Page 1 Operation & UENAM01522 Maintenance Manual HB215LC (WITH CONTINUOUS CAMERA VIEW) HYDRAULIC EXCAVATOR WARNING ORIGINAL INSTRUCTIONS 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.
Page 3 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).
Page 4 Keep it in the magazine box on the left side of the operator's seat. If this manual is lost, damaged, or unreadable, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5: Komatsu Machine Operator Privacy Policy
Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un- der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to MMS.
Page 6 FOREWORD • pictures, videos and sound recordings 4. Why is your personal data processed? When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea- sons: (a) Safety and security (b) Warranty (c) Misuse and theft prevention...
Page 7 (30) days after having received the request. If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you...
Page 8: Safety Information
SAFETY INFORMATION FOREWORD SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 9: Noise Emission Levels
FOREWORD NOISE EMISSION LEVELS NOISE EMISSION LEVELS Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator's station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator's position is 2.5 dB, in accordance with ISO 11201.
Page 10: Vibration Level
ISO 7096. For HB215LC-3 The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s , the uncertainty for this value is 0.53 m/s...
Page 11 FOREWORD VIBRATION LEVEL • Do not jump down from the cab or machine • Do not repeatedly handle and lift loads...
Page 12: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Ditching work • Loading work • Levelling work For details of the work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 13 FOREWORD INTRODUCTION This machine maintains a proximity visibility of a height of 1.2 m at a point 1 m away from the outside surface of the machine, and a visibility for a radius of 12 m . KS001602 CAUTION • During operation the movement of the work equipment (boom/arm) will affect the operator's field of vision.
Page 14: Outline Of Hybrid System
This machine is equipped with the hybrid system consisting of an electric motor and the diesel engine to reduce fuel consumption. If they need to be removed, ask your Komatsu distributor. CONFIGURATION OF HYBRID SYSTEM The hybrid system of this machine has high-voltage components such as high-voltage electric wirings which connect between the devices and the hybrid devices of approximately 550 V (motor-generator, capacitor, inver-...
Page 15: Engine Technology To Conform Exhaust Gas Emission
Diesel Exhaust Fluid is the aqueous urea solution for the SCR system. The Komatsu Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the ex- haust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decompo- ses the nitrogen oxides into nitrogen and water.
Page 16: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is located on the right bottom of the operator's cab.
Page 17: Fluorinated Greenhouse Gases
This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU UK Ltd Address: Durham Road Birtley Chester-le-Street County Durham DH3 2QX United Kingdom Distributor name...
Page 18: Serial Plate
SERIAL PLATE FOREWORD SERIAL PLATE KS000853 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER WEIGHT 1-16...
Page 19: Declaration Of Conformity
FOREWORD DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer: KOMATSU UK Ltd Durham Road Birtley Chester-le-Street County Durham DH3 2QX Declares that this machine: HB215LC-3 Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive 2014/30/EU Low Voltage Directive 2014/35/EU Outdoor Noise Directive...
Page 20: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 KOMATSU MACHINE OPERATOR PRIVACY POLICY ................1-3 SAFETY INFORMATION .......................... 1-6 NOISE EMISSION LEVELS ........................1-7 VIBRATION LEVEL........................... 1-8 INTRODUCTION ............................ 1-10 MAIN USE OF MACHINE ........................ 1-10 DIRECTIONS OF MACHINE......................
Page 21 FOREWORD TABLE OF CONTENTS PRECAUTIONS FOR ELECTROMAGNETIC WAVES ..............2-47 OPERATION ..............................3-1 GENERAL VIEW............................3-2 MACHINE EQUIPMENT NAME ......................3-2 CAB EQUIPMENT NAMES........................ 3-4 CONTROLS AND GAUGES NAMES ....................3-5 EXPLANATION OF COMPONENTS ......................3-8 EXPLANATION OF MACHINE MONITOR EQUIPMENT ..............3-8 SWITCHES ............................
Page 22 OTHER TROUBLE......................... 3-266 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 23 CONSUMABLE PARTS ........................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ..7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-7 INDEX................................8-1 1-21...
Page 25: Safety
SAFETY Please 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.
Page 26: Safety Labels
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. •...
Page 27: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 28 SAFETY LABELS SAFETY Options are shown with ★ marks in the figure. 1. Warning regarding operation, inspection, and main- 7. Stop rotation during inspection and maintenance tenance 8. Emergency escape (a) Caution for operation, inspection and maintenance 9. Caution against falling (b) Caution before operating 10.
Page 29: Contents Of Safety Labels
SAFETY SAFETY LABELS 22. Caution for handling DEF 26. Caution for disposing of capacitor 23. Caution for high-temperature resistance 27. Caution for using seat belt 24. Caution for operation, inspection and maintenance 25. Prohibition of disassembly of, stepping on, high pressure washing of hybrid components CONTENTS OF SAFETY LABELS Warning regarding operation, inspection, and...
Page 30 SAFETY LABELS SAFETY WARNING To open or close the front or ceiling window, never stand up from the operator's seat before throw- ing the safety lock lever to the lock position. Inadvertently touching any of the working equipment control levers might cause the machine to start moving all of a sudden, probably resulting in a serious injury.
Page 31 SAFETY SAFETY LABELS (f) Caution when opening or closing front window Before standing up from the operator's seat (such as when opening or closing the front window, or when removing or in- stalling the bottom window, or when adjusting the operator's seat), always lower the work equipment completely to the ground, set lock lever (1) securely to the LOCK position (L), then stop the engine.
Page 32 SAFETY LABELS SAFETY Caution when stowing front window “09803-A0481” • Sign indicates a hazard from falling window. • After raising window, be sure to lock it in place with lock pin. Caution for high-temperature coolant and hy- draulic oil “09653-A0481” •...
Page 33 SAFETY SAFETY LABELS Caution for handling cable “09808-A0881” • Sign indicates an electric shock hazard from handling the cable. • Read manual for safe and proper handling. Stop rotation during inspection and mainte- nance “09667-A0481” • Sign indicates a hazard of rotating parts, such as belt. •...
Page 34 SAFETY LABELS SAFETY Caution against falling “09805-C0481” • Sign indicates a hazard of falling. • Do not stand on this place here. Caution when swinging and travelling in re- verse “09833-A0881” • Before moving or operating the machine, look around and at mirror and monitor to confirm that no one is around the machine.
Page 35 SAFETY SAFETY LABELS Caution for work equipment “09134-A1681” • Sign indicates a hazard of being hit by the working device of the machine. • Keep away from machine during operation. Caution for handling battery “09664-60001” (a) Never smoke or use any naked flame near the batteries, no sparks.
Page 36 SAFETY LABELS SAFETY (e) Read the operator's manual before working with batteries. (f) Caution - explosive gases. Prohibition of start by short-circuiting “09842-A0642” • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit.
Page 37 (Lb) • If some modification is applied to the ROPS or FOPS, it may affect the strength and may not be comply with the standard. Consult Komatsu Distributor before altering. 09620-A3001 Komatsu Ltd. 2-3-6 Akasaka, Minato-ku, Tokyo, Japan 09620 - T2001 •...
Page 38 SAFETY LABELS SAFETY Caution for high-temperature resistance “09817–K064B” • Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation. • Never touch when hot. Caution for operation, inspection and mainte- nance “09651-A0841”...
Page 39 SAFETY SAFETY LABELS Caution for using seat belt “09848-A0480” • Always use seat belt when operating the machine to re- duce risk of injury or death in case of a roll-over. • Always check for damage or wear of the seat belt, damage of the connecting brackets, and tightness of bolts.
Page 40: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 41: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE KEEP MACHINE CLEAN • If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 42 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Do not jump off the machine. There is the danger of falling and it may cause personal injury. • The fume generated by a fire contains harmful materials which have a bad influence on your body when they are inhaled.
Page 43: Precautions When Getting On Or Off Machine
If there is any loose bolt on the handrails and steps, tighten it securely. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor for that work. •...
Page 44 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Do not get on or off the machine with tools in your hand. • Do not grab a foldable mirror as a handrail since it turns. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death.
Page 45: Do Not Get Caught In Work Equipment
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 46: Protection Against Falling, Flying Or Intruding Objects
No attempt should be made to repair these parts as this may have an adverse effect on component strength or durability. If such a repair is undertaken without authorisation from Komatsu there is a danger that a problem might occur that will lead to serious personal injury.
Page 47: Precautions Related To Cab Glass
When installing optional parts or attachments which are not written in this manual, the machine weight must not exceed ROPS certified value. Always contact your Komatsu distributor before installing. • Installing some work equipment combinations may cause interference and damage with the cab or other parts of the machine during operation and could cause serious personal injury or death.
Page 48: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 49 SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 50: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 51 • Adjust the cameras to have a good rear view and a good view of surrounding area from the operator's seat. For the adjustment, please contact your Komatsu distribu- tor. • Adjust the armrest to a position for easier operation, and fix it securely.
Page 52: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • When disconnecting the jumper cables, take care not to bring the clips in contact with each other or with the machine. PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance.
Page 53 SAFETY PRECAUTIONS FOR OPERATION • Always operate the machine only when seated on the operator's seat. • Before starting to move, check again that there are no people or obstacles in the surrounding area. • Before moving, sound the horn to warn people in the surrounding area.
Page 54 PRECAUTIONS FOR OPERATION SAFETY • When passing over bridges or structures, check first that the structure is strong enough to support the weight of the machine. When passing on a public road, check with authorities concerned and observe their instruction. •...
Page 55 SAFETY PRECAUTIONS FOR OPERATION • Do not drive the machine on a slope covered with the steel plates. Even with slight slopes there is a hazard that the machine may slip. • Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that the machine may slip.
Page 56 PRECAUTIONS FOR OPERATION SAFETY • For a quick escape in an emergency, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when performing operations. • Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other hauling equipment.
Page 57: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 58: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY • Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. (1) Chocks (2) Ramp (3) Center of ramp...
Page 59: Lifting Operation By Using Bucket With Hook
SAFETY PRECAUTIONS FOR OPERATION LIFTING OPERATION BY USING BUCKET WITH HOOK PRECAUTIONS FOR LIFTING OPERATIONS Falling of a lifted load or tipping over of the machine can cause serious personal injury or death. Always observe the following. • Do not perform lifting work on slopes, soft ground, or other places where the machine is not stable. •...
Page 60: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 61 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 62 PRECAUTIONS FOR MAINTENANCE SAFETY • Rotating parts such as the fan, fan belt are dangerous that they may easily catch a body part or an object someone wears. Be careful not to come close to the rotating part. • Never drop or insert tools or other objects into the fan, fan belt, or other rotating parts.
Page 63: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur. Al- ways observe the following. • Make sure the hoists or hydraulic jacks you use are in good condition and strong enough to handle the weight of the component.
Page 64 PRECAUTIONS FOR MAINTENANCE SAFETY HANDLE BATTERY Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. Danger of battery exploding When the battery is being charged, flammable hydrogen gas is generated and may explode.
Page 65 SAFETY PRECAUTIONS FOR MAINTENANCE • If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, pieces might be scattered, and it may cause serious personal injury or death. Always wear protective eyeglasses and gloves. •...
Page 66 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 67 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.
Page 68 • When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 69 SAFETY PRECAUTIONS FOR MAINTENANCE • The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval.
Page 70: Precautions For Def
PRECAUTIONS FOR DEF SAFETY PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 71: Precautions For Hybrid System
• If the hybrid component has got into water, ask your KOMATSU distributor for the inspection and repair. • If it gets into water during operation, stop the engine immediately and get out from the machine.
Page 73: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 74: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (6) Boom cylinder (2) Bucket cylinder (7) Sprocket (3) Arm (8) Track frame (4) Arm cylinder (9) Track (5) Boom (10) Idler...
Page 75 OPERATION GENERAL VIEW Details of parts A, B, C, D (11) SCR (19) Grease pump holder (12) Komatsu Closed Crankcase Ventilation (hereafter (20) DEF tank KCCV) ventilator (21) DEF hose (13) Engine hood (22) DEF pump (14) Battery (23) DEF injector...
Page 76: Cab Equipment Names
GENERAL VIEW OPERATION CAB EQUIPMENT NAMES (1) Front window (7) Fire extinguisher (if equipped) (2) Ceiling window (8) Emergency escape hammer (3) Door lock release lever (9) Magazine box (4) Drink box (10) Cup holder (5) Fuse (11) AUX (6) Auxiliary electric power (if equipped) (12) Ashtray...
Page 77: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Radio (16) Attachment control pedal (if equipped) (2) Lock lever (17) Attachment control pedal (if equipped) (3) L.H. work equipment control lever (18) Cigarette lighter (4) One-touch power maximizing switch (19) Room lamp switch (5) Travel pedal (20) Seat heater switch (6) Travel lever...
Page 78 GENERAL VIEW OPERATION (31) Breaker mode switch (35) Spare switch (32) Spare switch (36) Spare switch (33) Spare switch (37) Auto-greasing monitor (if equipped) (34) Quick coupler operation switch (38) Engine RPM switch MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Wiper switch (18) Fuel level caution lamp (2) Buzzer cancel switch...
Page 79 OPERATION GENERAL VIEW (35) Engine oil pressure caution lamp (40) Auto-deceleration pilot lamp (36) Water separator caution lamp (41) Hybrid caution lamp (37) Wiper pilot lamp (42) Hybrid temperature caution lamp (38) Swing lock pilot lamp (43) Function switches (F1 to F6) (39) Engine preheating pilot lamp or One-touch power (44) Maintenance time caution lamp maximizing pilot lamp...
