Komatsu HB215LC-3 Page 430 Operation & Maintenance Manual Download

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EVERY 8000 HOURS MAINTENANCE

Maintenance for every 100, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same
time.

METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP

Ask your Komatsu distributor for replacement of the fuel spray prevention caps.

EVERY 9000 HOURS MAINTENANCE

Maintenance for every 100, 250, 500, 1000 and 4500 hours service should be performed at the same time.

METHOD FOR REPLACING DEF HOSE

Ask your Komatsu distributor for replacement of the DEF hose.

END OF SERVICE LIFE

• For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor.

MAINTENANCE PROCEDURE

MAINTENANCE

4-86

Summary of Contents for HB215LC-3

Page 1: ...y cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and perio...

Page 2: ......

Page 3: ...uine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these re...

Page 4: ...able contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For details regarding the machine model name an...

Page 5: ...ng the processing of your personal data i e storage collection transfer etc of all information that relates to you as operator to the party with whom you have most direct relationship In principle thi...

Page 6: ...tion 4 above For the purposes a to l as indicated in section 4 above as well as for the purpose of informing a third party in the context of a possible merger acquisition or demerger the processing of...

Page 7: ...t data b the processing is illegitimate or c the data are no longer needed for the pur poses which are outlined above but you need them to defend yourself in judicial proceedings You have the right to...

Page 8: ...safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation wh...

Page 9: ...he standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5 dB in accordance with ISO 11201 Sound power level emitted by the machine...

Page 10: ...Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and traveling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager shoul...

Page 11: ...Do not jump down from the cab or machine Do not repeatedly handle and lift loads FOREWORD VIBRATION LEVEL 1 9...

Page 12: ...D APPLICATIONS DIRECTIONS OF MACHINE A Front B Rear C Left D Right E Operator s seat F Sprocket In this manual the terms front rear left and right refer to the travel direction as seen from the operat...

Page 13: ...boom arm will affect the operator s field of vision This will be strongly influenced by the type and dimension of any attachment that may be installed Pay attention to this and ensure that the working...

Page 14: ...also has component such as cooling system which becomes high temperature when the machine is operated 1 Engine 2 Motor generator 1 3 Hydraulic pump 4 High voltage electric wiring Orange 1 5 Capacitor...

Page 15: ...en the nitrogen oxides and ammonia generated from the urea solution and decompo ses the nitrogen oxides into nitrogen and water DEF is the abbreviation for Diesel Exhaust Fluid and is represented as D...

Page 16: ...owing items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is located on the right bottom of the operator s cab The design of the nameplate differs according to the district...

Page 17: ...ne monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU UK Ltd Durham Road Birtley Chester le Str...

Page 18: ...SERIAL PLATE KS000853 A B D F G C E A MACHINE DESIGNATION TYPE E ENGINE POWER B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER C YEAR OF CONSTRUCTION G MANUFACTURER D WEIGHT SERIAL PLATE FOREWORD 1 16...

Page 19: ...y Durham DH3 2QX Declares that this machine HB215LC 3 Machine Directive 2006 42 EC Electro Magnetic Compatibility Directive 2014 30 EU Low Voltage Directive 2014 35 EU Outdoor Noise Directive 2000 14...

Page 20: ...PREPARATIONS FOR SAFE OPERATION 2 16 PRECAUTIONS TO PREVENT FIRE 2 17 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 19 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 21 PRECAUTIONS RELATED TO PROTECTIVE STRUCTU...

Page 21: ...OF HYDRAULIC EXCAVATOR 3 201 METHOD FOR REPLACING AND INVERTING BUCKET 3 202 METHOD FOR PARKING MACHINE 3 205 METHOD FOR CHECKING AFTER FINISHING WORK 3 207 LOCK 3 207 HANDLE AIR CONDITIONER 3 217 EX...

Page 22: ...UEL COOLANT AND PERFORMING OIL CLINIC 4 4 HANDLE ELECTRICAL COMPONENTS 4 8 HANDLING HYBRID COMPONENTS AND HIGH VOLTAGE WIRING 4 8 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4 10 MAINTENANCE SCHEDUL...

Page 23: ...ERATING ATTACHMENT 6 21 LONG TERM STORAGE 6 26 MAINTENANCE OF ADDITIONAL FILTER FOR BREAKER 6 27 SPECIFICATIONS 6 30 ATTACHMENTS AND OPTIONS 6 32 INSTALL ATTACHMENT 6 32 TRACK SHOES SELECTION 6 32 BUC...

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Page 25: ...se read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions s...

Page 26: ...ly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new...

Page 27: ...LOCATION OF SAFETY LABELS SAFETY SAFETY LABELS 2 3...

Page 28: ...aution for handling accumulator and gas spring 5 Caution for adjusting track tension 6 Caution for handling cable 7 Stop rotation during inspection and maintenance 8 Emergency escape 9 Caution against...

Page 29: ...on and mainte nance Follow instructions and warnings in manual and in labels on machine Detailed explanations of the content of each label are as fol lows a Caution for operation inspection and mainte...

Page 30: ...ocated near seat to lock position to avoid hit ting unlocked operation levers Sudden and unwanted machine movement can cause seri ous injury or death d Caution for electric cables An electrocution haz...

Page 31: ...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 sudden ly move and cause serious injury or property...

Page 32: ...se personal injury and or burns Never remove the radiator cap or hydraulic tank oil filler when cooling water or hydraulic oil is at high temperatures Caution for handling accumulator and gas spring 0...

Page 33: ...rotation during inspection and mainte nance 09667 A0481 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance Emergency escape 09844 00050 This is an emerg...

Page 34: ...A0881 Before moving or operating the machine 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 Prohibition of e...

Page 35: ...machine Keep away from machine during operation Caution for handling battery 09664 60001 a Never smoke or use any naked flame near the batteries no sparks b Always wear protective eyeglasses when work...

Page 36: ...e 09845 00480 Sign indicates an explosion hazard caused by active radio transmitter at a blast site Keep machine at a safe distance from a blast site and det onator Caution for operating hydraulic qui...

Page 37: ...Distributor before altering ROPS or FOPS may provide less protection if it has been structurally damaged or involved roll over Consult Komatsu Distributor in that case Alway wear seat belt when moving...

Page 38: ...disassembly of stepping on high pressure washing of hybrid components 205 00 31281 This is danger of electrocution if the hybrid equipment or high voltage wiring is disassembled There is also danger...

Page 39: ...ge or wear of the seat belt damage of the connecting brackets and tightness of bolts Adjust seat position to allow full brake pedal travel with op erator s back against seat back After adjusting seat...

Page 40: ...in charge of safety for explanation PREPARATIONS FOR SAFE OPERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards and covers are in their proper position Repair them immediately if...

Page 41: ...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 serious p...

Page 42: ...n washing parts with oil use a non flammable oil Do not use diesel fuel or gasoline There is danger that they may catch fire Do not weld or use a cutting torch to cut any pipes or tubes that contain c...

Page 43: ...se lighting with anti explosion specifica tions PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falli...

Page 44: ...et it to LOCK position L and stop the engine If the control levers are touched by mistake there is danger that the machine may suddenly move and cause serious per sonal injury or death PRECAUTIONS WHE...

Page 45: ...mass exceeds the certified value shown on ROLL OVER PROTECTIVE STRUCTURE ROPS CERTIFICATION plate ROPS will not be able to fulfill its function Do not increase ma chine weight beyond the certified va...

Page 46: ...to the operator from falling objects flying objects and intruding objects as detailed in the previous section Operator cabin FOPS falling object protective structure Front window guard In the event an...

Page 47: ...s is broken during operations stop operations and repair the cab glass immediately If the cab glass on the work equipment side is broken there is a hazard that the operator may be directly hit or caug...

Page 48: ...PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse...

Page 49: ...e signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up additional lighting in the work area if necessary Stop operations...

Page 50: ...s work to ensure that there is no problem with the operation of the machine If these checks are not performed properly problems may occur with the operation of the machine and there is a danger which...

Page 51: ...sure the warming up operation is completed 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...

Page 52: ...heck for any problem in the sound vibration heat and smell of the machine or abnormalities of instruments Also check that there is no leakage of oil or fuel If any problem is found repair it immediate...

Page 53: ...stuck in the ground and the machine may tip over If the view to the right side is poor raise the boom to en sure better visibility Always turn the auto deceleration switch OFF cancel when driving the...

Page 54: ...y to help stop the ma chine When driving the machine up slopes set the operator s cab facing uphill when driving downhill set the operator s cab facing downhill Always be sure of the safety of the gro...

Page 55: ...fully Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded This opera tion is dangerous and may cause the machine to turn over If the machine has to be u...

Page 56: ...etract the boom cylinder It is dangerous that the machine may tip over by the impact In the operation using the fork or grapple do not attempt to pick up an object with the tips The picked up object c...

Page 57: ...ed on a trailer serious personal injury or death may result because of the acci dent during transportation Always observe the following Always check the machine dimensions carefully Depending on the w...

Page 58: ...and there is danger of the machine losing its balance Drive slowly over this point When loading or unloading to an embankment or platform make sure that it has suitable width strength and grade When s...

Page 59: ...als to be used and place a signalman in position Prohibit anyone to enter into place where there is danger of contact with a lifted load or the danger from a falling load It is dangerous if a lifted l...

Page 60: ...enable you to perform 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 When cleaning the ceiling window whi...

Page 61: ...fol lowing Lower the work equipment to the ground and stop the en gine before performing any inspection and maintenance Turn the starting switch to ON position Operate the work equipment control lever...

Page 62: ...And take steps to prevent unauthorized persons from entering the storage area PRECAUTIONS FOR WORKING AT HIGH PLACES When working at high places use a step ladder or other stand to ensure that the wor...

Page 63: ...the work equipment and machine are not supported they may come down and it may cause serious per sonal injury or death Never use concrete blocks for supports Concrete blocks may break under even ligh...

Page 64: ...lphuric acid Any mistake in handling may cause serious personal injury explosion or fire Always ob serve the following When handling the battery always wear protective eye glasses and rubber gloves If...

Page 65: ...cap or plug slowly to release the internal pressure and remove the cap or plug PRECAUTIONS FOR HIGH TEMPERATURE PARTS To prevent burns from touching high temperature parts when checking or performing...

Page 66: ...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 consult your Komatsu distributor Rep...

Page 67: ...ful 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 If it is necessary to disassemble it ask you...

Page 68: ...R DISPOSING OF WASTE MATERIALS and MAINTENANCE OF AIR CONDI TIONER PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution pay full attention to the way to dispose of waste materials Always...

