Komatsu PC20R-8, PC27R-8 Maintenance Manual

Operation &
Maintenance Manual

WEAM000101

PC20R-8
PC27R-8

HYDRAULIC EXCAVATOR

SERIAL NUMBER

PC20R-8 - F30791 and up
PC27R-8 - F31103 and up

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.

FOREWORD

CAUTION

1.1 FOREWORD

• This manual has been carr ied out by Komatsu Uti lity in order to supp ly their custom ers with all the nece ssary

information on the mach ine an d the safety r egulation s related to it, together with the use a nd mainten ance in­structions that ena ble the operat or to exploi t the capacity of the mac hine with optim al result s and to keep the
machine efficient over time.

• The operation manual, toget her with the sp are par ts cata log ue, is an in teg ra l part of the mac hin e and mu st ac -

company it, even when it is resold, until its final disposal.

• The manual must be h andled with th e greatest car e and always kept on boar d the machin e, so that it ca n 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 Utility or your Komatsu Utility Dealer.

• The illustrations contained in this manual may represent machine configurations available on request.

The machines are c onstan t ly upgraded in order to in crease their efficiency and r el ia bil it y; t his ma nua l s ums up
all the information regarding the state of technical progress at the moment in which the machine is launched on
the market.
Consult your Komatsu Utility Dealer for any updated information.

• Punctual periodic ann otations regarding the mainte nance ope rations tha t have bee n 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. The refore, it is advisa ble to consul t either th e hour meter a nd the maint enance
plan frequently.

• Over the years Komatsu Utility Dealers have gathered considerable experience in customer service.

If more information is need ed, do not h esitate to c ontac t your Kom atsu Uti lity Deal er: he alwa ys kn ows how to
get the best performa nce from the ma chine , he can su ggest the use of the equ ipmen t that i s most s uitab le 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 Utility Dealers also ensure their assistance for the supply of Komatsu Utility genuine
spare parts, which alone guarantee safety and interchangeability.

• The table included in th is ma nual m ust be fille d in with t he mac hine d ata, whi ch are th e data t hat mus t always

be indicated to the Dealer when requiring assistance and ordering spare parts.

• The incorrect use of the machine and inappropriate maintenance operations may cause serious inju-

ries 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 othe r than those descr ibed herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.

1

INFORMATION ON SAFETY

IMPORTANT

☞

1.2 INFORMATION ON SAFETY

Many accidents are caused by in sufficient 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 acciden ts, before starting work and be fore carrying out any maintenan ce 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, so that you can follow the instructions without making mistakes.
To identify the messages regarding safety that are included in this manual and written on the machine plates, the
following words have been used.

DANGER

CAUTION

Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op­eration or maintenance of the machi ne; for this re as on, the safet y mess ages inc lu ded in this manu al an d appl ied
onto the machine may not include all possible safety precautions.
If all the procedures and operations pr escribed for this m achine are kept t o, you can be sure t hat 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 Utility or your local Dealer.

• Th is word is us ed in the safet y warning s in the manual and on the pla tes when

the situation is dangerous and it may possibly result in serious injuries or even
death.
These messages describe the safety precautions to be taken in order to avoid
any risk. Non-compliance with these instructions may also result in serious
damage to the machine.

• This word is used in the safety warnings in the manual and on the plates to sig-

nal risks that may cause moderate damage or injuries.
The message can be used even to indica te the risk of damage to t he machine
only.

• This word is used when precautions are indicated, which must be taken to

avoid actions that may shorten the life of the machine.

DANGER

• Before starting any maintenance oper atio n, posit ion the mac hi ne on a firm and level sur face, low er t he

equipment to the ground, engage the safety locks of eithe r the equipment and t he controls and stop th e
engine.

DANGER

• T o 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 whe n the engine p rotection
casing is open, if this is not expressly prescribed for some specific maintenance operations.

2

INFORMATION ON SAFETY

DANGER

DANGER

DANGER

• It is strictly forbidden to modify the setting of the hyd raulic sys tem safety valv es; Komatsu Uti lity can-

not 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.

• Before carrying ou t any electrica l wel ding, d isconne ct th e batter y an d the a lternat or ( See “2.8 .13 PRE -

CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR”).

• Install only authorized additional equipment (See “6.1.3 CHARACTERISTICS OF THE OPTIONAL

EQUIPMENT”).

3

INTRODUCTION

IMPORTANT

☞

1.3 INTRODUCTION

1.3.1 INTENDED USES

The KOMATSU UTILITY MACHINES described in this m anual have be en designed a nd const ructed to be u sed
mainly for EXCAVATION and EARTH-MOVING OPERATIONS.

If provided with suita ble sa fety dev i ces, t hey ca n be us ed wi th a uth or ized o p tiona l equipment having th e char ac ­teristics illustrated at point “6.1 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 impos-

sible to predict all the possible improper uses, if the machine happens to be used for p articular applica­tions, contact your Komatsu Utility Dealer before carrying out the work.

• The instructions regarding the authorized optional equipment are given in the relevant operation and

maintenance manuals; if the equipment is supplied by Komatsu Utility, these publications are enclosed
to this manual.

• The instructions regarding the assembly of the authorized equipment, the controls requiring special ar-

rangements on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.

KOMATSU UTILITY MACHINES are constructed exc lusively for the h andling, ex cavation and tr eatment of in ert
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.

4

INTRODUCTION

IMPORTANT

☞

1.3.3 MAIN CHARACTERISTICS

• Simple and easy operation

• Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.

• Upper structure rotation achieved through an orbital hydraulic motor (for PC20R only).

• Upper structure rotation ach ieved through an axial piston hyd ra ulic moto r acti ng on an epi cyc li c redu cti on ge ar

(for PC27R only)

• Main equipment serv olevers ensuring also combined mov ements that can be modulated proport ionally 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.

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 hour s, in order to ensur e proper running- in of
the various components.
If the machine is subjected to excessive work load at the beginn ing of operatio n, its potential yield and its func ­tionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:

• After the start, let t he engine idle for 5 minutes, in such a way as to warm i t up gradual ly befor e actual op era-

tion.

• Avoid operating the machine with the limit loads allowed or at high speed.

• Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.

• After the first 250 hou rs, carry out the following ope rations, in addition to those to be performed every 250

hours:
1 - Change the oil in the travel reduction gears.
2 - Check and adjust the engine valve clearance.

SYNTHETIC BIODEGRADABLE OIL TYPE HEES

On machines in which the syn thet ic bio degrad abl e oi l ty pe HEES is used, the fol lo win g ope ra tio ns 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.

