Komatsu HB365LC-3 Operation & Maintenance Manual Download Page 14

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FLUORINATED GREENHOUSE GASES

Product contains fluorinated greenhouse gases.

SERVICE METER LOCATION

This is displayed on the machine 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-Street
County Durham DH3 2QX
United Kingdom

Distributor name

Address

Service Personnel

Phone/Fax

PRODUCT INFORMATION

FOREWORD

1-12

Summary of Contents for HB365LC-3

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

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: ...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 and th...

Page 5: ...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 6: ...the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manu...

Page 7: ...f the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 Sound power level emitted by the machi...

Page 8: ...tems Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager...

Page 9: ...Do not jump down from the cab or machine Do not repeatedly handle and lift loads FOREWORD VIBRATION LEVELS 1 7...

Page 10: ...een from the operator s seat when the operator s seat is facing the front and the sprocket is at the rear of the machine VISIBILITY FROM OPERATOR S SEAT This machine complies with the visibility stand...

Page 11: ...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 12: ...Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel...

Page 13: ...ttom of the operator s cab The design of the nameplate differs according to the district LOCATION OF EU REGULATIONS ENGINE NUMBER PLATE They are on top of the engine cylinder head cover Made in Great...

Page 14: ...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 15: ...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 FOREWORD SERIAL PLATE 1 13...

Page 16: ...his machine HB365LC 3 Fulfils all the relevant provisions of following EC Directives Machine Directive 2006 42 EC Electro Magnetic Compatibility Directive 2014 30 EU Low Voltage Directive 2014 35 EU O...

Page 17: ...MON TO OPERATION AND MAINTENANCE 2 19 PRECAUTIONS BEFORE STARTING OPERATION 2 19 PREPARATIONS FOR SAFE OPERATION 2 19 PRECAUTIONS TO PREVENT FIRE 2 20 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 22 D...

Page 18: ...NG ON SLOPE 3 207 METHOD FOR ESCAPING FROM MUD 3 208 RECOMMENDED APPLICATIONS 3 209 EFFECTIVE USE OF HYDRAULIC EXCAVATOR 3 210 METHOD FOR REPLACING AND INVERTING BUCKET 3 211 METHOD FOR PARKING MACHIN...

Page 19: ...CURELY 4 4 OUTLINE OF MAINTENANCE 4 5 HANDLE OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 5 HANDLE ELECTRICAL COMPONENTS 4 9 HANDLING HYBRID COMPONENTS AND HIGH VOLTAGE WIRING 4 9 STANDARD TIGHTENING...

Page 20: ...ATTACHMENT 6 31 TRACK SHOES SELECTION 6 32 BUCKET TEETH SELECTION 6 33 RECOMMENDED ATTACHMENT OPERATIONS 6 34 HYDRAULIC BREAKER 6 34 KomVision 6 39 PRECAUTIONS WHEN USING KomVision 6 39 MACHINE MONIT...

Page 21: ...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 22: ...ELECTROMAGNETIC INTERFERENCE 2 24 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 24 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 24 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 25 ACTIONS IN THE...

Page 23: ...OR WORK EQUIPMENT 2 44 USE PROPER TOOLS 2 44 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 44 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 44 PRECAUTIONS FOR WELDING 2 44 HANDLE BATTERY 2 45 PRECAUTIONS...

Page 24: ...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 25: ...LOCATION OF SAFETY LABELS 5 SAFETY SAFETY LABELS 2 5...

Page 26: ...ring inspection and maintenance 8 Emergency escape 9 Caution against falling 10 Caution against falling 11 Prohibition of entering within swing range 12 Caution for work equipment 13 Caution for handl...

Page 27: ...of each label are as fol lows Warning for operation inspection and maintenance Warning a Read the manual before operating inspection mainte nance disassembly assembly and transportation Warning when...

Page 28: ...erate where a danger of falling objects exists Consult your dealer for fitting of FOPS FALLING OBJECT PROTECTIVE STRUCTURE protection Warning going too close to electric cables e An electrocution haza...

Page 29: ...perator cab g Take care when standing in the operator cab Before standing up from the operator s seat such as when opening or closing the front window or when removing or installing the bottom window...

Page 30: ...ching any of the working equipment control levers might cause the machine to start mov ing all of a sudden probably resulting in a serious in jury Caution when stowing front window 2 Caution when stow...

Page 31: ...s a hazard of flying plug from track adjuster that could cause injury Read manual regarding adjusting track for safe and proper handling Caution for handling cable 6 Caution when handling cable 09808...

Page 32: ...alling 9 Caution against falling 09805 C0881 Sign indicates a hazard of falling Do not stand on the place here Caution against falling 10 Caution against falling 09805 C0481 Sign indicates a hazard of...

Page 33: ...ipment 12 Keeping out of working range area 09134 A1681 Sign indicates a hazard of being hit by the working device of the machine Keep away from the machine during operation Caution for handling batte...

Page 34: ...gases Caution do not start by short circuiting 14 Prohibition of short circuit start 09842 A0481 Warning for quick coupler system 15 Warning for use of hydraulic quick coupler piping system 20J 00 11...

Page 35: ...ion for blast jobsite 17 Caution of an explosive hazard caused by active radio transmitter at a blast zone 09845 00480 Keep machine at a safe distance from blast zone and a detonator Caution for high...

Page 36: ...d the manual before operating inspection maintenance disassembly assembly and transportation Prohibition of disassembly of stepping on high pressure washing of hybrid components 23 Danger of electrocu...

Page 37: ...precautions Caution when replacing fresh air filter 25 Caution when replacing fresh air filter 208 00 71261 After replacing fresh air filter remember to remove key from cover as the key may get damage...

Page 38: ...Caution for handling DEF 27 DEF Diesel Exhaust Fluid 09632 60800 To avoid engine damage or fire fill with Diesel Exhaust Fluid DEF only Never use diesel fuel SAFETY LABELS SAFETY 2 18...

Page 39: ...TION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of...

Page 40: ...ay cause fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects...

Page 41: ...in the specified place and do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any flammable materials to a safe place before starting Fire caused...

Page 42: ...INE To prevent personal injury caused by slipping or falling off the machine always observe the following Use the handrails and steps marked by arrows in the fig ure when getting on and off the machin...

Page 43: ...he bottom window or adjusting the posi tion of the seat always lower the work equipment to the ground set lock lever 1 to LOCK position L and stop the engine If the control levers are touched by mista...

Page 44: ...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 45: ...objects and intruding objects as detailed in the previous section Operator cabin FOPS falling object protective structure Front window guard In the event any of the above parts become broken or damage...

Page 46: ...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 47: ...IONS 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 under th...

Page 48: ...c shock the operator should not leave the operator s compartment until it has been confirmed that the electricity has been shut off Also prohibit any other persons to come close to the machine ENSURE...

Page 49: ...uty if there are areas where the visibility is poor Only one signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up additi...

Page 50: ...he air always operate the machine from an upwind position and make sure that all workers operate on the upwind side All workers should use anti dust masks Prohibit other personnel from coming close to...

Page 51: ...urrounding area from the operator s seat For the adjustment see METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 3 171 Adjust the armrest to a position for easier operation and fix it securely Operation in...

Page 52: ...the jumper cables Disconnect the negative cable ground side first when removing them When disconnecting the jumper cables take care not to bring the clips in contact with each other or with the machi...

Page 53: ...ople or obstacles in the surrounding area Before moving sound the horn to warn people in the surrounding area Check that the travel alarm and other alarms work properly If there is an area in the rear...

Page 54: ...machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine When passing over bridges or structures check first that the structure is s...

Page 55: ...ntrol levers immediately to NEUTRAL position set the lock lever to LOCK position and then start the engine PRECAUTIONS WHEN OPERATING ON SLOPES When working on slopes there is a hazard that the machin...

Page 56: ...uick escape in an emergency set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when performing operations Do not demolish the structure where the machine is pla...

Page 57: ...he machine on the flat ground as well as on slopes observe the follow ing Do not suddenly lower swing or stop the work equipment Do not suddenly extend or retract the boom cylinder It is dangerous tha...

Page 58: ...ion Always observe the following Always check the machine dimensions carefully Depending on the work equipment and optional devices installed the machine weight transportation height and overall lengt...

Page 59: ...ly at the joint between the ramps and the loading platform and there is danger of the machine losing its balance Drive slowly over this point When loading or unloading to an embankment or platform mak...

Page 60: ...form any lifting operation with a load heavier than the specified lifting load It may cause a seri ous accident such as tipping over of the machine Determine the signals to be used and place a signalm...

Page 61: ...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 62: ...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 63: ...installation operations for attachments Place attachments that have been removed from the ma chine in a stable condition so that they do not fall And take steps to prevent unauthorized persons from en...

