Komatsu PC210-10 DEMOLITION BASE SPEC. Page 341 Operation & Maintenance Manual Download | Manualshive

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MAINTENANCE

MAINTENANCE SCHEDULE TABLE

4–31

CHECK AND MAINTENANCE AIR CONDITIONER

CHECK AND MAINTENANCE AIR CONDITIONER:ALL-K500-001K01A

CHECK LEVEL OF REFRIGERANT (GAS)

CHECK LEVEL OF REFRIGERANT (GAS):PC220-K512-21DK00A

k

WARNING

If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of
sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is leaking.

If there is a lack of refrigerant (Freon 134a), the cooling perfor-
mance will be poor. When the engine is running at full throttle
and the cooler is running at high speed, look at the sight glass
(1) (inspection window) in the refrigerant hose fitting to check
the condition of the refrigerant gas (Freon 134a) flowing in the
refrigerant circuit.?
(A) No bubbles in refrigerant flow: Suitable
(B) Some bubbles in flow (bubbles pass continuously):

Lack of refrigerant

(C) Colourless, transparent: No refrigerant

REMARK

When there are bubbles, the refrigerant gas level is low, so
contact your Komatsu distributor to have refrigerant added. If
the air conditioner is run with the refrigerant gas level low, it will
cause damage to the compressor.

INSPECTION DURING OFF SEASON

Inspection During Off Season:ALL-K500-20DK00A

Even during the off-season, operate the air conditioner for three to five minutes once a month to maintain the oil
film at all parts of the compressor.

INSPECTION AND MAINTENANCE ITEMS

Inspection and Maintenance Items:ALL-K500-208K00A

Check, maintenance items

Content of check, maintenance

Guideline for maintenance

interval

Refrigerant (gas)

Charge amount

Twice a year (spring, autumn)

Air conditioner condenser

Clogged fins

Every 500 hours

Compressor

Operating condition

Every 4000 hours

V-belt

Damage, tension

Every 250 hours

Blower motor, fan

Operating condition(does it make abnormal
noise?)

When required

Control mechanism

Operating condition (does it function normally?) When required

Piping mounts

Mounting condition, looseness at tightening or
connecting portions, leakage of gas, damage

When required

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Summary of Contents for PC210-10 DEMOLITION BASE SPEC.

Page 1: ...DRAULIC EXCAVATOR Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should...

Page 2: ......

Page 3: ...emission control systems be genuine new Komatsu or Komatsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribut...

Page 4: ...ly and understand its contents fully q Read the safety messages and safety labels given in this manual carefully so that they should be understood fully q Keep this manual at the storage location for...

Page 5: ...lace the lock lever in the LOCK position If you accidentally touch the control levers when they are not locked this may cause serious injury or death The following signal words are used to alert you t...

Page 6: ...may not include all possible safety precau tions If any procedures or actions not specifically recommended or allowed in this manual are used it is your responsi bility to take the necessary steps to...

Page 7: ...ted working cycle The maximum value of the standard deviation of the measured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 q...

Page 8: ...system and linkages q Keep the terrain where the machine is working and travelling in good condition q Remove any large rocks or obstacles q Fill any ditches and holes q Site manager should provide m...

Page 9: ...om the operator s seat when the operator s seat is facing the front and the sprocket is at the rear of the machine OPERATOR PROTECTIVE STRUCTURE This machine is ROPS compliant to ISO12117 2 2008 when...

Page 10: ...SERIAL NO PLATE PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE PC 0000 20RK00A On the bottom right of the operator s cab The design of the nameplate differs according to the territory EPA R...

Page 11: ...INE SERIAL NUMBERS AND DISTRIBUTOR Your machine serial numbers and distributor ALL 0000 20EK01A Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU...

Page 12: ...PRODUCT INFORMATION FOREWORD 1 10 SERIAL PLATE A MACHINE DESIGNATION TYPE E ENGINE POWER B SERIAL F PRODUCT IDENTIFICATION NUMBER C YEAR OF CONSTRUCTION G MANUFACTURER D WEIGHT A B D F G C E...

Page 13: ...Birtley Chester Le Street County Durham DH3 2QX Declares that this machine PC210 10 PC210LC 10 Fulfils all the relevant provisions of the following EC Directives Machinery Directive 2006 42 EC Electr...

Page 14: ...PRODUCT INFORMATION FOREWORD 1 12...

Page 15: ...ES 2 22 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 23 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2 23 UNAUTHORIZED MODIFICATION 2 23 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIO...

Page 16: ...RTING ENGINE 3 166 STOPPING ENGINE 3 177 MACHINE OPERATION 3 178 STEERING MACHINE 3 182 SWINGING MACHINE 3 184 WORK EQUIPMENT CONTROLS AND OPERATIONS 3 185 WORKING MODE 3 187 PROHIBITED OPERATIONS 3 1...

Page 17: ...ONENTS 4 7 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4 8 TIGHTENING TORQUE LIST 4 8 MAINTENANCE SCHEDULE 4 9 MAINTENANCE SCHEDULE TABLE 4 9 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 11 MAINTENA...

Page 18: ...S 6 33 TRACK SHOES SELECTION 6 34 BUCKET TEETH SELECTION 6 35 HANDLING OF RUBBER PAD SHOE AND ROAD LINER 6 36 HANDLING TRAPEZOIDAL BUCKET 6 38 HANDLING EXTENSION ARM 6 40 HANDLING CLAMSHELL BUCKET 6 4...

Page 19: ...1K01A SAFETY k WARNING Please read and make sure that you fully understand the pre cautions described in this manual and the safety labels on the machine When operating or servicing the machine always...

Page 20: ...MACHINE 2 21 EMERGENCY EXIT FROM OPERATOR S CAB 2 21 ELECTROMAGNETIC INTERFERENCE 2 21 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 22 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 22 PROTECTION AGAINST FAL...

Page 21: ...WHEN WORKING WITH OTHERS 2 44 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2 44 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2 45 INSTALLING REMOVING OR STORING ATTACHMENTS 2 45 WO...

Page 22: ...that they are in the correct place and always keep them clean When cleaning them do not use organic solvents or petrol These may cause the labels to peel off q There are also other labels in addition...

Page 23: ...SAFETY SAFETY LABELS 2 5 LOCATION OF SAFETY LABELS Location of safety labels PC220_KU Q5L0 04DK00A a if equipped X g h 1 a b c d e f KS000651 X...

Page 24: ...peration and mainte nance Follow instructions and warnings in manual and in labels on machine q Warning q a Read the manual before operating maintenance disas sembly assembly and transportation q b Be...

Page 25: ...close to electric cables q An electrocution hazard if the machine is brought too near to electric power lines q Keep a safe distance from electric power lines q f Control levers operational function d...

Page 26: ...e engine If you accidentally touch the control levers pedals when they are not locked there is a hazard that the machine may suddenly move and cause serious injury or property damage q h Caution when...

Page 27: ...ing window be sure to lock it in place with lock pins 3 Caution for high temperature coolant and hydraulic oil 09653 A0481 q Never remove the cap when the engine is at operating high temperature Steam...

Page 28: ...adjusting track for safe and proper handling 6 Caution when handling cable 09808 A0881 q Sign indicates an electric hazard from handling the cable q Read manual for safe and proper handling 7 Stopping...

Page 29: ...lace here 10 Prohibited to enter swing radius 09133 A3281 q There is a danger of getting caught when upper structure swings q Do not enter range of swing 11 Keeping out of working range area 09134 A16...

Page 30: ...er of an exposed person being killed by fall ing attachment q Read the manual for safe operation 14 Caution when swinging or travelling in reverse 09833 A0881 k WARNING q When swinging or backing up e...

Page 31: ...batteries f Caution explosive gases 16 Caution when replacing fresh air filter 208 00 71261 q After replacing fresh air filter remember to remove key from cover as the key may get damaged when cab do...

Page 32: ...09620 A3000 q If any modification is applied to the ROPS it may affect the strength and may not comply with the standard Consult your Komatsu Distributor before altering q ROPS may provide less prote...

Page 33: ...operate and maintain the machine q Follow all safety precautions and instructions in this manual when operating or performing inspection or maintenance on the machine q If you are not feeling well or...

Page 34: ...will slip and fall Wipe off any mud or oil from the machine Always keep the machine clean q If water gets into the electrical system there is a hazard that it will cause malfunctions or misoperation...

Page 35: ...arry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used q Provide a first aid kit in the storage point Carry out periodic checks and add to the contents if...

Page 36: ...or tubes that contain flammable liquids q Determine well ventilated areas for storing oil and fuel Keep the oil and fuel in the determined place and do not allow unauthorized persons to enter q When...

Page 37: ...not bring any flammable close the outlet of the exhaust pipe q When there are thatched houses dry leaves or pieces of paper near the work site set the system to disa ble the regeneration before start...

Page 38: ...nd if there is any oil grease or mud on them wipe it off immediately In addition repair any damage and tighten any loose bolts q Do not grip the control levers or lock lever when getting on or off the...

Page 39: ...completely to the ground set lock lever 1 to lock position L and stop the engine In addition lock all parts always take the key with you and leave it in the specified place EMERGENCY EXIT FROM OPERAT...

Page 40: ...t beyond the certified value by modifying the machine or by installing attachments to the machine Also if the function of the protective equipment is impeded the protective equipment will not be able...

Page 41: ...the machine without an addi tional guard Be sure to consult with your Komatsu distributor about necessary guards ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES Unauthorized modification ALL 0000...

Page 42: ...not contact q When installing and using optional attachments read the instruction manual for the attachment and the gen eral information related to attachments in this manual PRECAUTIONS RELATED TO CA...

Page 43: ...ge any of these lines q Take necessary measures to prevent any unauthorized per son from entering the operating area q In particular if you need to operate on a road protect pedestrian and cars by des...

Page 44: ...GOOD VISIBILITY Ensure good visibility ALL 0000 17UK00A This machine is equipped with mirrors and cameras to ensure good visibility but even then there are places that cannot be seen from the operato...

Page 45: ...tarting work BEWARE OF ASBESTOS DUST Beware of asbestos dust ALL 0000 17WK00A Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsi...

Page 46: ...h the operation of the machine If this inspection is not carried out properly problems may occur with the operation of the machine and there is danger that this may lead to serious personal injury or...

Page 47: ...ine only while sitting in the operator s seat q When starting the engine sound the horn as a warning q Do not allow anyone apart from the operator to ride on the machine q Do not attempt to start the...

Page 48: ...ing in the opera tor s seat and the other working with the battery q When starting from another machine do not allow the two machines to touch q When connecting the booster cables turn the starting sw...

Page 49: ...185K00A q When travelling drive with sprocket 1 at the rear of the machine If sprocket 1 is at the front the operation of the travel levers will be the opposite of the actual direction of travel so t...

Page 50: ...o the left or right sides q When travelling on rough ground travel at low speed and do not operate the steering suddenly There is danger that the machine may turn over The work equipment may hit the g...

Page 51: ...r across the slope is extremely dangerous q Do not turn on slopes or travel across slopes Always go down to a flat place to change the position of the machine then travel on to the slope again q Do no...

