Komatsu PC16R-2 Maintenance Manual
WEAM007800
Operation & Maintenance
Manual
PC16R-2
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC16R-2 F00003
WARNING
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.
and up
FOREWORD
1.1 FOREWORD
q This manual has been compiled by Komatsu Utility S.p.A. in order to supply customers with all the necessary
information on the machine and on safety regulations, as well as the use and maintenance instructions that
enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient
over time.
q The operation manual, together with the spare parts catalogue, is an integral part of the machine and must
accompany it, even when it is resold, until its final disposal.
q The manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment inside the seat support, where the
registration documents and the logbook are usually kept.
q This manual must be given to the staff who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu or your Komatsu Dealer.
q The illustrations contained in this manual may represent machine configurations available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums
up all the information regarding the most recent technology applied at the moment in which the machine is
launched.
For any further and/or updated information, contact your Komatsu Dealer.
q Punctual periodic annotations regarding the maintenance operations that have been carried out are important,
since they provide a clear report on the situation and say exactly what has been done and what has to be done
after the next maintenance interval. Therefore, it is advisable to consult both the hour meter and the
maintenance plan frequently.
q Over the years Komatsu Dealers have gathered considerable experience in customer service.
If more information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the
best performance from the machine, he can recommend the equipment that is most suitable for specific needs
and can provide the technical assistance necessary for any change that may be required to conform the
machine to the safety standards and traffic rules.
Furthermore, Komatsu Dealers also offer assistance for the supply of Komatsu genuine spare parts, which
guarantee safety and interchangeability.
q The table included in this manual must be filled in with the machine data, which are also the data that must be
communicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
q The incorrect use of the machine and inappropriate maintenance operations may cause serious injury
and even death.
q Operators and maintenance personnel must carefully read this manual before using the machine or
performing maintenance operations.
q Any serious accident that may occur during the use of the machine or during maintenance operations is
due to failure to comply with the instructions given herein.
q The application of the procedures and precautions described in this manual will ensure safety only
provided that the machine is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
1
INFORMATION ON SAFETY
1.2 INFORMATION ON SAFETY
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations
prescribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to understand all the information and warnings contained in this manual and given on the plates
applied onto the machine. To enable the operator to use this machine safely, safety precautions are explained in
this manual and labels and warning plates are affixed to the machine to highlight situations involving potential
hazards and suggest how to avoid them.
Terminology used in the signs
The following words are used in the signs to inform the user that there is a potential hazard that may lead to
personal injury or damage to property.
In this manual, on the labels and on the plates, the following words are used to express the potential level of the
hazard.
DANGER
q Indicates a situation of imminent danger that, if not avoided, may cause serious injury and even death.
The use of this term must be limited to situations of extreme danger.
WARNING
q Indicates a situation of potential danger that, if not avoided, may cause serious injury and even death.
CAUTION
q Indicates a situation of potential danger that, if not avoided, may cause moderate injury. This term can
also be used as a warning against dangerous interventions.
Other terms used in the signs
In addition to those indicated above, the following warning terms are used to recommend the precautions to be
taken to protect the machine or to supply useful information.
IMPORTANT
q This term is used to indicate precautions that must be taken in order to avoid actions that may shorten
the life of the machine.
NOTE
q This word is used to indicate a useful piece of information.
Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation
or maintenance of the machine; for this reason, the safety warnings included in this manual and applied onto the
machine may not include all possible safety precautions.
If all the instructions given in relation to this machine are kept to, the operators and anyone in the vicinity can work
in total safety, and do not run the risk of damaging the machine. In case of doubt regarding the safety measures
necessary for some procedures, contact Komatsu or your local Komatsu Dealer.
2
INFORMATION ON SAFETY
DANGER
q Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of the equipment and the controls, and stop the
engine.
DANGER
q To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the hood is open,
unless this is expressly prescribed for certain maintenance operations.