Page 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...OR DISPOSING OF WASTE MATERIALS 2 49 and MAINTENANCE OF AIR CONDITIONER 2 49 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution pay full attention to the way to dispose of waste materia...

Page 70: ...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 specifie...

Page 71: ...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 anothe...

Page 72: ...tion 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 slower o...

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 11 Engine hood GENERAL VIEW OPERATION 3 2...

Page 75: ...sed Crankcase Ventilation hereafter KCCV ventilator 13 SCR 14 KDPF 15 Toolbox 16 Battery 17 Battery disconnect switch 18 System operating lamp 19 Fusible link 20 Grease pump holder 21 KomVision camera...

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: ...witch if equipped 16 Revolving lamp switch if equipped 17 Attachment control pedal if equipped 18 Attachment control pedal if equipped 19 Cigarette lighter 20 Room lamp switch 21 Seat heater switch 22...

Page 78: ...Hybrid temperature caution lamp 11 Engine coolant temperature gauge 12 Engine coolant temperature caution lamp 13 Fuel gauge 14 Fuel level caution lamp 15 DEF level gauge 16 DEF level caution lamp 17...

Page 79: ...e level caution lamp 39 Water separator caution lamp 40 Engine oil pressure caution lamp 41 Hybrid caution lamp 42 Hybrid temperature caution lamp 43 Function switches F1 to F6 44 Maintenance time cau...

Page 80: ...3 Meter display 4 Monitor switch part 5 Guidance icon display 6 Camera image display REMARK For the user menu to configure the settings of the machine in the machine monitor see USER MENU DIS PLAY SWI...

Page 81: ...screen HH is displayed for 2 seconds the screen switches to standard screen AA If the working mode when the engine is started is the B mode the opening screen GG is displayed for 2 seconds and the scr...

Page 82: ...switch 1 is turned OFF nor mal the machine monitor switches to the standard screen and you can start the engine with usual starting switch key op eration For the function and operating method of engi...

Page 83: ...or identification function with SKIP is set the opening 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...

Page 84: ...ON posi tion If inputting the incorrect ID number for 3 times continuously you cannot input the ID number for 5 minutes Wait for more than 5 minutes try inputting the ID number again As long as the ID...

Page 85: ...tarting 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...

Page 86: ...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 screen...

Page 87: ...level displays and required actions The caution lamp that lights up in red when an action level is displayed warns operator to stop the ma chine urgently stop or pause the current operation If no act...

Page 88: ...ine monitor By pressing the switch F5 on the standard screen while the ac tion level is displayed the list of the Current Abnormality is dis played For the display method of failures see CURRENT ABNOR...

Page 89: ...the warning 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 L0...

Page 90: ...ine stopped 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 syst...

Page 91: ...L01 Air conditioner system cau tion lamp Abnormal L01 Overload caution lamp Overload Quick coupler caution lamp Abnormal L03 Maintenance time caution lamp Due time is over Notice Seat belt caution la...

Page 92: ...ctions according to the message displayed on the monitor Operation on the Current Abnormality screen On Current Abnormality screen you can perform the following operations with switches F1 F2 and F5 F...

Page 93: ...see METHOD FOR ENGINE WARM UP OPERATION 3 182 When temperature is correct The caution lamp lights up in blue HYDRAULIC OIL TEMPERATURE CAUTION LAMP The hydraulic oil temperature caution lamp warns ab...

Page 94: ...en 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 low i...

Page 95: ...ights up 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 detail see DEF LEVEL...

Page 96: ...ys perform the inspection and maintenance Ask your Komatsu distributor for inspection and maintenance as needed KDPF SYSTEM CAUTION LAMP The KDPF system caution lamp warns about abnormality in the KDP...

Page 97: ...LAMP DEF level caution lamp alerts when DEF tank level becomes low Whenever the caution lamp lights up in red immediately add DEF Fault conditions that result in activation of the Inducement strat egy...

Page 98: ...ne power will be derated REMARK For more information about the Inducement strategy and Inducement status concerning engine power de ration see HANDLE UREA SCR SYSTEM WARNING 3 128 DEF SYSTEM HIGH TEMP...

Page 99: ...e specific times When action level L03 is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently Stop the operation and move the machine to a safe place then ask your K...

Page 100: ...DING OIL 3 155 If it occurs again in a short time the engine oil may be leaking Ask your Komatsu distributor for inspection and maintenance ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp...

Page 101: ...R CHECKING WATER SEPARA TOR DRAINING WATER AND SEDIMENT 3 150 REMARK The water separator forms one unit with the fuel prefilter The water separator is installed at the bottom of the fuel prefil ter as...

Page 102: ...tion level L03 is displayed The alarm buzzer sounds intermittently The oil pressure in the quick coupler system is dropped Stop the machine immediately and ask your Komatsu distribu tor for the inspec...

Page 103: ...up in yellow The maintenance time is approaching Prepare the necessary parts for the maintenance REMARK You can check the maintenance items on the maintenance tab screen by pressing switch F6 on the m...

Page 104: ...Wiper pilot lamp 8 Swing lock pilot lamp 9 One touch power maximizing pilot lamp 10 Preheating pilot lamp 11 Auto deceleration pilot lamp 12 Working mode display 13 Travel speed display 14 ECO guidanc...

Page 105: ...ghts up The swing lock is being actuated When the swing lock switch is turned on LOCK this lamp lights up When the swing parking brake cancel switch is turned to Can cel position this lamp flashes For...

Page 106: ...is on fuel consumption For the position of the working mode selector switch see MACHINE MONITOR EQUIPMENT NAME 3 6 When E mode is selected E0 to E03 are displayed See ADJUST ECONOMY MODE 3 69 TRAVEL S...

Page 107: ...ade OFF No messages ENGINE STOP PILOT LAMP The engine stop pilot lamp is displayed while the engine is stopped It goes out when the engine is started AFTERTREATMENT DEVICES REGENERATION PILOT LAMP k k...

Page 108: ...n caution lamp lights up If the KDPF soot accumulation caution lamp lights up cancel the regenera tion disable setting and perform the manual stationary regener ation For the procedures of cancellatio...

Page 109: ...e recommendation guidance If light load work is continued for more than 10 minutes in P or ATT P mode E mode recommendation message is displayed When working on light load set the working mode to E to...

Page 110: ...CES REGENERATION DISABLE SETTING 3 124 then stop the engine after run ning it at low idle for approximately 5 minutes The information about engine stop operation during the after treatment devices reg...

Page 111: ...is in green range during operation it is normal When the indicator nears the red range A during operation the hydraulic oil temperature has exceeded102 C Run the en gine at low idle or stop it and wa...

Page 112: ...fuel level caution lamp D lights up in red The correct fuel level may not be displayed for a short time after the starting switch is turned to ON position but this is not abnormal SERVICE METER CLOCK...

Page 113: ...Although there is no abnormality on the machine when the gauge enters the yellow range for the conservation of global environment reduce the engine output to a point where there is no adverse effect o...

Page 114: ...gauge to display the correct position Note that the following cases are not abnormal When DEF is added while the starting switch is kept at ON position When the starting switch is turned to ON positi...

Page 115: ...reases and the swing speed decreases Position in red range B Hybrid temperature caution lamp E indicates abnormality G and the alarm buzzer sounds si multaneously The maximum swing speed and swing acc...

Page 116: ...he guidance icon 2 is pressed it does not func tion Press the function switch 1 directly under the guid ance icon 2 to operate the function When the machine monitor display shows the standard screen t...

Page 117: ...es to the item below forward When on the last line it moves to the first line J Switch F4 Moves to the item above backward When on the first line it moves to the last line K Switch F5 Cancels any chan...

Page 118: ...display For the machines ready for installation of attachment the attachment mode is added to the display For handling of machines ready for installation of attachment see ATTACHMENTS AND OPTIONS 6 1...

Page 119: ...screen is highlighted in yellow 5 After 2 seconds the screen returns to the standard screen The working mode display highlighted in yellow in step 4 returns to blue REMARK When setting the working mod...

Page 120: ...nction is enabled if the work equipment lever and travel lever are returned to NEUTRAL position the engine speed will drop approximately after 4 seconds from the operating speed to idle speed Then the...

Page 121: ...d range speed travel Hi lights up High speed travel When the engine is started the speed is automatically set to Lo Each time that the switch is pressed the display changes Lo Mi Hi Lo in turn Even if...

Page 122: ...NT lights up Wiper operates intermittently Wiper pilot lamp ON lights up Wiper operates continuously Wiper pilot lamp off Wiper stops REMARK Each time wiper switch is pressed the mode is displayed in...

Page 123: ...operate for 2 cycles then stops If you keep pressing the switch when the wiper is moving intermittently the window washer fluid is sprayed out At the same time the wiper is actuated continuously When...