Page 52: ...horizontal as possible q Do not work on a slope covered with the steel plates Even with slight slopes there is a hazard that the machine may slip PROHIBITED OPERATIONS PROHIBITED OPERATIONS PC 0000 1...

Page 53: ...ing equipment There is danger that the load may spill or the bucket may hit the dump truck and cause serious personal injury or death q When working on or from the top of buildings or other structures...

Page 54: ...hazard that it may turn over or become buried in the snow Be careful not to leave the road shoulder or to get trapped in a snow drift q When clearing snow the road shoulder and objects placed beside...

Page 55: ...N 2 37 q If it is necessary to park the machine on a slope always do as follows q Set the work equipment on the downhill side and dig it into the ground q In addition put blocks under the tracks to pr...

Page 56: ...equipped with an auto deceleration device always turn the auto deceleration switch OFF If the machine is operated with the auto deceleration system ON there is danger that the engine speed will sud de...

Page 57: ...ot use tie down lugs PAGE 3 212 for towing q Always confirm that the wire rope or drawbar used for tow ing has ample strength for the weight of the machine being towed q Never use a wire rope which ha...

Page 58: ...q The lifting link RLL Rated Lifting Load and part number are stamped on the link as shown below q All components in the load line eg chains shackles etc must be rated correctly for the load to be li...

Page 59: ...etc visually for damage or defor mation before use to ensure that they are not damaged or worn Any damaged deformed or worn parts should not be used and must be replaced q Where possible the lifting...

Page 60: ...dangerous if the raised load hits any person or structure When swinging or operating the work equipment check carefully that the surrounding area is safe q Do not swing or operate the work equipment s...

Page 61: ...not kept clean and tidy there is the danger that you will trip slip or fall over and injure yourself q When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and a...

Page 62: ...ature or high pressure liquids Always observe the following q Lower the work equipment completely to the ground and stop the engine before performing any inspection and main tenance q Turn the startin...

Page 63: ...e temperature around KDPF increases During maintenance stop the KDPF regeneration according to Handling KDPF 3 129 q Release the residual pressure from the hydraulic system and place Lock lever 1 to i...

Page 64: ...the weight of the component Never use jacks at places where the machine is damaged bent or twisted Never use frayed twisted or pinched wire rope Never use bent or distorted hooks q It is extremely da...

Page 65: ...is generated and may explode In addition the battery elec trolyte includes dilute sulphuric acid Any mistake in handling may cause serious personal injury explosion or fire so always observe the foll...

Page 66: ...nd cause serious personal injury or death Always wear protective eye glasses and gloves q If the pin is hit with strong force there is a hazard that it may fly out and injure people in the surrounding...

Page 67: ...gine is running high pressure is generated in the engine fuel piping If you try to disassemble the pip ing before the internal pressure is released serious personal injury can result When carrying out...

Page 68: ...aking adjustment grease drain plug 1 may fly out and cause serious injury or prop erty damage q When loosening grease drain plug 1 to loosen the track tension never loosen it more than one turn Loosen...

Page 69: ...he filter element or radiator wear protective eyeglasses anti dust mask gloves and other protective equipment MAINTENANCE OF AIR CONDITIONER MAINTENANCE OF AIR CONDITIONER ALL K500 2AHK00A q If air co...

Page 70: ...terial of these components naturally changes over time and repeated use causes deterioration wear and fatigue As a result there is a hazard that these components may fail and cause serious personal in...

Page 71: ...OPERATION 3 1 OPERATION OPERATION ALL 0000 001K02A OPERATION k WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 72: ...L VIEW General view PC 0000 001K01A GENERAL VIEW OF MACHINE GENERAL VIEW OF MACHINE PC220 0000 04DK00A 1 Bucket 7 Sprocket 2 Bucket cylinder 8 Track frame 3 Arm 9 Track shoe 4 Arm cylinder 10 Idler 5...

Page 73: ...OPERATION GENERAL VIEW 3 3 11 KDPF 16 Battery 12 KCCV ventilator 17 Grease pump holder 13 Disconnect switch 18 Toolbox 14 System operating lamp 19 Engine hood 15 Fusible link...

Page 74: ...F CAB GENERAL VIEW OF CAB PC220_KU K000 04DK00A 1 Ceiling window 7 Ashtray 2 Front window 8 Power outlet 3 Emergency escape hammer 9 Fuse 1 4 Door unlock lever 10 Fuse 2 5 Drink box 11 Fire extinguish...

Page 75: ...OPERATION GENERAL VIEW 3 5...

Page 76: ...GENERAL VIEW OPERATION 3 6 GENERAL VIEW OF CONTROLS AND GAUGES GENERAL VIEW OF CONTROLS AND GAUGES PC220_KU K190 04DK00A...

Page 77: ...27 2nd attachment proportional control switch 9 Cigarette lighter if equipped 10 R H work equipment control lever 28 Breaker switch 11 Starting switch 29 Spare switch 12 Fuel control dial 30 Spare sw...

Page 78: ...6 Hydraulic oil temperature gauge 25 Engine preheating monitor or One touch power max 7 Service meter Clock monitor 8 Hydraulic oil temperature monitor 26 Auto deceleration monitor 9 Working mode moni...

Page 79: ...ance screen REMARK q For the user menus used for various machine setting done from the machine monitor see USER MENU SELECTOR SWITCH 3 49 q One of the features of liquid crystal display panels is that...

Page 80: ...e travel mode display screen HH q After the working mode travel mode display screen HH is displayed for 2 seconds the screen switches to standard screen AA q If the working mode when the engine is sta...

Page 81: ...For the function and operating method of engine stop sub switch 1 see ENGINE SHUTDOWN SECONDARY SWITCH 3 82 STOPPING ENGINE WHEN SITUATION IS NORMAL q When the starting switch is turned to the OFF po...

Page 82: ...e starting screen BB for 2 seconds the screen changes to the maintenance time warning screen CC q After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the stand...

Page 83: ...TY OCCURS DURING OPERATION q If any abnormality occurs during operation the standard screen AA changes to warning screen FF 1 or the error screen EE q After displaying warning screen FF 1 for 2 second...

Page 84: ...EXPLANATION OF COMPONENTS OPERATION 3 14 If there is any error existing is displayed on top of switch F5 Press switch F5 to check the detail of the error Existing error list screen is displayed...

Page 85: ...6 alter nately on a 2 second basis q Camera image display screen The currently issued alarm is displayed by flashing on alarm monitor 7 When two or more alarms are issued they are sequentially displa...

Page 86: ...emedy High I O Low L04 Sounds continuously Lights in red Stop the machine immediately and carry out the inspection and maintenance Ask your Komatsu distributor for inspection and maintenance L03 Sound...

Page 87: ...rmal Fuel level monitor Low level Normal System state monitor Abnormal L04 L03 Abnormal L01 Hydraulic system state monitor Abnormal L04 L03 Abnormal L01 KDPF system state monitor Abnormal L04 L03 Abno...

Page 88: ...s pressed while is displayed the screen of the monitor display section is changed to the occurred error list screen Take appropriate remedies according to the message dis played on the monitor panel A...

Page 89: ...ts up in red and displays the action level L02 The engine coolant temperature has risen abnormally high While this monitor is lighting the overheat prevention system is automatically actuated and the...

Page 90: ...w remaining fuel level q When remaining fuel level is low The monitor lights up red The remaining fuel amount is decreased to approximately 41 litres or below Add fuel as soon as possible q When condi...

Page 91: ...t the inspection and maintenance As needed ask your Komatsu distributor for inspection and maintenance KDPF SYSTEM OPERATING MONITOR KDPF SYSTEM OPERATING MONITOR PC A9HD 043K00A This monitor warns ab...

Page 92: ...NE SYSTEM OPERATING MONITOR ENGINE SYSTEM OPERATING MONITOR PC A9HC 043K00A k CAUTION If the operation is continued while the red monitor is lighting up accumulation and combustion of the soot in KDPF...

Page 93: ...ine oil may be leaking Please ask your Komatsu distributor for inspection and maintenance RADIATOR COOLANT LEVEL MONITOR RADIATOR COOLANT LEVEL MONITOR PC B255 043K00A This monitor warns about drop of...

Page 94: ...LEANER ELEMENT 4 12 AIR CONDITIONER SYSTEM OPERATING MONITOR AIR CONDITIONER SYSTEM OPERATING MONITOR PC K5V3 043K00A This monitor warns about abnormality in the air conditioner system q When conditio...

Page 95: ...of maintenance time notice yellow has been initially set to 30 hours but you can change it To change the initial setting contact your Komatsu distribu tors q For operations on the maintenance screen...

Page 96: ...erature is low in cold areas and the automatic preheating function is actuated the preheating monitor lights up When the preheating is completed it goes out Automatic preheating is for a maximum of ap...

Page 97: ...see GEN ERAL VIEW OF CONTROLS AND GAUGES 3 6 AUTO DECELERATION MONITOR Auto deceleration Monitor PC220_KU AF6F 043K00A This monitor 4 shows the setting of the auto deceleration either ON or OFF The m...

Page 98: ...reases while the knob switch is kept pressed for a maximum of 8 5 seconds Monitor goes out Power max function stopped q For details of the position of the knob switch see GEN ERAL VIEW OF CONTROLS AND...

Page 99: ...ION MONITOR PC A9HF 043K00A k CAUTION q Exhaust gas temperature may increase higher than the current models during KDPF regeneration Avoid getting near the exhaust pipe outlet to prevent being scalded...

Page 100: ...of regeneration disable set ting and setting of manual stationary regeneration see Han dling KDPF 3 129 ECO GUIDANCE ECO GUIDANCE PC Q1L3 043K00A The guidance for energy saving operation to reduce the...

Page 101: ...age goes out more than 10 seconds after or when switch F5 is pressed TRAVEL PARTIAL MODE RECOMMENDATION GUIDANCE D If the machine keeps travelling for more than 2 minutes with the travel mode Hi and t...

Page 102: ...at low temperatures Monitor background K is white q Display H at correct temperatures Monitor background K is blue q Display J when condition is abnormal Monitor back ground K is red HYDRAULIC OIL TE...

Page 103: ...ction and add fuel q A B Indicates red range q A C Indicates green range REMARK When the indicator reaches red range B the remaining fuel is 41 litres When the indicator is in red range B fuel level m...

Page 104: ...ellow range B the instantaneous fuel consumption is at a bad level q When the gauge enters the yellow range there is no abnor mality on the machine but to protect the environment reduce the engine out...

Page 105: ...layed on top of the switch q Switch 1 not displayed in guidance icon 9 does not func tion even if pressed q Even if guidance icon 9 is pressed it will not function Press switch 1 right under the guida...

Page 106: ...e erase switch While Energy saving ECO guidance is displayed E Switch F6 User menu display switch Guidance icons and their functions differ with the contents of the displayed screen but representative...

Page 107: ...MODE SELECTOR SWITCH PC220 PT5W 043K00A Use this switch 2 to set the movement or power of the work equipment The operation becomes easier if the mode is selected to match the content of the operation...

Page 108: ...u distributor to change the setting PROCEDURE FOR OPERATION 1 If working mode selector switch 2 is pressed the Working Mode screen is displayed on the monitor 2 Press function switches F3 or F4 at the...