WARNING
q It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be
held liable for any damage to persons, property or the machine, if this has been tampered with by
modifying the standard settings of the hydraulic system.
WARNING
q Before carrying out any electric welding, disconnect the battery and the alternator. (See "2.8.13
PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR").
WARNING
q Install only authorized optional equipment (see "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
DANGER
q It is absolutely forbidden to operate the machine while standing on the ground.
Every single manoeuvre must be carried out by the operator, correctly seated in driving position.
3
INTRODUCTION
1.3 INTRODUCTION
1.3.1 INTENDED USE OF THE MACHINE
The Komatsu machines described in this manual have been designed and constructed to be used mainly for
EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the
characteristics illustrated in paragraph "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
q This paragraph describes some of the improper or unauthorized uses of the machine; since it is
impossible to predict all the possible improper uses, if it is necessary to use the machine for particular
applications, contact your Komatsu Dealer before carrying out the work.
IMPORTANT
q The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are enclosed to this
manual.
q The instructions regarding the assembly of the authorized equipment, the controls requiring special
arrangements on the machine and the hydraulic couplings necessary for the operation of such
equipment are grouped in the final section of this manual.
Komatsu machines are constructed exclusively for the handling, excavation and treatment of inert materials;
therefore, the following uses are absolutely forbidden:
q USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
q USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
q TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
q USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
q USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
q Simple and easy operation.
q Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
q Rotation of the turret achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear.
q Main equipment controlled through servo levers ensuring also combined movements that can be modulated
proportionally and continually.
q Boom swing and optional equipment operated through foot pedal controls.
q Travel and blade operated through levers.
q Travel speed selection push button.
q Hydraulic track gauge adjustment (optional).
q Complete series of instruments visible from the operating position.
q Lever accelerator.
q Easy maintenance with simplified intervals.
4
INTRODUCTION
1.3.4 RUNNING-IN
Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to excessive work load at the beginning of operation, its potential productivity and its
functionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following instructions:
q After the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
q Avoid operating the machine with the limit loads allowed or at high speed.
q Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
For machines in which synthetic biodegradable oil type HEES is used, perform the following operations in addition
to the standard maintenance operations:
q After the first 50 hours of operation, change the hydraulic circuit drain filter.
q After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
q When changing the oil filters (cartridges), check their inner part to make sure that there are no deposits.
If considerable deposits are observed, find out what may have caused them before starting the machine.
q The number of operating hours is indicated by the hour meter.
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE
Front
Operator's seat
Left
Right
Sprocket
Rear
RYA00050
In this manual, the terms front/forward, rear/backward, left, and right refer to the travel direction as seen from the
operator seat when it is facing the front and the sprocket is at the rear of the machine.
5
PRODUCT IDENTIFICATION
1.4 PRODUCT IDENTIFICATION
The Komatsu excavator and its main components are identified by serial numbers stamped on the identification
plates.
The serial number and the identification numbers of the components are the only numbers that must be
communicated to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial number is stamped on the front upper part of
the main frame, on the left side.
RKAB5040
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
The Komatsu excavators described in this manual are CE
marked, in fact they are in compliance with the EU harmonised
standards.
The plate with the CE marking is applied to the front wall of the
main frame, on the right side.
RKAB5050
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
Product Identification Number
MANUFACTURER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
MODEL
Product Identification Number
ENGINE POWER
22L-09-R1370
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
kg
kw
RWA39210
kg
kw
MANUFACTURER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
6
PRODUCT IDENTIFICATION
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
The engine serial number is stamped on the plate positioned on
the engine itself.
The exhaust gas emission plate is applied to the counterweight.
RKA16540
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
The serial number is stamped on the plate positioned inside the
travel reduction gear and can be seen after removing the cover
(1).
RKA16550
1
RKAB5060
7
PRODUCT IDENTIFICATION
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
The serial number is stamped on the plate positioned on the
upper side of the swing motor.