Page 80: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
Page 81 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, the starting screen GG is displayed. • After the starting screen GG is displayed for 2 seconds, the screen changes to the check before starting screen BB.
Page 82 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While engine shutdown secondary switch (1) is ON (engine is stopped), when the starting switch is turned to ON position, the screen shown in the figure is displayed and engine does not start.
Page 83 EXPLANATION OF COMPONENTS End screen when any message has been re- ceived If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if the message is requesting a response, make a reply to it.
Page 84 Do not use it for the purpose of security enhancement. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third party.
Page 85 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION • If there is any abnormality when starting the engine, the check before starting screen BB changes to the maintenance time warning screen CC, warning screen FF, or error screen EE. •...
Page 86 EXPLANATION OF COMPONENTS OPERATION If there is any error existing, “!” is displayed above the switch Press the switch F5 to check the detail of the error. Current Ab- normality screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE •...
Page 87 OPERATION EXPLANATION OF COMPONENTS If there is any error existing, “!” is displayed above the switch Press the switch F5 to check the detail of the error. Current Ab- normality screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN OPERATING WORK EQUIP- MENT, SWING, TRAVEL AND ATTACHMENT Machine monitor screen automatically changes to the screen which displays the bird's eye view display of Kom- Vision when operating work equipment, swing, travel and attachment.
Page 88 EXPLANATION OF COMPONENTS OPERATION (A) Starting operation of work equipment, swing, travel and attachment • The screen at starting operation does not change to another screen while standard screen AA or enlarged screen of bird's eye view display BB is displayed even when operating work equipment, swing, travel and attachment.
Page 89 │ chine to a safe place, then perform the inspection and main- tenance. ↓ If the condition is not improved, ask your Komatsu distributor for the inspection and maintenance. Does not Lights up in Some functions may be restricted for use, but the machine...
Page 90 EXPLANATION OF COMPONENTS OPERATION CAUTION LAMP LIST NOTICE • These caution lamps do not guarantee the condition of the machine. Do not simply rely on the caution lamp when performing check before starting (start-up inspection). Always get off the machine and check each item directly. •...
Page 91 OPERATION EXPLANATION OF COMPONENTS Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue Abnormal Low performance Regeneration performance caution lamp (L03) (L01) Abnormal Sensing is DEF level caution lamp disabled (L04, L03) Abnormal Abnormal DEF system caution lamp (L04, L03) (L01) Engine stopped...
Page 92 EXPLANATION OF COMPONENTS OPERATION Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow White Blue Water separator caution Abnormal lamp Clogged Air cleaner clogging caution lamp (L01) Abnormal Air conditioner system cau- tion lamp (L01) When starting Hybrid system stop caution switch is in ON lamp...
Page 93 OPERATION EXPLANATION OF COMPONENTS CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed above the switch F5. While “!” is displayed, press the switch F5 to shift the monitor display screen to the Current Abnormality screen. Take appropriate actions according to the message displayed on the monitor.
Page 94 EXPLANATION OF COMPONENTS OPERATION ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature is abnormally high. While this monitor is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 95 If the swing operation is stopped once, the swing cannot be performed. Stop the machine immediately and ask your Komatsu distribu- tor for the inspection and maintenance. When the action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently.
Page 96 EXPLANATION OF COMPONENTS OPERATION Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for the inspection and maintenance. When the action level “L02” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently.
Page 97 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 98 EXPLANATION OF COMPONENTS OPERATION REGENERATION PERFORMANCE CAUTION LAMP This warns about the deterioration of regeneration performance of aftertreatment devices. When action level “L03” appears on screen. The caution lamp comes on in red and the alarm buzzer oper- ates continuously. Move the machine to a safe area and activate manual station- ary regeneration.
Page 99 The caution lamp comes on in red and the alarm buzzer oper- ates intermittently. Move the machine to a safe area and stop the machine, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” appears on screen.
Page 100 EXPLANATION OF COMPONENTS OPERATION Ask your Komatsu distributor for inspection and maintenance as needed. FAN CONTROL SYSTEM CAUTION LAMP The fan control system caution lamp warns about abnormality in the fan control system. When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently.
Page 101 For details, see “METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT”. If the coolant level drops again in a short time, the coolant may be leaking from the radiator. Ask your Komatsu distributor for the inspection and maintenance. CHARGE LEVEL CAUTION LAMP Charge level caution lamp warns about abnormality in the charging system while the engine is running.
Page 102 The caution lamp lights up in yellow and indicates action level “L01”. The air conditioner system has abnormality. Ask your Komatsu distributor for inspection and maintenance as soon as possible. OVERLOAD CAUTION LAMP This caution lamp warns that the machine is about to tip over due to the overload (alarm buzzer also sounds).
Page 103 The alarm buzzer sounds intermittently. The oil pressure in the quick coupler system is dropped. Stop the machine immediately and ask your Komatsu distribu- tor for the inspection and maintenance. During normal operation The lamp lights up when the quick coupler is enabled.
Page 104 Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for the inspection and maintenance. WARNING Do not move the machine when camera image is not displayed on the machine monitor.
Page 105 Visually check the safety around the machine always when operating the machine. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. CAMERA CONTROLLER CAUTION LAMP When an abnormality occurs in KomVision system controller, the caution lamp lights up in yellow, and the action level “L01”...
Page 106 EXPLANATION OF COMPONENTS OPERATION (16) Clock (20) Hydraulic oil temperature gauge (17) DEF level gauge (21) Engine coolant temperature gauge (18) Fuel gauge (22) ECO gauge (19) Hybrid temperature 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.
Page 107 OPERATION EXPLANATION OF COMPONENTS AUTO-DECELERATION PILOT LAMP The auto-deceleration pilot lamp shows the setting of the auto- deceleration function either ON or OFF. The pilot lamp display when the auto-deceleration switch is op- erated is as follows. Auto-deceleration pilot lamp is lit: Auto-deceleration ON Auto-deceleration pilot lamp is not lit: Auto-deceleration OFF REMARK During the aftertreatment devices regeneration, even if the au-...
Page 108 Pilot lamp goes out: Air conditioner OFF MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see PILOT DISPLAY, “MESSAGE DIS- PLAY”. Lights up in green (A): There is unread message.
Page 109 OPERATION EXPLANATION OF COMPONENTS AFTERTREATMENT DEVICES REGENERATION DISPLAY This displays the regeneration status and automatic regenera- tion setting status of the aftertreatment devices. (A): Comes on during regeneration. (B): Comes on when setting automatic regeneration disable. LOCK LEVER PILOT LAMP The lock lever pilot lamp lights up when the lock lever is in LOCK position.
Page 110 EXPLANATION OF COMPONENTS OPERATION Hydraulic relief deterrence guidance If the hydraulic oil is kept relieved for more than 3 seconds dur- ing operation, the hydraulic relief deterrence message is dis- played on the machine monitor. The hydraulic relief deterrence message goes out after more than 10 seconds or if the switch F5 is pressed.
Page 111 OPERATION EXPLANATION OF COMPONENTS When stopping the engine during regeneration of the aftertreat- ment devices, stop the aftertreatment devices regeneration first, then stop the engine after running it at low idle for approxi- mately 5 minutes. The information about engine stop operation during the after- treatment devices regeneration goes out after more than 10 seconds or if the switch F5 is pressed.
Page 112 EXPLANATION OF COMPONENTS OPERATION Display (G) when temperature is low: Caution lamp background (K) is white. Display (H) when temperature is correct: Caution lamp back- ground (K) is blue. Display (J) when the condition is abnormal: Caution lamp back- ground (K) is red. HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature.
Page 113 OPERATION EXPLANATION OF COMPONENTS REMARK When the indicator reaches red range (B), the remaining fuel is 41 ℓ or less. When the indicator is in (B) of the red range, the fuel level caution lamp (D) lights up in red. The correct fuel level may not be displayed for a short time after the starting switch is turned to ON position, but this is not a problem.
Page 114 EXPLANATION OF COMPONENTS OPERATION REMARK Although there is no abnormality on the machine when the gauge enters the yellow range, for the conservation of global environment reduce the engine output to a point where there is no adverse effect on the operation. Perform energy saving operations within the green range.
Page 115 OPERATION EXPLANATION OF COMPONENTS HYBRID TEMPERATURE GAUGE The hybrid temperature gauge indicates the temperature of hy- brid components. If the indicator is in green range during operation, it is normal. If the indicator goes beyond the red range (A) during operation, the overheat prevention system operates.
Page 116 EXPLANATION OF COMPONENTS OPERATION FUNCTION SWITCHES AND GUIDANCE ICONS • There are 6 function switches (1) (F1 to F6) at the bottom of the machine monitor display. The function of each switch differs according to the content of each screen. •...
Page 117 OPERATION EXPLANATION OF COMPONENTS (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).
Page 118 If you want to have an automatic setting of P, E, L, B, ATT/P, or ATT/E mode (optional default setting) when starting the engine, ask your Komatsu distributor to change the setting. How to use the working mode selector switch...
Page 119 OPERATION EXPLANATION OF COMPONENTS The screen returns to the standard screen after 2 seconds. The working mode display highlighted in yellow in step 4 returns to blue. REMARK When setting the working mode to B mode, to ensure safe- ty, the buzzer sounds and at the same time, the message in the illustration is displayed.
Page 120 EXPLANATION OF COMPONENTS OPERATION When the auto-deceleration switch is pressed and the au- to-deceleration function is turned on, the mode is dis- played in the center of the machine monitor display, and after 2 seconds, the screen returns to the standard screen. On the standard screen, the auto-deceleration pilot lamp lights up.
Page 121 OPERATION EXPLANATION OF COMPONENTS REMARK Each time the travel speed selector switch is switched, the mode is displayed in the center of the machine monitor display, and after 2 seconds, the screen returns to the standard screen. WIPER SWITCH Wiper switch actuates the wiper at the front window glass. Each time the switch is pressed, it changes INT →...
Page 122 EXPLANATION OF COMPONENTS OPERATION REMARK Each time wiper switch is pressed, the mode is displayed in the center of the machine monitor display, and after 2 seconds, the screen returns to the standard screen. WINDOW WASHER SWITCH Keep pressing the window washer switch continuously, and window washer fluid is sprayed out on the front glass.
Page 123 OPERATION EXPLANATION OF COMPONENTS REMARK The buzzer cannot be stopped depending on the content of 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 3-51...
Page 124 EXPLANATION OF COMPONENTS OPERATION MONITOR DISPLAY SELECTOR SWITCH By pressing the switch F3 on the standard screen, you can en- large the bird's eye view display, switch to the camera image screen. Operation on the camera image display screen Operate the following for changing the camera image display on the machine monitor. AA: Standard screen, BB: Enlarged bird's eye view display, CC: Camera image screen •...
Page 125 OPERATION EXPLANATION OF COMPONENTS CAMERA IMAGE SELECTOR SWITCH • By pressing the switch F4, you can switch the in-car cam- era to switch between the image of the right and left of the machine and that of the back. • Machine monitor screen automatically changes to the screen which displays the bird's eye view display of Kom- Vision when operating work equipment, swing, travel and...
Page 126 EXPLANATION OF COMPONENTS OPERATION OTHER MODE OPERATIONS WHILE CAMERA IMAGE IS DISPLAYED Even when the camera image is displayed, it is possible to op- erate the following modes. But operation of air conditioner and working mode cannot be changed while operating work equipment, swing, travel and at- tachment.
Page 127 OPERATION EXPLANATION OF COMPONENTS • Press the auto-deceleration switch to turn on or off the au- to-deceleration function. Even if the auto-deceleration switch is pressed, the cam- era image display screen neither switches to another screen nor returns to the standard screen display. •...
Page 128 EXPLANATION OF COMPONENTS OPERATION • If the caution lamp is displayed, press the switch F6 to re- turn to the standard screen, and check the content of the abnormality or warning display. While the caution lamp is flashing, if no lever is operated for 10 seconds or more, the screen automatically returns to the standard screen.
Page 129 OPERATION EXPLANATION OF COMPONENTS USER MENU The user menu consists of the following kinds. Press the switches F1 and F2 to move to right and left for selecting the menu screens. (a): “Energy Saving Guidance” (b): “Machine Setting” (c): “Aftertreatment Devices Regeneration” (d): “SCR Information”...
Page 130 EXPLANATION OF COMPONENTS OPERATION (c) “Aftertreatment Devices Regeneration” • Setting for “Regeneration Disable” • Operation of “Manual Stationary Regeneration” (d) “SCR Information” • Check of DEF level • Urea SCR system information (e) “Maintenance” • Check and resetting of various Maintenance Times (f) “Monitor Setting”...
Page 131 OPERATION EXPLANATION OF COMPONENTS On the user menu screen, you can perform the following opera- tions with switches F1 to F6. F1: Moves to the left menu. When it is on the left end menu, it moves to the right end menu. F2: Moves to the right menu.
Page 132 EXPLANATION OF COMPONENTS OPERATION CHECK OPERATING RECORD Select the Operation Records (1) from the Energy Saving Guid- ance menu screen, then press switch F6. On the Operation Records menu, the working hours, Average Fuel Consumption, Actual working hours, Ave. Fuel Consump- tion (Actual Working), Fuel Consumption, Idling Hours and E mode time ratio on daily basis or on a split measurement peri- od basis are displayed.