• When changing the oil filters (ca rtridges) , check their inner part to make sure that the re are no depos-

its.
If considerable deposits ar e observed, find out what may have caused them before star ting the ma­chine.

• The number of operating hours is indicated by the hour meter.

5

PRODUCT IDENTIFICATION

1.4 PRODUCT IDENTIFICATION

The KOMATSU UTILITY 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.

RWA08630

1.4.2 MACHINE IDENTIFICATION PLATE

The KOMATSU UTILITY EXCAVATORS described in the
present manual are provide d 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 i s appli ed on to the fron t wall of
the main frame, on the left side.

RWA08640

MODELLO - MODEL
TYP - MODELE

MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.

ANNO - YEAR
BAUJAHR - ANNEE

MASSA TOTALE MAX - TOTAL MAX WEIGHT
ZUL. GESAMTGEWICHT - POIDS TOTAL MAX

POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR

MASSA MAX ASSE ANT. - MAX WEIGHT FRONT AXLE
ZUL. ACHSLAST VORN - POIDS MAX ESSIEU AV

MASSA MAX ASSE POST. - MAX WEIGHT REAR AXLE
ZUL. ACHSLAST HINTEN - POIDS MAX ESSIEU AR

MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) ITALY UNDER LICENSE FROM KOMATSU LTD

kg

kw

kg

kg

20T-98-RB26441

RYA11760

MODEL

SERIAL N

YEAR

TOTAL MAX WEIGHT

ENGINE POWER

MAX WEIGHT FRONT AXLE

MAX WEIGHT REAR AXLE

MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) ITALY UNDER LICENSE FROM KOMATSU LTD

kg

kw

kg

kg

6

1.4.3 ENGINE SERIAL NUMBER AND EX­HAUST GAS EMISSION PLATE

The engine serial numb er is stam ped on the pl ate posi tioned on
the top of the engine cylinder head cover.

The exhaust gas emi ssion plate is ap plied on the t op of the en­gine cylinder head cover.

PRODUCT IDENTIFICATION

RWA08650

1.4.4 TRA VEL REDUCTION GEAR SERIAL NUMBER

The serial number of the travel reduction gear is stamped on the
plate positioned on the outer side of the reduction gear cover.

RWAA10520

RWA04970

7

PRODUCT IDENTIFICATION

1.4.5 SWING MOTOR SERIAL NUMBER (for PC20R only)

The serial number of the swing reduction gear is stamped on the
plate positioned on the swing motor head.

1.4.6 SWING REDUCTION GEAR SERIAL NUMBER (for PC27R only)

The serial number is stamped on the plate positioned laterally on
the reduction gear body.

RWA09980

1.4.7 CAB SERIAL NUMBER

The CAB serial number is stampe d on the plate positioned on
the top left side.

RWA09990

RYAA0050

8

1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS

Machine n. Model
Engine n.
Travel reduction gear n.
Swing motor (for PC20R only) n.
Swing reduction gear (for PC27R only) n.
Cab n.

Dealer:

PRODUCT IDENTIFICATION

Address:

Person to contact:

NOTES:

Tel.

9

10

T ABLE OF CONTENTS

Page

TABLE OF CONTENTS

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.4 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4.1 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4.2 MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 MOTOR SERIAL NUMBER (for PC20R only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.6 SWING REDUCTION GEAR SERIAL NUMBER (for PC27R only) . . . . . . . . . . . . . . . . . . . . 8

1.4.7 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SAFETY AND ACCIDENT PREVENTION

2.1 SAFETY, NOISE AND VIBRATION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.1.1 POSITION OF THE SAFETY PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB . . . . . . . . . . . . . . . . . . . . 26

2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY . . . . . . . . . . . . . . . . 27

2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED . . . . . . . . . . . . . . . . . . . . . . . 27

2.2 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.1 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.2 SAFETY DEVICES AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.4 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.2.5 LEAVING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.2.6 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2.8 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . 32

2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3.1 SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3.2 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . 33

2.3.4 ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES . . . . . . . . 34

11

TABLE OF CONTENTS

Page

2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.4.1 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . 35

2.4.3 CHECKS FOR TRAVELLING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.4.4 MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.4.5 MOVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.4.6 WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.4.7 UNAUTHORIZED OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.4.8 PREVENTING ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.4.9 VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.5.1 LOADING AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.5.2 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.6 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY . . . . . . . . . . . . . . . . . . . . . . 43

2.6.2 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.7 PRECAUTIONS FOR THE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.8 PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.1 WARNING PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.2 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.3 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.4 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.8.5 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.8.6 CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . 47

2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY . . . . . . . . . 47

2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION

OR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP . . . . . . . . . . . . . . . . . . 48

2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.8.12 USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR . . . . . . . . . . . . 49

2.8.14 PRECAUTIONS CONCERNING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.8.15 HANDLING HIGH-PRESSURE PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL . . . . . . . . . . . . 50

2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND

HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.8.18 COOLING FAN AND BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.8.19 WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES . . . . . . . . 51

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DESCRIPTION AND USE OF THE MACHINE

3.1 SAFETY LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.1.1 MACHINE LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.2 GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.3 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.3.1 INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.3.2 WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3.3.3 SWITCHES AND PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.3.4 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.3.5 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.4 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.4.1 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.4.1.1 EQUIPMENT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.4.1.2 MAIN FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.4.2 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3.5 GUARDS AND DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.5.1 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.5.2 RIGHT COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.5.3 CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.5.4 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.5.5 VENTILATION AND HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

3.5.6 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.5.7 SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.5.8 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

3.5.9 TECHNICAL DOCUMENTATION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

3.5.10 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.5.11 FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.6 USE OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.6.1 CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.6.1.1 VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.6.1.2 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.6.1.3 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.6.2 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES . . . . . . . . . 89

3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES . . . . . . . . . . . . . . . . 90

3.6.3 WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.6.4 HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.6.5 HOW TO MOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.6.5.1 STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.6.5.2 MOVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

3.6.5.3 MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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3.7 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

3.7.1 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

3.7.2 PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3.8 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.9.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.9.2 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.10 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.1 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.4 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.13 USING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.13.1 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 106

3.13.3 DIGGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.13.4 CHANGING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.14 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.14.1 BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.14.2 DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

3.14.3 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

3.15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.15.1 OCCURRENCES THAT ARE NOT FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.15.2 HOW TO REMOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.15.3 AFTER THE FUEL HAS RUN OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.15.4 IF THE BATTERY IS DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.15.4.1 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