RKAB5920
8
1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine no.° Model
Product identification number (PIN)
Engine no.°
Travel reduction gear no.°
Swing reduction gear no.°
Dealer:
PRODUCT IDENTIFICATION
Address:
Contact person:
NOTES:
Te l.
9
TABLE OF CONTENTS
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USE OF THE MACHINE ....................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES ................................................................................ 4
1.3.3 MAIN CHARACTERISTICS ...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE............................................................... 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE SERIAL NUMBER .................................................................................................. 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 7
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER ..................................................................... 8
1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS .................................................................... 9
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 18
2.1.1 POSITION OF THE SAFETY PLATES..................................................................................... 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS ......................................................................... 19
2.1.3 POSITION OF THE NOISE PLATES ...................................................................................... 24
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED................................................. 24
2.2 GENERAL PRECAUTIONS .................................................................................................................. 25
2.2.1 GENERAL SAFETY RULES..................................................................................................... 25
2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 25
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 25
2.2.4 UNAUTHORIZED MODIFICATIONS........................................................................................ 26
2.2.5 LEAVING THE OPERATOR SEAT ......................................................................................... 26
2.2.6 GETTING ON AND OFF THE MACHINE ................................................................................. 27
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL ...................................................................... 28
2.2.8 PREVENTING BURNS ............................................................................................................ 28
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ..................................................... 29
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 29
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT ......................................................................... 30
2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE.................................................... 30
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 30
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 31
2.3.1 SAFETY AT THE WORK SITE ................................................................................................. 31
2.3.2 FIRE PREVENTION ................................................................................................................ 31
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT ...................................................... 31
2.3.4 ROOM VENTILATION ............................................................................................................. 32
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 32
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 33
2.4.1 STARTING THE ENGINE ........................................................................................................ 33
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 33
10
TABLE OF CONTENTS
2.4.3 HAND SIGNALS ....................................................................................................................... 34
2.4.4 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 39
2.4.5 MOVING THE MACHINE ........................................................................................................39
2.4.6 MOVING ON SLOPES ............................................................................................................ 40
2.4.7 WORKING ON SLOPES .........................................................................................................41
2.4.8 UNAUTHORIZED OPERATIONS ........................................................................................... 41
2.4.9 PREVENTING ELECTROCUTION .......................................................................................... 43
2.4.10 VISIBILITY................................................................................................................................ 43
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES ........................................................ 43
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 44
2.4.13 WORKING ON LOOSE GROUND ........................................................................................... 44
2.4.14 PARKING THE MACHINE........................................................................................................ 44
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES ................................................................ 45
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 45
2.5.2 TRANSPORTING THE MACHINE ........................................................................................... 45
2.6 BATTERY .............................................................................................................................................. 46
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 46
2.6.2 STARTING WITH BOOSTER CABLES .................................................................................. 46
2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE ................................................................. 47
2.8 PRECAUTIONS FOR MAINTENANCE................................................................................................. 48
2.8.1 WARNING PLATES ................................................................................................................ 48
2.8.2 TOOLS .................................................................................................................................... 48
2.8.3 MAINTENANCE STAFF ........................................................................................................... 48
2.8.4 EQUIPMENT ........................................................................................................................... 49
2.8.5 WORKING UNDER THE MACHINE ....................................................................................... 49
2.8.6 CLEANING THE MACHINE .................................................................................................... 49
2.8.7 USE OF THE ENGINE DURING MAINTENANCE................................................................... 50
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 50
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 50