Page 109: ...UTO DECELERATION SWITCH AUTO DECELERATION SWITCH PC AF6C 043K00A If the control levers are at NEUTRAL this switch 3 automati cally lowers the engine speed and turns on the function to reduce fuel cons...

Page 110: ...d the auto deceleration function is turned ON the mode is displayed in the centre of the monitor display and after two seconds the screen returns to the standard screen 2 On the standard screen the Au...

Page 111: ...speed to 3 stages Lo lights up Low speed travel Mi lights up Medium speed travel Hi lights up Hi speed travel When the engine is started the speed is automatically set to Lo Each time that the switch...

Page 112: ...it changes ON to INT to Stop monitor goes out Wiper monitor INT lights up Wiper operates intermittently Wiper monitor ON lights up Wiper operates continuously Wiper monitor goes out Wiper stops REMAR...

Page 113: ...he wiper will be actuated continuously When switch 6 is released the wiper will continue to operate for 2 cycles then stop q If the wiper is moving intermittently and switch 6 is kept pressed continuo...

Page 114: ...OF COMPONENTS OPERATION 3 44 AIR CONDITIONER SWITCH AIR CONDITIONER SWITCH PC K5FK 04DK00A The air conditioner switches 8 consist of 9 switches For explanation of each switch see Handling air conditi...

Page 115: ...ximum of three cameras can be installed q If you want to install another camera please consult your Komatsu distributor OPERATION OF ONE CAMERA IMAGE DISPLAY SCREEN The following explanation describes...

Page 116: ...d at the same time the dis play changes more slowly than when only one screen is dis played q Press switch F5 to return to the standard screen OTHER MODE OPERATIONS WHEN DISPLAYING CAMERA IMAGE q Even...

Page 117: ...of the method of using the travel speed selector switch see TRAVEL SPEED SELECTOR SWITCH 3 41 When the travel speed is changed the pilot monitor display at the top right of the monitor screen is highl...

Page 118: ...hes q If the error monitor or alarm monitor is displayed press switch F6 return to the standard screen and check the content of the error or alarm display When the error monitor is flashing if no leve...

Page 119: ...9 USER MENU SELECTOR SWITCH USER MENU SELECTOR SWITCH PC220 Q1C3 100K00A When switch F6 is pressed on the standard screen the user menu screen will be displayed on which you can make various settings...

Page 120: ...he User Menu screen it is possible to carry out the fol lowing operations with switches F1 to F6 a ECO guidance c KDPF regeneration q Check of operating record q Setting for regeneration stop q Check...

Page 121: ...top line on the next page F4 Moves to previous item 1 line up When on the top line it moves to the last line on the previous page F5 Returns to the standard screen F6 Displays the setting screen for s...

Page 122: ...with switches F3 to F5 F3 Displays the next page When on the last page it displays the first page F4 Displays the previous page When on the first page it dis plays the last page F5 Returns to the ECO...

Page 123: ...display the graph of hourly average fuel consumption during the last 12 hours or the graph of daily fuel consumption during the last one week OPERATION ON THE FUEL CONSUMPTION RECORD SCREEN On the fue...

Page 124: ...last 12 hours and the other is daily average fuel consumption during the last one week Switching between them is available DELETING FUEL CONSUMPTION RECORD 1 When the switch F1 CLEAR is pressed the re...

Page 125: ...the top line on the next page F4 Moves to previous item 1 line up When on the top line it moves to the last line on the previous page F5 Returns to the ECO guidance menu screen F6 Displays the settin...

Page 126: ...fuel consumption REMARK If you select the split measurement the measurement stop switch STOP is displayed on the operating record screen and the energy saving ECO guidance record screen When you stop...

Page 127: ...turns to the display setting screen F6 Changes the setting and returns to the display setting screen SETTING THE TARGET FUEL CONSUMPTION VALUE DISPLAYED IN THE ECO GAUGE Is possible to change the targ...

Page 128: ...ing ECO guidance 10 on the standard screen q OFF Does not display energy saving ECO guidance 10 on the standard screen On the display setting screen it is possible to carry out the fol lowing operatio...

Page 129: ...ppears q ON Displays energy saving ECO guidance 12 on the exit screen q OFF Does not display energy saving ECO guidance 12 on the exit screen On the display setting screen it is possible to carry out...

Page 130: ...om E0 the lower engine output becomes however the fuel con sumption becomes better accordingly OPERATION ON THE ECONOMY MODE ADJUSTMENT SCREEN On the economy mode adjustment menu screen it is possible...

Page 131: ...and returns to machine setting menu screen F6 Allocates the selected setting to that of B mode CHANGING OF THE BREAKER SETTING NAME It is possible to change the breaker setting name as you like Alphab...

Page 132: ...ent setting menu is not displayed CHANGING ATTACHMENT SETTING 1 Move to the machine setting menu b on the user menu 2 Select the attachment setting menu 3 then press switch F6 3 On the attachment sett...

Page 133: ...g the name F6 Accepts change and returns to the attachment setting screen q It is not possible to change the name for No Attach ment setting CHANGING ATTACHMENT OIL FLOW SETTING 1 Select an attachment...

Page 134: ...llowing operations with switches F1 to F6 F1 Switches the display from attachment 2 oil flow setting screen to attachment 1 oil flow setting screen F2 Switches the display from attachment 1 oil flow s...

Page 135: ...tting the remaining time keep switch F6 pressed for at least 1 5 seconds If this time is short the switch operating sound can be heard but the screen does not switch to the screen for resetting the re...

Page 136: ...When cancelling the reset press switch F5 The screen returns to the maintenance menu screen q On the reset screen if no switch is operated for more than 30 seconds the screen automatically changes to...

Page 137: ...returns to the monitor setting menu screen F6 Accepts the change and then returns to the monitor setting menu screen REMARK q If the light switch is at night mode ON and the screen is adjusted it is p...

Page 138: ...may not change the screen brightness as long as mark is displayed However it is not an error CLOCK ADJUSTMENT CLOCK ADJUSTMENT PC Q1MC 100K00A On the clock adjustment menu it is possible to change th...

Page 139: ...ment where the radio waves from GPS cannot be received such as inside of a building the automatic setting function might be disable q Turning the GPS Synchronization menu ON disables selecting the men...

Page 140: ...screen F6 Proceeds to setting for date 4 When date display C is highlighted in yellow operate the switches as follows to change day display C If it is not necessary to change the day press switch F6 F...

Page 141: ...ss switch F6 F3 Time goes back one hour F4 Time advances one hour F5 Cancels change and returns to the clock adjustment screen F6 Proceeds to setting for minute 3 When minute display E is highlighted...

Page 142: ...T SAVING TIME If daylight saving time is turned ON the clock display becomes 1 hour earlier If daylight saving time is turned OFF the clock display returns to the set time 1 Select Daylight Saving Tim...

Page 143: ...turns to the monitor setting screen MESSAGE DISPLAY MESSAGE DISPLAY PC Q235 100K00A On machines equipped with KOMTRAX it is possible to see the messages from your Komatsu distributor on this menu f Wh...

Page 144: ...2 Select mail confirmation menu f and you can read the arrived message 3 In case of a message requesting for reply the column of Ten key input value is displayed in place 2 of the mail confirmation me...

Page 145: ...correct number press switch F5 and you can clear an input character at a time q If switch F5 is pressed when the input column is blank the screen returns to the standard screen 2 After inputting a sel...

Page 146: ...f equipped 4 Swing lock switch 15 Seat heater switch 5 Lamp switch 16 Quick coupler switch 6 Horn switch 17 Quick coupler switch 7 One touch power max switch 18 1st attachment proportional control swi...

Page 147: ...during cranking Immediately after starting the engine release the key It will automatically return to the ON position B FUEL CONTROL DIAL Fuel Control Dial ALL AGJ7 043K00A Dial 2 adjusts the engine s...

Page 148: ...ock is always applied and the upper structure will not swing even if the swing is oper ated In this condition the swing lock lamp lights up b OFF position cancelled The swing lock is released when ope...

Page 149: ...9 is provided to enable you to carry out operation temporarily when any problem occurred on the pump control system DO NOT use it except in emergencies Repair the problem as soon as possible q If thi...

Page 150: ...orarily when the swing holding brake system is out of order when no swing is possible even though L03 is not shown on the display a FREE When abnormal move switch up b NORMAL When normal move switch d...

Page 151: ...ing water q a Wiper position To actuate the ceiling window wiper q b Washer position While depressing the switch the washing water for the ceiling window is sprayed and wiper actuates at the same time...

Page 152: ...er is closed and the switch is in the NORMAL position If not set it to the NORMAL position This switch 13 is used to stop the engine when the starting switch is turned to the OFF position but the engi...

Page 153: ...peration 1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH 1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH PC220_KU PT0R 043K00A This switch 18 is a roller proportional control switch used to operate the 1st atta...

Page 154: ...3 84 ADDITIONAL LAMPS SWITCH ADDITIONAL LAMPS SWITCH PC220_KU Q6BC 043K00A if equipped Switch 21 is used to turn on the cab front lamps cab rear lamps and extra boom lamps NB If fitted by customer a O...

Page 155: ...ol lever q Before raising the lock lever make sure that all levers and pedals are set to the NEUTRAL position This lever 1 is a device to lock the work equipment swing travel and attachment control le...

Page 156: ...the track frame is facing the front or the rear If the sprocket is at the rear the track frame is facing the front This lever 2 is used to change the direction of travel between forward and reverse s...

Page 157: ...Boom LOWER Bucket control c Bucket DUMP d Bucket CURL N NEUTRAL The boom and bucket are held in position and do not move CEILING WINDOW CEILING WINDOW PC220_KU K18H 100K00A The operator cab is provid...

Page 158: ...q When opening the front window hold the handle securely with both hands pull up and do not let go until the automatic lock catch is locked q When closing the front window the window will move quicker...

Page 159: ...OPERATION EXPLANATION OF COMPONENTS 3 89...

Page 160: ...e the two handles A on the left and right top sides of the front window to pull up the front window Do not pull down the front window with the handles A 6 Check that lever B is securely at the LOCK po...

Page 161: ...ine 2 Set lock lever 1 securely to LOCK position L 3 Grip right and left handles A and pull down lever B to release the lock 4 Grip handle C at the bottom of the front window with your left hand and h...

Page 162: ...epeat the operation in Step 5 to engage the lock REMOVING LOWER WINDSHIELD UPPER SIDE 1 Open the front window upper side then hold grip 1 pull up and remove the lower side window q If sand or dust is...

Page 163: ...broken glass q To prevent injury remove the broken pieces of glass remaining in the frame before escaping through the window Be careful also not to slip on the broken pieces of glass If it should beco...

Page 164: ...put your hands on the door frame The door may suddenly close and cause injury Use the door lock to fix the door in position after opening it 1 Push the door against catch 1 to lock it in position 2 Wh...

Page 165: ...f its weight If the engine hood is not locked it may close suddenly because of wind etc q Just after the engine is stopped the engine hood and KDPF are hot Wait until they cool down and then open or c...

