Komatsu PC210-11 Operation & Maintenance Manual Download Page 257 | Manualshive

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• Engine coolant temperature caution lamp (1): Displays

proper temperature

• Hydraulic oil temperature caution lamp (7): Displays

proper temperature

• Radiator coolant level caution lamp (8): OFF
• Engine oil level caution lamp (9): OFF
• Air cleaner clogging caution lamp (10): OFF
• Charge level caution lamp (11): OFF
• Engine oil pressure caution lamp (12): OFF
• Water separator caution lamp (13): OFF
• Engine preheating pilot lamp (15): OFF
• Engine coolant temperature gauge (16): Indicator in

green range

• Hydraulic oil temperature gauge (17): Indicator in

green range

• Fuel level caution lamp (18): Displays appropriate lev-

el

• Fuel gauge (19): Indicator in green range

11. Check for abnormal exhaust gas colour, noise, or vibration.

If any problem is found, contact your Komatsu distributor.

NOTICE
In cold temperatures (ambient temperature below 0 °C), even when the hydraulic oil temperature caution
lamp displays the proper temperature, perform the "Hydraulic system warm-up operation in cold weath-
er" to warm up all the hydraulic equipment.

12. Hydraulic system warm-up operation in cold weather

1) Turn fuel control dial (4) to High idle (MAX) position.
2) Repeat the work equipment operation of step 6 for 3

to 5 minutes.

• Display (A) when temperature is proper: Caution

lamp background (C) is blue.

• Display (B) when temperature is low: Caution

lamp background (C) is white.

3) Check that the hydraulic oil temperature caution lamp displays proper temperature.

If it is not displaying the proper temperature, repeat
step 2) until hydraulic oil temperature caution lamp (7)
displays the proper temperature.

OPERATION

MACHINE OPERATIONS AND CONTROLS

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Summary of Contents for PC210-11

Page 1: ...AULIC 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 be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual UENAM01383 WARNING ORIGINAL INSTRUCTIONS ...

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Page 3: ...nuine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these recommendations could result in ineffective serv ice damage to the product or safety risks including personal injury or death 1 1 ...

Page 4: ... Keep it in the magazine box on the left side of the operator s seat If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For details regarding the machine model name and the serial No see the machine serial No plate In order to arrange the proper Operation and Maintenan...

Page 5: ...ing the processing of your personal data i e storage collection transfer etc of all information that relates to you as operator to the party with whom you have most direct relationship In principle this means that you should first and foremost refer to your employer if you are an employee or your customer if you are an independent contractor Komatsu Komatsu Europe Komatsu distributors and dealers ...

Page 6: ...ction 4 above For the purposes a to l as indicated in section 4 above as well as for the purpose of informing a third party in the context of a possible merger acquisition or demerger the processing of your personal data is necessary for our legitimate interests which in this case concern ensuring the safe and secure deployment of the machines preventing misuse and theft commercial interests which...

Page 7: ...at data b the processing is illegitimate or c the data are no longer needed for the pur poses which are outlined above but you need them to defend yourself in judicial proceedings You have the right to oppose the processing of personal data for the purposes a to l in section 4 but you are required to explain your particular circumstances on which your request for opposition is based As explained e...

Page 8: ... safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used...

Page 9: ... the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used it is your responsibility to take th...

Page 10: ... according to ISO 6396 Dynamic test method simulated working cycle The associated uncertainty KpA is 2 5dB A Sound power level emitted by the machine measured ac cording to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European directive 2000 14 EC This value includes an uncertainty of 1 0 dB NOISE FOREWORD 1 8 ...

Page 11: ... steering systems Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedule time to maintain terrain conditions 4 Use a seat that meets ISO 7096 and keep the seat maintained and adjusted Adjust the seat ...

Page 12: ... Do not jump down from the cab or machine Do not repeatedly handle and lift loads VIBRATION LEVELS FOREWORD 1 10 ...

Page 13: ...to demolish cut loosen separate pick up transport and distribute component parts of buildings or civil engineering structures This machine is not prepared for use in Demolition Using this machine in demolition work gives an in creased risk of serious injury or death All Komatsu machines that are specifically designed and can be used for demolition work will display the Komatsu demolition decal If ...

Page 14: ...oint 1 m away from the outside surface of the machine and a visibility for a radius of 12 m KS001602 k k CAUTION During operation the movement of the work equipment boom arm will affect the operator s field of vision This will be strongly influenced by the type and dimension of any attachment that may be installed Pay attention to this and ensure that the working area is free of groundworkers or o...

Page 15: ...l Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the reagent for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transpar...

Page 16: ...wing items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is located on the right bottom of the operator s cab The design of the nameplate differs according to the district LOCATION OF ENGINE NUMBER PLATE It is located on top of the engine cylinder head cover PRODUCT INFORMATION FOREWORD 1 14 ...

Page 17: ...ine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU UK Ltd Durham Road Birtley Chester le Street County Durham DH3 2QX United Kingdom Distributor name Address Service Personnel Phone Fax FOREWORD PRODUCT INFORMATION 1 15 ...

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

Page 19: ...this machine PC210 11 PC210LC 11 PC210NLC 11 PC230NHD 11 Fulfils all the relevant provisions of following EC Directives Machine Directive 2006 42 EC Electro Magnetic Compatibility Directive 2014 30 EU Outdoor Noise Directive 2000 14 EC amended by 2005 88 EC Radio Equipment Directive 2014 53 EU FOREWORD DECLARATION OF CONFORMITY 1 17 ...

Page 20: ...RE STARTING OPERATION 2 17 PREPARATIONS FOR SAFE OPERATION 2 17 PRECAUTIONS TO PREVENT FIRE 2 18 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 20 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 22 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 22 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 23 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2 23 UNAUTHORIZED MODIFICATION 2 24 PRECAUTIONS RELA...

Page 21: ...APPLICATIONS 3 205 EFFECTIVE USE OF HYDRAULIC EXCAVATOR 3 206 METHOD FOR REPLACING AND INVERTING BUCKET 3 207 METHOD FOR PARKING MACHINE 3 210 METHOD FOR CHECKING AFTER FINISHING WORK 3 212 LOCK 3 212 HANDLE AIR CONDITIONER 3 222 EXPLANATION OF AIR CONDITIONER EQUIPMENT 3 223 METHOD FOR OPERATING AIR CONDITIONER 3 227 HANDLE RADIO 3 235 EXPLANATION OF RADIO EQUIPMENT 3 235 METHOD FOR CONTROLLING R...

Page 22: ...E 4 4 CLOSE ENGINE HOOD SECURELY 4 4 OUTLINE OF MAINTENANCE 4 5 HANDLE OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 5 HANDLE ELECTRICAL COMPONENTS 4 9 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4 10 MAINTENANCE SCHEDULE 4 12 MAINTENANCE SCHEDULE TABLE 4 12 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 13 MAINTENANCE PROCEDURE 4 15 WHEN REQUIRED 4 15 CHECK AUTOMATIC GREASE SYSTEM 4 38 CHECKS BEFO...

Page 23: ...ITH HOOK 6 35 PRECAUTIONS FOR OPERATION 6 35 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 36 EXPLANATION OF COMPONENTS ON MACHINE EQUIPPED WITH ATTACHMENT 6 36 METHOD FOR CHANGE OVER AND CONNECT HYDRAULIC CIRCUIT FOR MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 41 METHOD FOR REMOVING AND INSTALLING ATTACHMENT 6 44 METHOD FOR OPERATING ATTACHMENT 6 48 LONG TERM STORAGE 6 52 MAINTENANCE O...

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Page 25: ...ase read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions strictly 2 1 ...

Page 26: ...2 ELECTROMAGNETIC INTERFERENCE 2 22 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 22 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 22 PROTECTION AGAINST FALLING FLYING OR INTRUDING OBJECTS 2 23 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2 23 UNAUTHORIZED MODIFICATION 2 24 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 24 PRECAUTIONS RELATED TO CAB GLASS 2 24 PRECAUTIONS WHEN RUNNING ENGINE INS...

Page 27: ... 2 41 PRECAUTIONS WHEN WORKING ON MACHINE 2 41 PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2 42 USE PROPER TOOLS 2 42 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 42 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 42 PRECAUTIONS FOR WELDING 2 42 HANDLE BATTERY 2 43 PRECAUTIONS WHEN USING HAMMER 2 43 PRECAUTIONS FOR HIGH TEMPERATURE COOLANT 2 44 PRECAUTIONS FOR HIGH TEMPERATURE OIL 2 44 PR...

Page 28: ...rly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the safety labels see this manual or the actual label and place an order to your Komatsu distributor There are also other labels in addition to the warning s...

Page 29: ...e d f g h KS001064 1 Combined safety information label a Warning for operation inspection and maintenance b Warning when leaving the operator s seat c Warning no passengers d Warning danger of falling objects SAFETY SAFETY LABELS 2 5 ...

Page 30: ...travelling in reverse 15 Caution for handling batteries 16 Caution when replacing fresh air filter 17 Caution for blast jobsite 18 Caution against high pressure fuel 19 Caution against high temperature 20 Warning for handling ROPS 21 Caution for overloading machine 22 Caution against high temperature 23 Caution for handling DEF 24 Caution for handling DEF 25 Warning for operation inspection and ma...

Page 31: ...or s seat Lower the work equipment to the ground and move safety lock lever located near seat to lock position to avoid hit ting unlocked operation levers Sudden and unwanted machine movement can cause seri ous injury or death Warning no passengers c No passengers allowed to ride on the machine while it is moving Warning danger of falling objects d Do not operate where a danger of falling objects ...

Page 32: ...r lines Control levers operational function diagram f Control levers operating pattern In order to prevent an accident resulting in injury or death caused by error operation confirm the machine motion and in dicated operating pattern when operating machines Pay atten tion to the circumference and operate slowly when confirming the machine motion Caution when standing in operator cab g Take care wh...

Page 33: ...eversing To prevent SEVERE INJURY or DEATH do the following be fore moving machine or its attachments Sound horn to alert people nearby Be sure no one is on or near machine or in swing area Rotate cab for full view of travel path if it can be done safe ly Use spotter if view is obstructed Follow the above even if machine is equipped with travel alarm mirrors and rear view camera k k WARNING To ope...

Page 34: ...e personal injury and or burns Never remove the radiator cap or hydraulic tank oil filler cap when cooling water or hydraulic oil is at high tempera ture Caution for handling accumulator and gas spring 4 Caution for handling accumulator and gas spring 09659 A057B There is a hazard of explosion causing injury Do not disassemble the accumulator make holes in it weld it cut it roll it or bring it nea...

Page 35: ...manual for safe and proper handling Caution stop rotation during inspection and maintenance 7 Stopping rotation for inspection and maintenance 09667 A0481 Sign indicates a hazard of rotating parts such as belt fan etc Turn off before inspection and maintenance Emergency escape 8 Emergency escape 09844 00050 SAFETY SAFETY LABELS 2 11 ...

Page 36: ...ange 10 Prohibited to enter swing radius 09133 A3281 There is a danger of getting caught when upper structure swings Do not enter range of swing Caution for work equipment 11 Keeping out of working range area 09134 A1681 Sign indicates a hazard of being hit by the working device of the machine Keep away from the machine during operation SAFETY LABELS SAFETY 2 12 ...

Page 37: ...falling attachment Read the manual for safe operation Warning when swinging or travelling in reverse 14 Warning when swinging or travelling in reverse 09833 A0881 k k WARNING Before moving or operating the machine look around and at mirror and monitor to confirm that no one is around the machine Failure to do so can result in seri ous injury or death Caution for handling battery 15 Caution when ha...

Page 38: ...teries d Caution battery acid e Read the operator s manual before working with batteries f Caution explosive gases Caution when replacing fresh air filter 16 Caution when replacing fresh air filter 208 00 71261 After replacing fresh air filter remember to remove key from cover as the key may get damaged when cab door is opened SAFETY LABELS SAFETY 2 14 ...

Page 39: ...perature 19 Caution for high temperature 09817 K064B Warning for handling ROPS 20 Caution for machine with ROPS 09620 J2001 09620 A3001 If any modification is applied to the ROPS it may affect the strength and may not comply with the standard ROPS may provide less protection if it has been structural ly damaged or involved in roll over Always wear seat belt when moving Caution for overloading mach...

Page 40: ...e diesel fuel Caution for handling DEF 24 Caution for handling DEF 09632 61480 To avoid engine damage or fire fill with Diesel Exhaust Fluid DEF only Never use diesel fuel Warning for operation inspection and maintenance 25 Warning for operation inspection and maintenance 09651 A0841 Read the manual before operating inspection maintenance disassembly assembly and transportation SAFETY LABELS SAFET...

Page 41: ... in charge of safety for explanation PREPARATIONS FOR SAFE OPERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards and covers are in their proper position Repair them immediately if they are dam aged Be sure that all cameras where installed and mirrors are in their proper positions Repair them immediate ly if they are damaged Understand the using method of the safety related dev...

Page 42: ...r machine parts lying around inside the operator s compartment If tools or parts get into the control devices it may obstruct operation and cause the machine to move unexpectedly resulting in serious personal injury or death Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use a cellular phone when driving or operating the machine This may lead to ...

Page 43: ...hen washing parts with oil use a non flammable oil Do not use diesel fuel or gasoline There is danger that they may catch fire Do not weld or use a cutting torch to cut any pipes or tubes that contain combustible liquids Determine well ventilated areas for storing oil and fuel Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter When performing grinding or we...

Page 44: ...ighly heated exhaust gas during the aftertreatment devices regen eration For setting see HANDLE KOMATSU DIESEL PARTICULATE FILTER KDPF Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting with anti explosion specifica tions When taking the electrical power for the lighting equipment from the machine see POWER SUPPLY OUT LET PRECAUTIONS WH...

Page 45: ...ine starts to move when there is no operator on the machine do not jump on to the machine and try to stop it LIFTING OF PERSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel NO PEOPLE ON ATTACHMENTS Never let anyone ride on the work equipment or other attachments There is a hazard of falling and suffering serious personal injury or death PRECAUTIONS W...

Page 46: ...bserved The display on the monitor panel may behave erratically The warning buzzer may sound These effects do not signify a malfunction and the machine will return to normal as soon as the source of inter ference is removed DO NOT GET CAUGHT IN WORK EQUIPMENT The clearance in the area around the work equipment changes according to the movement of the link If you are caught this may lead to serious...

Page 47: ...ng objects scattering fragments When performing breaker operations install a front guard and use a fully transparent laminated coating sheet on the front glass Keep all the windows closed when operating In addition always check that there is no one except the operator in the surrounding area where there is a danger of scattering fragments Above precautions are developed for the standard jobsite De...

Page 48: ...r work equipment always check for potential interference while operating the machine Always ensure the operator s safety when working with unfamiliar work equipment When installing and using optional attachments always read the instruction manual for the attachment and the general information related to attachments in this manual PRECAUTIONS RELATED TO CAB GLASS If the cab glass is broken during o...

Page 49: ...l PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground should collapse under the weight or vibration of the machine there is a hazard that the machine may fall or tip over Remember that the soil is weak in these areas after heavy rain or blasting or after earthquakes Wh...

Page 50: ...ne signalman should give signals When working in dark places turn on the working lamp and headlamps installed to the machine and set up additional lighting in the work area if necessary Stop operations if the visibility is poor because of mist snow rain or dust When checking the mirrors installed to the machine remove all dirt and adjust the angle of the mirror to ensure good visibility Clean off ...

Page 51: ...y s work to ensure that there is no problem with the operation of the machine If these checks are not performed properly problems may occur with the operation of the machine and there is a danger which may lead to serious personal injury or death Remove all dirt from the surface of the window glass to ensure a good view Perform the walk around check securely Remove all dirt from the surface of the...

Page 52: ... sure the warming up operation is completed If the battery electrolyte is frozen do not charge the battery or start the engine with a different power source There is a hazard that this will ignite the battery and cause the battery to explode Before charging or starting the engine with a different power source melt the battery electrolyte and check that there is no leakage of electrolyte before sta...

Page 53: ...Check for any problem in the sound vibration heat and smell of the machine or abnormalities of instruments Also check that there is no leakage of oil or fuel If any problem is found repair it immediately WHEN TRAVELLING IN FORWARD OR REVERSE AND SWINGING When driving the machine drive with sprocket 1 at the rear of the machine If sprocket 1 is at the front the oper ation of the travel levers will ...

Page 54: ...t stuck in the ground and the machine may tip over If the view to the right side is poor raise the boom to en sure better visibility Always turn the auto deceleration switch OFF cancel when driving the machine on rough ground or steep slopes If the machine is operated with the auto decelera tion system ON activated the engine speed will rise and the machine travel speed may suddenly become faster ...

Page 55: ...ly to help stop the ma chine When driving the machine up slopes set the operator s cab facing uphill when driving downhill set the operator s cab facing downhill Always be sure of the safety of the ground under the front of the machine when driving When driving the machine up a steep slope extend the work equipment to the front to improve the balance keep the work equipment approximately 20 to 30 ...

Page 56: ...efully Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded This opera tion is dangerous and may cause the machine to turn over If the machine has to be used on a slope pile the soil to make a platform A that will keep the machine as horizon tal as possible Do not work on a slope covered with the steel plates Even with slight slopes there is a hazard ...

Page 57: ...retract the boom cylinder It is dangerous that the machine may tip over by the impact In the operation using the fork or grapple do not attempt to pick up an object with the tips The picked up object can easily slip off Machine may be damaged or personal injury or death may occur PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES Snow covered or frozen surfaces are slippery so be extremely care...

Page 58: ...ted on a trailer serious personal injury or death may result because of the acci dent during transportation Always observe the following Always check the machine dimensions carefully Depending on the work equipment and optional devices installed the machine weight transportation height and overall length differ Check beforehand that all bridges and other structures on the transportation route are ...

Page 59: ...e machine losing its balance Drive slowly over this point When loading or unloading to an embankment or platform make sure that it has suitable width strength and grade When swinging the upper structure on the loading platform lower the work equipment retract it and per form the operation slowly Always fold the mirrors and stow the radio antenna For machines equipped with a cab always lock the doo...

Page 60: ...ing Load and part number are stamped on the link as shown below All components in the load line eg chains shackles etc must be rated correctly for the load to be lifted When swinging or operating the work equipment check carefully that the surrounding area is clear from ob jects structures or any persons working around the machine During the lifting operation reduce the engine speed and carry out ...

Page 61: ...ation before use to ensure that they are not dam aged or worn Any damaged deformed or worn parts should not be used and must be replaced Where possible the lifting operation should be carried out with the bucket curled in order to increase visibility and prevent any obstruction or deflection of the sling or chain away from the vertical position If the load is to be lifted at a height where this is...

Page 62: ...structure When swinging or operating the work equip ment check carefully that the surrounding area is safe Do not swing or operate the work equipment suddenly There is a danger that this may cause the load to swing and the machine to become unstable or tip over Do not leave the operator seat when there is a raised load Do not use the work equipment or swing to pull the load in any direction There ...

Page 63: ...ll over and injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and avoid use of organic solvents for cleaning An organic solvent like benzene toluene or methanol can invite a chemical reaction like dissolution and decomposition on the window glass deteriorating polycarbonate in use SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop th...

Page 64: ...g switch to ON position Operate the work equipment control lever back and forth right and left a few times fully to release the remaining internal pressure in the hydraulic circuit Then move lock lever 1 to LOCK posi tion L and turn the starting switch to OFF position Check that the battery relay is off and main power is not conducted After turning the starting switch to OFF posi tion wait for app...

Page 65: ...re starting removal or installation operations for attachments Place attachments that have been removed from the ma chine in a stable condition so that they do not fall And take steps to prevent unauthorized persons from entering the storage area PRECAUTIONS FOR WORKING AT HIGH PLACES When working at high places use a step ladder or other stand to ensure that the work can be performed safely There...

Page 66: ...f the work equipment and machine are not supported they may come down and it may cause serious per sonal injury or death Never use concrete blocks for supports Concrete blocks may break under even light loads USE PROPER TOOLS Use the tools suited to the task and use them correctly Using damaged deformed or low quality tools or making improper use of the tools may cause serious personal injury or d...

Page 67: ...ulphuric acid Any mistake in handling may cause serious personal injury explosion or fire Always ob serve the following When handling the battery always wear protective eye glasses and rubber gloves If battery electrolyte gets into your eyes immediately wash your eyes with large amounts of fresh water After that get medical attention immediately If battery electrolyte gets on your clothes or skin ...

Page 68: ... cap or plug slowly to release the internal pressure and remove the cap or plug PRECAUTIONS FOR HIGH TEMPERATURE PARTS To prevent burns from touching high temperature parts when checking or performing maintenance after stop ping engine check the parts have been cooled down to touch with bare hand before checking or maintenance PRECAUTIONS FOR HIGH PRESSURE OIL The hydraulic system is always under ...

Page 69: ... loose or oil or fuel is found to be leaking from the mount stop operations and tighten to the specified torque If any damaged or deformed hoses or piping are found consult your Komatsu distributor Replace the hose if any of the following problems are found Damaged hose or deformed hydraulic fitting Frayed or cut covering or exposed reinforcement wire layer Covering swollen in places Twisted or cr...