2.8.10 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL..................................... 51
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................................... 51
2.8.12 USING LAMPS ........................................................................................................................ 51
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY
AND THE ALTERNATOR......................................................................................................... 52
2.8.14 PRECAUTIONS CONCERNING THE STARTER .................................................................... 52
2.8.15 HANDLING HIGH-PRESSURE HOSES .................................................................................. 52
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 53
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH
TEMPERATURES AND HIGH PRESSURE............................................................................. 53
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE
GREASE TO ADJUST THE TRACK TENSION ...................................................................... 54
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE
SHOCK ABSORBER UNIT ...................................................................................................... 54
2.8.20 HYDRAULIC ACCUMULATOR ............................................................................................... 54
2.8.21 COOLING FAN AND BELT .....................................................................................................55
2.8.22 WASTE MATERIALS .............................................................................................................. 55
2.8.23 COMPRESSED AIR ................................................................................................................. 55
2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS
AND ELASTOMERS ................................................................................................................ 56
2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE
OIL TYPE HEES....................................................................................................................... 56
11
TABLE OF CONTENTS
THE MACHINE AND ITS OPERATIONS
3.1 MACHINE ILLUSTRATIONS ................................................................................................................ 58
3.1.1 OVERALL VIEW OF THE MACHINE ....................................................................................... 58
3.1.2 CONTROLS AND GAUGES ..................................................................................................... 59
3.2 INSTRUMENTS AND CONTROLS ....................................................................................................... 60
3.2.1 WARNING LIGHTS AND GAUGES ......................................................................................... 60
3.2.1.1 EMERGENCY WARNING LIGHTS ......................................................................... 61
3.2.1.2 GAUGES ................................................................................................................. 62
3.2.1.3 WARNING LIGHTS ................................................................................................. 63
3.2.2 SWITCHES AND PUSH BUTTONS ......................................................................................... 65
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 68
3.2.4 COVERSWITH LOCK............................................................................................................... 75
3.2.5 ENGINE HOOD ........................................................................................................................ 76
3.2.6 RADIATOR COVER ................................................................................................................. 77
3.2.7 BATTERY COVER ................................................................................................................... 78
3.2.8 TILTING THE CAB FLOOR ......................................................................................................79
3.2.9 FUSES...................................................................................................................................... 82
3.2.10 MAIN FUSE .............................................................................................................................. 83
3.2.11 TECHNICAL DOCUMENTATION COMPARTMENT ............................................................... 83
3.2.12 TOOL BOX ............................................................................................................................... 83
3.3 USE OF THE MACHINE AND RELATED CONTROLS........................................................................ 84
3.3.1 BEFORE STARTING THE ENGINE ......................................................................................... 84
3.3.1.1 VISUAL CHECKS.................................................................................................... 84
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE .................. 85
3.3.1.3 ADJUSTMENTS...................................................................................................... 92
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ......... 94
3.3.2 STARTING THE ENGINE......................................................................................................... 96
3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES............................... 96
3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES ................................. 98
3.3.3 AFTER STARTING THE ENGINE ............................................................................................ 100
3.3.3.1 RUNNING IN A NEW MACHINE............................................................................. 100
3.3.3.2 WARMING-UP OPERATIONS ................................................................................ 101
3.3.4 STOPPING THE ENGINE ........................................................................................................103
3.3.5 HOW TO MOVE THE MACHINE.............................................................................................. 104
3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE
MOVING THE MACHINE ........................................................................................ 104
3.3.5.2 MOVING THE MACHINE FORWARD .................................................................... 104
3.3.5.3 MOVING THE MACHINE IN REVERSE ................................................................. 106
3.3.5.4 STOPPING THE MACHINE .................................................................................... 107
3.3.6 STEERING THE MACHINE...................................................................................................... 108
3.3.6.1 STEERING (CHANGING DIRECTION) .................................................................. 108
3.3.7 SWINGING THE TURRET ....................................................................................................... 110
3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS............................................................. 111
3.3.9 UNAUTHORIZED OPERATIONS............................................................................................. 114
