,645
G Max. digging reach at ground level mm 9,700
(For 5,700 mm boom, and 2,900 mm arm)
5–3
EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC-10

1-PIECE BOOM
LEGEND
A: Reach from swing centre
B: Bucket hook height
OF: Lifting capacity (rating overfront)

OS: Lifting capacity (rating overside)
LEGEND
(1) Position of lifting point

(2) Arm length
(3) Boom length
(4) Hydraulic pressure
WORKING CONDITIONS:
3
q WITH BUCKET (0.78m ISO). (650 kg)
q IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED, THE WEIGHT DIFFERENCE
OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE.
q WITH FULLY EXTENDED BUCKET CYLINDER.
q ON A COMPACT HORIZONTAL LEVEL GROUND.
PC210-10 with 600 width shoe

PC210LC-10 with 600mm width shoe
Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity
rather than tipping).
5–4
PC210-10
5–5
PC210LC-10
5–6
ATTACHMENTS AND OPTIONS
ATTACHMENTS AND
OPTIONS
ATTACHMENTS AND OPTIONS:ALL-RA17-001K00A
k WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.
6–1
GENERAL PRECAUTIONS FOR SAFETY ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS FOR SAFETY

k
GENERAL PRECAUTIONS FOR SAFETY:PC-RA17-170K00A
WARNING
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for
any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu.
When installing attachments or options to the machine, it is necessary to pay attention to safety. Please observe
the following precautions strictly when selecting, installing, or using attachments or options.
PRECAUTIONS WHEN SELECTING

q Please consult your Komatsu distributor before installing attachments or options to the machine. Depending
on the type of attachment or option, it may be necessary to install a front guard, overhead guard, or other
safety structure to the machine. There may also be problems of the attachment or option hitting the operator's
cab.
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY
q Before installing or using any attachment or option, make sure that you thoroughly read and understand the
instruction manuals for the machine and the attachment or option.
q If you lose the instruction manual or it is damaged, always obtain an new copy from the attachment manufac-
turer or your Komatsu distributor.
PRECAUTIONS WHEN REMOVING OR INSTALLING

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

When long or heavy work equipment is installed, remember the following precautions. Before starting operations,
move the machine to a safe place and carry out a test operation to make sure that you fully understand the move-
ment, centre of gravity, and working range of the machine.
q Do not swing the work equipment if the machine is at an angle. If the work equipment is swung with the
machine at an angle, there is a danger that the machine will tip over.
q Always maintain a safe distance from obstacles in the surrounding area when operating the attachment or
options. If long work equipment is installed, the working range becomes larger.
q If heavy work equipment is installed, pay attention to the following precautions.
q The swing overrun (the distance the work equipment moves before completely stopping after the swing
brake is applied) will be greater. There is a danger of hitting objects if the swing overrun is miscalculated,
so allow extra space to the swing position when swinging.
q The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own
weight when it is stopped in a raised position) also becomes greater. Do not stop the work equipment in a
raised position; always lower it to the ground.
q Do not swing, lower, or stop the work equipment suddenly. There is a danger that the machine may tip
over.
q Do not suddenly extend or retract the boom cylinder rod. The shock may cause the machine to tip over.
6–2
ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY
k
PRECAUTIONS WHEN USING:ALL-RA17-170K00A
WARNING
NOTE: When calculating the allowable mass of attachments, the mass of the bucket, see the following:
explanation of lifting capacity chart PC210, PC210LC-10 1-PIECE BOOM (5-4) should be taken into consid-
eration.
For an attachment not intended to bear a load, for example a breaker, it should not exceed the minimum
lift capacity of the machine as shown on the related lift capacity charts (see SPECIFICATIONS section
Chapter 5).
For attachment intended to bear a load, for example clamshell bucket or grapple, the combined mass of the
attachment plus load, should not exceed the maximum lift capacity figures as shown in the related lift capacity
charts (see SPECIFICATIONS section Chapter 5).
6–3
HANDLING QUICK COUPLER ATTACHMENTS AND OPTIONS
HANDLING QUICK COUPLER

k WARNING
Quick coupler operation can be dangerous. There is a risk of death to exposed persons. Follow these
instructions strictly.
1. Use only quick coupler which comply with European standard EN474. In particular, it must be possible to con-
firm from the operator's position that the locking of the attachment or bucket has been completed.
2. Use only quick coupler which include a pilot operated check valve in the locking cylinder. This is to ensure that
there is no risk of the bucket or attachment coming loose in the case of loss of hydraulic pressure. If in doubt
consult the manufacturer of the coupler.
3. Read the instruction manual of the quick coupler carefully and follow the recommendations. If in doubt about
the installation or operation consult your Komatsu distributor.
4. Pressure regulation valve (4) and (5) allow the attachment pressure and the release pressure for the quick
coupler to be limited according to the quick coupler manufacturer's recommendation respectively.
Maximum circuit pressure 34.3 MPa (350 kgf/cm2).
5. Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu
distributor.
NAME OF EACH PART
3
4
(1) Switch (See following page) (4) Adjustable pressure regulating valve (Attach)
(2) Piping (quick coupler lock direction) (5) Adjustable pressure regulating valve (Attach)
(3) Piping (quick coupler release direction)
HOW TO OPERATE
To release a bucket or attachment
k WARNING
Pressure in the system can cause injury. Follow all instructions in ATTACHMENT REMOVAL AND INSTAL-
LATION.
6–4
ATTACHMENTS AND OPTIONS HANDLING QUICK COUPLER
1. If the bucket or attachment has any hydraulic connections

to the machine these must be disconnected before pro-
ceeding.
2. Position the attachment on the ground safely where it is to
be left. Take care that it will not roll or side after release.
3. Operation switch (1).
REMARK
The switch has a safety lock mechanism to prevent accidental
operation. Slide the lock towards you then rock the switch. The
lamp on the switch will come on and a warning buzzer will
sound. (NB Operation will only take place if button (2) is also
pressed).
(A): when depressed at this point quick coupler deactivated
[NB – LOCK bucket/attachment].
(B): When depressed at this point quick coupler is ready to
be activated [NB – RELEASE bucket/attachment].
4. With switch (1) in position "B" press and hold button (2) on
the left hand lever to activate quick coupler.
5. Depending on the design of the quick coupler it may be
necessary to operate one of the hydraulic functions of the
machine (bucket, boom, arm, or swing) to raise the pres-
sure in the hydraulic system. If using the swing function
activate the Swing Lock first ("Lamp Switch (3-78)").
6. The quick coupler will now release the attachment/bucket.
To pick up a new bucket or attachment
k WARNING
q European safety standards require that is possible to check the locked position of the quick coupler
from the operator's position. Failure to check could cause the death of exposed persons. Check care-
fully that the locking of the quick coupler is complete and secure. Follow the manufacturer's instruc-
tions carefully, including the installation of any safety device, if required.
q Check daily that the hoses and fittings in the quick coupler piping system are in good condition. Pay
particular attention to the hoses and fittings at the arm end as these can be damaged easily. In case of
damage or leakage of oil stop work. Loss of oil could lead to the bucket or attachment falling and kill-
ing an exposed person. The damage or leakage must be repaired before continuing work.
q This machine has a system installed to give a warning if there is a failure to maintain pressure in the
quick coupler system. If the buzzer sounds in the cab make sure that the cause is clarified before con-
tinuing work. In particular check for leaks in the system. If in doubt call your Komatsu distributor.
6–5
HANDLING QUICK COUPLER ATTACHMENTS AND OPTIONS
1. Position the quick coupler over the new bucket or attach-

ment.
2. Operate switch (1).
REMARK
The switch has a safety lock mechanism to prevent acci-
dental operation. Slide the lock towards you then rock the
switch. The lamp on the switch will come on and a warning
buzzer will sound.
3. With switch (1) in position "B" press and hold button (2) on
the left hand lever, to activate quick coupler.
4. Depending on the design of the quick coupler it may be
necessary to operate one of the hydraulic functions of the
machine (bucket, boom, arm or swing) to raise the pressure
in the hydraulic system. If using the swing function activate
the Swing Lock first ("Lamp Switch (3-78)"). The quick cou-
pler will move to the 'released' position.
5. Position the quick coupler in the mating portion of the
bucket or attachment, moving the bucket cylinder, arm and
boom as necessary. Follow the quick coupler manufac-
turer's instructions.
6. Release button (2). The quick coupler will lock onto the
bucket or attachment, if necessary operate one of the
machine control levers to raise the system pressure.
Return switch (1) to position "A" (OFF). The lamp will go off
and the buzzer stop.
7. If the bucket or attachment needs a connection to the
hydraulic system of the machine follow all instructions in
"REMOVAL AND INSTALLATION OF ATTACHMENT (6-
25)".
6–6
ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM

AUTOMATIC GREASE SYSTEM:PC220_KU-Q850-100K00A
The machine may be equipped with an automatic greasing system. The system will automatically lubricate all
points connected to the system on a timed cycle, with the correct quantity of grease.
RECOMMENDED GREASE
q Komatsu genuine grease is provided to maintain reliability and durability of Komatsu construction equipment
and components.
q In order to keep you machine in the best condition for long periods of time, it is essential to follow the instruc-
tions in this Operation and Maintenance Manual.
q Commercially available grease additives may be good for the machine, but they may also cause harm.
Komatsu does not recommend any commercially available grease additive.
q Refer also to section ( "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)").
NOTICE
Your automatic grease system has been set up before shipping from the factory. Changing the grease
settings could adversely change the performance of the machine. If in doubt please consult your
The automatic grease system consists of:
q Grease pump (1) with integrated control unit.
q Distribution blocks with grease metering units.
q In-cab display (2).
(1) Automatic greasing pump, Control unit (6) System error lamp
(2) Automatic greasing system monitor (7) Coupling for greasing
(3) Greasing mode selector switch (8) Grease tank
(4) Greasing mode display lamp (9) Test button
(5) Greasing pump
6–7
AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS
DIAGRAM OF GREASING POINTS