Page 70: ...rful spring that acts to reduce the impact on the idler If it is disassembled by mistake the spring may shoot out and cause serious personal injury or death If it is necessary to disassemble it ask your Komatsu distributor to perform the work HANDLE ACCUMULATOR AND GAS SPRING This machine is equipped with an accumulator Even after the engine stops if the work equipment control lever is operated af...

Page 71: ...ISPOSING OF WASTE MATERIALS 2 47 and MAINTENANCE OF AIR CONDITIONER 2 47 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution pay full attention to the way to dispose of waste materials Always drain the oil from your machine in containers Nev er drain the oil and coolant directly onto the ground or dump into the sewage system rivers seas or lakes Obey appropriate laws and regulations ...

Page 72: ...il and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspection or the feeling when operating so always replace them at the specified interval Replace or repair defined life parts if any defect is found even when they have not reached the specified replacement time PRECAUTIONS FOR MAINTENANCE SAFETY 2 48 ...

Page 73: ...Only open containers in a well ventilated area For the method of storing see STORE DEF 4 8 When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is n...

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Page 75: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 76: ...GENERAL VIEW MACHINE EQUIPMENT NAME 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Boom cylinder 7 Sprocket 8 Track frame 9 Track 10 Idler GENERAL VIEW OPERATION 3 2 ...

Page 77: ...r 14 Engine hood 15 Battery 16 Battery disconnect switch 17 System operating lamp 18 Fusible link 19 Toolbox 20 Grease pump holder PC210 11 PC210LC 11 21 DEF tank 22 DEF hose 23 DEF pump 24 DEF injector 25 DEF mixing tube 26 KomVision 27 Grease pump holder PC210NLC 11 PC230NHD 11 OPERATION GENERAL VIEW 3 3 ...

Page 78: ...w 2 Ceiling window 3 Door lock release lever 4 Drink box 5 Fuse 6 Auxiliary electric power if equipped 7 Fire extinguisher if equipped 8 Emergency escape hammer 9 Magazine box 10 Cup holder 11 AUX 12 Ashtray GENERAL VIEW OPERATION 3 4 ...

Page 79: ...CONTROLS AND GAUGES NAMES KS000908 1 Radio 2 Lock lever 3 L H work equipment control lever 4 One touch power maximizing switch 5 Travel pedal 6 Travel lever OPERATION GENERAL VIEW 3 5 ...

Page 80: ...l switch 26 2nd attachment proportional control switch if equipped 27 Breaker switch 28 Spare switch DAB radio mute if equipped 29 Spare switch 30 Quick coupler switch 31 Spare switch 32 Spare switch 33 Quick coupler switch 34 Lower wiper switch 35 Automatic grease system monitor if equipped 36 Additional lamps switch if equipped 37 AUX MACHINE MONITOR EQUIPMENT NAME AA Standard screen BB Check be...

Page 81: ...ion pilot lamp 28 Aftertreatment devices regeneration disable pilot lamp 29 Message display 30 Air conditioner pilot lamp 31 Engine oil level caution lamp 32 Air cleaner clogging caution lamp 33 Charge level caution lamp 34 Engine oil pressure caution lamp 35 Wiper pilot lamp 36 Swing lock pilot lamp 37 Engine preheating pilot lamp or One touch power maximizing pilot lamp 38 Auto deceleration pilo...

Page 82: ...itor switch area 5 Guidance icon display 6 Camera image display REMARK For the user menu used for setting various items of the machine on the machine monitor see USER MENU DISPLAY SWITCH One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on the screen When there are fewer than 10 black or white spots t...

Page 83: ...de travel mode display screen HH is displayed for 2 seconds the screen switches to standard screen AA If the working mode when the engine is started is B mode the opening screen GG is displayed for 2 sec onds and the screen then switches to the breaker mode confirmation screen II When starting with B mode press switch F6 If you do not want to start B mode press switch F5 In this case the system st...

Page 84: ...ayed and engine does not start If engine shutdown secondary switch 1 is turned OFF nor mal the machine monitor switches to the standard screen and the engine can be started with usual starting switch key operation BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION 5 When the starting switch is turned to OFF position end screen JJ or KK is displayed for 5 seconds then the ...

Page 85: ... is set the opening screen GG switches to ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting ID number for operator identification function without SKIP is set the opening screen GG switches to ID number input screen MM without SKIP when the starting switch is turned to ON position On the ID number input screen LL with SKIP or MM without SKIP input t...

Page 86: ... If inputting incorrect ID number for 3 times continuously you cannot input ID number for 5 minutes Wait for more than 5 minutes try inputting ID number again As long as ID number input screen is displayed the engine cannot be started If you forget the ID number and cannot start the engine ask the person in charge of the machine NOTICE Since the purpose of the operator identification function is n...

Page 87: ...starting screen BB for 2 seconds the screen changes to the maintenance time warning screen CC After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the stand ard screen AA After displaying the check before starting screen BB for 2 seconds the screen changes to the warning screen FF 1 or error screen EE After displaying warning screen FF 1 for 2 seconds the sc...

Page 88: ...top of switch F5 switch F5 Press switch F5 to check the detail of the current abnormality Current Abnormality screen is displayed BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE EXPLANATION OF COMPONENTS OPERATION 3 14 ...

Page 89: ... screen EE After displaying warning screen FF 1 for 2 seconds the screen automatically changes to warning screen FF 2 If there is any error existing is displayed on top of switch F5 Press switch F5 to check the detail of the error Current Abnor mality screen is displayed OPERATION EXPLANATION OF COMPONENTS 3 15 ...

Page 90: ...layed when operating work equipment swing and travel The screen automatically changes to the standard screen AA while the no camera image screen DD is dis played when operating work equipment swing and travel The screen does not change to the camera image screen CC and the no camera image screen DD while operating work equipment swing and travel To change the screen to the camera image screen CC a...

Page 91: ... location of caution lamp 2 If there are two activated warnings they are displayed in the location of caution lamps 2 and 3 If there are three or more activated warnings they are displayed in the location of caution lamps 2 and 3 alternately every two seconds Warning display on the entire camera image display screen The activated warning is shown by flashing of caution lamp 9 If multiple warnings ...

Page 92: ...he machine to a safe place then ask your Komatsu distributor for inspection and mainte nance L02 Sounds inter mittently Lights up in red Stop the operation and run the engine at medium speed with no load or stop it If the condition is not improved ask your Komatsu distributor for inspection and maintenance L01 Does not sound Lights up in yellow Some functions may be restricted from use but the mac...

Page 93: ...bnormal L04 L03 Abnormal L01 Hydraulic system caution lamp Abnormal L04 L03 Abnormal L01 KDPF system caution lamp Abnormal L04 L03 Abnormal L01 KDPF soot accumulation caution lamp Abnormal L03 Accumulated L01 DEF level caution lamp Abnormal L04 L03 Sensing is disabled DEF system caution lamp Abnormal L04 L03 Abnormal L01 DEF system high tempera ture stop caution lamp Engine stopped at high tempera...

Page 94: ...tor caution lamp Abnormal Air cleaner clogging caution lamp Clogged L01 Overload caution monitor Overload KS001069 Quick coupler caution lamp Abnormal L03 Air conditioner system cau tion lamp Abnormal L01 Maintenance time caution lamp Due time is over Notice Seat belt caution lamp Seat belt is not fastened Engine overspeed Abnormal L02 Abrupt engine stop by AIS Excessive fre quency L03 Excessive f...

Page 95: ... CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated is displayed on top of switch F5 While is displayed press switch F5 to shift the monitor dis play screen to the Current Abnormality screen Take appropriate remedies according to the message displayed on the monitor Operation on the Current Abnormality screen On the Current Abnormality screen you can perform the fol...

Page 96: ... While this monitor is lit the overheat prevention system is auto matically actuated and the engine speed drops Stop operations and run it at low idle until the caution lamp changes to the normal display colour blue at an proper tem perature When temperature is low The caution lamp lights up in white The engine coolant temperature is low The engine needs to be warmed up Perform the warm up operati...

Page 97: ...uel level caution lamp warns about low remaining fuel lev el When fuel level is low The caution lamp lights up in red The remaining fuel amount is approximately 41 ℓ or less Add fuel as soon as possible When normal The caution lamp lights up in blue SYSTEM CAUTION LAMP The system caution lamp warns about abnormality in the ma chine system including the sensors When action level L04 is displayed Th...

Page 98: ...aintenance Ask your Komatsu distributor for inspection and maintenance as needed KDPF SYSTEM CAUTION LAMP The KDPF system caution lamp warns about abnormality in the KDPF system When action level L04 is displayed The caution lamp lights up in red and the alarm buzzer sounds continuously Stop the machine immediately and ask your Komatsu distribu tor for inspection and maintenance When action level ...

Page 99: ...neration see HANDLE KOMATSU DIESEL PARTICULATE FILTER KDPF DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low Whenever the caution lamp lights up in red immediately add DEF Fault conditions that result in activation of the Inducement strat egy for engine derates to prompt to maintain or repair the emis sion control system When Lightning in red With Action level L0...

Page 100: ...tatus is Warning or Continuous Warning When Continuous Warning If no maintenance advancing to the next Inducement status Engine power will be derated REMARK For more information about the Inducement strategy and Inducement status concerning engine power deration see HANDLE UREA SCR SYSTEM WARNING DEF SYSTEM HIGH TEMPERATURE STOP CAUTION LAMP DEF system Temperature stop caution lamp alerts when the...

Page 101: ...intenance as needed ENGINE OIL PRESSURE CAUTION LAMP Engine oil pressure caution lamp warns about abnormality of engine lubricating oil pressure When oil pressure is low The caution lamp lights up in red and indicates action level L03 The alarm buzzer sounds intermittently Stop the operation and move the machine to a safe place then ask your Komatsu distributor for inspection and maintenance ENGIN...

Page 102: ... running When abnormal The caution lamp lights up in red and indicates action level L03 The alarm buzzer sounds intermittently Charging is not being performed normally while the engine is running Stop the engine and check the alternator belt for damage then ask your Komatsu distributor for inspection and maintenance WATER SEPARATOR CAUTION LAMP The water separator caution lamp warns that water is ...

Page 103: ... Ask your Komatsu distributor for inspection and maintenance as soon as possible MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displays notices and alarms concerning maintenance time This lamp lights up when the starting switch is turned to the ON position It goes out after 30 seconds and the display changes to the standard screen When the due time is over The caution lamp lights up ...

Page 104: ...ns on the maintenance tab screen see MAIN TENANCE SCREEN SETTING OVERLOAD CAUTION LAMP The overload caution lamp warns that the machine is close to tipping due to the load an audible warning is also given if the warning is given lower the load Refer to the lifting capacity chart for safe load SEATBELT CAUTION LAMP The seat belt caution lamp lights up when the seat belt is not fastened It goes out ...

Page 105: ...l attention to the label when there is any labels Follow the instructions from the conductor When the action level L01 is displayed The caution lamp lights up in yellow If the caution lamp is lit the camera image is not displayed on the machine monitor Visually check the safety around the machine always when operating the machine When you finish the operation always perform the inspection and main...

Page 106: ...F level gauge 19 Fuel gauge 20 Hydraulic oil temperature gauge 21 Engine coolant temperature gauge 22 ECO gauge PILOT DISPLAY The pilot display at the top of the screen consists of the pilot lamps to check the actuation of each function When the starting switch is turned on and the display items are functioning the pilot lamps light up PREHEATING PILOT LAMP The preheating pilot lamp is displayed w...

Page 107: ...y When nothing lights up Wiper stops For the position of the windshield wiper switch see MACHINE MONITOR EQUIPMENT NAME AUTO DECELERATION PILOT LAMP The auto deceleration pilot lamp shows the setting of the auto deceleration either ON or OFF The pilot lamp display when the auto deceleration switch is op erated is as follows Auto deceleration pilot lamp lights up Auto deceleration ON Auto decelerat...

Page 108: ...uated The following pilot lamp is displayed when the knob switch on the L H control lever is operated The actual pilot lamp display is shown at the position of preheating pilot lamp Pilot lamp lights up Digging power increases while the knob switch is kept pressed for a maximum of 8 5 seconds Pilot lamp goes out Power maximizing function stopped For the position of the knob switch see MACHINE MONI...

Page 109: ...during the aftertreatment devices regeneration Stay away from the exhaust pipe outlet to prevent yourself from getting burnt Also keep combustible materials away from the exhaust pipe outlet to prevent a fire When there are thatched houses dry leaves or pieces of paper near the job site set the system to the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the a...

Page 110: ...of manual stationary regeneration see HANDLE KOMATSU DIESEL PARTICULATE FILTER KDPF LOCK LEVER PILOT LAMP The lock lever pilot lamp lights up when the lock lever is in LOCK position It goes out when the lock lever is set in FREE position ECO GUIDANCE The guidance for energy saving operation to reduce the fuel consumption may be displayed during operation The details of the guidance are as follows ...

Page 111: ...avel mode Hi and the fuel control dial at the High idle MAX position the travel partial mode recommendation message is displayed When traveling for a long time the fuel consumption can be reduced by lowering the fuel control dial The travel partial mode recommendation message goes out more than 10 seconds after or when switch F5 is pressed Low Fuel Level Guidance If the operable time estimated fro...

Page 112: ...mperature If the indicator is in green range during operations it is normal When the indicator goes beyond A of red range during opera tions the overheat prevention system is actuated A to B Red range A to C Green range C to D White range The overheat prevention system is actuated as follows Red range A position Engine coolant temperature caution lamp E shows abnormality display Red range B positi...

Page 113: ...range B position 105 C or more When the indicator is in red range A to B hydraulic oil temperature caution lamp E indicates abnormality When the engine is started if the indicator is at position C the hydraulic oil temperature is below 20 C and hydraulic oil temperature caution lamp E indicates low temperature In this case perform warm up operation For details see METHOD FOR HYDRAULIC SYSTEM WARM ...

Page 114: ... regardless of the engine speed Service meter display Clock display 12 hour display Clock display 24 hour display REMARK If the battery is disconnected for a long period for storage etc the time information may be lost Clock display 12 hour or 24 hour display is available For the setting and correction of time see CLOCK AD JUSTMENT ECO GAUGE ECO gauge shows the instantaneous fuel consumption The i...

Page 115: ... during opera tion check and add DEF A to B Red range A to C Green range When the indicator is in red range from A to B DEF level caution lamp 1 lights up in red If DEF level further decreases after the monitor lights up in red the engine power is derated For detail see HANDLE UREA SCR SYSTEM WARNING When remaining level of DEF cannot be detected DEF level caution lamp 1 lights up in white REMARK ...

Page 116: ...h screen On each screen you can confirm the function of switches 1 by guidance icons 2 displayed on top of the switch While guidance icon 2 is not displayed function switch 1 does not function even if it is pressed Even if guidance icon 2 is pressed it does not function Press function switch 1 directly under guidance icon 2 to operate the function When the monitor display shows the standard screen...

Page 117: ...he displayed screen but representative guidance icons fre quently used and their functions are as follows F Switch F1 Moves to the left item When on the left end it moves to the right end G Switch F2 Moves to the right item When on the right end it moves to the left end H Switch F3 Moves to the item below forward When on the last line it moves to the first line on the next page I Switch F4 Moves t...

Page 118: ...ady for installation of attachment ATT E mode For operations emphasizing fuel consumption out of those of 2 way attachments like crusher machines ready for installation of attachment When the monitor is turned ON it is automatically set to the mode used when the starting switch was turned to OFF position last Press the switch to display the working mode selection screen 2 For each set mode P E L B...

Page 119: ...ng mode and the screen changes to the one for steps 3 and 4 REMARK To return to the standard screen without changing the working mode press function switch F5 3 After selecting the desired mode press function switch F6 and the mode is displayed in the center of the monitor dis play Example When the power mode is selected P 4 After 2 seconds the working mode display at the top right of the screen i...

Page 120: ... lamp goes off Auto deceleration OFF Each time the switch is pressed the auto deceleration is switched between ON and OFF Function of auto deceleration When the auto deceleration function is ON if the work equipment lever and travel lever are returned to NEU TRAL position the engine speed will drop approximately after 4 seconds from the operating speed to idle speed As a result fuel consumption ca...

Page 121: ...the ma chine before switching the travel speed Travel speed selector switch is used to select the travel speed from 3 stages Lo lights up Low speed travel Mi lights up Mid range speed travel Hi lights up High speed travel When the engine is started the speed is automatically set to Lo Each time that the switch is pressed the display changes Lo Mi Hi Lo in turn Even if the travel speed is set to hi...

Page 122: ...per switch actuates the front window windshield wiper Each time the switch is pressed it changes INT ON stop monitor goes out Windshield wiper pilot lamp INT lights up Windshield wiper op erates intermittently Windshield wiper pilot lamp ON lights up Windshield wiper op erates continuously Windshield wiper pilot lamp off Windshield wiper stops EXPLANATION OF COMPONENTS OPERATION 3 48 ...

Page 123: ...r fluid is sprayed out At the same time the wiper is actuated continuously When releasing switch the wiper continues to operate for 2 cycles then stops If the wiper is moving intermittently and the switch is kept pressed continuously the window washer fluid is sprayed out At the same time the wiper is actuated continuously When releasing switch the wiper continues to operate for 2 cycles then retu...

Page 124: ... the warning AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches For explanation of each switch see HANDLE AIR CONDI TIONER FUNCTION SWITCHES The operation of the function switches in the standard screen EXPLANATION OF COMPONENTS OPERATION 3 50 ...

Page 125: ...oaded into the machine are displayed on the left and right sides of the machine monitor respectively On the standard screen AA when the switch F3 is pressed the enlarged bird s eye view display BB is dis played If the switch F3 is pressed on the enlarged bird s eye view display BB the camera image screen CC is dis played On the camera image screen CC the camera image is displayed in the entire mon...

Page 126: ...and travel On the start screen the camera image switch display flashes in the position shown in the figure The green range of the camera image switch display shows of which camera the image is displayed Camera switch display Displayed camera position Rear camera Left rear camera Right front camera Right rear camera The shooting direction of the camera loaded into the machine is as follows 1 Back o...

Page 127: ...en In addition if no operation is performed for 5 seconds after the screen switches to the air conditioner operation screen the screen automatically returns to the camera im age screen It is possible to change the working mode by pressing the working mode selector switch When the working mode is changed the screen returns automatically to the camera image screen At this time the working mode displ...

Page 128: ... neither switches to another screen nor returns to the standard screen Depending on the warning alarm buzzer does not stop sounding by pressing the buzzer cancel switch Press the wiper switch and washer switch to operate the wipers and washer Even if the wiper switch or washer switch is pressed the camera image display screen neither switches to another screen nor returns to the standard screen AC...

Page 129: ...part of the screen If a caution lamp is displayed move the machine to set it in a safe posture then have inspection performed immedi ately USER MENU DISPLAY SWITCH On the standard screen press the switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display Machine monitor screen automatically changes to the screen which displays the bird ...

Page 130: ...tions in each menu see the detailed explanation pa ges of respective items a Energy Saving Guidance Check of Operation Records Check of ECO Guidance Records Check and reset of Average Fuel Consumption Record Configurations b Machine Setting Economy Mode Adjustment Breaker Setting if equipped Attachment Setting if equipped Auto Idle Stop Timer Setting When the attachment control setting is effectiv...

Page 131: ... d SCR Information Check of DEF level Information on DEF system e Maintenance Check and reset of various maintenance times f Monitor Setting Screen Adjustment Screen Adjustment camera Clock Adjustment Language Operator ID g Mail Check Check of mail contents and reply to mail OPERATION EXPLANATION OF COMPONENTS 3 57 ...

Page 132: ... the previous item 1 line above When it is on the first line it moves to the last line F5 Returns the screen to the standard screen F6 Displays the setting screen for selected item If no switch is operated for 30 seconds on the user menu screen the screen automatically returns to the previous screen ENERGY SAVING GUIDANCE Each item of Energy Saving Guidance menu a is used for displaying and settin...

Page 133: ... F3 Displays the next page When on the last page it displays the first page F4 Displays the previous page When on the first page it dis plays the last page F5 Returns the screen to the Energy Saving Guidance menu screen CHECK ECO GUIDANCE RECORD Select the ECO Guidance Records 2 on the Energy Saving Guidance menu screen then press switch F6 On the ECO Guidance Records menu display the frequency of...

Page 134: ...ing the last 12 hours or the graph of daily fuel consumption during the last 1 week Operation on the Average Fuel Consumption Record screen Press switch F1 F2 or F5 on the Average Fuel Consumption Record screen to perform the following operations F1 Clears the graph data F2 Switches graphical displays of the average fuel consump tion F5 Returns the screen to the Energy Saving Guidance menu screen ...