Page 124: ...ch switch see HANDLE AIR CONDI TIONER 3 223 FUNCTION SWITCHES The operation of the function switches in the standard screen CAMERA IMAGE SELECTOR SWITCH On the standard screen you can select a display...

Page 125: ...ration of one camera image display screen Operate the following for the method of operation when it is desired to display only one camera image on the monitor On the standard screen when the switch F3...

Page 126: ...ress the switch F3 and the screen returns to the stand ard screen Operation of image display screen when two camera images are shown simulta neously Even if three cameras are installed only the images...

Page 127: ...oner operation see HANDLE AIR CON DITIONER 3 223 It is possible to change the working mode by pressing the working mode selector switch For the working mode selector switch see WORKING MODE SELECTOR S...

Page 128: ...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 129: ...NG DISPLAY 3 15 and TROUBLES AND ACTIONS 3 262 ENERGY MONITOR SCREEN SELECTOR SWITCH When the function switch F2 is pressed on the standard screen the monitor display screen switches to the Energy Mon...

Page 130: ...Devices Regeneration d SCR Information e Maintenance f Monitor Setting g Mail Check These menus a to g are for setting and confirming the fol lowing items For operations in each menu see the detailed...

Page 131: ...CR Information 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 Adjustme...

Page 132: ...he 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 opera...

Page 133: ...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 134: ...l consumption during 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 Fue...

Page 135: ...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 136: ...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 137: ...erage Fuel Consumption 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 t...

Page 138: ...s 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 change and returns the screen to...

Page 139: ...a 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 sc...

Page 140: ...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 141: ...F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels...

Page 142: ...setting name as you like You can use alphabet letters A to Z Arabic numerals 0 to 9 symbols and and the space 1 On the Breaker Setting screen select a setting to change its name then press switch F6...

Page 143: ...Select Attachment Setting 3 on Machine Setting menu b screen then press the switch F6 2 On Attachment Setting screen shown in the figure select an attachment setting to adjust and press the switch F6...

Page 144: ...ing screen It is not possible to change the name for No Attachment setting Changing 2 Way Attachment Oil Flow Rate Setting 1 On Attachment Setting screen select a setting to change its oil flow rate t...

Page 145: ...s played On 2 Way Attachment Oil Flow Rate Setting screen you can perform the following operations with switches F1 to F6 F1 Switches the display from attachment 2 oil flow setting screen to attachmen...

Page 146: ...the setting 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 fun...

Page 147: ...ied in the service 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 If you set the lock lever t...

Page 148: ...TION Each item of Aftertreatment Devices Regeneration menu c is for settings of the aftertreatment devices regeneration For details of the aftertreatment devices regeneration see HANDLE Komatsu Diesel...

Page 149: ...hange 2000 KDPF Filter Cleaning 4500 DEF Tank Washing 4500 Hydraulic Oil Change 5000 a Maintenance items b Default maintenance interval settings h c Time remaining to maintenance h 1 When using the en...

Page 150: ...ration on Maintenance Due Time Reset screen On Maintenance menu screen if the switch F6 is kept pressed for at least 1 5 seconds the screen changes to Maintenance Due Time Reset screen Reset the remai...

Page 151: ...or 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 r...

Page 152: ...een then 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 Savin...

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: ...s to the next item 1 line below Moves to the 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...

Page 156: ...ck 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 Koma...

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: ...r Komatsu distributor Reply to the message in accord ance with the replying method mentioned below If the starting switch is turned to OFF position when there is any unread message the message will be...

Page 160: ...sing 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 If...

Page 161: ...at heater switch 13 Engine shutdown secondary switch 14 Pump secondary drive switch 15 Swing parking brake cancel switch 16 Lock lever automatic lock cancel switch 17 Hybrid system stop switch 18 Lowe...

Page 162: ...ition 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 c...

Page 163: ...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 164: ...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 165: ...ancel When abnormal switch is set to upper position b Normal When normal switch is set to lower position When the upper structure does not swing but the display does not show L03 move this switch to C...

Page 166: ...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 is...

Page 167: ...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 168: ...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 169: ...decreased the machine is less moved up during digging work and the operator can dig smoothly Use this position for the general normal operation for ordinary soil soft rocks blasted rocks etc b High p...

Page 170: ...is a roller propor tional control switch that operates the attachment 2 proportion al circuit e g rotating the clamshell For details see ATTACHMENTS AND OPTIONS ATTACH MENT 2 PROPORTIONAL CONTROL SWI...

Page 171: ...ever or pushing it down Before setting the lock lever to FREE position make sure that all control levers and pedals are set to NEUTRAL position If any of them is out of NEUTRAL position the work equip...

Page 172: ...k 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 automatically and the message...

Page 173: ...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 174: ...e front window stop the machine on a level ground lower the work equipment to the ground stop the engine then perform the operation When opening the front window hold the handle securely with both han...

Page 175: ...aces 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 top of the front window will come out OPERATION EXPLANATION...

Page 176: ...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 177: ...rip right and left handles A and pull down lever B to release the lock 3 Grip the handle C at the bottom of the front window with your left hand and the handle D at the top with your right hand push t...

Page 178: ...k Removal of front window lower side 1 Open the front window upper side then hold grip 1 pull it up and remove the lower side window REMARK If sand or dust is collected at the bottom of the front win...

Page 179: ...use the hammer A to break the glass and escape through the window METHOD FOR USING DOOR LOCK k k WARNING Before the releasing the door lock always place the machine on a level ground Never release th...

Page 180: ...caps and covers For the locations and opening and closing method of the cap with lock and cover see LOCK 3 216 Insert the key as far as it will go to the shoulder A and turn it If the key is turned w...

Page 181: ...TRAY This is on top of the console box on the left side of the opera tor s seat Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid NOTICE While removing the...

Page 182: ...W 12 V x 12 A When it is used at 1 place 144 W 12 V x 12 A When it is used at 2 places 144 W in total REMARK Use 12 V power source while engine is running FUSE NOTICE Before replacing a fuse be sure t...

Page 183: ...r supply 14 5A Key ACC signal 15 10A Working lamp 16 10A Radio backup room lamp system operating lamp 17 20A Monitor pump controller 18 30A Engine controller 19 5A Air conditioner ECU backup 20 25A Op...

Page 184: ...he engine starting switch is turned to START position the fusible links 1 and 2 may be broken Remove the cover 3 inside the rear right of the machine and perform the inspection or re placement REMARK...

Page 185: ...on always remove the switch key 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...

Page 186: ...urned on Lamp 1 lights up in green when the controller is turned on and goes out in 2 to 6 minutes after the starting switch is turned to OFF position Before operating the battery disconnect switch ch...

Page 187: ...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 7 5 NOTICE The auto greas...

Page 188: ...tarting switch is in ON position 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...

Page 189: ...cessary 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 test button 1 second or longer with the st...

Page 190: ...regardless of the quantity of the accumulat ed soot During the KDPF regeneration aftertreatment devices regeneration pilot lamp 1 lights up on the monitor REMARK Even if aftertreatment devices regener...

Page 191: ...y increase but this is not a fail ure Even just after the regeneration is completed the soot ac cumulation level may not be 0 This is caused by the ac cumulated noncombustible material in the exhaust...

Page 192: ...n A is displayed first The action level goes out 2 seconds later and the screen changes to standard screen B If the lock lever is set to LOCK position or all the work equipment control levers are set...

Page 193: ...ary regeneration PROCEDURE FOR MANUAL STATIONARY REGENERATION k k CAUTION Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regen eration Avoid get...

Page 194: ...in step 6 the screen shown in the figure may be displayed This indi cates that the operations in steps 1 to 4 were not per formed correctly or there is trouble other than the KDPF soot accumulation a...

Page 195: ...ion is displayed for 30 seconds and then the screen re turns to the standard screen At this time to display the explanation of the manual stationary regeneration again press the function switch F6 on...

Page 196: ...at the procedure from step 6 If the machine needs to be moved during the manual stationary regeneration stop the regeneration tempo rarily and move the machine by referring to the after treatment devi...

Page 197: ...e function switch F6 on the standard screen 2 Operate the function switches F1 and F2 to select After treatment Devices Regeneration menu C to display the Aftertreatment Devices Regeneration screen 3...

Page 198: ...p 3 may light up but this does not indicate abnormality Also during the regeneration to protect the system the regener ation disable cannot be operated When the regeneration is performed to protect th...

Page 199: ...eatment Devices Regeneration screen is dis played If the screen is not displayed operate the function switches F1 and F2 to display Aftertreatment Devices Re generation screen 2 Select the cancel of r...

Page 200: ...and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water The Komatsu Urea SCR System continuously monitors its operation conditions and stores information on i...

Page 201: ...em automatically starts operating as soon as the engine is started Even after the engine starting switch is turned to the OFF position the devices will still be in operation for sever al minutes to pu...