No. part
1 Swing circle
2 Boom cylinder foot pin
3 Boom foot pin
4 Boom cylinder rod end
5 Arm cylinder foot pin
6 Boom arm coupling
7 Arm cylinder rod end
8 Bucket cylinder foot pin
Bucket cylinder rod end (may not be available with
9
some specifications)
Bucket—link coupling pin (may not be available with
10
some specifications)
11 Arm-bucket coupling pin
12 Arm-link coupling pin
Link coupling pin (may not be available with some
13
specifications)
SYSTEM PERFORMANCE
The system performs all operations automatically. When the
starting switch is in the ON position the grease pump will, at
pre-defined intervals, supply measured quantities of grease to
all the points connected to the system.
Within 60 seconds after switching the starting switch to the ON
position the in-cab display (2) shows the selected greasing
interval by flashing green lamp (4).
(A): Light Duty greasing interval
(B): Normal Duty greasing interval
(C): Heavy Duty greasing interval
CHANGING THE GREASE INTERVAL WITH THE IN-CAB DISPLAY

q Make sure the ignition is switched on.
q Select the interval required by pushing button (3) on the in-
cab display (2).
6–8
INDICATION ON THE IN-CAB DISPLAY

Indication Meaning
The red lamp (6) flashes as soon 1. The pump is not powered. Check fuses and connections to earth. Immedi-
as the ignition has been switched ate action required.
on. 2. The connection between the in-cab display and pump is defective, replace
if necessary.
No lamp is lighting up when the 1. The system is not powered. Check fuses and connections to earth. Immedi-
starting switch is in the ON posi- ate action required.
tion. 2. The display or wiring of the in-cab display is defective.Check in-cab display
and wiring and replace if necessary.
Yellow lamp (5) flashing
Minimum level in the reservoir has been reached. Reset by refilling the reser-
voir.
System out of order. Immediate action required!

Red lamp (6) flashing Possible causes:
- Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive
times in the same main line). Check for cause and reset by depressing the
test button at the pump for at least 1 second while the ignition is switched on.
- Reservoir empty; reset by refilling the reservoir and after that depressing the
test button for at least 1 second while the ignition is switched on.
Green lamp (4) flashing
Low duty
Normal duty
Heavy duty
A green lamp is flashing during

one complete cycle (2.0 sec. on/ Single test run being executed (see tests).
2.0 sec. off)
A green lamp is flashing continu-
Continuous test run being executed (see tests).
ously (0.2 sec. on/ 0.2 sec. off).
6–9
CHECK AUTO-GREASING SYSTEM

CHECK AUTO-GREASING SYSTEM:PC220_KU-Q850-280K00A
Periodic Checks
q Check the grease level in the reservoir, but do not refill the reservoir before minimum level is reached.
q Check the in-cab display is functioning.
q Check if the selected interval time is correct for the working conditions of the machine.
q Check the pump for damage and leakage.
q Check the grease pipes for damage and leakage.
q Check the condition of the grease points served by the system. Sufficient fresh grease should be visible.
q Check the operation of the system. Perform a cycle test.
q Check the pump unit and its surroundings. Attention — avoid using high pressure wash directly on the pump.
q Replace or clean the pump filler filter behind the connector on the reservoir every 500 hours.
6–10
REFILLING GREASE
If the yellow lamp (5) on the in-cab display (2) illuminates, the
minimum grease level in the reservoir has been reached. The
grease reservoir must be refilled as soon as possible.
GREASING PROCEDURE
1. Remove the dust cap from the filler coupling (7).
2. Carefully clean the filter coupling (7) and the filler coupling
on the filler hose.
3. Fix the filler hose on the filler coupling (7).
4. Fill the reservoir up to the maximum level indicated on the
reservoir (8).
5. Remove the filler hose and fit the dust cap.
6. Fix the filler hose on the filler coupling of the filler pump so
that filler hose stays clean.
REMARK
Do not fill the reservoir before you have a low level indication
(5) on the in-cab display.
SYSTEM TEST
In order to check the system a single lubrication cycle can be
performed as follows:
Move the starter switch to the ON position (B).
Depress the test button (9) on the pump for 3 to 5 seconds.
The system will run a single test. During this test the green
LED (4) of the selected interval on the in-cab display (2) will
flash (2 sec. on/ 2 sec. off).
In order to provide additional grease to all grease points (i.e.
after cleaning the machine) or to vent the system a continuous
lubrication cycle run can be performed.
Move the starter switch to the ON position (B).
Depress the test button (9) on the pump for more than 6
seconds. The system will perform a continuous lubrication
test. During this run the green LED (4) of the selected
interval on the in-cab display (2) will flash (0.2 sec. on / 0.2
sec. off).
The continuous test cycle ends after the starter switch is
moved to the OFF position (A).
6–11
A test cycle can only be started when the system is not in the pump phase of a current greasing cycle. If the sys-
tem is busy with a pump cycle, it will not react to the test push button.
NOTICE
Only use grease tests cycles if necessary. Every time a test cycle is carried out grease is added to the
grease points. This will increase grease usage and can cause excessive greasing of the grease points.
6–12
ATTACHMENTS AND OPTIONS BUCKET WITH HOOK
BUCKET WITH HOOK

Bucket with hook:PC-LBKN-001K00A
HOOK CONDITION
HOOK CONDITION:PC-LBKN-280K00A
Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu
distributor.
Prohibited operations:PC-LBKN-001K01A
SAFETY RULES FOR LIFTING OPERATIONS

Safety rules for lifting operations:PC-LBKN-170K01A
q During lifting operations, reduce the engine speed and carry

out the operation in L mode.
q Depending on the posture of the work equipment, there is a
danger that the wire or load may slip off the hook. Be care-
ful always to maintain the correct hook angle to prevent the
slip-off from happening.
q Never travel the machine while lifting a load.
q If the bucket with hook is turned and used for operations, it
will hit the arm during dumping operations. Be careful when
using it.
q If you are planning to newly install a hook, ask your
6–13
MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS
MACHINE READY FOR INSTALLATION OF ATTACHMENT

Machine ready for installation of attachment :PC-L411-001K00A
EXPLANATION OF COMPONENTS:PC220_KU-LGC0-04DK00A
(1) Stop valve (6) Accumulator (for low pressure)

(2) Selector valve (7) 1st-line attachment proportional switch
(3) Attachment control pedal (8) 2nd-line attachment proportional switch
(4) Lock pin (9) Breaker switch
(5) Additional filter for breaker
STOP VALVE
Stop Valve::PC220_KU-PQK0-043K00A
This valve (1) stops the flow of the hydraulic oil.

(a) FREE: Hydraulic oil flows.
(b) LOCK: Hydraulic oil stops.
When removing or installing attachments, set this valve to the
LOCK position.

-5
6–14
ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT
SELECTOR VALVE
SELECTOR VALVE:PC220-PQH0-043K00A
This valve (2) switches the flow of hydraulic oil.

It is automatically switched according to the selected working
mode. It is necessary to switch the working mode to match the
attachment that is installed. When changing the working mode,
see "HYDRAULIC CIRCUIT (6-18)".
NOTICE
If a service circuit from the attachment maker has been
added, the return circuit may not switch automatically.
ATTACHMENT CONTROL PEDAL

k
Attachment Control Pedal:PC-PK41-043K00A
WARNING
Do not carry out operations with your foot on the pedal. If the pedal is depressed by mistake, the attach-
ment may suddenly move and cause a serious personal injury. Lock the pedal with the lock pin when you
are not operating the attachment with the pedal.
Do not press breaker switch when using attachment control pedal.
This pedal (3) is used to control the attachment.

When the front, centre (neutral), and rear of the pedal are
depressed, the movement of the attachment is as follows.
Hydraulic breaker
Front of pedal (A): Actuated
Centre of pedal (N): Stopped
Rear of pedal (B): Stopped
Regarding other attachments, hold a meeting with the attach-
ment manufacturer at the time of installation to see the opera-
tion of the pedal and attachment before using it.
LOCK PIN
Lock Pin:PC-PK42-043K00A
This pin (4) locks the control pedal.