Page 135: ...on during the last 1 week Switching be tween them is available Deleting the average fuel consumption records 1 When switch F1 CLEAR is pressed the reconfirmation screen shown in the figure is displayed 2 When the switch F6 is pressed graphs of data of the last 12 hours and the last 1 week are both deleted and the screen returns to the Average Fuel Consumption Record screen REMARK Press switch F5 t...

Page 136: ...FF Operations on the Configurations screen Press switches F3 to F6 to perform the following operations on the Configurations screen F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Returns the screen to the Energy Saving Guidance menu screen F6 Displays the setting ...

Page 137: ...moves to the last line on the previous page F5 Cancels the setting and returns to Configurations screen F6 Changes the setting and returns to Configurations screen 2 The Average Fuel Consumption Display screen appears 1 Day Displays the average fuel consumption from 0 00 a m of the day to 0 00 a m of the next day Split Time Displays the average fuel consumption during the split measurement period ...

Page 138: ...or ECO Guidance Records 2 screen then press the measure ment stop switch F1 STOP SWITCH DISPLAY NON DISPLAY OF ECO GAUGE It is possible to change the setting of Display Non display of ECO gauge 7 1 Select the ECO Gauge display 8 from the Configurations screen then press switch F6 2 ECO Gauge Display setting screen appears ON Displays the ECO gauge 7 on the standard screen OFF Does not display ECO ...

Page 139: ...o change the target fuel consumption value the upper limit value of the green range of the ECO gauge 1 Select the ECO Gauge Target Value 9 from the Configu rations screen then press switch F6 2 ECO Gauge Display Fuel Target Value appears On this screen it is possible to perform the following oper ations with switches F3 to F6 F3 Decreases the target fuel consumption value by 1 ℓ h F4 Increases the...

Page 140: ...t line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting change and returns to Configurations screen F6 Changes the setting and returns to Configurations screen SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF It is possible to change the setting of Display Non di...

Page 141: ...m 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting change and returns to Configurations screen F6 Changes the setting and returns to Configurations screen MACHINE SETTINGS Each item of Machine Setting menu b is used for setting items of machine Economy Mode Adjustment Breaker Setting Attachment Setting Auto Idle Stop Timer Setting When the a...

Page 142: ...F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels selection and returns the screen to Machine Set ting menu screen F6 Selects the Adjustment Mode and returns the screen to Machine Setting menu screen BREAKER SETTING On the Breaker Setting menu you can change the name of breaker displayed on the monitor and the breaker oil flow setting For machin...

Page 143: ...Breaker Setting screen select a setting to change its name then press switch F1 2 The Breaker Name Setting screen is displayed On the Breaker Name Setting screen you can perform the following operations with switches F1 to F6 F1 CLEAR Clears all the letters If some letters are left F1 DEFAULT Displays the initial name If all the letters are deleted F2 Moves to the right letter F3 Moves to the next...

Page 144: ...achment Setting 3 on the Machine Setting menu b screen then press switch F6 2 On the Attachment Setting screen shown in the figure select an attachment to adjust and press switch F6 On the Attachment Setting screen shown in the figure you can perform the following operations with switches F1 to F6 F1 Changes the name of the selected attachment setting F2 Changes the oil flow rate of the selected a...

Page 145: ...tting screen It is not possible to change the name for No Attachment setting Changing 2 Way Attachment Oil Flow Rate Setting 1 Select an attachment setting to change its oil flow rate on the Attachment Setting screen then press switch F2 2 The 2 Way Attachment Oil Flow Rate Setting screen is displayed On the 2 Way Attachment Oil Flow Rate Setting screen you can perform the following operations wit...

Page 146: ...ting F3 Moves to the next item 1 line below When it is on the last line it moves to the first line F4 Moves to the previous item 1 line above When it is on the first line it moves to the last line F5 Cancels the selection and returns the screen to Machine Setting menu screen F6 Allocates the selected setting to that of ATT P or ATT E mode Changing Attachment Setting name You can change the name fo...

Page 147: ...ine is not in warm up operation The machine is not in L mode You can set the time to operate the auto idle stop function on the auto idle stop timer setting screen 1 Select Auto Idle Stop Timer Setting 4 on the Machine Setting menu b screen and then press switch F6 2 Select the set time on the Auto Idle Stop Timer Setting screen shown in the figure and then press switch F6 On the Auto Idle Stop Ti...

Page 148: ...top is activated only the engine is stopped and the machine monitor inverter etc as well as the electrical components including the air conditioner ra dio lamps and wipers keep their states before the engine is stopped 6 To prevent battery discharging turn the starting switch to OFF position 7 When restarting the engine turn the starting switch as usual REMARK While the auto idle stop function is ...

Page 149: ...u e on Maintenance screen is used for displaying and setting the notification relevant to mainte nance The items on the maintenance display are as follows a b Air Cleaner Clean and Change Coolant Change Hydraulic Oil Additional Filter Change Hydraulic Oil Pilot Filter Change Engine Oil Change 1 500 Engine Oil Filter Change 1 500 Fuel Prefilter Change 500 Fuel Main Filter Change 1000 Hydraulic Tank...

Page 150: ...aintenance menu screen the screen automatically returns to the standard screen When the maintenance time caution lamp is lit on the standard screen press F6 on the standard screen and the screen automatically displays the Maintenance menu screen On the Maintenance menu screen if the time remaining to the maintenance for any item is less than 30 hours initial setting value the remaining time displa...

Page 151: ...nitor Setting menu f is to make settings for the monitor SCREEN ADJUSTMENT Use Screen Adjustment menu to adjust brightness of the monitor screen 1 Select screen adjustment 1 on the Monitor Setting menu screen then press switch F6 2 Use switches F2 to F6 to adjust brightness of the screen F2 Resets an adjusted value to default value F3 Moves the indicator to the left by one notch F4 Moves the indic...

Page 152: ...tches F2 to F6 to adjust brightness of the screen F2 Resets an adjusted value to default value F3 Moves the indicator to the left by one notch F4 Moves the indicator to the right by one notch F5 Cancels the change and returns the screen to Monitor Setting menu screen F6 Accepts the change and returns the screen to Monitor Setting menu screen REMARK As long as mark is displayed in the upper right c...

Page 153: ...n F6 Displays the setting screen for selected item REMARK When the machine is in the environment where the radio waves from GPS cannot be received such as inside of a building the automatic setting function may not work While GPS synchronization menu is turned on the menu for Calendar b and Time c cannot be selected CALENDAR SETTING Adjust the date of the monitor REMARK As long as GPS Synchronizat...

Page 154: ... F5 Cancels change and returns to the month setting screen F6 Accepts change and returns the screen to Clock Ad justment screen TIME SETTING Adjust the time of the monitor clock REMARK As long as GPS Synchronization is turned on Time menu is not selectable 1 Select Time c on Clock Adjustment screen then press switch F6 2 The Time screen is displayed When the hour display D is highlighted in yellow...

Page 155: ...e d on Clock Adjustment screen then press switch F6 2 12h 24h Mode screen appears F3 Moves to the next item 1 line below Moves to the top line when it is on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when it is on the top line F5 Cancels the change and returns the screen to Clock Adjustment screen F6 Accepts change and returns to Clock Adjustment screen DAY...

Page 156: ...in nish Icelandic Czech Hungarian Polish Slovak Slovene Romanian Croatian Estonian Latvian Lithuanian Bulgarian Greek 1 Select Language 4 on the Monitor Setting menu then press switch F6 2 Select the language to use for the display then press switch F6 The screen display changes to the selected lan guage On Language screen it is possible to perform the follow ing operations with switches F3 to F6 ...

Page 157: ...he Monitor Set ting menu screen 1 Select Operator ID 5 on the Monitor Setting menu screen then press switch F6 for 1 second 2 The Operator ID Change screen is displayed Input the already registered ID on the Operator ID Change screen and press F6 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen On the Monitor Setting menu ...

Page 158: ...returns to the Monitor Setting menu screen In this case the identified ID is not changed On the Operator ID Change screen if no switch is operated for more than 30 seconds the screen auto matically changes to the Monitor Setting menu screen In this case the identified ID is not changed WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is avai...

Page 159: ...u you can select the cam era image which will be displayed on the right side on the screen when starting up the machine monitor You can select one of four camera images from rear cam era rear right camera front right camera and rear left camera Previous camera image which was displayed at the last key off is displayed when Camera at Previous Key off is selected 1 Select Key on Camera Position 1 on...

Page 160: ...There is any read message to which no reply is made OFF No messages REMARK When the message display lights up in blue B it means that no reply has been made yet to any read message to your Komatsu distributor Reply to the message according to the replying method mentioned below If the starting switch is turned to OFF position when there is any unread message the message will be displayed on the en...

Page 161: ... box 1 on the screen of mail confir mation menu g The selected item number is written in place 2 of the message text Input the number by using the monitor switch Each switch corresponds to the value shown on the right side below the switch If you input an incorrect number press switch F5 and you can clear an input character at a time If switch F5 is pressed when the input column is blank the scree...

Page 162: ...d 8 Ceiling window wiper switch if equipped 9 Cigarette lighter 10 Room lamp switch 11 Seat heater switch if equipped 12 Engine shutdown secondary switch 13 Pump secondary drive switch 14 Swing parking brake cancel switch 15 Lock lever automatic lock cancel switch 16 Quick coupler switch 17 1st attachment proportional control switch EXPLANATION OF COMPONENTS OPERATION 3 88 ...

Page 163: ...uel control dial is used to control the engine speed and out put a Low idle MIN The position where the dial is turned fully to the left b High idle MAX The position where the dial is turned fully to the right CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes When the cigarette lighter is pushed in it will return to its origi nal position after a few seconds so pull it out to use ...

Page 164: ...amps light up and monitor illumination is set to day mode c OFF position Lamps go out The monitor illumination is set to day mode HORN SWITCH Horn switch is located on R H work equipment control lever When switch is pressed the horn sounds ONE TOUCH POWER MAXIMIZING SWITCH One touch power maximizing switch is used to actuate the one touch power maximizing function Press once single click and keep ...

Page 165: ...control system Do not use it except for emergency Repair the problem as soon as possible If this switch is moved to Emergency position by mistake while the machine is operating normally L03 appears in the display If L03 is displayed during operation press the moni tor function switch F5 to check whether the current failure code includes any of the hydraulic system er rors DXA9KB DXA8KB DXA9KA or D...

Page 166: ... L03 a Cancel When abnormal switch is set up b Normal When normal switch is pushed down When the upper structure does not swing but the display does not show L03 move this switch to Cancel position a and operation can be performed When the switch is moved to Cancel position a the swing lock pilot lamp flashes LOCK LEVER AUTOMATIC LOCK CANCEL SWITCH NOTICE The lock lever automatic lock cancel switc...

Page 167: ...monitor display and after 2 seconds the screen returns to the standard screen After moving the machine or work equipment temporarily by operating this switch stop the engine return the switch to normal position b and then ask your Komatsu distribu tor for repair REVOLVING LAMP SWITCH if equipped Revolving lamp switch is used to light up the yellow revolving lamp on top of the cab a ON Lights up b ...

Page 168: ...ndary switch only in an emergency Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch If the engine shutdown secondary switch is moved to the stop engine position by mistake while the machine is operating normally Engine Shutdown Secondary SW In Operation is displayed on the machine monitor If Engine Shutdown Secondary SW In Operation is displayed o...

Page 169: ...becomes warm QUICK COUPLER SWITCHES To operate the quick coupler circuit switches 23 on RHS console 17 on LH PPC lever must be operated to gether Refer to PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS 6 2 for an explanation of these switches operation 1ST ATTACHMENT PROPORTIONAL CONTROL SWITCH The 1st attachment proportional control switch is a roller proportional control switch used to operate the...

Page 170: ...k WARNING When leaving the operator s seat set the lock lever securely to LOCK position If the lock lever is not at LOCK position and the control levers or control pedals are touched by mistake it may lead to serious personal injury or death Always check that the lock lever is in LOCK position When pulling the lock lever up or when pushing the lock lever down be careful not to touch the work equip...

Page 171: ...en the viscosity of the hydraulic oil used is higher than that of the genuine hydraulic oils which Komatsu recommends Before setting the lock lever to FREE position make sure that all control levers and pedals are set to NEUTRAL position If any of them is out of NEUTRAL position the work equipment or machine may move suddenly and cause a serious personal injury or death The lock lever automatic lo...

Page 172: ...nt or the rear If the sprocket is at the rear the track frame is facing the front The travel lever is used to change the direction of travel be tween forward and reverse shows the pedal operation a FORWARD The lever is pushed forward Depress the front side of pedal b REVERSE The lever is pulled back Depress the rear side of pedal N NEUTRAL The machine stops REMARK If the lever is shifted to FORWAR...

Page 173: ...is in FREE position it may cause serious personal injury or death When opening or closing the front window stop the machine on a level ground lower the work equipment to the ground stop the engine then perform the operation When opening the front window hold the handle securely with both hands to pull up and do not release your hands until the front window is locked by the automatic lock catch Whe...

Page 174: ...tsu distributor for repair a Correct stowing position The wiper blade is on the cab b Wrong stowing position The wiper blade is on the glass 3 Hold handles A 2 places on the right and left top sides of the front window and pull levers B 2 places to re lease the locks at the top of the front window The top of the front window will come out EXPLANATION OF COMPONENTS OPERATION 3 100 ...

Page 175: ...the front win dow are not for pulling up the front window Do not pull up the front window with the handles A 5 Check that lever B is securely at LOCK position If the arrow on lock case F matches the position of the arrow on lever B the lock is engaged Check vis ually If the arrow on lock case F does not match the posi tion of the arrow on lever B the lock is not engaged Repeat the operation in ste...

Page 176: ...he machine on a level ground lower the work equip ment to the ground then stop the engine Operate the operating portion g of the lock lever 1 to set it securely to LOCK position L 2 Check that the wiper blade is stowed in the right stay If the wiper blade is stowed in wrong stowing position b lift it to move to the correct stowing position a or ask your Komatsu distributor for repair a Correct sto...

Page 177: ... down the front window with the handles A 5 When the bottom of the window reaches the top of lower side window push the top of the window to the front to push it against right and left lock catches G and engage the lock 6 Check that lever B is securely at LOCK position If the arrow on lock case F matches the position of the arrow on lever B the lock is engaged Check vis ually If the arrow on lock ...

Page 178: ...ck position B to hold it securely in position 3 When removing it set lever 2 to release position C hold the glass with both hands and pull it up EMERGENCY ESCAPE HAMMER k k CAUTION If it is necessary to break the window glass with the hammer be extremely careful not to get injured with scattered pieces of broken glass To prevent injury remove the broken pieces of glass remaining in the frame befor...

Page 179: ...ne or do not put your hands on the door frame The door may suddenly close and cause injury 1 Use the door lock to keep and fix the door opened 2 Push the door against catch 1 to lock it in position When closing the door push down lever 2 on the left side of the operator s seat and the catch is released 3 When keeping the door open fix it securely to the catch CAB DOOR HINGE The cab door hinge has ...

Page 180: ... DRINK BOX It is provided on the rear right side of the operator s seat to store drinks Air according to the setting of the air conditioner blows into the drink box MAGAZINE BOX Located on the left side of the operator s seat Keep Operation and Maintenance Manual in this box so that it can be taken out and read whenever necessary CUP HOLDER The cup holder is located on the left side of the operato...

Page 181: ...er supply for 12 V equipment This will cause failure of the equipment When cigarette lighter is removed the lighter socket can be used as a power source The capacity of the cigarette lighter is 85 W 24 V x 3 5 A REMARK Use 24 V power source while engine is running 12 V power source This power source can be used up to a capacity of 144 W 12 V x 12 A When it is used at 1 place 144 W 12 V x 12 A When...

Page 182: ...o protect the electrical component and wiring from burning out If the fuse becomes corroded or looks white powdery or the fuse is loose in the fuse holder replace the fuse Replace the fuse with the one of the same capacity KS000913 EXPLANATION OF COMPONENTS OPERATION 3 108 ...

Page 183: ... 13 5 A Air conditioner ECU power source 14 5 A Key ACC signal 15 20 A Working lamp 16 10 A Radio backup room lamp system operating lamp 17 20 A Monitor Pump controller 18 30 A Engine controller 19 5 A Air conditioner ECU backup 20 10 A Optional power source continuous power supply 21 10 A CAB headlamp 1 22 10 A CAB Rear lamp 23 10 A Lower window wiper 24 10 A Quick coupler 25 15 A Refuelling pump...

Page 184: ...e starting switch key is turned to START position fusible link 1 2 places may be broken Open the cover on the left side of the machine to check the fusible links and replace them REMARK A fusible link refers to the large sized fuse wiring installed in the high current flow portion of the circuit It protects electrical components and wiring from burning in the same way as an ordinary fuse TOOL BOX ...

Page 185: ...rous NOTICE Keep battery disconnect switch in ON position except the following cases When the machine is stored for a long time more than a month When repairing the electrical system When performing electric welding When handling the battery When replacing fuse etc Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit If the battery disconnect switch is t...

Page 186: ...r is turned ON and goes out in 1 to 7 minutes after the starting switch is turned to OFF position Before operating the battery disconnect switch check that sys tem operating lamp 1 is turned OFF NOTICE If the battery disconnect switch is turned to OFF position while the system operating lamp is lit the data in the con troller will be lost and system abnormality may occur REMARK Even if the startin...

Page 187: ...tem regardless of the quantity of the accumulat ed soot During the KDPF regeneration the aftertreatment devices regeneration pilot lamp 1 stays lit on the machine monitor REMARK Even if aftertreatment devices regeneration pilot lamp 1 lights up the machine does not need to be stopped and the work can be continued unless the caution lamp is displayed at the cen tre of the monitor The KDPF regenerat...

Page 188: ... increase but this is not a fail ure Even just after the regeneration is completed the soot ac cumulation level may not be 0 This is caused by the ac cumulated noncombustible material in the exhaust gas and is not a failure Since noncombustible matter which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals For d...

Page 189: ...creen A is displayed first The action level goes out 2 seconds after and the screen changes to standard screen B If the lock lever is set to LOCK position or all the work equipment control levers are set in NEUTRAL the screen changes to Aftertreatment Devices Regeneration screen C after 3 seconds only the first time If the manual sta tionary regeneration is not performed the screen returns to stan...

Page 190: ...stationary regeneration PROCEDURE FOR MANUAL STATIONARY REGENERATION k k CAUTION Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regen eration Avoid getting near the exhaust pipe outlet and around the Aftertreatment devices to prevent being burnt Also keep combustible materials away from the exhaust pipe outlet and around the Aftertreatment de...

Page 191: ...step 6 the screen shown in the figure may be displayed This indicates that the opera tions in steps 1 to 4 were not performed correctly or there is trouble other than KDPF soot accumulation abnormality Check that the engine is running normal the lock lever is in LOCK position L and the fuel control dial is in Low idle MIN position then repeat the procedure from step 6 If the manual stationary rege...

Page 192: ...ration dis appears and the screen returns to the standard screen At this time to display the explanation of the manual stationary regeneration again press switch F6 on the standard screen to display the Aftertreatment Devices Regeneration screen 7 This screen is displayed during the manual stationary re generation It may take more than 40 minutes to complete the manual stationary regeneration Do n...

Page 193: ...en repeat the procedure from step 6 If the machine needs to be moved during the manual stationary regeneration stop the regeneration tempo rarily and move the machine referring to the after treatment devices regeneration disable and cancel procedures described below When restarting the manual stationary regeneration secure the safety of the machine and around it then cancel the regeneration disabl...

Page 194: ...dard screen Press switch F6 on the standard screen 2 Operate switches F1 and F2 to select Aftertreatment De vices Regeneration menu C to display Aftertreatment Devices Regeneration screen 3 Select the regeneration disable and press switch F6 then the regeneration function is disabled and the regeneration cannot be performed EXPLANATION OF COMPONENTS OPERATION 3 120 ...

Page 195: ...lamp 3 may light up but this does not indicate abnormality Also during the regeneration to protect the system the regener ation disable cannot be operated When the regeneration is performed to protect the system the exhaust temperature is lower than that of when the re generation is performed to burn soot and is almost the same level as the normal exhaust gas temperature While regeneration is bein...

Page 196: ...After treatment Devices Regeneration screen is displayed If the screen is not displayed operate switches F1 and F2 to display Aftertreatment Devices Regeneration screen 2 Select Cancel of the regeneration disable and press switch F6 and the regeneration disable is cancelled If soot accumulation level 4 is lit 3 or more the regenera tion is started automatically REMARK When cancelling the regenerat...

Page 197: ...acts with nitrogen oxides for the conversion to nitrogen and water The Komatsu Urea SCR System continuously monitors its operation conditions and stores information on inap propriate operations including malfunctions The information is used for system diagnostics and also for Induce ment required by the authorities on engine systems that use Urea SCR systems Inducement is intended for the operator...

Page 198: ... automatically starts operating as soon as the engine is started Even after the engine starting switch is turned to the OFF position the devices will still be in operation for sever al minutes to purge any DEF in the lines the injector and the supply pump back to the DEF tank It does not indicate any abnormality When DEF has been returned to the tank the devices stop Do not turn OFF the battery di...