Page 202: ...lamp 1 on the machine monitor will light up audible alert will start then Action level will be dis played on the machine monitor and engine power will be derat ed in steps In Action Level L03 Low leve...

Page 203: ...l gauge light up in the red range DEF level caution lamp 1 lights up in red No Action level is displayed Press F6 to display the SCR Information screen Inducement status 4 2 Without treatment engine p...

Page 204: ...engine power through the machine monitor For the engine power restoration procedure refer to the section of Temporary Restoration from Inducement in this manual Once in Severe Inducement and it becom...

Page 205: ...te Action Level L01 once shows up in yellow on the machine monitor 2 for 2 seconds and goes out Press F6 to display the SCR Information screen SCR Information screen message 4 1 Please inspect and mai...

Page 206: ...y 2 and stays on Press F6 to display the SCR Information screen SCR Information screen message 4 3 Engine power is under deration Due to the engine power deration capability of the ma chine will be li...

Page 207: ...is manual Inducement strategy when abnormality is found in the KDPF System by the Urea SCR system If any abnormality is detected in the KDPF System through the Urea SCR system the Inducement strategy...

Page 208: ...the safe place and contact your Ko matsu Distributor If operation continues for 5 hours after Warning started without taking any actions instructed by the Action Level table Inducement advances to Con...

Page 209: ...4 lights up in red at action level display 3 Press F6 to display the SCR Information screen SCR Information screen message 5 4 Engine power is under heavy deration Due to the further deration of engin...

Page 210: ...power will be further derated If L03 is displayed move the machine to a safe place and contact your Komatsu distributor The content of the warning can be checked on the SCR Information screen of the u...

Page 211: ...tes till the next Induce ment status of Low level Inducement is displayed in the column 6 of SCR Information screen In Low level Inducement engine power will be derated Low level Inducement The audibl...

Page 212: ...s to Severe In ducement and it becomes necessary to restore engine power use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor Temporary Re...

Page 213: ...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 is...

Page 214: ...ducement 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 previo...

Page 215: ...ement system that remotely manages the machines equipped with the KOM TRAX device by using satellite communication or portable radio communication The GPS Global Positioning System receiver and commun...

Page 216: ...stered and used if the machine is purchased as second hand For the registration and usage records of KOMTRAX consult your Komatsu distributor If the machine has been lent out by the customer the borro...

Page 217: ...ce turbocharger or other high temperature engine parts If any dirt or combustible materials are found remove them For removal of dirt from the radiator see METHOD FOR CHECKING AND CLEANING RADIATOR FI...

Page 218: ...15 Check around the aftertreatment devices for exhaust gas leakage Check the pipe connecting the turbocharger to the aftertreatment devices and also KDPF connections for leakage of exhaust gas and de...

Page 219: ...he hose end is clean Close the hose strainer valve cap H in order to prevent the fuel from leaking or overflowing if refu elling pump is not used Contact your Komatsu distributor if there is any malfu...

Page 220: ...ing can be stopped anytime by turning off the master switch 4 Keep pressing the switch 5 to further refuel the fuel tank with fuel after the float switch stopped the refuel ling pump Keep pressing the...

Page 221: ...8 is installed to this system Check the fuse if the refuelling pump does not op erate 7 Perform the following to clear up after the refuelling is completed 1 Push the float gauge G straight down with...

Page 222: ...er is accumu lated in transparent cup 2 In this case also use the procedure above to drain the wa ter REMARK When only the water separator caution lamp lights up it lights up in the position shown in...

Page 223: ...se 3 then remove the drain valve 4 6 Apply a suitable amount of grease to the O ring 7 REMARK When applying the grease be careful not to allow the grease to adhere to the water drain port 8 and thread...

Page 224: ...engine and move each control lev er for work equipment and travel to the full stroke in all directions The internal pressure is released by this operation 3 Stop the engine 4 Open the door on the left...

Page 225: ...r 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 A...

Page 226: ...AC of the same density as Non Amine Engine Coolant AF NAC in the radiator and then add it to the reservoir tank 5 Check that the hybrid radiator coolant sight gauge 3 is fil led with coolant If it is...

Page 227: ...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 because of water vapor...

Page 228: ...clogged with dirt or dust wash the 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 inspe...

Page 229: ...es up to the highest point Fuel tank capacity 605 Position of tip a of float gauge G when fuel tank is full Approximately 50 mm REMARK If breather hole 3 on the cap is clogged the pressure in the tank...

Page 230: ...tting 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 tank When opening...

Page 231: ...DEF the strainer may be broken Do not use a funnel When using a portable refill container use it up each time If any of it is left completely seal it up Remove foreign material if there is any Do not...

Page 232: ...ng it clockwise by 90 REMARK 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 When the specified nozzle is used the magnet...

Page 233: ...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 234: ...e for operation then release the lever REMARK Sit with your back against the backrest when adjusting If your back is not touching the backrest the backrest may suddenly move forward METHOD FOR TILTING...

Page 235: ...of the armrest Armrest height adjustment 43 mm 4 steps 1 Loosen knob 1 at the rear of the armrest 2 Pull plunger 2 3 Adjust the height of armrest 3 while pulling plunger 2 4 Push back plunger 2 after...

Page 236: ...SION SEAT HARDNESS Air suspension seat if equipped Operate the suspension switch 9 to adjust the hardness of the suspension If you press the suspension switch 9 the suspension be comes hard If you pul...

Page 237: ...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 238: ...person at the rear left end of the machine 3 If you cannot adjust loosen mounting bolts 1 of the mir ror and stay and adjust the angles If the mirror is adjusted by loosening the mounting bolts be sur...

Page 239: ...ue of mounting bolt 6 6 0 to 7 0 Nm 0 61 to 0 71 kgm Mounting position 7 166 mm NOTICE Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L bec...

Page 240: ...The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Adjust the mirror so that you can see a person at the rear right of the machine...

Page 241: ...el ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped When returning the mirror to its regular position perform the following...

Page 242: ...e met before starting the work to 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...

Page 243: ...lways adjust the camera before starting work If it is not adjusted properly you cannot secure the visibility and a serious personal injury or death may result When adjusting the angle of the camera pr...

Page 244: ...on the monitor is not aligned correctly adjust mounting angle A of the rearview camera in the following pro cedure Angle A can be adjusted within the range from 32 to 53 1 Insert a flat head screwdriv...

Page 245: ...rding to the record Take care of shim 6 since it comes off together with cover 1 4 Loosen camera mounting bolts 5 3 places and adjust camera mounting angle A so that corner D of mounting bracket C is...

Page 246: ...seat belt has a retractable device so it is not necessary to adjust the length METHOD FOR FASTENING SEAT BELT 1 Hold grip 2 and pull out the belt from retractable device 1 2 Check that the belt is no...

Page 247: ...he battery disconnect switch S is in ON posi tion I 2 Check that the lock lever 1 is at LOCK position L 3 Check that all the control levers and control pedals are at NEUTRAL position If all the contro...

Page 248: ...5 Hybrid temperature caution lamp 6 Engine oil level caution lamp 7 Air cleaner clogging caution lamp 8 Water separator caution lamp 9 Hybrid caution lamp 10 If any caution lamp does not light up or t...

Page 249: ...the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Check that the fuel control dial 2 is at Low idle MIN position before starting the engine The engine will ac cel...

Page 250: ...ay screen will be indicated on the machine monitor screen but the preheat ing pilot lamp also operates as in the standard screen 4 If the preheating pilot lamp does not light up or it lights up and th...

Page 251: ...ted to thaw DEF after the engine is started The devi ces do not operate until DEF is thawed and supplied but this does not indicate any abnormality When the ambient temperature decreases to a level wh...

Page 252: ...is any trouble such as emergency stop abnor mal actuation etc turn the starting switch key to OFF position Do not perform operations nor operate the levers or pedals abruptly while the hydraulic oil...

Page 253: ...of driving or lower the braking effi ciency and as a result lead to an unexpected accident In that case ask your Komatsu distributor to check the engine as soon as possible When stopping the machine d...

Page 254: ...s automatically When the engine automatic warm up operation starts the engine speed is maintained higher than the normal speed at low idle If the engine coolant temperature goes 30 C or more or if the...

Page 255: ...utomatic warm up operation or to lower the engine speed to Low idle MIN do as follows 1 Turn the fuel control dial 2 to High idle MAX position and hold it for 3 seconds or more 2 Turn the fuel control...

Page 256: ...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 equipment boom arm and buck et sw...

Page 257: ...tween Low idle MIN and High idle 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 with the machine o...

Page 258: ...kground 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 te...

Page 259: ...raulic system warm up operation in 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...