Page 69: ...l 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 specif...

Page 70: ...n tainer for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with anoth...

Page 71: ...pection and repair If it gets into water during operation stop the engine immediately and get out from the machine If any abnormality is detected in the hybrid system the swing operation becomes slowe...

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Page 73: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1...

Page 74: ...GENERAL VIEW MACHINE EQUIPMENT NAME 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Boom cylinder 7 Sprocket 8 Track frame 9 Track 10 Idler GENERAL VIEW OPERATION 3 2...

Page 75: ...hereafter KCCV ventilator 13 Engine hood 14 Battery 15 Battery disconnect switch 16 System operating lamp 17 Fusible link 18 Toolbox 19 Grease pump holder 20 DEF tank 21 DEF hose 22 DEF pump 23 DEF in...

Page 76: ...2 Ceiling window 3 Door lock release lever 4 Drink box 5 Fuse 6 Auxiliary electric power if equipped 7 Fire extinguisher if equipped 8 Emergency escape hammer 9 Magazine box 10 Cup holder 11 AUX 12 A...

Page 77: ...switch if equipped 16 Attachment control pedal if equipped 17 Attachment control pedal if equipped 18 Cigarette lighter 19 Room lamp switch 20 Seat heater switch 21 Engine shutdown secondary switch 22...

Page 78: ...l consumption gauge 10 Service meter 11 Working mode display 12 Travel speed display 13 Camera switch display 14 Clock 15 DEF level gauge 16 DEF level caution lamp 17 Fuel gauge 18 Fuel level caution...

Page 79: ...zing pilot lamp 40 Auto deceleration pilot lamp 41 Hybrid caution lamp 42 Hybrid temperature caution lamp 43 Function switches F1 to F6 44 Maintenance time caution lamp REMARK The above figure does no...

Page 80: ...OR EQUIPMENT AA Standard screen EE Warning or Error screen DD Guidance screen 1 Warning display 2 Pilot display 3 Meter display 4 Monitor switch part 5 Guidance icon display 6 Camera image display REM...

Page 81: ...splay screen HH is displayed for 2 seconds the screen changes to standard screen AA If the working mode when the engine is started is the B mode the starting screen GG is displayed for 2 seconds and t...

Page 82: ...ayed and engine does not start If engine shutdown secondary switch 1 is turned OFF nor mal the machine monitor switches to the standard screen and the engine can be started with usual starting switch...

Page 83: ...the starting screen GG switches to ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting ID number for operator identification function without SKIP is se...

Page 84: ...ed to ON position If the incorrect ID number is inputted for 3 times in a row you cannot input the ID number in the next 5 minutes Wait for more than 5 minutes and try inputting the ID number again As...

Page 85: ...ing screen BB for 2 seconds the screen changes to the maintenance time warning screen CC After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the stand ard scre...

Page 86: ...yed BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any abnormality occurs during operation the standard screen AA changes to the warning screen FF 1 or the error scr...

Page 87: ...TRAVEL AND ATTACHMENT Machine monitor screen automatically changes to the screen which displays the bird s eye view display of Kom Vision when operating work equipment swing travel and attachment AA...

Page 88: ...uipment swing travel and attachment To change the screen to the camera image screen CC and the no camera image screen DD finish the op eration of work equipment swing travel and attachment WARNING DIS...

Page 89: ...el is displayed the list of the Current Abnormality is dis played Take appropriate actions by following the message displayed on the machine monitor List of action level displays and required actions...

Page 90: ...ng Caution lamps and display colors Symbol Type of caution lamp Display color Machine condition Action level Red Yellow White Blue Engine coolant temperature caution lamp High temperature L02 Low temp...

Page 91: ...ped at high tempera ture L01 Engine system caution lamp Abnormal L04 L03 Abnormal L01 Auto idle stop sudden stop caution lamp Excessive fre quency L03 Excessive fre quency L01 Fan control system cauti...

Page 92: ...caution lamp When starting switch is in ON position Overload caution lamp Overloaded Quick coupler caution lamp Abnormal L03 Maintenance time caution lamp Due time is over Notice Seat belt caution la...

Page 93: ...ons according to the message displayed on the monitor Operation on the Current Abnormality screen On the Current Abnormality screen you can perform the follow ing operations with the switches F1 F2 an...

Page 94: ...normal display color blue at an proper temperature When temperature is correct The caution lamp lights up in blue HYDRAULIC OIL TEMPERATURE CAUTION LAMP The hydraulic oil temperature caution lamp war...

Page 95: ...When abnormal The caution lamp lights up in red and the action level L02 is displayed The temperature of hybrid devices becomes abnormally high Stop the operations and stop the engine or run it at lo...

Page 96: ...in red and the action level L04 or L03 is displayed If the engine power is under deration the hybrid system output is limited as well and the hybrid system is stopped For details see DEF LEVEL CAUTION...

Page 97: ...rate When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for inspection and maintenance as needed AFTERTREATMENT DEVICE SYSTEM CAUTION LAMP This wa...

Page 98: ...er deration This results in low swing motor power With No Action level display DEF tank level is lower Inducement status is Continuous Warning Need to add DEF immediately to avoid advancing to the nex...

Page 99: ...or inspection and maintenance When action level L03 appears on screen The caution lamp comes on in red and the alarm buzzer oper ates intermittently Move the machine to a safe area and stop the machin...

Page 100: ...AMP Engine oil pressure caution lamp warns about abnormality of engine lubricating oil pressure When oil pressure is low The caution lamp lights up in red and indicates action level L03 The alarm buzz...

Page 101: ...tails see METHOD FOR CHECKING COOLANT LEV EL ADDING COOLANT When the coolant level is low The caution lamp lights up in yellow and the action level L01 is displayed The radiator coolant is insufficien...

Page 102: ...evel L01 The air cleaner is clogged Stop the engine and check and clean the air cleaner For detail see METHOD FOR CHECKING CLEANING AND REPLACING AIR CLEANER AIR CONDITIONER SYSTEM CAUTION LAMP Air co...

Page 103: ...p in red Return the hybrid system stop switch to OFF position For details of the hybrid system stop switch see HYBRID SYSTEM STOP SWITCH MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp dis...

Page 104: ...MERA SYSTEM CAUTION LAMP Camera system caution lamp warns about the signal trouble caused by such as breakage in cables loose and disconnected connectors When the action level L03 is displayed The rea...

Page 105: ...01 is displayed If the caution lamp is lit the camera image is not displayed on the machine monitor Visually check the safety around the machine always when op erating the machine Ask your Komatsu dis...

Page 106: ...ating is for a maximum of approximately 30 seconds SWING LOCK PILOT LAMP Swing lock pilot lamp informs that the swing lock is being actu ated Lights up The swing lock is being actuated When the swing...

Page 107: ...king mode The pilot lamp displays as follows according to the operation of the working mode selector switch P P mode for heavy load operations E E mode for operations with emphasis on fuel consumption...

Page 108: ...d while the knob switch is being pressed Even if the knob switch continues to be pressed the power maximizing operation ends in 8 5 seconds AIR CONDITIONER PILOT LAMP The air conditioner pilot lamp sh...

Page 109: ...et in FREE position ECO GUIDANCE 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 guidan...

Page 110: ...l dial at High idle MAX posi tion the travel partial mode recommendation message is dis played When traveling for a long time the fuel consumption can be reduced by lowering the fuel control dial The...

Page 111: ...nt temperature gauge shows the engine coolant temperature If the indicator is in green range during operation it is normal If the indicator goes beyond red range A during operation the overheat preven...

Page 112: ...d range A position 102 C or more Red range B position 105 C or more When the indicator is in red range A to B hydraulic oil temperature caution lamp E indicates abnormality When the engine is started...

Page 113: ...inutes regardless of the engine speed Service meter display Clock display 12 hour display Clock display 24 hour display REMARK If the battery is disconnected for a long period for storage etc the time...

Page 114: ...mes close to A of red range during opera tion check and add DEF A to B Red range A to C Green range When the indicator is in red range from A to B DEF level caution lamp 1 lights up in red If DEF leve...

Page 115: ...red The overheat prevention system operates as follows Position in red range A to B Hybrid temperature caution lamp E indicates abnormality G the swing power de creases and the swing speed decreases P...

Page 116: ...icon 2 to operate the function When the machine monitor display shows the standard screen the types of guidance icons and functions of function switches are as follows For the details of each function...

Page 117: ...nd their functions not explained above see the pages where the control methods of re spective screens are explained WORKING MODE SELECTOR SWITCH Use the working mode selector switch 1 to set the movem...

Page 118: ...or to change the setting How to use the working mode selector switch 1 When the working mode selector switch 1 is pressed the Working Mode selector screen is displayed on the machine monitor 2 Press t...

Page 119: ...eration pilot lamp is not lit Auto deceleration OFF Each time the switch is pressed the auto deceleration is switched between ON and OFF REMARK When the hybrid system capacitor needs to be charged the...

Page 120: ...ine is traveling the machine may deviate to one side even when traveling in a straight line Stop the machine before switching the travel speed Travel speed selector switch is used to select the travel...

Page 121: ...dard screen WIPER SWITCH Wiper switch actuates the wiper at the front window glass Each time the switch is pressed it changes INT ON stop lamp goes out Wiper pilot lamp INT lights up Windshield wiper...

Page 122: ...he same time the windshield wiper is actuated continuously When releasing your hand from the switch the windshield wiper continues to operate for 2 cycles then stops If you keep pressing the switch wh...

Page 123: ...the warning AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches For explanation of each switch see HANDLE AIR CONDI TIONER FUNCTION SWITCHES The operation of the function switches...

Page 124: ...nto the machine are displayed on the left and right sides of the machine monitor respectively On the standard screen AA when the switch F3 is pressed the enlarged bird s eye view display BB is dis pla...

Page 125: ...and attachment On the start screen the camera image switch display flashes in the position shown in the figure The green range of the camera image switch display shows of which camera the image is di...

Page 126: ...screen In addition if no operation is performed for 5 seconds after the screen switches to the air conditioner operation screen the screen automatically returns to the camera im age screen It is poss...

Page 127: ...neither switches to another screen nor returns to the standard screen Depending on the warning alarm buzzer does not stop sounding by pressing the buzzer cancel switch Press the wiper switch and washe...

Page 128: ...If a caution lamp is displayed move the machine to set it in a safe posture then have inspection performed immedi ately USER MENU DISPLAY SWITCH On the standard screen press the switch F6 to display...