Page 133 OPERATION EXPLANATION OF COMPONENTS REMARK ECO guidance denotes displaying the guidance for energy sav- ing operation. This display may appear on the standard screen while the machine is in operation. CHECK FUEL CONSUMPTION RECORD Select the Average Fuel Consumption Record (3) from the En- ergy Saving Guidance menu screen, then press switch F6.
Page 134 EXPLANATION OF COMPONENTS OPERATION Switching of displayed graph Press F2 on the Average Fuel Consumption Record screen to change the currently displayed graph to another. REMARK There are 2 types of graphs. One shows hourly average fuel consumption during the last 12 hours and the other is daily average fuel consumption during the last 1 week.
Page 135 OPERATION EXPLANATION OF COMPONENTS CHANGE DISPLAY SETTING Select Configurations (4) from the Energy Saving Guidance menu screen, then press switch F6. On the Configurations menu, following operations are availa- ble. • Setting the Average Fuel Consumption Display • Switching ON/OFF of the ECO Gauge Display •...
Page 136 EXPLANATION OF COMPONENTS OPERATION Select "Average Fuel Consumption Display" (6) from the "Configurations" screen, then press switch F6. On the Configurations screen, it is possible to perform the following operations with switches F3 to F6. F3: Moves to the next item (1 line below). When it is on the last line, it moves to the first line.
Page 137 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE The setting of Display/Non-display of ECO gauge (7) can be changed. Select the ECO Gauge Display (8) from the Configurations screen, then press the switch F6. ECO Gauge Display setting screen appears. ON: Displays the ECO gauge (7) on the standard screen.
Page 138 EXPLANATION OF COMPONENTS OPERATION 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 target fuel consumption value by 1 ℓ/h. F5: Cancels the setting and returns to Configurations screen.
Page 139 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF It is possible to change the setting of Display/Non-display of guidance (12) when the starting key is turned off. Select ECO Guidance at Key OFF (13) from the Configu- rations screen, then press switch F6.
Page 140 EXPLANATION OF COMPONENTS OPERATION When the attachment control setting is effective (if equipped) • “Economy Mode Adjustment” • “Breaker/Attachment Setting” • “Auto-deceleration Setting” • “Auto Idle Stop Timer Setting” ADJUST ECONOMY MODE Select the “Economy Mode Adjustment” (1) on the “Machine Setting (b)”...
Page 141 OPERATION EXPLANATION OF COMPONENTS Select “Breaker Setting” (2) on the “Machine Setting” menu (b) screen, then press the switch F6. On the “Breaker Setting” screen shown in the figure, select the breaker to adjust and press the switch F6. On the “Breaker Setting” screen shown in the figure, you can perform the following operations with switches F1 to F1: Changes the name of the selected breaker setting.
Page 142 EXPLANATION OF COMPONENTS OPERATION Changing “Breaker Oil Flow Rate Setting” On the “Breaker Setting” screen, select a setting to change its oil flow rate, then press the switch F2. The “Breaker Oil Flow Rate Setting” screen is displayed. On the “Breaker Oil Flow Rate Setting” screen, you can perform the following operations with switches F3 to F6.
Page 143 OPERATION EXPLANATION OF COMPONENTS 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 for the attachment setting to desired name. You can use alphabet letters A to Z, Arabic numerals 0 to 9, symbols #, *, +, -, and /, and the space.
Page 144 It is not possible to change the oil flow rate for “No Attachment” setting. Perform the setting for the attachment 2. Ask your Komatsu distributor to have the monitor setting changed so that two attachments are available if the attachment 2 system is to be equipped.
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “Attachment Setting” (1) on the “Machine Setting” menu (b) screen, then press the switch F6. On the “Attachment Setting” screen shown in the figure, select an attachment setting to adjust and press the switch On “Attachment Setting” screen shown in the figure, you can perform the following operations with switches F1 to F1: Changes the name of the selected attachment setting.
Page 146 EXPLANATION OF COMPONENTS OPERATION SET AUTO-DECELERATION On “Auto Deceleration Setting”, you can configure the auto-de- celeration function. Select “Auto Deceleration Setting” (4) on “Machine Setting” menu (b) screen, then press the switch F6. The screen changes to “Auto Deceleration Setting” selec- tion menu screen.
Page 147 OPERATION EXPLANATION OF COMPONENTS Select the set time on “Auto Idle Stop Timer Setting” screen shown in the figure, and then press the switch F6. On “Auto Idle Stop Timer Setting” screen shown in the fig- ure, you can perform the following operations with switches F3 to F6.
Page 148 EXPLANATION OF COMPONENTS OPERATION REMARK While the auto idle stop function is enabled, the number of the times that the engine was stopped when it was not at low idle is displayed as “L01” from 1000th and as “L03” from 2000th on the machine monitor.
Page 149 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE SCREEN SETTING Each item of the setting menu (e) on “Maintenance” screen is used for displaying and setting the notification relevant to main- tenance. The items on "Maintenance" display are as follows. Air Cleaner Cleaning or Change Coolant Change Additional Hyd Oil Filter Change Hyd Oil Pilot Filter Change...
Page 150 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on “Maintenance Due Time Reset” screen If you keep pressing the switch F6 for 1.5 seconds or longer on Maintenance menu screen, the screen changes to Maintenance Due Time Reset screen.
Page 151 OPERATION EXPLANATION OF COMPONENTS Select screen adjustment (1) on the “Monitor Setting” menu screen, then press the switch F6. Use the switches F2 to F6 to adjust the brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one level.
Page 152 EXPLANATION OF COMPONENTS OPERATION Use the switches F2 to F6 to adjust the brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one level. F4: Moves the indicator to the right by one level. F5: Cancels the change and returns to “Monitor Setting”...
Page 153 OPERATION EXPLANATION OF COMPONENTS 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 se- lected.
Page 154 EXPLANATION OF COMPONENTS OPERATION TIME SETTING Adjust the time of the monitor clock. REMARK As long as “GPS Synchronization” is turned on, “Time” menu is not selectable. Select “Time” (c) on “Clock Adjustment” screen, then press switch F6. The “Time” screen is displayed. When the hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D).
Page 155 OPERATION EXPLANATION OF COMPONENTS “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.
Page 156 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or cancelling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 157 OPERATION EXPLANATION OF COMPONENTS Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second. 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.
Page 158 EXPLANATION OF COMPONENTS OPERATION WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is available without SKIP, the identified ID number is not displayed in the “Operator ID” column of “Monitor Setting” screen. Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second.
Page 159 MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (g). When there is any message, the User Message at the left end of the standard screen lights up.
Page 160 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 in accord- ance with the replying method mentioned below. •...
Page 161 OPERATION EXPLANATION OF COMPONENTS In case of a message requesting for reply, the column of “Numeric Input: []” is displayed in place (2) of the mail con- firmation menu. Make a reply to the message. REMARK • (3) is the subject of the received message. When no message is received, “No message.”...
Page 162: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES (1) One-touch power maximizing switch (13) Pump secondary drive switch (2) Horn switch (14) Swing parking brake cancel switch (3) Starting switch (15) Lock lever automatic lock cancel switch (4) Fuel control dial (16) Hybrid system stop switch (5) Lamp switch (17) Lower wiper switch (if equipped) (6) Swing lock switch...
Page 163 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting switch is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electri- cal system (except room lamp) are all turned off, and the en- gine is stopped.
Page 164 EXPLANATION OF COMPONENTS OPERATION Swing lock switch is used to lock the upper structure so that it cannot swing. (a) ON position The swing lock is always applied, and the upper structure does not swing even when the swing is operated. In this condition, the swing lock pilot lamp lights up.
Page 165 OPERATION EXPLANATION OF COMPONENTS Use room lamp switch to light up the room lamp. (a) ON position Lights up (b) OFF position The room lamp lights up even when the starting switch is at OFF position. PUMP SECONDARY DRIVE SWITCH CAUTION When the pump secondary drive switch (1) is being used or immediately after it is used, the temperature of resistor...
Page 166 EXPLANATION OF COMPONENTS OPERATION If the Current Abnormality list includes any of the hydraulic sys- tem errors “DXA9KB”, “DXA8KB”, “DXA9KA”, or “DXA8KA”, you can perform operation temporarily by setting this switch to "Emergency" position (a). SWING PARKING BRAKE CANCEL SWITCH WARNING Do not operate the swing parking brake cancel switch on the slopes.
Page 167 The hybrid system stop switch is used to stop the hybrid system temporarily when a problem oc- curs in the machine. Do not use it except in an emergency. If any problem occurs, ask your Komatsu distributor for the inspection and maintenance immediate- •...
Page 168 OFF position but the engine does not stop. • Use the engine shutdown secondary 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”...
Page 169 OPERATION EXPLANATION OF COMPONENTS Raise cover (C) and open it. Turn the engine shutdown secondary switch to upper posi- tion (a) and the engine stops. (a) Engine stopped When abnormal (switch is set to upper position) (b) Normal When normal (switch is set to lower position) •...
Page 170 EXPLANATION OF COMPONENTS OPERATION SEAT HEATER SWITCH This seat heater switch is used to warm the seat. (a) OFF Stops the seat heating. (b) ON Start the seat heating and the seat becomes warm. QUICK COUPLER SWITCH The switch (1) on the R.H. console and the switch (2) on the L.H.
Page 171 OPERATION EXPLANATION OF COMPONENTS The attachment 2 proportional switch is a roller proportional control switch that operates the attachment 2 proportional cir- cuit (e.g. rotating the clamshell). For details, see ATTACHMENTS AND OPTIONS, “ATTACH- MENT 2 PROPORTIONAL SWITCH”. BREAKER MODE SWITCH The breaker mode switch is used to operate the breaker.
Page 172: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS (1) Lock lever (4) R.H. work equipment control lever (with auto-de- celeration system) (2) Travel levers (with pedal and auto-deceleration system) (3) L.H. work equipment control lever (with auto-decel- eration system) LOCK LEVER WARNING •...
Page 173 • When 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.
Page 174 EXPLANATION OF COMPONENTS OPERATION 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)
Page 175: Other Equipment
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. 3-103...
Page 176 EXPLANATION OF COMPONENTS OPERATION (a) Correct stowing position The wiper blade is on the cab. (b) Wrong stowing position The wiper blade is on the glass. 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.
Page 177 OPERATION EXPLANATION OF COMPONENTS Hold lower handle (C) with your left hand from inside the operator's cab, and with your right hand, grip top handle (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window. REMARK Handles (A) on the right and left top sides of the front win- dow are not for pulling up the front window.
Page 178 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 stowing position The wiper blade is on the cab.
Page 179 OPERATION EXPLANATION OF COMPONENTS Grip right and left handles (A), and pull down lever (B) to release the lock. Grip the handle (C) at the bottom of the front window with your left hand and the handle (D) at the top with your right hand, push the window to the front, then lower it slowly.
Page 180 EXPLANATION OF COMPONENTS OPERATION Removal of front window (lower side) Open the front window (upper side), then hold grip (1), pull it up, and remove the lower side window. REMARK If sand or dust is collected at the bottom of the front win- dow (lower side), it will be difficult to remove the window.
Page 181 OPERATION EXPLANATION OF COMPONENTS To escape from the operator's cab, use the hammer (A) to break the glass and escape through the window. METHOD FOR USING DOOR LOCK WARNING • Before the releasing the door lock, always place the machine on a level ground. •...
Page 182 EXPLANATION OF COMPONENTS OPERATION CAP AND COVER WITH LOCK Use the starting switch key to open and close the locks on the caps and covers. Insert the key as far as it will go to the shoulder (A) and turn it. If the key is turned when it is not inserted all the way to the end, it may break.
Page 183 OPERATION EXPLANATION OF COMPONENTS ASHTRAY This is on top of the console box on the left side of the opera- tor's seat. Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid. NOTICE While removing the ashtray, if it is stuck in the console cover and hard to be removed, open lid (A) of ashtray, then hold the ashtray body (B) and twist it to remove.
Page 184 EXPLANATION OF COMPONENTS OPERATION • The fuse holder is at the rear of the operator's seat. • The fuses 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. •...
Page 185 OPERATION EXPLANATION OF COMPONENTS (28) 20 A Automatic lubricating system (29) 30 A OPT heater (30) 10 A Spare (31) 20 A Sensor power supply relay (1) (32) 10 A Sensor power supply relay (2) (33) 10 A DEF line heater relay (1) (34) 20 A DEF line heater relay (2)
Page 186 EXPLANATION OF COMPONENTS OPERATION GREASE PUMP HOLDER It is located at front right of the machine. Keep the grease pump hooked on the grease pump holder while it is not used. FIRE EXTINGUISHER (if equipped) A fire extinguisher is provided at the rear part inside the opera- tor's cab.
Page 187 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute leakage of current and not an abnormal phenomenon.
Page 188 Recommended grease • Komatsu genuine grease is provided to maintain the reliability and durability of Komatsu construction equip- ment and components. • Handle the auto-greasing system as described in the Operation and Maintenance Manual in order to main- tain the optimal state of the machine for a long period of time.
Page 189 OPERATION EXPLANATION OF COMPONENTS Chart of greasing points for auto-greasing Name of circuit Swing circle Boom cylinder foot pin Boom foot pin Arm cylinder rod end Arm cylinder foot pin Boom arm coupling Boom cylinder rod end Bucket cylinder foot pin Bucket cylinder rod end (unavailable for some specifica- tions) Bucket - Link coupling pin (unavailable for some specifi-...
