Komatsu PC20MR-2 Maintenance Manual
WEAM007000
Operation & Maintenance
Manual
PC20MR-2
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC20MR-2 15001
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
• This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with 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.
• 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.
• 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 also
the ownership documents and the logbook are usually kept.
• This manual must be given to the persons 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.
• 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 techniques applied at the moment in which the machine is marketed.
For any further and/or updated information, contact your Komatsu Dealer.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important to
have a clear prospect of the situation and to know exactly what has been done and what has to be done after the
next maintenance interval. Therefore, it is advisable to consult either the hour meter and the maintenance plan
frequently.
• 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 suggest the use of 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 ensure their assistance for the supply of Komatsu genuine spare parts,
which alone guarantee safety and interchangeability.
• The table included in this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
• The incorrect use of the machine and inappropriate maintenance operations may cause serious injuries
and even death.
• Operators and maintenance personnel must carefully read this manual before using the machine or performing maintenance operations.
• 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.
• The procedures and precautions described in this manual are valid for application to the machine only
when it 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 on to the machine. To enable you to use this machine safely, safety precautions and labels are given in this
manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
q Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This signal word is to be limited to most extreme situations.
WARNING
q Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
q Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is are useful to know.
IMPORTANT
• This word is used for precautions that must be taken to avoid actions which could shorten the life of the
machine.
NOTE
• This gives information that is useful to know.
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 messages included in this manual and applied onto the
machine may not include all possible safety precautions.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity can work in total safety, with no risk of damaging the machine. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu or your local Dealer.
DANGER
• 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 either the equipment and the controls and stop the
engine.
DANGER
• 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 engine protection
casing is open, if this is not expressly prescribed for some specific maintenance operations.
2
INFORMATION ON SAFETY
WARNING
• 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 setting of the hydraulic system.
WARNING
• Before carrying out any electrical welding, disconnect the battery and the alternator (See "2.8.13 PRE-
CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR").
WARNING
• Install only authorized additional equipment (See "6.1 ATTACHMENTS AND OPTIONS - GENERAL IN-
FORMATION").
DANGER
• 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 USES
The Komatsu MACHINES described in this manual have been designed and constructed to be used mainly for
EXCAVATI ON a nd EAR TH-MO VIN G OPERATIO NS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point “6. AUTHORIZED OPTIONAL EQUIPMENT”.
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
• 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 the machine happens to be used for particular applications, contact your Komatsu Dealer before carrying out the work.
IMPORTANT
• 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.
• 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 the 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:
• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
• USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
• Simple and easy operation.
• Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
• Rotation of the upper structure achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear.
• Main equipment servolevers ensuring also combined movements that can be modulated proportionally and continually.
• Pedal controls for the boom swing and the optional equipment.
• Lever controls for travel and blade.
• Travel speed increase achieved through a pedal-operated push button.
• Complete series of instruments visible from the operating position.
• Lever accelerator.
• 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 yield and its functionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
• After the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
• Avoid operating the machine with the limit loads allowed or at high speed.
• Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
On machines in which the synthetic biodegradable oil type HEES is used, the following operations are to be performed besides the standard maintenance operations:
• After the first 50 hours of operation, change the hydraulic circuit drain filter.
• After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
• 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.
• The number of operating hours is indicated by the hour meter.
1.3.5 DIRECTIONS OF MACHINE
Front
Operator's seat
Left
Right
Sprocket
Rear
RYA00050
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat 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 indicated
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.
RKA01330
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
The Komatsu EXCAVATORS described in the present manual are
provided with the CE mark, which certifies that they are in compliance with the harmonized standards of the European Community.
The plate provided with the mark is applied onto the front wall of
the main frame, on the left side.
Product Identification Number
MANUFACTURER
Product Identification Number
RKA01331
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
22L-09-R1370
MODEL
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 serial number is stamped on the plate positioned on the engine.
.
The exhaust gas emission plate is positioned on the radiator chassis.
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).
1
RKAA0300
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.
1.4.6 CAB SERIAL NUMBER
The CAB serial number is stamped on the plate positioned on the
top left side.
RKAB2570
RKAB1750
8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine n. Model
Product identification number (PIN)
Engine n.
Travel reduction gear n.
Swing reduction gear n.
Cab n.