Page 129: ...ach menu see the detailed explanation pa ges of respective items a Energy Saving Guidance Check of Operation Records Check of ECO Guidance Records Check and reset of Average Fuel Consumption Record Co...

Page 130: ...ion Check of DEF level Urea SCR system information e Maintenance Check and resetting of various Maintenance Times f Monitor Setting Screen Adjustment Screen Adjustment Camera Clock Adjustment Language...

Page 131: ...o the previous item 1 line above When it is on the first line it moves to the last line F5 Returns the screen to the standard screen F6 Displays the setting screen for selected item If no switch is op...

Page 132: ...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 the screen to the Energy Saving...

Page 133: ...ing the last 12 hours or the graph of daily fuel consumption during the last 1 week Operation on the Average Fuel Consumption Record screen Press switch F1 F2 or F5 on the Average Fuel Consumption Rec...

Page 134: ...n during the last 1 week Switching be tween them is available Deleting the average fuel consumption records 1 When switch F1 CLEAR is pressed the reconfirmation screen shown in the figure is displayed...

Page 135: ...FF Operations on the Configurations screen Press switches F3 to F6 to perform the following operations on the Configurations screen F3 Moves to the next item 1 line below When on the last line it move...

Page 136: ...nsumption Display screen appears 1 Day Displays the average fuel consumption from 0 00 a m of the day to 0 00 a m of the next day Split Time Displays the average fuel consumption during the Split Time...

Page 137: ...ext item 1 line below When it is on the last line it moves to the first line F4 Moves to the previous item 1 line above When it is on the first line it moves to the last line F5 Cancels the setting ch...

Page 138: ...ura tions screen then press the switch F6 2 ECO Guidance Display setting screen appears ON Displays the ECO Guidance 10 on the standard screen OFF Does not display the ECO Guidance 10 on the standard...

Page 139: ...ible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line on the next page F4 Moves to the previous item 1...

Page 140: ...ode adjustment screen On the economy mode adjustment screen it is possible to per form the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it m...

Page 141: ...tes the selected setting to that of B mode Changing the Breaker Setting name You can change the breaker setting name as you like You can use alphabet letters A to Z Arabic numerals 0 to 9 symbols and...

Page 142: ...on of attachment you can adjust the oil flow rate in ATT P mode and ATT E mode according to the installed attachment with Attachment Setting menu For the machines that have no attachment Attachment Se...

Page 143: ...the next alphabet numeral or symbol F4 Moves to the previous alphabet numeral or symbol F5 Returns the screen to the attachment setting screen without changing the name F6 Enters the change and return...

Page 144: ...can perform the following operations with switches F1 to F6 F1 Switches the display from attachment 2 oil flow setting screen to attachment 1 oil flow setting screen F2 Switches the display from attac...

Page 145: ...E mode Changing Attachment Setting name You can change the name for the attachment setting to desired name You can use alphabet letters A to Z Arabic numerals 0 to 9 symbols and and the blank space 1...

Page 146: ...ting change and returns the screen to the Machine Setting screen F6 Changes the setting and returns the screen to the Machine Setting screen AUTO IDLE STOP TIMER SETTING The auto idle stop function st...

Page 147: ...ice menu 3 When the idling time reaches 30 seconds before the set time the machine monitor returns to the standard screen and changes to the countdown screen When you set the lock lever to FREE positi...

Page 148: ...1000th and as L03 from 2000th on the machine monitor AFTERTREATMENT DEVICES REGENERATION Each item of Aftertreatment Devices Regeneration menu c is to make settings for the aftertreatment devices reg...

Page 149: ...Case Oil Change 2000 DEF Filter Change 2000 KCCV Filter Change 2000 DEF Tank Washing 4500 Hydraulic Oil Change 5000 A Maintenance item B Default maintenance interval settings h C Time remaining to ma...

Page 150: ...ance Due Time Reset screen If you keep pressing the switch F6 for 1 5 seconds or longer on Maintenance menu screen the screen changes to Maintenance Due Time Reset screen Reset the remaining time to t...

Page 151: ...r screen night mode If the light switch is at day mode ON and the screen is adjusted it is possible to adjust the brightness of the monitor screen day mode As long as mark is displayed in the upper ri...

Page 152: ...hen press switch F6 The screen switches to the selection menu for the clock adjustment The following 5 items can be changed a GPS Synchronization b Calendar c Time d 12h 24h Mode e Daylight Saving Tim...

Page 153: ...switch F6 F3 Calendar goes back 1 year F4 Calendar advances 1 year F5 Cancels change and returns the screen to Clock Ad justment screen F6 Proceeds to setting for month 3 When month display B is highl...

Page 154: ...the screen to Clock Ad justment screen F6 Proceeds to setting for the minute 3 When minute display E is highlighted in yellow operate the switches as follows to change minute display E If it is not ne...

Page 155: ...top line when on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when on the top line F5 Cancels change and returns to Clock Adjustment screen F6 Accepts change an...

Page 156: ...and change the Operator ID which is under identification on the Operator ID menu The Operator ID menu is not displayed when the operator identification function is disabled REMARK Contact your Komatsu...

Page 157: ...the screen returns to the Monitor Setting menu screen On the Monitor Setting menu screen as the same way when the starting switch is ON and SKIP is se lected is displayed in the column of Operator ID...

Page 158: ...screen and press F6 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen When you press switch F6 after inputting the ID which i...

Page 159: ...mera position to be displayed on the right side on the machine monitor and press the switch F6 then the camera position o be displayed at key on is set The following operations are available with swit...

Page 160: ...rting switch is turned to OFF position when there is any unread message the message will be displayed on the end screen and when the monitor is started next time the message will change to a read mess...

Page 161: ...using the monitor switch Each switch corresponds to the value shown on the right side below the switch If you input an incorrect number press switch F5 and you can clear an input character at a time I...

Page 162: ...tch 12 Engine shutdown secondary switch 13 Pump secondary drive switch 14 Swing parking brake cancel switch 15 Lock lever automatic lock cancel switch 16 Hybrid system stop switch 17 Lower wiper switc...

Page 163: ...tion where the dial is turned fully to the left b High idle MAX The position where the dial is turned fully to the right CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes When the ci...

Page 164: ...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 is located on top of the R H work equipment con trol leve...

Page 165: ...pump control system Do not use it except for emergency Repair the problem as soon as possible If this switch is moved to Emergency position by mistake while the machine is operating normally L03 appea...

Page 166: ...m in the swing parking brake system when the upper structure does not swing but the display does not show L03 a Cancel When abnormal switch is set to upper position b Normal When normal switch is set...

Page 167: ...y by canceling this switch stop the engine return the switch to the normal position b and then ask your Komatsu dis tributor for repair HYBRID SYSTEM STOP SWITCH NOTICE The hybrid system stop switch i...

Page 168: ...ceiling window wiper stops ENGINE SHUTDOWN SECONDARY SWITCH NOTICE The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to OFF position but the engine do...

Page 169: ...osition b When the starting switch is turned to ON position while the engine shutdown secondary switch is in the engine stopped position a Engine Shutdown Sec ondary SW In Operation is displayed on th...

Page 170: ...witches to operate the quick coupler For details see ATTACHMENTS AND OPTIONS HANDLE QUICK COUPLER ATTACHMENT 1 PROPORTIONAL SWITCH The attachment 1 proportional switch is a roller proportional control...

Page 171: ...breaker For details see ATTACHMENTS AND OPTIONS BREAKER MODE SWITCH ADDITIONAL LAMP SWITCH if equipped The additional lamp switch is used to turn on the lamps which are additionally installed to the f...

Page 172: ...ion make sure that all control levers and pedals are set to NEUTRAL position If any of them is out of NEUTRAL position the work equipment or machine may move suddenly and cause a serious personal inju...

Page 173: ...el lever is operated The lock lever is set in the same state as when it is locked automatically When this function works the operations of the work equip ment swing travel and attachment are locked au...

Page 174: ...nds to warn that the machine is starting to move WORK EQUIPMENT CONTROL LEVER The L H work equipment control lever is used to operate the arm and upper structure Arm control a Arm OUT b Arm IN Swing c...

Page 175: ...engine then perform the operation When opening the front window hold the handle securely with both hands to pull up and do not release your hands until the front window is locked by the automatic loc...

Page 176: ...tion The wiper blade is on the glass 3 Hold handles A 2 places on the right and left top sides of the front window and pull levers B 2 places to re lease the locks at the top of the front window The t...

Page 177: ...he front win dow are not for pulling up the front window Do not pull up the front window with the handles A 5 Check that lever B is securely at LOCK position If the arrow on lock case F matches the po...

Page 178: ...e machine on a level ground lower the work equip ment to the ground then stop the engine Operate the operating portion g of the lock lever 1 to set it securely to LOCK position L 2 Check that the wipe...

Page 179: ...down the front window with the handles A 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 a...

Page 180: ...k 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 EMERGENCY ESCAPE HAMMER k k CAUTION If it is necessary t...

Page 181: ...e or do not put your hands on the door frame The door may suddenly close and cause injury 1 Use the door lock to keep and fix the door opened 2 Push the door against catch 1 to lock it in position Whe...

Page 182: ...DRINK BOX It is provided on the rear right side of the operator s seat to store drinks Air according to the setting of the air conditioner blows into the drink box MAGAZINE BOX Located on the left sid...

Page 183: ...er supply for 12 V equipment This will cause failure of the equipment When cigarette lighter is removed the lighter socket can be used as a power source The capacity of the cigarette lighter is 85 W 2...

Page 184: ...relay 7 10 A Revolving lamp 8 10 A Radio speaker L H knob switch 9 10 A Rear working lamp relay headlamp 10 20 A Air conditioner unit 11 10 A Optional power supply 1 12 30 A Optional power supply 2 12...

Page 185: ...the starting switch to OFF position and after confirming that the system operating lamp is not lit set the battery disconnect switch key to OFF position If the starting motor is not cranked when the...

Page 186: ...F position If someone turns the key to ON position carelessly this is extremely dangerous NOTICE Keep the battery disconnect switch in ON position except the following cases When the machine is stored...

Page 187: ...rned on and goes out in 1 to 7minutes after the starting switch is turned to OFF position Before operating the battery disconnect switch check that sys tem operating lamp 1 is not lit NOTICE If the ba...

Page 188: ...r grease however it has a pos sibility to harm the machine Komatsu does not recommend any commercially available additive agent for grease For details see RECOMMENDED FUEL COOLANT AND LUBRICANT NOTICE...

Page 189: ...sition the grease pump distributes the measured amount of grease at regular time intervals that have been set beforehand to all of the greasing points which are connected to this system The selected l...