Page 199: ...lamp 1 on the machine monitor will light up audible alert will start then Action level will be dis played on the machine monitor and engine power will be derat ed in steps In Action Level L03 Low level Inducement and L04 Severe Inducement engine power will be derated When Action Level 03 or 04 is displayed move the machine to a safe place and add DEF The content of the warning can be checked on th...

Page 200: ... gradations of the DEF level gauge light up in the red range DEF level caution lamp 1 lights up in red No Action level is displayed Press F6 to display the SCR Information screen Inducement status 4 2 Without treatment engine power will be derated Add DEF to the DEF tank immediately Low level Inducement The audible alert sounds in short and sharp beeps 1 gradation of the DEF level gauge light up i...

Page 201: ...es necessary to restore engine power use the engine power restoration function to move the machine to a safe place and add DEF Inducement strategy when abnormalities are detected in the Urea SCR System devices Except abnormalities in the KDPF and the EGR system If any abnormality is detected in the DEF quality or in the Urea SCR system the Inducement strategy is activat ed The inducement strategy ...

Page 202: ...n Level L01 once shows up in yellow on the machine monitor 2 for two seconds and goes out Press F6 to display the SCR Information screen SCR Information screen message 4 1 Please inspect and maintain SCR system Move the machine to the safe place and contact your Ko matsu Distributor If operation continues for 5 hours after Warning started without taking any actions instructed by the Action Level t...

Page 203: ...gine power deration capability of the ma chine will be limited Move the machine to the safe place and contact your Ko matsu Distributor The duration of Low level Inducement is 10 hours The remaining time Hours and Minutes to Severe Induce ment is displayed in the column 5 of the SCR Informa tion screen In Severe Inducement engine power will be derated fur ther Severe Inducement The audible alert s...

Page 204: ...p 1 DEF system caution lamp 2 and Action Level displayed on the machine monitor 3 au dible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine power deration starts with Action Level L03 Warning Continuous Warning and Low level Inducement and advances to further deration when L04 Severe Inducement is displayed Once the sys tem advances to Sever...

Page 205: ...n red The DEF system caution lamp 2 lights up in yellow The action level L03 lights up in red at action level dis play 3 Press F6 to display the SCR Information screen SCR Information screen message 5 2 Without treat ment engine power will be derated Move the machine to the safe place and contact your Ko matsu Distributor The duration time of Continuous Warning is 5 hour The remaining time Minutes...

Page 206: ...y from power derate This engine power restoration works only when the Inducement status is Severe Induce ment and relieves back temporarily to the power deration of Low level Inducement The operator can re store engine power through the machine monitor For the engine power restoration procedure refer to the section of Temporary Restoration from Inducement in this manual If Inducement advances to S...

Page 207: ... while the Urea SCR system is in Inducement SCR Information screen displays remaining time to the next Inducement status in the column 6 and information on the Urea SCR System condition 4 and the current status of In ducement 5 Warning The audible alert sounds in short and sharp beeps The Engine system caution lamp 1 lights up in red The action level L03 lights up in red at action level dis play 3...

Page 208: ...rp beeps The Engine system caution lamp 1 lights up in red DEF system caution lamp 2 lights up in red The action level L03 lights up in red at action level dis play 3 Press F6 to display the SCR Information screen SCR Information screen message 5 3 Engine power is under deration Due to the reduction of engine power the machine normal operation will be limited The duration time of Low level Inducem...

Page 209: ...ncluded in Urea SCR systems In case the Urea SCR system advances to Severe Inducement engine power is derated heavily This may cause difficulties of moving the machine to a safe place for adding DEF or troubleshooting and correcting abnor malities of the Urea SCR system For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of Low leve...

Page 210: ...s displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Low level Inducement for the maximum of 30 minutes The remaining time minutes seconds of Temporary Re storation from Inducement is displayed in the column 2 on the SCR Information screen If it is decided NOT to activate Temporary Restoration from Inducement after having progresse...

Page 211: ...of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the previous Inducement and whether the new abnormality abnormalities is the same as the previous ones or not it is judged as a recurrence If a recurrence occurs Severe Inducement will be activated Inducement in the recurrence resumes counti...

Page 212: ...will cause the failure of the machine Never reuse the DEF filter KOMTRAX KOMTRAX equipment may not be mounted on machines for some countries or regions OUTLINE OF KOMTRAX KOMTRAX is a system that remote controls machines equipped with the KOMTRAX device by using satellite communication or portable radio communication Each customer can check the machine information of various types machine position...

Page 213: ...Then remove the key When the battery disconnect switch is turned to OFF position it is possible to prevent power consumption of the battery but the functions of KOMTRAX stop at the same time Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof REMARK The KOMTRAX device uses wireless communications so it cannot be used inside tunnels undergroun...

Page 214: ...r shall be held liable for any resulting impacts or damages NOTICE For more information on KOMTRAX and the Radio Equipment Directive 2014 53 EU please refer to the Komatsu Europe website https www komatsu eu Komtrax Radio Equipment Directive EXPLANATION OF COMPONENTS OPERATION 3 140 ...

Page 215: ...e materials are found remove them 3 Check around the engine for coolant and oil leakage Check for oil leakage from the engine and coolant leakage from the cooling system If any problem is found repair it 4 Check the fuel line for leakage Check for leakage of fuel or damage to the hoses and tubes If any problem is found repair it 5 Remove dirt and check DEF line for leakage Check for dirt accumulat...

Page 216: ...of exhaust gas and deposition of soot If any problem is found ask your Komatsu distributor for repair 16 Check around SCR for exhaust gas leakage Check the pipe between the KDPF and SCR and also the SCR connections for leakage of exhaust gas and urea deposit If any problem is found ask your Komatsu distributor for repair METHOD FOR CHECKING BEFORE STARTING Always check the items in this section be...

Page 217: ...om the machine Unscrew the strainer valve cap H to open position J Place the fuel hose 2 into the fuel barrel placed next to the machine Remove the fuel cap F 3 Refuel Pump with Auto Shut off Refuel System Refuel switch box 1 is located in the tool case at the front right of the machine Switch ON the master switch of the refuel system 4 on the refuel switch box To start refuelling press switch 5 o...

Page 218: ...lling make sure the master switch 4 is returned to the OFF position A float gauge G will rise out of the filler neck of the tank when it is nearing full capacity Position of tip a of the float gauge when the tank is full 50 mm 4 After refuelling is complete a Push float gauge G straight down with fuel filler cap F be careful not to get the float gauge G caught in the tab of the fuel filler cap F a...

Page 219: ...nitor it indicates that water is accumu lated in transparent cup 2 In this case also use the procedure above to drain the wa ter REMARK When only the water separator caution lamp lights up it lights up in the position shown in the figure If other caution lamps also light up at the same time the water separator caution lamp lights up at a different position NOTICE If the water accumulated in transp...

Page 220: ...the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pres sure then remove it 1 Set the machine in the posture shown in the figure If the machine is not set as shown in the figure set it ac cording to th...

Page 221: ...r the suction tube comes between the right and left tracks Stop the engine After the hydraulic oil has been cooled down remove cover 1 and drain the excess oil through drain plug P to the container for receiving the oil REMARK The oil level vary with the oil temperature Accordingly use the followings as a guide Before starting operation Between H and L levels Oil temperature 10 to 30 C Normal oper...

Page 222: ...e then re move the cap with care 1 Open the door on the rear left side of the machine NOTICE If the sub tank is empty leakage of coolant should be suspected After checking repair any abnormality im mediately REMARK If the inside of sub tank is so dirty that you cannot check the coolant level see METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 2 Check sub tank 1 If the coolant level is within the rang...

Page 223: ...oolant level is normal it is not a problem 1 Open the engine hood 2 Pull out dipstick G and wipe the oil off with a cloth 3 Fully insert dipstick G into the dipstick pipe then remove it 4 Check if the oil is sticking up to between marks H and L on dipstick G It is appropriate if the oil level is between marks H and L If the oil level is below the L mark add oil through oil filler port F 5 If the o...

Page 224: ...damage to the coating Perform inspection to confirm that there is no loose terminals and tighten any loose parts if found Always check if there is any accumulation of combustible material around the battery and remove such combustible material METHOD FOR CHECKING FUEL LEVEL ADDING FUEL k k WARNING When adding fuel never spill the fuel or let it overflow It may cause fire If any fuel has spilled wi...

Page 225: ...fuel filler cap F securely METHOD FOR CHECKING DEF LEVEL ADDING DEF PC210 11 PC210LC 11 k k WARNING Do not put fluid other than DEF into DEF tank When opening the cap of DEF tank of the machine the ammonia vapour may escape Keep your face away from the filler port Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder operation of the devices Before removin...

Page 226: ...ontainer Do not use a funnel when to add DEF The strainer may be broken When using a portable DEF refill container use up DEF each time If any of DEF is left remove for eign material if there is any Do not wash the adding nozzle in city water Minerals may clog the devices Do not dilute DEF with water If you add fluid other than DEF diesel fuel low concentration DEF etc by mistake the caution lamp ...

Page 227: ... 11 of the filler port and close the cap securely by turning it clock wise by 90 REMARK It is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop function to add DEF When the specified nozzle is used the magnet installed inside the filler port of the tank cancels the wrong fluid addition prevention device and you can add DEF This mechanism prevents ...

Page 228: ...reful of the DEF line to be added when performing operations on a slope or travelling on a rough ground When the remaining DEF level is low it may become the warning level if DEF pump sucks air or if DEF level suddenly drops If DEF is stored in unspecified container foreign material may mix in it and toxic gas or corrosive substance may be produced by chemical reactions When adding DEF do not tran...

Page 229: ...ap 3 counterclockwise The caps of DEF tanks are blue as required by emission regulations 5 By sight gauge 4 add DEF through the filler port until float 5 reaches line F 6 Refill capacity of DEF tank 23 1 ℓ Line 7 in the sight gauge indicates approximately 5 ℓ be low line F and line 8 indicates approximately 10 ℓ Line 9 is the max adding line when DEF may freeze in cold weather KS001169 OPERATION M...

Page 230: ...our hand and add DEF carefully while checking the sight gauge Add only DEF in clearly marked DEF tanks that have the blue cap METHOD FOR CHECKING WORKING LAMP Check that the working lamps and lamps inside the instruments light up properly Check also that there is no dirt or damage 1 Turn the starting switch to ON position 2 Check that the working lamp lights up properly when the lamp switch is at ...

Page 231: ...ing each operation or when the operators change shift Adjust the operator s seat so that control levers and switches can be operated freely and easily with the operator s back against the backrest METHOD FOR ADJUSTING SEAT IN FORE AND AFT DIRECTION Pull up the fore aft adjustment lever set the seat to the desired position then release the lever Fore and aft adjustment 160 mm 16 stages METHOD FOR R...

Page 232: ...le 2 to adjust the height Height adjustment 75 mm METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION Move the headrest up or down to the desired height Amount of adjustment 60 mm 2 stages NOTICE When adjusting the headrest height operate it so that the shaft of the headrest becomes straight If it is forcibly twisted the installation part may be broken METHOD FOR ADJUSTING ARMREST HEIGHT k k CAUTI...

Page 233: ...bottom of the armrest 5 Angle adjustment 9 in lower direction 4 in upper direction METHOD FOR ADJUSTING SEAT UNIT IN FORE AND AFT DIRECTION Pull the fore aft adjustment lever to the right set the seat to the desired position then release the lever The operator s seat right and left control levers and lock lever move together Fore and aft adjustment 180 mm 9 stages METHOD FOR ADJUSTING AIR SUSPENSI...

Page 234: ...ch retain heat such as blankets or floor cushions on the seat The seat heater will overheat and it can cause burn injury or failure Do not use it while the seat is wet If water or beverage is spilled immediately wipe it off with a dry cloth and dry it well Do not use the seat heater to dry the seat Turn the seat heater switch ON a OFF position b ON position The seat cushion and backrest become war...

Page 235: ... work make sure that the following conditions are met before starting the work The machine is placed on a firm level ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Mirror A Machine L H front mirror Mirror B Machine R H front mirror Mirror C Machine R H side mirror PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR A k k ...

Page 236: ...E Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L become equal If the mirror and stay mounting bolts are tightened excessively the bracket may be damaged Be sure to tighten bolts to the specified torque PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR A k k CAUTION To prevent the machine from moving during the work ...

Page 237: ...gm 2 Adjust mirror 6 Tightening torque of mounting bolt 7 6 0 to 7 0 Nm 0 61 to 0 71 kgm Mounting position 8 172 mm NOTICE Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L become equal If the mirror and stay mounting bolts are tightened excessively the bracket may be damaged Be sure to tighten bolts to the specified torque OPERATION MACH...

Page 238: ...CK position The engine is stopped Adjust the mirror so that you can see a person at the rear right of the machine 1 Adjust the mirror with your hand so that the side of the ma chine is reflected in the mirror as shown in the figure 2 Check that you can see a person at the rear right of the machine at a height of 1 2 m and a distance of 1 0 m from the machine 3 If you cannot adjust loosen mounting ...

Page 239: ...equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped Adjust the mirror so that you can see a person at the rear right of the machine 1 Adjust the mirror with your hand so that the side of the ma chine is reflected in the mirror as shown in the figure 2 Check that you can see a person at the rear right of the machine at a 1 2 m height and a d...

Page 240: ...he work make sure that the following conditions are met before starting the work The machine is placed on a firm level ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position The engine is stopped When returning the mirror to its regular position perform the following adjustment Adjust mirror 1 Tightening torque of mounting bolt 2 6 0 to 7 0 Nm 0 61 ...

Page 241: ...as shown in the figure PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR B PC210NLC 11 PC230NHD 11 k k CAUTION To prevent the machine from moving during the work make sure that the following conditions are met before starting the work The machine is placed on a firm level ground The work equipment is lowered to the ground in secure posture The lock lever is in LOCK position Th...

Page 242: ... tightened ex cessively the bracket may be damaged Be sure to tighten bolts to the specified torque Adjust the mirror so that the side of the machine is reflected in the mirror as shown in the figure PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR C k k CAUTION To prevent the machine from moving during the work make sure that the following conditions are met before starting the work The machine ...

Page 243: ...FASTENING SEAT BELT k k WARNING Before fastening the seat belt check that there is no problem in the belt mounting bracket or belt If it is worn or damaged replace it Even if no problem can be seen in the belt replace the seat belt every 3 years from starting usage or 5 years after manufacture whichever comes sooner Be sure to use the seat belt during operation Do not twist the seat belt when fast...

Page 244: ...lt is automatically wound in hold grip 2 and return the belt slowly to retractable device 1 REMARK If the tongue is not inserted in the buckle of the seat belt the seat belt caution lamp is displayed at the left top of the ma chine monitor Fasten the seat belt METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE k k WARNING When starting the engine check that the lock lever is se curely at LOCK...

Page 245: ...oportion al control slide switches otherwise the Neutral Detection System will recognise the wrong position as Neutral and this may result in unexpected movement of the Attach ment Next carry out the following checks 5 On the input display screen displayed on the monitor input the password and push input confirmation switch F6 3 If a password is set the input display screen will be indi cated on t...

Page 246: ...robably a failure in the caution lamp so ask your Komatsu distributor for repair 2 After approximately 2 seconds the screen changes to the working mode travel speed display Then it will switch to the standard screen DEF level gauge 9 DEF system caution lamp 10 Fuel gauge 11 Fuel level caution lamp 12 Hydraulic oil temperature gauge 13 Hydraulic oil temperature caution lamp 14 Engine coolant temper...

Page 247: ...onfined spaces be particularly careful to ensure good ventilation NOTICE Before starting the engine check that fuel control dial 2 is at Low idle MIN position If the fuel control dial is at High idle MAX position the engine will acceler ate suddenly and cause damage to the engine parts Do not keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the engin...

Page 248: ... input display screen will be indicated on the monitor screen but the preheating pilot lamp also operates as in the standard screen 4 If the preheating pilot lamp does not light up or it lights up and then goes out to inform that the engine pre heating has been completed turn the key in starting switch 3 to START position C The engine starts REMARK If the ambient temperature is low the engine may ...

Page 249: ...hawed auto matically after the engine starts The devices do not oper ate until DEF is thawed and supplied but this does not in dicate any abnormality When the ambient temperature decreases so much that DEF may freeze while the machine is in operation DEF system is warmed automatically to prevent freezing When the ambient temperature decreases so much that freezing of DEF is not preventable the dev...

Page 250: ...ect function is actuated the engine speed is held at approximately 1000 rpm or less even if the fuel control dial is operated When the turbo protect function is cancelled the engine speed is set to the speed for the position of the fuel control dial The actuation time of the turbo protect function is limited to 20 seconds REMARK White smoke may be discharged for a short time immediately after the ...

Page 251: ...on the environment the method of performing the warm up operation may differ so perform the warm up operation according to the descriptions given in the appropriate section The hydraulic equipment is not warmed by simply performing engine warm up operation Perform the warm up operations for the hydraulic equipment and engine separately Warm up of the hydraulic equipment thoroughly ensures that the...

Page 252: ...on for 5 minutes after the engine is started Avoid operation with heavy loads or at high speeds Immediately after starting the engine avoid sudden starts sudden acceleration unnecessary sudden stops and sudden changes in direction of the machine METHOD FOR ENGINE WARM UP OPERATION NOTICE Do not accelerate the engine abruptly until it is warmed up Do not run the engine at low idle or high idle unde...

Page 253: ...lamp background C is white If the engine coolant temperature caution lamp displays the proper temperature the engine warm up operation is completed Then perform the warm up operation for the hydraulic components METHOD FOR CANCELLING AUTOMATIC WARM UP OPERATION If it becomes necessary in an emergency to cancel the auto matic warm up operation or to lower the engine speed to low idle do as follows ...

Page 254: ...s no person or obstacle in the surrounding area then sound the horn and start the operation Perform the warm up operation for the hydraulic equipment until the hydraulic oil temperature caution lamp displays the proper temperature When the hy draulic oil temperature is low the low temperature dis play shown in the figure is given Display A when temperature is proper Caution lamp background C is bl...

Page 255: ...erature For detail see METHOD FOR ENGINE WARM UP OPERATION 2 Set swing lock switch 2 to ON position and check that the swing lock pilot lamp is lit 3 Set the working mode to P mode heavy duty operation mode The hydraulic component is warmed up quickly For the details of the working mode setting procedure see WORKING MODE SELECTOR SWITCH 4 Move lock lever 3 slowly to FREE position F then raise the ...

Page 256: ... hydraulic oil temperature caution lamp 7 displays proper temperature If the hydraulic oil temperature caution lamp is not displaying the proper temperature it is displaying low temperature repeat steps 6 to 7 until the monitor displays the proper temperature Display A when temperature is proper Caution lamp background C is blue Display B when temperature is low Caution lamp background C is white ...

Page 257: ...ny problem is found contact your Komatsu distributor NOTICE In cold temperatures ambient temperature below 0 C even when the hydraulic oil temperature caution lamp displays the proper temperature perform the Hydraulic system warm up operation in cold weath er to warm up all the hydraulic equipment 12 Hydraulic system warm up operation in cold weather 1 Turn fuel control dial 4 to High idle MAX pos...

Page 258: ...following operation 3 to 5 times Circulate warm hydraulic oil through all control circuits Boom operation RAISE E LOWER F Arm operation IN B OUT A Bucket operation CURL D DUMP C Swing operation LEFT G RIGHT H When performing swing operations release swing lock switch 2 check that the swing lock pilot lamp is OFF then operate the swing Travel Lo operation FORWARD A REVERSE B For attachment operatio...

Page 259: ...er temperature the hydraulic equipment warm up operation is completed After checking that the hydraulic oil temperature caution lamp displays the proper temperature perform the op eration after completion of the warm up operation METHOD FOR OPERATION AFTER COMPLETION OF WARM UP OPERATION 1 Check that hydraulic oil temperature caution lamp displays proper temperature Display A when temperature is p...

Page 260: ...ting operations B mode For breaker operations ATT P mode For operations of 2 way attachments like crusher ATT E mode For operations of 2 way attachments like crusher fuel economy conscious operations METHOD FOR STOPPING ENGINE k k WARNING Keep away from the exhaust pipe immediately after stopping the engine MACHINE OPERATIONS AND CONTROLS OPERATION 3 186 ...

Page 261: ...during the aftertreatment devices regeneration the components may be damaged When stopping the engine stop the aftertreatment devices regeneration first and run the engine at low idle for ap proximately 5 minutes Then stop the engine Stop the engine according to the following procedure 1 Operate the control grip g of the lock lever to set it se curely to LOCK position L 2 Run the engine at low idl...

Page 262: ...vices are operating to purge After the purge is completed the devices stop automatically METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND STOPPING MACHINE k k WARNING Before operating the travel levers or travel pedals check the direction of the track frame If the track frame is facing the rear if the sprocket is at the front the machine moves in the opposite direction to the direction o...