Page 260: ...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 261: ...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 262: ...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 263: ...the engine stop the aftertreatment devices regeneration first according to PROCEDURE FOR AFTER TREATMENT DEVICES REGENERATION DISABLE SET TING 3 124 then stop the engine after running it at low idle f...

Page 264: ...battery disconnect switch to OFF posi tion while the devices are purging DEF After the purg ing operation is finished the devices stop automatical ly METHOD FOR STARTING MACHINE TRAVEL FORWARD AND RE...

Page 265: ...and it is 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 s...

Page 266: ...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 267: ...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 268: ...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 269: ...SWINGING MACHINE k k WARNING The tail of the machine extends outside the tracks Check that there is no one around the machine before operating the swing If the travel levers are operated when the eng...

Page 270: ...creased by the auto deceleration function the en gine speed will suddenly increase Operate the levers carefully Use the R H and L H work equipment control levers to operate the work equipment When the...

Page 271: ...d 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 th...

Page 272: ...de selection 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 s...

Page 273: ...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 274: ...extended PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging nor use the dropping force of the bucket as a mattock breaker or pile driver Th...

Page 275: ...large vibration occurs in the machine and can crack the work equipment or frame If the bucket blade slides and collides with a rock an excessive impact load occurs in the work equipment and frame and...

Page 276: ...damage the undercover and frame In the worst case the hydraulic components are dam aged and a serious accident can result During operation keep checking the track top for crushed stones soil and sand...

Page 277: ...to cool down If the machine travels continuously for a long time with the tracks loosened it may break the undercarriage parts When driving the machine for a long time check the track ten sion every...

Page 278: ...use the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in water or soil and dirt deeper than the center of carrier roller 1 After the job be sure to s...

Page 279: ...le driving and operating the machine in order to stop it safely when the machine slips or be comes unstable When the machine is travelling uphill if the shoes slip or it is impossible to travel uphill...

Page 280: ...en start the engine again Pay attention to DEF level Before working on a slope or travelling on a rough ground check DEF tank and add sufficient amount of DEF as necessary If the remaining DEF level b...

Page 281: ...d set the travel lever to FORWARD position to drive the machine out RECOMMENDED APPLICATIONS In addition to the following it is possible to further increase the range of applications by using various...

Page 282: ...ncy can be enhanced by locating the dump truck in a place easily visi ble to the operator Loading is easier and capacity greater if you begin from the rear of the dump truck body than if loading is do...

Page 283: ...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 284: ...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 285: ...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 286: ...standard machine METHOD FOR PARKING MACHINE k k WARNING Stop the machine gradually Avoid a sudden stop Place the machine on a firm and level place Do not park the machine on a slope Block the tracks...

Page 287: ...e machine stops 2 Turn the fuel control dial 2 to low idle MIN position in or der to lower the engine speed 3 Lower the bucket to the ground with its bottom face hori zontal 4 Set the lock lever 3 to...

Page 288: ...ine and check the work equipment machine exterior and undercarriage also check for any leakage of oil or coolant If any problems are found repair them 2 Fill the fuel tank 3 Check the engine compartme...

Page 289: ...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 290: ...se of its own 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 after treatment devices are still hot Accord...

Page 291: ...OCKING ENGINE HOOD 1 Hold knob 5 and support the engine hood 2 Push stay 6 in the direction of the arrow and remove stay 6 from LOCK position 7 3 Check that stay 6 is set in guide groove 8 and then lo...

Page 292: ...form the operation When opening it do not release 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 d...

Page 293: ...ecurely in position 4 to lock it METHOD FOR LOCKING DEF TANK FILLER CAP COVER 1 Pull stay 3 toward you and unlock the stay 2 Lower the cover 3 Turn the key clockwise to lock and remove it Position A O...

Page 294: ...lot 2 Turn the key clockwise to unlock the key then open the door handle Position A OPEN Position B CLOSE LOCK When locking the door 1 Close the door and insert the key into the key slot 2 Turn the st...

Page 295: ...the air conditioner may not work In this case circulate recirculation air to warm the inside of the cab After that turn on the air conditioner switch the air conditioner will work If any abnormality i...

Page 296: ...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 297: ...e can be set in stages of 0 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 I...

Page 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...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 304: ...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 305: ...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 3 233...

Page 306: ...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 307: ...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 308: ...ctor button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX...

Page 309: ...character numeric information 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...

Page 310: ...ust 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 311: ...ile 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 FO...

Page 312: ...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 reg...

Page 313: ...na 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 t...

Page 314: ...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 315: ...work equipment for loading and unloading operations Always use ramps The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer and it is dangerous that the m...

Page 316: ...event 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...

Page 317: ...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 at the point wh...

Page 318: ...sportation put a block under the tip of the bucket link to prevent the bucket cylinder from touching the floor After loading the machine onto a trailer secure the machine as follows 1 Extend the bucke...

Page 319: ...TIE DOWN POINT Place blocks under both ends of the tracks to prevent the ma chine from moving during transportation and secure the ma chine with chains or wire ropes of suitable strength In particu l...

Page 320: ...upport 3 2 Loosen the bolts 4 and remove the support 3 and clamp 5 from the handrail Mirror C Loosen the mounting bolts 2 then remove the mirror 1 from support 3 METHOD FOR INSTALLING MIRROR Mirrors A...

Page 321: ...om high place that can lead to serious personal injury or death Check the scaffolding and ensure your safety before starting the work If installation or removal work of the handrail is improper there...

Page 322: ...1 Tightening torque 98 to 123 Nm 10 0 to 12 5 kgm METHOD FOR REMOVING AND INSTALLING CLIMBING HANDLE When removing and installing handle A for transportation of the machine etc perform the operation...

Page 323: ...ring B in a clean vinyl bag or the like to protect it from water etc during transportation and fix it to the operator s cab with sealing tape or the like 3 Tilt down lock D of revolving lamp bracket C...

Page 324: ...tself to prevent damage 7 Remove revolving lamp bracket C from fixing claw F of base bracket E METHOD FOR INSTALLING REVOLVING LAMP 1 Hold grip G and turn it counterclockwise seeing it from the rear o...

Page 325: ...oad shoulder 1 Apply the brake of the trailer securely 2 Set the chocks 1 to the tires to secure the trailer 3 Set the right and left ramps 2 parallel to each other and equally spaced to the right and...

Page 326: ...ch 7 and operate the fuel control dial to set the engine to low speed Each time the auto deceleration switch 7 is pressed it switches OFF to ON to OFF in turn When the auto deceleration switch 7 is tu...

Page 327: ...r that the machine loses 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 de...

Page 328: ...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 329: ...of Non Amine Engine Coolant AF NAC see METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4 21 DEF NOTICE The DEF freezes at 11 C If the DEF in the DEF tank freezes it may expand and the devices in the tan...

Page 330: ...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 water on the...

Page 331: ...l for all equipment with the ones of the specified viscosity For details see RECOM MENDED FUEL COOLANT AND LUBRICANT 7 5 If the machine is parked for long time in the cold weather condition quality of...

Page 332: ...attachment set the stop valve to LOCK position Install the plugs to the elbows For the explanation of LOCK and FREE states of the stop valve see METHOD FOR REMOVING AND INSTALLING ATTACHMENT 6 16 To...

Page 333: ...ghly according to the procedure in METHOD FOR ENGINE WARM UP OPERATION 3 182 If the machine has been stored for more than 2 months do as follows Before starting the engine replace the DEF filter and f...

Page 334: ...rous Bleed air according to the following procedure 1 Fill the fuel tank until full to FULL mark on the fuel gauge with fuel 2 Insert the key into the starting switch 3 Turn the starting switch key to...

Page 335: ...ilures When the arm is operated IN from a high position for dig ging with no load the arm speed drops momentarily at the vertical position When performing bucket CURL operation from a high posi tion f...

Page 336: ...eing towed Operate the machine slowly and be careful not to ap ply any sudden load to the wire rope Do not use the holes for towing light objects or tie down holes when towing the machine NOTICE The m...

Page 337: ...ot to apply any sudden load 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 loa...

Page 338: ...g 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 connect the c...

Page 339: ...tery then connect the negative 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 bat...

Page 340: ...d with a 24 V power supply Use the jumper cables and clips that corresponds the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the cables...

Page 341: ...per cables in the reverse of the order in which they were con nected 1 Remove the clip of jumper cable B from the revolving frame E of the failed machine 2 Remove the clip of jumper cable B from the n...

Page 342: ...level and add oil by refer ring to EVERY 1000 HOURS MAIN TENANCE Improper lubrication of electric swing motor Check oil level and add oil by refer ring to EVERY 1000 HOURS MAIN TENANCE Defective monit...

Page 343: ...und observe the following instructions set the machine in a safe posture and lower the work equipment to the ground Do not operate the swing parking brake cancel switch on the slopes There is a danger...