Page 190 EXPLANATION OF COMPONENTS OPERATION Automatic greasing system monitor Display Meaning The system error lamp (red) (6) flashes The electric power does not reach the pump. at the same time as the starting switch is Check that the fuse and the ground are connected. turned to ON position.
Page 191 The inducement of the engine modifies the inappropriate behavior of the urea SCR system. Alerts in In- ducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the ma- chine monitor and audible sounds for engine power deration to avoid getting into unsafe conditions.
Page 192 DEF and that mixture is used, the devices will not function properly, and conformance to the exhaust gas regulations will be lost. In addition, it may cause failures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu distributor. aftertreatment devices regeneration automatically raises the...
Page 193 OPERATION EXPLANATION OF COMPONENTS When the degree of urgency is low • If regeneration performance caution lamp (2) lights up in yellow (action level (3): “L01”), screen (A) is displayed first. • The action level goes out 2 seconds later, and the screen changes back to standard screen (B).
Page 194 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR MANUAL STATIONARY REGENERATION The manual stationary regeneration can be performed while the regeneration performance caution lamp (1) is lit. During the manual stationary regeneration, engine speed may increase when the engine is running at low idle. Move the machine to a safe place and stop it while the en- gine is running.
Page 195 OPERATION EXPLANATION OF COMPONENTS If the manual stationary regeneration still cannot be performed, return to the standard screen, press the switch F5, and follow the instructions shown on the screen. It may take more than 40 minutes to complete during the man- ual stationary regeneration.
Page 196 EXPLANATION OF COMPONENTS OPERATION The aftertreatment devices regeneration display (1) may light up even if the regeneration disable is set, but the operation of Regeneration Disable cannot be performed. When the aftertreatment devices regeneration should be stopped during being regenerated. (When the aftertreatment devices regeneration display (1) is displayed on the standard screen) When switch F6 is pressed on the standard screen, the...
Page 197 OPERATION EXPLANATION OF COMPONENTS When switch F6 is pressed on the standard screen, the “Aftertreatment Devices Regeneration” screen is dis- played. (If the “Aftertreatment Devices Regeneration” screen is not displayed, display it by operating switches F1 and F2.) Select the Cancel of Regeneration Disable and press the switch F6, and the regeneration disable is restored.
Page 198 EXPLANATION OF COMPONENTS OPERATION The inducement strategy progresses in 4 levels, “Warning”, “Continuous Warning”, “Low level Inducement” and “Severe Inducement”. The DEF level caution 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.
Page 199 OPERATION EXPLANATION OF COMPONENTS • Continuous Warning: The audible alert sounds in repetition of “Triple-beep alarm”. 2 gradations of the DEF level gauge (2) light up in red. The DEF level caution lamp (1) lights up in red. No action level is displayed. Press F6 to display the “SCR Information”...
Page 200 “L04 (Severe Inducement)” is displayed. When action level “L03” is displayed, move the ma- chine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 201 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 202 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 203 “L04 (Severe Inducement)” is displayed. When action level “L03” is displayed, move the machine to a safe place and con- tact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 204 The remaining time (Hours and Minutes) to “Severe In- ducement” is displayed in the column (6) of “SCR Informa- tion” screen. In “Severe Inducement”, engine power will be derated fur- ther. Move the machine to the safe place and contact your Komatsu distributor. 3-132...
Page 205 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 206 EXPLANATION OF COMPONENTS OPERATION Press F6 to display the menu windows popping up in the bottom half of the “SCR Information”. The menu windows popping up in the bottom half of the “SCR Information” screen alternate every 15 seconds as shown in the graphics A and B.
Page 207 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and contact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed. To activate “Temporary Restoration from Inducement”, refer to the “Temporary Restoration from Inducement”...
Page 208 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 209 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 210: Machine Operations And Controls
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Perform the following inspections and cleaning every day before starting the engine for the day's work.
Page 211 “METHOD FOR ADJUSTING MIRRORS”. 11. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one.
Page 212 • Contact your Komatsu distributor if there is any malfunction in the auto shut-off refuel system. Do not use the system unless the problem is solved. The fuel can be refuelled by using the refuelling pump from the fuel barrel if the machine is operated in a site where there is neither a fuel container nor a pump.
Page 213 OPERATION MACHINE OPERATIONS AND CONTROLS Remove the oil filler cap (F). Turn on the master switch (4) for the refuel auto stop sys- tem on the refuel switch box (3). The refuel switch box (3) is located inside the door on the rear right of the machine.
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION Push the float gauge (G) straight down with the fuel filler cap (F). Be careful not to get the float gauge (G) caught in the tab of the fuel filler cap, and tighten the fuel filler cap (F). Tighten the strainer valve cap (H) until it comes to CLOSE position (K).
Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS When fuel starts to be drained from the drain hose (3), tighten the drain valve (4) immediately to stop draining. On this machine, a sensor is installed to detect if water ac- cumulates in transparent cup (2). When the water separator caution lamp (5) lights up in red on the machine monitor, it indicates that water is accumu- lated in transparent cup (2).
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the valve (6) at the lower part of the fuel tank to OPEN position (O). Bleed air from the fuel circuit. METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in- jury.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK The oil level varies with the oil temperature. Use the fol- lowing as a guide for check. • Before starting operation: Between H and L levels (Oil temperature 10 to 30 °C) • Normal operation: Around H Level (Oil temperature 50 to 80 °C) METHOD FOR INSTALLING HYDRAULIC TANK OIL FILLER CAP CAUTION...
Page 218 After checking the engine radiator, hybrid compo- nent radiator, and their respective coolant pipings, if any problem is found, ask your Komatsu distrib- utor for repair. If no problem is found, check the level of the cool- ant in the engine radiator and hybrid component radiator.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS Radiator for engine (6) Engine radiator (7) Engine radiator cap Radiator for hybrid component (8) Hybrid component radiator (4) Hybrid component radiator cap METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Page 220 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the starting switch to ON position. When the fuel level caution lamp (1) lights up in red, check the fuel level with fuel gauge (2) on the machine monitor. When the fuel gauge pointer indicates the red range, the fuel quantity is 41 ℓ...
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION Open the cover of case at front right of the machine, look into the capacitor inspection window (1), and check that one of LED lamps is lit. • If the engine has not been operated for a long period, all of LED lamps may go out.
Page 223 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Open the cover (2) on the right side of the machine, and clean the DEF tank cap and the area around. Turn the cap of filler port (3) counterclockwise. The cap of filler port is opened. By sight gauge (4), add DEF through the filler port until float (5) reaches the line F (6).
Page 225 After checking, turn the starting switch back to OFF posi- tion. If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. METHOD FOR CHECKING HORN Turn the starting switch to ON position.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION 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 RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is moved backward.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING ARMREST HEIGHT CAUTION Firmly tighten the knob. If it is found loosened, tighten it further. Height of the armrest can be adjusted up or down by using the knob at the rear of the armrest. Armrest height adjustment: 43 mm Loosen knob (1) at the rear of the armrest.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION Fore-and-aft adjustment: 180 mm (9 stages) METHOD FOR ADJUSTING AIR SUSPENSION SEAT HARDNESS Air suspension seat Operate the suspension switch (9) to adjust the hardness of the suspension. • If you press the suspension switch (9), the suspension be- comes hard.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR REMOVING AND INSTALLING HEADREST METHOD FOR REMOVING HEADREST When the headrest is not necessary, remove it according to the following procedure. Pull up the headrest 80 mm or more. The headrest is pulled out. NOTICE When removing the headrest, operate it so that the shaft of the headrest becomes straight.
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work. • The machine is placed on a level ground. •...
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust stay (1). Mounting position (2): 77 mm Mounting angle (3): 89 ° Mounting angle (4): 107 ° Tightening torque of mounting bolt (5): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Adjust the 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...
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work. • The machine is placed on a level ground. •...
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work. • The machine is placed on a level ground. •...
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION 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) CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing the work.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the mirror (1). Tightening torque of mounting bolt (2):6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting position (3): 55 mm Mounting angle (4): 5 ° Mounting angle (5): 27 ° METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR FASTENING SEAT BELT Hold grip (2) and pull out the belt from retractable device (1). Check that the belt is not twisted, and then inset tongue (3) into buckle (4) securely. Pull the belt lightly to check that it is properly locked. METHOD FOR UNFASTENING SEAT BELT Press the button (5) in buckle (4) and remove the tongue (3) from buckle (4).
Page 237 REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. Perform the following inspection on the machine monitor. The buzzer sounds for approximately 2 seconds and the following caution lamps and meters light up for ap- proximately 2 seconds.
Page 238 If any caution lamp does not light up or the buzzer does not sound, there is probably a failure in the caution lamp, so ask your Komatsu distributor for repair. The screen changes to the working mode and travel speed display screen after approximately 2 sec- onds, and then it changes to the standard screen.
Page 239: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING ENGINE WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a serious personal injury or death or fire. •...
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION Turn starting switch key (3) to ON position (B). REMARK If the ambient temperature is low, the preheating pilot lamp lights up and automatic preheating is performed. Keep the starting switch key (3) at ON position (B) until the preheat- ing pilot lamp goes out.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK White smoke may be discharged for a short time immediately after the engine is started or during the after- treatment devices regeneration in the cold season, but this is not a failure. REMARK Urea SCR system has the function of heating system and keeping it warm to prevent freezing of DEF. If DEF is frozen, the DEF system is automatically heated to thaw DEF after the engine is started.
Page 242: Method For Operations And Checks After Starting Engine
Check that there is no abnormal noise when the engine is idling or when the engine speed rises slightly. When there is an abnormal noise at the engine startup and if that condition continues, the engine may be dam- aged. In that case, ask your Komatsu distributor to check the engine as soon as possible. 3-170...
Page 243 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION Check that the engine coolant temperature caution lamp (1) displays the correct temperature. If it displays the low temperature, perform additional warm- up operation according to step 2 until it displays the correct temperature. • Display (A) when temperature is correct: Caution lamp background (C) is blue.
Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CANCELING 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. Turn fuel control dial (2) to High idle (MAX) position and hold it for 3 seconds or more.
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR HYDRAULIC SYSTEM WARM-UP OPERATION WARNING • Before performing the warm-up operation for the hy- draulic component, set the swing lock switch on, check on the monitor that the swing lock is actuated, then start the warm-up operation. •...
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS Set the swing lock switch (2) to ON position and check that the swing lock pilot lamp is lit. Set the working mode to P mode (heavy-duty operation mode). The hydraulic component is warmed up quickly. For setting the working mode, see “WORKING MODE SE- LECTOR SWITCH”.
Page 248 MACHINE OPERATIONS AND CONTROLS OPERATION Next, move the L.H. work equipment control lever (6) slowly in the direction of arm IN position (B). Op- erate the lever to the end of its stroke and hold it in the position for 30 seconds. Move the L.H.
Page 249 Fuel gauge (23): Indicator is in green range 11. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. NOTICE Warm-up all the hydraulic component by performing the warm-up operation for hydraulic system in cold weather (ambient temperature less than 0°C) even when the hydraulic oil temperature caution lamp dis-...
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION 14. Repeat the following operation slowly 3 to 5 times before starting actual work. Circulate the warm hydraulic oil through all control circuits. • Boom operation: RAISE (E) ←→ LOWER (F) • Arm operation: IN (B) ←→ OUT (A) •...
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Attachment operation: One way (A) ←→ Other way 15. Check that the hydraulic oil temperature caution lamp (7) displays the correct temperature. If the hydraulic oil temperature caution lamp is not display- ing the correct temperature (it is displaying the low temper- ature), repeat the steps 6 to 7 until it displays the correct temperature.
Page 252: Method For Stopping Engine
MACHINE OPERATIONS AND CONTROLS OPERATION Display of working mode P mode E mode For heavy-duty operations For operations with emphasis on fuel consumption L mode B mode For operations requiring fine control For breaker operations ATT/P mode ATT/E mode For operation of 2-way attachment like crusher For operation of 2-way attachment like crusher (fuel economy conscious operations) METHOD FOR STOPPING ENGINE...
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not stop the engine abruptly except in an emergency. Otherwise, the service lives of component parts of the en- gine will be reduced. If the engine is overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradu- ally, and then stop it.
Page 254: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • When the key in starting switch (1) is turned to OFF (A) position, the engine stops, but the machine's main power supply is not turned off immediately. This is because that the power is supplied for the con- troller to save the operating condition and then finish the system.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS Set the swing lock switch (1) to ON (actuated) position and check that the swing lock pilot lamp (2) is lit. (a): ON position (b): OFF position Turn the fuel control dial (3) to High idle (MAX) position. Increase the engine speed.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION If the travel alarm does not sound, ask your Komatsu distributor for repair. REMARK In low temperatures, if the machine travel speed is not normal, thoroughly perform the warm-up operation. In addition, if the undercarriage is packed with mud and the machine travel speed is not normal, remove the soil and mud from the undercarriage.
Page 257: Method For Steering Machine
OPERATION MACHINE OPERATIONS AND CONTROLS Set right and left travel levers (1) in NEUTRAL position (N). The machine stops. METHOD FOR STEERING MACHINE METHOD FOR STEERING (CHANGE THE DIRECTION) MACHINE WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket).
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION • (A): Turning FORWARD LEFT Push the right travel lever forward. The machine turns forward LEFT. • (B): Turning REVERSE LEFT Push the right travel lever backward. The machine turns in reverse LEFT. REMARK When turning to the RIGHT, read the preceding procedure by replacing the word "LEFT"...