Page 190: ...system has a problem Immediate action is necessary Possible cause The greasing pressure is insufficient throughout 10 cycles or 10 times in the same main line Find out the cause Keep pressing the pump...

Page 191: ...haust gas during the aftertreatment devices regeneration Urea SCR system is a device which converts toxic nitrogen oxides NOx in the exhaust gas into harmless nitro gen and water Spraying the DEF int...

Page 192: ...aftertreatment devices regeneration automatically raises the exhaust gas temperature for the regeneration in order to main tain the function of aftertreatment devices including urea SCR system During...

Page 193: ...eneration performance caution lamp 2 lights up in yellow stop the machine in a safe place after finishing the work and perform the manual stationary regeneration When the degree of urgency is high reg...

Page 194: ...cularly in the direction of the ex haust gas flow 3 Operate the operating portion g of the lock lever to set it to LOCK position L 4 Set the fuel control dial to Low idle MIN position 5 Press the swit...

Page 195: ...machine the automatic active aftertreatment devices regeneration can be disabled Also the regeneration in progress can be stopped When the aftertreatment devices regeneration should be started 1 when...

Page 196: ...witch F6 is pressed on the standard screen the Aftertreatment Devices Regeneration screen is dis played 2 Select the Regeneration Disable and then press the switch F6 and the regeneration stops Regene...

Page 197: ...ro viding heat to thaw frozen DEF The pump and the injector start working only after a proper amount of DEF is thawed This may be noticed as a delay in the start of functioning of the pump and the inj...

Page 198: ...If the lock lever is set to LOCK position or the travel lever and control levers are in NEUTRAL position for over 3 seconds SCR Information screen of the user menu will pop up auto matically while th...

Page 199: ...d caution lamp lights up in red The action level L03 is displayed in red 5 Press F6 to display the SCR Information screen SCR Information screen message 4 3 Engine power is under deration The hybrid s...

Page 200: ...ality or in the Urea SCR system the Inducement strategy is activat ed The inducement strategy progresses in 4 levels Warning Continuous Warning Low level Inducement and Severe In ducement The Induceme...

Page 201: ...instructed by the action level ta ble Inducement advances to Continuous Warning Continuous Warning The audible alert sounds in repetition of Triple beep alarm The DEF system caution lamp 1 lights up i...

Page 202: ...red 2 Press F6 to display the SCR Information screen SCR Information screen message 4 4 Engine power is under heavy deration Due to the further deration of engine power capability the machine will be...

Page 203: ...t is displayed When action level L03 is displayed move the machine to a safe place and con tact your Komatsu distributor The content of the warning can be checked on the SCR Information screen of the...

Page 204: ...tor The duration time of Continuous Warning is 5 hours The remaining time Hours and Minutes to Low level Induce ment is displayed in the column 6 of SCR Information screen In Low level Inducement engi...

Page 205: ...section of Temporary Restoration from Induce ment in this manual TEMPORARY RESTORATION FROM INDUCEMENT Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included...

Page 206: ...f Temporary Resto ration from inducement is displayed in the column 1 of the pop up menu window B 4 Press F6 while the Engine power Recovery window is displayed Temporary Restoration from Inducement i...

Page 207: ...Inducement other than the amount of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the pre...

Page 208: ...d with the KOM TRAX device by using satellite communication or portable radio communication The GPS Global Positioning System receiver and communication system are equipped in the vehicle man agement...

Page 209: ...he machine has been lent out by the customer the borrower or another third party may have been using the KOMTRAX Confirm with the lessor about using condition of KOMTRAX Komatsu may suspend KOMTRAX co...

Page 210: ...irt or combustible materials are found remove them 3 Check around the engine for coolant and oil leakage Check for oil leakage from the engine and coolant leakage from the cooling system If any proble...

Page 211: ...ger to the aftertreatment devices and also connections of the after treatment devices for leakage of exhaust gas and sticking of urea deposit If any problem is found ask your Komatsu distributor for r...

Page 212: ...e strainer valve cap in order to prevent the fuel from leaking or overflowing if refuel ling pump is not used Contact your Komatsu distributor if there is any malfunction in the auto shut off refuel s...

Page 213: ...the float switch stopped the refuelling pump Keep pressing the switch 5 then the refuelling pump makes the fuel tank full Releasing the switch 5 stops the refuelling pump in this state that the refuel...

Page 214: ...2 to OPEN position O to drain all the sediment and water accumulated at the bottom together with fuel 4 When only the clean fuel flows out turn the drain valve 2 to CLOSE position S 5 Close the door M...

Page 215: ...es the frozen water melts and the water separator caution lamp may suddenly light up In cold season even if the water separator caution lamp is not lit drain the water frequently If the drain valve 4...

Page 216: ...ON position within 15 seconds after stopping the engine and move each control lever for work equipment and travel to the full stroke in all directions The internal pressure is released by this operat...

Page 217: ...er cap and the tank and insert it 2 Rotate the oil filler cap clockwise and lock it with the key The mark on the oil filler cap matches with the key mark on the tank METHOD FOR CHECKING COOLANT LEVEL...

Page 218: ...or and reservoir tank If the coolant level is low add Non Amine Engine Coolant AF NAC of the same density as the one in the radiator 7 Check that the hybrid radiator coolant sight gauge 3 is fil led w...

Page 219: ...he machine is inclining make it level before checking 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...

Page 220: ...he battery cap with water to clear the vent hole NOTICE In particular inspect the wiring of battery starting motor and alternator with care Perform the following inspection Perform inspection to confi...

Page 221: ...t Fuel tank capacity 400 Position of tip a of float gauge G when fuel tank is full approximately 50 mm REMARK If the breather hole 4 in the cap is clogged the pressure inside the tank will go down and...

Page 222: ...s are lit Outputting high voltage 1 lamp is lit Charged at high voltage No lamp is lit Not charged METHOD FOR CHECKING DEF LEVEL ADDING DEF k k WARNING Do not put any fluid other than DEF into DEF tan...

Page 223: ...d DEF the strainer will be broken When using a portable refill container use it up each time If any of it is left completely seal it up Remove the foreign material if there is any Do not wash the supp...

Page 224: ...t is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop function to add DEF When the specified nozzle is used the magnet installed inside the filler p...

Page 225: ...oes not sound ask your Komatsu distributor for repair METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR S SEAT k k WARNING When adjusting the position of the operator s seat always set the lock lever...

Page 226: ...t the backrest when adjusting If your back is not touching the backrest the backrest may suddenly move forward METHOD FOR TILTING SEAT Pull up the tilt adjustment lever and adjust the front angle of t...

Page 227: ...ing it to the height adjust ment hole of armrest 3 5 Tighten knob 1 at the rear of the armrest METHOD FOR ADJUSTING ARMREST ANGLE Angle of the armrest can be adjusted vertically by turning ad justment...

Page 228: ...son s ability to perceive the tempera ture is decreased When a person s ability to feel pain is decreased When a person has a delicate skin Do not put a heavy object on the seat cushion Do not stick t...

Page 229: ...erate it so that the shaft of the headrest becomes straight If it is forcibly twisted the installation part may be broken METHOD FOR ADJUSTING MIRRORS k k WARNING Be sure to adjust the mirrors before...

Page 230: ...e of 1 0 m from the edge of the machine 3 If you cannot adjust loosen mounting bolts 1 and 2 of the mirror and stay and adjust the angles If the mirror is adjusted by loosening the mounting bolts be s...

Page 231: ...kgm Mounting position 8 172 mm NOTICE Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L become equal If the mirror and stay mounting bolts...

Page 232: ...1 Adjust the mirror with your hand so that the side of the ma chine is reflected in the mirror as shown in the figure 2 Check that you can see a person at the rear right end of the machine at a height...

Page 233: ...sition perform the following adjustment Adjust the mirror 1 Tightening torque of mounting bolt 2 6 0 to 7 0 Nm 0 61 to 0 71 kgm Mounting position 3 452 mm Mounting position 4 16 mm Mounting angle 5 93...

Page 234: ...prevent the machine from moving dur ing the work The machine is placed on a level ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is...

Page 235: ...een in the belt replace the seat belt every 3 years from starting usage or 5 years after manufacture whichever comes sooner Be sure to use the seat belt during operation Do not twist the seat belt whe...

Page 236: ...isplayed at the top left of the machine monitor Fasten the seat belt METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE k k WARNING When starting the engine check that the lock lever is securely...

Page 237: ...n displayed on the machine monitor input the password and press the input confirma tion switch F6 If a password is set the input display screen will be indi cated on the machine monitor screen REMARK...

Page 238: ...lamp 16 Hydraulic oil temperature gauge 17 Hydraulic oil temperature caution lamp 18 Engine coolant temperature gauge 19 Engine coolant temperature caution lamp 20 3 If the caution lamp 21 stays lit...

Page 239: ...ing switch key 3 at START posi tion continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes then start again from the beginning After the engine starts wait for...

Page 240: ...engine may not start even when the key in starting switch 3 is kept at START position for 20 seconds If this happens wait for at least 2 minutes then start again from the beginning To preheat the eng...

Page 241: ...ting switch 3 counterclockwise from OFF position A The preheating pilot lamp lights up and preheating of the engine starts Preheating continues while the key in starting switch 3 is held counterclockw...

Page 242: ...nd immediately after stopping the engine In addition do not bring any combustible material close to the outlet of the exhaust pipe There are 2 types of warm up operation warm up of the engine and warm...

Page 243: ...horten 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 then run in the...

Page 244: ...l dial 2 to the middle between Low idle MIN and High idle MAX to run the engine at a medi um speed Run the engine with no load until the engine coolant tempera ture caution lamp 1 displays the correct...

Page 245: ...or more 2 Turn fuel control dial 2 to Low idle MIN position The engine automatic warm up is canceled and the en gine speed is lowered REMARK Turbo protect function takes priority over the engine autom...

Page 246: ...tor but also for the control circuits Do not perform the opera tion just for one cylinder or motor or the operation just in one direction Perform the operation in all direc tions for all the work equi...

Page 247: ...int midway between low speed MIN and full speed MAX 6 Operate the work equipment to warm up the hydraulic components NOTICE When the work equipment is operated take care that it does not interfere wit...

Page 248: ...d C is blue Display B when temperature is low Caution lamp background C is white If it displays the low temperature perform additional warm up operation of the engine until the engine coolant temper a...

Page 249: ...cold weather 1 Turn the fuel control dial 4 to High idle MAX posi tion 2 Repeat the work equipment operation in step 6 for 3 to 5 minutes Display A when temperature is correct Caution lamp background...