Page 344: ...repair Defective starting motor Replace Insufficient battery charge Charge battery Battery disconnect switch at OFF po sition Turn ON Engine shutdown secondary switch at STOP ENGINE position Set it to...

Page 345: ...IRED Boom rises slowly or does not rise Lack of hydraulic oil Set oil to specified level See CHECKS BEFORE STARTING Does not swing Swing lock switch still applied Turn swing lock switch OFF Swing brak...

Page 346: ...00 HOURS MAINTENANCE Defective thermostat Replace thermostat Loosened radiator filler cap in high altitude operation Tighten cap or replace packing Defective coolant level sensor Replace sensor Defect...

Page 347: ...your Komatsu distributor for the inspection and repair Even though the machine has not run out of fuel if CA2249 or CA559 is displayed on the Current Abnor mality screen replace both fuel main filter...

Page 348: ......

Page 349: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1...

Page 350: ...not remove the strainer while adding DEF WELDING INSTRUCTIONS When performing welding turn the starting switch to OFF position check that the system operating lamp is not lit Turn the battery disconn...

Page 351: ...AIR FROM HYDRAULIC CIRCUIT 4 42 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with ne...

Page 352: ...OSE ENGINE HOOD SECURELY When closing the engine hood after inspection or maintenance make sure that the catch is securely locked If the engine hood catch is not locked there is a danger that the engi...

Page 353: ...ce Manual Even if the oil is not dirty 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 met...

Page 354: ...nk or the fuel tank of the machine as soon as possible COOLANT AND WATER FOR DILUTION The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas wh...

Page 355: ...e to the exhaust gas regulations will be lost GREASE Grease is used to prevent seizure and noises at the joints This construction equipment is used under heavy duty conditions Komatsu recommends using...

Page 356: ...sheet or take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first STORE DEF Comp...

Page 357: ...ical components Wipe off the water drops stuck around connectors before removing the connectors and do not let water drops get into the connectors when removing the connectors of electrical components...

Page 358: ...Komatsu distributor 1 Engine 2 Motor generator 3 Hydraulic pump 4 High voltage electric wiring Orange 5 Capacitor Storage battery 6 Inverter Control device 7 Cooling system 8 Electric swing motor OUTL...

Page 359: ...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 360: ...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 361: ...METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 4 42 METHOD FOR CHECKING AUTO GREASING SYSTEM 4 43 CHECKS BEFORE STARTING 4 46 EVERY 50 HOURS MAINTENANCE 4 46 METHOD FOR LUBRICATING WORK EQUIPMENT 4 4...

Page 362: ...83 EVERY 4000 HOURS MAINTENANCE 4 83 REPLACE DEFINED LIFE PARTS 4 83 METHOD FOR CHECKING WATER PUMP 4 84 METHOD FOR CHECKING VIBRATION DAMPER 4 84 METHOD FOR CHECKING STARTING MOTOR 4 84 METHOD FOR RE...

Page 363: ...use of the breaker operating ratio of the breaker 50 or more and replace the element ac cording to the table X Breaker operating ratio Y Replacement interval H A Hydraulic tank element pilot filter el...

Page 364: ...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 performanc...

Page 365: ...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 366: ...eaner element face where no hole is drilled B and C come to the cover 3 end If it is installed in wrong direction it may cause breakage of the air cleaner ele ment or serious damage to the engine When...

Page 367: ...ights up just after cleaning of the element has been finished replace the inner and outer elements METHOD FOR CHANGING AIR CLEANER ELEMENT Replace the element in the following procedure 1 Open the doo...

Page 368: ...to damage of the engine Do not use such improper part 6 Remove the inner element 6 then install the new inner element immediately Install the inner element securely so that it does not move 7 Push in...

Page 369: ...eaning of inside of cooling system and re placement of coolant Non Amine Engine Coolant AF NAC Every 2 years or 4000 hours whichever comes sooner The coolant has the important function of preventing c...

Page 370: ...ace Non Amine Engine Coolant AF NAC is already diluted with distilled water so it is not flammable Check the density with a coolant tester Prepare a container whose capacity is larger than the specifi...

Page 371: ...TIONS AND CONTROLS METHOD FOR OPERA TIONS AND CHECKS BEFORE STARTING ENGINE 3 174 and METHOD FOR STARTING ENGINE 3 177 10 Set the swing lock switch to ON position and check that the swing lock pilot l...

Page 372: ...P side C Operate the lever to the end of its stroke and hold it in position for 30 seconds 3 Move the L H work equipment control lever slowly in the direction to the arm IN side B Operate the lever to...

Page 373: ...f the port For the density of Non Amine Engine Coolant see the Coolant density table 20 Run the engine at low idle for 5 minutes to remove the air from the coolant then run it at high idle for further...

Page 374: ...it for approximately 3 minutes Then add the Non Amine Engine Coolant through the cool ant filler port up to the mouth of the port 23 Tighten the radiator cap 2 24 Close the engine hood 1 MAINTENANCE P...

Page 375: ...ontainer under the drain hose 3 to catch the coolant mixture 6 Open the drain plug 4 at the bottom of the drain block and drain the coolant Width across flats 17 mm 1 place 7 After draining the coolan...

Page 376: ...18 Add coolant through the water filler port up to the mouth of the port For the mixing proportion of coolant and city water see the Coolant density table 19 Turn the starting switch key to ON positio...

Page 377: ...ack shoes park the machine on the level and solid ground METHOD FOR CHECKING TRACK TENSION 1 Run the engine at low idle then move the machine forward for a distance equal to the track length on ground...

Page 378: ...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 379: ...it 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 the condi tion below...

Page 380: ...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 381: ...EPLACING BUCKET TEETH 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...

Page 382: ...when replacing the side cutter and shroud of the bucket Set the work equipment in a stable condition set the lock lever securely to LOCK position L and stop the engine As the pin is driven out with s...

Page 383: ...LEARANCE 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 set it in a stable condition stop the engine and...

Page 384: ...t or dust get in when adding fluid Mixture ratio of pure washer fluid and water The proper mixing proportion varies with the ambient temperature Add washer fluid diluted with water at the following pr...

Page 385: ...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 386: ...curely 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 extrem...

Page 387: ...e machine is set at angle 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...

Page 388: ...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 389: ...n doing this 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 r...

Page 390: ...drain port Oil will come out when the drain hose is removed so se cure the hose fitting at a position higher than the level of the oil in the hydraulic tank 3 After completing the air bleeding operati...

Page 391: ...completing the air bleeding operation stop the engine and leave the machine for 5 minutes before starting operations This will remove the air bubbles in the oil inside the hydraulic tank If a breaker...

Page 392: ...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 clean the greasing coupling...

Page 393: ...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 394: ...ing point CHECKS BEFORE STARTING For the following items see OPERATION METHOD FOR CHECKING BEFORE STARTING 3 146 Method for draining water and sediment from fuel tank Method for checking water separat...

Page 395: ...tion pin 1 place 3 Link connection pin 2 places 4 Bucket cylinder rod end pin 1 place 5 Bucket and link connection pin 1 place 3 After greasing wipe off any old grease that is pushed out EVERY 250 HOU...

Page 396: ...after refilling with the purified water such as a commercial battery fluid do the replenishment before the day s work on the next day 1 Open the door 1 on the rear right of the machine The batteries...

Page 397: ...ide of the battery check as follows 1 Remove the cap 4 at the top of the battery and check the electrolyte level through electrolyte filler port 5 2 If the electrolyte does not reach the sleeve 6 alwa...

Page 398: ...sor 4 to move around the mounting position of bolt 2 2 Adjust by moving compressor 4 3 When the compressor is positioned fix it by tightening bolts 2 and 3 NOTICE Check each pulley for damage wear of...

Page 399: ...l Perform greasing every 10 hours for the first 50 hours of operation on a new machine Also perform greasing at 250 hours and 500 hours of operation on a new machine After the machine is subjected to...

Page 400: ...r greasing wipe off any old grease that is pushed out METHOD FOR CHANGING OIL IN ENGINE OIL PAN REPLACING ENGINE OIL FILTER CARTRIDGE k k WARNING Immediately after the engine is stopped its parts and...

Page 401: ...cartridge 3 counterclockwise by using the filter wrench and remove it 8 Clean the filter holder fill the new filter cartridge with clean engine oil coat the thread and packing surface of the new filte...

Page 402: ...for all parts to cool down before starting the work High pressure is generated inside the engine fuel piping system when the engine is running When replacing the filter wait for at least 30 seconds a...

Page 403: ...Turn the filter cartridge 4 counterclockwise by using the filter wrench and remove it 10 Install the currently removed transparent cup 3 to the bottom of the new filter cartridge At this time be sure...

Page 404: ...the filter cartridge is tightened too much the packing may be damaged and this will cause the leakage of fuel If it is not tightened enough fuel will leak through the gap at packing Be sure to observ...