Page 259: Method For Swinging Machine
OPERATION MACHINE OPERATIONS AND CONTROLS COUNTER-ROTATION TURN • Counter-rotation turn to left Pull the left travel lever toward you. Push the right travel lever forward. The machine make a counter-rotation turn to the left. • Counter-rotation turn to right Pull the right travel lever toward you. Push the left travel lever forward.
Page 260: Method For Operating Work Equipment
MACHINE OPERATIONS AND CONTROLS OPERATION Operate the L.H. work equipment control lever (3) to swing the upper structure. (A): Swing LEFT (B): Swing RIGHT When not performing the swing, turn the swing lock switch (1) to ON position (actuate). (a): ON position (b): OFF position Check that the swing lock pilot lamp (2) is lit.
Page 261: Handle Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS • Boom operation Move the R.H. work equipment control lever back and forth. You can operate the boom. • Bucket operation Move the R.H. work equipment control lever to the right and left. You can operate the bucket. If the work equipment control levers are returned to NEUTRAL position when the machine is stopped, even if the fuel control dial is set to High idle (MAX) position, the auto-deceleration mechanism works to reduce the en- gine speed to the low speed.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION Working Applicable operations mode Operations of 2-way attachment such as crusher, etc. ATT/P mode (production conscious operation) Operations of 2-way attachment such as crusher, etc. ATT/E mode (fuel consumption conscious operation) NOTICE Do not perform the breaker operations in any mode other than the breaker mode. Otherwise, the hy- draulic component may break.
Page 263: Prohibited Operations
OPERATION MACHINE OPERATIONS AND CONTROLS • If the breaker mode is selected, "Really set breaker mode?" is displayed on the screen. When setting to the breaker mode, press the switch If switch F5 is pressed, the screen returns to the work- ing mode selection screen.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF OPERATIONS USING TRAVEL FORCE Do not use the travel force to perform excavation by digging the bucket into the ground. This damages the machine or work equipment. PROHIBITION OF OPERATIONS USING HYDRAULIC CYLINDERS TO STROKE If the work equipment is used with the cylinder rod operated to its stroke end, and given impact by some external force, the hy- draulic cylinders may be damaged, causing personal injury.
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS 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 to the chassis and buck- et, and the machine may break.
Page 266 MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITION OF DIGGING OPERATION AT AN ANGLE WITHOUT ENGAGING TEETH If the machine swings and digs simultaneously while the bucket blade does not bite into hard rocks at a position higher than the machine, the teeth slide down on the rock surfaces. As a result, large vibration occurs in the machine and can crack the work equipment or frame.
Page 267 OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITION OF SWINGING OR TRAVELLING WHEN ROCK IS ON TOP OF TRACK ASSEMBLY If the machine travels or swings with crushed stones, soil, or sand on the track, they hit and damage the undercover and frame.
Page 268: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION DO NOT TRAVEL LONG -TIME CONTINUOUSLY If the machine travels continuously at high speed for 1.5 hours or more, the temperature of lubricating oil inside the track roll- ers and final drive will rise up. This may cause breakage to the oil seal or leakage of oil.
Page 269 If someone touches the hybrid devices or high-voltage electrical wiring by mistake, it is dangerous that causes an electric shock. Always ask your Komatsu distributor for the inspection and repair. 3-197...
Page 270: Precautions For Working On Slope
MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS FOR WORKING ON SLOPE WARNING • Swinging operations or operating the work equipment on slopes machine may lose its balance and turn over. Avoid such operations as much as possible. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 271: Method For Escaping From Mud
OPERATION MACHINE OPERATIONS AND CONTROLS When travelling up a steep hill of more than 15°, set the work equipment to the posture shown in the figure. When travelling up a steep slope, extend the work equip- ment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm above the ground, and travel at low speed.
Page 272: Recommended Applications
MACHINE OPERATIONS AND CONTROLS OPERATION Tracks on both sides stuck When the tracks on both sides get stuck and slip, lay logs, wooden blocks, etc. according to the preceding procedure. Stick the bucket into the front ground, pull in the arm as in dig- ging operation, and set the travel lever to FORWARD position to drive the machine out.
Page 273: Effective Use Of Hydraulic Excavator
Reducing excavation at high position • Operation at minimum swing angle • Travelling at low engine speed We can provide our users the training for operating methods to increase the productivity and to reduce the fuel consumption. Contact your Komatsu distributor for details. 3-201...
Page 274: Method For Replacing And Inverting Bucket
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR REPLACING AND INVERTING BUCKET WARNING • When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When performing this operation, always wear protective eyeglasses, hard hat, gloves, and other protective equipment.
Page 275 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket, for arm pin part (A), fit O-ring (5) to bucket (6) in the position shown in the figure. After inserting the pin, fit it in the regular groove. For link pin part (B), install the bucket with O-ring (5) fitted in the regular groove.
Page 276 MACHINE OPERATIONS AND CONTROLS OPERATION Invert the removed bucket. Align the pin hole of arm (1) with replacement bucket hole (2), then align the pin hole of link (3) with hole (4), and in- stall pins (A) and (B) which are coated with grease. REMARK When inverting, do not install the O-rings.
Page 277: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS REMARK The machine with the auto-greasing system require one time lubrication each time the bucket is changed. Lubricate at the bucket linkage and at the grease metering valve as indicated until grease comes out from the end faces. It will be necessary to replace the plug at the grease metering valve with a grease nipple during lubrication.
Page 278 MACHINE OPERATIONS AND CONTROLS OPERATION Set the right and left travel levers (1) in NEUTRAL posi- tion. The machine stops. Turn the fuel control dial (2) to low idle (MIN) position in or- der to lower the engine speed. Make the undercarriage and upper structure point to the same direction, and lower the bucket to the ground with its bottom face horizontal.
Page 279: Method For Checking After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS Check the engine coolant temperature and the engine oil pressure with the machine monitor. • If the engine coolant temperature gauge is in the red range, cool down the coolant until the gauge enters the green range, and stop the engine. Then, inspect and take necessary remedy according to “TROUBLES AND ACTIONS”.
Page 280 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key clockwise, align the matching marks (1) of the key groove and the cap, then open the cap. Position (A): OPEN Position (B): CLOSE (LOCK) PROCEDURE FOR CLOSING CAP WITH LOCK Screw in the cap until it becomes tight, then insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key.
Page 281 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING ENGINE HOOD CAUTION • When opening or closing the engine hood, place the machine on a level ground, lower the work equipment to the ground, stop the engine, then perform the operation. •...
Page 282 MACHINE OPERATIONS AND CONTROLS OPERATION Take off the hoop (2) from hook (3). Hold the handle (4) and pull up the engine hood. Push the stay (5) in the direction of arrow and set it in the intermediate LOCK position (6) securely. The engine hood can be locked at 2 different opening an- gles.
Page 283 OPERATION MACHINE OPERATIONS AND CONTROLS While pushing the stay (5) in the direction of arrow, open the engine hood. Set the stay (5) in LOCK position (9). METHOD FOR LOCKING ENGINE HOOD Hold the handle (4) and support the engine hood. Hold the handle (7), pull the stay (5) in the direction of ar- row, and remove the stay (5) from intermediate LOCK po- sition (6).
Page 284 MACHINE OPERATIONS AND CONTROLS OPERATION Hitch the hoops (2) of R.H. and L.H. levers (1) to hooks (3). Pull up the levers (1) and lock them. METHOD FOR OPENING AND CLOSING DEF TANK FILLER CAP COVER CAUTION • When opening or closing the DEF tank filler cap cover, place the machine on a level place, lower the work equipment to the ground, stop the engine, then perform the operation.
Page 285 OPERATION MACHINE OPERATIONS AND CONTROLS Hold grip (1), unlock lock (2), and pull up the cover. Set stay (3) securely in position (4) to lock it. 3-213...
Page 286 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR LOCKING DEF TANK FILLER CAP COVER Hold handle (1), and pull up stay (3) to the direction of the arrow while supporting the cover. Remove stay (3) from lock position (4). Check that stay (3) is set in guide groove (5), and then lower the cover.
Page 287 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING DEF PUMP COVER METHOD FOR OPENING DEF PUMP COVER Unlock cover (1) at the right front of the machine with the starting switch key. Open cover (1) with your hand, and latch lock stay (2). METHOD FOR LOCKING DEF PUMP COVER Unlatch lock stay (2) and close cover (1).
Page 288 MACHINE OPERATIONS AND CONTROLS OPERATION Position (B): CLOSE (LOCK) When locking the door Close the door and insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key. 3-216...
Page 289: Handle Air Conditioner
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 machine monitor screen. If the air conditioner system caution lamp lights up, ask your Komatsu distributor for inspection and repair. Ventilation while cooling •...
Page 290: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Sunlight sensor (5) Auto switch OFF SWITCH This switch is used for stopping the fan and air conditioner.
Page 291 OPERATION HANDLE AIR CONDITIONER Monitor display and air flow Monitor display Air flow rate Air flow "low" Air flow "medium 1" Air flow "medium 2" Air flow "medium 3" Air flow "medium 4" Air flow "high" TEMPERATURE SET SWITCH Use the temperature set switch to adjust the temperature inside the cab.
Page 292 HANDLE AIR CONDITIONER OPERATION (A): Rear vent (4 places) (B1): Face vent (1 place) (C): Foot vent (1 place) (D): Front window glass vent (2 places) (B2): Front window glass vent (1 place) Air blows out from the vents marked with ○. Vent LCD display Air vent mode...
Page 293 OPERATION HANDLE AIR CONDITIONER FRESH/RECIRC AIR SELECTOR SWITCH Use FRESH/RECIRC air selector switch to switch the air source between recirculation of the air inside the cab and in- take of fresh air from the outside. During automatic operation, the selection of inside air (RE- CIRC) and outside air (FRESH) is performed automatically.
Page 294: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION SUNLIGHT SENSOR Sunlight sensor automatically adjusts the flow of air from the vents to match the strength of the sun's rays. In addition, it au- tomatically detects changes in the temperature inside the cab caused by changes in the strength of the sun's rays beforehand and automatically adjusts the temperature.
Page 295 OPERATION HANDLE AIR CONDITIONER Use temperature control switch (2) to set to the desired temperature. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated auto- matically to provide the set temperature.
Page 296 HANDLE AIR CONDITIONER OPERATION METHOD FOR MANUAL OPERATION 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. Turn air conditioner switch (2) ON. Use temperature control switch (3) to set to the desired temperature.
Page 297 OPERATION HANDLE AIR CONDITIONER Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the monitor changes according to the selection. 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).
Page 298 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blow- ing to the feet, set as follows. 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.
Page 299 OPERATION HANDLE AIR CONDITIONER Turn on the air conditioner switch (3). Adjust fan switch (1), temperature control switch (4) and FRESH/RECIRC selector switch (5) to the desired posi- tions. 3-227...
Page 300 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING DEFROSTER 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. Press vent selector switch (2) and set vent display on the monitor to (f) or (g) as shown in drawing.
Page 301 OPERATION HANDLE AIR CONDITIONER Press FRESH/RECIRC selector switch (3) and set it to FRESH mode. Press temperature control switch (4) and set temperature on the monitor to 32.0 of maximum heating. Adjust vents (A), (B1), and (B2) so that the air blows onto the window glass. (Vents (C) and (D) are fixed and cannot be adjusted.) When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify...
Page 302: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them. •...
Page 303 OPERATION HANDLE RADIO DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display. Each time you press this button, frequency, clock and band are shown on the display in this order. If 1.5 seconds passes while a band is shown, a frequency will be displayed. As long as AUX is selected, this button alternately switches the display between AUX and the clock.
Page 304: Method For Controlling Radio
HANDLE RADIO OPERATION Open cap (a). Connect a portable audio equipment by using a commer- cially available audio cable. Press band/AUX selector button (1) to select “AUX”. METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency.
Page 305 OPERATION HANDLE RADIO METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING) Press band/AUX selector button (1) and select FM or AM. Hold down sound control button (2). When a proper frequency is picked up, it is automatically registered to preset memories 1 to 6. METHOD FOR CALLING PRESET Press band/AUX selector button (1) and select FM or AM.
Page 306 HANDLE RADIO OPERATION METHOD FOR ADJUSTING SOUND BALANCE Press sound control button (1) to light up “BAL” on the dis- play. You can adjust the sound (balance). Press tuning/time adjustment button (2) to adjust the sound (balance). Press the △ button, and the speaker output on the R •...
Page 307: Stow Antenna
If the installation is needed, remove the front cover (1), and connect the speaker wires and the antenna to the radio cas- sette player. For the installation, consult your Komatsu distributor. Do not operate the radio in the L.H. console if a radio cassette player is installed to this place.
Page 308: Komvision
• If the normal range cannot be confirmed in the confirmation of the camera visibility, it is necessary to adjust the 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.
Page 309 OPERATION KomVision KomVision synthesizes the images of 4 cameras and displays the image from 300 ° above the machine. The shaded area in the figure is not displayed on the monitor screen even if the camera images are synthesized. Since this image is electronically synthesized, the objects in the image may be displayed 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).
Page 310: Transportation
Note 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. •...
Page 311: Loading And Unloading With Trailer
OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER WARNING Always observe the following when loading or unloading the machine from a trailer. • Select the firm, level ground when loading or unload- ing the machine. Maintain a safe distance from the road shoulder •...