3.3.10 PRECAUTIONS FOR USE.......................................................................................................116
3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES ...................................... 118
3.3.12 GETTING THE MACHINE OUT OF MUD ................................................................................ 120
3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR .......... 121
3.3.14 CHANGING THE BUCKET.......................................................................................................123
3.3.15 PARKING THE MACHINE........................................................................................................ 124
3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK ...................................................... 126
3.3.16.1 BEFORE STOPPING THE ENGINE ....................................................................... 126
3.3.16.2 AFTER STOPPING THE ENGINE .......................................................................... 126
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TABLE OF CONTENTS
3.3.17 LOCKING THE MACHINE........................................................................................................ 126
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only) ........................................... 127
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS .......................................................... 127
3.3.18.2 WARRANTY ON RUBBER TRACKS ...................................................................... 127
3.3.18.3 USE OF THE RUBBER TRACKS ........................................................................... 128
3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME ................................ 128
3.4 TRANSPORTING THE MACHINE ........................................................................................................ 132
3.4.1 TRANSPORT PROCEDURE ................................................................................................... 132
3.4.2 LOADING AND UNLOADING THE MACHINE......................................................................... 132
3.4.3 LIFTING THE MACHINE .......................................................................................................... 138
3.5 USING THE MACHINE IN THE COLD SEASON ................................................................................. 140
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON ..... 140
3.5.1.1 FUEL AND LUBRICANTS....................................................................................... 140
3.5.1.2 COOLANT............................................................................................................... 140
3.5.1.3 BATTERY................................................................................................................ 141
3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK................................. 142
3.5.3 HOW TO PROCEED AT THE END OF THE COLD SEASON ................................................ 142
3.6 LONG PERIODS OF INACTIVITY ........................................................................................................ 143
3.6.1 BEFORE A PERIOD OF INACTIVITY...................................................................................... 143
3.6.2 DURING A PERIOD OF INACTIVITY ...................................................................................... 143
3.6.3 AFTER A PERIOD OF INACTIVITY ......................................................................................... 143
3.7 TROUBLESHOOTING .......................................................................................................................... 144
3.7.1 IF FUEL RUNS OUT COMPLETELY ....................................................................................... 144
3.7.2 OCCURRENCES THAT ARE NOT FAILURES ....................................................................... 144
3.7.3 REMOVING THE MACHINE .................................................................................................... 144
3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS ............ 145
3.7.5 IF THE BATTERY IS DOWN .................................................................................................... 145
3.7.5.1 REMOVING AND INSTALLING THE BATTERY .................................................... 146
3.7.5.2 CHARGING THE BATTERY ................................................................................... 146
3.7.5.3 STARTING WITH BOOSTER CABLES .................................................................. 147
3.7.6 OTHER TROUBLES................................................................................................................. 149
3.7.6.1 ELECTRICAL CIRCUIT........................................................................................... 149
3.7.6.2 FRAME.................................................................................................................... 150
3.7.6.3 ENGINE .................................................................................................................. 150
MAINTENANCE
4.1 GUIDE TO MAINTENANCE .................................................................................................................. 154
4.2 MAINTENANCE NOTES ....................................................................................................................... 156
4.2.1 OIL, FUEL AND COOLANT...................................................................................................... 156
4.2.1.1 OIL .......................................................................................................................... 156
4.2.1.2 FUEL ....................................................................................................................... 157
4.2.1.3 COOLANT............................................................................................................... 157
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS) ........................................................... 158
4.2.1.5 STORING OIL AND FUEL ...................................................................................... 159
4.2.1.6 FILTERS ................................................................................................................. 159
4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM ...................................... 160
4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM........................................ 160
4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION .......................................................... 160
4.3 PARTS SUBJECT TO WEAR ............................................................................................................... 161
4.3.1 LIST OF THE PARTS SUBJECT TO WEAR............................................................................ 161
13
TABLE OF CONTENTS
4.4 FUEL, COOLANT AND LUBRICANTS.................................................................................................162
4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES............................ 164
4.5 TIGHTENING TORQUES ...................................................................................................................... 165
4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS ....................................... 165
4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS......................................... 166