Position (a): Locked
Position (b): Only front of pedal can be operated to full travel
position (rear is locked)
Position (c): Both front and rear of pedal can be operated to full
travel position
q When not using the attachment, set the lock pin to position
(a).
q When using the breaker, use the working mode selector
switch on the monitor switch portion to set the working
mode to B mode, and set the lock pin to position (b) when
using the pedal, and position (a) when using the breaker
switch (9).
q When using the crusher, use the working mode selector
switch on the monitor switch portion to set the working
mode to ATT mode, and set the lock pin to position (c) when
using the pedal and position (a) when using the rolling
switch (7).
6–15
NOTICE
q When using the breaker, if the lock pin is set to position (c) and the pedal is depressed in direction (D),
it will cause damage or defective operation of the breaker. To prevent it, when using the breaker,
always set the lock pin to position (b).
q Before changing the position of the lock pin, stop the engine.
ADDITIONAL FILTER FOR BREAKER

ADDITIONAL FILTER FOR BREAKER:PC220-LGC5-043K00A
This filter (5) prevents deterioration of the hydraulic oil when

using a breaker.
Oil flows only when B mode is selected on the monitor.
NOTICE
Machines are equipped with additional filter (5) as stand-
ard when they are shipped from the factory.
ACCUMULATOR
k
ACCUMULATOR:PC220-LG25-043K00A
WARNING
following.
q When disposing of the accumulator, the gas must be released. Ask your Komatsu distributor to have
this work carried out.
These accumulators (6) are installed to reduce the peak pres-

sure in the hydraulic circuit when the breaker is being used.Do
not touch them usually.
NOTICE
On the machines equipped with a breaker, it is necessary to install an accumulator to the breaker piping
to match the model number of the breaker manufacturer. If no accumulator is installed and the breaker is
operated, the service life of the machine will be reduced. For questions about the breaker, contact your
If the pressure of the nitrogen gas charging the accumulator drops, it will be impossible to release the
remaining pressure in the control circuit after the engine has stopped. In addition, if operations are con-
tinued with the nitrogen gas at low pressure, it will cause damage to the hydraulic circuit or machine.
Check the nitrogen charge pressure periodically.
See "CHECK CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) (4-
67)".
6–16
1ST-LINE ATTACHMENT PROPORTIONAL SWITCH

k
1st-line attachment proportional switch:PC220_KU-PT0R-043K01A
WARNING
When operating attachment using rolling switch, lock the pedal with the lock pin to avoid accidental oper-
ation.
Switch (7) operates the 1st attachment circuit (e.g. crusher).

The switch (7) is a roller proportional control switch. Rolling the
switch up produces movement of the attachment, rolling down
produces opposite movement. Slight movement of the roller
will give slight movement of the attachment; full movement of
the roller will give faster movement of the attachment.
2ND-LINE ATTACHMENT PROPORTIONAL SWITCH

2nd-line attachment proportional switch:PC220_KU-PT0T-043K01A
(if equipped)
Proportional control rolling switch.
Switch (8) operates the 2nd attachment circuit (e.g. clamshell
rotation). The switch (8) is a roller proportional control switch.
Rolling the switch up produces rotation in one direction, rolling
down produces rotation in the opposite direction. Slight move-
ment of the roller will give slight movement of the clamshell; full
movement of the roller will give faster movement of the clam-
shell.
REMARK
If installing 2nd attachment as a field kit, ask the distributor to
change monitor setting to allow 2 attachment mode.
BREAKER MODE SWITCH
k
Breaker mode switch:PC220_KU-LGGA-043K01A
WARNING
When operating breaker using breaker switch, lock the pedal with the lock pin to avoid accidental opera-
tion.
Switch (9) operates the breaker.

Press switch (9) to operate breaker and release to stop.
6–17
HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT:PC220_KU-RA18-043K00A
NOTICE
q The return circuit when a breaker is installed must return directly to the return filter, so do not use it in
the mode other than B mode.
q The standard set pressure of the safety valve of the service valve is 20.6 MPa {210 kg/cm2} if you
select B mode set at the shipment from the plant and it becomes 27.4 MPa {280 kg/cm2} when ATT/P or
ATT/E mode is selected. Depending on the attachment, it may be necessary to adjust the pressure.
Ask your Komatsu distributor for the adjustment.
SWITCHING THE HYDRAULIC CIRCUIT
q Depending on the type of attachment, set the working mode on the monitor as follows.
q The hydraulic circuit and the set pressure of the safety valve in the service valve switch according to the work-
ing mode selected.
Set pressure of
Attachment Working mode Hydraulic circuit safety valve of ser-
vice valve
When shipped from
Return circuit automatically
Breaker or other attachment factory:
B mode becomes the circuit that does not
with one-way circuit 20.6 MPa {210 kg/
pass through control valve
cm2}
When shipped from
Return circuit automatically
Crusher or other attachment ATT/P or ATT/E factory:
becomes the circuit that does not
with two-way circuit mode 27.4 MPa {280kg/
pass through control valve
cm2}
Depending on the attachment, it is necessary to change the oil flow in the service circuit.
For details of setting the oil flow, see "ATTACHMENT OPERATIONS (6-28)".
SWITCHING OF BREAKER AND GENERAL ATTACHMENT
q When optional attachment is installed and working mode is set to B mode
(1) Breaker circuit (one-way circuit) is formed.
(2) Hydraulic oil flowing through breaker circuit passes through additional filter for breaker.
(3) Relief valve is set to low pressure.
When shipped from factory: 20.6 MPa (210kg/cm2)
(4) Maximum oil flow can be adjusted in user mode.
q If ATT/P or ATT/E mode is turned on when the optional attachment is installed
(1) Crusher circuit (2-way circuit) is formed.
(2) Hydraulic oil flowing through crusher circuit does not pass through additional filter for breaker.
(3) Relief valve is set to high pressure.
When shipped from factory: 27.4 MPa (280 kg/cm2)
(4) Maximum oil flow can be adjusted in user mode.
6–18
HYDRAULIC CIRCUIT CONNECTION

Hydraulic Circuit Connection::PC220_KU-PQK0-100K00A
When installing the attachment, connect the hydraulic circuit as follows.

1. Check that stop valve (1) is located at LOCK position (b).
(a) FREE: Hydraulic oil flows (direction of arrow is parallel to
longish direction of arm)
(b) LOCK: Hydraulic oil does not flow (direction of arrow is at
right angle to longish direction of arm)

-5
q When setting the FREE or LOCK position of the stop valve,

remove bolt (1) and washer (2) fit lever (3) and refit bolt (1)
and washer (2) rotate valve to furthest position clockwise or
anti-clockwise. After setting Remove lever (3) and refit bolt
(1) washer (2).
2. Remove plate (4) at the tip of the stop valve piping. (Right
and left, 2 places)
Be careful not to lose or damage the removed parts.
3. After removing plug, connect the attachment piping (5)
which is provided by the attachment manufacturer.
For the fitting size and accumulator add-on, the action to
take differs according to the attachment manufacturer, so
consult your Komatsu distributor.
6–19
OIL FLOW PATH

OIL FLOW PATH:PC220-RA18-044K00A
The direction of operation of the pedal and the path of the oil flow is as shown in the figure below.
When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the
rear of the pedal is depressed, oil flows to the piping on the right side of the work equipment. (When a breaker is
installed, only the front of the pedal can be used.)
6–20
REPLACE ELEMENT FOR ADDITIONAL FILTER FOR BREAKER

k
REPLACE ELEMENT FOR ADDITIONAL FILTER FOR BREAKER:PC220-LGC5-923K00A
WARNING
q Immediately after the engine is stopped, the parts or oil
are at high temperature and may cause burns. Wait for
q If compressed air is used, there is a danger of dirt scat-
tering and causing personal injury.
Always wear protective eyeglasses, dust mask, and
other protective equipment.
NOTICE
For the details of the element replacement interval, see "MAINTENANCE INTERVAL FOR HYDRAULIC
BREAKER (4-11)".
q Prepare a container to catch the oil.
1. Lower the work equipment to the ground and stop the

engine.
2. Turn the starting switch to ON position (B), then set the lock
lever to FREE position (F).
3. After carrying out Step 2, operate each work equipment
control lever and attachment control pedal fully to the front,
rear, right, and left 2 to 3 times within 15 seconds to release
the internal pressure in the hydraulic circuit.
6–21
5. Loosen slowly oil filler cap (F) on the top of the hydraulic
tank to release the internal pressure in the hydraulic circuit.
6. Place a container under the filter element to catch the oil.
7. Place a container in position to catch the drained oil, then

remove plug (3) and drain the oil accumulated in filter case
(1).
8. After checking that the hydraulic oil temperature has gone
down, turn filter case (1) counterclockwise, remove it, then
take out element (2).
9. Clean the removed parts, then install new element (2).
q Element (2) must be installed facing in the correct direc-
tion. Set direction Y with the holes in it up, and fit the
hole in element (2) on the protruding portion inside filter
head (6).
10. Install new O-ring (4) to filter case (1), then screw filter case
(1) into filter head (6). When the top of filter case (1) comes
into contact with the filter head, tighten it at least a further 1/
2 turns.
11. Clean plug (3), then fit a new O-ring (5) to plug (3).
12. Install plug (3) to filter case (1).
Tightening torque: 27.4 to 58.8 Nm (2.8 to 6.0 kgm).
6–22
REPLACE ELEMENT FOR ADDITIONAL PILOT FILTER FOR BREAKER

k
REPLACE ELEMENT FOR ADDITIONAL PILOT FILTER FOR BREAKER:PC220-LGC6-923K00A
WARNING
q Immediately after the engine is stopped, the parts or oil
are at high temperature and may cause burns. Wait for
q If compressed air is used, there is a danger of dirt scat-
tering and causing personal injury.
Always wear protective eyeglasses, dust mask, and
other protective equipment.
NOTICE
For the details of the element replacement interval, see "MAINTENANCE INTERVAL FOR HYDRAULIC
BREAKER (4-11)".
q Prepare a container to catch the oil.
1. Lower the work equipment to the ground and stop the

engine.
6–23
6. Place a container under the filter element to catch the oil.

down, turn filter case (1) counterclockwise, remove it, then
take out element (2).
8. Clean the removed parts, then install new element (2).
q Element (2) must be installed facing in the correct direc-
tion. Set direction Y with the holes in it up, and fit the
hole in element (2) on the protruding portion inside filter
head (4).
9. Install new O-ring (3) to filter case (1), then tighten the
mounting bolts for filter case (1) to a tightening torque of 25
to 35 Nm (2.6 to 3.6 kgm).
6–24
REMOVAL AND INSTALLATION OF ATTACHMENT

REMOVAL AND INSTALLATION OF ATTACHMENT:PC-L411-922K00A
REMOVAL
Removal:PC220-L411-520K00A
1. Lower the attachment to the ground and stop the engine.