Dealer:
PRODUCT IDENTIFICATION
Address:
Person to contact:
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 USES..................................................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES ................................................................................ 4
1.3.3 MAIN CHARACTERISTICS ...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.3.5 DIRECTIONS OF 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 CAB SERIAL NUMBER ........................................................................................................... 8
1.4.7 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 ON MACHINES WITH CAB ......................................... 24
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY .................................. 25
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED................................................. 25
2.2 GENERAL PRECAUTIONS .................................................................................................................. 26
2.2.1 GENERAL SAFETY RULES..................................................................................................... 26
2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 26
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 26
2.2.4 UNAUTHORIZED MODIFICATIONS........................................................................................ 27
2.2.5 LEAVING THE OPERATOR’S SEAT ...................................................................................... 27
2.2.6 GETTING ON AND OFF THE MACHINE ................................................................................. 28
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL ...................................................................... 29
2.2.8 PREVENTING BURNS ............................................................................................................ 29
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ..................................................... 30
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 30
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT ......................................................................... 31
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 31
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 31
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 32
2.3.1 SAFETY ON THE WORK SITE ............................................................................................... 32
2.3.2 FIRE PREVENTION ................................................................................................................ 32
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB.............................................. 32
2.3.4 ROOM VENTILATION ............................................................................................................. 33
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 33
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES .................. 33
10
TABLE OF CONTENTS
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 34
2.4.1 STARTING THE ENGINE .......................................................................................................34
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 34
2.4.3 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 35
2.4.4 MOVING THE MACHINE ........................................................................................................35
2.4.5 MOVING ON SLOPES ............................................................................................................ 36
2.4.6 WORKING ON SLOPES .........................................................................................................37
2.4.7 UNAUTHORIZED OPERATIONS ........................................................................................... 37
2.4.8 PREVENTING ELECTROCUTION .......................................................................................... 39
2.4.9 VISIBILITY ................................................................................................................................ 39
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES ........................................................ 39
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 40
2.4.12 WORKING ON LOOSE GROUND ........................................................................................... 40
2.4.13 PARKING THE MACHINE ....................................................................................................... 40
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES ................................................................ 41
2.5.1 LOADING AND UNLOADING ................................................................................................. 41
2.5.2 TRANSPORT ........................................................................................................................... 41
2.6 BATTERY .............................................................................................................................................. 42
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 42
2.6.2 STARTING WITH BOOSTER CABLES .................................................................................. 42
2.7 PRECAUTIONS FOR THE REMOVAL ................................................................................................ 43
2.8 PRECAUTIONS FOR MAINTENANCE................................................................................................. 44
2.8.1 WARNING PLATES ................................................................................................................ 44
2.8.2 TOOLS .................................................................................................................................... 44
2.8.3 PERSONNEL ........................................................................................................................... 44
2.8.4 EQUIPMENT ........................................................................................................................... 45
2.8.5 WORKING UNDER THE MACHINE ....................................................................................... 45
2.8.6 CLEANING THE MACHINE .................................................................................................... 45
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS .......................................... 46
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 46
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 46
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP ...................................... 47
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................................... 47
2.8.12 USING LAMPS ........................................................................................................................ 47
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR ......................... 48
2.8.14 PRECAUTIONS CONCERNING THE STARTER ................................................................... 48
2.8.15 HANDLING HIGH-PRESSURE PIPES .................................................................................... 48
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 49
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES
AND HIGH PRESSURE .......................................................................................................... 49
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE
TO ADJUST THE TRACK TENSION ...................................................................................... 50
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK
ABSORBER UNIT .................................................................................................................... 50
2.8.20 HYDRAULIC ACCUMULATOR ............................................................................................... 50
2.8.21 COOLING FAN AND BELT .....................................................................................................51
2.8.22 WASTE MATERIALS .............................................................................................................. 51
2.8.23 COMPRESSED AIR ................................................................................................................. 51
2.8.24 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES .................. 51
11
TABLE OF CONTENTS
THE MACHINE AND ITS OPERATIONS
3.1 MACHINE VIEW ILLUSTRATIONS ...................................................................................................... 54
3.1.1 OVERALL MACHINE VIEW ..................................................................................................... 54
3.1.2 CONTROLS AND GAUGES ..................................................................................................... 55
3.2 DETAILED CONTROLS AND GAUGES .............................................................................................. 56
3.2.1 MONITORING SYSTEM........................................................................................................... 56
3.2.1.1 EMERGENCY MONITORS ..................................................................................... 57
3.2.1.2 METER DISPLAY PORTION .................................................................................. 59
3.2.1.3 PILOT LAMPS......................................................................................................... 61
3.2.1.4 MONITOR SWITCHES PORTION .......................................................................... 62
3.2.2 SWITCHES............................................................................................................................... 64
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 67
3.2.4 WINDSHIELD (Machines equipped with cab) .......................................................................... 74
3.2.5 SLIDING DOOR (Machines equipped with cab) ....................................................................... 78
3.2.6 SLIDING WINDOW (Machines equipped with cab) .................................................................. 78
3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab) ......................................... 79
3.2.8 CAPS AND COVERS WITH LOCK ......................................................................................... 80
3.2.9 ENGINE REAR COVER ........................................................................................................... 81
3.2.10 COOLING COVER ................................................................................................................... 82
3.2.11 TANK COVER .......................................................................................................................... 83
3.2.12 METHOD OF OPENING (TILTING) FLOOR ............................................................................ 84
3.2.13 FUSE ........................................................................................................................................ 88
3.2.14 BLOCK FUSE ........................................................................................................................... 88
3.2.15 OPERATION MANUAL STORAGE .......................................................................................... 89
3.2.16 TOOL BOX ............................................................................................................................... 89
3.2.17 GREASE GUN HOLDER.......................................................................................................... 89
3.2.18 ASHTRAY (Machines equipped with cab) ................................................................................ 89
3.3 MACHINE OPERATIONS AND CONTROLS ....................................................................................... 90
3.3.1 BEFORE STARTING ENGINE ................................................................................................. 90
3.3.1.1 WALK-AROUND CHECKS ..................................................................................... 90
3.3.1.2 CHECKS BEFORE STARTING .............................................................................. 92
3.3.1.3 ADJUSTMENT ........................................................................................................ 98
3.3.1.4 OPERATIONS BEFORE STARTING ENGINE ....................................................... 101
3.3.1.5 STARTING ENGINE ............................................................................................... 103
3.3.2 AFTER STARTING ENGINE .................................................................................................... 106
3.3.2.1 BREAKING-IN THE NEW MACHINE...................................................................... 106
3.3.2.2 WARMING-UP OPERATION .................................................................................. 106
3.3.3 STOPPING THE ENGINE ........................................................................................................108
3.3.4 MACHINE OPERATION ........................................................................................................... 109
3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF .......................................... 109
3.3.4.2 MOVING MACHINE FORWARD............................................................................. 109
3.3.4.3 MOVING MACHINE BACKWARD .......................................................................... 111
3.3.4.4 STOPPING MACHINE ............................................................................................ 112
3.3.5 STEERING THE MACHINE...................................................................................................... 113
3.3.5.1 STEERING .............................................................................................................. 113
3.3.6 SWINGING ............................................................................................................................... 115
3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS.......................................................... 116
3.3.8 PROHIBITED OPERATIONS ................................................................................................... 118
3.3.9 GENERAL OPERATION INFORMATION ................................................................................ 120
3.3.10 TRAVELING ON SLOPES........................................................................................................ 122
3.3.11 ESCAPE FROM MUD .............................................................................................................. 124
3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR ....................................... 125
3.3.13 CHANGING THE BUCKET.......................................................................................................127
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TABLE OF CONTENTS
3.3.14 PARKING MACHINE ................................................................................................................ 128
3.3.15 CHECK AFTER SHUT OFF ENGINE ...................................................................................... 129
3.3.16 MACHINE INSPECTION AFTER DAILY WORK...................................................................... 129