Page 312 TRANSPORTATION OPERATION PROCEDURES FOR LOADING MACHINE Load on a firm and level ground. Maintain a safe distance from the road shoulder. Apply the brake of the trailer securely. Set the chocks (1) to the tires to secure the trailer. Set the right and left ramps (2) parallel to each other and equally spaced to the right and left of center (3) of the trail- er.
Page 313 OPERATION TRANSPORTATION If the machine is equipped with work equipment, set the work equipment at the front, and drive the machine for- ward to load it; if it has no work equipment, drive it in re- verse to load it. Follow the instructions and signals of a conductor particu- larly when driving the machine in reverse.
Page 314 TRANSPORTATION OPERATION When the machine passes over the rear wheels, it inclines backward. Carefully drive the machine in reverse to the specified point, and then stop it. METHOD FOR SECURING MACHINE NOTICE • Stow the radio antenna. Retract the mirrors so that they are within the width of the machine. For stowing radio antenna, see “STOW ANTENNA”.
Page 315 OPERATION TRANSPORTATION Operate the operating portion (g) of the lock lever to set it securely to LOCK position (L). Stop the engine, then remove the key from the starting switch. Close all of the doors, windows, and covers. Lock the lockable doors, covers, and caps. Select the way of secure the machine according to the transportation form of each territory from the following.
Page 316 TRANSPORTATION OPERATION METHOD FOR SECURING MACHINE WITHOUT TIE-DOWN POINT Place blocks under both ends of the tracks to prevent the ma- chine from moving during transportation, and secure the ma- chine with chains or wire ropes of appropriate strength. In particular, fix the machine securely to prevent it from slipping sideways.
Page 317 OPERATION TRANSPORTATION METHOD FOR INSTALLING MIRROR Mirrors (A), (B) Install the support (3) and clamp (5) to the handrail with the mounting bolts (4). Install the mirror (1) to support (3), then tighten it with mounting bolt (2). Mirror (C) Install the mirror (1) to support (3), then tighten it with mounting bolt (2).
Page 318 TRANSPORTATION OPERATION Remove the bolts (1), and remove the handrail (A) and cover (2). Remove the bolts (3), and remove the handrail (B). METHOD FOR INSTALLING HANDRAIL Install handrail (B) first, then install (A). Install the handrail (A), then tighten it with bolts (3). Install the handrail (A) and cover (2), then tighten them with bolts (1).
Page 319 OPERATION TRANSPORTATION Tilt down lock (D) of revolving lamp bracket (C). Remove the hook of lock (D) from the claw of base bracket (E). Hold grip (G) and turn it clockwise, seeing it from the rear of the machine. Remove revolving lamp bracket (C) from the claw of base bracket (E).
Page 320 TRANSPORTATION OPERATION METHOD FOR INSTALLING REVOLVING LAMP 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.
Page 321 OPERATION TRANSPORTATION Insert connector (A). Securely insert the connector until it clicks. PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm and level ground. Maintain a safe distance from the road shoulder. Apply the brake of the trailer securely. Set the chocks (1) to the tires to secure the trailer.
Page 322 TRANSPORTATION OPERATION When the auto-deceleration switch (7) is turned off, the au- to-deceleration pilot lamp (8) goes out. Raise the work equipment and move the machine slowly. 10. When the machine is horizontal on the top of the rear end of the trailer, stop the machine.
Page 323: Method For Lifting Machine
OPERATION TRANSPORTATION METHOD FOR LIFTING MACHINE WARNING • The person using the crane to perform lifting operations must be a qualified crane operator. • Never perform lifting operation if any person is on the machine being lifted. • Always use a wire rope that has ample strength for the weight of the machine being lifted. •...
Page 324 TRANSPORTATION OPERATION Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. However, for machines equipped with full roller guards for the track rollers, pass the wire ropes under the tracks. When the wire rope contacts with the edge of the machine, put wooden block or backing metal between them.
Page 325: Cold Weather Operation
If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 326: Precautions After Daily Work Completion In Cold Weather
COLD WEATHER OPERATION OPERATION When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be started easily in the next morning.
Page 327: After Cold Weather Season
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-255...
Page 328: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 329 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 330: Troubles And Actions
TROUBLES AND ACTIONS OPERATION TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill it up with fuel and bleed air from the fuel system before stating. Always check the fuel level to prevent running out of fuel. PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures.
Page 331: Precautions For Towing Machine
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR TOWING MACHINE WARNING Use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method for towing a disabled machine and being towed may lead to serious personal injury or death. •...
Page 332: Precautions For Severe Job Condition
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR USING LIGHTWEIGHT TOWING HOLE WARNING • Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to seri- ous personal injury or death.
Page 333: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 334 TROUBLES AND ACTIONS OPERATION • Tightening torque of battery terminal fixing nut (A): 9.8 to 11.8 Nm {1.0 to 1.2 kgm} • When replacing the battery, secure it with the battery mounting hardware. Tightening torque of mounting bolt (B): 9.8 to 19.6 Nm {1.0 to 2.0 kgm} PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled...
Page 335 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 336: If Troubles On Hybrid System Occur
The problems of the hybrid system are shown in the following table. • Contact your Komatsu distributor for the remedies indicated with ( ) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below.
Page 337 After the swing stops, be sure to ask your Komatsu distributor for repair.
Page 338: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. 3-266...
Page 339 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Defective wiring, deterioration of bat- Check and repair loose terminal or tery wire breakage, replace battery. (*) Lamp does not glow brightly even when the engine runs at high speed. Loosening and damage of alternator Check alternator belt tension and re- belt place.
Page 340 PHENOMENA AND ACTIONS FOR CHASSIS • 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...
Page 341 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Engine oil pressure caution lamp Insufficient oil in engine oil pan (suck- Make the oil level to the specified lev- lights up. ing in air) el. See CHECKS BEFORE START- ING. Improper oil is used. (Viscosity is im- Replace oil by referring to METHOD proper.) FOR USING FUEL, COOLANT AND...
Page 342 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Starting motor turns but engine does Add fuel by referring to CHECKS BE- Lack of fuel not start. FORE STARTING. Repair place where air is sucked in Air in fuel system by referring to EVERY 500 HOURS MAINTENANCE.
Page 343 PLACING FUEL PREFILTER CARTRIDGE” and “METH- OD FOR REPLACING FUEL MAIN FILTER CARTRIDGE”. If “CA2249” or “CA559” is not cleared even after the replacement, ask your Komatsu distributor for the in- spection and repair immediately, even though the machine can perform normal operation.
Page 345: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 346: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 347: Dusty Jobsites
MAINTENANCE PRECAUTIONS FOR MAINTENANCE DUSTY JOBSITES When working at dusty jobsites, observe the following. • Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. • Replace the fuel filter more frequently.
Page 348: Outline Of Maintenance
Komatsu distributor. • When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend you to use the Komatsu oil clinic to check the characteristics of the oil in detail. FUEL •...
Page 349 Always use ultra-low-sulfur diesel fuel. (≤10 ppm) The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Do not use any additive agent which includes metallic constituent.
Page 350 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 351 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 352: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 353 MAINTENANCE OUTLINE OF MAINTENANCE 3. Hydraulic pump 6. Inverter (Control device) 4. High-voltage electric wiring (Orange) 7. Cooling system 5. Capacitor (Storage battery) 8. Electric swing motor...
Page 354: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 355 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Taper seal Tightening torque Nominal Thread size “a” Width across flats Target value Allowable range No. of hose (mm) “b” (mm) Nm kgm Nm kgm 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132...
Page 356: Maintenance Schedule
See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .......... 4-16 WHEN REQUIRED ............................
Page 357: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ..........4-67 METHOD FOR REPLACING DEF TANK BREATHER ELEMENT............4-68 METHOD FOR CHECKING FAN BELT TENSION AND REPLACING FAN BELT ........4-69 EVERY 2000 HOURS MAINTENANCE ......................4-69 METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ............... 4-69 METHOD FOR CLEANING HYDRAULIC TANK STRAINER ..............
Page 358: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE SCHEDULE MAINTENANCE Replace hydraulic oil filter element On a new machine, replace the element after the first 100 to 150 hours, then perform further replacement of the element ac- cording to the table on the right. Change oil in hydraulic tank Change the oil according to the table.
Page 359 MAINTENANCE MAINTENANCE SCHEDULE Fuel main fil- Replace. Replace. Replace. Replace. ter cartridge 4-15...
Page 360: Maintenance Procedure
MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) As the 1st maintenance of a new machine, perform the following maintenance after operating initial 250 hours. • Lubricating method (EVERY 500 HOURS MAINTENANCE) For details of the method of replacement or maintenance, see EVERY 500 HOURS MAINTENANCE. WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING...
Page 361 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT NOTICE • Never remove the inner element. If it is removed, dirt will enter and can cause an engine trouble. • Do not use a screwdriver or other tool. • When cleaning the element, do not hit it or hit anything with the element.
Page 362 MAINTENANCE PROCEDURE MAINTENANCE 10. Peel off a seal after cleaning the element each time. 11. After the cleaning, illuminate the inside of the element with an electric bulb to check. If any hole or thin place is found, replace the inner and out- er elements.
Page 363 MAINTENANCE MAINTENANCE PROCEDURE Check that the O-ring (8) is fitted to the cover (3). Align the cover (3) with the element. Lock the tip of hook (2) on the protrusion of the air cleaner body. Always install the cover (3) so that vacuator (4) faces the ground (A).
Page 364 MAINTENANCE PROCEDURE MAINTENANCE Hold the outer element (5), rock it lightly up and down and to the right and left, and pull it out while turning it to the right or left. Do not remove the inner element (6) at this time. When the outer element (5) is removed, check that the in- ner element does not come out of position and is not at an angle.
Page 365: Method For Cleaning Inside Of Cooling System
4000 hours. As a rule, Komatsu does not recommend the use of the coolant other than 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.
Page 366 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, request a qualified company to perform the operation or contact your Komatsu distributor. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 367 MAINTENANCE MAINTENANCE PROCEDURE Remove the undercover (3). Place a container under the drain valve (4) on the radiator side to catch the coolant mixture. Open the drain valve (4) to drain the coolant. After draining the coolant, close the drain valve (4) and add city water.
Page 368 MAINTENANCE PROCEDURE MAINTENANCE NOTICE When the work equipment is operated, take care that it does not interfere with the machine or ground. 15. Operate the work equipment control levers according to the following procedure. Move the R.H. work equipment control lever (5) slowly in the direction of the bucket CURL position (D).
Page 369 MAINTENANCE MAINTENANCE PROCEDURE 17. Open the door at the rear left of the machine, drain the coolant from the reservoir tank (5), clean the inside of the reservoir tank, then fill with coolant up to the middle be- tween FULL and LOW marks. NOTICE If it is extremely dirty and it is difficult to clean, replace it with a new one.
Page 370 MAINTENANCE PROCEDURE MAINTENANCE Hybrid component radiator cleaning Place the machine on a level ground, then stop the engine. Check that cap (2) of radiator for hybrid component (1) is cool enough to touch by bare hands. Turn the radiator cap (2) slowly until it hits the stopper and release the pressure.
Page 371: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE MAINTENANCE PROCEDURE 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. Check for looseness of the shoe bolt (1). If any looseness of the bolt is found, tighten it in order shown in the figure.
Page 372: Method For Replacing Bucket Teeth (Vertical Pin Type)
Check the track tension again, and if the tension is not correct, adjust it again. If the track tension cannot be decreased by the 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.
Page 373 MAINTENANCE MAINTENANCE PROCEDURE To make it possible to drive out a pin of tooth (1), put block (5) under the bottom of the bucket, and make the bottom of the bucket horizontal. Check that the work equipment is in a stable condition, then operate the operating portion (g) of the lock lever to set it to LOCK position (L).
Page 374 MAINTENANCE PROCEDURE MAINTENANCE • The steel ball sinks. The rubber of the rubber pin lock is deteriorated and steel ball (7) sinks into it when you press it. Remove the soil stuck to adapter (4) by using a knife. Use your hand or a hammer to push rubber pin lock (3) in- to the hole of adapter (4).
Page 375: Method For Replacing Bucket Teeth (Horizontal Pin Type)
MAINTENANCE MAINTENANCE PROCEDURE • After the lock pin (2) is driven in completely, its tip sur- face is flush with the surface of tooth (1). • Lightly hit lock pin (2) in the reverse direction from which it was hit in. •...
Page 376: Method For Adjusting Bucket Clearance
(2). REMARK If it cannot be removed by this method, ask your Komatsu distributor to have the replacement performed. 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.
Page 377: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE Use a feeler gauge for easy and accurate measurement. Loosen plate mounting bolts (2) (4 pieces) and loosen plate (3). The shim is a split type, so the work can be performed without removing the bolts. Remove shim (4) corresponding to the amount of play "a". For shim (4), 2 types of 1.0 mm and 0.5 mm are installed.
Page 378 MAINTENANCE PROCEDURE MAINTENANCE Check and mainte- Content of check and mainte- Guideline for maintenance interval nance items nance conditioner con- Clogged fins Every 500 hours denser See “METHOD FOR CHECKING AND CLEAN- ING RADIATOR FINS FOR ENGINE AND HY- BRID COMPONENTS, OIL COOLER FINS, AF- TER COOLER FINS, AND AIR CONDITIONER CONDENSER FINS”...
Page 379: Method For Washing Washable Floor
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low. Contact your Komatsu distributor to have refrigerant added. If the operation is continued while the refrigerant gas is insufficient, it may cause breakage of the com- pressor.