6–25
6. After checking that the oil temperature is low, set the rotor
of the stop valve installed to the inlet port on the side face of
the arm and the outlet port piping to LOCK position (b).
q When setting the FREE or LOCK position of the stop
valve, remove bolt (1), and washer (2) fit lever (3) and
refit bolt (1) and washer (2) rotate valve to furthest posi- -5
tion clockwise or anti-clockwise. After setting Remove
lever (3) and refit bolt (1) washer (2).
7. Remove the hoses on the attachment side. Install the plate
(4) to the two outlets.
The plugs are used to prevent the attachment from making
incorrect operation caused by mixing in of foreign matter.
After the plugs are correctly installed, store the attachment.
8. Pull out the mounting pins (2 places), remove the attach-

ment, then install the bucket.
For details of the procedure for installing the bucket, see
"REPLACING AND INVERTING BUCKET (3-200)".
9. After installing the bucket, check the oil level in the hydrau-
lic tank.
INSTALLATION
Installation:PC-L411-720K00A
Remove the bucket.

For bucket dismounting procedure, see REPLACING AND
INVERTING BUCKET (3-200).
1. Place the attachment on a horizontal place, then install pin
(A) and then pin (B) to the arm.
Pin (A) 80 mm diameter
Pin (B) 80 mm diameter
2. Lower the attachment to the ground and stop the engine.
3. Turn the starting switch to the ON position (B), then set the
lock lever to the FREE position (F).

rear, right, and left 2 or 3 times within 15 seconds to release
6–26
down, remove the plugs from 2 places at the outlet port and
inlet port.
Be careful not to get any dirt or mud on the hose fitting.
If the O-ring is damaged, replace it with a new part.
8. Connect the hose on the attachment side.
When doing this, check the direction of flow of the oil and be
careful not to make any mistake.
9. Set the rotor of the stop valve installed to the inlet port on
the side face of the arm and the outlet port piping to FREE
position (a).
q When setting the FREE or LOCK position of the stop
valve, remove bolt (1), and washer (2) fit lever (3) and
refit bolt (1) and washer (2) rotate valve to furthest posi- -5
tion clockwise or anti-clockwise. After setting Remove
lever (3) and refit bolt (1) washer (2).
10. After installing the attachment, check the oil level in the
hydraulic tank.
6–27
ATTACHMENT OPERATIONS
k
ATTACHMENT OPERATIONS:PC220_KU-L411-130K00A
WARNING
q If the pedal is operated when the auto-deceleration is being actuated and the engine speed is dropped,
the engine speed will suddenly increase, so be careful when operating.
q If you leave your foot resting on the pedal and depress the pedal by mistake, there is a danger that the
attachment may suddenly move and cause serious personal injury. If you do not need to operate the
pedal, do not rest your foot on the pedal.
q When the attachment is not used, set the lock pin of the pedal to the LOCK position to prevent the
pedal from being operated.
q When changing the oil flow setting for the breaker mode and attachment mode for the crusher, see "Machine
settings (3-60)" for details.
The method of operating the attachment is as follows.
WHEN USING THE BREAKER:
NOTICE
When carrying out breaker operations, use the breaker mode. If the breaker mode is not used, the breaker
may be damaged.
Breaker can be operated using either the breaker switch or
attachment control pedal.
(1) Breaker Switch: With the working mode set to B mode,
press switch to operate breaker and release to stop.
When operating breaker using breaker switch, lock the pedal

with the lock pin to avoid accidental operation.
(2) Attachment Control Pedal - With the working mode set to B

mode, insert the lock pin in front-only FREE position (b).
Press the front of the pedal to operate the breaker.
6–28
If the pilot monitor in the working mode does not display B for
the breaker mode, press working mode selector switch (1) and
set to the breaker mode as follows.
q When working mode selector switch (1) is pressed, the
screen switches to the working mode selection screen.
1. Press working mode selector switch (1) or press switches

F3 or F4 to select breaker mode B.
2. With breaker mode B highlighted in yellow, do one of the
following to accept selection:-
q Keep working mode selector switch (1) pressed.
q Press switch F6.
q Leave as it is for 5 seconds.
3. If the breaker mode is selected, "Really Set Breaker
Mode?" is displayed on the screen. To set to the breaker
mode, press switch F6.
q If switch F5 is pressed, the screen returns to the working
mode selection screen without changing to the breaker
mode.
k WARNING
When a slide arm or other special attachment is installed,
if the mode is switched to the breaker mode by mistake, it
may lead to serious danger, such as sudden drop of the
work equipment.
If breaker operations are carried out in a mode other than the breaker mode, the warning screen is displayed.
Always carry out breaker operations in the breaker mode.
Precautions when using
q Check that the stop valve is in the FREE position.
q Check that the working mode is B mode.
For details of the path of the oil, see "HYDRAULIC CIRCUIT (6-18)".
q When considering whether it is necessary to install an accumulator for the attachment circuit, contact the
attachment manufacturer and then decide.
q For other precautions when handling the breaker, follow the instruction manual from the breaker manufacturer
and use the breaker correctly.
q The deterioration of the hydraulic oil when using the breaker is much faster than in the normal operations, so
reduce the maintenance interval for the hydraulic oil and element.
See "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (4-11)" for details.
6–29
WHEN USING GENERAL ATTACHMENTS SUCH AS CRUSHER:

If the pilot monitor in the working mode does not display ATT
for the attachment mode, press working mode selector switch
(1) and set to the attachment mode as follows.
q Even if P, E, or L mode are selected, the attachment is not
operated.
1. Press working mode selector switch (1) or press switches

F3 or F4 to select attachment mode ATT/P or ATT/E.
2. With attachment mode ATT/P or ATT/E highlighted in yel-
low, do one of the following to accept the selection.
q Keep working mode selector switch (1) pressed.
q Leave as it is for 5 seconds.
q Press switch F6.
q On the user menu attachment setting, it is possible to

make the attachment mode inactive.
q When using the attachment mode, check that the
attachment mode is active before starting operations.
Precautions when using
q Check that the stop valve is in the FREE position.
q Check that the working mode is ATT/P mode or ATT/E mode.
For details of the path of the oil, see "HYDRAULIC CIRCUIT (6-18)".
q For other precautions when handling the attachment, follow the instruction manual from the attachment manu-
facturer and use the attachment correctly.
6–30
OPERATION WHEN USING GENERAL ATTACHMENT 1 (E.G. CRUSHER)
k WARNING
When operating the attachment using rolling switch, lock the pedal with the lock pin to avoid accidental
operation.
General attachment 1 can be operated using either the rolling switch on the right lever or right attachment control
pedal.
1. Proportional Control Rolling Switch
With the working mode set to ATT/P or ATT/E mode, rolling
the switch up produces movement of the attachment, rolling
down produces opposite movement of the attachment.
Slight movement of the roller will give slight movement of the
attachment; full movement of the roller will give faster move-
ment of the attachment.
2. Attachment Control Pedal

With the working mode set to ATT mode, insert the lock pin
in FREE position (c) for both front and rear. Depress the
front or rear of the pedal to operate the attachment.
OPERATION WHEN USING ATTACHMENT 2 (E.G. CLAMSHELL ROTATION, CRUSHER ROTATION)

REMARK
If installing 2nd attachment line as a field kit, ask distributor to change monitor setting to allow 2 attachments.
The switch on left lever is a roller proportional control switch.
Rolling the switch up produces rotation in one direction, rolling
down produces rotation in the opposite direction. Slight move-
ment of the roller will give slight movement of the attachment;
full movement of the roller will give faster movement of the
attachment.
If the working mode pilot monitor does not display ATT/P or
ATT/E for the attachment mode, follow the instructions, see
“WHEN USING GENERAL ATTACHMENT SUCH AS
CRUSHER”.
LONG-TERM STORAGE
Long-term storage:PC-L411-870K00A
If the equipment is not to be used for a long time, do as follows.

q Set the stop valve in the LOCK condition.
q Install the plugs to the valves.
q Set the lock pin at the LOCK position.
If there is no breaker or general attachment installed, operating the pedal may cause overheating and other prob-
lems.
6–31
SPECIFICATIONS
SPECIFICATIONS:PC-RA18-030K00A
Hydraulic specifications
q Max. flow at merge: 214 x 2 litres / min
2
q Safety valve relief set pressure for service valve: 27.4 MPa {280 kg/cm } (except B mode)
2
q Safety valve cracking pressure for service valve: 24.5 MPa {250 kg/cm } (except B mode)
2
q Safety valve relief set pressure for service valve: 20.6 MPa {210 kg/cm } (B mode)
2
q Safety valve cracking pressure for service valve: 15.2 MPa {155 kg/cm } (B mode)
In addition, valves with safety valve relief set pressure of 24.5 MPa {250 kg/cm2} and relief valve cracking pres-
sure of 20.1 MPa {205 kg/cm2} are also available. Contact your Komatsu distributor.
ARM/PIN INFORMATION
2 4
1 3
KS000339
+0 +0.5
1 325 mm 3 325 mm
-0.5 -0.5
-0.030 -0.030
2 80 mm 4 80 mm
-0.075 -0.075
6–32
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS

k
ATTACHMENTS AND OPTIONS:PC-RA17-056K00A
WARNING
q Please read the instruction manual for the attachment and the sections of this manual related to
attachments and options.
q When installing any attachment or optional equipment, there may be problems with safety, so please
contact your Komatsu distributor before installing.
q Installing attachments or optional equipment 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.
q Any personal injuries, accidents, or damage resulting from the use of unauthorized attachments or
optional equipment will not be the responsibility of Komatsu.
ATTACHMENT COMBINATIONS
k
ATTACHMENT COMBINATIONS:PC-L410-056K00A
WARNING
Depending on the type or combination of work equipment, there is a danger that the work equipment may
hit the cab or machine body.
When using unfamiliar work equipment for the first time, check before starting if there is any danger of
interference, and operate it with care.
PC210-10, PC210LC-10
NOTICE
q When the boom is fully lowered during oblique digging, the boom interferes with the undercarriage.
Operate the boom carefully.
NOTE:
1. Bucket size based on ISO 7451, heaped material with a 1:1 angle of repose.
Max Bucket Volume/Weight are for reference only and are not necessarily available from the factory.
2. Table is based on General Purpose buckets and both conditions of Volume (m3) and weight (kg) must not be
exceeded.
Please consult with your distributor for the correct selection of buckets and attachments to suit the application.
The recommendations are given as a guide only, based on typical conditions.
q For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durabil-
ity and high wear resistance be employed.
PC210-10
Max Bucket Volume / 1 - Piece Boom
Weight ISO 1.8 m 2.4 m 2.9 m
Bucket 1.2 t/m3 m3 / kg 1.56 / 1100 1.38 / 1025 1.27 / 950
Bucket 1.5 t/m3 m3 / kg 1.53 / 1000 1.18 / 925 1.08 / 875
Bucket 1.8 t/m3 m3 / kg 1.15 / 900 1.00 / 850 0.94 / 800
PC210LC-10
Max Bucket Volume / 1 - Piece Boom
Weight ISO 1.8 m 2.4 m 2.9 m
Bucket 1.2 t/m3 m3 / kg 1.68 / 1200 1.62 / 1150 1.47 / 1075
Bucket 1.5 t/m3 m3 / kg 1.50 / 1075 1.38 / 1025 1.25 / 950
Bucket 1.8 t/m3 m3 / kg 1.30 / 975 1.20 / 925 1.09 / 875
Values shown are in accordance with EN474-5:2006+A1:2009 (E)
6–33
TRACK SHOES SELECTION

TRACK SHOES SELECTION:PC-DTL0-05AK00A
Select the appropriate track shoe to match the operating conditions.

TRACK SHOES SELECTION
Check the category from the uses in the table below, then select the shoes from the table further below.
q Category of use "B"and "C"are the wide shoe, so there are restrictions on the use. Check the precautions for
use, examine the conditions of use thoroughly, and use the optimum shoes for the situation.
q When selecting the shoe width, choose the narrowest shoes possible to bring the machine within the range
where there is no problem regarding the machine flotation and ground contact pressure. If the wider shoes
than necessary are used, the load on the shoe will increase. It may cause problems such as bending of the
shoe, cracking of the link, damage of the pin, and looseness of the shoe bolts.
Category Use Precautions when using
Rocky
ground, riv- q On rough ground with large obstacles such as boulders or fallen trees, travel at Lo
A
erbeds speed.
Normal soil
q These shoes cannot be used on rough ground where there are large obstacles
Normal soil such as boulders or fallen trees.
B
Soft ground q Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid travel-
ling over obstacles, shift down and travel at half speed in Lo.
q Use the shoes only in places where the machine sinks and it is impossible to use
Extremely A or B shoes.
soft ground q These shoes cannot be used on rough ground where there are large obstacles
C
(swampy such as boulders or fallen trees.
ground) q Travel at Hi or Mi speed only on flat ground, and if it is impossible to avoid travel-
ling over obstacles, shift down and travel at half speed in Lo.
D Paved road q Take note of low gradeability due to the flat shoes and exercise due care.
q Be sure to follow the instructions set forth in the “Handling of Road Liner” section
E Paved road
for the protection of the rubber pad shoes.
PC210-10 PC210LC-10
Specifications Category Specifications Category
Standard 600 mm Triple A 700 mm Triple B
Option 700 mm Triple B 600 mm Triple A
Option 800 mm Triple C 800 mm Triple C
Option N/A N/A 900 mm Triple C
6–34
BUCKET TEETH SELECTION

BUCKET TEETH SELECTION:PC-LBM0-05AK00A
Depending on the working conditions, there is a danger that an adapter and tooth may be lost. Select either one
from the vertical pin type of tooth or horizontal pin type of tooth that is suitable for the purpose.
While the standard teeth of both vertical and horizontal pin types may be used widely, the following kinds of teeth
are recommended depending on the working conditions.
VERTICAL PIN TYPE TOOTH
Vertical Pin Type Tooth:PC-LBM0-05AK02A
General digging: Digging and loading normal soil, such as sand, gravel, clay, etc.Light-duty digging: digging and
loading dry and loose sandy soil, or muddy soil.Loading: loading of dry and loose earth.
HORIZONTAL PIN TYPE TOOTH
Horizontal Pin Type Tooth:PC-LBM0-05AK03A
Heavy-duty digging: Digging and hammering work on hard soil, soil with rocks, scraping or other heavy-duty work
q The heavy-duty bucket is of a horizontal pin type and as such, use it for heavy duty-digging.
LONG-LIFE TOOTH
Long-life Tooth:PC-LBM0-05AK04A
q Jobsites where long wear life is required, such as when loading hard rocks.
q Jobsites where no penetration is needed, such as when working with crushed rocks after blasting or ripping.
q Jobsites where heavy-duty operations are carried out, such as hitting or pulling up rocks with the tips of the
teeth.
SELF-SHARPENING TOOTH (HORIZONTAL PIN TYPE, VERTICAL PIN TYPE)
Self-sharpening Tooth (Horizontal Pin Type, Vertical Pin Type):PC-LBM0-05AK05A
q Jobsites requiring penetration such as digging and loading sandy or clayey soil.
SELECTION GUIDE FOR HORIZONTAL OR VERTICAL PIN TYPE TOOTH

Selection Guide for Horizontal or Vertical Pin Type Tooth:PC-LBM0-05AK06A
Applicable Work Site

Clayey soil,
Rock Crushed stone Decompressed Sand
weathered granite
Digging with hammer- Horizontal pin type teeth
Horizontal pin type teeth
ing work Vertical pin type teeth
io Heavy
Work Contents

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

Loading
6–35
HANDLING OF RUBBER PAD SHOE AND ROAD LINER

HANDLING OF RUBBER PAD SHOE AND ROAD LINER:PC-DTLJ-170K00A
Be sure to observe the following instructions, when using a machine equipped with rubber pad shoes or Road
Liner.
WORKING ENVIRONMENT
Use a machine equipped with rubber pad shoes or Road Liner mainly for jobs on the paved roads.
If it is used otherwise, breakage or chipping will occur on the rubber and the service life will be considerably
reduced.
Particularly the following jobsites must be avoided.
q Jobsite with crushed concrete strewed or on sand
q Jobsite with protruding edged objects like steel bar, glass and the like (Particularly a ride over the sheet
piles driven into the ground must be avoided.)
q A ride over a concrete road shoulder, or jobsite on rocky terrain or in a river with many rocks
q Be careful of machine skidding on the road covered with water, ice, snow or gravel. Take special care when
unloading a machine from a truck.
q Use a machine equipped with rubber pad shoes or Road Liner in the ambient temperature range of -25 °C to
65 °C due to the properties of rubber.
WORKING CONDITIONS
Work using the undercarriage as a fulcrum, side digging work, digging work on a slope and a work requiring fre-
quent steering, as shown in the picture, cause an excessive load on the rubber and there is a danger that it may
be damaged.
q Durability of rubber pad shoes may not be covered with
warranty, if a special work equipment is mounted.
STORAGE AND MAINTENANCE

q Take care that no oil or grease sticks to the rubber. If it
does, wipe it off immediately.
q Install rubber pad shoes and Road Liner (A) corresponding
to the number of the links.
If there is any missing pad or liner, the rubber will be greatly
deformed and damaged.
q If rubber pad shoes or Road Liner has to be stored for a
long period, keep them indoors to avoid direct sunlight and
rain.
#
-5
6–36
EXTENT OF DAMAGE TO RUBBER

When travelling on a concrete pavement, rubber may stick to
the road surface, leaving a dark track (B) behind.
$ -5
q The rubber is still usable, even if it does not look in good shape with part of the rubber chipped or cuts devel-
oped on the surface, so long as damage has not developed all over the shoe or it does not damage a road sur-
face.
CHECK ROAD LINER

Check Road Liner:PC-DTLK-360K00A
If the Road Liners (A) are in the following condition, they must be repaired or replaced, so please contact your
Komatsu distributor for repairs or replacement.
HEIGHT OF LUG
q If lug height "a" is reduced by wear, the drawer pull will
drop. #
If "a" is less than 5 mm, replace with a new part.
-5
REPLACE ROAD LINER

Replace Road Liner:PC-DTLK-923K00A
q When all the road liners of the machine need to be replaced, ask your Komatsu distributor to replace them.
q When replacing only part of the road liner, use the special road liner removal tool. Order the tool from your
6–37
HANDLING TRAPEZOIDAL BUCKET