3.15.5 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.15.5.1 ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.15.5.2 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.15.5.3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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MAINTENANCE

4.1 GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

4.2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.2.1 NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.2.1.1 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.2.1.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.2.1.3 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.2.4 NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . 123

4.3 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS . . . . . . . . . . . . . . 126

4.4 DRIVING TORQUES FOR SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.4.1 STANDARD DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.4.2 SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

4.5.1 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY . . . . 129

4.6.1 CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.7 MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

4.7.1 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

4.7.1.a WASHING THE COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

4.7.1.b DRAINING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4.7.1.c CHECKING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.7.1.d CHECKING THE STEEL TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.7.1.e CHECKING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

4.7.1.f CHECKING THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4.7.1.g CHANGING THE RUBBER TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE . . 146

4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE

DEMOLITION HAMMER (BREAKER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.7.2.a CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.7.2.b CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.7.3 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.7.3.a VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.7.3.b CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.7.3.c CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.7.3.d CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . 150

4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR . . . . . . . . . . . . . . . . 151

4.7.3.g CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER . . . . . . . . . . . . 151

4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION

(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 152

4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING . . . . . . . . . . . . . . 153

15

TABLE OF CONTENTS

4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . 155

4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.7.7.a ADJUSTING THE FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . 156

4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS . . . . . . . . 156

4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER . . . . . . . . . . . . . . . . . . . . . 157

4.7.7.e CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION

(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 159

4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

4.7.9.a CHANGING THE ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

4.7.9.b CHANGING THE FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

4.7.9.c CHANGING THE FUEL PUMP PRECLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS . . . . . . . . . . . . . . . . . . . . . . . 162

4.7.9.e DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the

synthetic biodegradable oil type HEES is used) . . . . . . . . . . . . . . . . . . . . . . . . . . 163

4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 164

4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS . . . . . . . . . . . . . . 164

4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION

FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.7.11.b CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE . . . . . . . . . 169

4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER . . . . . . . . . . . . . . . . . . . . 169

Page

TECHNICAL SPECIFICATIONS

5.1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5.1.1 STANDARD OVERALL DIMENSIONS (for model PC20R only) . . . . . . . . . . . . . . . . . . . . . . 172

5.1.2 TECHNICAL CHARACTERISTICS PC20R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

5.1.3 STANDARD OVERALL DIMENSIONS (for model PC27R only) . . . . . . . . . . . . . . . . . . . . . . 174

5.1.4 TECHNICAL CHARACTERISTICS PC27R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

5.1.5 LIFTING CAPACITY WITH CAB (for model PC20R only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.1.6 LIFTING CAPACITY WITH CANOPY (for model PC20R only) . . . . . . . . . . . . . . . . . . . . . . . . 177

5.1.7 LIFTING CAPACITY WITH CAB (for model PC27R only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

5.1.8 LIFTING CAPACITY WITH CANOPY (for model PC27R only) . . . . . . . . . . . . . . . . . . . . . . . 179

16

T ABLE OF CONTENTS

Page

AUTHORIZED OPTIONAL EQUIPMENT

6.1 AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

6.1.1 PRECAUTIONS REGARDING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . 183

6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) . . . . 185

6.2.1 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED . . . . . . . . . . . . . . 185

6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER . . . . . . . . . . . . . . . . . . . . . . . 189

6.2.3.1 INSTALLING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

6.2.3.2 REMOVING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

6.2.4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 191

6.3.1 SELECTION VALVE (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

6.3.2 CONTROL PEDAL (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

6.3.4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

17

18

SAFETY AND
ACCIDENT PREVENTION

SAFETY, NOISE AND VIBRATION PLA TES

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 Utility or to your Komatsu Utility 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 pl ates in addition to those indicated bel ow; keep also to the instruc-

tions given in the additional plates, in any case.

MACHINE WITH CAB

RYA11880

RWA00020

RWA00030

20

RWA00010

MACHINE WITH CANOPY

RYA11890

SAFETY, NOISE AND VIBRATION PLATES

RWA00030

RWA00020

RWA00010

21

SAFETY, NOISE AND VIBRATION PLA TES

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 eq uip men t operating radi-

us when the boom and the bucket are raised.

RWA00020

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 ma-

chine or performing maintenance operations.

RWA00010

HYDRAULIC OIL TOPPING UP

22

RWA00030

RWA00050

FILLING THE HYDRAULIC SYSTEM WITH
OIL

(Only for machines in which the synthetic biodegradable oil
type HEES is used)

SAFETY, NOISE AND VIBRATION PLATES

REFUELLING

ENGINE LUBRICATING OIL FILTER

FUEL FILTER

BIO-OIL

D

RWA00040

RWA00080

RWA34380

ENGINE AIR SUCTION FILTER

ENGINE COOLANT

D

RWA00060

RWA00090

RWA00130

23

SAFETY, NOISE AND VIBRATION PLA TES

ENGINE COOLANT PRESSURE

HYDRAULIC OIL LEVEL

HYDRAULIC OIL FILTER

RWA00110

RWA00100

ELECTRIC OUTLET

ANCHORAGE POINT

EMERGENCY EXIT

RWA00120

RWA00070

12 V

RWA00200

24

RWA00190

LIFTING POINT

DO NOT LIFT MORE THAN 1000 kg

SAFETY, NOISE AND VIBRATION PLATES

RWA04920

> 1000 Kg

RWA00210

25

SAFETY, NOISE AND VIBRATION PLA TES

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB

• The noise plates must always be legible and in good condi-

tions; for this reason, if they are dirty with dust, oil or grease, it
is necessary to clean them with a solu tion made of water and
detergent.
Do not use fuel, petrol or solvents.

• If the plates are damaged, ask for new ones to Komatsu Utility

or to your Komatsu Utility Dealer.

• In case of replacement of a c omponent provided wi th a noise

plate, make sure that this plate is applied also on the new
piece.

NOISE OUTSIDE THE CAB

• This value indic ates the noise level outside the machine an d

refers to the noise pe rceived by persons i n 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.

L

( 89/514/CE - 95/27/CE )

RYA11900

WA

RYA11910

26

L

( 89/514/CE - 95/27/CE )

p

A

RYA11920

2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY

• The noise plates must always be legible and in good condi-

tions; for this reason, if they are dirty with dust, oil or grease, it
is necessary to clean them with a solu tion made of water and
detergent.
Do not use fuel, petrol or solvents.

• If the plates are damaged, ask for new ones to Komatsu Utility

or to your Komatsu Utility Dealer.