4.6 LUBRICATION ...................................................................................................................................... 167
4.6.1 LUBRICATION DIAGRAM........................................................................................................167
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS ...................................................... 168
4.7.1 SAFETY-RELATED PARTS ..................................................................................................... 169
4.8 MAINTENANCE PLAN.......................................................................................................................... 170
4.8.1 MAINTENANCE PLAN ............................................................................................................. 170
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER............... 171
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER ........................................................... 171
4.8.2.b CHANGING THE HYDRAULIC OIL ........................................................................ 171
4.9 MAINTENANCE PROCEDURES .......................................................................................................... 172
4.9.1 WHEN REQUIRED ................................................................................................................... 172
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE............ 172
4.9.1.b CHECKING THE BATTERY CHARGE LEVEL ....................................................... 174
4.9.1.c CLEANING THE WATER SEPARATOR FILTER .................................................. 175
4.9.1.d DRAINING THE FUEL TANK .................................................................................. 176
4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION............................. 176
4.9.1.f CHECKING THE RUBBER TRACKS...................................................................... 178
4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION ......................... 180
4.9.1.h CHANGING THE RUBBER TRACKS ..................................................................... 182
4.9.1.i BLEEDING THE HYDRAULIC SYSTEM ................................................................ 185
4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ................................... 186
4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used) .......................... 186
4.9.4 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used) .......................... 186
4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION ......................................................... 187
4.9.5.a LUBRICATION ........................................................................................................ 187
4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE ..... 189
4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE ....................................................... 190
4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS ...................... 191
4.9.5.e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND
OF THE EXCHANGER ........................................................................................... 191
4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION .................................... 192
4.9.5.g DRAINING THE HYDRAULIC OIL TANK
(Only for machines in which synthetic biodegradable oil type HEES is used) ........ 193
4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION ....................................................... 194
4.9.6.a CHANGING THE HYDRAULIC OIL FILTER ........................................................... 194
4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS .................................. 196
4.9.6.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ..................... 196
4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION ....................................................... 197
4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER 197
4.9.7.b CHANGING THE COOLANT .................................................................................. 199
4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER ......................................... 200
14
TABLE OF CONTENTS
TECHNICAL SPECIFICATIONS
5.1 TECHNICAL DATA ............................................................................................................................... 202
5.2 LIFTING CAPACITIES .......................................................................................................................... 204
5.2.1 LIFTING CAPACITIES ............................................................................................................. 204
AUTHORIZED OPTIONAL EQUIPMENT
6.1 AUTHORIZED OPTIONAL EQUIPMENT ............................................................................................. 208
6.1.1 PRECAUTIONS REGARDING SAFETY .................................................................................. 208
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................. 209
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT ........................................................ 210
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....................................... 210
6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS ................................ 211
6.2.1 POSITION OF THE DEVICES ................................................................................................. 211
6.2.2 HYDRAULIC CIRCUIT ............................................................................................................. 213
6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT ........................................... 213
6.2.2.2 MAINTENANCE ...................................................................................................... 213
6.2.2.3 BLEEDING .............................................................................................................. 214
6.3 OPERATING THE EQUIPMENT ........................................................................................................... 215
6.3.1 LONG PERIODS OF INACTIVITY ........................................................................................... 216
6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT ......................................... 217
6.4.1 HYDRAULIC BREAKER........................................................................................................... 217
15
PAGE INTENTIONALLY LEFT BLANK
16
SAFETY AND
ACCIDENT PREVENTION
17
SAFETY, NOISE AND VIBRATION PLATES
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
q The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean them with a solution made of water and detergent.
Do not use fuel, petrol or solvents.
q If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer.
q In case of replacement of a component provided with a safety plate, make sure that such a plate is applied also
to the new part.
q The machine can be provided with other plates in addition to those indicated below; keep also to the instructions
given in the additional plates, in any case.
18
RKA16560
SAFETY, NOISE AND VIBRATION PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
The warning and danger plates applied onto the machine include or are accompanied by pictograms.