Page 380 MAINTENANCE PROCEDURE MAINTENANCE Referring to “METHOD FOR SETTING MACHINE AT ANGLE”, select a safe method, depending on the state of the machine. In this example, the machine is set at angle by using blocks. Swing the upper structure slowly so that water drain holes (3) in the cab floor are at a low position.
Page 381 MAINTENANCE MAINTENANCE PROCEDURE Pull out projections (2) (6 places) on the back of the floor mat and remove the floor mat. Remove the cap from water drain hole (3). Flush out the dirt on the floor directly with water through water drain hole (3).
Page 382: Method For Checking Gas Spring
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. 4-38...
Page 383: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE PROCEDURE The gas springs are located at the engine hood (2 places on the right and left). In the following cases, ask your Komatsu distributor for inspection, repair, and replacement. • The engine hood is heavy to open. •...
Page 384: Method For Checking Auto-Greasing System
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR BLEEDING AIR FROM TRAVEL MOTOR Bleed air only when the oil inside the travel motor case is drained. Run the engine at low idle, loosen air bleeder (4), and tighten it when oil flows out. Run the engine at low idle and swing the upper structure 90 °...
Page 385 MAINTENANCE MAINTENANCE PROCEDURE • Check that the pump is not damaged and no grease is leaked. • Check that the grease pump is not damaged and no grease is leaked. • Check that the condition of the greasing points to be lubricated by the system. An adequate amount of fresh grease can be seen.
Page 386 MAINTENANCE PROCEDURE MAINTENANCE Turn the starting switch to ON position (B). Keep pressing the test button (9) for 3 to 5 seconds. The system performs the one cycle test. The green LED (4) of the selected lubrication interval on the display inside the cab (2) flashes (lit 2 seconds, not lit 2 seconds) while this test is being proceeded.
Page 387: Method For Checking Camera Visibility
(B) is approximately 1 m outside of it. If the traffic cone can be seen on the monitor screen, it is nor- mal. If the traffic cone cannot be seen on the monitor screen, ask your Komatsu distributor for adjustment of the cam- era image. 4-43...
Page 388: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING SWING PARKING BRAKE For checking the swing parking brake, ask your Komatsu distributor to perform the work. CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING”. • Method for draining water and sediment from fuel tank •...
Page 389: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE (3) Link connection pin (2 places) (4) Bucket cylinder rod end (1 place) (5) Bucket-Link connection pin (1 place) After greasing, wipe off any old grease that is pushed out. EVERY 250 HOURS MAINTENANCE METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL Perform this procedure before operating the machine.
Page 390 If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed electrolyte with baking soda (sodium bicarbon- ate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 391: Method For Checking And Adjusting Air Conditioner Compressor Belt Tension
(sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or your battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 392: Every 500 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE Loosen the bolts (3) (2 pieces). There is no need of removing bolts (3). Do not loosen it too far. REMARK Loosening the bolt (3) allows the compressor (5) to move around the mounting position of bolt (4). Move the compressor (5) to the direction (D) to stretch the compressor belt.
Page 393 MAINTENANCE MAINTENANCE PROCEDURE 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. By using a grease pump, pump in grease through the grease fitting shown by arrow. (1) Boom cylinder foot pin (2 places) (2) Boom foot pin (2 places) (3) Boom cylinder rod end (2 places)
Page 394 MAINTENANCE PROCEDURE MAINTENANCE Items to be prepared • Container to catch drained oil • Filter wrench Remove the undercover just under the engine of the ma- chine and put a container under drain valve (P) to catch the drained oil. To prevent getting oil on yourself, lower the lever of drain valve (P) slowly, drain the oil, then raise the lever to close the valve.
Page 395: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system 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.
Page 396 MAINTENANCE PROCEDURE MAINTENANCE Turn the transparent cup (4) counterclockwise to remove it by using the filter wrench. The transparent cup (4) will be used again. Turn the filter cartridge (2) counterclockwise by using the filter wrench, and remove it. Install the currently removed transparent cup (4) to the bot- tom of the new filter cartridge.
Page 397: Method For Checking Swing Pinion Grease Level, Add Grease
MAINTENANCE MAINTENANCE PROCEDURE 14. Turn the valve (1) at the lower part of the fuel tank to OPEN position (O). 15. Install the drain hose. 16. Fill up the fuel tank with fuel (to the level where the float is at the highest position).
Page 398: Method For Lubricating Swing Circle
Check that the grease is not milky white. Total amount of grease: 14.6 ℓ If it is milky white, it is necessary to change the grease. Ask your Komatsu distributor for change. Install the cover (2) with bolt (1). METHOD FOR LUBRICATING SWING CIRCLE Lower the work equipment to the ground.
Page 399 Visually check the rubber hose connected to the heat exchange equipment. Check the hose clamp for looseness as well. If the rubber hose is cracked or become fragile, ask your Komatsu distributor for the replacement. If the hose clamp is loose, tighten it.
Page 400: Method For Cleaning Air Conditioner Fresh/Recirc Filters
MAINTENANCE PROCEDURE MAINTENANCE 11. After cleaning the air conditioner condenser, close and in- stall it with bolts (A) (3 places). Tightening torque: 59 to 74 Nm {6.0 to 7.5 kgm} METHOD FOR CLEANING AIR CONDITIONER FRESH/RECIRC FILTERS WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear protective equipment such as protective eyeglasses and dust mask.
Page 401 MAINTENANCE MAINTENANCE PROCEDURE While holding the cover (4) open, remove the filter (5) in- side it. REMARK • When removing, insert your finger into dent (D) of duct and pull it toward you. If you grasp the filter with excessive force, it will be de- formed or damaged.
Page 402: Method For Checking Oil Level In Swing Machinery Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE, ADDING WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Remove the dipstick (G) and wipe off oil on it with a cloth.
Page 403: Method For Checking Oil Level In Motor-Generator Case, Add Oil
MAINTENANCE MAINTENANCE PROCEDURE Remove the dipstick (K) from the oil filler port (J) and wipe off oil on it with a cloth. Fully insert the dipstick (K) into the guide. Remove the dipstick (K) and check that the oil level is be- tween the (H) and (L) marks on the dipstick.
Page 404: Method For Checking Oil Level In Final Drive Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE Remove the dipstick (G) and check that the oil level is be- tween the (H) and (L) marks on the dipstick. If the oil level does not reach (L) mark on dipstick (G), add oil through oil filler port (F). If the oil level is above the mark (H) on dipstick (G), re- move the cover (A) under the motor-generator, and loosen the drain valve (P) to drain the excessive oil.
Page 405: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Set the TOP mark at the top with the line running on TOP mark and plug (P) perpendicular to the ground surface. Remove plug (F) by using the handle. When the oil level reaches a point 10 mm below the bot- tom of the plug hole, the oil level is appropriate.
Page 406: Change Oil In Swing Machinery Case And Electric Swing Motor Case
MAINTENANCE PROCEDURE MAINTENANCE Remove the cap of hydraulic tank oil filler port (F), and re- lease the internal pressure. Loosen the bolts (6 pieces) and remove the cover (1). The cover may jump out under the force of spring (2). Hold the cover down when removing the bolts. REMARK If the cover (1) is left approximately 5 minutes with the mounting bolts loosened, the internal pressure of the case...
Page 407 MAINTENANCE MAINTENANCE PROCEDURE Power train oil TO10 Electric swing motor case 1.6 ℓ Every 1 years or every (Komatsu genuine) 1000 hours whichever Power train oil TO30 comes sooner Swing machinery case 6.5 ℓ (Komatsu genuine) Remove the inspection cover (A). Place the containers to catch the oil under the drain valve (P) for the swing machinery at the bottom of the machine, and under the drain valve (Q) for the electric swing motor.
Page 408: Method For Changing Oil In Motor-Generator Case, Clean Oil Filter
Perform the oil replacement of motor-generator case and cleaning of oil filter according to the following table. Replacement or cleaning Item Item Type of oil Refill capacity interval Power train oil TO10 Every 1 years or every Replacement of oil 6.5 ℓ Motor- (Komatsu genuine) 1000 hours whichever generator comes sooner Cleaning of filter 4-64...
Page 409: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system 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.
Page 410 MAINTENANCE PROCEDURE MAINTENANCE Items to be prepared • Container to catch drained oil • Filter wrench Turn the valve (1) at the bottom of the fuel tank to CLOSE position (S). Open the door on the right side of the machine. Place a container under the filter cartridge (2) to catch the fuel.
Page 411: Method For Checking All Tightening Points Of Engine Intake Pipe Clamps
METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRES- SURE IN ACCUMULATOR (FOR BREAKER) (if equipped) A special tool is needed for checking and charging of nitrogen gas. Ask your Komatsu distributor to perform this work. METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING •...
Page 412: Method For Replacing Def Tank Breather Element
If the machine is operated without DEF tank breather element attached, or with the element 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 tank breather element at- tached, nor use the element other than Komatsu genuine parts.
Page 413: Every 2000 Hours Maintenance
METHOD FOR CHECKING FAN BELT TENSION AND REPLACING FAN BELT Special tools are required for the inspection and replacement. Ask your Komatsu distributor to perform this work. REMARK As the automatic fan belt tensioner is installed to this machine, no belt tension adjustment is required.
Page 414: Method For Cleaning Hydraulic Tank Strainer
MAINTENANCE PROCEDURE MAINTENANCE Set the TOP mark at the top with the line running on TOP mark and plug (P) perpendicular to the ground surface. Place the oil container to receive oil under plug (P). Remove plugs (P) and (F) by using the handle, and drain oil.
Page 415: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
• 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 a failure occurs on the ma- chine.
Page 416 MAINTENANCE PROCEDURE MAINTENANCE Hold the work equipment in the maximum reach posture (arm fully OUT, bucket fully DUMP) at height (A) 1.5 m from the ground. 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.
Page 417 If the work equipment does not go down or stops in midway, the charged pressure of the gas in the accumulator for the hy- draulic circuit has probably dropped. Ask your Komatsu distrib- utor for inspection. This completes the inspection. After completion of the inspection, set the lock lever to LOCK position and turn the starting switch to OFF position.
Page 418: Method For Checking Alternator
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. METHOD FOR REPLACING KCCV FILTER ELEMENT WARNING Do not replace the element immediately after the engine is stopped.
Page 419 MAINTENANCE MAINTENANCE PROCEDURE NOTICE • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil. Therefore, never start the engine without the filter element. •...
Page 420 MAINTENANCE PROCEDURE MAINTENANCE Oil may be accumulated in or sticking to the case and ele- ment. When replacing the element, be careful not to spill out the oil. REMARK When the ambient temperature is low, water or emulsified matter may stick to the inside of KCCV because of con- densation of water vapor in the blowby gas.
Page 421: Method For Replacing Def Filter
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.
Page 422 MAINTENANCE PROCEDURE MAINTENANCE After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF pump and return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or deposition of urea. After the engine is stopped, the devices are operated for a few minutes.
Page 423 MAINTENANCE MAINTENANCE PROCEDURE Check that filter removal tool (3) is fully inserted to the end. Insert the filter to the end where you cannot thrust it in any further. Turn filter removal tool (3) in reverse, and remove filter (6). Filter (6) is removed and you can take it out together with filter removal tool (3).
Page 424: Every 4000 Hours Maintenance
METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY FILTER Ask your Komatsu distributor for checking and cleaning of the cooling oil delivery filter of the swing motor. EVERY 4000 HOURS MAINTENANCE Maintenance for every 100, 250, 500, 1000 and 2000 hours service should be performed at the same time.
Page 425: Method For Checking Water Pump
• 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 a failure occurs on the ma- chine.
Page 426: Method For Checking Air Conditioner Compressor Operation
ON-OFF? Is any abnormal noise generated by the magnet clutch or the air conditioner compressor body? If any abnormality is found, ask your Komatsu distributor to have the parts disassembled, repaired, or re- placed. METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIP-...
Page 427: Method For Replacing Radiator Cap
Check visually and touch by hand to check that there are no missing fuel spray prevention cap, loose bolts or hardening of the rubber. Replacement is required if any trouble is found. Ask your Komatsu distributor for that work. METHOD FOR REPLACING RADIATOR CAP...
Page 428: Every 4500 Hours Maintenance
Ask your Komatsu distributor for cleaning of the DEF tank. METHOD FOR REPLACING DEF TANK FILLER PORT FILTER Ask your Komatsu distributor for replacement of the DEF tank filler port filter. EVERY 5000 HOURS MAINTENANCE Maintenance for every 100, 250, 500 and 1000 hours service should be performed at the same time.
Page 429 MAINTENANCE MAINTENANCE PROCEDURE Items to be prepared • Container to catch drained oil • Socket wrench handle Swing the upper structure so that the drain plug (P) on the lower side of the suction tube comes to the middle be- tween the right and left tracks.
Page 430: Every 8000 Hours Maintenance
Maintenance for every 100, 250, 500, 1000 and 4500 hours service should be performed at the same time. METHOD FOR REPLACING DEF HOSE Ask your Komatsu distributor for replacement of the DEF hose. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-86...
Page 431: Specifications
SPECIFICATIONS...
Page 432: Specifications: Hb215Lc-3
Unit HB215LC-3 Operating weight kg 23000 Bucket capacity m Engine model Komatsu SAA4D107E-3 diesel engine 110 / 2000 (ISO 14396) Engine Power kW / min 110 / 2000 (ISO 9249) A Overall length mm 9705 B Overall height (work equipment) mm...