SAFETY, NOISE AND VIBRATION PLATES

• In case of replacement of a c omponent provided wi th a noise

plate, make sure that this plate is applied also on the new
piece.

EXTERNAL NOISE

• This value indic ates the noise level outside the machine an d

refers to the noise pe rceived by persons i n the vicinity of the
work area.

NOISE PERCEIVED BY THE OPERATOR

• This value indicates the maximum noise level perceived by the

operator’s ears.

L

( 89/514/CE - 95/27/CE )

RYA11930

WA

RYA11940

L

p

A

( 89/514/CE - 95/27/CE )

RYA11950

2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED

• According to the r esults of the tes ts carried out to d etermine the v ibrations transmi tted to the operat or 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.

27

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 op-

erations.

• When working with o ther o perators or when the work si te is o ften occ upi ed by oth er 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 guard s and covers are in the correct positio n. Have guards and cover s changed or re-

paired if damaged. Neither use the machine without guards, nor remov e the guards when the engine is run­ning.

• Always use the proper safety devices to lock the machine when parking and fasten the safety belt.

• For the safety devices, see “3.1 SAFETY LOCKS”.

• For the safety belt, see “3.5.7 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 lo ose clothes, r ings and watc hes and d o

not approach the machin e with l oose l ong hair, since they can
get entagled in the moving parts of the machine and cause se­rious injuries or damage.
Avoid also wearing clothes dirty wi th oil or fuel, s ince they ar e
flammable.

• Wear a hard hat, goggles, safety shoes, mask, gloves and

headphones when operati ng the machine o r perfor ming main­tenance operations.

• Always wear safety goggle s, a hard hat and heavy gloves if

your job involves scattering metal chips or minute materia ls;
these precautions are particularly useful when driving the
equipment connect ion pins with a h ammer and when blowing
compressed air into the air filter and the radiator to clean them.
During these operations , make a lso sure tha t no one is sta nd­ing or working near the machine without the necessary protec­tions.

• When working for 8 hours with a noise level exceeding 90

dBA, it is necessa ry to use headphones or ear p lugs and be
particularly careful, especially at the end of the work shift.

28

RWA00960

GENERAL PRECAUTIONS

2.2.4 UNAUTHORIZED MODIFICATIONS

• Any modification made without the authorization of Komatsu Utility can involve hazards.

• Before making a modific ation, consult your Kom atsu Utility Dealer. Komatsu Utility declin es any responsib ility

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 oper-

ations 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 contr o l by s hi fti ng th e s afe ty dev ice le-

ver to the lock position.

4 - Stop the engine (See “3.8 STOPPING THE ENGINE”).

RWA04980

If you have to go so far awa y th at you wil l n ot be abl e t o see th e
machine, extract the ignition key.

RWA08660

RYA11740

RWA08670

29

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, alway s 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 ge tting 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.

RYA11870

2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL

Fuel, oil and some types of antif reeze can be easily ignited if
they get in contac t with a flame. Fuel is particularly flammable
and therefore extremely hazardous.

• Keep any naked flame away from flammable fluids.

• Stop the engine and do not smoke when refuelling.

• Top up wit h fuel and oil only after stopping the engine and in

well ventilated areas.

• Top up with fuel a nd oil in a well delim ited area and do not al-

low unauthorized persons to approach.

• 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.

RWA05020

RWA00970

• After topping up, tighten the fuel and oil safety caps securely.

• Do not fill the tank completely, in order to leave room for the fu-

el to expand.

• In case some fuel is spilled, wipe it up immediately.

30

RWA00980

2.2.8 PREVENTING BURNS

• If the engine coolant, the engin e oil and the hydraulic oil are

hot, use heavy cloths and wear gloves, heavy clothing and
safety goggles befor e carrying out any check or touching th e
hot parts.

• Before checking the c oolant level, stop the engine and let th e

fluid cool down.
If a check is necessary due to the overheating of the eng ine,
slowly loosen the radia tor plug to release any residual pre s­sure before removing it. The hot fluid that spurts out may
cause serious burns.

• Before checking th e engine oil and hydraul ic circuit oil leve ls,

stop the engine and le t the oil cool down. The hot o il that can
be sprayed out of the tank may cause serious burns.

GENERAL PRECAUTIONS

RWA00990

2.2.9 PREVENTING DAMAGE DUE TO AS­BESTOS POWDER

• Asbestos powder ca n be hazardous to your health i f it is in-

haled.

• If you handle material s co ntaini ng a sb es tos fiber s , keep to the

instructions given below:
1 - Do not use compressed air, but only aspirators to clean

the machine and make sur e that the r oom in whic h yo u ar e
working is properly ventilated.

2 - Use low-pressure water to keep down the dust when clean-

ing.

3 - If there is danger that there may be asbestos powder in the

air, operate the machine with the wind to your back when­ever possible.

4 - Even if the cab provides suitable protection, use an ap-

proved and homologated respira tor.

5 - The powder gathered during t he cleaning operations must

be dampened and put in a sealed and marked container, so
that it can be safely di sposed of according to the regula­tions in force.

RWA01000

RWA01010

31

GENERAL PRECAUTIONS

2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT

• Do not stand within or approach the operating radius of the

work equipment, even when the operat or is on b oard the ma­chine and the engine is running.

• Do not stand or work unde r the ar m s or the a rti cula tio ns whe n

the arms are lifted, if you are not sure that the safety locks
have been duly engaged.

• Do not carry out any operation re quiri ng the lifting of the arms,

if you are not sure tha t the locks are co rrectly positioned an d
coupled to the arms.

2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT

• Make sure that fire extinguishers have been provided and

check their position.

• Periodically make sure that the fire extingui shers are loaded

and that you know how to use them.

RWA01020

• Find out where the first aid kit has been located.

• Periodically mak e s ur e th at th e fi r st aid ki t c onta in s th e ne ce s-

sary disinfectants, bandages, medicins, etc.

• It is necessary to know what to do in case of fire.

• Make sure that you have the phone numbers of the persons or

structures you may need to contact in case of an emergency at
hand (either at the work si te and where maintenance opera­tions are performed).

RWA01030

2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE

• If the cab is inadv er tent ly hit or the machine ov er turn s dur in g wo r k, the cab may be damaged with consequen t

reduction of its stiffness and of the safety that must be guaranteed to the operator.
Consult Komatsu Utility or your Komatsu Utility Dealer to have the cab structure and resistance checked in case
of impact or damage.

2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT

• When installing and using optional equipment, carefully read the relevant instruction manual and keep to the in-

dications given therein.