Page 166: ...RK To open the engine hood fully hold handle D and pull up the engine hood Stay E stops first at branch portion 3 of the guide groove Then while pushing stay E in the direction of the arrow open the e...

Page 167: ...y be deformed q Do not release handle D until the engine hood is lowered fully 2 Lower the engine hood hitch rings B of right and left levers A to hooks C and pull up levers A and lock them REMARK q T...

Page 168: ...OF COMPONENTS OPERATION 3 98 q Do not lower the engine hood while stay E is not set in guide grooves 4 and 5 If you do so stay E may be deformed q Do not release handle D until the engine hood is low...

Page 169: ...it will go to the shoulder A If the key is turned before it is inserted all the way it may break OPEN AND CLOSE CAPS WITH LOCK OPEN AND CLOSE CAPS WITH LOCK ALL Q8E1 100K00A OPENING THE CAP 1 Insert t...

Page 170: ...D PC H54B 100K00A OPENING THE HOOD LOCKED HOOD 1 Insert the key into the key slot 2 Turn the key counterclockwise A and take the key out Position A OPEN Position B CLOSE 3 Pull lever grip 1 and take o...

Page 171: ...OPENING THE DOOR LOCKED DOOR 5 Insert the key into the key slot 6 Turn the key clockwise to unlock the key then open the door handle Position A OPEN Position B LOCK LOCKING THE DOOR 1 Close the door a...

Page 172: ...old Hot or cold air blows into the box according to the setting of the air conditioner MAGAZINE BOX Magazine box PC K820 043K00A Located on the left side of the operator s seat Keep the Operation and...

Page 173: ...eat Always put out your cigarette before putting it in the ashtray and be sure to close the lid NOTICE While removing the ashtray if it is stuck in the console cover and hard to remove open the lid A...

Page 174: ...SWITCH OFF Switch ALL K5V4 043K00A Switch 1 is used to stop the fan and air conditioner REMARK Even if this switch 1 is pressed the monitor screen does not switch to the air conditioner adjustment sc...

Page 175: ...WITCH Temperature Control Switch ALL K5V6 043K00A Switch 3 is used to control temperature inside the cab The temperature can be set between 18 C and 32 C q Press the E switch to raise the set temperat...

Page 176: ...tically selected A Rear vent 4 places B1 Face vent 1 place C Foot vent 1 place D Front window glass vent 2 places B2 Front window glass vent 1 place Note1 Air blows out from vents marked O Liquid crys...

Page 177: ...side q During automatic operation the selection of inside air RECIRC and outside air FRESH is performed automati cally DISPLAY MONITOR DISPLAY MONITOR PC220 K5VA 043K00A Monitor 7 displays the status...

Page 178: ...e strength of the sun s rays In addition it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun s rays before hand and automatically adjusts th...

Page 179: ...flow combination of vents and selection of fresh or recirculated air is automatically selected according to the set temperature and the air conditioner is operated automatically to provide the set te...

Page 180: ...emperature setting a and air flow b are displayed on monitor 7 2 Turn air conditioner switch 8 ON 3 Press temperature setting switch 3 and adjust tempera ture inside the cab 4 Press vent selector swit...

Page 181: ...de FRESH STOP MANUAL OPERATION Press OFF switch 1 Operation stops OPERATION WITH COLD AIR BLOWING TO THE FACE AND WARM AIR BLOWING TO THE FEET To operate with cold air blowing to the face and warm air...

Page 182: ...hown in the diagram on the right 3 Turn air conditioner switch 8 ON 4 Adjust fan switch 2 temperature setting switch 3 and RECIRC FRESH selector switch 6 to the desired posi tions OPERATION TO DEFROST...

Page 183: ...ch 4 and set vent display on the display monitor to f or g as shown in diagram on the right 3 Press RECIRC FRESH selector switch 6 and set it to take in fresh air 4 Press temperature setting switch 3...

Page 184: ...B1 and B2 so that the air blows onto the window glass Vents C and D are fixed and cannot be adjusted When operating in the rainy season or when it is desired to remove the mist from the window glass...

Page 185: ...when entering the cab 5 or 6 C lower than the outside temperature This temperature difference is considered to be the most suitable for your health so always be careful to adjust the temperature prope...

Page 186: ...ase or radio it may lead to an unexpected failure so be careful not to get water on the equipment q Do not wipe the display or buttons with solvent such as benzene or thinner Wipe with a dry soft clot...

Page 187: ...ance you can select the station by touching this button once It is possible to preset 6 stations each for both AM and FM For details of the presetting method see OPERATION METHOD 3 119 DISPLAY SELECTI...

Page 188: ...UX PC K866 043K00A You can hear the voice through the speaker of the machine when you connect a commercially available portable audio equipment to the machine 1 Open cap a 2 Connect a portable audio e...

Page 189: ...buttons 1 to 6 of preset button 5 and the frequency being received now is memorized to the corresponding preset number Example While a frequency is displayed keep pressing button 1 of preset station...

Page 190: ...le to hear outside sounds during operation q If water gets into the speaker case or radio it may lead to an unexpected failure so be careful not to get water on the equipment q Do not wipe the scales...

Page 191: ...uipment If the cigarette lighter is removed the socket can be used as a power source Maximum usable electric power is 85 W 24 V x 3 5 A REMARK Use this power source while engine is running 12V POWER S...

Page 192: ...switch to the OFF position q The fuse holders are installed for fuse 1 a at the rear right and for fuse 2 b at the rear left of the operator s seat q It protects the electrical equipment and wiring f...

Page 193: ...1 20 A Working lamp Boom Rear 12 10 A Optional power source 1 13 30 A Optional power source 2 12 V power source Air suspension seat with heater 14 5 A Air conditioner ECU power source 15 5 A Key ACC s...

Page 194: ...ine starting motor does not operate even when the engine starting switch is turned to the START position fusi ble links 1 and 2 are suspected of disconnection q Fusible link 3 is suspected of disconne...

Page 195: ...NOTICE q Be careful not to get water mud or juice on the controller This will cause failures q If any problem occurs in the controller do not disassemble it yourself Contact your Komatsu distributor...

Page 196: ...left of the machine Keep the grease pump hooked on this holder while it is not used FIRE EXTINGUISHER Fire extinguisher PC Q5G1 043K00A if equipped A fire extinguisher is prepared at the rear part in...

Page 197: ...g lamp is lighting up The electri cal system may have trouble or abnormality q If this switch is turned to the OFF position all the electrical system is cut out and the functions of KOMTRAX stop In ad...

Page 198: ...ttery disconnect switch is turned OFF while this lamp is lighting the data in the controller may be lost If the data are lost when the engine is tried to be started next time L04 is displayed on the m...

Page 199: ...ation function of KDPF con tinues for long hours the regeneration is performed to protect the KDPF system regardless of the quantity of the accumu lated soot During the KDPF regeneration KDPF regenera...

Page 200: ...after finishing the work and perform the manual stationary regeneration 2 When level of urgency is high q If KDPF soot accumulation monitor 2 lights up red Action level monitor 3 L03 screen D is displ...

Page 201: ...ust after the regeneration is completed the soot accumulation level may not be 0 This is caused by the accumulated noncombustible material in the exhaust gas and is not trouble q Since noncombustible...

Page 202: ...onitor 1 is lighting 1 Move the machine to a safe place and stop it with engine running 2 Check that there is no person or combustible matter around the machine particularly in the direction of the ex...

Page 203: ...press switch F5 to check the contents of other occurring troubles stop the operation and carry out inspection and maintenance REMARK q The explanation of the manual stationary regeneration is display...

Page 204: ...minutes q If the lock lever or fuel control dial is operated during the manual stationary regeneration the regeneration is stopped automatically Return the lock lever to LOCK position L and return the...

Page 205: ...monitor 2 on the standard screen is hatched q The regeneration disable setting is cancelled if starting switch is turned to the OFF position If the automatic regen eration needs to be kept disabled p...

Page 206: ...ation monitor 3 is lighting on standard screen 1 If switch F6 is pressed on the standard screen the KDPF regeneration screen is displayed 2 Select regeneration disable and then press switch F6 and the...

Page 207: ...screen is not displayed display it by operating switches F1 and F2 2 Select cancel of regeneration disable and press switch F6 and the regeneration disable is cancelled If soot accumulation level 4 l...

Page 208: ...nt needs to be replaced every 2000 hours For details of the replacement procedure see REPLACE KCCV FILTER ELEMENT 4 71 q If the engine is operated without the KCCV filter ele ment or if a filter eleme...

Page 209: ...e blasting jobsite or a remote controlled blasting device the power supply cable of KOMTRAX must be disconnected in advance If you want to do this ask your Komatsu distributor for disconnecting power...

Page 210: ...e machine is purchased second hand For the registration and usage records of KOMTRAX consult your Komatsu distributor If the machine has been lent out by the customer the borrower or another third par...

Page 211: ...l leakage around the engine Check for oil leakage from the engine and coolant leaks from the cooling system If any problem is found repair it 4 Check for leakage from fuel line Check that there is no...

Page 212: ...terials dry leaves and twigs If any dirt or flammable materials are found remove them 14 Checking gas leakage in the space around KDPF Check the pipe connecting KDPF to turbocharger and also KDPF conn...

Page 213: ...flames near fuel k CAUTION Ensure that the machine is parked on level ground during refuelling operation Do not leave machine unattended during refuelling and monitor Following any over filling or sp...

Page 214: ...ce Refuelling will continue automatically until the tank has reached capacity float switch 6 will reach its limit and the pump will stop It is important to ensure the machine is parked on level ground...

Page 215: ...n K to prevent leakage of fuel left in the hose 7 Replace the fuel hose in tool case 3 DRAIN WATER AND SEDIMENT FROM FUEL TANK DRAIN WATER AND SEDIMENT FROM FUEL TANK PC220 AD10 220K00A 1 Open the doo...

Page 216: ...ure above to drain the water REMARK When only the water separator monitor lights up it lights up in the position shown in the diagram on the right If other monitors also light up the same time the wat...

Page 217: ...transparent cap 2 and also the fuel accumu lated in filter cartridge 1 4 Check that nothing more comes out from drain hose 3 then remove drain valve 4 5 Coat O ring portion 7 with a suitable amount of...

Page 218: ...tact with the ground and stop the engine 3 Within 15 seconds after stopping the engine move each control lever for work equipment and travel to the full stroke in all directions to release the interna...

Page 219: ...the rear left of the machine and check if the coolant in sub tank 1 shown in the diagram on the right is between the FULL and LOW marks If the coolant level is low add coolant to the FULL level throu...

Page 220: ...checking If the machine is at an angle make it to a horizontal position before checking q When the ambient temperature is low water or emulsified matter may stick to the dipstick fuel filler cap etc...

Page 221: ...to the ON position and check the fuel level gauge 1 on the monitor panel for fuel level After checking turn the switch back to the OFF position 2 If fuel is found to be low unscrew fuel filler cap F o...

Page 222: ...not light up the bulb is probably blown up or there is a disconnection so ask your Komatsu dis tributor for repair 1 Turn the starting switch to the ON position 2 Turn the lamp switch ON night mode a...