HANDLING TRAPEZOIDAL BUCKET:PC-LBR2-130K00A
Use the trapezoidal bucket when digging trapezoidal ditches in

fields. By installing the angle plate with different angle, it is pos-
sible to excavate three angles of ditch slope face (45°, 40°, # $
38°).
q The position of installation of the angle plate is different for
%
each ditch slope face angle (45°, 40°, 38°).
(A) - 45°, 40°, 38° ditch common hole
(B) - 45° ditch hole &
(C) - 40° ditch hole
'
(D) - 38° ditch hole -5
(E) - 38°, 40° ditch common hole
DIGGING WORK
Operate the boom, arm, and bucket so that line A of the side plate of the bucket is always perpendicular to the
ground face, then carry out digging.
Horizontal indexing plate B is welded to the bucket pin hole
portion, so when digging, operate so that the plate is horizontal
during the digging operation.
DITCH SLOPE FACE 45 DEGREES

Use the bucket only or install the angle plate using the ditch
slope angle holes, and use the method above for digging.
6–38
DITCH SLOPE FACE 40 DEGREES, 38 DEGREES

Install the angle plate using the respective ditch slope angle
holes, and use the method above for digging.
Even when the angle plate is fitted, keep the line on the bucket
side plate perpendicular to the ground face during the digging
operation.
6–39
HANDLING EXTENSION ARM

HANDLING EXTENSION ARM:PC-L850-170K00A
When an extension arm is installed, the bucket will hit the

boom cylinder foot and revolving frame when the arm is pulled
in, so be extremely careful during operations and when trans-
porting the machine.
q When an extension arm is installed, use a narrow bucket
(width: 750 mm with side cutters, 560 mm without side cut-
ters). If the standard bucket is used, the stability is poor, and
the bucket will also hit the operator's cab when the arm is
pulled in, so do not install the standard bucket.
q For operations on hard soil or rock, do not use the exten-
sion arm. The service life of the extension arm, boom, and
arm will be reduced.
(A) Prohibited zone to be operated
-5
6–40
HANDLING CLAMSHELL BUCKET

HANDLING CLAMSHELL BUCKET:PC-LC60-130K00A
Use a clamshell bucket for digging or loading soil for side ditching and in limited areas.
DIGGING WORK
Digging is carried out with the clamshell pushed by the boom, but when operating the bucket, raise the boom
slightly and carry out digging.
When the clamshell bucket rotates, relieve the hydraulic pressure in the bucket cylinder, then return the lever to
the HOLD position. The rotation is locked for a short time.
PRECAUTIONS DURING OPERATION

Precautions During Operation:PC-LC60-170K00A
q It is dangerous to carry out sudden steering, sudden swings, or sudden stops when using the clamshell
bucket. Avoid such operations.
q When pushing with the boom, keep the clamshell straight.
q Do not swing the bucket to the side to break up or cut rocks or soil.
q Do not use the bucket for driving piles or removing piles.
q When the machine is not being used, open the bucket and lower it to the ground to set the bucket in a stable
position.
REMARK
Remove the clamshell bucket from the arm before transporting the machine.
LUBRICATION
Lubrication:PC-LC60-242K00A
q Prepare a grease pump.

1. Lower the work equipment to the ground and set it in a sta-
ble condition before stopping the engine.
2. Using a grease gun, apply grease to the grease fittings
marked by arrows (12 places).
3. After greasing, wipe off any old grease that was pushed out.
REMARK
Clamshell bucket is NOT part of Automatic Grease System.
Above procedure should be followed.
6–41
RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS
RECOMMENDED ATTACHMENT OPERATIONS

RECOMMENDED ATTACHMENT OPERATIONS:PC-L411-171K00A
Below described are instructions which must be followed without fail when doing the work using a hydraulic exca-
vator equipped with an attachment.
NOTICE
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted.
q Depending on machine models of hydraulic excavator, the kind of attachments or the model of spe-
cific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selec-
tion of optimum attachments.
HYDRAULIC BREAKER
HYDRAULIC BREAKER:PC-LG10-130K00A
APPLICABLE WORK
q Demolition work
q Crushing rock
q Road construction
This attachment can be used for a wide range of applications
including demolition of buildings, breaking up road surfaces or
slag, tunnel work, rock crushing and breaking operations in
quarries.
Keep the chisel pushed perpendicularly against the impact sur-

face when carrying out breaking operations.
When applying impact, push the chisel against the impact sur-
face and operate so that the chassis rises approximately 5 cm
off the ground. Do not let the machine come further off the
ground than this amount.
6–42
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS
When applying continuous impact to the same impact surface,

if the chisel does not penetrate or break the surface within one
minute, change the point of impact and carry out breaking
operations closer to the edge.
The direction of penetration of the chisel and the direction of

the breaker body will gradually move out of line with each
other, always adjust the bucket cylinder to keep them aligned.
Always keep the chisel pressed against the impact surface

properly to prevent using the impact force when there is no
resistance.
WRONG USAGE
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.
q Do not operate all cylinders to the end of their strokes. Always leave approximately 5 cm to spare.
Using the mount to gather in pieces of rock
6–43
Operations using the swing force
Moving the chisel while carrying out impacting operations
Holding the chisel horizontal or pointed up when carrying out

impacting operations
Twisting the chisel when it penetrates the rock
Pecking operations
6–44
ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS
Extending the bucket cylinder rod fully and thrusting to raise

the machine off the ground
POSTURE OF HYDRAULIC BREAKER TO BE GREASED

Be sure to grease the breaker, holding it in the right posture.
NOTICE
If the breaker is greased in an improper posture, it is filled
with more grease than necessary. As a result, soil and
sand will enter the hydraulic circuit and can damage the
hydraulic components while the breaker is in use. Be sure
to grease the breaker, holding it in the right posture.
REMARK
Breaker is NOT part of Automatic Grease System.
Above procedure should be followed.
6–45
6–46
REPLACEMENT PARTS
REPLACEMENT PARTS
Replacement parts:ALL-0000-001K16A
REPLACEMENT PARTS
7–1
SAFETY CRITICAL PARTS REPLACEMENT PARTS
SAFETY CRITICAL PARTS

SAFETY CRITICAL PARTS:ALL-0000-20LK00A
For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts listed in the table of important parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is
important to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all
loose hoses and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.
SAFETY CRITICAL PARTS LIST

Safety critical parts listPC220-0000-20MK00A
No. Parts for periodic replacement Q'ty Replacement interval

1 Fuel hose (between fuel tank and fuel pre-filter) 1
2 Fuel hose (fuel pre-filter - supply pump) 1
3 Fuel return hose, cooler (engine - fuel cooler) 1
4 Fuel return hose (fuel cooler - fuel tank) 1
5 Fuel hose (supply pump - fuel main filter) 2
6 Engine oil hose (between engine and oil filter) 2
7 Pump outlet hose (between pump and control valve) 2
8 Work equipment hose (boom cylinder inlet port) 4
9 Work equipment hose (bucket cylinder line, boom foot) 2
10 Work equipment hose (bucket cylinder inlet port) 2
11 Work equipment hose (arm cylinder line, boom foot) 2
12 Work equipment hose (arm cylinder inlet port) 2 Every 2 years or 4000
13 Attachment additional line hose (boom foot) 2 hours, whichever
14 Attachment additional line hose (boom top) 2 comes sooner
15 Swing line hose (swing motor inlet port) 2
16 Main suction hose 1
17 Heater hose 2
18 Travel line hose (between control valve and swivel joint) 4
19 Travel line hose (between swivel joint and travel motor) 4
20 Pump branch hose 2
21 Pump LS hose 2
22 Pump pressure hose 1
23 Accumulator (for control circuit) 1
each
24 Accumulator (For additional attachment low pressure, high pressure)
1
25 KCCV hose 9 Every 4500 hours
26 Fuel spray prevention cap 1 set Every 8000 hours
Every 3 years from start
of usage or 5 years
27 Seat belt 1 after manufacturing of
seat belt, whichever
comes sooner
7–2
REPLACEMENT PARTS CONSUMABLE PARTS
CONSUMABLE PARTS
Consumable parts:PC-0000-202K00A
Replace consumable parts such as the filter element or air cleaner element at the time of periodic maintenance or
before they reach the wear limit. The consumable parts should be replaced correctly in order to ensure more
economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check the latest part number when ordering parts.
CONSUMABLE PARTS LIST

CONSUMABLE PARTS LIST:PC220-0000-20NK00A
The parts in parentheses are to be replaced at the same time.

Replacement
Item Part No. Part Name Q'ty
interval
Engine oil filter 6736-51-5142 Cartridge 1 Every 500 hours
Fuel pre-filter 600-319-3610 Cartridge 1 Every 500 hours
Hydraulic tank breather 20Y-60-21470 Element 1 Every 500 hours
207-60-71182 Element 1 Every 1000
Hydraulic oil filter
(07000-15195) (O-ring) (1) hours
Every 1000
Main fuel filter 600-319-3750 Cartridge 1
hours
Every 2000
KCCV filter 600-331-2900 Element 1
hours
Air conditioner RECIRC air
2A5-979-1551 Filter 1 Every one year
filter
Air conditioner FRESH air filter 17M-911-3530 Element 1 Every one year
Air cleaner 600-185-3100 Element assembly 1 –
Additional filter for breaker 20Y-62-K5890 Element 1
–
(if equipped) (20Y-62-K8690) (O-ring kit) (1)
Electric heater 6754-11-4120 Gasket 2 –
Vertical pin type
205-70-74272 Tooth 5
(205-70-74281) (Pin) (5)
(205-70-74291) (Lock) (5)
Horizontal pin type
Bucket 205-70-19570 Tooth 5 –
(09244-02496) (Pin) (5)
205-70-74180 Side cutter (left) 1
205-70-74190 Side cutter (right) 1
(176-32-11210) (Bolt) (8)
(01803-02430) (Nut) (8)
20Y-934-2150 Side shroud 2
Side shroud (209-32-11234) (Bolt) (6) –
(195-32-11222) (Bolt) (6)
Pilot filter 20Y-62-51691 Element 1
–
(if equipped) (706-76-71390) (O-ring) (1)
7–3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS
RECOMMENDED FUEL, COOLANT, AND LUBRICANT