Page 263: ...t lock lever 4 to FREE position F Set the work equipment in the travel posture and raise it to 40 to 50 cm If the work equipment blocks the view and it is difficult to travel safely raise the work equipment further 2 Operate right and left travel levers 5 or right and left trav el pedals 6 as follows 3 Check the position of the sprocket When sprocket A is at the rear of the machine Start the machi...

Page 264: ...d it is difficult to travel safely raise the work equipment further 2 Operate right and left travel levers 5 or right and left trav el pedals 6 as follows 3 Check the position of the sprocket When sprocket A is at the rear of the machine Start the machine either by pulling levers 5 backward slowly or by depressing the rear parts of pedals 6 slowly When sprocket A is at the front of the machine Sta...

Page 265: ...rack frame is facing the position of the sprocket When the sprocket is at the front the directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine Use the travel levers to change direction Avoid sudden changes of direction to travel as much as possible Especially when performing counter rotation turn spin turn stop the machine befor...

Page 266: ...ION OF MACHINE When turning LEFT during straight travel A Forward left turn Return the left travel lever from FORWARD to NEUTRAL position The machine turns forward LEFT B Reverse left turn Return the left travel lever from REVERSE to NEUTRAL position The machine turns in reverse LEFT REMARK When turning to the forward RIGHT return the right travel lever from FORWARD to NEUTRAL position When turnin...

Page 267: ... outside the tracks Check that there is no one around the machine before operating the swing If the travel levers are operated when the engine speed is decreased by the auto deceleration function the en gine speed will suddenly increase Operate the levers carefully When you operate work equipment control lever the screen will switch to the screen including bird s eye view automatically When swingi...

Page 268: ...ill suddenly increase Operate the levers carefully When you operate work equipment control lever the screen will switch to the screen including bird s eye view automatically Use the R H and L H work equipment control levers to operate the work equipment When the levers are released they return to NEUTRAL position and the work equipment is held in that position Arm control Move the L H work equipme...

Page 269: ...be used for releasing the remaining pressure in the hydraulic cylinder circuits or for lowering the boom after loading the machine onto a trailer HANDLE WORKING MODE METHOD FOR SELECTING WORKING MODE Use working mode selector switch 1 to select the working mode that matches the operating conditions or purpose This will make it possible to perform operations efficiently Use the following procedure ...

Page 270: ...tch 1 The screen changes to the working mode selection screen 2 Press working mode selector switch 1 or function switch F3 or F4 to select the appropriate mode 3 After selecting the desired mode press function switch F6 to accept the change The screen returns to the standard screen If function switch F5 is pressed the screen returns to the standard screen without changing the mode If a working mod...

Page 271: ...e operating power increases as long as the switch is press ed REMARK However the increased power is automatically stopped after 8 5 seconds This function is not actuated when the working mode is set to L mode or B mode PROHIBITED OPERATIONS k k WARNING Do not operate the work equipment control lever when the machine is travelling If any lever is operated when the auto deceleration is being actuate...

Page 272: ...y extended PROHIBITION OF OPERATIONS USING BUCKET DROPPING FORCE Do not use the dropping force of the machine for digging nor use the dropping force of the bucket as a mattock breaker or pile driver This will drastically reduce the life of the machine PROHIBITION OF OPERATIONS USING BUCKET AS LEVER Do not put the bucket back to a rock and use it as a lever to dig This can apply an excessive force ...

Page 273: ... large vibration occurs in the machine and can crack the work equipment or frame If the bucket blade slides and collides with a rock an excessive impact load occurs in the work equipment and frame and can shorten the service life of the machine PROHIBITION OF DIGGING OPERATION ON HARD ROCKY GROUND Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavat...

Page 274: ...d damage the undercover and frame In the worst case the hydraulic components are dam aged and a serious accident can result During operation keep checking the track top for crushed stones soil and sand PROHIBITION OF SUDDEN LEVER OR PEDAL SHIFT DURING HIGH SPEED TRAVEL 1 Do not operate the levers and pedals suddenly nor take any other action to move the machine quickly 2 Do not operate the levers ...

Page 275: ...it may break the undercarriage parts When driving the machine for a long time check the track ten sion every 1 5 hours and adjust any looseness For the adjustment see MAINTENANCE METHOD FOR CHECKING AND ADJUSTING TRACK TENSION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR TRAVELLING Travelling over boulders tree stumps or other obstacles will cause a big shock to the chassis and in particular to the u...

Page 276: ...ar of the upper structure will go under water and water will be thrown up by the cooling fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in water or soil or sand deeper than the centre of upper carrier roller 1 After the job be sure to supply grease to the parts which have been under water for a long time until the used grease...

Page 277: ...y Always operate or travel in such a way that it is possi ble to stop safely at any time if the machine slips or becomes unstable When travelling uphill if the shoes slip or it is impos sible to travel uphill using only the force of the tracks do not use the pulling force of the arm to help the ma chine travel uphill There is danger that the machine may tip over Accordingly don t travel uphill wit...

Page 278: ...f DEF as necessary If the remaining DEF level becomes low sudden drop of its level or abnormality in urea SCR system may be detected If DEF level caution lamp or DEF system caution lamp lights up in red move the machine to a level place immediately and add DEF METHOD FOR ESCAPING FROM MUD Always operate carefully to avoid getting stuck in mud If the machine does get stuck in mud do as follows to g...

Page 279: ...ine is as shown in the figure angle between bucket cylinder and link and between arm cyl inder and arm is 90 the maximum excavation force is ob tained from the pushing force of each cylinder When excavating you can optimize your working efficiency by using this angle effectively The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle towards the machine There m...

Page 280: ...ou begin from the rear of the dump truck body than if loading is done from the side EFFECTIVE USE OF HYDRAULIC EXCAVATOR Operation for reducing fuel consumption Carbon dioxide emissions reducing operation The operating methods for reducing fuel consumption are as follows Avoiding unnecessary engine idle running Avoiding hydraulic relief Running at low engine speed Reducing excavation at high posit...

Page 281: ...es Stop the machine on a firm and flat surface and do the work When performing joint work appoint a leader and follow that person s instructions and signals METHOD FOR CHANGING BUCKET Replace the bucket according to the following procedure 1 Lower the bucket to the flat surface of the ground NOTICE After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at bot...

Page 282: ...f pin and cause abnormal wear of the pin METHOD FOR INVERTING BUCKET Invert the bucket according to the following procedure 1 Lower the bucket to the flat ground REMARK When removing the pins place the bucket so that it is in light contact with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to re move the pins NOTICE After remov...

Page 283: ...l the next use 6 Install the stopper bolts and nuts for each pin then grease the pins REMARK Lubricate with grease thoroughly until the grease comes out from the end faces When replacing the bucket replace the dust seal with a new one if it is damaged If a damaged one is used without being replaced sand and dirt may enter the part of pin and cause abnormal wear of the pin OPERATION MACHINE OPERATI...

Page 284: ...ndard machines METHOD FOR PARKING MACHINE k k WARNING Avoid a sudden stop Stop the machine gradually Place the machine on a firm and level place Do not park the machine on a slope If it is unavoidably necessary to park the machine on a slope block the tracks from movement As an addi tional safety measure thrust the work equipment into the ground If the control lever is touched by accident the mach...

Page 285: ...MIN position and lower the engine speed 3 Make the undercarriage and upper structure point to the same direction and lower the bucket to the ground with its bottom face horizontal 4 Operate the control grip g of the lock lever 3 to set it se curely to LOCK position L OPERATION MACHINE OPERATIONS AND CONTROLS 3 211 ...

Page 286: ... around the machine and check the work equipment machine exterior and undercarriage also check for any leakage of oil or coolant If any problems are found repair them 2 Fill the fuel tank 3 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove mud etc from the undercarriage if any LOCK Lock position Always lock the following places 1 Opera...

Page 287: ... key to CLOSE position B then remove the key METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pulling the cover handle Position A OPEN Position B LOCK METHOD FOR LOCKING COVER WITH LOCK 1 Close the cover and insert the key into the key slot 2 Turn the starting switch key to CLO...

Page 288: ...cause of its weight If the engine hood is not locked it may close suddenly because of wind etc Immediately after the engine is stopped the engine hood and aftertreatment devices are still hot Accordingly wait until they have cooled down before opening or closing the engine hood METHOD FOR OPENING ENGINE HOOD 1 Stop the machine on a level ground lower the work equipment to the ground then stop the ...

Page 289: ...can be locked at 2 different opening an gles However lock it to intermediate LOCK position 6 usually for inspection etc 8 To open the engine hood fully perform the following proce dure 1 Hold knob 4 and pull down the engine hood 2 Hold knob 7 and pull stay 5 in the direction of the arrow Stay 5 stops first at branch portion 8 of the guide groove OPERATION MACHINE OPERATIONS AND CONTROLS 3 215 ...

Page 290: ...ay 5 in the direction of the arrow and remove stay 5 from intermediate LOCK position 6 3 Check that stay 5 is set in guide groove 10 and then lower the engine hood k k CAUTION Do not lower the engine hood forcibly while stay 5 is not set in guide groove 10 If you do so stay 5 may be deformed Do not release knob 4 until the engine hood is low ered fully MACHINE OPERATIONS AND CONTROLS OPERATION 3 2...

Page 291: ...se the handle until the stay is set in the lock position securely When closing it hold the handle securely since the DEF tank filler cap cover may move down be cause of its own weight If it is not locked it may close suddenly because of wind etc METHOD FOR OPENING DEF TANK FILLER CAP COVER 1 Stop the machine on a level ground lower the work equipment to the ground then stop the engine 2 Insert the...

Page 292: ...4 Hold grip 1 unlock lock 2 and pull up the cover 5 Set stay 3 securely in position 4 to lock it MACHINE OPERATIONS AND CONTROLS OPERATION 3 218 ...

Page 293: ...e arrow while supporting the cover 2 Remove stay 3 from lock position 4 3 Check that stay 3 is set in guide groove 5 and then lower the cover Check that lock 2 is applied 4 Turn the key clockwise to lock and remove it Position A OPEN Position B CLOSE LOCK OPERATION MACHINE OPERATIONS AND CONTROLS 3 219 ...

Page 294: ...2 METHOD FOR LOCKING DEF PUMP COVER 1 Unlatch lock stay 2 and close cover 1 2 Lock cover 1 with the starting switch key Do not forget to pull the starting switch key out METHOD FOR OPENING AND CLOSING CAB DOOR When opening the door locked door 1 Insert the key into the key slot 2 Turn the key clockwise to unlock the key then open the door handle Position A OPEN MACHINE OPERATIONS AND CONTROLS OPER...

Page 295: ...n B CLOSE LOCK When locking the door 1 Close the door and insert the key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key OPERATION MACHINE OPERATIONS AND CONTROLS 3 221 ...

Page 296: ...ab is low the air conditioner may not work In this case circulate recirculation air to warm the inside of the cab After that turn the air conditioner switch ON the air conditioner will work If any abnormality is detected in any equipment or sensor used on the air conditioner the air conditioner system caution lamp lights up on the monitor screen If the air conditioner system caution lamp lights up...

Page 297: ...s used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH You can adjust the air flow by using the fan switch The air flow can be adjusted to 6 levels Press the switch to increase the air flow press the switch to decrease the air flow During auto operation the air flow is automati...

Page 298: ... 5 C Monitor display and function Monitor display C Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to set temperature 32 0 Max heating REMARK If the mode is set to auto mode and the temperature setting is set to 18 0 C or 32 0 C the air flow from the fan is always set to HIGH and does not change even when the temperature reaches the set value VENT SELECTOR SWITCH The ...

Page 299: ... mode AUTO SWITCH Use the auto switch for automatic selection of the air flow vents and air source FRESH RECIRC according to the set temperature Press this switch then use temperature control switch 1 to set the temperature and run the air conditioner under automatic control When switching from automatic operation to manual oper ation it is possible to use the switches to select the vents and air ...

Page 300: ...setting to take in fresh air or to demist the window glass DISPLAY MONITOR This monitor display indicates the status of temperature setting a air flow rate b and vents c When OFF switch 1 is pressed the display of temperature setting a and air flow rate b go out and operation stops AIR CONDITIONER SWITCH Use air conditioner switch for turning the air conditioner cool ing dry heating ON or OFF Pres...

Page 301: ...e the cab caused by changes in the strength of the sun s rays beforehand and automatically adjusts the temperature METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of operation as desired METHOD FOR AUTOMATIC OPERATION 1 Turn auto switch 1 ON Set temperature a and air flow b are displayed OPERATION HANDLE AIR CONDITIONER 3 227 ...

Page 302: ...o the set temperature and the air conditioner is operated auto matically to provide the set temperature REMARK When vent monitor c displays d or e and engine coolant temperature is low the air flow is automatically limited to pre vent cold air from blowing out METHOD FOR STOPPING AUTOMATIC OPERATION Press OFF switch 1 The air conditioner stops HANDLE AIR CONDITIONER OPERATION 3 228 ...

Page 303: ...adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Turn air conditioner switch 2 ON 3 Use temperature control switch 3 to set to the desired temperature OPERATION HANDLE AIR CONDITIONER 3 229 ...

Page 304: ...e monitor changes according to the selection 5 Press FRESH RECIRC air selector switch 5 and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH METHOD FOR STOPPING MANUAL OPERATION Press OFF switch 1 The air conditioner stops HANDLE AIR CONDITIONER OPERATION 3 230 ...

Page 305: ...ir blow ing to the feet set as follows 1 Press fan switch 1 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch 2 and set the vent display on the monitor to the display shown in the figure OPERATION HANDLE AIR CONDITIONER 3 231 ...

Page 306: ...3 Turn on the air conditioner switch 3 4 Adjust fan switch 1 temperature control switch 4 and FRESH RECIRC selector switch 5 to the desired posi tions HANDLE AIR CONDITIONER OPERATION 3 232 ...

Page 307: ... and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch 2 and set vent display on the monitor to f or g as shown in drawing OPERATION HANDLE AIR CONDITIONER 3 233 ...

Page 308: ...2 0 of maximum heating 5 Adjust vents A B1 and B2 so that the air blows onto the window glass Vents C and D are fixed and cannot be adjusted 6 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air turn on the air conditioner switch 5 HANDLE AIR CONDITIONER OPERATION 3 234 ...

Page 309: ...r button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX on it Press the button again to turn the power off BAND AUX SELECTOR BUTTON Press band AUX selector button to select the desired band or AUX Each time the button is pressed the band changes FM AM AUX FM VOLUME CONTROL BUTTON Use the volume control button to control the v...

Page 310: ...7 DISPLAY A Band name AUX frequency clock and other character numeric information are displayed B Frequencies are displayed at steps of 50 kHz in certain areas C Lights up when a stereo broadcasting is heard while a FM station is selected D Lights up at the time of balance adjustment in the sound adjusting condition E Lights up at the time of treble adjustment in the sound ad justing condition F L...

Page 311: ...djust the fre quency Press the button and the frequency increases press the button and the frequency decreases Hold down the button and the frequency increases continuously hold down the button and the fre quency decreases continuously Hold down the button and release it then the fre quency increases continuously Hold down the but ton and release it them the frequency decreases continuously as an ...

Page 312: ...While a frequency is displayed press button 1 of preset button 2 and the preset number P 1 appears on the display The preset number is shown for 0 5 seconds and then the frequency is displayed METHOD FOR REGISTERING PRESET Hold down one of 1 to 6 of preset button 1 while listening to the radio The currently received frequency is registered to the preset number corresponding to the pressed button E...

Page 313: ...W REGISTER RANGE BASS 1 Press sound control button 1 to light up BAS on the dis play You can adjust the low register range bass of the sound 2 Press tuning time adjustment button 2 to adjust the low register range bass Press the button and the low register range bass level increases by 1 Maximum 7 Press the button and the low register range bass level decreases by 1 Minimum 7 METHOD FOR ADJUSTING ...

Page 314: ...of antenna 1 and stow the antenna 1 to the bottom part 2 After stowing the antenna 1 tighten the bolt 2 to fix it SPACE FOR RADIO CASSETTE The radio cassette is not factory fitted If fitment is required 1 Remove front cover 1 2 Connect speakers and aerial to radio cassette Please contact your Komatsu distributor for a fitting instruction REMARK If radio is fitted in this location do not operate ra...

Page 315: ...e monitor screen Ask your Komatsu distributor to perform this work The machine monitor image may not be displayed due to darkness at night or in a tunnel fog snow rain cloud of dust etc Obstacles above the camera of the machine are not displayed Be careful enough of the work equipment of a large machine tree branches etc in high positions Reference line is displayed with reference to the flat grou...

Page 316: ...layed double or distortions or misalignment may occur in the shaded areas of the back of the machine A and B and the right of the machine C For the camera image the image shot by each of the loaded cameras is displayed Reference line is displayed as follows Display area Display colour Quadrangle A in which the rear of the machine is inscribed when the machine swings Red Quadrangle 2 m B in which t...

Page 317: ... that the weight and dimension given in SPECIFICATIONS weight and dimension may differ accord ing to the type of track shoe or arm or other attachments Consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard installed for the operator s cab Consult your Komatsu distributor for handling of the handrails when transporting the machine OPERATION ...

Page 318: ...he work equipment for loading and unloading operations Always use ramps The centre of gravity of the machine shifts suddenly at the joint between the ramps and the trailer and it is dangerous that the machine loses its balance Accordingly pass this point slowly If it is necessary to swing the upper structure on the trailer platform the footing is unstable so be extreme ly careful that the machine ...

Page 319: ...mps to prevent them from bending 4 Push travel speed selector switch 5 to set the travel speed to low Lo lights up The travel speed Lo Mi Hi is displayed on travel speed display 6 5 Turn auto deceleration switch 7 OFF and operate the fuel control dial to set the engine to low speed Each time auto deceleration switch 7 is pressed it switches OFF to ON to OFF in turn When auto deceleration switch 7 ...

Page 320: ...f the trailer 9 Set the travel direction toward the ramps and drive slowly Lower the work equipment as far as possible without caus ing interference On the ramps operate only the travel lever Do not operate any other lever 10 When loading a machine with the work equipment instal led at the point where the tracks are on both the ramps and the ground surface turn the swing lock switch OFF 11 Swing t...

Page 321: ...enna see STOW ANTENNA For stowing mirror see PROCEDURE FOR AD JUSTING MACHINE LEFT FRONT MIRROR A To prevent damage to the bucket cylinder during transportation put a wooden block under the tip of the bucket link to prevent the bucket cylinder from touching the floor Check that the engine hood catcher is locked Hold the handle of the engine hood and raise it slight ly If it does not open the catch...

Page 322: ...oors covers and caps Select the way of secure the machine according to the transportation form of each territory from the following METHOD FOR SECURING MACHINE WITH TIE DOWN POINT Tie one end of each chain or wire rope of appropriate strength to the tie down holes on the track frame X 50 to 100 mm Keep the chains off the track frame F Forward travel direction R Reverse travel direction TRANSPORTAT...

Page 323: ... METHOD FOR REMOVING AND INSTALLING MIRROR If they are to be removed for shipment or are to be installed again perform the following procedure After installation of mirror always adjust it For details see METHOD FOR ADJUSTING MIRRORS METHOD FOR REMOVING MIRROR Mirrors A B 1 Loosen mounting bolt 2 then remove mirror 1 from sup port 3 2 Loosen bolt 4 and remove support 3 and clamp 5 from the handrai...

Page 324: ...efore inspection and maintenance Use the crane etc for carrying the handrails There is a danger of rolling over or falling from high place that can lead to serious personal injury or death Check the scaffolding and ensure your safety before starting the work If installation or removal work of the handrail is improper there is a hazard that someone may fall from the machine during the installation ...

Page 325: ... tighten them with bolts 1 Tightening torque 98 to 123 Nm 10 0 to 12 5 kgm METHOD FOR REMOVING AND INSTALLING REVOLVING WARNING LAMP METHOD FOR REMOVING AND INSTALLING CAB PARTS METHOD FOR REMOVING CAB PARTS NOTICE If the door is opened completely while door stoppers are removed there is a danger that the door may be damaged by hitting the cab Do not open the door completely while the door stopper...

Page 326: ...n adaptor 4 to remove stoppers 1 and 2 Do not loosen nut 5 silver of stopper 1 and nut 6 black of stopper 2 There is a danger that the door may be damaged 2 Removal of striker TRANSPORTATION OPERATION 3 252 ...

Page 327: ...ve striker 3 Keep the removed parts and removal procedure manual in the magazine box 3 Covering stoppers and striker Cover the mounting holes of stoppers and striker with tape b etc to prevent dust from entering the holes METHOD FOR INSTALLING CAB PARTS 1 Removal of covering of stoppers and striker OPERATION TRANSPORTATION 3 253 ...

Page 328: ...of stoppers Tighten adaptor 4 to install stoppers 1 and 2 Tightening torque for adaptor 4 59 to 98 Nm 6 0 to 10 0 kgm 3 Installation of striker 1 Tighten nuts 8 2 places to install striker 3 2 Install cap 7 to inside the door picking protrusion a of cap 7 with fingers TRANSPORTATION OPERATION 3 254 ...