Page 223: ...lining decreases as the seat is pushed back so when moving the seat back return the seat back to the upright position Pull up lever 2 and set the backrest to a position that is com fortable for operat...

Page 224: ...rotation in the same direction causes the lumber sup port to return to the original position MIRRORS ADJUSTMENT Mirrors adjustment PC220_KA K810 270K00A k WARNING Be sure to adjust the mirrors before...

Page 225: ...o 0 71 kgm Mounting position 8 89mm NOTICE q Tighten the right and left bolts of each bracket alter nately so that their right and left clearances R and L become equal q If the mirror and stay mountin...

Page 226: ...Tighten the right and left bolts of each bracket alter nately so that their right and left clearances R and L become equal q If the mirror and stay mounting bolts are tightened excessively the bracket...

Page 227: ...njured or may injure someone seri ously q When adjusting the angle of the rear view camera pre pare a scaffold first in order to provide a safe working platform If you try to make such an adjustment s...

Page 228: ...from 2 places 3 Remove cover 1 REMARK q Shims 6 may be installed to adjust the clearance on cover outer periphery portion When removing cover 1 take a note of position and numbers of the shims to res...

Page 229: ...elt so that it is not twisted REMARK The date attached to the seat belt is the manufactured date It is the start of the 5 year period It is not the start of the 3 year period of actual usage FASTENING...

Page 230: ...lock lever is securely at the LOCK position If the lock lever is not locked securely and the control levers or control pedals are touched when the engine is started the machine may move unexpectedly...

Page 231: ...tion If the control levers and control pedals are not being touched they will be at the NEUTRAL position 4 Insert the key in starting switch 2 turn the key to the ON position B DO NOT touch the left D...

Page 232: ...failure in the monitor so please ask your Komatsu distributor for repair 2 After approximately 2 seconds the screen will change to the working mode travel speed display monitor Next it will switch to...

Page 233: ...position If the fuel control dial is at the full speed MAX position the engine will accelerate suddenly and cause damage to the engine parts q Do not keep the key in starting switch 3 at the START po...

Page 234: ...ART position for 20 seconds If this happens wait for at least 2 min utes then start again from the beginning 5 After the engine starts release the key in starting switch 3 The key will automatically r...

Page 235: ...TECT FUNCTION The turbo protect function is a function to protect the turbocharger by keeping the engine speed at less than approx 1 000 rpm immediately after the engine is started q When the turbo pr...

Page 236: ...operation may differ so carry out the warm up operation according to the descriptions given in the appropriate section When only the engine is warmed up the hydraulic equipment is not warmed up so alw...

Page 237: ...ints when breaking in the machine q Run the engine at idle for 15 seconds after starting it During this time do not operate the control levers or fuel control dial q Warm up the engine for five minute...

Page 238: ...e procedure in Step 3 to carry out additional warm up of the engine until the monitor displays the proper temperature q Display A when temperature is proper Monitor back ground C is blue q Display B w...

Page 239: ...Carry out the warm up operation for the hydraulic equipment until the hydraulic oil temperature monitor displays the proper temperature When the hydraulic oil temperature is low the low temperature d...

Page 240: ...p of the engine until engine coolant temperature monitor 1 displays the proper temperature See ENGINE WARM UP OPERATION 3 167 2 Turn swing lock switch 2 to the ON position and check that the swing loc...

Page 241: ...lever 6 slowly in the direction to push out arm A Operate the lever to the end of its travel and hold it in position for 30 seconds 10 Repeat the operation in Steps 6 to 9 for five minutes 11 Check t...

Page 242: ...ture q Fuel gauge 17 Indicator in green range q Fuel level monitor 18 Displays appropriate level 14 Check for abnormal exhaust gas colour noise or vibration If any problem is found contact your Komats...

Page 243: ...ng operations repeat the following operations slowly 3 to 5 times to circulate warm oil through the all con trol circuits q Boom operation RAISE E ioLOWER F q Arm operation IN B ioOUT A q Bucket opera...

Page 244: ...temperature the hydraulic equipment warm up operation is completed After checking that the hydraulic oil temperature monitor displays the proper temperature carry out the following procedure OPERATIO...

Page 245: ...N MACHINE OPERATIONS AND CONTROLS 3 175 1 P mode For heavy duty operations 2 E mode For operations with emphasis on fuel economy 3 L mode For operations requiring fine control 4 B mode For breaker ope...

Page 246: ...OLS OPERATION 3 176 5 ATT P mode For operations with crusher or other double acting action attachment 6 ATT E mode For operations with crusher or other double acting action attachment operations with...

Page 247: ...parts of the engine may be considerably reduced Do not stop the engine abruptly except the case in an emergency If the engine is overheated do not try to stop it abruptly but run it at medium speed t...

Page 248: ...nd the horn q Do not allow anyone to enter the area around the machine q Clear any obstacles from the travel path q There is a blind spot at the rear of the machine so be particularly careful when tra...

Page 249: ...machine Start the machine either by pushing lever 5 forward slowly or by depressing the front part of pedal 6 slowly q When sprocket A is situated at the front of the machine Start the machine either...

Page 250: ...ar part of pedal 6 slowly q When sprocket A is situated at the front of the machine Start the machine either by pushing lever 5 forward slowly or by depressing the front part of pedal 6 slowly 3 Check...

Page 251: ...OPERATION MACHINE OPERATIONS AND CONTROLS 3 181...

Page 252: ...to the direction of movement of the machine Use the travel levers to change direction Avoid sudden changes of direction to travel as much as possi ble Especially when performing counter rotation spin...

Page 253: ...Forward left turn B Reverse left turn REMARK When turning to the right operate the right travel lever in the same way COUNTER ROTATION TURN SPIN TURN Counter rotation Turn Spin Turn PC 0000 13PK03A Wh...

Page 254: ...ed is decreased by the auto deceleration function the engine speed will suddenly increase Operate the levers carefully 1 Before starting the swing operation turn swing lock switch 1 OFF and check that...

Page 255: ...erate the work equipment Note that when the levers are released they return to the HOLD position and the work equipment is held in that position q Arm control Move the left work equipment control leve...

Page 256: ...ntrol circuit on this machine is equipped with an accumulator Even if the engine is stopped if the starting switch key is turned to the ON position within 15 seconds after stopping the engine and the...

Page 257: ...the type of work NOTICE q If breaker operations are carried out in a mode other than the breaker mode there is danger of breakage of the hydraulic equipment Do not carry out breaker operations in any...

Page 258: ...screen returns to the standard screen without changing the mode q If a working mode is selected and nothing is done for five seconds the selected working mode is automati cally accepted and the screen...

Page 259: ...e the power Make effective use of this function whenever necessary in combination with the working mode q Press the left knob switch and keep it pressed The power is increased as long as the switch is...

Page 260: ...nly dangerous but also drastically reduces the life of the machine OPERATIONS USING TRAVEL FORCE Operations Using Travel Force PC 0000 189K02A Do not use the travel force to carry out excavation by di...

Page 261: ...ng Hard Rocky Ground PC 0000 189K06A Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it after breaking up by some other means This will not only...

Page 262: ...and a half hours or more The lubricating oil inside the track rollers and final drive will rise to a high temperature And there is a danger that this will cause damage to the oil seal or leakage of o...

Page 263: ...oid travelling over such obsta cles as far as possible If there is no way to avoid travelling over an obstacle reduce the travel speed keep the work equipment close to the ground and try to travel so...

Page 264: ...er structure will go under water and water will be thrown up by the cooling fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in w...

Page 265: ...30 cm from the ground Do not travel downhill in reverse q Never turn on slopes or travel across slopes Always go down to a flat place to perform these opera tions It may be longer but it will ensure...

Page 266: ...l at low speed BRAKING ON DOWNHILL SLOPE BRAKING ON DOWNHILL SLOPE PC 0000 18QK00A Put the travel lever in the neutral position This will cause the brake to be automatically applied IF ENGINE STOPS ON...

Page 267: ...e between the boom and arm should be 90 to 110 The same applies when using the bucket installed in the reverse direction When only one side is stuck in mud use the bucket to raise the track then lay b...

Page 268: ...ly to optimize your working efficiency The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle towards the machine There may be some differences depending on the e...

Page 269: ...e the swing angle is narrow work efficiency can be enhanced by locating the dump truck in a place easily visi ble to the operator When loading the soil into dump truck body it is easier to load from t...

Page 270: ...get your fingers caught q Never insert your fingers into the pin holes when aligning the holes Stop the machine on a firm and flat surface and do the work When performing joint work appoint a leader a...

Page 271: ...aged If a damaged seal is used without being replaced sand and dirt may enter the pin portion and cause abnormal wear of the pin INVERT INVERT PC LBK0 6D5K00A 1 Place the bucket in contact with a flat...

Page 272: ...verting do not install O rings Keep the O rings in a safe place until using them next 5 Install the stopper bolts and nuts for each pin then grease the pins REMARK q Lubricate with grease thoroughly u...

Page 273: ...te at the bucket linkage and at the grease metering valve as indicated until grease comes out from the end faces It will be necessary to replace the plug at the grease metering valve with a grease nip...

Page 274: ...achine on a slope put blocks to the track shoes As an additional safety measure thrust the bucket into the ground q If the control lever is touched by accident the machine may move suddenly and this m...

Page 275: ...lant temperature gauge is in the red range allow it to cool until the indicator enters the green range then stop the engine Perform the inspection and action to take according to Troubles and actions...

Page 276: ...the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove any mud stuck to the undercarriage LOCKING LOCKING PC220 Q8E0 100K00A Always lock the followi...

Page 277: ...od of transportation to match the weight and dimensions given in SPECIFICATIONS 5 2 Note that the weight and dimension given in SPECIFICATIONS weight and dimension may differ according to the type of...

Page 278: ...q On the ramps do not operate any lever except the travel lever q The centre of gravity of the machine will change sud denly at the joint between the ramps and the trailer and there is danger of the m...

Page 279: ...to set the engine speed to low idling q Each time auto deceleration switch 7 is pressed it switches OFF ON OFF in turn q When auto deceleration switch 7 is turned OFF the auto deceleration monitor 8...

Page 280: ...k switch ON to apply the swing lock q When the swing lock switch is turned to the ON position pilot monitor display 9 lights up a ON position b OFF position 10 When the machine travels over the rear w...

Page 281: ...her is locked Hold the handle of the engine hood and raise it slightly If it does not open the catcher is locked If the engine hood catcher is not locked there is a danger that the engine hood may ope...

Page 282: ...ne from moving during transportation and secure the machine with chains or wire rope of suitable strength Be par ticularly careful to secure the machine in position so it does not slip to the side STO...

Page 283: ...ed or are to be removed for shipment or are to be installed again use the following procedure q After installing the mirrors be sure to adjust them referring toMirrors adjustment 3 154 REMOVAL q Mirro...

Page 284: ...istributor for handling of the handrail transportation k WARNING q After transporting the machine be sure to install the handrails before inspection and maintenance q Use the crane etc for carrying th...

Page 285: ...s 1 then remove handrail A 2 Remove bolts 2 then remove handrail B and cover 3 INSTALLATION OF HANDRAILS 1 Install handrail B and cover 3 then tighten them with bolt 2 2 Install handrail A then tighte...