Page 250: ...UT A Bucket operation CURL D DUMP C Swing operation LEFT G RIGHT H When performing the swing operation release the swing lock switch 2 check that the swing lock pilot lamp 24 is not lit then perform t...

Page 251: ...ution lamp displays the correct temperature perform the op eration after completion of the warm up operation REMARK If it is obliged to move the machine before warming it up fully recognize the differ...

Page 252: ...ne control B mode For breaker operations ATT P mode For operation of 2 way attachment like crusher ATT E mode For operation of 2 way attachment like crusher fuel economy conscious operations METHOD FO...

Page 253: ...ts may be damaged When stopping the engine stop the aftertreatment devices regeneration first run the engine at low idle for approxi mately 5 minutes and then stop the engine Stop the engine according...

Page 254: ...rging DEF After the purg ing operation is finished the devices stop automatical ly METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND STOPPING MACHINE k k WARNING Check the direction of the tr...

Page 255: ...difficult to travel safely raise the work equipment further 2 Operate right and left travel levers 5 or right and left trav el pedals 6 as follows 3 Check the position of the sprocket When sprocket A...

Page 256: ...follows 3 Check the position of the sprocket When sprocket A is at the rear of the machine Start the machine either by pulling levers 5 backward slowly or by depressing the rear parts of pedals 6 slo...

Page 257: ...e 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 c...

Page 258: ...ON OF MACHINE When turning LEFT during straight travel A Forward left turn Return the left travel lever from FORWARD to NEUTRAL position The machine turns forward LEFT B Reverse left turn Return the l...

Page 259: ...he track width Check the safety around the machine before swinging the upper structure If the travel levers are operated when the engine speed is decreased by the auto deceleration function the en gin...

Page 260: ...rate the levers carefully When the work equipment operation or swing operation is performed the screen on the machine monitor is au tomatically switched to the bird s eye view display of KomVision Use...

Page 261: ...sed for releasing the remaining pressure in the hydraulic cylinder circuits or for lowering the boom after loading the machine onto a trailer HANDLE WORKING MODE METHOD FOR SELECTING WORKING MODE Use...

Page 262: ...election screen 2 Press the working mode selector switch 1 or switch F3 or F4 to select the appropriate mode 3 Select a desired working mode and press the switch F6 The change is entered and the scree...

Page 263: ...erating power increases as long as the switch is press ed REMARK The increased power is automatically stopped after 8 5 sec onds This function is not actuated when the working mode is set to L mode or...

Page 264: ...hydraulic cylinder fully retracted or fully extended DO NOT PERFORM THE WORK IF FOREIGN MATERIAL IS ACCUMULATED AROUND HYDRAULIC CYLINDER If operation is continued while something sticks between the...

Page 265: ...machine may break In this case dig by using only the force of the arm or bucket If an excessive force is applied the safety valve of the hydraulic system controls it into a proper range to prevent br...

Page 266: ...can shorten the service life of the machine PROHIBITION OF DIGGING OPERATION ON HARD ROCKY GROUND Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavat...

Page 267: ...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...

Page 268: ...NG Travelling over boulders tree stumps or other obstacles will cause a big shock to the chassis and in particular to the under carriage and this will cause damage to the machine For this reason alway...

Page 269: ...re 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 k k WARNING If the hybrid devices motor generator e...

Page 270: ...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 When travelling uphill if the shoes slip or it is impos sible to travel...

Page 271: ...DEF as necessary If the remaining DEF level becomes low sudden drop of its level or abnormality in urea SCR system may be detected If DEF level caution lamp or DEF system caution lamp lights up in re...

Page 272: ...ne is as shown in the figure angle between bucket cylinder and link and between arm cyl inder and arm is 90 the maximum excavation force is ob tained from the pushing force of each cylinder When excav...

Page 273: ...u begin from the rear of the dump truck body than if loading is done from the side EFFECTIVE USE OF HYDRAULIC EXCAVATOR Operation for reducing fuel consumption Carbon dioxide emissions reducing operat...

Page 274: ...s Stop the machine on a firm and flat surface and do the work When performing joint work appoint a leader and follow that person s instructions and signals METHOD FOR CHANGING BUCKET Replace the bucke...

Page 275: ...R INVERTING BUCKET NOTICE The rock bucket cannot be used for shovel work in the inverted position since it interferes with the arm Invert the bucket according to the following procedure 1 Lower the bu...

Page 276: ...Keep them until the next use 5 Install the stopper bolts and nuts for each pin then grease the pins REMARK Lubricate with grease thoroughly until the grease comes out from the end faces When replacin...

Page 277: ...he standard machine METHOD FOR PARKING MACHINE k k WARNING Avoid a sudden stop Stop the machine gradually Place the machine on a firm level ground Do not park the machine on a slope Block the tracks f...

Page 278: ...e MIN position in or der to lower the engine speed 3 Make the undercarriage and upper structure point to the same direction and lower the bucket to the ground with its bottom face horizontal 4 Operate...

Page 279: ...ound 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 eng...

Page 280: ...key to CLOSE position B then remove the key METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK 1 Insert the key into the key slot 2 Turn the key counterclockwise and ope...

Page 281: ...be cause of its weight If the engine hood is not locked it may close suddenly because of wind etc Immediately after the engine is stopped the engine hood and aftertreatment devices are still hot Accor...

Page 282: ...ked at 2 different opening an gles However lock it to the intermediate LOCK position 6 usually for inspection and such 8 To open the engine hood fully perform the following proce dure 1 Hold the handl...

Page 283: ...he stay 5 in the direction of ar row and remove the stay 5 from intermediate LOCK po sition 6 3 Check that stay 5 is set in guide groove 10 and then lower the engine hood k k CAUTION Do not lower the...

Page 284: ...lease the handle until the stay is set in the lock position securely When closing it hold the handle securely since the DEF tank filler cap cover may move down be cause of its own weight If it is not...

Page 285: ...4 Hold grip 1 unlock lock 2 and pull up the cover 5 Set stay 3 securely in position 4 to lock it OPERATION MACHINE OPERATIONS AND CONTROLS 3 213...

Page 286: ...arrow while supporting the cover 2 Remove stay 3 from lock position 4 3 Check that stay 3 is set in guide groove 5 and then lower the cover Check that lock 2 is applied 4 Turn the key clockwise to lo...

Page 287: ...METHOD FOR LOCKING DEF PUMP COVER 1 Unlatch lock stay 2 and close cover 1 2 Lock cover 1 with the starting switch key Do not forget to pull the starting switch key out METHOD FOR OPENING AND CLOSING...

Page 288: ...B CLOSE LOCK When locking the door 1 Close the door and insert the key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key MACHINE OPERATIONS AND CONTROLS OPERATI...

Page 289: ...r conditioner may not work In this case circulate the recircu lation air to warm the inside of the cab After that turn on the air conditioner switch and the air conditioner will work If any abnormalit...

Page 290: ...used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH You can adjust the air f...

Page 291: ...5 C Monitor display and function Monitor display C Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to set temperature 32 0 Max heating REMARK If the mode is set to auto mo...

Page 292: ...mode AUTO SWITCH Use the auto switch for automatic selection of the air flow vents and air source FRESH RECIRC according to the set temperature Press this switch then use temperature control switch 1...

Page 293: ...etting to take in fresh air or to demist the window glass DISPLAY MONITOR This monitor display indicates the status of temperature setting a air flow rate b and vents c When OFF switch 1 is pressed th...

Page 294: ...the cab caused by changes in the strength of the sun s rays beforehand and automatically adjusts the temperature METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically...

Page 295: ...the set temperature and the air conditioner is operated auto matically to provide the set temperature REMARK When vent monitor c displays d or e and engine coolant temperature is low the air flow is...

Page 296: ...djust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Turn air conditioner switch 2 ON 3 Use temperature control switch 3 to set to the desi...

Page 297: ...monitor changes according to the selection 5 Press FRESH RECIRC air selector switch 5 and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH METHOD FOR ST...

Page 298: ...r blow ing to the feet set as follows 1 Press fan switch 1 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector sw...

Page 299: ...3 Turn on the air conditioner switch 3 4 Adjust fan switch 1 temperature control switch 4 and FRESH RECIRC selector switch 5 to the desired posi tions OPERATION HANDLE AIR CONDITIONER 3 227...

Page 300: ...and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch 2 and set vent display on the monitor to f or g as sho...

Page 301: ...0 of maximum heating 5 Adjust vents A B1 and B2 so that the air blows onto the window glass Vents C and D are fixed and cannot be adjusted 6 When operating in the rainy season or when it is desired t...

Page 302: ...er button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX on it Press the button again to turn the power off BAND AUX SELECTOR B...

Page 303: ...on are displayed B Frequencies are displayed at steps 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 adjus...

Page 304: ...just the fre quency Press the button and the frequency increases press the button and the frequency decreases Hold down the button and the frequency increases continuously hold down the button and the...

Page 305: ...hile a frequency is displayed press button 1 of preset button 2 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 METHOD F...

Page 306: ...REGISTER RANGE BASS 1 Press sound control button 1 to light up BAS on the dis play You can adjust the low register range bass of the sound 2 Press tuning time adjustment button 2 to adjust the low re...

Page 307: ...nna 1 to the bottom part 2 After stowing the antenna 1 tighten the bolt 2 to fix it SPACE FOR RADIO CASSETTE The radio cassette player is not installed at factory If the installation is needed remove...

Page 308: ...monitor screen Ask your Komatsu distributor to perform this work The machine monitor image may not be displayed due to darkness at night or in a tunnel fog snow rain cloud of dust etc Obstacles above...

Page 309: ...d double or distortions or misalignment may occur in the shaded areas of the back of the machine A and B and the right of the machine C For the camera image the image shot by each of the loaded camera...

Page 310: ...t and dimension given in SPECIFICATIONS weight and dimension may differ accord ing to the type of track shoe or arm or other attachments Consult your Komatsu distributor for details of the procedure f...

Page 311: ...e work equipment for loading and unloading operations Always use ramps The centre of gravity of the machine shifts suddenly at the joint between the ramps and the trailer and it is dangerous that the...

Page 312: ...t them from bending 4 Press the travel speed selector switch 5 to set the travel speed to low Lo lights up The travel speed Lo Mi Hi is displayed on the travel speed display 6 5 Turn off the auto dece...

Page 313: ...work equipment as far as possible without caus ing interference On the ramps operate only the travel lever Do not operate any other lever 10 When loading a machine with the work equipment instal led a...

Page 314: ...revent 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 Check that the engine hood catcher...