• Do not use optional or spec ial equipment without the authori zation of Komatsu Utility or the Kom atsu Utility

Dealer.
The installation an d use of unau thorized equi pment may cre ate safety p roblems and a dversely affect t he effi­ciency and life of the machine.

• Komatsu Utility cannot be held li able for any inj ury, accident, product failure result ing from the inst allation and

use of unauthorized equipment.

32

PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE

2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE EN­GINE

2.3.1 SAFETY ON THE WORK SITE

• Before starting the engine, thoroughly che ck the area for any

unusual condition of the ground due to which work may be
dangerous.

• Check the conditions of the ground at the work site and before

starting the engine def ine the wor k plan and the best and s af­est operating procedure.

• Make the ground sur face as level a s possible befo re carrying

out any operation.

• In case of work on the r oad, protect pedestrians and cars by

designating a person for work site traffic duty and install fences
around the work site.

• If water lines, gas line s, and tel ephone or high-voltag e electri-

cal lines are located un der the work site, contact the relevant
utility company in or der to find out their exact positio ns or to
make them ineffective until the end of the operations. Be care­ful not to sever or damage any of these lines.

RWA00220

• Check the depth and flow of water before operating in water or

on river banks.

2.3.2 FIRE PREVENTION

• Completely remove all wood ch ips, rubbish, paper and other

flammable materials that may have accumulated inside the en­gine compartment, since they can cause fires.

• Check the fuel and hydraulic system pipes for leaks and if nec-

essary repair them. Wipe up any exces s oil, fu el or othe r flam­mable fluids.

• Make sure that fire extinguishers are available in the work ar-

ea.

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB

RWA01040

• Do not leave object s or tools ly ing ar ound in the o perat or’s cab. They m ay hin der th e operati on of th e cont rols

and cause serious accidents.

• Keep the cab floor and th e co ntr ol s (pe dal s and l ev er s) c lean, by removing any trac e o f oi l an d grea se and, as

far as the floor is concerned, remove any excess dirt (earth, stones, etc.).

• Check the safety belt and change it if it is broken or damaged.

Replace any component only with homologated parts available at Komatsu Utility or its Dealers.

33

PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE

2.3.4 R O OM VE NTIL ATION

• Before starting the machine in confined or poorly ventilated

places, provide for proper ventilation or connect the engine ex­haust pipe to a suction duct. The engine exhaust gases can be
deadly.

RWA01050

2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS

• Remove any trace of dirt from the lights, in such a way as to ensure perfect visibility on the work area.

• Make sure that the working lights are installed as prescribed. Make also sure that they come on correctly.

2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES

• Remove any trace of dirt from the cab windows, in order to ensure perfect visibility on the work area.

• Check the conditions o f the windshield wi per blades; the sc raping wire must be smooth, with no ind entations

and attached to the rubber back of the blade.
In case of doubts on the efficiency of the scraping wire, change the blades.

34

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.1 STARTING THE ENGINE

• Before getting on the machine, walk around it and check for people and objects that might be in the way.

• Do not start the engine if warning plates have been attached to the control levers.

• When starting the engine, sound the horn as an alert signal.

• Start the engine only while seated with fastened safety belt.

• Do not allow anyone to get on the machine.

2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE

• Before operating the machine tr avel le ve rs, check the posi tion

of the blade.
If the blade is positioned on the back of the machine, the oper­ation of the travel levers is inverted.
In this condition, take care not to mistake the travel move­ments during the use of the machine.
(See “3.6.5 HOW TO MOVE THE MACHINE”).

2.4.3 CHECKS FOR TRAVELLIN G IN RE­VERSE

• When operating in areas that may be haz ardous or hav e poor

visibility, designate a person to direct the movements of the
machine and traffic on the work site.

• Make sure that no un authorized pers on is within the m achine

operating radius or in its travel direction.
If necessary, put up appropriate fences.

• Before moving the machine , sound the horn in order to warn

the persons near the work area.

• There are blind spots behind the machine, which cannot be

seen and where someone may be standing: therefore, it is
necessary to make sure that there is no one behind the ma­chine before travelling in reverse.

RWA06750

RWA06760

RWA06770

35

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.4 MOVING THE MACHINE

• When moving the machine, position the bucket at about 40÷50

cm from the ground; this position makes it possible to evaluate
the space required for the movements more precisely and at
the same time ensures the stability of the machine.

• Make sure that the driver’s seat is directed towards the blade.

Otherwise, pay attention to the steering and advance manoeu­vres, since they are inverted.

• If the equipment control levers must be used during travel,

avoid moving the m abruptly; sud den manoeuvre s change the
attitude of the machine and make driving difficult.

• When travelling on rough ground, keep the speed low and

avoid sudden movements of the bucket arm.

• If possible, avoid moving on obstacles.

If the machine has to travel over an obs tacle, keep the equip­ment as close to the ground as possible and travel at low
speed.
Never move on obstacles that may incline the machine consid­erably (over 10°).

40÷50 cm

WRONG

RWA06780

• If one of the two rubber tracks moves on an obstacle or gets

into a hole in the ground, the machine may overturn.
In these cases, reduce the speed to minimum and be very
careful to the balance of the machine.

RWA05040

36

2.4.5 MOVING ON SLOPES

• Operations on slopes and on river or lake banks with damp

ground may result in the tipping over or slipping of the ma­chine.

• On hills, banks or s lopes, keep the bucket very close to th e

ground (20÷30 cm from the ground) and in case of emergency
quickly lower it to the ground to help the machine stop.

• Do not change direct ion and avoid travelling obliquely whe n

working on slopes. I t is advisable to go down or up to a flat
place to perform these operations.

• Do not travel on wet grass o r thick lay ers of leaves : if the ma-

chine moves obliquely in these conditions, it may slip.

• Do not move on slopes with inclination exceeding 30°, since

the machine may overturn.

• When the fuel level indicator reaches the red reserve area dur-

ing work on a slope, immedi ately provide for refue lling; due to
the inclination of the mach ine, the engine may suck in air and
suddenly stop, whic h represents a gra ve risk for the safe ty of
the operator and of the persons before the machine.

• If the engine should stop all of a sudden, immediately lower

the bucket to the ground.

PRECAUTIONS TO BE TAKEN WHEN WORKING

20÷30 cm

RWA06790

20÷30 cm

RWA06800

WRONG

CORRECT

RWA06820

RWA06930

37

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.6 WORKING ON SLOPES

• When working on slopes, i f possible avoid rotating the upper

structure, since the machine may lose balance and overturn.
It is particularly dangerous to swing on slopes when the bucket
is full.
If these operations must la st longer, accumulate soil in such a
way as to create a horizo ntal platform on which the machin e
can be positioned.