Page 286: ...the claw in the centre of the connector 2 Place the connector for wiring B in a clean vinyl bag or the like to protect it from water etc during transportation and fix it to the operator s cab with se...

Page 287: ...can be heard REMOVAL AND INSTALLATION OF CAB PARTS Removal and installation of cab parts PC K16F 822K00A HOW TO REMOVE CAB PARTS BEFORE TRANSPORTATION NOTICE If the door is opened completely while do...

Page 288: ...oval of striker 1 Remove cap 7 from inside the door by picking the pro trusion a of cap 7 with fingers 2 Loosen the inside nuts 8 2 pieces to remove striker 3 q Keep the removed parts and the removal...

Page 289: ...t dust from entering the holes HOW TO INSTALL CAB PARTS AFTER TRANSPORTATION 1 Removal of covering of stoppers and striker Completely remove the covering tapes b for mounting holes of stoppers and str...

Page 290: ...Installation of striker 1 Tighten nuts 8 2 pieces to install striker 3 2 Install cap 7 to inside the door by picking protrusion a of cap 7 with fingers q Be careful to install cap 7 so that the part w...

Page 291: ...ropes fastening the machine 4 Start the engine Warm the engine up fully 5 Set the lock lever to FREE position F 6 Turn the travel speed selector switch to low speed travel Lo lamp lights up q Press tr...

Page 292: ...moving onto the ramps do not thrust the bucket into the ground This will cause damage to the hydrau lic cylinders 10 When moving from the rear of the trailer on to the ramps set the angle of the arm a...

Page 293: ...rom moving unexpectedly q Never enter the area under or around a raised machine Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting equipm...

Page 294: ...is nothing around the operator s compartment then get off the machine Close the cab door and front window securely 5 Pass wire ropes between the 1st and 2nd track rollers from the front and between t...

Page 295: ...or all compo nents For detail see RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 BATTERY Battery ALL AW10 265K00A k WARNING q The battery generates flammable gas Do not bring fire or sparks near the batte...

Page 296: ...ound and allow the machine to be moved the next morning q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing q Fill the fuel tank to capacity This minimi...

Page 297: ...the attachment control pedal to the lock position on the machines ready for attachments q Set the stop valve to the LOCK position on the machines ready for attachments Install the blind plugs to the e...

Page 298: ...the engine If there is water in the oil change all the oil q Insert the battery disconnect switch key and turn it to the ON position For details of the operating method see BATTERY DISCONNECT SWITCH 3...

Page 299: ...en the arm control lever is operated to the IN position and the work equipment is lowered under no load from a high position the arm speed drops momentarily when the arm is more or less at the vertica...

Page 300: ...e being towed q Operate the machine slowly and be careful not to apply any sudden load to the wire rope q Do not use the holes for towing light objects or tie down holes when towing the machine NOTICE...

Page 301: ...en towing the machine There is a hole in the track frame to fit the shackle when towing light objects Permissible towing load Max 58 800 N 6 000 kgf NOTE Do not use tie down lugs PAGE 3 212 for towing...

Page 302: ...s or on your skin immediately wash it off with a large amount of water If it gets into your eyes wash them immediately with fresh water then consult a doctor for treatment q When handling batteries al...

Page 303: ...d do as follows q Set the voltage of the charger to match the voltage of the battery to be charged If the correct voltage is not selected the charger may overheat and cause an explosion q Connect the...

Page 304: ...r cable exercise good care so that the booster cable clips may not contact each other or they contact the chassis NOTICE q The starting system for this machine uses 24 V For the normal machine also us...

Page 305: ...k WARNING Check both of normal machine and failed machine that the lock lever is set to the LOCK position Check also that all the control levers are in the NEUTRAL position 1 Make sure the clips are f...

Page 306: ...ng motor does not turn when starting switch is turned to ON position Defective wiring Check repair Defective starting motor Replace Insufficient battery charge Charge Battery disconnect switch is turn...

Page 307: ...ERY 2000 HOURS SERVICE Excessive rise in hydraulic oil temperature Loose fan belt Check of fan belt tension and its replacement Dirty oil cooler Clean see EVERY 500 HOURS SERVICE Lack of hydraulic oil...

Page 308: ...ng system see When required Clogged radiator fins or damaged fin Clean or repair see Every 500 hours service Defective thermostat Replace thermostat Loose radiator filler cap in high altitude operatio...

Page 309: ...fuel Exhaust gas occasionally turns black Broken KDPF Replace KDPF Combustion noise occasionally makes breathing sound Defective nozzle Replace nozzle Abnormal noise generated combustion or mechanical...

Page 310: ...59 appears on the occur ring failure code screen and yet the machine has not run out of fuel replace both fuel main filter element and fuel pre filter element immediately If the display of CA2249 or C...

Page 311: ...MAINTENANCE 4 1 MAINTENANCE MAINTENANCE ALL 0000 001K03A MAINTENANCE k WARNING Please read and make sure that you understand the SAFETY section before reading this section...

Page 312: ...m oil and grease CHECK DRAINED OIL AND USED FILTER Check drained oil and used filter ALL C940 2A4P01A After oil is changed or filters are replaced check the old oil and filters for metal particles and...

Page 313: ...be careful not to forget to assemble the O rings and gaskets q When installing the hoses do not twist them or bend them sharply If they are installed so their service life will be shortened extremely...

Page 314: ...of such impurities Take particular care not to let any impurities get in when storing or adding oil q Never mix oils of different grades or brands q Always add the specified amount of oil Having too...

Page 315: ...the recom mended grease and follow the change intervals and recommended ambient temperatures given in this Opera tion and Maintenance Manual q Grease fittings not included in the maintenance section a...

Page 316: ...ntity of iron particles of 5mm or more enabling early detection of failures q Others Measurements are made of items such as the ratio of water in the oil concentration of the coolant ratio of fuel in...

Page 317: ...s dangerous For the operation of the battery disconnect switch see BATTERY DISCONNECT SWITCH 3 127 q It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is...

Page 318: ...the following table for hydraulic hose Thread diameter of bolt a mm Width across flats b mm Tightening torque Target value Allowable range 6 8 10 12 14 10 13 17 19 22 13 2 1 35 31 3 2 66 6 7 113 11 5...

Page 319: ...E AIR CONDITIONER 4 31 WASH WASHABLE FLOOR 4 32 CHECK GAS SPRING 4 36 BLEED AIR FROM HYDRAULIC CIRCUIT 4 36 CHECKS BEFORE STARTING CHECKS BEFORE STARTING ALL 3340 001A00A EVERY 100 HOURS MAINTENANCE E...

Page 320: ...HIGH PRESSURE PIPING CLAMP HARDENING OF RUBBER 4 76 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 76 CHECK OPERATING CONDITION OF COMPRESSOR 4 77 EVERY 4500 HOURS MAINTENANCE EVERY...

Page 321: ...ange oil in hydraulic tank Change the oil according to the table on the right q Replace additional filter element for breaker if equipped Replace pilot filter element if equipped Use a guideline of 25...

Page 322: ...element until the air cleaner clogging monitor on the monitor panel light up If the element is cleaned frequently before the air cleaner clogging monitor light up the air cleaner will not be able to...

Page 323: ...le push it straight to the bottom by your hand 4 After removing outer element 5 cover the inner element 6 with a clean cloth or tape to prevent dirt or dust from entering 5 Wipe off or brush off the d...

Page 324: ...lems Do not use them again 10 Check that there is no dirt or oil stuck to the sealing portion of the new element or cleaned element Wipe any dirt or oil off 11 Push the outer element straight into the...

Page 325: ...ces the ground A 3 When cover 3 is installed check that the clearance between the air cleaner body and cover 3 is not too large If it is too large repeat the installation REPLACE ELEMENT REPLACE ELEME...

Page 326: ...ve inner element 6 then quickly install the new inner element Install the inner element securely so that it does not move 7 Push new outer element 5 in straight with your hand into the air cleaner bod...

Page 327: ...3 with a new decal CLEAN INSIDE OF COOLING SYSTEM CLEAN INSIDE OF COOLING SYSTEM PC220_KU B000 255K00A k WARNING q Immediately after the engine is stopped the coolant is at a high temperature and the...

Page 328: ...the actual temperature The coolant density varies according to the ambient temperature but it must always be a minimum of 30 Coolant density table k WARNING q Coolant is toxic When open the drain val...

Page 329: ...container under drain valve 3 to catch the coolant Open drain valve 3 at the bottom of the radiator and drain the coolant 6 After draining the coolant close drain valve 3 and fill the radiator with c...

Page 330: ...ment control lever slowly in the direction to push out bucket C Operate the lever to the end of its travel and hold it in position for 30 seconds 13 Next move the left work equipment control lever slo...

Page 331: ...tank 5 with NON Amine Engine Coolant AF NAC to the middle between the FULL and LOW marks For density of the Non Amine Engine Coolant AF NAC see the COOLANT DENSITY TABLE 23 Run the engine at low idle...

Page 332: ...MAINTENANCE SCHEDULE TABLE MAINTENANCE 4 22 26 Close engine hood 1...

Page 333: ...he link mating surfaces CHECK AND ADJUST TRACK TENSION CHECK AND ADJUST TRACK TENSION PC DTL0 92CK00A Wear on pins and bushings of the undercarriage vary with working conditions and type of soil so in...

Page 334: ...und then stop the machine 3 Check the track tension again and if the tension is not cor rect adjust it again 4 Grease can be pumped in until dimension S becomes zero 0 Please ask your Komatsu distribu...

Page 335: ...rea q There is a hazard that fragments will fly during the replacement work so always wear protective equip ment like protective eyeglasses and gloves 1 To make it possible to knock out a pin of tooth...

Page 336: ...this be careful that rubber pin lock 3 does not fly out from the adapter surface 7 Clean the inside of teeth 1 then install it to adapter 4 If there is mud affixed to it or if there are protrusions th...

Page 337: ...the following 1 After lock pin 2 is knocked in completely check that it is secured by teeth 1 and surface 2 Lightly hit lock pin 2 in the reverse direction from which it was hit in 3 Lightly hit the...

Page 338: ...q There is a hazard that fragments will fly during the replacement work so always wear protective equip ment like protective eyeglasses and gloves 1 To make it possible to knock out pin 1 of tooth 2...

Page 339: ...ent is easier if you move the bucket to one side so that all the play can be measured at one place the right side in the figure Use a clearance gauge for easy and accurate measurement 3 Loosen four pl...

Page 340: ...ATIO OF PURE WASHER FLUID AND WATER Mixture Ratio of Pure Washer Fluid and Water PC K7B0 217K01A The proportion differs according to the ambient temperature so dilute the washer fluid with water to th...

Page 341: ...frigerant C Colourless transparent No refrigerant REMARK When there are bubbles the refrigerant gas level is low so contact your Komatsu distributor to have refrigerant added If the air conditioner is...

Page 342: ...ing the opera tor s seat NOTICE q When carrying out this work be careful not to water the monitor and connectors inside the operator s cab q Never water the things above the pedestal of the opera tor...