Page 405: ...ft and stop the machine 2 Remove bolts 1 2 pieces on the top of the revolving frame and remove cover 2 3 Insert ruler 3 into the grease through inspection and ad justment hole A Check that the height...

Page 406: ...essed air high pressure water or steam there is a danger of personal injury Wear the protective equipment such as the protective eyeglasses and dust mask NOTICE When using the compressed air for clean...

Page 407: ...forming the work If steam cleaning high pressure ma chine wash is performed at close distance there is a danger that the internal fins of the heat exchange equipment may be deformed and this will cau...

Page 408: ...if the filter is extremely dirty wash it in a neutral detergent After rinsing it in water dry it thoroughly before using it again Replace the filter with a new one every year If the clog ging of the...

Page 409: ...irst If short end S is inserted first filter 5 will get stuck with protrusion B of the sheet metal Keep the filter away from protrusion B of the sheet metal and insert it from the top first If the ins...

Page 410: ...filler port F METHOD FOR CHECKING OIL LEVEL IN ELECTRIC SWING MOTOR CASE ADD OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Wai...

Page 411: ...start the work 1 Remove the dipstick G from the oil filler port F and wipe off oil on it with a cloth 2 Insert the dipstick G fully into the oil filler port F 3 Pull out the dipstick G and check that...

Page 412: ...verflows from the hole of plug F 4 After the inspection install plug F Tightening torque of plugs P and F 68 6 9 8 Nm 7 1 kgm REMARK Plug F is installed at 2 places Add oil through the one with which...

Page 413: ...ed the internal pressure of the case is re leased and the oil in the element is drained and accord ingly less oil drips when the element is removed 4 After removing the spring 2 valve 3 and strainer 4...

Page 414: ...drain plug P for the swing machinery at the bottom of the machine and under the drain plug Q for the electric swing motor 3 Loosen the drain plug P for the swing machinery at the bottom of the machine...

Page 415: ...replacement of motor generator case and cleaning of oil filter according to the following table Item Item Type of oil Refill capacity Replacement or cleaning interval Motor generator Motor Oil change...

Page 416: ...t the internal pressure go down before replacing the filter Do not bring any open flame close When opening the air bleeding plug of the fuel filter head take care There may be remaining pres sure and...

Page 417: ...vent fuel from flowing out be sure not to leave the machine without the filter cartridge 6 Clean the filter head Thinly apply oil to the packing of the new filter cartridge and install the cartridge t...

Page 418: ...king the tightening of the clamps between the air cleaner turbocharger aftercooler engine METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRES SURE IN ACCUMULATOR FOR BREAKER if equipped A speci...

Page 419: ...ne parts Do not flush DEF tank breather element Flushing or regenerating of it will degrade the performance of element and will cause the breakage of DEF tank Never reuse the DEF element Always stop t...

Page 420: ...atsu distributor to perform this work REMARK As the auto alternator belt tensioner is installed to this machine no belt tension adjustment is required EVERY 2000 HOURS MAINTENANCE Maintenance for ever...

Page 421: ...ts parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spurt out Turn it slow...

Page 422: ...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 impossible to release the remaini...

Page 423: ...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 424: ...rn the starting switch to OFF position METHOD FOR RELEASING PRESSURE IN ACCUMULATOR 1 Lower the work equipment to the ground Keep the crusher attachment jaws etc closed 2 Set the lock lever to LOCK po...

Page 425: ...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 inspection performed every 1000 ho...

Page 426: ...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 oil...

Page 427: ...all 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 into th...

Page 428: ...parts to cool down before starting the work NOTICE Komatsu recommends using Komatsu genuine parts for replacement parts If the machine is operated without the DEF filter attached or with the filter o...

Page 429: ...fore replacing the filter clean around the DEF pump first after the DEF system devices stop Items to be prepared DEF filter removal tool The DEF filter is located at the position shown in the figure 1...

Page 430: ...from the DEF pump grip the filter removal tool 3 pull it down then it will be removed 7 Slide the filter 6 down and remove spacer 5 from filter removal tool 3 8 Pull the filter 6 up while pushing in t...

Page 431: ...2 years or every 4000 hours whichever comes sooner DEFINED LIFE PARTS LIST No Periodical replacement parts Replacement interval 1 Fuel system Fuel hose Every 2 years or 4000 hours whichever comes soo...

Page 432: ...bserve the following The pressure in the hydraulic circuit cannot be completely removed When removing the hydraulic equipment do not stand in the direction that the oil spurts out when performing the...

Page 433: ...e engine and causing a fire if the fuel should leak or spray out If there are any problems the related parts must be replaced Ask your Komatsu distributor for replacement EVERY 4500 HOURS MAINTENANCE...

Page 434: ...than in the nor mal bucket digging operation Accordingly perform the maintenance by referring to MAINTENANCE SCHEDULE 4 13 Refill capacity 188 Items to be prepared Container to catch the drained oil...

Page 435: ...e G For applicable oils see USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEM PERATURE 7 6 For the check of oil level and the installation procedure of the oil filler cap see METHOD FOR CHEC...

Page 436: ......

Page 437: ...SPECIFICATIONS 5 1...

Page 438: ...14396 201 1950 ISO 9249 A Overall length mm 11145 B Overall height work equipment mm 3285 C Overall width mm 3190 2990 D Shoe width mm 600 E Cab height mm 3160 F Tail swing radius mm 3445 G Overall l...

Page 439: ...th 6400 E Maximum dumping height 7050 F Minimum dumping height 2640 G Maximum digging reach at ground level 10920 EXPLANATION OF LIFT CAPACITY CHART 1 PIECE BOOM 1 Piece Boom HB365LC 3 HB365NLC 3 LEGE...

Page 440: ...ER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND WITH 600 mm WIDTH SHOE Load...

Page 441: ...HB365LC 3 SPECIFICATIONS SPECIFICATIONS 5 5...

Page 442: ...HB365NLC 3 SPECIFICATIONS SPECIFICATIONS 5 6...

Page 443: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1...

Page 444: ...leader and follow his 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...

Page 445: ...s the mass of the bucket see the following EXPLANATION OF LIFT CAPACITY CHART 1 PIECE BOOM 5 3 should be taken into consideration For an attachment not intended to bear a load for example a breaker it...

Page 446: ...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 447: ...ick coupler if there is anything unclear 3 Read thoroughly the Operation and Maintenance Manual for the quick coupler and follow the recommenda tions Consult your Komatsu distributor if there is anyth...

Page 448: ...eration if the buzzer inside the cab sounds In particular check that there is no leakage in the system Consult your Komatsu distributor if there is anything unclear METHOD FOR REMOVING ATTACHMENT k k...

Page 449: ...r REMARK The alarm buzzer sounds intermittently if the oil pressure in the quick coupler system is dropped during the work The action level L03 is displayed and the quick coupler cau tion lamp is disp...

Page 450: ...r at the engag ing portion on the bucket or attachment by performing the necessary operation with bucket cylinder arm and boom For details follow the instructions of the manu facturer of the quick cou...

Page 451: ...8 Attachment 2 proportional switch 9 Breaker mode switch STOP VALVE The stop valve stops the flow of the hydraulic oil a FREE Hydraulic oil flows direction of arrow is parallel to longitudinal direct...

Page 452: ...pin when pedal operation is not necessary Control pedal is used to control the attachment When the front center neutral and rear of the pedal are depressed the movement of the attachment is as follow...

Page 453: ...pressure nitrogen gas so improper operation may cause an ex plosion which will lead to serious injury or death For handling always observe the following The pressure in the hydraulic circuit cannot be...

Page 454: ...s slightly Operate the roller fully and the attachment moves quickly ATTACHMENT 2 PROPORTIONAL CONTROL SWITCH if equipped The attachment 2 proportional control switch is a roller propor tional control...

Page 455: ...h one way circuit B mode Return circuit automatically becomes the circuit that does not pass through con trol valve When shipped from factory 21 6 MPa 220 kg cm 2 Crusher or other attach ment with two...

Page 456: ...clockwise end or the counterclockwise end 4 Remove the lever 3 5 Install the bolt 1 and washer 2 again 2 Remove the plate 4 at the tip of the stop valve piping 2 places on the right and left Be carefu...

Page 457: ...ws into piping of the left side of the work equipment Depress the rear side of pedal The oil flows into piping of the right side of the work equipment REMARK When a breaker is installed depress only t...

Page 458: ...onal attachment and set the working mode to ATT P or ATT E mode Hydraulic oil flowing through crusher circuit does not pass through additional filter for breaker Relief valve is set to high pressure M...

Page 459: ...side face of the arm to 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 arrow is perpendicular to lo...