RECOMMENDED FUEL, COOLANT, AND LUBRICANT:D65-RA1B-05AK00A
NOTICE
q Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu
construction equipment and components.
In order to keep your machine in the best condition for long period of time, it is essential to follow the
instructions in this Operation and Maintenance Manual.
q Failure to follow these recommendations may result in shortened life or excessive wear of the engine,
power train, cooling system, and/or other components.
q Commercially available lubricant additives may be good or bad for the machine. Komatsu does not
recommend any commercially available lubricant additive.
q Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu
genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the
engine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening
of the machine life, lowering of performance and increase of fuel consumption.
q Use the oil according to the ambient temperature as recommended in the chart below.
q If the machine is operated at a temperature below -20°C, a separate device is needed, so consult your
NOTICE
The fuel used must be ultra low-sulfur diesel oil (≤10ppm).
To ensure good fuel consumption characteristics and
exhaust gas characteristics, the engine mounted on this
machine uses an electronically controlled high-pressure
fuel injection device and emission gas control system
(KDPF). Since the high-pressure fuel injection device
requires high precision parts and lubrication, if low
viscosity fuel with low lubricating ability is used, its
durability may drop remarkably. Using fuel with high sulfur
content can deteriorate the engine parts and KDPF
catalyzer, inducing failures, decrease of the life and
degradation in performance.
7–4
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
LUBRICATION CHART
LUBRICATION CHART:PC220_KU-2131-930A00A
q The lubrication standard chart uses symbols to show the lubrication points and types of lubricant by each
lubrication interval.
Keep this standard chart in the magazine box inside the cab so that the people concerned can reference it any
time needed during lubrication.
q Even if the same symbol is used in the lubrication standard chart, the recommended genuine oil may differ
according to the location and the ambient temperature. For details, see "FUEL, COOLANT, AND
LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE (PAGE 7-7)".
q For details of lubrication, see "Maintenance schedule (PAGE 4-9)".
q The symbols used in the lubrication standard chart are explained as follows.
7–5
Symbols used in the lubrication standard chart

Symbol Meaning of symbol Symbol Meaning of symbol
Read Operation and Maintenance Manual Supply grease
Change engine oil Check engine oil level
Change hydraulic oil Check hydraulic oil level
Change power train oil Check power train oil level
Replace engine oil filter Replace hydraulic oil filter
Replace hydraulic tank breather element Replace fuel filter
Replace KCCV filter
7–6
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT

TEMPERATURE
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE:PC220-RA1B-05AK03A
Ambient tempera-
Reservoir Fluid type ture, degrees Celsius Recommended Komatsu Fluids
Min Max
Engine oil for KDPF Komatsu EOS5W30-LA
-25°C 35°C
used in cold terrain (KES Diesel Engine Oil) (Note.1)
(Oil Change interval Komatsu EOS5W40-LA
250 hours) -25°C 40°C
(KES Diesel Engine Oil) (Note.1)
Engine oil pan
Komatsu EO10W30-LA
Engine oil for KDPF -20°C 40°C
(KES Diesel Engine Oil)
(Oil Change interval
500 hours) Komatsu EO15W40-LA
-15°C 50°C
(KES Diesel Engine Oil)
Swing machinery case
TO30
Final drive case Power train oil -30°C 50°C
(KES) (Note.2)
Damper case
TO10
Power train oil -20°C 50°C
(KES) (Note.5)
Hydraulic system HO56-HE
-30°C 50°C
(KES)
Hydraulic oil
HO46-HM
-20°C 50°C
(KES) (Note.5)
G2-TE
Hyper grease -20°C 50°C
(KES) (Note.3)
Grease fitting
G2-LI
Lithium EP grease -20°C 50°C
(KES)
Non-Amine Engine
AF-NAC
Cooling system Coolant -30°C 50°C
(KES) (Note.4)
(AF-NAC)
-30°C 20°C
Fuel tank Diesel fuel EN 590
-10°C 50°C
q ASTM: American Society of Testing and Material
Swing Final drive

Engine oil Damper Hydraulic Cooling
machinery case Fuel tank
pan case system system
case (each)
Specified
Litre 25.4 7.1 5.4 0.65 234 30.7 400
capacity
Refill
Litre 23.1 6.5 5.0 0.65 132 30.7 -
capacity
REMARK
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity means
the amount of oil needed to refill the system during inspection and maintenance.
Note 1: KDPF engine oil for cold district is deteriorated easily than that for normal area (replace every 500 hours),
so replace oil and filter cartridge every 250 hours. For changing maintenance interval of machine monitor, ask
Komatsu distributor to carry out.
Note 2: Powertrain oil has different properties from engine oil.
Be sure to use the recommended oils.
Note 3: Hyper grease (G2-TE) has a high performance.
7–7
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.
Note 4: Non-Amine Engine Coolant (AF-NAC)
1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of coolant is essential.
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or
4000 hours.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2) For details of the Non-Amine Engine Coolant (AF-NAC) density, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-17)".
Non-Amine Engine Coolant (AF-NAC) is supplied in diluted state, so always fill up with diluted coolant. (Never
dilute the Non-Amine Engine Coolant (AF-NAC) with ordinary water.)
Note 5: If this oil is used for hydraulic system, fuel consumption increases.
We strongly recommend HO56-HE for hydraulic oil.
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN

KOMATSU GENUINE OIL
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL:PC-RA1B-05AK01A
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
7–8
INDEX
8–1
INDEX
INDEX
A E
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY EMERGENCY ESCAPE HAMMER 3-93
STRUCTURES 2-23 END OF SERVICE LIFE 2-43, 4-81
AFTER COLD WEATHER SEASON 3-226 EPA REGULATIONS, ENGINE NUMBER PLATE 1-8
AFTER DAILY WORK COMPLETION 3-226 ESCAPE FROM MUD 3-197
AFTER DAILY WORK COMPLETION 3-206 EVERY 100 HOURS MAINTENANCE 4-40
AFTER STORAGE 3-228 EVERY 1000 HOURS MAINTENANCE 4-59
ALWAYS USE CLEAN WASHER FLUID 4-2 EVERY 2000 HOURS MAINTENANCE 4-65
ASHTRAY 3-103 EVERY 250 HOURS MAINTENANCE 4-41
ATTACHMENT COMBINATIONS 6-33 EVERY 4000 HOURS MAINTENANCE 4-74
ATTACHMENT OPERATIONS 6-28 EVERY 4500 HOURS MAINTENANCE 4-78
ATTACHMENTS AND OPTIONS 6-33 EVERY 500 HOURS MAINTENANCE 4-45
AUTOMATIC GREASE SYSTEM 6-7 EVERY 5000 HOURS MAINTENANCE 4-79
AUXILIARY ELECTRIC POWER 3-121 EVERY 8000 HOURS MAINTENANCE 4-80
AVOID MIXING OIL 4-3 EXPLANATION OF COMPONENTS 6-14
EXPLANATION OF COMPONENTS 3-9
B EXPLANATION OF LIFTING CAPACITY CHART 5-4
BATTERY DISCONNECT SWITCH 3-127
BEFORE STORAGE 3-227 F
BLEEDING AIR FROM HYDRAULIC CIRCUIT 4-3 FIRE EXTINGUISHER 3-126
BUCKET TEETH SELECTION 6-35 FIRE PREVENTION 2-18
BUCKET WITH HOOK 6-13 FOREWORD 1-2
FRESH AND CLEAN LUBRICANTS 4-2
C FUEL AND LUBRICANTS TO MATCH THE AMBIENT
CAB DOOR HINGE 3-94 TEMPERATURE 4-3
CAPS AND COVERS WITH LOCK 3-99 FUEL STRAINER 4-2
CEILING WINDOW 3-87 FUEL, COOLANT, AND LUBRICANTS TO MATCH
CHECK AUTO-GREASING SYSTEM 6-10 THE AMBIENT TEMPERATURE 7-7
CHECK DRAINED OIL AND USED FILTER 4-2 FUSE 3-122
CHECKS AFTER INSPECTION AND FUSIBLE LINK 3-124
MAINTENANCE 4-3
CHECKS AND ADJUSTMENT BEFORE STARTING G
ENGINE 3-141 GENERAL PRECAUTIONS COMMON TO
CHECKS BEFORE STARTING 4-39 OPERATION AND MAINTENANCE 2-15
CLOSE ENGINE HOOD SECURELY 4-3 GENERAL PRECAUTIONS FOR SAFETY 6-2
COLD WEATHER OPERATION 3-225 GENERAL VIEW 3-2
COLD WEATHER OPERATION GENERAL VIEW OF CAB 3-4
INFORMATION 3-225 GENERAL VIEW OF CONTROLS AND GAUGES 3-6
CONSUMABLE PARTS 7-3 GENERAL VIEW OF MACHINE 3-2
CONSUMABLE PARTS LIST 7-3 GREASE PUMP HOLDER 3-126
CONTROL LEVERS AND PEDALS 3-85
CUP HOLDER 3-102 H
HANDLING AIR CONDITIONER 3-104
D HANDLING CLAMSHELL BUCKET 6-41
DECLARATION OF CONFORMITY 1-11 HANDLING ELECTRICAL COMPONENTS 4-7
DISCHARGED BATTERY 3-232 HANDLING EXTENSION ARM 6-40
DO NOT DROP THINGS INSIDE MACHINE 4-2 HANDLING KCCV 3-138
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-22 HANDLING KDPF 3-129
DOOR LOCK 3-94 HANDLING MACHINES EQUIPPED WITH
DRINK BOX 3-102 KOMTRAX 3-139
DURING STORAGE 3-227 HANDLING OF RUBBER PAD SHOE AND ROAD
DUSTY WORKSITES 4-3 LINER 6-36
HANDLING OIL, FUEL, COOLANT, AND
PERFORMING OIL CLINIC 4-4
HANDLING QUICK COUPLER 6-4
8–2
INDEX
HANDLING RADIO 3-116 PRECAUTIONS BEFORE STARTING INSPECTION