Page 329: ... upside METHOD FOR REMOVING REVOLVING LAMP Remove the revolving lamp according to the following procedure 1 Remove connector A of the revolving lamp When removing the connector pull it out while pressing the claw in the center of the connector OPERATION TRANSPORTATION 3 255 ...

Page 330: ...wn lock D of revolving lamp bracket C 4 Remove the hook of lock D from the claw of base bracket E 5 Hold grip G and turn it clockwise seeing it from the rear of the machine 6 Remove revolving lamp bracket C from the claw of base bracket E k k CAUTION When removing and installing the revolving lamp be sure to hold grip G instead of lamp itself to prevent damage TRANSPORTATION OPERATION 3 256 ...

Page 331: ...REVOLVING LAMP 1 Hold grip G and turn it counterclockwise seeing it from the rear of the machine At this time insert revolving lamp bracket C into the re volving lamp fixing claw side of base bracket E and in stall it 2 Install the hook of lock D to base bracket E OPERATION TRANSPORTATION 3 257 ...

Page 332: ...arallel to each other and equally spaced to the right and left of centre 3 of the trail er Make angle of installation 4 a maximum of 15 If the ramps bend a large amount under the weight of the machine put blocks under the ramps to prevent them from bending 4 Remove the chains and wire ropes fastening the machine 5 Start the engine Warm the engine up fully in cold weather 6 Operate the operating po...

Page 333: ...the machine 11 Set the angle between the arm and boom to 90 to 110 NOTICE When unloading the machine always set the angle be tween the arm and boom to 90 to 110 If the machine is unloaded while the arm is IN it will cause damage to the machine 12 Lower the bucket to the ground NOTICE Do not hit the bucket against the ground to prevent damage to the hydraulic cylinders 13 With the bucket lowered to...

Page 334: ... losing its balance NOTICE This method of lifting applies to the standard specification machine The method of lifting differs depending on the attachments and options installed For details of the procedure for machines other than the standard specification machine consult your Komatsu distributor For the weight see SPECIFICATIONS 5 1 When lifting the machine perform the operation on flat ground as...

Page 335: ...rollers pass the wire ropes under the tracks When the wire rope contacts with the edge of the machine put wooden block or backing metal between them 8 Set the lifting angle A of the wire rope to 30 to 40 then sling the machine slowly 9 After the machine comes off the ground check the hook condition and the lifting posture and then sling the ma chine upward slowly OPERATION TRANSPORTATION 3 261 ...

Page 336: ...ine Engine Coolant AF NAC see METH OD FOR CLEANING INSIDE OF COOLING SYSTEM DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break the devices in the tank The parts inside the tank may be affected Add DEF to the specified amount for cold weather below the level of when DEF may freeze For the specified amount of DEF see METHOD FOR CHECKING DEF LEVEL ADDING DEF PC210 11 PC2...

Page 337: ...serve the following precautions Remove all the mud and water from the machine body In particular wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud dirt or drops of water on the rod from getting inside the seal Place the machine on a firm dry ground If this is impossible park the machine on boards The boards prevent the tracks from freezing to the ground and allow t...

Page 338: ...il for all equipment with the ones of the specified viscosity For details see RECOM MENDED FUEL COOLANT AND LUBRICANT 7 5 If the machine is parked for long time in the cold weather condition quality of DEF may be affected by repeated freeze ask your Komatsu distributor to inspect COLD WEATHER OPERATION OPERATION 3 264 ...

Page 339: ...n Install the blind plugs to the elbows For explanation of LOCK and FREE states of the stop valve see METHOD FOR REMOVING AND IN STALLING ATTACHMENT To prevent rust fill the cooling circuit with Non Amine Engine Coolant AF NAC to give a density of at least 30 for the engine coolant MAINTENANCE DURING LONG TERM STORAGE k k WARNING If it is necessary to perform the rust prevention operation while th...

Page 340: ...HOD FOR ENGINE WARM UP OPERATION If the machine has been stored for more than 2 months perform the following procedure Before starting the engine replace DEF filter and fill up DEF tank according to the procedure in METHOD FOR REPLACING DEF FILTER Start the engine and check that SCR system is free from abnormality If SCR system has any abnormality warning is displayed on the monitor screen and the...

Page 341: ...ted IN from a high position for dig ging under no load the arm speed drops momentarily at the vertical position When performing bucket CURL operation from a high posi tion for digging under no load the bucket speed drops mo mentarily at the horizontal position The bucket or arm wobbles by itself during heavy duty dig ging operations When starting or stopping the swing a noise is generated from the...

Page 342: ... towed machine Move the machine slowly and be careful not to apply any sudden load to the wire rope Do not use the holes for towing light objects or tie down holes when towing the machine NOTICE The maximum towing capacity for this machine is 158000 N 16100 kg Do not tow any load greater than this If the machine sinks in mud and cannot get out under its own power or if the machine tows a heavy obj...

Page 343: ... not to apply any sudden load to the wire rope Do not use the tie down holes for towing the machine There is a hole in the track frame to fit the shackle when towing light objects Permissible towing load Max 58800 N 6000 kg PRECAUTIONS FOR SEVERE JOB CONDITION When performing digging operations in water if the work equipment mounting pin goes into the water per form greasing every time the operati...

Page 344: ...ling batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the ground normally the negative terminal When installing first connect the cable to the positive terminal If a tool touches the positive terminal and the chassis it is dangerous that it may cause a spark Be extremely careful If the terminals are loose it is dangerous that ...

Page 345: ...he battery then connect the negative charger clip of the charger to the nega tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or the battery cells will dry up and this...

Page 346: ... machine must be the same capacity as that of the failed machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected Check that the lock levers and parking brake levers if equipped of both machine are in LOCK posi tion Check that each lever is in NEUTRAL position To prevent damage of the electric devices of the failed machine turn the startin...

Page 347: ...ove the clip of jumper cable A from the positive terminal of battery C on the failed machine OTHER TROUBLE PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM For the remedies indicated with in the remedy column always contact your Komatsu distributor In cases of problems or causes which are not listed below ask your Komatsu distributor for repairs Problem Main causes Remedy Lamp does not glow brightly ev...

Page 348: ... pressure caution switch Replace When startability at low temperature is poor if you touch the outside of the electric heater by hand after pre heating it is not felt warm Defective wiring Check repair Wire breakage in electrical intake air heater Replace Defective operation of heater relay Replace Fuse of the heater is blown Replace Engine does not start L04 lights up on monitor Damaged data in t...

Page 349: ...ng in air Set it to specified oil level See CHECKS BEFORE STARTING Improper oil is used Viscosity is im proper Replace oil See USE OF FUEL COOLANT AND LUBRICANTS AC CORDING TO AMBIENT TEMPERA TURE and KOMATSU GENUINE LU BRICANTS Clogged oil filter cartridge Replace cartridge See EVERY 500 HOURS MAINTENANCE Oil leakage due to improper connec tion or breakage of oil pipe or pipe joint Check repair D...

Page 350: ...TE NANCE Defective fuel injection pump or de fective nozzle Replace pump or nozzle Starting motor turns engine sluggish ly See ELECTRICAL SYSTEM Preheating pilot lamp does not light up See ELECTRICAL SYSTEM Defective compression Defective valve clearance Adjust valve clearance Exhaust gas color is white or bluish Water entry in KDPF Check repair Broken KDPF Replace KDPF Excessive oil in oil pan Se...

Page 351: ...9 appears on the Current Abnormality screen re place both fuel main filter and fuel pre filter immediately For details of replacement see METHOD FOR REPLACING FUEL PRE FILTER CARTRIDGE and METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE If CA2249 or CA559 does not disappear even after the replacement ask your Komatsu distributor for inspection immediately even though the machine can perform normal...

Page 352: ......

Page 353: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 354: ...ing oil or fuel PRECAUTIONS FOR ADDING DEF Do not remove the strainer while adding DEF It is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop function to add DEF WELDING INSTRUCTIONS When performing welding turn the starting switch to OFF position check that the system operating lamp is not lit Turn the battery disconnect switch to OFF position a...

Page 355: ...denly shut by the wind and cause personal injury BLEED AIR FROM HYDRAULIC CIRCUIT When hydraulic equipment is repaired or replaced or the hydraulic piping is disconnected the air must be bled from the circuit PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with new parts When doing this...

Page 356: ...t according to the ambient temperature For details see RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 CLOSE ENGINE HOOD SECURELY When closing the engine hood after inspection or maintenance make sure that the catch is securely locked If the engine hood catch is not locked there is a danger that the engine hood may open PRECAUTIONS FOR MAINTENANCE MAINTENANCE 4 4 ...

Page 357: ...dy always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too much oil or too little oil a...

Page 358: ... anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu recommends the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious problems such as corrosion of the engine and aluminum parts of the cooling system When using antifreeze always observe the precautions given in Operation and Maintenance Manual Non Amin...

Page 359: ...com mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual Grease fittings not included in the periodic maintenance section are the grease fittings for overhaul so they do not need grease If any part becomes stiff after being used for long time add grease Always wipe off all of the old grease that is pushed out when gr...

Page 360: ...o protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first STORE DEF Completely seal up its container for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container Make sure that transfer equip ment and tank must meet DEF compatible ...

Page 361: ...witch someone may turn ON the power by mistake It is dangerous that causes an electric shock It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is damaged This will cause an electrical leakage and may lead to malfunction of the machine Do not wash the inside of the operator s cab with water When washing the machine be careful not to let water get into t...

Page 362: ...s the part that is removed Thread diame ter of bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 11 8 14 7 27 34 59 74 98 123 153 190 1 2 1 5 2 8 3 5 6 0 7 5 10 0 12 5 15 5 19 5 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 0 52 3 70 3 90 0 235 285 320 400 455 565 610 765 ...

Page 363: ...arget value Allowable range Nm kgm Nm kgm 02 19 44 4 5 35 to 54 3 5 to 5 5 03 22 74 7 5 54 to 93 5 5 to 9 5 04 27 103 10 5 84 to 132 8 5 to 13 5 05 32 157 16 0 128 to 186 13 0 to 19 0 06 36 216 22 0 177 to 245 18 0 to 25 0 10 41 215 22 0 176 to 234 18 0 to 24 0 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4 11 ...

Page 364: ...SYSTEM 4 38 PERIODIC CHECKS 4 38 REFILLING GREASE 4 39 GREASING PROCEDURE 4 39 SYSTEM TEST 4 39 CHECKS BEFORE STARTING 4 40 EVERY 100 HOURS MAINTENANCE 4 41 METHOD FOR LUBRICATING WORK EQUIPMENT 4 41 EVERY 250 HOURS MAINTENANCE 4 42 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 4 42 METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 4 44 EVERY 500 HOURS MAINTENANCE 4 45 METH...

Page 365: ...CONTROL CIRCUIT 4 75 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR OPERATION 4 75 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIPING CLAMP HARD ENING OF RUBBER 4 76 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 76 EVERY 4500 HOURS MAINTENANCE 4 77 METHOD FOR CLEANING KDPF 4 77 REPLACE KCCV HOSE 4 77 METHOD FOR CLEANING DEF TANK 4 77 METHOD FOR REPLA...

Page 366: ...AKER 6 54 Replace pilot filter element if equipped Use a guideline of 250 hours for use of the breaker operating ratio of the breaker 50 or more and replace the element ac cording to the table For detail see METHOD FOR REPLACING ADDITIONAL PI LOT FILTER ELEMENT FOR BREAKER 6 55 X Breaker operating ratio Y Replacement interval H A Hydraulic tank element pilot filter element B Hydraulic oil C Elemen...

Page 367: ...inner element If any dirt enters the engine it can damage the engine Be sure to stop the engine before checking cleaning or servicing the air cleaner Do not check clean or service the air cleaner when strong wind is blowing or in a dusty place When replacing the inner element take extreme care Replace the outer element if it is cleaned 6 times repeatedly or used throughout a year Replace the inner...

Page 368: ... or dust from entering 5 Clean dusts in inside and on cover 3 of air cleaner body 7 by using a clean cloth or brush 6 If any dust is attached to vacuator valve 4 installed to cover 3 remove it 7 When the outer element has been cleaned 6 times or used for 1 year replace it When the element needs to be replaced Replace the inner and outer elements with new ones For details see METHOD FOR REPLACING E...

Page 369: ...cing in the correct direction Install so that the bottom of the air cleaner element face where no hole is drilled B C comes to cover 3 end If it is installed in wrong direction it may cause breakage of the air cleaner element or serious damage to the engine When inserting the element into the body if the rubber at the tip is swollen or outer element 4 is not pushed in straight and cover 3 is insta...

Page 370: ...l If it light up just after cleaning of the elements has been finished replace the inner and outer elements METHOD FOR CHANGING AIR CLEANER ELEMENT NOTICE Do not clean and reuse the inner element When replacing the outer element replace the inner ele ment with a new one at the same time If the outer element and cover are installed while the inner element is not installed properly the out er elemen...

Page 371: ...4 installed to cover 3 remove it 6 Remove inner element 6 then quickly install the new in ner element Install the inner element securely so that it does not move 7 Push new outer element 5 in straight with your hand into the air cleaner body Hold the element and rock it lightly up and down and to the right and left while pushing it in the element can be inserted easily 8 Install cover 3 according ...

Page 372: ...OCK position to prevent the machine from moving When the undercover is removed there is a danger of touching the fan Never enter in the rear part of the machine when the engine is running Place the machine on a level ground when cleaning or changing the coolant Clean the inside of the cooling system change the coolant according to the table Coolant Cleaning of inside of cooling system and re place...

Page 373: ...ide of the cooling system according to the following procedure 1 Place the machine on a level ground then stop the engine 2 Open engine hood 1 3 Check that the coolant temperature is low enough to make it possible to touch the radiator cap surface by bare hand turn radiator cap 2 slowly until it hits the stopper and re lease the pressure 4 While pushing radiator cap 2 turn it until it touches to t...

Page 374: ...oint of 2 3 between Low idle MIN position and High idle MAX position NOTICE When the work equipment is operated take care that it does not interfere with the machine or ground 14 Operate the work equipment control levers according to the following procedure 1 Move the R H work equipment control lever slowly in the direction to the bucket CURL side D Operate the lever to the end of its travel and h...

Page 375: ...n for approximately 10 minutes 15 Stop the engine and open drain valve 3 to drain the cool ant 16 Open the door at the rear left of the machine drain the coolant from sub tank 5 clean the inside of the sub tank then fill with coolant up to the middle between FULL and LOW marks NOTICE If the sub tank is extremely dirty and it is difficult to clean replace it with a new one 17 After draining the coo...

Page 376: ... level is between FULL and LOW marks it is proper If it is insufficient fill with Non Amine Engine Coolant to the middle between FULL and LOW marks 24 Close engine hood 1 METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS NOTICE If the machine is used with track shoe bolts loose they will break If any looseness of the shoe bolt is found retighten it 1 Check for looseness of the shoe bol...

Page 377: ...dard deflection Deflection a should be 10 to 30 mm If the deflection is out of the standard value range adjust it into the standard value range METHOD FOR INCREASING TRACK TENSION Items to be prepared Grease pump 1 Pump in grease through grease fitting 2 by using a grease pump Grease fitting 2 forms one part with plug 1 2 To check if the tension is correct run the engine at low idle move the machi...

Page 378: ...he above procedure ask your Komatsu distributor for repair METHOD FOR REPLACING BUCKET TEETH VERTICAL PIN TYPE Replace the bucket teeth before the adapter starts to wear k k WARNING It is dangerous if the work equipment moves by mistake when the tooth is being replaced Set the work equipment in a stable condition set the lock lever securely to LOCK position and stop the engine As the pin is driven...

Page 379: ...oken The steel ball sinks The rubber of the rubber pin lock is deteriorated and steel ball 7 sinks into it when you press it 6 Remove the soil stuck to adapter 4 by using a knife 7 Use your hand or a hammer to push rubber pin lock 3 in to the hole of adapter 4 When doing this be careful that rubber pin lock 3 does not fly out from the adapter surface 8 Clean the inside of teeth 1 then install it t...

Page 380: ... Confirm that rubber pin lock 6 and lock pin 2 are set as shown in the right figure REMARK If the tooth is turned the wear will become uniform This will extend the service life of the tooth and reduce the frequency of replacement When replacing the tooth replace the rubber pin lock and lock pin with new parts at the same time This will prevent the tooth from falling out METHOD FOR REPLACING BUCKET...

Page 381: ...EMARK If it cannot be removed by this method ask your Komatsu distributor to have the replacement performed 4 Clean the mounting face Fit a new tooth 2 in the adapter push in pin 1 partially by hand then lock it with a hammer to install the tooth to the bucket METHOD FOR ADJUSTING BUCKET CLEARANCE k k WARNING It is dangerous if the work equipment moves by mistake when adjusting the bucket clearanc...

Page 382: ...olt 5 for easier tightening 6 Arm 7 Bucket Example In the case of play of 3 mm remove 1 0 mm 2 pieces shims and 0 5 mm 1 piece shim Play becomes 0 5 mm METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL ADDING FLUID 1 If air is in the window washer fluid check the fluid level in window washer tank 1 2 If the level is low add window washer fluid for automobile Be careful not to let dirt or dust get in w...

Page 383: ...mechanism Operating condition Check that func tion is normal When required Piping mounts Mounting condition looseness at tightening or connecting portions leakage of gas damage When required Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of the compressor CHECK LEVEL OF REFRIGERANT GAS k k WARNING If the refrigerant used...

Page 384: ...securely to LOCK position L before leaving the operator s seat Select a firm flat place for work When setting the machine at an angle use strong blocks to stabilize the base of the machine and be extremely care ful when performing the work METHOD FOR CLEANING WASHABLE FLOOR MAT 1 Stop the machine on a level ground lower the bucket to the ground stop the engine and then perform the cleaning 2 When ...

Page 385: ... by using blocks 2 Swing the upper structure slowly so that water drain holes 3 in the cab floor are at a low position 3 Lower the work equipment to the ground and set the ma chine in a stable condition 4 Operate the operating portion g of the lock lever 1 to set it securely to LOCK position L and stop the engine MAINTENANCE MAINTENANCE PROCEDURE 4 33 ...

Page 386: ...ojections 2 into the holes METHOD FOR SETTING MACHINE AT ANGLE You can set the machine at an angle by using a slope or blocks Consider the condition of the machine and select the safe method METHOD FOR USING SLOPE k k WARNING Select a solid and smooth slope Always block the tracks from movement and thrust the work equipment into the ground 1 Stop the machine with the work equipment on the downhill...

Page 387: ...en doing this check that the machine is always stable METHOD FOR CHECKING GAS SPRING k k WARNING The gas spring is charged with high pressure nitrogen gas so improper handling may cause an explo sion resulting in serious personal injury or death When handling always observe the following Do not disassemble Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling ...

Page 388: ...he hydraulic tank 3 After completing the air bleed operation tighten air bleeder 1 and install the drain hose METHOD FOR STARTING ENGINE Start the engine according to OPERATION METHOD FOR STARTING ENGINE and run it at low idle for 10 minutes and then start the following work METHOD FOR BLEEDING AIR FROM CYLINDER NOTICE If the engine runs at high speed immediately after startup or a cylinder is ope...

Page 389: ...ill automatically bleed the air from the swing circuit When replacing the swing motor safety valve ask your Komatsu distributor for the replacement and the air bleeding METHOD FOR BLEEDING AIR FROM TRAVEL MOTOR Bleed air only when the oil inside the travel motor case is drained 1 Run the engine at low idle loosen air bleeder 4 and tighten it when oil flows out 2 Run the engine at low idle and swin...

Page 390: ... and wipe off any oil that is spilled 4 After completing the air bleeding operation check the oil level and if the oil level is low add oil METHOD FOR CHECKING CAMERA VISIBILITY The direction of camera may be changed by a shock to the camera Check the visibility of the camera Put a traffic cone on a stand at the position approximately 1 m A rearward from the rear end of the machine and approxi mat...

Page 391: ...ir must be refilled as soon as possible GREASING PROCEDURE 1 Remove the dust cap from the filler coupling 7 2 Carefully clean the filter coupling 7 and the filler coupling on the filler hose 3 Fix the filler hose onto the filler coupling 7 4 Fill the reservoir up to the maximum level indicated on the reservoir 8 5 Remove the filler hose and fit the dust cap 6 Fix the filler hose onto the filler co...

Page 392: ... sec on 0 2 sec off 3 The continuous test cycle ends after the starter switch is moved to the OFF position A A test cycle can only be started when the system is not in the pump phase of a current greasing cycle If the system is busy with a pump cycle it will not react to the test push button NOTICE Only use grease tests cycles if necessary Every time a test cycle is carried out grease is added to ...

Page 393: ...he first 50 hours operation on a new machine After the machine is subjected to digging work in the water be sure to grease the wet pins Items to be prepared Grease pump 1 Park the machine on a level and firm ground lower the work equipment to the ground in the posture shown in the figure and stop the engine 2 By using a grease pump pump in grease through the grease fittings shown by arrows 1 Arm L...