3.3.17 LOCKING ................................................................................................................................. 129
3.3.18 RUBBER SHOES (Machines equipped only with rubber shoes) ............................................. 130
3.3.18.1 OPTIMAL USE OF THE RUBBER SHOES ............................................................ 130
3.3.18.2 RUBBER SHOE WARRANTY................................................................................. 130
3.3.18.3 USING THE RUBBER SHOES ............................................................................... 130
3.4 TRANSPORTATION ............................................................................................................................. 134
3.4.1 TRANSPORTATION PROCEDURE ........................................................................................ 134
3.4.2 LOADING AND UNLOADING WITH TRAILER ........................................................................ 134
3.4.3 LIFTING MACHINE .................................................................................................................. 140
3.5 COLD WEATHER OPERATION ........................................................................................................... 142
3.5.1 COLD WEATHER OPERATION INFORMATION .................................................................... 142
3.5.1.1 FUEL AND LUBRICANTS....................................................................................... 142
3.5.1.2 COOLING SYSTEM COOLANT.............................................................................. 142
3.5.1.3 BATTERY................................................................................................................ 143
3.5.2 CAB HEATER IN COLD WEATHER (Machines equipped with cab) ....................................... 143
3.5.3 AFTER DAILY WORK COMPLETION ..................................................................................... 144
3.5.4 AFTER COLD WEATHER SEASON........................................................................................ 144
3.6 LONG TERM STORAGE....................................................................................................................... 145
3.6.1 BEFORE STORAGE ................................................................................................................ 145
3.6.2 DURING STORAGE ................................................................................................................. 145
3.6.3 AFTER STORAGE ................................................................................................................... 145
3.7 TROUBLES AND ACTIONS ................................................................................................................. 146
3.7.1 RUNNING OUT OF FUEL ........................................................................................................ 146
3.7.2 PHENOMENA THAT ARE NOT FAILURES ............................................................................ 146
3.7.3 TOWING THE MACHINE ......................................................................................................... 146
3.7.4 SEVERE JOB CONDITION ...................................................................................................... 147
3.7.5 DISCHARGED BATTERY ........................................................................................................ 147
3.7.5.1 BATTERY REMOVAL AND INSTALLATION .......................................................... 148
3.7.5.2 BATTERY CHARGES ............................................................................................. 148
3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES ................................................... 149
3.7.6 OTHER TROUBLE ................................................................................................................... 151
3.7.6.1 ELECTRICAL SYSTEM .......................................................................................... 151
3.7.6.2 CHASSIS ................................................................................................................ 152
3.7.6.3 ENGINE .................................................................................................................. 152
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TABLE OF CONTENTS
MAINTENANCE
4.1 MAINTENANCE INFORMATION .......................................................................................................... 156
4.2 LUBRICANTS, COOLANT AND FILTERS ........................................................................................... 159
4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ................................... 159
4.2.1.1 OIL........................................................................................................................... 159
4.2.1.2 FUEL ....................................................................................................................... 159
4.2.1.3 COOLING SYSTEM COOLANT.............................................................................. 160
4.2.1.4 GREASE ................................................................................................................. 160
4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) .............................. 161
4.2.1.6 OIL AND FUEL STORAGE ..................................................................................... 162
4.2.1.7 FILTERS..................................................................................................................162
4.2.2 ELECTRIC SYSTEM MAINTENANCE ..................................................................................... 163
4.2.3 HANDLING HYDRAULIC SYSTEM.......................................................................................... 163
4.3 WEAR PARTS....................................................................................................................................... 164
4.3.1 WEAR PARTS LIST ................................................................................................................. 164
4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.................................................................. 165
4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS.............................. 169
4.5 TIGHTENING TORQUE SPECIFICATIONS ......................................................................................... 170
4.5.1 TIGHTENING TORQUE LIST................................................................................................... 170
4.6 LUBRICATION ...................................................................................................................................... 171
4.6.1 LUBRICATION DIAGRAM........................................................................................................171
4.7 SAFETY CRITICAL PARTS .................................................................................................................. 172
4.7.1 SAFETY CRITICAL PARTS LIST ............................................................................................. 172
4.8 MAINTENANCE SCHEDULE................................................................................................................ 173
4.8.1 MAINTENANCE SCHEDULE CHART...................................................................................... 173
4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER .................................................... 174
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER ........................................................... 174