WRONG

RWA05150

CORRECT

RWA05260

2.4.7 UNAUTHORIZED OPERATIONS

• Do not dig under overhangs.

The protruding surface, in fact, may collapse on the machine.

• Do not dig too deeply under the front part of the machine,

since the ground may collapse and ca use the machine to fall
down.

RWA05350

RWA05340

38

PRECAUTIONS TO BE TAKEN WHEN WORKING

DANGER

2.4.8 PREVENTING ELECTROCUTION

• Digging operations ne ar overhe ad electric lines ar e extremely danger ous and the y may also cause death due

to electrocution; for this reason, when working near overhead electrical lines always respect the minimum safe­ty distances prescrib ed by the co mpe tent authorities and by the accident-prev en tio n rul es in force.

• As far as underground lo ng-distance lines a re concerned, the m inimum distance depen ds on the covering o f

the ducts in which the cables are laid.

• The basic safety precautions to be taken to prevent this risk are the following:

1 - Wear shoes with thick rubber or leather soles.
2 - Request the aid of another person who can warn you if the machine gets too close to the electric line.
3 - Operate at low speed.
4 - Learn what is to be done first in case of electrocution.
5 - Keep the phone number of the electricity company and of the nearest first aid station at hand.

• If the work equipmen t gets accide ntally enta ngled in the c ables, the operator mus t not leave the cab until the

electric ity company has insulated th e line.

• When carrying out this kind of operations, warn everyone standing in the work area to keep at the minimum dis-

tance prescribed from the machine and the work equipment.

• Ask the electricity company what are the voltage of the cables and the minimum safety distance in advance.

• The minimum distances from overhead lines can vary in the different countries, according to the cli-

mate and to the humidity percentage in the air.
Indicatively, the distances indicated in the table should be respected.

Min. safety

Cable volt age

1.0 kV (distribution line) 5 m

6.6 kV (2÷3 insulators) 5.2 m
33 kV (min. 3 insulators) 5.5 m
66 kV (min. 6 insulators) 6 m

154 kV (min. 10 insulators) 8 m
275 kV (min. 19 insulators) 10 m

distance

RWA05360

39

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.9 VISIBILITY

• Switch on the working lights as soon as visibility decreases.

• If visibility decre ases due to mist, smoke or heavy rai n, stop the machine in a safe positio n and wait for the

weather to improve until visibility becomes acceptable.

2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES

• If the ground is ic y or c overed with snow, even a slig ht slope ma y ca use the m achi ne to s lip side wards, th ere-

fore it is advisable to move at low speed and to avoid abrupt starts, stops or turns.

• When it has snowed heavil y, the road shoulders and any obstacle are buried in the sn ow and are not visible,

therefore proceed with care when clearing the snow.

2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT

• When working in tunn els , gal ler ies , un der e lec tric c ables or o the r d uct s ( air, telephone line s) an d wh er ever the

height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.

2.4.12 WORKING ON LOOSE GROUND

• Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.

These areas may collapse, mak ing the ma chine fall down or tip ov er and this could res ult in seri ous injurie s or
death.
Remember that after heavy rain or earthquakes these dangerous conditions usually get worse.

• The earth laid near ditches is loose and can easily collapse due to the weight or vibrations of the machine.

Be extremely careful: always fasten the safety belt and close the cab door, if provided.

• In case of work in areas where stones or other material may fall on the machine, install the FOPS protection de-

vice.

40

2.4.13 PARKING THE MACHINE

• Park the machine o n fi r m a nd lev el ground. If this is not po ss i-

ble and it is necessary to park on a slope, position the ma­chine with the bu cket directed downwards and carry out the
following operations:

1 - Rotate the bucket to the dumping position and lower the

arms until thrusting the teeth into the ground.
2 - Stop the engine.
3 - Put wedges or safety blocks under the tracks.

PRECAUTIONS TO BE TAKEN WHEN WORKING

• Always rest the w ork equipment on th e ground; if it i s neces-

sary to park with rais ed arms, m ake sure th at the safet y locks
are engaged.

• Lock the equipment con trol by shifting the safety device lever

to the lock position.

• When leaving the machine, remove the ignition key.

• If it is necessary to pa rk on publ ic roads , provid e for s ignallin g

the presence of the machine according to the local regulations
in force (signalling fires, fe nces, road w orks ahead, alternate d
direction and direction signs , etc.).

RWA07010

RWA02000

RYA11740

41

TRANSPORTING THE MACHINE ON MOTOR VEHICLES

2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES

2.5.1 LOADING AND UNLOADING

• Loading and unloadin g the machine on/from a motor vehicl e

always involves potential hazards. Proceed with extreme care.

• Perform loading a nd unl oading on fi rm, level g round . Main tain

a safety distance from the edges of ditches or from road sides.

• If the vehicles used have not been appositely equipped, put

support blocks under the ramps, in order to avoid any bending.

Ramps

• Always lock the wheel s of the trans porting vehicle with wedg-

es.

• Always use ramps that are sufficiently wide an d can support

the weight of the m achin e. Th e lon gitudi nal axes of t he ra mps
must be parallel to each other and perpendicular to the loading
side board and their distanc e must be suitabl e for the tread of
the machine.

• Make sure that the ramps are securely positioned and fas-

tened to the loading board and that they have the same length.

• Position the ramps with a maximum inclination of 15°.

• Make sure that the ramp surface is cl ean and there is no trac e

of grease, oil, soil an d ice; remove di rt from the tracks before
starting to load the machine on the vehicle.

• The machine must be loaded on the vehicle with the bucket di-

rected forwards, that is, in the dir ection of adv ance ment of the
vehicle.

• Do not correct the trajectory of the machine on the ramps. If

necessary, get down the ramps and start the operation again.

• After loading the machi ne, block the tracks with wedges and

secure it with tie-downs or chains that pre vent even any si de­ward shift (see “3.9 TRANSPORTING THE MACHINE ON
MOTOR VEHICLES”).

Max.15°

Blocks

Blocks

RWA00240

2.5.2 TRANSPORT

• Define the route to be followed, taking in consideration the width, height and weight of the transport means and

of the machine.
Make sure that the dim ensions of the mac hine are compatib le with the road and any gallery, subway, bridge,
electric and telephone lines, etc.

• Keep to the regulation s in force regardi ng the permiss ible width, hei ght, weight of th e machine an d the trans-

port speed.