Page 315: ...ors covers and caps Select the way of secure the machine according to the transportation form of each territory from the following METHOD FOR SECURING MACHINE WITH TIE DOWN POINT Tie one end of each c...

Page 316: ...OVING AND INSTALLING MIRROR If they are to be removed for shipment or are to be installed again perform the following procedure After installation of mirror always adjust it For details see METHOD FOR...

Page 317: ...ils before inspection and maintenance Use the crane etc for carrying the handrails There is a danger of rolling over or falling from high place that can lead to serious personal injury or death Check...

Page 318: ...123 Nm 10 0 to 12 5 kgm METHOD FOR REMOVING AND INSTALLING REVOLVING LAMP METHOD FOR REMOVING REVOLVING LAMP Remove the revolving lamp according to the following procedure 1 Remove connector A of the...

Page 319: ...kwise seeing it from the rear of the machine 6 Remove revolving lamp bracket C from the claw of base bracket E k k CAUTION When removing and installing the revolving lamp be sure to hold grip G instea...

Page 320: ...ine At this time insert revolving lamp bracket C into the re volving lamp fixing claw side of base bracket E and in stall it 2 Install the hook of lock D to base bracket E 3 Raise the lever of lock D...

Page 321: ...end largely under the weight of the machine put blocks under the ramps to prevent them from bending 4 Remove the chains or wire ropes which are fastening the machine 5 Start the engine Warm up the eng...

Page 322: ...ng the machine always set the angle be tween the arm and boom to 90 to 110 If the machine is unloaded while the arm is IN it will cause damage to the machine 12 Lower the bucket to the ground NOTICE D...

Page 323: ...oses its balance NOTICE This method of lifting applies to the standard specification machine The method of lifting differs depending on the attachments and options installed For details of the procedu...

Page 324: ...ollers pass the wire ropes under the tracks When the wire rope contacts with the edge of the machine put wooden block or backing metal between them 8 Set the lifting angle A of the wire rope to 30 to...

Page 325: ...h distilled water so it is not flammable For details on the coolant change interval and the density of Non Amine Engine Coolant AF NAC see USE OF FUEL COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TE...

Page 326: ...erve the following precautions Remove all the mud and water from the machine body In particular wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud dirt or drops of wate...

Page 327: ...nt with the ones of the specified viscosity For details see METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE If the machine is parked for long time in the cold weather con...

Page 328: ...Install the blind plugs to the elbows For explanation of LOCK and FREE states of the stop valve see METHOD FOR REMOVING AND IN STALLING ATTACHMENT To prevent rust fill the cooling circuit with Non Am...

Page 329: ...stored for more than 2 months perform the following procedure Before starting the engine replace DEF filter and fill up DEF tank according to the procedure in METHOD FOR REPLACING DEF FILTER Start the...

Page 330: ...ation from a high posi tion for digging under no load the bucket speed drops mo mentarily at the horizontal position The bucket or arm wobbles by itself during heavy duty dig ging operations When star...

Page 331: ...n the towing machine and the machine being towed Move the machine slowly and be careful not to apply any sudden load to the wire rope Do not use the holes for towing light objects or tie down holes wh...

Page 332: ...d to the wire rope Do not use the tie down holes for towing the machine There is a hole in the track frame to fit the shackle when towing light objects Permissible towing load 58800 N 6000 kg or less...

Page 333: ...hen handling batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the ground normally the negative terminal When installing first co...

Page 334: ...ive charger clip of the charger to the nega tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when performi...

Page 335: ...al machine must be the same capacity as that of the failed machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected Check that the lock lever...

Page 336: ...SYSTEM OCCUR The problems of the hybrid system are shown in the following table Contact your Komatsu distributor for the remedies indicated with in the remedy column Ask your Komatsu distributor for r...

Page 337: ...eplace the device Overcurrent in hybrid device Replace the device Hybrid device is abnormally heated Replace the device 1 If any problem is found in hybrid devices during the swing operation the hybri...

Page 338: ...ng procedures 1 Set the bucket height to just above the ground a is 20 to 30 cm high from the ground 2 On the slopes perform the inching operation of the swing parking brake cancel switch to the relea...

Page 339: ...gine stop position Set it to normal position Put cover on it Pinion of starting motor repeats en gaging and disengaging rattles Insufficient battery charge Charge battery Defective safety relay Replac...

Page 340: ...rise in hydraulic oil temper ature Dirty oil cooler Clean See EVERY 500 HOURS MAINTENANCE Lack of hydraulic oil Set oil to specified level See CHECKS BEFORE STARTING Track comes off Track too loose A...

Page 341: ...n of dirt or scale in cool ing system Change coolant flush inside of cool ing system by referring to WHEN RE QUIRED Clogged radiator fins or damaged fin Clean or repair by referring to EVERY 500 HOURS...

Page 342: ...es Excessive oil in oil pan Make the oil level to the specified lev el See CHECKS BEFORE START ING Improper fuel Replace with specified fuel Exhaust gas turns black from time to time Breakage of the a...

Page 343: ...LACING FUEL MAIN FILTER CARTRIDGE If CA2249 or CA559 is not cleared even after the replacement ask your Komatsu distributor for the in spection and repair immediately even though the machine can perfo...

Page 344: ......

Page 345: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1...

Page 346: ...the strainer while adding DEF It is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop function to add DEF WELDING INSTRUCTIONS When performing weldi...

Page 347: ...to forget to assemble O rings and gaskets When installing the hoses do not twist them or bend them sharply If they are installed so their service life will be extremely shortened and they may be dama...

Page 348: ...ty always change the oil at the specified interval Oil corresponds to blood in the human body always be careful when handling it to prevent any impurities water metal particles dirt etc from getting i...

Page 349: ...necessary to prevent freezing always use Non Amine Engine Coolant AF NAC with a density of over 30 in order to prevent corrosion of the cooling system Non Amine Engine Coolant AF NAC is diluted with...

Page 350: ...would cause wear of the rotating parts PERFORM KOWA Komatsu Oil Wear Analysis KOWA is a maintenance service that makes it possible to prevent machine failures and downtime With KOWA the oil is period...

Page 351: ...e of storage area Storage period Max 10 C Up to 36 months Max 25 C Up to 18 months Max 30 C Up to 12 months Max 35 C Up to 6 months Do not store DEF in the temperature of 35 C or above Handling DEF in...

Page 352: ...k of damage of the fan belt and the check of battery fluid level Komatsu recommends installing electric components specified by Komatsu External electro magnetic interference may cause malfunction of...

Page 353: ...3 Hydraulic pump 4 High voltage electric wiring Orange 5 Capacitor Storage battery 6 Inverter Control device 7 Cooling system 8 Electric swing motor MAINTENANCE OUTLINE OF MAINTENANCE 4 9...

Page 354: ...bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 3 31 67 111 172 1 35 3 2 6 8 11 3 17 5 11 8 to 14 7 27 to 34 59 to 74 98...

Page 355: ...7 to 245 18 0 to 25 0 10 33 41 216 22 0 177 to 245 18 0 to 25 0 Face seal Nominal No of hose Nominal size thereads per inch a Width across flats b mm Tightening torque Target value Allowable range Nm...

Page 356: ...ETHOD FOR CHECKING AUTO GREASING SYSTEM 4 40 METHOD FOR CHECKING CAMERA VISIBILITY 4 43 METHOD FOR CHECKING SWING PARKING BRAKE 4 44 CHECKS BEFORE STARTING 4 44 EVERY 100 HOURS MAINTENANCE 4 44 METHOD...

Page 357: ...TARTING MOTOR 4 81 METHOD FOR REPLACING ACCUMULATOR FOR CONTROL CIRCUIT 4 81 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR OPERATION 4 82 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIP...

Page 358: ...If the diesel fuel which does not include the bio fuel is changed to the diesel fuel mixed with bio fuel set the maintenance interval as follows Replace the fuel pre filter cartridge When the machine...

Page 359: ...Fuel main fil ter cartridge Replace Replace Replace Replace MAINTENANCE MAINTENANCE SCHEDULE 4 15...

Page 360: ...e machine monitor lights up If the element is cleaned frequently before the air cleaner clogging caution lamp on the machine monitor lights up the air cleaner will not be able to display its performan...

Page 361: ...is not at an angle If it is at an angle push it straight to the bottom with your hand 4 After removing the outer element 5 cover the inner ele ment 6 with a clean cloth or tape to prevent dirt or dust...

Page 362: ...facing in the correct direction Install so that the bottoms B and C of the air cleaner element face where no hole is drilled come to the cover 3 end If it is installed in wrong direction it may cause...

Page 363: ...ng of the elements has been finished replace the inner and outer elements METHOD FOR CHANGING AIR CLEANER ELEMENT NOTICE Do not clean and reuse the inner element Replace it with a new one at the same...

Page 364: ...any dust is attached to the vacuator valve 4 installed to the cover 3 remove it 6 Remove the inner element 6 then install the new inner element immediately Install the inner element securely so that i...

Page 365: ...t the machine from moving When the undercover is removed there is a danger of touching the fan Never enter the rear part of the machine when the engine is running Place the machine on a level ground w...

Page 366: ...h water and see a doctor immediately When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator request a qualified company to perform t...

Page 367: ...for approximately 10 minutes 11 Set the swing lock switch to ON position and check that the swing lock pilot lamp is lit 12 To complete the warm up operation of the hydraulic com ponent more quickly s...

Page 368: ...s stroke and hold it in posi tion for 30 seconds 3 Move the L H work equipment control lever slowly in the direction to the arm IN position B Operate the lever to the end of its stroke and hold it in...

Page 369: ...Amine Engine Coolant through the water filler port up to the mouth of the port For the concentration of Non Amine Engine Coolant see Coolant density table 22 Run the engine at low idle for 5 minutes t...

Page 370: ...ximately 10 minutes 8 Stop the engine and open the drain plug 4 to drain the coolant 9 After draining the coolant clean the sub tank with deter gent liquid For the cleaning method follow the usage ins...

Page 371: ...ionally and keep it in the standard range For performing the inspection and adjustment of the track shoes park the machine on the level and solid ground METHOD FOR CHECKING TRACK TENSION 1 Run the eng...

Page 372: ...se does not come out smoothly move the machine forward and backward a short distance 3 Tighten plug 1 4 To check if the tension is correct run the engine at low idle move the machine slowly forward by...

Page 373: ...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 5 If lock pin 2 and rubber pin lock 3 are used in t...

Page 374: ...t 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 th...

Page 375: ...H HORIZONTAL PIN TYPE Replace the bucket teeth before the adapter starts to wear k k WARNING It is dangerous if the work equipment moves by mistake when the tooth is being replaced Set the work equipm...