Page 394: ...E Do not add the electrolyte to the battery exceeding UPPER LEVEL line If the electrolyte level is too high it may leak and cause damage to the paint surface or corrode other parts If there is a fear that the battery water may freeze after refilling with purified water such as a commer cial battery fluid do the replenishment before the day s work on the next day Open cover 1 at the rear left of th...

Page 395: ...r a battery manufacturer METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO CHECK FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery or there is no UPPER LEVEL line on the side of the battery check as follows 1 Remove cap 4 at the top of the battery and check the electrolyte level through electrolyte filler port 5 2 If the electrolyte d...

Page 396: ...ING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION The followings are the periodic maintenance items for the air conditioner Perform inspection and maintenance to use the air conditioner effectively METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 1 Remove bolts 2 2 pieces 2 Remove guard 1 3 Press the center between drive pulley A and compressor pulley B with a finger approximately 60 N ...

Page 397: ...touches boss 7 then tight en it further in direction B to prevent it from loosening Tightening torque108 to 132 Nm 11 0 to 13 5 kgm 9 After fixing check again that the belt tension is proper Adjust it again if the tension is not within the proper range 10 Check each pulley for damage wear of the V groove and the wear of the V belt In particular be sure to check that the V belt is not touching the ...

Page 398: ...form the greas ing every 100 hours 1 Set the work equipment on the level and firm ground in the maintenance posture as shown in the figure then lower it to the ground and stop the engine 2 By using a grease pump pump in grease through the grease fittings shown by arrows 1 Boom cylinder foot pin 2 places 2 Boom foot pin 2 places 3 Boom cylinder rod end 2 places 4 Arm cylinder foot pin 1 place 5 Boo...

Page 399: ...lf lower the lever of drain valve P slowly drain the oil then raise the lever to close the valve 3 Open the rear right cover 4 Turn filter cartridge 1 counterclockwise by using the filter wrench and remove it 5 Clean the filter head 2 fill the new filter cartridge with clean engine oil coat the thread and packing surface of the new filter cartridge with clean engine oil or thinly apply the grease ...

Page 400: ...s generated inside the engine fuel piping system when the engine is running When replacing the filter wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter Do not bring any open flame close NOTICE Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing parts Komatsu reco...

Page 401: ...the packing surface then install it to the filter head NOTICE When filling the filter cartridge with fuel do not re move cap B Always fill with fuel from 8 small holes A on the dirty side After filling with fuel remove cap B and install the fuel filter Always fill with clean fuel Be careful not to let any dirt or dust get into the fuel In particular center portion is the clean side so do not remov...

Page 402: ...filter head When the engine runs out of fuel use the same procedure to operate feed pump 7 and bleed the air 18 After bleeding air push in the knob of feed pump 7 19 After replacing the filter cartridge start the engine and run it at low idle for 10 minutes 20 Check for leakage of oil from the filter seal surface and transparent cup mounting face If the leakage is noticed check the filter cartridg...

Page 403: ...with bolt 1 METHOD FOR LUBRICATING SWING CIRCLE Lower the work equipment to the ground 1 By using a grease pump pump in grease through the grease fittings shown by arrows 2 places 2 After greasing wipe off any old grease that is pushed out METHOD FOR CHECKING AND CLEANING RADIATOR FINS OIL COOLER FINS AFTERCOOLER FINS FUEL COOLER FINS AND AIR CONDITIONER CONDENS ER FINS k k WARNING If compressed a...

Page 404: ... used instead of the com pressed air However when performing powerful steam cleaning high pressure machine wash of the heat exchange equipment oil cooler radiator after cooler air conditioner condenser or fuel cooler maintain sufficient distance from the machine when performing the work If steam cleaning high pressure machine wash is performed at close distance there is a danger that the internal ...

Page 405: ...ys wear protective equipment such as protective eyeglasses and dust mask NOTICE The cleaning interval of 500 hours is a rough standard Clean at shorter intervals in dusty jobsites REMARK If the element becomes clogged the air flow will be reduced and there will be a rumbling sound from the air conditioner unit METHOD FOR CLEANING RECIRCULATION AIR FILTER 1 Remove wing bolts 1 from the inspection w...

Page 406: ...essive force it may be deformed or damaged If the filter is damaged or deformed replace it with new one 3 Clean the filter with compressed air Set the compressed air pressure below 0 49 MPa 5 kg cm2 and blow it in the arrow direction If there is oil on the filter or if the filter is extremely dirty wash it in a neutral detergent After rinsing it in water dry it thoroughly before using it again Rep...

Page 407: ...of duct 6 5 Close the cover and lock with the starting switch key Do not forget to remove the starting switch key after lock ing METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work 1 Remove dipstick G a...

Page 408: ...l level reaches a point 10 mm below the bot tom of the plug hole the oil level is appropriate If the oil level is low check it again according to the follow ing procedure 1 Install plug F 2 Operate the travel lever to move the machine forward or reverse and rotate the sprocket by 1 turn 3 Then repeat Step 2 to check again 3 If the oil is insufficient add oil through plug F hole Add oil until oil o...

Page 409: ... BREAKER Items to be prepared Container to catch drained oil 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 for oil filler F and release the internal pressure 3 Loosen the bolts 6 pieces and remove cover 1 The cover may be jumped out by spring 2 While pressing down the cover rem...

Page 410: ...inutes and then start it This will remove the air bubbles in the oil inside the tank 13 Check that there is no leakage of oil and wipe off any oil that is spilled METHOD FOR CHANGE OIL IN SWING MACHINERY CASE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work Refill...

Page 411: ... ADDING OIL IN DAMPER CASE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work NOTICE Park the machine on flat ground and stop the engine When more than 30 minutes elapse after stopping the engine check the oil level 1 Open the door on the right side of the machine 2...

Page 412: ...m used on this machine consists of more precise parts than those in the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a substitute When performing inspection and maintenance of the fuel system be careful not to let any dirt or dust get in more than ever b...

Page 413: ...ridge 2 bleed air from the circuit METHOD FOR STARTING ENGINE USING FUEL FEED PUMP 1 Fill up the fuel tank with fuel to the level where the float is at the highest position 2 Loosen the knob of feed pump 4 pull it out then pump it in and out until the movement becomes heavy 3 Push in and tighten the knob of feed pump 4 4 After replacing the filter cartridge start the engine and run it at low idle ...

Page 414: ...ury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pres sure then remove it 1 Remove nut 2 of breather assembly 1 at the top of the hydraulic tank 2 Remove cover 3 3 Replace filter element 4 with a new one 4 Install cover 3 and nut 2 In order not to damage the threaded portion of nu...

Page 415: ...tes Replace the element after DEF system devices stop Improper assembly of DEF tank breather element may cause leakage of DEF Replace the element in the correct procedure 1 Open DEF tank cover at the right of the machine upward 2 Remove nut 2 of breather assembly 1 at the top of DEF tank then remove cover 3 3 Replace breather 4 with a new one 4 Install cover 3 and nut 2 In order not to damage the ...

Page 416: ...l under plug P 3 Remove plugs P and F by using the handle and drain oil Check O rings attached to the plugs for damage If neces sary replace them with new ones 4 Tighten plug P 5 Refill oil through plug F hole Plug F is installed at 2 places Add oil through the one with which it is easier to add oil and through which no in ternal gears are seen 6 When oil begins to overflow from the plug F hole in...

Page 417: ...completely removed When removing the hydraulic equipment do not stand in the direction that the oil spurts out when performing the operation In addition loosen the bolts slowly when performing the work Do not disassemble it Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disp...

Page 418: ...om the ground 3 Perform the following procedure within 15 seconds After the engine stops the accumulator pressure decreases gradually You can check only just after the en gine stops 1 Keep the work equipment at the maximum reach pos ture turn the starting switch to OFF position A and stop the engine 2 Turn the starting switch to ON position B 3 With the lock lever at FREE position F operate the wo...

Page 419: ...FF position METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT 1 Lower the work equipment to the ground Keep the crusher attachment jaws etc closed 2 Operate the operating portion g of the lock lever to set it securely to LOCK position L If an attachment is installed set the lock pin of the attach ment control pedal to position c where you can operate the pedal 3 Perform the following procedure wi...

Page 420: ...o that you cannot operate the attachment control pedal METHOD FOR CHECKING ALTERNATOR Ask your Komatsu distributor to have the alternator checked If the engine is started frequently have this inspection performed every 1000 hours METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance Ask your Komatsu distributor to perform this work METH...

Page 421: ...rty and the perform ance lowers or the crankcase pressure increases Never reuse the filter element since it can cause an engine failure After the filter element is replaced if KCCV is not assembled correctly oil or blowby gas may leak Replace the filter element in the correct procedure Items to be prepared Container to catch drained oil Special wrench for KCCV The KCCV ventilator is located in the...

Page 422: ...nstall a new O ring contained in the service kit Apply engine oil to the new O ring 4 While matching marks 7 of the new element with mark 8 of the body label insert the element firmly into the end of the body The element can be installed only when its claws 9 are correctly inserted in grooves 10 of the filter body Bases 11 and 12 are oval When inserting take extreme care so that those bases are ma...

Page 423: ...t until all of parts cool down before starting the work NOTICE Komatsu recommends using Komatsu genuine parts for replacement parts If the machine is operated without DEF filter attached or with the filter other than Komatsu genuine parts foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine Never operate the machine without DEF filter attached nor use ...

Page 424: ...acing the filter clean around the DEF pump first after DEF system devices stop Items to be prepared DEF filter removal tool The DEF filter is located at the positions shown in the figure on the right 1 Remove filter cap 1 at the bottom of DEF pump and re move equalizing element 2 2 Turn cap 4 of filter removal tool 3 and remove it 3 Check the installation of spacer 5 4 Insert filter removal tool 3...

Page 425: ...moved 7 Slide filter 6 down and remove spacer 5 from filter re moval tool 3 8 Pull filter 6 up while pushing in the tip of filter removal tool 3 and remove it 9 Return the removed spacer 5 to filter removal tool 3 and keep them 10 Insert a new filter and a new equalizing element into the bottom of DEF pump and lightly tighten them with hand 11 Tighten filter cap 1 Tightening torque 20 to 25 Nm 2 0...

Page 426: ...ent hydraulic system Main pump delivery hose Pump delivery hose Pump branch hose Main pump LS hose External work equipment hose Boom foot connection hose Boom cylinder hose Arm connection hose Arm cylinder hose Line hose for additional attachment 4 Others PPC accumulator Accumulator for additional attachment METHOD FOR CHECKING WATER PUMP Check around the water pump for oil leakage and water leak ...

Page 427: ...it in fire Do not perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disposing of it the gas must be released Ask your Komatsu distributor to have this work per formed NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued it becomes impossible to release the remaining pressure inside the hydraulic circuit if ...

Page 428: ...re piping must be made as an assembly If there are any problems the parts must be replaced Ask your Komatsu distributor for replacement METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER The fuel spray prevention caps on the fuel injection piping and both ends of the high pressure piping act to pre vent the fuel from coming into contact with high temperature parts of the...

Page 429: ...ould be performed at the same time METHOD FOR CHANGING OIL IN HYDRAULIC TANK k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pres sure then remove it carefully NOTICE I...

Page 430: ...d of checking the oil level see METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 10 Bleed air from the hydraulic circuit For the air bleeding procedure of hydraulic circuit see METHOD FOR BLEEDING AIR FROM HYDRAUL IC CIRCUIT 11 Install undercover 1 EVERY 8000 HOURS MAINTENANCE Maintenance for every 100 250 500 1000 2000 and 4000 hours service should be performed at the same time METHOD F...

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

Page 432: ... mm 600 700 500 550 E Cab height mm 3045 3064 3070 F Tail swing radius mm 3020 2880 G Overall length of track mm 4070 4450 4240 H Distance between tumbler centres mm 3275 3655 3410 I Height of handrail mm 3135 3154 3160 J Min ground clear ance mm 440 465 Travel speed Lo Mi Hi km h 3 0 4 1 5 5 Swing speed rpm 12 4 J KS000711 Dimensions shown are for PC210 11 PC210LC 11 with 2900 mm arm and PC210NLC...

Page 433: ...m 2645 3240 3265 G Max reach at ground level mm 9700 9150 9130 For PC210 11 PC210LC 11 with 5700 mm boom and 2900 mm arm and for PC210NLC 11 PC230NHD 11 with 5700mm boom and 2400mm arm EXPLANATION OF LIFT CAPACITY CHART 1 PIECE BOOM 1 Piece Boom PC210 11 PC210LC 11 PC210NLC 11 PC230NHD 11 LEGEND A Reach from swing centre B Bucket hook height OF Lifting capacity rating overfront OS Lifting capacity...

Page 434: ...E WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND PC210 11 WITH 600 mm WIDTH SHOE PC210LC 11 WITH 600 mm WIDTH SHOE Loads do not exceed 87 of hydraulic capacity or 75 of tipping capacity load limited by hydraulic capacity rather than tipping PC210 11 SPECIFICATIONS SPECIFICATIONS 5 4 ...

Page 435: ...PC210LC 11 PC210NLC 11 SPECIFICATIONS SPECIFICATIONS 5 5 ...

Page 436: ...PC230NHD 11 SPECIFICATIONS SPECIFICATIONS 5 6 ...

Page 437: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1 ...

Page 438: ... leader and follow his her instructions Use a crane when handling heavy objects 25 kg or more The crane must be operated by a qualified operator Never go under a load raised by the crane Do not perform operations with the load kept raised by the crane Always use a stand to prevent the load from falling When removing a heavy part consider the machine balance after it is removed To prevent the machi...

Page 439: ...ts the mass of the bucket see the following EXPLANATION OF LIFT CAPACITY CHART 1 PIECE BOOM 5 3 should be taken into consideration For an attachment not intended to bear a load for example a breaker it should not exceed the minimum lift capacity of the machine as shown on the related lift capacity charts see SPECIFICATIONS section Chapter 5 For attachments intended to bear a load for example clams...

Page 440: ...tions If in doubt about the installation or operation consult your Komatsu distributor Pressure regulation valves 5 and 6 allow the attachment pressure and the release pressure for the quick coupler to be limited according to the coupler manufacturer s recommendation respectively Maximum cir cuit pressure 34 3 MPa 350 kgf cm2 Ensure that the quick coupler is installed by a suitably qualified techn...

Page 441: ... roll or slide after release 1 Operation switch REMARK The switch has a safety lock mechanism to prevent acci dental operation Slide the lock towards you then rock the switch The lamp on the switch will come on and a warning buzzer will sound NOTICE Operation will only take place if button 2 is also pressed A When depressed at this point quick coupler deactivat ed Lock bucket attachment B When dep...

Page 442: ...sk your Komatsu distributor for inspection and maintenance TO PICK UP A NEW BUCKET OR ATTACHMENT k k WARNING Check daily that the hoses and fittings in the quick coupler piping system are in good condition Pay particular attention to the hoses and fittings at the arm end as these can be damaged easily In case of damage or leakage of oil stop work Loss of oil could lead to the bucket or attachment ...

Page 443: ... bucket cylinder arm and boom as necessary Follow the quick coupler manufacturer s instructions 5 Release button 2 If the bucket or attachment needs a connection to the hydraulic system of the machine follow all instruc tions in ATTACHMENT REMOVAL AND INSTALLATION The quick coupler will lock onto the bucket or attachment if necessary operate one of the machine control levers to raise the system pr...

Page 444: ... keep your machine in the best condition for long periods of time it is essential to follow the instructions in this Operation and Maintenance Manual Commercially available grease additives may be good for the machine but they may also cause harm Komatsu does not recommend any commercially available grease additive Refer also to section RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 The automatic grea...

Page 445: ...y not be available with some specifica tions SYSTEM OPERATION The system performs all operations automatically When the starting switch is in the ON position the grease pump will at pre defined intervals supply measured quantities of grease to all the points connected to the sys tem Within 60 seconds after switching the starting switch to the ON position the in cab display 2 shows the select ed gr...

Page 446: ...cessary Yellow lamp 5 flashing Minimum level in the reservoir has been reached Reset by filling the reservoir Red lamp 6 flashing System out of order Immediate action required Possible causes Insufficient grease pressure during 10 consecutive cycles or 10 consecutive times in the same main line Check for cause and reset by depressing the test button at the pump for at least one second while the ig...

Page 447: ...p unit and its surroundings Attention avoid using high pressure wash directly on the pump 9 Replace or clean the pump filler filter behind the connector on the reservoir every 500 hours REFILLING GREASE If the yellow lamp 5 on the in cab display 2 illuminates the minimum grease level in the reservoir has been reached The grease reservoir must be refilled as soon as possible GREASING PROCEDURE 1 Re...

Page 448: ...ning the machine or to vent the system a continuous lubrication cycle run can be performed 1 Move the starter switch to the ON position B 2 Depress the test button 9 on the pump for more than six seconds The system will perform a continuous lubrication test During this run the green LED 4 of the selected interval on the in cab display 2 will flash 02 sec on 0 2 sec off 3 The continuous test cycle ...

Page 449: ...cles if necessary Every time a test cycle is carried out grease is added to the grease points This will increase grease usage and can cause excessive greasing of the grease points ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM 6 13 ...

Page 450: ...m 2 Second Boom 5 Top of boom foot 5 grease points located here for joints D E and F 3 First Boom Raise Cylinder 6 Second boom adjust cylinder OPERATION Explanation of Components 2 piece boom control pedal The control pedal to the left of the travel levers controls the operation of the second boom adjust cylinder Press ing down on the front of the pedal pushes the second boom away from the cab pre...

Page 451: ... 1 2 Piece Boom control pedal A Retract second boom raise cylinder B Extend second boom raise cylinder A Press the rear of the pedal 9JH02584E A B KS001275 ATTACHMENTS AND OPTIONS 2 PIECE BOOM 6 15 ...

Page 452: ...When leaving the machine for a short time LIFTING Recommended posture during lifting operations is with adjust cylinder fully retracted k k WARNING Do not operate the adjust cylinder during lift opera tions as work equipment may move suddenly and cause serious damage When the second boom adjust cylinder is extended the bucket or attachment can hit the operator cab or chassis Operate work equipment...

Page 453: ...s in base metal checks before starting NOTICE If any abnormality is found during inspection please contact your Komatsu distributor For details of inspection and maintenance items for the chassis other than those listed above see MAINTE NANCE PERIODIC MAINTENANCE Changing the hydraulic oil When changing the hydraulic oil set the work equipment in the posture as shown below Additional quantity of o...

Page 454: ...ter When carrying out heavy duty operations such as hydraulic breaker opeartions carry out the greasing every 100 hours 1 Set the work equipment in the greasing position below then lower the work equipment to the ground and stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Adjust cylinder ...

Page 455: ... mm PC210 11 A 9715 9570 B 5970 5185 C 3090 3030 PC210LC 11 A 9715 9570 B 6160 5375 C 3090 3030 PC210NLC 11 A 9690 9545 B 6160 5375 C 3090 3030 PC230NHD 11 A 9690 9545 B 6065 5280 C 3100 3040 KS001280 A C B PC210 11 PC210LC 11 PC210NLC 11 Working ranges Unit 2400 mm 2900 mm A Max digging reach mm 9440 9935 ATTACHMENTS AND OPTIONS 2 PIECE BOOM 6 19 ...

Page 456: ...Working ranges Unit 2400 mm 2900 mm A Max digging reach mm 9440 9935 B Max digging depth mm 5675 6185 C Max digging height mm 10685 11085 D Max vertical wall digging depth mm 4720 5225 E Max dumping height mm 7720 8115 F Min swing radius mm 2890 2640 G Max digging reach at ground level mm 9250 9750 A EXPLANATION OF LIFT CAPACITY CHART 2 PIECE BOOM 2 Piece Boom PC210 11 PC210LC 11 PC210NLC 11 PC230...

Page 457: ...NSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND PC210 11 WITH 600 mm WIDTH SHOE PC210LC 11 WITH 700 mm WIDTH SHOE PC210NLC 11 WITH 500 mm WIDE SHOE PC230NHD 11 WITH 550 mm WIDE SHOE Loads do not exceed 87 of hydraulic capacity or 75 of tipping capacity load limited by hydraulic capac...

Page 458: ...PC210 11 2 Piece Boom PC210LC 11 2 Piece Boom PC210NLC 11 2 Piece Boom 2 PIECE BOOM ATTACHMENTS AND OPTIONS 6 22 ...

Page 459: ...PC230NHD 11 2 Piece Boom ATTACHMENTS AND OPTIONS 2 PIECE BOOM 6 23 ...

Page 460: ...per long front machine and to identify any damage to the equipment early carry out the following checks before starting the machine Check daily for any loose nuts or bolts and tighten any that are found Check daily for any oil leakage Check all parts of the work equipment for any cracks bending buckling and play of the boom and arm If any abnormality is found contact your Komatsu distributor immed...