42

2.6 BATTERY

2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY

• Electrolytic batteries contain sulphuric acid that can quickly

burn the skin and corrode clothes making holes in the fabric. If
you spill acid on yo urself, immediately ri nse the involv ed area
with plenty of water.

• Battery acid may cause blindness if splashed into the eyes.

If acid gets accidentally into your eyes, flush them immediately
with plenty of water and consult a doctor without delay.

• If you accidentally swallow some acid, drink a large quantity of

water or milk, beaten egg white or vegetable oil and in any
case antiacid substan ces like ma gnesia, bi carbona te, etc. cal l
a doctor or a poisoning prevention center immediately.

• When handling batteries, always wear safety goggles.

• Batteries generate hydrogen. Hydrogen is highly explosive

and can be easily ignited with small sparks or naked flames.

• Before working with batteries, stop the engine and remove the

ignition key.

BATTERY

RWA01060

WRONG

• Avoid short-circuiting the battery termi nals through accidental

contact with metal objects or tools or through the inv ersion of
the terminals.

• Tighten the battery terminals securely. Loose terminals may

generate sparks and even cause the explosion of the battery.

2.6.2 STARTING WITH BOOSTER CA­BLES

• When starting the mach ine with booster cables, always wear

safety goggles.

• When starting the engine by means of another machine, avoid

any contact between the two machines.

• Be sure to connect the positive cable (+) first and then the neg-

ative or earth ca ble (–) when connecting the booster cables.
Disconnect first the n egative or earth (–) cable and the n the
positive cable (+) after the start.

• Connect the batteries in parallel: positive to positive and nega-

tive to negative.

RWA01080

RWA01180

RWA01190

• When connecting the ear th cable to the frame of the machine

to be started, operate as far as possible from the battery.
(See “3.15.4 IF THE BATTERY IS DOWN”).

43

PRECAUTIONS FOR THE REMOVAL

2.7 PRECAUTIONS FOR THE REMOVAL

• The draw hook must be used only for the first aid and not for

towing the machine.

• Before moving the machine, make sure that all the controls are

in neutral.

• Incorrect manoeuvres may result in serious injuries or even

death.

• To mov e the mac hine, use prope rly d imensio ned stee l cabl es;

do not use worn cables or cables with broken strands (A),
twisted cables (B), deformed cables (C).

• During the removal, no one can be allowed to get near the ma-

chines or the cable.

• Do not get astride the cable.

• Remove the machine only as much as necessary to permit the

required repairs.

• Put wooden blocks between the towing cable and the machine

body, in order to avoid wear or damage.

• Do not remove the machine in any way other than that indicat-

ed at point “3.15.2 HOW TO REMOVE THE MACHINE”).

CAUTION

• The maximum applicable force for the removal is the fol-

lowing:
F=2675 kg (for PC20R only)
F=3065 kg (for PC27R only).

• Use cables having the same length an d draw continuosly

and constantly, without jerks.

• Arrange and couple the machine to be removed by posi-

tioning it on the same axis as the towing vehicle; the
drawing force must be parallel to the axis of movement of
the machine.

RWA05380

RWA05390

44

2.8 PRECAUTIONS FOR MAINTENANCE

2.8.1 WARNING PLATES

• Before starting any maintenance operation, position the ma-

chine on a firm and level sur face, rest th e equipme nt onto the
ground, engage the safety locks of either the eq uipment and
the controls and stop the engine.

• If another person starts the engine and operates the control le-

vers while the operator is pr ovidin g for ser vice, this may res ult
in serious injuries or even death.

• To avoi d these risks, a lways attac h warnin g plates to the con-

trol levers and to the igniti on key befo re performing any main­tenance operation; if necessary, attach additional warning tags
also around the machine and in particular on the cab door
handles.

PRECAUTIONS FOR MAINTENANCE

DO NOT

START

ENGINE

RWA01210

2.8.2 TOOLS

• Use only the tools pr ovided with the mach ine an d high-qual ity

tools suitable for the tasks to be performed.

• Do not use worn, damage d, low-quality too ls or tools that ar e

not suitab le f or t he t asks t o be perf orm ed, in or der t o av oid a ny
personal injury.

• After use, always clean th e tools carefu lly and put them in th e

appropriate compartment (1) positioned inside the seat sup­port.

RWA01310

1

RYA12300

2.8.3 PERSONNEL

• Only authorized and duly trained personnel can service and repair the machine; additional precautions must be

taken when grinding, welding and using a sledge hammer or heavy hammers.

• When assemblying t he equipment or cylin der connection pins, use wooden, plasti c or in any case not exc es-

sively hard tools to check the centering of the holes.
Do not use your fingers, since you run the risk of cutting them.

45

PRECAUTIONS FOR MAINTENANCE

2.8.4 EQUIPMENT

• The normal or spe ci al eq uip men t t hat mu st be i ns tall ed on th e

machine or that have been removed must be stored in safe
places, preventing them from falling down. If they fall on some­one, they can cause serious bodily harm.

• When assemblying or removing any equipment, make sure

that the ropes and the lifting h ook are in goo d conditions and
properly dimensioned for the load to be lifted.

2.8.5 WORKING UNDER THE MACHINE

• Always lower the work equipment to the ground or in any case

to its lowest positio n before performing serv ice or repairs un­der the machine.

• Always lock the m achine tracks securely.

RWA01320

• Do not work under the mac hine, if this is not sufficien tly sup-

ported.

2.8.6 CLEANING THE MACHINE

• Spilled oil or grease, scattered tools or broken pieces are dan-

gerous, because they may cause someone to slip or trip . Al­ways keep the machine and the work site clean and tidy.

• To clea n the machine, use a press urized jet o f warm water or

steam and the appropriate detergents available on the market.
Do not use gas oil, oil or solvents, si nce the former leave an
oily coat that favours the sticking of dust, while the latter (even
if weak) damage the painted su rfaces and therefore facilitate
rusting.

• While cleaning the machine, keep the pressurized jet at a min-

imum distance of approx. 60 cm in or der not to damage the
warning plates and the pictograms.
If the plates are damaged , r equ est Komatsu Utility or yo u r Ko­matsu Utility Dealer to send you spare plates and change
them.

RWA02520

RWA01330

• Water into the electrical system provokes the oxidation of the

contacts and may hinder the start of the machine or even
make it start suddenly and abruptly. For this reason, never use
water or steam jets to cl ean sens ors, con nectors or the inside
of the operator’s cab.

46

PRECAUTIONS FOR MAINTENANCE

2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS

• During maintenance oper ations, let th e engine run on ly when indispen sable. If it is nec essary to hav e the en-

gine running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator
should constantly remain in the cab, in order to be able to stop the engine whenever necessary.