Page 376: ...USTING BUCKET CLEARANCE k k WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearance Lower the work equipment to the ground stably set the lock lever securely...

Page 377: ...when adding the flu id Mixing proportion of pure window washer fluid and water The mixing proportion differs according to the ambient temperature so add the window washer fluid diluted with water as f...

Page 378: ...gas damage When required Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of the compressor CHECK LEVEL OF REFRIGERANT GAS...

Page 379: ...securely to LOCK position L before leaving the operator s seat Select a firm flat place for work When setting the machine at an angle use strong blocks to stabilize the base of the machine and be ext...

Page 380: ...by using blocks 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 ma chine in a stable conditio...

Page 381: ...jections 2 into the holes METHOD FOR SETTING MACHINE AT ANGLE You can set the machine at an angle by using a slope or blocks Consider the condition of the machine and select the safe method METHOD FOR...

Page 382: ...his check that the machine is always stable METHOD FOR CHECKING GAS SPRING k k WARNING The gas spring is charged with high pressure nitrogen gas so improper handling may cause an explo sion resulting...

Page 383: ...the hydraulic tank 3 After completing the air bleeding operation tighten the air bleeder 1 and install the drain hose METHOD FOR STARTING ENGINE Start the engine according to OPERATION METHOD FOR STAR...

Page 384: ...his will remove the air bubbles in the oil inside the hydraulic tank Immediately after the attachment is replaced air can be mixed into the attachment 2 variable relief pressure valve and the pulsatio...

Page 385: ...e grease level of grease tank has reached the lowest level Add grease to the grease tank as soon as possible Procedure for adding grease 1 Remove the dust cap from the greasing coupling 7 2 Thoroughly...

Page 386: ...s lit 2 seconds not lit 2 seconds while this test is being proceeded In order to provide additional grease to all grease points i e after cleaning the machine or to vent the system a con tinuous lubri...

Page 387: ...when it is necessary The grease is supplied to the greasing points every time the lubrication test is performed This may re sult in the increase of grease usage and excessive lubrication to the greasi...

Page 388: ...EF Method for checking working lamp Method for checking horn function Method for checking capacitor EVERY 100 HOURS MAINTENANCE METHOD FOR LUBRICATING WORK EQUIPMENT NOTICE If any abnormal noise is ge...

Page 389: ...ery generates the flammable gas Battery electrolyte is dangerous object If it gets in your eyes or on your skin wash it off with a large amount of water and consult a doctor Do not use a dry wipe to c...

Page 390: ...butor or a battery manufacturer METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO CHECK FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the batter...

Page 391: ...JUSTING AIR CONDITIONER COMPRESSOR BELT TENSION The followings are the periodic maintenance items for the air conditioner Perform inspection and maintenance to use the air conditioner effectively METH...

Page 392: ...tment or has slipping sound or squeak because of cuts or cracks of the belt NOTICE When the new V belt is installed readjust it after operating for 1 hour When replacing the V belt be careful not to d...

Page 393: ...ces 4 Arm cylinder foot pin 1 place 5 Boom and arm connection pin 1 place 6 Arm cylinder rod end 1 place 7 Bucket cylinder foot pin 1 place 3 After greasing wipe off any old grease that is pushed out...

Page 394: ...ck to the filter head 2 If any old packing is stuck it will cause oil leakage 6 When installing tighten until the packing surface contacts the seal surface of filter head 2 then tighten it a further 3...

Page 395: ...the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a sub...

Page 396: ...l not to let any dirt or dust get into the fuel In particular centre portion is the clean side so do not remove the cap B when filling with fuel Be careful not to let dirt or dust get into the centre...

Page 397: ...art the engine and run it at low idle for 10 minutes 20 Check for leakage from the filter seal surface and transpar ent cup mounting face If any leakage is found check the filter cartridge for its tig...

Page 398: ...shown by arrows 2 places 2 After greasing wipe off any old grease that is pushed out METHOD FOR CHECKING AND CLEANING RADIATOR FINS FOR ENGINE HY BRID EQUIPMENT OIL COOLER FINS AFTERCOOLER FINS AND AI...

Page 399: ...med at close distance there is a danger that the internal fins of the heat exchange equipment will be deformed and this will cause early clogging and breakage of the equipment 5 Visually check the rub...

Page 400: ...rom the inspection window at the bottom rear left inside the operator s cab 2 Take out the recirculation air filter 3 Clean the filter with compressed dry air Blow compressed air 0 2 MPa 2 1 kg cm2 fr...

Page 401: ...f the filter is damaged or deformed replace it with the new one 4 After cleaning return the filter 5 REMARK The fresh air filter must be installed facing it in the cor rect direction When installing d...

Page 402: ...ark on dipstick G add oil through the oil filler port F 5 If the oil level is above the mark H on dipstick G loosen the drain valve P to drain the excessive oil Tightening torque of drain valve P 19 6...

Page 403: ...drain the excessive oil Tightening torque of drain valve Q 19 6 to 24 5 Nm 2 0 to 2 5 kgm Set a container to catch the oil under drain valve Q be fore draining the oil 6 After checking the oil level o...

Page 404: ...gm 6 After checking the oil level or adding oil insert the dipstick G into the oil filler port F REMARK If the machine is inclining make it level before checking METHOD FOR CHECKING OIL LEVEL IN FINAL...

Page 405: ...hrough which no in ternal gears are seen EVERY 1000 HOURS MAINTENANCE Maintenance for every 100 250 and 500 hours should be performed at the same time METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT...

Page 406: ...en installed 8 Place the strainer 4 valve 3 and spring 2 onto the element 9 Set the cover 1 in position press it down by hand and install the cover with the mounting bolts 10 Install the oil filler ca...

Page 407: ...temperature is low swing the upper structure to raise the oil temperature slightly before starting the oil draining operation Never swing the upper structure while draining the oil This may cause brea...

Page 408: ...nd then start the work Park the machine on a firm level ground and change oil Perform the oil replacement of motor generator case and cleaning of oil filter according to the following table Item Item...

Page 409: ...FILTER CARTRIDGE k k WARNING Do not replace the filter immediately after the engine is stopped The parts are still very hot Wait for all of parts to cool down before starting the work High pressure i...

Page 410: ...o the packing of the new filter cartridge and install the cartridge to the filter head Replace the inner seal 3 with a new one NOTICE Do not fill the new filter cartridge with fuel Remove the cap B at...

Page 411: ...ridge with a new one For details see METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE 6 After the engine starts run it for approximately 5 minutes to bleed all air from the fuel circuit 7 After approxi...

Page 412: ...tor which will cause failure of the machine Never operate the machine without DEF tank breather element at tached nor use the element other than Komatsu genuine parts Do not flush DEF tank breather el...

Page 413: ...ributor to perform this work REMARK As the automatic fan belt tensioner is installed to this machine no belt tension adjustment is required EVERY 2000 HOURS MAINTENANCE Maintenance for every 100 250 5...

Page 414: ...nd oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the in...

Page 415: ...the gas must be released Ask your Komatsu distributor to have this work per formed NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued it becomes impossib...

Page 416: ...s gradually You can check only just after the en gine stops 1 Keep the work equipment at the maximum reach pos ture turn the starting switch to OFF position A and stop the engine 2 Turn the starting s...

Page 417: ...F position METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT 1 Lower the work equipment to the ground Keep the crusher attachment jaws etc closed 2 Operate the operating portion g of the lock lever t...

Page 418: ...ition a so that you cannot operate the attachment control pedal METHOD FOR CHECKING ALTERNATOR Ask your Komatsu distributor to have the alternator checked If the engine is started frequently have this...

Page 419: ...e per formance lowers or the crankcase pressure increases Never reuse the filter element since it can cause an engine failure After the filter element is replaced if KCCV is not assembled correctly oi...

Page 420: ...install a new O ring contained in the service kit Apply the engine oil to the new O ring 4 While matching the marks 7 of the new element with the mark 8 of the body label insert the element firmly in...

Page 421: ...l all of parts cool down before starting the work NOTICE Komatsu recommends using Komatsu genuine parts for replacement parts If the machine is operated without DEF filter attached or with the filter...

Page 422: ...cing the filter clean around the DEF pump first after DEF system devices stop Items to be prepared DEF filter removal tool The DEF filter is located at the positions shown in the figure on the right 1...

Page 423: ...pump grip filter removal tool 3 pull it down then it will be removed 7 Slide filter 6 down and remove spacer 5 from filter re moval tool 3 8 Pull filter 6 up while pushing in the tip of filter removal...

Page 424: ...em every 2 years or every 4000 hours whichever comes sooner DEFINED LIFE PARTS LIST No Parts for periodic replacement Replacement interval 1 Fuel system Fuel hose Spill hose Ask your Komatsu distribut...

Page 425: ...ot be completely removed When removing the hydraulic equipment do not stand in the direction that the oil spurts out when performing the operation In addition loosen the bolts slowly when performing t...

Page 426: ...is found ask your Komatsu distributor to have the parts disassembled repaired or re placed METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIP ING CLAMP HARDENING OF RUBBER Check visually an...

Page 427: ...pray prevention cap loose bolts or hardening of the rubber Replacement is required if any trouble is found Ask your Komatsu distributor for that work METHOD FOR REPLACING RADIATOR CAP k k WARNING Imme...

Page 428: ...MAINTENANCE Maintenance for every 100 250 and 500 hours should be performed at the same time METHOD FOR CLEANING DEF TANK Ask your Komatsu distributor for cleaning of the DEF tank METHOD FOR REPLACING...

Page 429: ...be careful not to get oil on yourself 7 Remove the drain plug P and drain the oil Check the installed O ring for damage Replace the O ring with a new one if necessary 8 After draining the oil tighten...

Page 430: ...ment of the fuel spray prevention caps EVERY 9000 HOURS MAINTENANCE Maintenance for every 100 250 500 1000 and 4500 hours service should be performed at the same time METHOD FOR REPLACING DEF HOSE Ask...

Page 431: ...SPECIFICATIONS 5 1...

Page 432: ...00 ISO 9249 A Overall length mm 9705 B Overall height work equipment mm 2970 C Overall width mm 3080 D Track width mm 700 E Cab height mm 3045 F Tail swing radius mm 3020 G Overall length of track mm...

Page 433: ...mum dumping height mm 7110 F Minimum dumping height mm 2645 G Maximum reach at ground level mm 9700 EXPLANATION OF LIFT CAPACITY CHART 1 PIECE BOOM 1 Piece Boom HB215LC 3 LEGEND A Reach from swing cen...