Page 343: ...C220 K151 255K00A 1 Set the machine at an angle For details see SET MACHINE AT ANGLE 4 35 2 Swing the upper structure slowly so that water drain holes 3 in the cab floor are at a low position 3 Lower...

Page 344: ...the back of the floor mat and remove the floor mat 6 Remove the cap from water drain hole 3 7 Flush out the dirt on the floor directly with water through water drain hole 3 8 After completing the wash...

Page 345: ...is on the downhill side Put blocks under the track and dig the work equipment into the ground USE BLOCK USE BLOCK PC K151 255K03A k WARNING Select a firm flat place Put strong blocks under the underca...

Page 346: ...acement q When the engine hood cannot be opened with light effort q When the engine hood do not stay open q When oil or gas is found to be leaking from the gas spring BLEED AIR FROM HYDRAULIC CIRCUIT...

Page 347: ...un at high speed immediately after startup or a cylinder rod is pushed up to its stroke end air taken inside the cylinder may cause damage to the piston packing 4 Bleeding air from swing motor 1 Run t...

Page 348: ...nt is installed run the engine at low idle and operate the attachment pedal repeat edly approximately 10 times until the air is completely bled from the attachment circuit NOTICE q If the method of ai...

Page 349: ...N section q Drain of water and sediment from fuel tank q Check of water separator drain of water and sediment q Check of oil level in hydraulic tank addition of oil q Check of coolant level addition o...

Page 350: ...every 10 hours for the first 50 hours operation on a new machine q After the machine is subjected to digging work in the water be sure to grease the wet pins 1 Set the machine to the greasing posture...

Page 351: ...n wash it off with a large amount of water and consult a doctor NOTICE q When adding distilled water to the battery do not allow the battery electrolyte to go above the UPPER LEVEL line If the electro...

Page 352: ...HECKED FROM A SIDE OF THE BATTERY If it is impossible to check the electrolyte level from the side of the battery or there is no display of the UPPER LEVEL line on the side of the battery check as fol...

Page 353: ...00A Press the belt with a finger force of approx 60 N 6 2 kg at a point midway between drive pulley 1 and compressor pulley 2 Deflection A should be 6 3 to 8 7 mm ADJUSTMENT ADJUSTMENT PC220 K5A0 27CK...

Page 354: ...it loosening Tightening torque 108 to 132 Nm 11 0 to 13 5 kgm 7 After fixing pulley check that the belt tension is appropriate again Adjust it again If the tension is not within the correct range NOTI...

Page 355: ...val q Carry out greasing every 10 hours for the first 50 hours on a new machine Carry out the greasing also at 250 hours and 500 hours on a new machine q After the machine was subjected to jobs in the...

Page 356: ...foot pin 1 place LUBRICATE SWING CIRCLE LUBRICATE SWING CIRCLE PC J110 242K00A 1 Lower the work equipment to the ground 2 Using a grease pump pump in grease through the grease fittings shown by arrows...

Page 357: ...h to turn filter cartridge 1 to the left to remove it 4 Clean filter holder 2 fill the new filter cartridge with clean engine oil coat the thread and packing surface of the new filter cartridge with c...

Page 358: ...ied mat ter may stick to the oil level gauge oil filler cap etc or the drained oil may be milky white because of water vapour in the blow by gas However if the coolant level is normal it is not a prob...

Page 359: ...oid using substitute parts q When carrying out inspection or maintenance of the fuel system pay more attention than normal to the entry of foreign material If dirt etc should stick to the parts in the...

Page 360: ...leak from the packing so always keep the tightening angle specified q When tightening with a filter wrench be extremely careful not to dent or damage the filter 12 Check that drain valve 2 is closed s...

Page 361: ...ADD GREASE CHECK SWING PINION GREASE LEVEL ADD GREASE PC J136 218K00A Prepare a scale 1 Remove bolts 1 2 pieces on the top of the revolving frame and remove cover 2 2 Insert scale 3 into the grease t...

Page 362: ...all it in Step 7 4 Check the front and rear surfaces of oil cooler fins 4 radi ator fins 5 aftercooler fins 6 air conditioner condenser fins 7 and fuel cooler fins 8 If there is any mud dirt or leaves...

Page 363: ...1 Open the rear door on the left side of the machine and remove bolts A at 2 places on the right end of the con denser 2 Pull the condenser forward to open it 3 After cleaning the condenser close and...

Page 364: ...e filter becomes clogged the air flow will be reduced and there will be an abnormal noise from the air condi tioner unit CLEAN RECIRCULATED AIR FILTER CLEAN RECIRCULATED AIR FILTER PC220 K521 250K00A...

Page 365: ...over When doing this lock it with the starting key After locking it do not forget to remove the starting key REMARK q The fresh air filter must be installed facing it in the correct direction q When r...

Page 366: ...e parts and oil are at high temperature after the engine is stopped and may cause serious burns Wait for the temperature to go down before cleaning the engine breather q When removing the oil filler c...

Page 367: ...stick G and wipe the oil on the dipstick with a cloth 2 Fully insert dipstick G into the filler pipe 3 Pull out dipstick G and check that the oil level is between the H and L marks on the dipstick 4 I...

Page 368: ...rive 1 Set the TOP mark at the top with the line running on TOP mark and plug P perpendicular to the ground surface 2 Remove plug F by using the handle When the oil level reaches a point 10 mm below t...

Page 369: ...intenance 1 Set the work equipment on the hard and flat ground in the maintenance posture as shown in the figure then lower it to the ground and stop the engine 2 Remove the cap of oil filler F and re...

Page 370: ...il 3 Loosen drain valve P under the machine body drain the oil then tighten the drain valve again REMARK q If the oil becomes thin thread condition there is no problem in stopping the draining operati...

Page 371: ...on flat ground and stop the engine When more than 30 minutes elapse after stopping the engine check the oil level 1 Open the cover on the right side of the machine 2 Remove plug G and check the oil l...

Page 372: ...than the conventional injection pump and nozzles If any part other than the genuine Komatsu filter cartridge is used dust or dirt may get in and cause problems with the injection system Always avoid u...

Page 373: ...f the filter holder then tighten it 3 4 of a turn If the filter cartridge is tightened too far the packing will be damaged which will cause leakage of fuel If the filter cartridge is tightened too loo...

Page 374: ...Sometimes some air is still left inside the water separator after air bleeding but the engine can be started by operating feed pump 4 until its motion gets hard The remaining air is naturally bled wh...

Page 375: ...not stand in front of the plug when you loosen the plug q Refill capacity for both right and left 5 0 litres q Prepare a sliding T handle with 1 2 square drive 1 Set the TOP mark at the top with the...

Page 376: ...e it 1 Remove the cap for oil filler F and release the internal pressure 2 Remove six bolts then remove cover 1 When doing this cover 1 may jump out under the force of spring 2 so press the cover down...

Page 377: ...r dispose of it in fire q Do not make holes in it or weld it q Do not hit it roll it or subject it to any impact q When disposing of the accumulator the gas must be released Ask your Komatsu distribut...

Page 378: ...ucket fully dumped at height A 1 5 m from the ground Carry out Steps 3 to 5 within 15 seconds When the engine is stopped the pressure in the accumulator gradually goes down For this reason the check c...

Page 379: ...tch to the OFF position METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT PC C000 22AP00A 1 Lower the work equipment to the ground Close the crusher a...

Page 380: ...rt ing switch to the OFF position 8 Insert the lock pin in position a so that the attachment con trol pedal cannot be operated if equipped CHECK ALTERNATOR CHECK ALTERNATOR ALL AKK0 360K00A Contact yo...

Page 381: ...start the engine without the filter element q The filter element cannot be cleaned If the filter element is cleaned the filter performance lowers As a result the turbocharger and aftercooler become di...

Page 382: ...ring contained in the service kit Apply engine oil to the new O ring before installing 4 While matching diamond marks 7 of the new element with diamond mark 8 of the body label insert the element fir...

Page 383: ...h the hand firmly until it stops 7 Using the special wrench further tighten the ring 1 15 to 2 15 turns 1 to 2 ridges of the ring If the engine is operated with the ring tightened insufficiently oil a...

Page 384: ...check and replacement of the vibration damper special tools are required Ask Komatsu Ltd or your Komatsu distribu tor for the replacement It has to be replaced with a new one in the following cases Ma...

Page 385: ...stand in the direction in which the oil spurts out when carrying out the work In addition loosen the bolts slowly when carrying out the work q Do not disassemble the accumulator q Do not bring it near...

Page 386: ...replacement Replacement of the high pressure piping must be made as an assembly CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUB BER CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING O...

Page 387: ...LL K590 280K00A Check the following two items 1 When the air conditioner switch is turned ON OFF do the compressor and magnet clutch also turn ON OFF 2 Is any abnormal noise generated by the clutch or...

Page 388: ...rry out the periodic maintenance work of every 100 250 and 500 hours of operation at the same time CLEAN KDPF CLEAN KDPF PC A9H0 923K00A Komatsu recommends contacting your Komatsu distributor for clea...

Page 389: ...wer side of the suction tube comes to the middle of the right and left tracks 2 Retract the arm and bucket cylinder rods then lower the boom and put the teeth in contact with the ground 3 Set the lock...

Page 390: ...00 1000 2000 and 4000 hours of operation at the same time REPLACE FUEL SPRAY PREVENTION CAP REPLACE FUEL SPRAY PREVENTION CAP ALL AEFU 923K00A Contact your Komatsu distributor to have the fuel spray p...

Page 391: ...MAINTENANCE END OF SERVICE LIFE 4 81 END OF SERVICE LIFE For safe dismantling of the machine at end of service life please contact your local Komatsu Distributor...

Page 392: ...END OF SERVICE LIFE MAINTENANCE 4 82...

Page 393: ...SPECIFICATIONS 5 1 SPECIFICATIONS SPECIFICATIONS ALL 0000 001K04A SPECIFICATIONS...

Page 394: ...2 diesel engine Engine Power kW rpm 118 2 000 ISO 9249 123 2 000 ISO14396 A Overall length mm 9 625 B Overall height mm 2 970 C Overall width mm 2 800 3 080 D Track width mm 600 700 E Height of cab mm...

Page 395: ...Working ranges Unit PC210 10 PC210LC 10 A Max digging reach mm 9 875 B Max digging depth mm 6 620 C Max digging height mm 10 000 D Max vertical wall depth mm 5 980 E Max dumping height mm 7 110 F Min...

Page 396: ...ength 4 Hydraulic pressure WORKING CONDITIONS q WITH BUCKET 0 78m3 ISO 650 kg q IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE V...

Page 397: ...SPECIFICATIONS SPECIFICATIONS 5 5 PC210 10...

Page 398: ...SPECIFICATIONS SPECIFICATIONS 5 6 PC210LC 10...

Page 399: ...S AND OPTIONS 6 1 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS ALL RA17 001K00A ATTACHMENTS AND OPTIONS k WARNING Please read and make sure that you understand the SAFETY section before reading thi...

Page 400: ...the crane q Do not carry out operations with the load kept raised by the crane Always use a stand to prevent the load from falling q When removing a heavy part consider the balance after it is remove...