4.8.2.b CHANGING THE HYDRAULIC OIL ........................................................................ 174
4.9 MAINTENANCE PROCEDURE ............................................................................................................ 175
4.9.1 WHEN REQUIRED ................................................................................................................... 175
4.9.1.a CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ................................ 175
4.9.1.b CLEAN INSIDE OF COOLING SYSTEM ................................................................ 177
4.9.1.c CHECK LEVEL OF BATTERY ELECTROLYTE..................................................... 180
4.9.1.d CLEANING THE FUEL FILTER (WITH WATER SEPARATOR) ........................... 182
4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK........................................... 182
4.9.1.f CHECK AND ADJUST TRACK TENSION
(Machines equipped with steel shoes) .................................................................... 183
4.9.1.g CHECKING THE RUBBER SHOES
(Machines equipped with rubber shoes) ................................................................. 185
4.9.1.h CHECK AND ADJUST RUBBER SHOE TENSION
(Machine equipped with rubber shoes) ................................................................... 187
4.9.1.i REPLACE RUBBER SHOES
(Machine equipped with rubber shoes) ................................................................... 189
4.9.1.j CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
(Machine equipped with cab) .................................................................................. 191
4.9.1.k CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER
(Machine equipped with cab) .................................................................................. 192
4.9.1.l BLEEDING AIR FROM HYDRAULIC SYSTEM ...................................................... 192
14
TABLE OF CONTENTS
4.9.2 CHECK BEFORE STARTING .................................................................................................. 193
4.9.3 EVERY 500 HOURS MAINTENANCE ..................................................................................... 194
4.9.3.a LUBRICATING ........................................................................................................ 194
4.9.3.b
4.9.3.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR) ......... 197
4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................... 198
4.9.3.e REPLACE FEED PUMP PRE-FILTER.................................................................... 199
4.9.3.f CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS...................... 199
4.9.3.g CHECK AND ADJUST COOLING FAN BELT TENSION ....................................... 200
4.9.4 EVERY 1000 HOURS MAINTENANCE ................................................................................... 201
4.9.4.a CHANGING THE HYDRAULIC OIL FILTER ELEMENT ......................................... 201
4.9.4.b CHANGE OIL IN FINAL DRIVE CASE.................................................................... 202
4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST ................................................. 202
4.9.5 EVERY 2000 HOURS MAINTENANCE ................................................................................... 203
4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER .................................... 203
4.9.5.b CHECK ALTERNATOR, STARTING MOTOR ........................................................ 204
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
196
TECHNICAL SPECIFICATIONS
5.1 SPECIFICATIONS................................................................................................................................. 206
5.2 LIFTING CAPACITIES .......................................................................................................................... 208
5.2.1 LIFTING CAPACITIES (WITH CANOPY)................................................................................. 208
5.2.2 LIFTING CAPACITIES (WITH CABIN) ..................................................................................... 211
AUTHORIZED OPTIONAL EQUIPMENT
6.1 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION .......................................................... 216
6.1.1 SAFETY FIRST ........................................................................................................................ 216
6.1.2 ATTACHMENT INSTALLATION .............................................................................................. 217
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT........................................................ 218
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....................................... 218
6.2 MACHINE READY FOR ATTACHMENT .............................................................................................. 219
6.2.1 LOCATIONS ............................................................................................................................. 219
6.2.2 HYDRAULIC CIRCUIT ............................................................................................................. 221
6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT ...................................... 221
6.2.2.2 MAINTENANCE ...................................................................................................... 222
6.2.2.3 BLEEDING AIR ....................................................................................................... 222
6.3 ATTACHMENT OPERATIONS ............................................................................................................. 223
6.3.1 LONG TERM STORAGE.......................................................................................................... 224
6.3.2 SPECIFICATIONS.................................................................................................................... 224
6.4 ATTACHMENT GUIDE.......................................................................................................................... 225
6.4.1 ATTACHMENT COMBINATIONS ............................................................................................ 225
6.5 RECOMMENDED ATTACHMENT OPERATIONS ............................................................................... 226
6.5.1 HYDRAULIC BREAKER........................................................................................................... 226
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
• 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.
• If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer.
• In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on
the new piece.
• 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
RKA13410
SAFETY, NOISE AND VIBRATION PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
The warning and danger plates applied onto the machine are accompanied or represented by pictograms.
The personnel in charge with the operation and maintenance of the machine must know the symbols contained in
the pictograms perfectly; the following description illustrates what they look like and their respective meanings.
DANGER IN THE WORK AREA
• Do not approach or stand within the equipment operating radius
when the boom and the bucket are raised.
DO NOT OPEN THE HOOD
• Do not open or remove the hood when the engine is running.
CONSULT THE MANUAL
• Carefully read the contents of the manual before using the machine or performing maintenance operations.
3F05B2612
3F30B2612
RWA00020
RWA00010
SAFETY DISTANCE
• Do not get too near the machine and do not stand within its operating radius.