The staff in charge with the operation and maintenance of the machine must be perfectly familiar with the symbols
contained in the pictograms; the following list illustrates what they look like and their respective meanings.
WORK IN PROGRESS
q Do not approach or stand within the equipment operating range
when the boom and the bucket are raised.
DO NOT OPEN THE ENGINE HOOD
q Do not open or remove the hood when the engine is running.
CONSULT THE MANUAL
q Carefully read the contents of the manual before using the
machine or performing maintenance operations.
3F05B2612
3F30B2612
RWA00020
RWA00010
SAFETY DISTANCE
q Do not get too near the machine and do not stand within its
operating range.
09651-A0481
RWA00030
22L-98-22270
19
SAFETY, NOISE AND VIBRATION PLATES
PLATFORM LIFTING SAFETY PLATE
HYDRAULIC OIL TOPPING UP
q (Only for machines in which synthetic biodegradable oil type
HEES is used)
22L-98-R2390
RKA01380
HYDRAULIC OIL TOPPING UP
REFUELLING
BIO-OIL
RWA00050
D
RWA00040
RWA34380
ENGINE OIL FILTER
20
RWA00080
FUEL FILTER
ENGINE AIR INTAKE FILTER
ENGINE COOLANT
SAFETY, NOISE AND VIBRATION PLATES
D
RWA00060
RWA00090
ENGINE COOLANT PRESSURE
HYDRAULIC OIL LEVEL
RWA00130
RWA00110
RWA00100
HYDRAULIC OIL FILTER
RWA00070
21
SAFETY, NOISE AND VIBRATION PLATES
POWER OUTLET
ANCHORAGE POINT
LIFTING POINT
RWA00120
12 V
RWA00200
RWA04920
22
LIFTING CAPACITIES
B
SAFETY, NOISE AND VIBRATION PLATES
A
W=400mm
kg 23
W
RKA16650
L
L=965mm
L=1210mm
B
3m
2m
1m
-1m
0
0
A
1m
825kg
2m 3m MAX
310kg
285kg
300kg
280kg
280kg
275kg
165kg
155kg
150kg
310kg
170kg
140kg
145kg
195kg
125kg
>
20W-98-91510
23
SAFETY, NOISE AND VIBRATION PLATES
2.1.3 POSITION OF THE NOISE PLATES
q The noise plates must always be legible and in good conditions;
for this reason, if they are dirty with dust, oil or grease, it is
necessary to clean them with a solution made of water and
detergent.
Do not use fuel, petrol or solvents.
q If the plates are damaged, ask for new ones to Komatsu or to
your Komatsu Dealer.
q In case of replacement of a component provided with a noise
plate, make sure that such a plate is applied also to the new
part.
EXTERNAL NOISE
q This value indicates the noise level outside the machine and
refers to the noise perceived by persons in the vicinity of the
work area.
RKAB5950
2000/14/EC
NOISE PERCEIVED BY THE OPERATOR
q This value indicates the noise level perceived by the operator
when seated in driving position.
ISO 6396
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
q According to the results of the tests carried out to determine the vibrations transmitted to the operator by the
machine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body
is subjected to vibrations lower than 0.5 m/sq.sec.
24
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
q Only trained and authorized staff can use the machine and perform maintenance operations.
q Follow all the safety rules, precautions and instructions when using the machine or performing maintenance
operations.
q When working with other operators or when the work site is often occupied by other operators, make sure that
everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as
to be able to see the machine and to be visible to the operator.
2.2.2 SAFETY DEVICES AND GUARDS
q Make sure that all the guards and covers are in the correct position. Have guards and covers changed or
repaired if damaged. Neither use the machine without guards, nor remove the guards when the engine is
running.
q Always use the proper safety devices to lock the machine when parking; always fasten the seat belt.
q Do not remove the safety devices and always keep them in good operating conditions.
q Any improper use of the safety devices may result in serious injury or even death.