Page 401: ...n into consid eration For an attachment not intended to bear a load for example a breaker it should not exceed the minimum lift capacity of the machine as shown on the related lift capacity charts see...

Page 402: ...l of the quick coupler carefully and follow the recommendations If in doubt about the installation or operation consult your Komatsu distributor 4 Pressure regulation valve 4 and 5 allow the attachmen...

Page 403: ...using the swing function activate the Swing Lock first Lamp Switch 3 78 6 The quick coupler will now release the attachment bucket To pick up a new bucket or attachment k WARNING q European safety sta...

Page 404: ...arm or swing to raise the pressure in the hydraulic system If using the swing function activate the Swing Lock first Lamp Switch 3 78 The quick cou pler will move to the released position 5 Position t...

Page 405: ...rcially available grease additives may be good for the machine but they may also cause harm Komatsu does not recommend any commercially available grease additive q Refer also to section RECOMMENDED FU...

Page 406: ...sing interval B Normal Duty greasing interval C Heavy Duty greasing interval CHANGING THE GREASE INTERVAL WITH THE IN CAB DISPLAY q Make sure the ignition is switched on q Select the interval required...

Page 407: ...mum level in the reservoir has been reached Reset by refilling the reser voir Red lamp 6 flashing System out of order Immediate action required Possible causes Insufficient grease pressure during 10 c...

Page 408: ...nterval time is correct for the working conditions of the machine q Check the pump for damage and leakage q Check the grease pipes for damage and leakage q Check the condition of the grease points ser...

Page 409: ...level indication 5 on the in cab display SYSTEM TEST In order to check the system a single lubrication cycle can be performed as follows Move the starter switch to the ON position B Depress the test...

Page 410: ...se of a current greasing cycle If the sys tem is busy with a pump cycle it will not react to the test push button NOTICE Only use grease tests cycles if necessary Every time a test cycle is carried ou...

Page 411: ...ting operations PC LBKN 170K01A q During lifting operations reduce the engine speed and carry out the operation in L mode q Depending on the posture of the work equipment there is a danger that the wi...

Page 412: ...TOP VALVE Stop Valve PC220_KU PQK0 043K00A This valve 1 stops the flow of the hydraulic oil a FREE Hydraulic oil flows b LOCK Hydraulic oil stops When removing or installing attachments set this valve...

Page 413: ...he front centre neutral and rear of the pedal are depressed the movement of the attachment is as follows Hydraulic breaker Front of pedal A Actuated Centre of pedal N Stopped Rear of pedal B Stopped R...

Page 414: ...rts out when carrying out the work In addition loosen the bolts slowly when carrying out the work q Do not disassemble the accumulator q Do not bring it near flame or dispose of it in fire q Do not ma...

Page 415: ...WITCH 2nd line attachment proportional switch PC220_KU PT0T 043K01A if equipped Proportional control rolling switch Switch 8 operates the 2nd attachment circuit e g clamshell rotation The switch 8 is...

Page 416: ...WITCHING OF BREAKER AND GENERAL ATTACHMENT q When optional attachment is installed and working mode is set to B mode 1 Breaker circuit one way circuit is formed 2 Hydraulic oil flowing through breaker...

Page 417: ...ish direction of arm q When setting the FREE or LOCK position of the stop valve remove bolt 1 and washer 2 fit lever 3 and refit bolt 1 and washer 2 rotate valve to furthest position clockwise or anti...

Page 418: ...f the pedal and the path of the oil flow is as shown in the figure below When the front of the pedal is depressed oil flows to the piping on the left side of the work equipment when the rear of the pe...

Page 419: ...ng and causing personal injury Always wear protective eyeglasses dust mask and other protective equipment NOTICE For the details of the element replacement interval see MAINTENANCE INTERVAL FOR HYDRAU...

Page 420: ...il temperature has gone down turn filter case 1 counterclockwise remove it then take out element 2 9 Clean the removed parts then install new element 2 q Element 2 must be installed facing in the corr...

Page 421: ...t tering and causing personal injury Always wear protective eyeglasses dust mask and other protective equipment NOTICE For the details of the element replacement interval see MAINTENANCE INTERVAL FOR...

Page 422: ...r checking that the hydraulic oil temperature has gone down turn filter case 1 counterclockwise remove it then take out element 2 8 Clean the removed parts then install new element 2 q Element 2 must...

Page 423: ...e starting switch to ON position B then set the lock lever to FREE position F 3 After carrying out Step 2 operate each work equipment control lever and attachment control pedal fully to the front rear...

Page 424: ...ing incorrect operation caused by mixing in of foreign matter After the plugs are correctly installed store the attachment 8 Pull out the mounting pins 2 places remove the attach ment then install the...

Page 425: ...this check the direction of flow of the oil and be careful not to make any mistake 9 Set the rotor of the stop valve installed to the inlet port on the side face of the arm and the outlet port piping...

Page 426: ...position to prevent the pedal from being operated q When changing the oil flow setting for the breaker mode and attachment mode for the crusher see Machine settings 3 60 for details The method of oper...

Page 427: ...RNING When a slide arm or other special attachment is installed if the mode is switched to the breaker mode by mistake it may lead to serious danger such as sudden drop of the work equipment If breake...

Page 428: ...ighlighted in yel low do one of the following to accept the selection q Keep working mode selector switch 1 pressed q Leave as it is for 5 seconds q Press switch F6 q On the user menu attachment setti...

Page 429: ...r of the pedal to operate the attachment OPERATION WHEN USING ATTACHMENT 2 E G CLAMSHELL ROTATION CRUSHER ROTATION REMARK If installing 2nd attachment line as a field kit ask distributor to change mon...

Page 430: ...service valve 24 5 MPa 250 kg cm2 except B mode q Safety valve relief set pressure for service valve 20 6 MPa 210 kg cm2 B mode q Safety valve cracking pressure for service valve 15 2 MPa 155 kg cm2...

Page 431: ...d operate it with care PC210 10 PC210LC 10 NOTICE q When the boom is fully lowered during oblique digging the boom interferes with the undercarriage Operate the boom carefully NOTE 1 Bucket size based...

Page 432: ...rge obstacles such as boulders or fallen trees travel at Lo speed B Normal soil Soft ground q These shoes cannot be used on rough ground where there are large obstacles such as boulders or fallen tree...

Page 433: ...and as such use it for heavy duty digging LONG LIFE TOOTH Long life Tooth PC LBM0 05AK04A q Jobsites where long wear life is required such as when loading hard rocks q Jobsites where no penetration is...

Page 434: ...ocks q Be careful of machine skidding on the road covered with water ice snow or gravel Take special care when unloading a machine from a truck q Use a machine equipped with rubber pad shoes or Road L...

Page 435: ...ROAD LINER Check Road Liner PC DTLK 360K00A If the Road Liners A are in the following condition they must be repaired or replaced so please contact your Komatsu distributor for repairs or replacement...

Page 436: ...ch slope face angle 45 40 38 A 45 40 38 ditch common hole B 45 ditch hole C 40 ditch hole D 38 ditch hole E 38 40 ditch common hole DIGGING WORK Operate the boom arm and bucket so that line A of the s...

Page 437: ...CE 40 DEGREES 38 DEGREES Install the angle plate using the respective ditch slope angle holes and use the method above for digging Even when the angle plate is fitted keep the line on the bucket side...

Page 438: ...when trans porting the machine q When an extension arm is installed use a narrow bucket width 750 mm with side cutters 560 mm without side cut ters If the standard bucket is used the stability is poo...

Page 439: ...or sudden stops when using the clamshell bucket Avoid such operations q When pushing with the boom keep the clamshell straight q Do not swing the bucket to the side to break up or cut rocks or soil q...

Page 440: ...mounted will vary Hence consult your Komatsu distributor for the selec tion of optimum attachments HYDRAULIC BREAKER HYDRAULIC BREAKER PC LG10 130K00A APPLICABLE WORK q Demolition work q Crushing rock...

Page 441: ...body will gradually move out of line with each other always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly to prevent using the imp...

Page 442: ...TIONS 6 44 Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the ch...

Page 443: ...breaker holding it in the right posture NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result soil and sand will enter the hydraulic circuit...

Page 444: ...RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS 6 46...

Page 445: ...REPLACEMENT PARTS 7 1 REPLACEMENT PARTS Replacement parts ALL 0000 001K16A REPLACEMENT PARTS...

Page 446: ...r replace the critical parts SAFETY CRITICAL PARTS LIST Safety critical parts listPC220 0000 20MK00A No Parts for periodic replacement Q ty Replacement interval 1 Fuel hose between fuel tank and fuel...

Page 447: ...y 500 hours Fuel pre filter 600 319 3610 Cartridge 1 Every 500 hours Hydraulic tank breather 20Y 60 21470 Element 1 Every 500 hours Hydraulic oil filter 207 60 71182 07000 15195 Element O ring 1 1 Eve...

Page 448: ...d it may shorten cleaning interval of KDPF filters adversely affect the engine such as deteriorated oil may reduce lubricating function and it may cause failure shortening of the machine life lowering...

Page 449: ...box inside the cab so that the people concerned can reference it any time needed during lubrication q Even if the same symbol is used in the lubrication standard chart the recommended genuine oil may...

Page 450: ...aning of symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check engine oil level Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil...

Page 451: ...Ambient tempera ture degrees Celsius Recommended Komatsu Fluids Min Max Engine oil pan Engine oil for KDPF used in cold terrain Oil Change interval 250 hours 25 C 35 C Komatsu EOS5W30 LA KES Diesel E...

Page 452: ...d continuously for two years or 4000 hours Non Amine Engine Coolant AF NAC is strongly recommended wherever available 2 For details of the Non Amine Engine Coolant AF NAC density see CLEAN INSIDE OF C...

Page 453: ...8 1 INDEX...

Page 454: ...GE 3 227 DUSTY WORKSITES 4 3 E EMERGENCY ESCAPE HAMMER 3 93 END OF SERVICE LIFE 2 43 4 81 EPA REGULATIONS ENGINE NUMBER PLATE 1 8 ESCAPE FROM MUD 3 197 EVERY 100 HOURS MAINTENANCE 4 40 EVERY 1000 HOUR...

Page 455: ...ND MAINTENANCE 2 43 PRECAUTIONS BEFORE STARTING OPERATION 2 15 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 47 PRECAUTIONS FOR JOBSITE 2 25 PRECAUTIONS FOR MAINTENANCE 2 43 PRECAUTIONS FOR OPERATION 2...

Page 456: ...3 182 STOPPING ENGINE 3 177 SWINGING MACHINE 3 184 SWITCHES 3 76 SYSTEM OPERATING LAMP 3 128 T TIGHTENING TORQUE LIST 4 8 TOOL BOX 3 125 TOWING 2 39 TOWING MACHINE 3 230 TRACK SHOES SELECTION 6 34 TRA...

Page 457: ...COLOPHON 18...

Page 458: ...COLOPHON 9 2 PC210_LC 10 HYDRAULIC EXCAVATOR Form No UENAM00902 2013 KOMATSU All Rights Reserved Printed in Belgium 13 07...

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