HANDLING TRAPEZOIDAL BUCKET 6-38 AND MAINTENANCE 2-43
HOOK CONDITION 6-13 PRECAUTIONS BEFORE STARTING
HYDRAULIC BREAKER 6-42 OPERATION 2-15
HYDRAULIC CIRCUIT 6-18 PRECAUTIONS FOR INSPECTION AND
MAINTENANCE 2-47
I PRECAUTIONS FOR JOBSITE 2-25
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER PRECAUTIONS FOR MAINTENANCE 2-43
THE FIRST 250 HOURS) 4-12 PRECAUTIONS FOR OPERATION 2-25
PRECAUTIONS RELATED TO ATTACHMENTS AND
OPTIONS 2-24
K PRECAUTIONS RELATED TO CAB GLASS 2-24
KOMATSU GENUINE LUBRICANTS 4-2 PRECAUTIONS RELATED TO PROTECTIVE
KOMATSU GENUINE REPLACEMENT PARTS 4-2 STRUCTURES 2-22
PRECAUTIONS WHEN GETTING ON OR OFF
L MACHINE 2-20
LIFTING MACHINE 3-223 PRECAUTIONS WHEN INSTALLING HYDRAULIC
LIFTING OBJECTS WITH BUCKET LINK LIFTING HOSES 4-3
DEVICE 2-40 PRECAUTIONS WHEN REMOVING OR
LIFTING OBJECTS WITH BUCKETS 2-42 INSTALLING 6-2
LIGHTWEIGHT TOWING HOLE 3-231 PRECAUTIONS WHEN RUNNING ENGINE INSIDE
LOADING AND UNLOADING WITH TRAILER 3-208 BUILDING 2-24
LOCATIONS OF SAFETY LABELS 2-5 PRECAUTIONS WHEN SELECTING 6-2
LOCKING 3-206 PRECAUTIONS WHEN USING 6-3
LOCKING INSPECTION COVERS 4-3 PREPARATIONS FOR SAFE OPERATION 2-16
LONG-TERM STORAGE 3-227, 6-31 PRODUCT IDENTIFICATION NUMBER
LUBRICATION CHART 7-5 (PIN)／MACHINE SERIAL NO. PLATE 1-8
PRODUCT INFORMATION 1-8
M PROHIBITED OPERATIONS 6-13
MACHINE MONITOR 3-9 PROHIBITED OPERATIONS 3-190
MACHINE OPERATION 3-178 PROTECTION AGAINST FALLING, FLYING, OR
MACHINE OPERATIONS AND CONTROLS 3-141 INTRUDING OBJECTS 2-23
MACHINE READY FOR INSTALLATION OF
ATTACHMENT 6-14 R
MAGAZINE BOX 3-102 READ THE OPERATION AND MAINTENANCE
MAINTENANCE INTERVAL FOR HYDRAULIC MANUAL THOROUGHLY 6-2
BREAKER 4-11 RECOMMENDED APPLICATIONS 3-198
MAINTENANCE PROCEDURE 4-12 RECOMMENDED ATTACHMENT
MAINTENANCE PROCEDURE 4-12 OPERATIONS 6-42
MAINTENANCE SCHEDULE 4-9 RECOMMENDED BRANDS AND QUALITY FOR
MAINTENANCE SCHEDULE TABLE 4-9 PRODUCTS OTHER THAN KOMATSU GENUINE
OIL 7-8
N RECOMMENDED FUEL, COOLANT, AND
NOISE LEVELS 1-5 LUBRICANT 7-4
REMOVAL AND INSTALLATION OF
ATTACHMENT 6-25
O REPLACING AND INVERTING BUCKET 3-200
OPENING AND CLOSING CAB FRONT RULES FOR MAINTENANCE 4-2
WINDOW 3-88 RULES FOR OPERATION 3-193
OPENING AND CLOSING ENGINE HOOD 3-95 RUNNING OUT OF FUEL 3-229
OPERATIONS AND CHECKS AFTER STARTING
ENGINE 3-166
OTHER TROUBLE 3-236 S
OUTLINE OF SERVICE 4-4 SAFETY 2-2
SAFETY CRITICAL PARTS 7-2
SAFETY CRITICAL PARTS LIST 7-2
P SAFETY INFORMATION 1-3
PHENOMENA THAT ARE NOT FAILURES 3-229 SAFETY LABELS 1-4, 2-4, 2-6
8–3
INDEX
SAFETY MACHINE OPERATION 2-28

SAFETY RULES FOR LIFTING OBJECTS 2-42
SERVICE METER LOCATION 1-9
SERVICE METER READING 4-2
SEVERE JOB CONDITION 3-231
SPACE FOR RADIO CASSETTE 3-120
SPECIFICATIONS 5-2, 6-32
STANDARD TIGHTENING TORQUE FOR BOLTS
AND NUTS 4-8
STARTING ENGINE 3-163
STARTING ENGINE 2-28
STARTING MACHINE AFTER LONG-TERM
STORAGE 3-228
STEERING MACHINE 3-182
STOPPING ENGINE 3-177
SWINGING MACHINE 3-184
SWITCHES 3-76
SYSTEM OPERATING LAMP 3-128
T
TIGHTENING TORQUE LIST 4-8
TOOL BOX 3-125
TOWING 2-39
TOWING MACHINE 3-230
TRACK SHOES SELECTION 6-34
TRANSPORTATION 2-38, 3-207
TRANSPORTATION PROCEDURE 3-207
TRAVELLING ON SLOPES 3-195
TROUBLES AND ACTIONS 3-229
U
UNAUTHORIZED MODIFICATION 2-23
V
VIBRATION LEVELS 1-6
W
WELDING INSTRUCTIONS 4-2
WHEN OPERATING 2-31
WHEN PARKING MACHINE 3-204
WHEN REQUIRED 4-12
WORK EQUIPMENT CONTROLS AND
OPERATIONS 3-185
WORKING MODE 3-187
Y
YOUR MACHINE SERIAL NUMBERS AND
DISTRIBUTOR 1-9
8–4
COLOPHON
18
COLOPHON
PC210_LC-10 HYDRAULIC EXCAVATOR

Form No. UENAM00902
© 2013 KOMATSU
All Rights Reserved
Printed in Belgium 13-07
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Operation & UENAM00902

Read this manual thoroughly and understand its contents fully.

Storage location for the Operation and Maintenance Manual:

Example of safety message using signal word

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

NOISE (PC210-10, PC210LC-10)

q Sound power level emitted by the machine, measured

(A) Front (D) Right

OPERATOR PROTECTIVE STRUCTURE

VISIBILITY FOR OPERATOR

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

On the bottom right of the operator's cab

EPA REGULATIONS, ENGINE NUMBER PLATE

On the top of the engine cylinder head cover.

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.

A MACHINE DESIGNATION TYPE E ENGINE POWER

Declares that this machine:

Fulfils all the relevant provisions of the following EC Directives.

DOOR LOCK ........................................................................................................................... 3-94

TOWING MACHINE .............................................................................................................. 3-230

CHECK AUTO-GREASING SYSTEM ..................................................................................... 6-10

WHEN OPERATING ON SLOPES ............................................................................................. 2-34

LOCATION OF SAFETY LABELS

q a. Read the manual before operating, maintenance, disas-

q b. Before standing up from operator’s seat.

q Lower work equipment to ground and move safety lock

q Sudden and unwanted machine movement can cause seri-

q d. WARNING — DANGER OF FALLING OBJECTS

q e. Caution for going close to electric cables.

q An electrocution hazard if the machine is brought too near

q Keep a safe distance from electric power lines.

q f. Control levers operational function diagram.

q g. Caution when standing in operator cab

q Before standing up from the operator’s seat (such as when

q (h) Caution when reversing

To prevent SEVERE INJURY or DEATH, do the following

Follow the above even if machine is equipped with travel alarm,

(2) Caution when stowing front window (09803-A0481)

q Sign indicates a hazard from falling window.

q After raising window, be sure to lock it in place with lock

(3) Caution for high-temperature coolant and hydraulic oil

q Never remove the cap when the engine is at operating

q Never remove the radiator cap or hydraulic tank oil filler

(4) Caution for handling accumulator and gas spring

q There is a hazard of explosion causing injury.

q Do not disassemble the accumulator, make holes in it, weld

(5) Caution when adjusting track tension (09657-A0881)

q Sign indicates a hazard of flying plug from track adjuster

(6) Caution when handling cable (09808-A0881)

q Sign indicates an electric hazard from handling the cable.

(7) Stopping rotation for inspection and maintenance (09667-

q Sign indicates a hazard of rotating parts, such as belt.

(8) Emergency escape (09844-00050)

(9) Caution against falling (09805-C0481)

q Sign indicates a hazard of falling.

q Do not stand on this place here

(10) Prohibited to enter swing radius (09133-A3281)

q There is a danger of getting caught when upper structure