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
q Do not wear large or loose clothes, rings and watches, and do
not approach the machine with loose long hair, since they can
get entagled in the moving parts of the machine and cause
serious injury or damage.
Avoid also wearing clothes dirty with oil or fuel, since they are
flammable.
q Wear a hard hat, goggles, safety shoes, mask, gloves and ear
muffs when operating the machine or performing maintenance
operations.
q Always wear safety goggles, a hard hat and heavy gloves if
your job involves scattering metal chips or minute materials;
these precautions are particularly useful when hammering the
equipment connection pins and when blowing compressed air
into the air filter and the radiator.
During these operations, make also sure that no one is standing
or working near the machine without the necessary protection
items.
q When working for 8 hours with a noise level exceeding 90 dBA,
it is necessary to use headphones or ear plugs and be
particularly careful, especially at the end of the work shift.
RKA00510
25
GENERAL PRECAUTIONS
2.2.4 UNAUTHORIZED MODIFICATIONS
q Any modification made without the authorization of Komatsu can involve hazards.
q Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injury or
damage caused by unauthorized modifications.
2.2.5 LEAVING THE OPERATOR SEAT
q When leaving the operator seat, even if temporarily, make sure
that the machine is in a safe position. (See "2.4.14 PARKING
THE MACHINE").
q Before leaving the operator seat, carry out the following
operations in the sequence indicated below:
1 - Lower the equipment to the ground.
2 - Engage the safety locks of the boom swing, optional
equipment and turret swing controls.
F
3 - Lock the equipment control by shifting the safety lever (1) to
the “locked” position (L).
4 - Stop the engine. (See "3.3.4 STOPPING THE ENGINE").
5 - If you have to go so far away that you will not be able to see
the machine, extract the ignition key.
L
9JA05440
RKA10550
CAB
26
RKA16340
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
q Do not jump on or off the machine, neither when it is at rest nor
when it is moving.
q When getting on or off the machine, always use the handles
and the tracks; get on and off the machine very carefully.
q Do not hold or rest on the control levers.
q Both when getting on and when getting off the machine, always
maintain three points of contact (holding or resting points), in
order to avoid losing your balance and falling down.
q Tighten the handle screws if they are loose, and clean the
handles and tracks if they are dirty with oil or grease.
Carefully clean the cab floor if it is dirty with oil, grease, mud or
rubble.
CANOPY
RWA18670
27
GENERAL PRECAUTIONS
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
Fuel, oil and some types of antifreeze can easily ignite if they get
in contact with a flame. Fuel is flammable and therefore very
dangerous.
q Keep any naked flame away from flammable fluids.
q Stop the engine and do not smoke when refuelling.
q Refuel and add oil only after stopping the engine and in well
ventilated places.
q Refuel and add oil in a well delimited area and do not allow
unauthorized persons to approach.
q When refuelling, hold the fuel gun firmly and keep it constantly
in contact with the filler until you have finished, in order to avoid
sparks due to static electricity.
q After refuelling or adding oil, tighten the fuel or oil cap securely.
q Do not fill the tank completely, in order to leave room for the fuel
to expand.
q In case some fuel is spilled, wipe it up immediately.
RKA00480
2.2.8 PREVENTING BURNS
q If the engine coolant, the engine oil and the hydraulic oil are hot,
use heavy cloths and wear gloves, heavy clothing and safety
goggles before carrying out any check or touching the hot parts.
q Before checking the coolant level, stop the engine and let the
fluid cool down.
If a check is necessary due to the overheating of the engine,
slowly loosen the radiator cap to release any residual pressure
before removing it. The hot fluid that spurts out may cause
serious burns.
q Before checking the engine oil and hydraulic circuit oil levels,
stop the engine and let the oil cool down. The hot oil that can be
sprayed out of the tank may cause serious burns.
RKA00490
RKA00500
28
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