09651-A0481
RWA00030
22L-98-22270
19
SAFETY, NOISE AND VIBRATION PLATES
CAB LIFTING SAFETY LOCK
FILLING THE HYDRAULIC SYSTEM WITH OIL
• (Only for machines in which the synthetic biodegradable
oil type HEES is used)
22L-98-R2390
RKA01380
HYDRAULIC OIL TOPPING UP
REFUELLING
BIO-OIL
RWA00050
D
RWA00040
RWA34380
ENGINE LUBRICATING OIL FILTER
20
RWA00080
FUEL FILTER
ENGINE AIR SUCTION 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
ELECTRIC OUTLET
ANCHORAGE POINT
EMERGENCY EXIT
RWA00120
12 V
RWA00200
RWA00190
LIFTING POINT
RWA04920
22
LIFTING CAPACITIES
>
B
SAFETY, NOISE AND VIBRATION PLATES
A
W=450mm
kg 34
L
L=1015mm
L=1365mm
B
3m
2m
1m
0
-1m
0
A
2m 3m MAX
380kg
640kg
585kg
560kg
570kg
555kg
335kg
320kg
310kg
300kg
265kg
235kg
255kg
350kg
210kg
>
22K-98-R2110
23
SAFETY, NOISE AND VIBRATION PLATES
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB
• 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.
• If the plates are damaged, ask for new ones to Komatsu or to
your Komatsu Dealer.
• In case of replacement of a component provided with a noise
plate, make sure that this plate is applied also on the new piece.
RKA01410
NOISE OUTSIDE THE CAB
• This value indicates the noise level outside the machine and re-
fers to the noise perceived by persons in the vicinity of the work
area.
NOISE INSIDE THE CAB
• This value indicates the maximum noise level perceived by the
operator’s ears inside the cab when this is completely closed.
RKA13430
RKA01530
2000/14/EC
24
RKA13420
ISO 6396
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY
• 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.
• If the plates are damaged, ask for new ones to Komatsu or to
your Komatsu Dealer.
• In case of replacement of a component provided with a noise
plate, make sure that this plate is applied also on the new piece.
EXTERNAL NOISE
• This value indicates the noise level outside the machine and re-
fers to the noise perceived by persons in the vicinity of the work
area.
SAFETY, NOISE AND VIBRATION PLATES
RKA01420
RKA13430
2000/14/EC
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma-
chine, 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.
25
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
• Only trained and authorized personnel can use the machine and perform maintenance operations.
• Follow all the safety rules, precautions and instructions when using the machine or performing maintenance operations.
• 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
• 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.
• Always use the proper safety devices to lock the machine when parking and fasten the safety belt.
• Do not remove the safety devices and always keep them in good operating conditions.
• Any improper use of the safety devices may result in serious injuries or even death.
2.2.3 CLOTHING AND PERSONAL
PROTECTION ITEMS
• 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 injuries or damage.
Avoid also wearing clothes dirty with oil or fuel, since they are
flammable.
• Wear a hard hat, goggles, safety shoes, mask, gloves and
headphones when operating the machine or performing maintenance operations.
• 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 driving the equipment connection pins with a hammer and when blowing compressed air into the air filter and the radiator to clean them.
During these operations, make also sure that no one is standing
or working near the machine without the necessary protections.
• 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
26
GENERAL PRECAUTIONS
2.2.4 UNAUTHORIZED MODIFICATIONS
• Any modification made without the authorization of Komatsu can involve hazards.
• Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injuries or
damage caused by unauthorized modifications.
2.2.5 LEAVING THE OPERATOR’S SEAT
• When leaving the operator’s seat, even if temporarily, make
sure that the machine is in a safe position. (See "2.4.13 PARKING THE MACHINE").
• Before leaving the operator’s seat, carry out the following operations in the sequence indicated below:
1 - Rest the equipment onto the ground.
2 - Connect the safety devices of the boom swing, optional
equipment and upper structure rotation controls.
3 - Lock the equipment control by shifting the safety device le-
ver to the lock position.
4 - Stop the engine (See "3.3.3 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.
RKA01600
CABIN
CANOPY
27
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
• Do not jump on or off the machine, either when it is at rest and
when it is moving.
• When getting on or off the machine, always use the handles
and the tracks; get on and off the machine very carefully.
• Never hold or rest on the control levers.
• Either when getting on and when getting off the machine, al-
ways maintain three points of contact (holding or resting points),
in order to avoid losing your balance and falling down.
• Tighten the handle connection 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
CABIN
28
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