Page 434: ...WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND WITH 600 mm WIDTH SHOE Loads do not exceed 87 of...

Page 435: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1...

Page 436: ...her instructions Use a crane when handling heavy objects 25 kg or more The crane must be operated by a qualified operator Never go under a load raised by the crane Do not perform operations with the...

Page 437: ...sition also becomes greater Do not stop the work equip ment in air Do not suddenly swing lower or stop the work equipment It is dangerous that the machine may tip over Do not suddenly extend or retrac...

Page 438: ...ions If in doubt about the installation or operation consult your Komatsu distributor Pressure regulation valves 5 and 6 allow the attachment pressure and the release pressure for the quick coupler to...

Page 439: ...roll or slide after release 1 Operation switch 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 wil...

Page 440: ...k your Komatsu distributor for inspection and maintenance TO PICK UP A NEW BUCKET OR ATTACHMENT k k WARNING Check daily that the hoses and fittings in the quick coupler piping system are in good condi...

Page 441: ...bucket cylinder arm and boom as necessary Follow the quick coupler manufacturer s instructions 5 Release button 2 If the bucket or attachment needs a connection to the hydraulic system of the machine...

Page 442: ...e speed and perform the operation in L mode The wire or sling may come off the hook depending on the working posture Pay sufficient attention to the hook angle so that the sling does not come off Neve...

Page 443: ...olenoid 11 Variable relief pressure valve 12 Attachment 2 variable relief pressure valve 10 11 12 For the machines with attachment control function STOP VALVE The stop valve stops the flow of the hydr...

Page 444: ...o the ma chine the pressure to the attachment will be held by setting the pedals at NEUTRAL position VARIABLE RELIEF PRESSURE VALVE When the attachment control function is installed to the ma chine th...

Page 445: ...start using the attachment make sure that the attach ment operates normally LOCK PIN NOTICE Before changing the position of the lock pin stop the engine If you depress the pedal to D side with lock p...

Page 446: ...utting Do not hit or roll it or subject it to any impact When disposing of it the gas must be released Ask your Komatsu distributor to have this work per formed NOTICE To the machine equipped with a b...

Page 447: ...2 proportional circuit e g rotating the clamshell Rolling up the switch generates the attachment movement in one direction Rolling down the switch generates the attach ment movement in an opposite di...

Page 448: ...s follows 1 Check that the stop valve is located at LOCK position b a FREE Hydraulic oil flows direction of arrow is parallel to longitu dinal direction of arm b LOCK Hydraulic oil stops direction of...

Page 449: ...tate the valve to FREE position a at the clockwise end or the counterclockwise end 4 Remove the lever 3 5 Install the bolt 1 and washer 2 again PEDAL OPERATION AND OIL FLOW OF MACHINE EQUIPPED WITH AT...

Page 450: ...E mode Hydraulic oil flowing through crusher circuit does not pass through the additional filter for breaker Pressure of relief valve is set to high Maximum oil flow can be adjusted in the user mode S...

Page 451: ...thin 15 seconds to release the internal pres sure in the hydraulic circuit 4 Operate the operating portion g of the lock lever to set it to LOCK position L 5 Loosen the oil filler cap F slowly on the...

Page 452: ...e hose on the attachment side and install the plate 4 at the tip of the stop valve piping Right and left 2 places The plates are used to prevent the wrong operation of attachment due to mixing in of f...

Page 453: ...uipment control lever and attach ment control pedal fully to the front rear right and left for 2 to 3 times within 15 seconds to release the internal pres sure in the hydraulic circuit 7 Operate the o...

Page 454: ...op valve which is installed to the piping for the inlet port and the outlet port on the side face of the arm to FREE position a a FREE Hydraulic oil flows direction of arrow is parallel to longitu din...

Page 455: ...nal switches while holding the object When the attachment operation is performed the screen on the machine monitor is automatically switched to the bird s eye view display of KomVision For the change...

Page 456: ...tion message is displayed k k WARNING When a special attachment is installed if the mode is switched to the Breaker Mode carelessly it may lead to serious danger such as falling of the work equipment...

Page 457: ...acturer and use the break er correctly METHOD FOR OPERATING GENERAL ATTACHMENT SUCH AS CRUSHER ETC 1 Set the working mode to ATT P or ATT E mode 2 Set both front and rear lock pins to FREE position c...

Page 458: ...ng mode ATT P or ATT E For the oil passage route see METHOD FOR CHANGE OVER AND CONNECT HYDRAULIC CIRCUIT FOR MACHINE READY FOR INSTALLATION OF ATTACHMENT When handling the attachment follow the instr...

Page 459: ...Komatsu distributor METHOD FOR OPERATING ATTACHMENT 1 CRUSHER ETC k k WARNING Lock the pedal with the lock pin in order to prevent the attachment from moving incidentally when oper ating the attachme...

Page 460: ...g down the switch generates the attachment movement in an opposite direction Operate the roller slightly and the attachment moves slightly Operate the roller fully and the attachment moves quickly If...

Page 461: ...ent such as the protective eyeglasses and dust mask NOTICE For the element replacement interval see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER Items to be prepared Container to catch drained oil Prepa...

Page 462: ...on L After preparation is completed replace the additional filter for breaker according to the following procedure METHOD FOR REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER 1 Loosen the oil filler ca...

Page 463: ...g 4 to filter case 1 and screw the filter case 1 into filter head 6 7 After the top of filter case 1 touches the filter head 6 tighten it further at least 1 2 turn 8 Clean the removed plug 3 and fit t...

Page 464: ...MPa 305 kg cm2 other than B mode Port B 29 9 MPa 305 kg cm2 other than B mode Safety valve cracking pressure of service valve Port A 24 5 MPa 250 kg cm2 other than B mode Port B 24 5 MPa 250 kg cm2 o...

Page 465: ...B 44 3 MPa 452 kg cm2 Safety valve cracking pressure of service valve Port A 38 9 MPa 397 kg cm2 Port B 38 9 MPa 397 kg cm2 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT...

Page 466: ...th care HB215LC 3 NOTICE 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 materia...

Page 467: ...ple A Optional 800 Triple C Optional 900 Triple C Optional 860 Swamp C Optional 600 Flat D Precaution for track shoe selection Since the classifications by use B and C are for wide shoe their use is l...

Page 468: ...y duty operations are performed such as hitting or pulling up rocks with the tips of the teeth SELF SHARPENING TOOTH HORIZONTAL PIN TYPE VERTICAL PIN TYPE Jobsites requiring penetration such as diggin...

Page 469: ...e attachments or the models consult your Komatsu distributor HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows Crushing rock Road construction This attachm...

Page 470: ...of the chisel gradually deviates from the direction of the breaker body Adjust the direction with the bucket cylinder so that it keeps the proper direction Always keep the chisel pressed against the i...

Page 471: ...o not work by using the swing force Do not move the chisel while performing breaking operation Do not perform breaker operation in horizontal or upward direc tion Do not work under water ATTACHMENTS A...

Page 472: ...th any cylinder at the stroke end Posture of hydraulic breaker to be greased NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt will...

Page 473: ...olding it in the right posture shown below Lower the chisel perpendicularly to the ground Insert the grease gun perpendicularly to the greasing point Wrong posture ATTACHMENTS AND OPTIONS RECOMMENDED...

Page 474: ......

Page 475: ...REPLACEMENT PARTS 7 1...

Page 476: ...ps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Retighten all loose hoses and replace defective hoses as required Whe...

Page 477: ...efilter 600 319 3610 Cartridge 1 Hydraulic oil filter 207 60 71183 07000 15195 Element O ring 1 1 Every 1000 hours Fuel main filter 600 319 3750 Cartridge 1 Hydraulic tank breather 421 60 35170 Elemen...

Page 478: ...is filled into the storage tank or the fuel tank of the machine as soon as possible When the diesel fuel is changed to the one mixed with the bio fuel replace the fuel prefilter cartridge and the fue...

Page 479: ...l Check oil level in engine oil pan Change hydraulic oil Check oil level in hydraulic tank Change power train oil Check power train oil level Replace engine oil filter Replace hydraulic oil filter Rep...

Page 480: ...train oil TO10 KES Note5 30 50 Hydraulic oil HO56 HE KES 30 50 HO46 HM KES Note5 20 50 Grease fitting Hyper grease Note 3 G2 TE KES 30 50 Lithium EP grease G2 LI KES 20 50 Cooling system Hybrid equip...

Page 481: ...s preventing freezing 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 NA...

Page 482: ......

Page 483: ...er fresh recirc filter Clean 4 56 Air conditioner pilot lamp 3 36 Air conditioner recirculation air filter Clean 4 56 Air conditioner switch 3 51 3 221 Air conditioner system caution lamp 3 30 Air sus...

Page 484: ...er with lock Open Close 3 208 Cup holder 3 110 Current Abnormality display switch 3 21 Cylinder Bleed air 4 39 D Daylight saving time Set 3 83 Declaration of conformity 1 17 DEF 3 253 4 5 DEF Check le...

Page 485: ...rs maintenance 4 48 Every 5000 hours maintenance 4 84 Every 8000 hours maintenance 4 86 Every 9000 hours maintenance 4 86 Explanation of air conditioner equipment 3 218 Explanation of components 3 8 E...

Page 486: ...are found in the EGR valve system by the urea SCR system device 3 131 Inducement strategy when the def tank level be comes low 3 125 Initial 250 hours maintenance only 1st maintenance of new machine 4...

Page 487: ...ith bio fuel is used 4 14 Maintenance of air conditioner 2 44 Maintenance procedure 4 16 Maintenance schedule 4 12 Maintenance schedule table 4 12 Maintenance screen setting 3 77 Maintenance time caut...

Page 488: ...ring 2 46 Precautions for towing and being towed 2 34 Precautions for towing machine 3 259 Precautions for transportation 2 33 Precautions for transporting machine 3 238 Precautions for travelling 3 1...

Page 489: ...Seat Adjust in fore and aft 3 154 Seat Heat 3 156 Seat belt Fasten 3 164 Seat belt Fasten Unfasten 3 163 Seat belt Unfasten 3 164 Seat heater switch 3 98 Seat reclining Adjust 3 154 Seat tilt Adjust...

Page 490: ...tal pin type tooth Select 6 34 Vertical pin type tooth Use 6 33 Vibration level 1 8 Visibility from operator s seat 1 10 Volume control button 3 230 W Warning display 3 16 Washable floor Wash 4 35 Was...

Page 491: ......

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Komatsu HB215LC-3, Operation & Maintenance Manual

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