Page 460: ...raulic tank For details see METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 3 152 METHOD FOR INSTALLING ATTACHMENT 1 Remove the bucket For the removal procedure of the bucket see METHOD FOR...

Page 461: ...lease the internal pressure in the hydraul ic tank 9 Check that the hydraulic oil temperature is low 10 Remove the plates 4 2 places at the outlet and inlet Be careful not to lose or damage the remove...

Page 462: ...pedals are operated when the engine speed is decreased by the auto decel eration function the engine speed will suddenly increase Be careful If you perform operations with your foot on the pedal the a...

Page 463: ...llowing to enter the selection 1 Hold down the working mode selector switch 1 2 Press the switch F6 3 Leave as it is for 5 seconds If you enter the selection of the Breaker Mode the confir mation mess...

Page 464: ...circuit needs to be installed or not Follow the instruction manual from the breaker manufacturer and use the breaker correctly for handling the breaker METHOD FOR OPERATING GENERAL ATTACHMENT SUCH AS...

Page 465: ...INSTALLATION OF ATTACHMENT 6 13 When handling the attachment follow the instruction manual from the manufacturer and use the attachment correctly METHOD FOR OPERATING ATTACHMENT 1 CRUSHER ETC k k WARN...

Page 466: ...rates 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 the working mode pilot...

Page 467: ...Always wear protective equipment such as protective eyeglasses and dust mask NOTICE For the element replacement interval see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 14 Items to be prepared Conta...

Page 468: ...n is completed replace the additional filter for breaker according to the following procedure METHOD FOR REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER 1 Loosen oil filler cap F slowly on the top of...

Page 469: ...truding part inside filter head 4 6 Fit new O ring 5 to filter case 2 and screw filter case 2 into filter head 4 7 After the top of filter case 2 touches the filter head tight en it further at least 1...

Page 470: ...o 3 6 kgm SPECIFICATIONS Hydraulic specifications Max flow at merge 267 5 2 min Safety valve relief set pressure of service valve Port A 29 9 MPa 305 kg cm2 other than B mode Port B 29 9 MPa 305 kg cm...

Page 471: ...ARM PIN INFORMATION A A B B 2 4 1 3 A A B B KS001081 HB365LC 3 HB365NLC 3 1 345 mm 0 0 5 3 343 mm 0 5 0 5 2 90 mm 0 036 0 090 4 90 mm 0 036 0 090 ATTACHMENTS AND OPTIONS ARM PIN INFORMATION 6 29...

Page 472: ...ent there is a danger that the work equipment may hit the cab or machine body When using unfamiliar work equipment for the first time check before starting if there is any danger of interference and o...

Page 473: ...may hit the cab or machine body When using unfamiliar work equipment for the first time check before starting if there is any danger of interference and operate it with care Categories of use Select a...

Page 474: ...When selecting the shoe width choose the narrowest shoes possible to bring the machine within the range where there is no problem regarding the machine flotation and ground contact pressure If the wid...

Page 475: ...ging and loading dry and loose sandy soil or muddy soil Loading Loading of dry and loose earth HORIZONTAL PIN TYPE TOOTH Heavy duty digging Digging and hammering work on hard soil soil with rocks scra...

Page 476: ...Applicable work Major works suitable to the hydraulic breaker are as follows Demolition work Crushing rock Road construction This attachment can be used for a wide range of applications including dem...

Page 477: ...e breaker body will gradually move out of line with each oth er always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly not to strike...

Page 478: ...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 RECOMMENDED A...

Page 479: ...the hydraulic breaker set it in the specified posture NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt will enter the hydraulic ci...

Page 480: ...e pump perpendicularly to the greasing point Wrong posture Do not perform greasing when the hydraulic breaker is lowered to the ground Do not perform greasing when the chisel is not lowered to the gro...

Page 481: ...may not be displayed due to darkness at night or in a tunnel fog snow rain cloud of dust etc Obstacles above the camera of the machine are not displayed Be careful enough of the work equipment of a la...

Page 482: ...lever pilot lamp 30 Aftertreatment devices regeneration pilot lamp 31 Aftertreatment devices regeneration disable pilot lamp 32 Message display 33 Air conditioner pilot lamp 34 Air cleaner clogging ca...

Page 483: ...reduced auto matically to protect the liquid crystal but it is not an abnormality WARNING DISPLAY 1 Seat belt caution lamp 2 Caution lamp 3 Caution lamp 4 Action level display 5 Engine coolant tempera...

Page 484: ...les are the typical causes The machine monitor will not show the image from the defec tive camera Physically make sure the adjacent safety around the machine Consult your Komatsu distributor for inspe...

Page 485: ...machine The shaded area in the figure is not displayed on the monitor screen even if the camera images are synthesized Since this image is electronically synthesized the objects in the image may be di...

Page 486: ...2 m B in which the rear of the machine is in scribed when the machine swings Yellow MONITOR DISPLAY SELECTOR SWITCH By pressing the switch F3 on the standard screen you can en large the bird s eye vi...

Page 487: ...the entire monitor If the switch F3 is pressed on the camera image screen CC the standard screen AA is displayed CAMERA IMAGE SELECTOR SWITCH By pressing the switch F4 you can switch the in car camera...

Page 488: ...camera may be changed by a shock to the camera Check the visibility of the camera Put the traffic cone of approximately 70 cm height C to the po sition at the rear outside of the machine where the di...

Page 489: ...REPLACEMENT PARTS 7 1...

Page 490: ...lamps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses and replace defective hoses as required Wh...

Page 491: ...Cartridge 1 Every 500 hours Fuel prefilter 600 319 3610 Cartridge including O ring 1 Every 500 hours Breather of hydraulic tank 421 60 35170 Element 1 Every 1000 hours Hydraulic oil filter 207 60 711...

Page 492: ...5 5 5 Horizontal pin type 207 70 14151 09244 02516 Tooth Pin 5 5 Side cutter type 207 70 34160 207 70 34170 Side cutter left Side cutter right 1 1 Shroud type 208 934 7132 113 78 21170 209 939 7110 20...

Page 493: ...NOTICE The fuel used must be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electroni...

Page 494: ...e power train oil Check powertrain oil level Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter Replace DEF tank bre...

Page 495: ...C TO10 KES Note 5 Hydraulic system Power train oil 20 C 50 C TO10 KES Note 5 Hydraulic oil 30 C 50 C HO56 HE KES 20 C 50 C HO46 HM KES Note 5 Grease fitting Hyper grease 20 C 50 C G2 TE KES Note 3 Lit...

Page 496: ...T or G2 TE is recommended Note 4 SUPERCOOLANT AF NAC 1 Coolant has the important function of anticorrosion as well as antifreeze Even in the areas where freezing is not an issue the use of coolant is...

Page 497: ...ss Adjust 3 164 Alternator Check 4 77 Alternator belt tension Check Replace 4 72 Always use clean washer fluid 4 2 Antenna Stow 3 241 Appoint leader when working with others 2 41 Arm Pin information 6...

Page 498: ...D Daylight saving time Set 3 83 Declaration of conformity 1 14 DEF 3 257 4 6 DEF Check level Add 3 158 DEF Store 4 8 DEF filter 3 143 DEF filter Replace 4 80 DEF hose Replace 4 87 DEF level caution la...

Page 499: ...ent 3 236 F Fan belt tension Check Replace 4 72 Fan control system caution lamp 3 27 Fan switch 3 224 Filter 4 8 Final drive case Change oil 4 72 Final drive case Check oil level Add oil 4 64 Fire ext...

Page 500: ...losed Crankcase Ventilation KCCV 3 128 Komatsu genuine lubricants 4 2 Komatsu genuine replacement parts 4 2 KOMTRAX 3 143 KomVision 6 39 L Lamp switch 3 91 Language Set 3 83 Left front mirror Adjust 3...

Page 501: ...move 3 248 Mirror Remove Install 3 247 Mirrors Adjust 3 165 Monitor display 6 43 Monitor display selector switch 6 44 Monitor settings 3 78 Monitor switches 3 43 N Nitrogen gas charge pressure for bre...

Page 502: ...utions related to protective structure 2 24 Precautions to prevent fire 2 20 Precautions when installing hydraulic hoses 4 3 Precautions when leaving machine 2 23 Precautions when loading and unloadin...

Page 503: ...Service meter Clock 3 40 Service meter location 1 12 Shovel work 3 210 Shroud Replace 4 35 Sound balance Adjust 3 240 Sound control button 3 237 Space for radio cassette 3 241 Specifications 5 2 6 28...

Page 504: ...k 4 84 Water separator Check Drain water and sediment 3 150 Water separator caution lamp 3 29 Wear well fitting clothes and protective equipment 2 19 Welding instructions 4 2 When handling accumulator...

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Komatsu HB365LC-3, Operation & Maintenance Manual

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Summary of Contents for HB365LC-3

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