Page 433: Explanation Of Lift Capacity Chart (1-Piece Boom)
2645 G Maximum reach at ground level mm 9700 EXPLANATION OF LIFT CAPACITY CHART (1-PIECE BOOM) 1-Piece Boom - HB215LC-3 LEGEND A: Reach from swing centre B: Bucket hook height OF: Lifting capacity (rating overfront) OS: Lifting capacity (rating overside)
Page 434 WITH FULLY EXTENDED BUCKET CYLINDER. • ON A COMPACT HORIZONTAL LEVEL GROUND 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). HB215LC-3...
Page 435: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 436: Precautions For Using Attachment And Options
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any not authorized by Komatsu. Any personal injury, failure, or property damage caused by the use of unauthorized attachments or options will not be the responsibility of Komatsu.
Page 437 ATTACHMENTS AND OPTIONS PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS • The hydraulic drift of the work equipment (the amount of the work equipment moves down under its own weight when it is stopped in a raised position) also becomes greater. Do not stop the work equip- ment in air.
Page 438: Quick Coupler System
Maximum cir- cuit pressure 34.3 MPa (350 kgf/cm • Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu dealer. • After assembly of a hydraulic quick coupler and before first use of such quick coupler, ensure that the set- ting in machine control system setting is correct.
Page 439 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM QUICK COUPLER MANIFOLD PORT LOCATION AND HYDRAULIC CONNECTIONS OPERATION OF QUICK COUPLER TO RELEASE A BUCKET OR ATTACHMENT WARNING Pressure in the system can cause injury. Follow all instructions in ATTACHMENT REMOVAL AND IN- STALLATION.
Page 440 This machine has a system installed to give a warning if there is a failure to maintain pressure in the quick coupler system. If the buzzer sounds in the cab make sure that the cause is clarified be- fore continuing work. In particular check for leaks in the system. If in doubt call your Komatsu dis- tributor.
Page 441 ATTACHMENTS AND OPTIONS QUICK COUPLER SYSTEM Operate switch (1), and with switch (1) in position “B” press and hold button (2) on the left hand lever, to activate quick coupler. NOTICE The switch has a safety lock mechanism to prevent ac- cidental operation.
Page 442: Handle Bucket With Hook
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 to newly install a hook, ask your Komatsu distributor for installation.
Page 443: Handle Machine Ready For Installation Of Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT HANDLE MACHINE READY FOR INSTALLATION OF AT- TACHMENT EXPLANATION OF COMPONENTS ON MACHINE EQUIPPED WITH AT- TACHMENT (1) Stop valve (7) Attachment 1 proportional switch (2) Selector valve (8) Attachment 2 proportional switch (3) Attachment control pedal (9) Breaker mode switch (4) Lock pin...
Page 444 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS SELECTOR VALVE The selector valve switches the flow of the hydraulic oil. It is automatically switched according to the selected working mode. It is necessary to switch the working mode to match the attachment that is installed.
Page 445 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT CONTROL PEDAL WARNING If you perform operations with your foot on the pedal, the attachment may suddenly move if you de- press the pedal by mistake, and this may lead to serious personal injury or death. Lock the pedal with the lock pin when pedal operation is not necessary.
Page 446 • Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE To the machine equipped with a breaker, you need to install an accumulator whose model number matches to that of the breaker manufacturer to the breaker piping.
Page 447 REMARK Ask your Komatsu distributor to have the monitor setting changed so that two attachments are available if the attach- ment 2 system is to be equipped as a field kit.
Page 448: Method For Change-Over And Connect Hydraulic Circuit For Machine Ready For Installation Of Attachment
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. METHOD FOR CONNECTING HYDRAULIC CIRCUIT When installing the attachment, connect the hydraulic circuit as follows.
Page 449 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Set the stop valve to FREE position (a). (a) FREE Hydraulic oil flows. (direction of arrow is parallel to longitu- dinal direction of arm) (b) LOCK Hydraulic oil stops. (direction of arrow is perpendicular to longitudinal direction of arm) Follow the procedure below for setting the stop valve to FREE position (a).
Page 450: Method For Removing And Installing Attachment
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS REMARK When a breaker is installed, depress only the front side of pedal. METHOD FOR SWITCHING HYDRAULIC CIRCUIT Depending on the type of attachment, set the working mode on the monitor. The hydraulic circuit and the set pressure of the safety valve in the service valve switch according to the working mode selected.
Page 451 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Operate the operating portion (g) of the lock lever to set it to FREE position (F). Operate each work equipment control lever and attach- ment control pedal fully to the front, rear, right, and left for 2 to 3 times within 15 seconds to release the internal pres- sure in the hydraulic circuit.
Page 452 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Turn the rotor of the stop valve, which is installed to the piping for the inlet port and the outlet port on the side face of the arm, to LOCK position (b). (a) FREE Hydraulic oil flows (direction of arrow is parallel to longitu- dinal direction of arm)
Page 453 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Turn the starting switch to ON (B) position. Operate the operating portion (g) of the lock lever to set it to FREE position (F). Operate each work equipment control lever and attach- ment control pedal fully to the front, rear, right, and left for 2 to 3 times within 15 seconds to release the internal pres- sure in the hydraulic circuit.
Page 454 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Loosen the oil filler cap (F) slowly on the top of the hy- draulic tank to release the internal pressure in the hydraul- ic tank. Check that the hydraulic oil temperature is low. 10.
Page 455: Method For Operating Attachment
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT METHOD FOR OPERATING ATTACHMENT WARNING • If the pedal is operated when the auto-deceleration is being actuated and the engine speed is drop- ped, the engine speed will suddenly increase, so be careful when operating. •...
Page 456 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Press the working mode selector switch (1). The screen changes to the working mode selection screen. Press the working mode selector switch (1) or press the switches F3 or F4 to select the Breaker Mode B. With the breaker mode B highlighted in yellow, do one of the following to enter the selection.
Page 457 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT The deterioration of the hydraulic oil when 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.
Page 458 If the attachment pressure adjustment system has a failure, stop the operation and move the machine to a safe place, then consult your Komatsu distributor for the inspection and maintenance. Change the working mode and enter the Attachment Mode.
Page 459 (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 OPERATING ATTACHMENT 1 (CRUSHER ETC) WARNING Lock the pedal with the lock pin in order to prevent the attachment from moving incidentally when oper- ating the attachment by using the attachment 1 (crusher etc) proportional switch.
Page 460: Long-Term Storage
CRUSHER ROTATION ETC) REMARK Ask your Komatsu distributor to have the monitor setting changed so that two attachments are available if the attachment 2 system is to be equipped as a field kit. Operate the attachment 2 proportional switch on L.H. lever.
Page 461: Maintenance Of Additional Filter For Breaker
ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT MAINTENANCE OF ADDITIONAL FILTER FOR BREAKER WARNING • After the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. •...
Page 462 HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS Operate each work equipment control lever and attach- ment control pedal fully to the front, rear, right, and left for 2 to 3 times within 15 seconds to release the internal pres- sure in the hydraulic circuit.
Page 463 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Remove the plug (3) and drain the hydraulic oil accumula- ted in filter case (1) into the prepared oil container. After checking that the hydraulic oil temperature has drop- ped, turn the filter case (1) counterclockwise, remove it, then remove the element (2).
Page 464: Specifications
} (B mode) The safety valve relief set pressure: 20.6 MPa {210 kg/cm } and the safety valve cracking pressure: 15.2 MPa {155 kg/cm } are provided. Consult your Komatsu distributor. When the attachment control is installed • Safety valve relief set pressure of service valve Port A: 44.3 MPa {452 kg/cm...
Page 465 ATTACHMENTS AND OPTIONS HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT Port B: 44.3 MPa {452 kg/cm • Safety valve cracking pressure of service valve Port A: 38.9 MPa {397 kg/cm Port B: 38.9 MPa {397 kg/cm 6-31...
Page 466: Attachments And Options
• Installing attachments or optional equipment without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the ma- chine and the life of the equipment.
Page 467: Bucket Teeth Selection
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS Track shoe selection Classification by use Classifica- Precautions when using tion Rocky ground, riv- • On rough ground with large obstacles such as boulders or fallen trees, travel at erbeds Lo speed. Normal soil •...
Page 468 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS Loading: Loading of dry and loose earth. HORIZONTAL PIN TYPE TOOTH Heavy-duty digging: Digging and hammering work on hard soil, soil with rocks, scraping or other heavy-duty work • The heavy-duty bucket is of a horizontal pin type and as such, use it for heavy duty-digging. LONG-LIFE TOOTH •...
Page 469: Recommended Attachment Operations
Select the optimum attachment model for the hydraulic excavator body. The attachments and models ready for installation differ according to the machine body. For details of the selection of the attachments or the models, consult your Komatsu distributor. HYDRAULIC BREAKER Applicable work Major works suitable to the hydraulic breaker are as follows.
Page 470 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Push the chisel against the impact surface and operate so that the chassis rises approximately 5 cm off the ground. Do not raise it off the ground unnecessarily. When the chisel does not penetrate or break the surface by continuous impact to the same impact surface for 1 minute, change the point of impact and perform breaking operations by scraping from the edge.
Page 471 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Do not use the mount to gather in pieces of rock. 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.
Page 472 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Do not pry the ground or rock with the chisel penetrated. Do not perform pick work. Do not perform the operation with bucket cylinder rod extended fully to raise the machine off the ground. Do not perform the breaker work with any cylinder at the stroke end.
Page 473 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Grease the breaker while 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 6-39...
Page 475: Replacement Parts
REPLACEMENT PARTS...
Page 476: Periodic Replacement Of Defined Life Parts
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 Parts for periodic replacement...
Page 477: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 478: Recommended Fuel, Coolant, And Lubricant
Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construction equipment and components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recom- mend any commercially available lubricant additive. •...
Page 479 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication standard chart are explained as follows. Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check oil level in hydraulic tank Change power train oil...
Page 480: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
(AF-NAC) (Note.4) system EN 590 Class2 Fuel tank Diesel fuel EN 590 Grade D DEF tank DEF (Note. 6) KES: Komatsu Engineering Standard Reservoir Specified capacity (Litre) Refill capacity (Litre) Engine oil pan 20.0 18.0 Swing machinery Case Final drive case (each)
Page 481: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Note 6: DEF freezes at -11 °C. If thawing is necessary, the DEF system is automatically heated to thaw DEF after the engine is started. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 483: Index
INDEX INDEX Symbols Alternator - Check..........4-74 Always use clean washer fluid........ 4-2 12H/24H display mode - Switch......3-82 Antenna - Stow........... 3-235 Appoint leader when working with others..... 2-36 Armrest angle - Adjust........3-155 Armrest height - Adjust........3-155 About the operation in cold weather....3-125 Ashtray..............
Page 484 INDEX Bucket teeth - Select..........6-33 Bucket tooth (horizontal pin type) - Replace..4-31 Daylight saving time - Set........3-83 Bucket tooth (vertical pin type) - Replace..... 4-28 Declaration of conformity........1-17 Bucket with hook - Handle........6-8 DEF...............3-253,4-5 Burn prevention............4-2 DEF - Check level / Add........3-150 Buzzer cancel switch..........
Page 485 INDEX Electric wiring - Check........3-148 Explanation of radio equipment......3-230 Electrical components - Handle......4-8 Electrical system - Act for phenomena....3-266 Electromagnetic interference........ 2-21 Fan belt tension - Check / Replace.......4-69 Emergency escape hammer....... 3-108 Fan control system caution lamp......3-28 Emergency exit from operator's cab.....
Page 486 Horn - Check............3-153 Komatsu genuine lubricants........4-2 Horn switch............3-92 Komatsu genuine replacement parts...... 4-2 Hybrid caution lamp..........3-23 Komatsu machine operator privacy policy....1-3 Hybrid components and high voltage wiring - Handle.. KOMTRAX............3-136 .................4-8 KomVision............3-236 Hybrid system stop caution lamp......3-31 Hybrid temperature caution lamp....3-23,3-43...
Page 487 Pedal and oil flow of machine equipped with attach- Manual operation - Stop........3-225 ment - Operate..........6-15 Manual stationary regeneration - Operate..3-122 Perform KOWA (Komatsu Oil Wear Analysis)..4-6 Message - Check..........3-88 Periodic replacement of defined life parts..2-44,7-2 Message - Reply........... 3-89...
Page 488 INDEX Phenomena and actions for chassis....3-268 Precautions for transportation.......2-33 Phenomena and actions for engine related parts..Precautions for transporting machine....3-238 ..............3-268 Precautions for travelling........3-196 Phenomena that are not failures......3-258 Precautions for travelling on slopes...... 2-30 Pilot display............3-34 Precautions for using..........
Page 489 Sound balance - Adjust........3-234 Quick coupler system..........6-4 Sound control button...........3-231 Space for radio cassette........3-235 Specifications..........5-2,6-30 Specifications - HB215LC-3........5-2 Radiator cap - Replace......... 4-83 Stability..............2-37 Radiator coolant level caution lamp...... 3-29 Standard tightening torque for bolts and nuts..4-10 Radiator fins for engine and hybrid components / Oil Start engine............2-26...
Page 490 INDEX Track tension - Check........... 4-27 Wiper switch............3-49 Track tension - Check / Adjust......4-27 Work equipment - Lubricate........4-44 Track tension - Decrease........4-28 Work equipment - Operate........3-188 Track tension - Increase........4-27 Work equipment control lever......3-102 Transportation............. 3-238 Working lamp - Check.........3-152 Transportation method - Select......3-238 Working mode.............3-189 Travel lever............

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