Page 461: ...k R Recommended work C Work requiring caution N Work that is not permitted Applicable operations 1 Dredge rivers specific gravity max 1 8 R 2 Hauling loading dry sand specific gravity max 1 8 R 3 Digging hauling piled soil specific gravity max 1 8 R 4 Cutting and removing weeds R 5 Digging clay layers C 6 Digging bank C ATTACHMENTS AND OPTIONS SUPER LONG FRONT BOOM AND ARM 6 25 ...

Page 462: ...slowly Do not use any bucket with a capacity greater than shown in this table Buckets which do not conform to this table must not be used Item Unit PC210LC 11 15m Max digging radius mm 1200 General Purpose Bucket material density 1 8 t m3 Capacity ISO m3 0 49 Maximum Width mm 955 Maximum Weight kg 425 General Purpose Bucket material density 1 2 t m3 Capacity ISO m3 0 66 Maximum Width mm 955 Maximu...

Page 463: ... like breakers and fork grabs may not be used k k CAUTION Use with engine throttle at 70 80 for ease of use and safety k k CAUTION Do not operate the Super Long Front control levers in the same way as a standard excavator The Super Long Front equipment has a higher inertia and will achieve higher velocities causing wear and damage WHEN TRAVELLING Lower the boom pull in the arm keep the work equipm...

Page 464: ... the pin D and snap ring E When doing this raise the boom slightly and retract the arm cylinder slightly from the end of the stroke 5mm 10mm to align the holes correctly 4 It is dangerous to carry out this operation with the arm raised from the ground MAINTENANCE k k WARNING Before carrying out maintenance always attach the WARNING TAG to the control lever in the operator s cab SPECIAL SERVICE REQ...

Page 465: ...50 HOURS SERVICE LUBRICATING MANUAL GREASE SYSTEM NOTICE For the first 100 hours on new machines where the parts are setting in carry out greasing every 10 hours 1 Set the work equipment in the greasing posture below then lower the work equipment to the ground and stop the engine 2 Using the grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old gr...

Page 466: ...al is 100 hours However more frequent greasing will be required depending on conditions environment 1 Set the work equipment in the greasing posture below then lower the work equipment to the ground and stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out AM091470C 1 2 KS000661 5 3 4 3 SUPER LO...

Page 467: ...m cylinder foot pin 1 place 2 Boom Arm coupling pin 1 place 3 Arm cylinder rod end 1 place 4 Bucket cylinder foot pin 1 place 5 Arm Link coupling pin 1 place AM091520C 2 3 4 ATTACHMENTS AND OPTIONS SUPER LONG FRONT BOOM AND ARM 6 31 ...

Page 468: ...1 15m Super Long Front A Overall shipping height mm 3475 B Overall shipping length mm 13020 C Transport length mm 12255 D Track length mm 4450 E Track length on ground mm 3655 F Tail swing radius mm 3020 G Machine tail height mm 2250 H Overall height of cab mm 3045 I Height of handrail mm 3150 AM091470D 5 6 AM091480D 9 7 8 7 SUPER LONG FRONT BOOM AND ARM ATTACHMENTS AND OPTIONS 6 32 ...

Page 469: ...g Front Max Digging Reach to bucket teeth mm 15435 NOTICE Specifications are subject to change without notice Working ranges Unit PC210LC 11 15m Super Long Front A Maximum digging height mm 13977 B Maximum dumping height mm 11238 C Maximum digging depth mm 14635 D Maximum digging reach mm 11790 G Maximum digging reach at ground level mm 15435 H Minimum swing radius mm 15339 ATTACHMENTS AND OPTIONS...

Page 470: ... Not including tail swing SUPER LONG FRONT BOOM AND ARM ATTACHMENTS AND OPTIONS 6 34 ...

Page 471: ...e speed and perform the operation in L mode The wire or sling may come off the hook depending on the working posture Pay sufficient attention to the hook angle so that the sling does not come off Never drive the machine while lifting a load If the bucket with hook is turned 180 and used for operations it will hit the arm during the bucket DUMP operation Be careful when using it If you are planning...

Page 472: ...achment proportional switch 8 2nd line attachment proportional switch if equip ped 9 Breaker mode switch 10 ATT bypass solenoid 11 Variable relief pressure valve 12 Attachment 2 variable relief pressure valve 10 11 12 For the machines with attachment control function STOP VALVE The stop valve stops the flow of the hydraulic oil a FREE Hydraulic oil flows b LOCK Hydraulic oil stops HANDLE MACHINE R...

Page 473: ...CE If a service circuit from the attachment manufacturer is added the return circuit may not switch automatically ATT BYPASS SOLENOID When the attachment control function is installed to the ma chine the pressure to the attachment will be held by setting the pedals at NEUTRAL position VARIABLE RELIEF PRESSURE VALVE When the attachment control function is installed to the ma chine the attachment se...

Page 474: ...ly Control pedal is used to control the attachment When the front centre neutral and rear of the pedal are depressed the movement of the attachment is as follows Hydraulic breaker Front of pedal A Actuated Centre of pedal N Stop Rear of pedal B Stop REMARK Regarding other attachments discuss with the attachment manufacturer how the pedal and attachment operate at the time of installation before us...

Page 475: ...events deterioration of the hy draulic oil when using a breaker REMARK Oil flows only when B mode is selected on the monitor ACCUMULATOR k k WARNING The accumulator is charged with high pressure nitrogen gas so improper operation may cause an ex plosion which will lead to serious injury or death For handling always observe the following The pressure in the hydraulic circuit cannot be completely re...

Page 476: ...portional switch operates the 1st attachment circuit e g crusher The 1st line attachment proportional switch is a roller propor tional control switch Rolling the switch up produces movement of the attachment rolling down produces opposite movement Slight movement of the roller will give slight movement of the attachment full movement of the roller will give faster move ment of the attachment 2ND L...

Page 477: ...re is applicable for the attachment or the breaker mode If the attachment mode of which the setting pressure is applicable for the attachment is not available on the machine monitor consult your Komatsu distributor for the pressure setting SWITCHING THE HYDRAULIC CIRCUIT Depending on the type of attachment set the working mode on the monitor as follows The hydraulic circuit and the set pressure of...

Page 478: ...ic circuit as follows 1 Check that stop valve 1 is located at LOCK position b a FREE Hydraulic oil flows direction of arrow is parallel to longitudinal direction of arm b LOCK Hydraulic oil does not flow direction of arrow is at right angle to longitudinal direction of arm 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 ...

Page 479: ...e the oil flow in the service circuit For setting of the flow see MACHINE SETTINGS Switching method of breaker and general attachment Install an optional attachment and set the working mode to B mode Breaker circuit one way circuit is formed Hydraulic oil flowing through breaker circuit passes through additional filter for breaker Relief valve is set to low pressure Maximum oil flow can be adjuste...

Page 480: ...ine METHOD FOR REMOVING ATTACHMENT 1 Turn the starting switch to ON B position 2 Set the lock lever to FREE position F 3 Operate each work equipment control lever and attach ment control pedal fully to the front rear right and left a few times within 15 seconds to release the internal pres sure in the hydraulic circuit HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 6 4...

Page 481: ...valve to furthest po sition clockwise or anti clockwise After setting re move lever 3 and refit bolt 1 and washer 2 7 Remove the hoses on the attachment side Install the plate 4 to the two outlets The plugs are used to prevent the attachment from making incorrect operation caused by mixing in of foreign matter After the plugs are correctly installed store the attach ment 8 Pull out the mounting pi...

Page 482: ...rn the starting switch to ON B position 5 Set the lock lever to FREE position F 6 Operate each work equipment control lever and attach ment control pedal fully to the front rear right and left a few times within 15 seconds to release the internal pres sure in the hydraulic circuit HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 6 46 ...

Page 483: ...rt on the side face of the arm and the outlet piping to FREE po sition a a FREE Hydraulic oil flows direction of arrow is parallel to longitudinal direction of arm b LOCK Hydraulic oil does not flow direction of arrow is at right angle to longitudinal direction of arm When setting FREE or LOCK position of the stop valve re move bolt 1 and washer 2 fit lever 3 and refit bolt 1 and washer 2 rotate v...

Page 484: ...dals and proportional switches while holding the object When you operate attachment the screen will switch to the screen including bird s eye view automati cally For the change of the flow setting for the breaker mode and attachment mode for the crusher etc see MA CHINE SETTINGS METHOD FOR OPERATING MACHINE WHEN WORKING MODE IS NOT IN BREAKER MODE Change the working mode and enter the Breaker Mode...

Page 485: ...hen using the breaker is much faster than in the normal operations so check the maintenance time with MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER When considering whether it is necessary to install an accumulator for the attachment circuit contact the attachment manufacturer and then decide When handling the breaker follow the instruction manual from the breaker manufacturer and use the break er co...

Page 486: ...nt Mode inactive CHECK POINTS WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER ETC Is the stop valve in FREE position Is the working mode ATT P or ATT E For the oil passage route see METHOD FOR CHANGE OVER AND CONNECT HYDRAULIC CIRCUIT FOR MACHINE READY FOR INSTALLATION OF ATTACHMENT When handling the attachment follow the instruction manual from the manufacturer and use the attachment correctly METH...

Page 487: ...tch F6 REMARK Even if P E or L mode is selected the attachment is not operated Page feeding can be done by pressing the switches F1 and F2 A shows the flow rate which flows through the at tachment and B shows the hydraulic oil pressure which flows through the attachment For the hydraulic oil pressure through the attachment consult your Komatsu distributor METHOD FOR OPERATION WHEN USING GENERAL AT...

Page 488: ...tachments The switch on left lever is a roller proportional control switch Rolling the switch up produces rotation in one di rection rolling down produces rotation in the opposite direction Slight movement of the roller will give slight movement of the attachment full movement of the roller will give faster movement of the attachment If the working mode pilot monitor does not display ATT P or ATT ...

Page 489: ...y Always wear protective equipment such as protective eyeglasses and dust mask NOTICE For the element replacement interval see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 13 Items to be prepared Container to receive drained oil Prepare for the maintenance so that it can be performed as follows 1 Lower the work equipment to the ground and stop the en gine 2 Turn the starting switch to ON B positio...

Page 490: ...n is completed replace the additional filter for breaker according to the following procedure METHOD FOR REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER 1 Loosen oil filler cap F slowly on the top of the hydraulic tank to release the internal pressure in the hydraulic tank 2 Set a container to receive the oil under the additional filter at the position pointed with the arrow 5 HANDLE MACHINE READY...

Page 491: ... ring 5 to filter case 2 and screw filter case 2 into filter head 4 7 After the top of filter case 2 touches the filter head tight en it further at least 1 2 turn 8 Clean removed plug 1 and fit brand new O ring 6 to plug 1 9 Install plug 1 to filter case 2 Tightening torque 27 4 to 58 8 Nm 2 8 to 6 0 kgm METHOD FOR REPLACING ADDITIONAL PILOT FILTER ELEMENT FOR BREAK ER 1 Loosen oil filler cap F sl...

Page 492: ...2 ℓ min Safety valve relief set pressure of service valve Port A 29 9 MPa 305 kg cm2 other than B mode Port B 29 9 MPa 305 kg cm2 other than B mode Safety valve cracking pressure of service valve Port A 24 5 MPa 250 kg cm2 other than B mode Port B 24 5 MPa 250 kg cm2 other than B mode Safety valve relief set pressure of service valve Port A 29 9 MPa 305 kg cm2 B mode Port B 24 5 MPa 250 kg cm2 B m...

Page 493: ...cm2 Port B 44 3 MPa 452 kg cm2 The safety valve relief set pressure 20 6 MPa 210 kg cm2 and the safety valve cracking pressure 15 2 MPa 155 kg cm2 are provided Consult your Komatsu distributor ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 6 57 ...

Page 494: ...ARM PIN INFORMATION A A B B KS000370 2 4 1 3 A A B B PC210 LC 11 1 325 mm 0 0 5 3 325 mm 0 5 0 5 2 80 mm 0 030 0 075 4 80 mm 0 030 0 075 ARM PIN INFORMATION ATTACHMENTS AND OPTIONS 6 58 ...

Page 495: ...ce and operate it with care PC210 1 PC210LC 11 NOTICE When the boom is fully lowered during oblique digging the boom interferes with the undercarriage Operate the boom carefully NOTE 1 Bucket size based on ISO 7451 heaped material with a 1 1 angle of repose Max Bucket Volume Weight are for reference only and are not necessarily available from the factory 2 Table is based on General Purpose buckets...

Page 496: ... The tool control system monitor is located in the operator cab on the door pillar 1 Esc button return cancel 2 Navigation button up 3 Enter button 4 Navigation button left 5 Navigation button down 6 Navigation button right 7 Monitor display screen SYSTEM OPERATION The system is automatically activated when the ignition key is turned to ON position On startup the tool control system monitor screen...

Page 497: ...t this value as doing so will have no effect on the attach ment performance NOTICE When operating in P E or L mode select ATTACHMENT 16 OFF as the attachment pre set this will deactivate the at tachment controls for standard digging or lifting opera tions SYSTEM ERRORS The system automatically monitors for system abnormalities in the event of an error the monitor display screen 7 will display ERR ...

Page 498: ...iple C Optional 900 Triple C Optional 860 Swamp C Optional 600 Flat D Optional 600 Road liner E Precaution for track shoe selection Since working conditions B and C are for wide shoe their use is limited Check the precautions for use and the using condition and then use a suitable shoe When selecting the shoe width choose the narrowest shoes possible to bring the machine within the range where the...

Page 499: ...rushed stone Clayey soil De compressed gran ite soil Sand Typ e of op era tion Hea vy Light Digging with hammer ing work Horizontal pin type teeth Vertical pin type teeth Scraping down Horizontal pin type teeth Vertical pin type teeth General excavation Vertical pin type teeth Loading Vertical pin type teeth HANDLE EXTENSION ARM When an extension arm is installed the bucket will hit the boom cylin...

Page 500: ...he attachments or the models consult your Komatsu distributor HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows Crushing rock Road construction This attachment can be used for a wide range of applications including breaking up road surfaces or slag tunnel work rock crushing and breaking operations in quarries Precautions when performing breaking operati...

Page 501: ... of the chisel gradually deviates from the direction of the breaker body Adjust the direction with the bucket cylinder so that it keeps the proper direction Always keep the chisel pressed against the impact surface properly not to strike at the air Prohibited operations To ensure that the machine has a long life and to ensure that operations are performed in safety do not operate the machine in an...

Page 502: ...Do not work by using the swing force Do not move the chisel while performing breaking operation Do not perform breaker operation in horizontal or upward direc tion Do not work under water RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS 6 66 ...

Page 503: ...ith any cylinder at the stroke end Posture of hydraulic breaker to be greased NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result dirt will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use Be sure to grease the breaker keeping it in the right posture ATTACHMENTS AND OPTIONS RECOMMENDED ATTAC...

Page 504: ...holding it in the right posture shown below Lower the chisel perpendicularly to the ground Insert the grease gun perpendicularly to the greasing point Wrong posture RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS 6 68 ...

Page 505: ...REPLACEMENT PARTS 7 1 ...

Page 506: ...mps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Retighten all loose hoses and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the defined life parts DEFINED LIFE PARTS LIST No Parts for periodic repla...

Page 507: ... 207 60 71183 07000 15195 Element O ring 1 1 Every 1000 hours Fuel main filter 600 319 3750 Cartridge 1 Hydraulic tank breather 421 60 35170 Element 1 DEF tank breather 421 60 35170 Element 1 DEF filter 6540 71 2320 Element 1 Every 2000 hours KCCV filter 600 331 2900 Element 1 DEF filler port filter 423 02 62110 Filter 1 Every 4500 hours Air conditioner RECIRC air filter 2A5 979 1551 Filter 1 Ever...

Page 508: ...Item Part No Part Name Q ty Replacement in terval Additional pilot filter for breaker 20Y 62 51691 706 76 71390 Element O ring 1 1 CONSUMABLE PARTS REPLACEMENT PARTS 7 4 ...

Page 509: ... used must be ultra low sulfur diesel fuel 10ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high precision parts and lubrication if low viscosity fuel with low lubr...

Page 510: ...aulic oil level Change power train oil Check power train oil level Replace engine oil filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter Replace DEF tank breather element Replace DEF filter USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Reservoir Fluid Type Ambient Temperature degrees Celsius Recommended Komatsu ...

Page 511: ... 50 C HO56 HE KES 20 C 50 C HO46 HM KES Note 5 Grease fitting Hyper grease 20 C 50 C G2 TE KES Note 3 Lithium EP grease 20 C 50 C G2 LI KES Cooling system Non Amine En gine Coolant AF NAC 30 C 50 C AF NAC KES Note 4 Fuel tank Diesel fuel 30 C 20 C EN590 10 C 50 C DEF tank DEF tank 30 C 50 C DEF Note 6 Engine oil pan Swing machi nery case Final drive case each of right and left Damp er case Hy drau...

Page 512: ...of pins and bushings the use of G2 T or G2 TE is recommended Note 4 SUPERCOOLANT AF NAC 1 Coolant has the important function of anti corrosion as well as antifreeze Even in the areas where freezing is not an issue the use of coolant is essential Komatsu machines are supplied with SUPERCOOLANT AF NAC SUPERCOOLANT AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used ...

Page 513: ...r conditioner compressor belt tension Check Ad just 4 44 Air conditioner fresh air filter Clean 4 54 Air conditioner fresh recirc filter Clean 4 53 Air conditioner pilot lamp 3 34 Air conditioner recirculation air filter Clean 4 53 Air conditioner switch 3 50 3 226 Air conditioner system caution lamp 3 29 Air suspension seat hardness Adjust 3 159 Alternator Check 4 68 Always use clean washer fluid...

Page 514: ... weather operation information 3 262 Consumable parts 7 3 Consumable parts list 7 3 Contents of safety labels 2 6 Control levers and pedals 3 96 Control pedals 6 38 Controls and gauges names 3 5 Coolant 3 262 Coolant Check level Add 3 148 Coolant and water for dilution 4 6 Cooling system Clean inside 4 20 Counter rotation turn 3 193 Cover with lock Lock 3 213 Cover with lock Open 3 213 Cover with ...

Page 515: ... lamp 3 35 Engine system caution lamp 3 26 Engine technology to conform exhaust gas emission 1 13 Engine valve clearance Check Adjust 4 68 Ensure good visibility 2 26 Ensuring safe operation 2 17 Every 100 hours maintenance 4 41 Every 1000 hours maintenance 4 56 Every 2000 hours maintenance 4 63 Every 250 hours maintenance 4 42 Every 4000 hours maintenance 4 73 Every 4500 hours maintenance 4 77 Ev...

Page 516: ...nt Replace 4 62 Hydraulic tank strainer Clean 4 64 I If any problem is found 2 18 If machine monitor shows warning display 3 277 Indicator Check electrolyte level 4 44 Inside operator s compartment 2 18 Inspecting machine 2 17 Inspection and maintenance 6 17 Introduction 1 11 Investigate and confirm jobsite conditions 2 25 J Jumper cable Connect 3 272 Jumper cable Disconnect 3 273 K KCCV filter el...

Page 517: ...4 Machine monitor equipment name 3 6 Machine monitor when operating work equipment swing and travel Basic operation 3 16 Machine operations and controls 3 141 Machine ready for installation of attachment 6 36 Machine settings 3 67 Magazine box 3 106 Main use of machine 1 11 Maintenance 6 28 Maintenance during long term storage 3 265 Maintenance interval for hydraulic breaker 4 13 Maintenance of ai...

Page 518: ...h trailer 3 244 Precautions for long term storage 3 265 Precautions for maintenance 2 39 4 2 Precautions for noise 2 45 Precautions for operation 2 25 2 29 3 201 6 35 Precautions for refilling oil or fuel 4 2 Precautions for SCR assembly 4 3 Precautions for severe job condition 3 269 Precautions for towing and being towed 2 35 Precautions for towing machine 3 268 Precautions for transportation 2 3...

Page 519: ...switch 3 93 Right front mirror B Adjust 3 164 3 165 Right front mirror B Adjust to regular position 3 166 3 167 Right side mirror C Adjust 3 168 Roof window 3 99 Roof wiper switch 3 93 Room lamp switch 3 90 S Safety 2 2 Safety information 1 6 Safety labels 1 7 2 4 Safety rules for lifting objects 2 36 Safety rules for lifting objects using bucket 2 38 Safety rules for storage 2 49 Safety related e...

Page 520: ...SCR system warning Handle 3 123 Use handrails and steps when getting on or off ma chine 2 20 Use proper tools 2 42 Use warning tags 2 27 User menu 3 56 User menu display switch 3 55 V Vacuator valve Check Replace 4 20 Variable relief pressure valve 6 37 Vent selector switch Select 3 224 Vertical or horizontal pin type tooth Select 6 63 Vertical pin type tooth Use 6 62 Vibration damper Check 4 74 V...

Page 521: ......

Page 522: ...PC210 11 PC210LC 11 PC210NLC 11 PC230NHD 11 HYDRAULIC EXCAVATOR Form No UENAM01383 2019 KOMATSU All Rights Reserved Printed in Belgium 02 2019 ...

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