• During maintenance operations with running engine, never move the control locking devices from the “lock” po-

sition or change the position of the travel levers.
Service personnel must not move any control lever.

• When carrying out mai ntenance operat ions, do not to uch the movi ng parts of the ma chine and av oid wearing

large and loose clothes.

2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY

• Periodically change the following parts, which are important to prevent fires.

Fuel supply system: fuel delivery and return pipes.
Hydraulic system: main delivery pipes of the hydraulic pump.

• Even if they seem to be in good conditions, these components must be periodically changed with new ones. In

fact, these components tend to deteriorate over time.

• If one of these parts is defect ive, chan ge or repair it e ven if the cha nge int erva l has not e lapse d yet. ( See “4.6

PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY).

2.8.9 STOP THE ENGINE BEFORE CAR­RYING OUT ANY MAINTENANCE
OPERATION OR INSPECTION

• Stop the machine onl y on firm and lev el ground and sto p the

engine before carrying out an y maintenance operation or in­spection.

• If the engine must turn during a maintenance operation, shift

the safety device leve r to the L OCK positi on and carry out th e
maintenance operation with the help of another person; one
operator must remain on the machine and the words and signs
to be used must be agreed upon in advance.

• The person who carries out th e maintenance operation must

be very careful not to touch any moving part of the engine.

RWA02000

RYA11740

47

PRECAUTIONS FOR MAINTENANCE

2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP

• Keep away from naked fla mes while refuelling or topping up

oil.

• Spilled fuel or oil make the ground slippery and may cause ac-

cidents; clean any dirty area immediately and carefully.

• Always tighten the fuel ta nk and the hydr aulic cir cuit oil sa fety

caps securely.

• Do not use fuel to clean any part of the mach ine that may b e

dirty with oil or dust.

• Always top up the fuel and oil tanks in properly ventilated place

and avoid smoking.

• 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.

• Do not fill the tank completely, in order to leave room for the fu-

el to expand.

2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR

• Let the engine and the radi ato r coo l d own b efor e ch eck i ng th e

coolant level.

• If it is necessary t o rem ov e th e c ap wi th h ot e ngi ne, wea r su it-

able clothes and protecti ons and loosen th e cap slowly, in or­der to gradually release the pressure.

RWA00970

RWA00980

2.8.12 USING LAMPS

• When checking the f uel, oil, cool ant or battery elec trolyte lev-

els, always use homologated explosion-proof lamps.
If such lighting equipment is not used, there is danger of fire or
explosion.

48

RWA01340

RWA01350

PRECAUTIONS FOR MAINTENANCE

IMPORTANT

☞

2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR

• When repairing the el ectrical system , disconnet the b attery in

order to stop the flow of current.

• Disconnect first the negative earth cable (–) and then the

positive cable (+).
At the end of the operation, reconnect first the positive ca­ble (+) and then the negative cable (–).

• If electrical welding operations are to be carried out on the ma-

chine, it is necessary to disconnect the battery and also the al­ternator.

REMOVAL

12

RWA01370

2.8.14 PRECAUTIONS CONCERNING THE STARTER

• Do not start the engine by ta mpering with the te rminals of the

starter, since the machine may move.

• Sudden or accidental mov ements of the machine may caus e

serious injuries or even death.

RWAA0860

RWA04890

RW

RWAA0850

49

PRECAUTIONS FOR MAINTENANCE

;

2.8.15 HANDLING HIGH-PRESSURE PIPES

• Do not bend high-pressure pipes or rub them with abrasive or cutting objects.

Do not use any bent or cracked pipes or hos es th at wer e prev iou sl y rej ected bec au se of leaks or fasten in g de­fects, since they may burst during use.

• Always repair or replace any loose or faulty fuel or oil pipe. Any leakage of fuel or oil may cause fires.

2.8.16 PRECA UTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL

• Do not forget that the wor k equipment circu its are always un-

der pressure; for this reason, when it is necess ary to add or
drain hydraulic o il or to perfo rm ma intena nce op erations or in­spections on the hy draulic circuit, it is advisable to l ower the
equipment to the ground and completely release the pres­sures and the residual pressure present in the tank.
Small leakages from pipes under pressure and the resulting
jets are extremely dangerous, since they can perforate the
skin and penetrate in the blood circulation or injure the eyes.
For this reason, always wear goggles and thick gl oves during
the inspections and use a piece of cardboard or a sheet of ply­wood to check for oil leakages.
If you are hit by a jet of high-pressure oil or are injured, even if
slightly, immediately consult a doctor.

DANGEROUS!

;;;;

RWA01480

CORRECT

2.8.17 PRECAUTIONS FOR MAINTE­NANCE OPERATIONS AT HIGH
TEMPERATURES AND HIGH PRES­SURE

• When the machine is stopped at the end of operations, the en-

gine coolant, the oil an d all the components are hot and the
hydralic circuits are under pressure.
In these conditions , if t he c ool an t, the hy draul ic oil and the en­gine oil are to be drained in order to change them or the filters,
there are serious risks of damage and burns.
Wait for the temperature to lower within the norma l operating
range (40÷45) before carrying out the maintenance operations
in accordance with the procedures indicated in the relevant
sections of this manual).

RWA01580

RWA00990

50

2.8.18 COOLING FAN AND BELT

• Be careful to the revolving parts and do not allow anyone to

get too close to these pa rts, si nce cloth es or pa rts of the b ody
may get caught into them.

• If hands, clothes, or tools touch the fan blades or the belt, they

may be cut, torn or seriously d amaged; for this reason, av oid
touching the revolving parts.

2.8.19 WASTE MATERIALS

• Do not dispose of used oil in the sewer system, rivers, etc.

• Always put used oil in containers. Never drain the oil directly

onto the ground.

PRECAUTIONS FOR MAINTENANCE

RWA01660

• Keep to the laws and regu lations in force when disposing of

harmful substances s uc h as oi l, fue l, s ol vents , u sed fi lte rs an d
batteries.

RWA01670

2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADA­BLE OIL TYPE HEES

• It is not possible to mix the synthetic biodegrada ble oil type HEES wit h ordinary hydr aulic oils, si nce when the

temperature increases insoluble compounds are ge nerated, which are deposi ted on the filters and clog them
(the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).

• The biodegradable oil can be used only in the hy drau li c sy s tem ; i t c ann ot b e u se d fo r the en doth er mi c eng ine,

the transmissions, the braking system, etc.

• Before introducing the sy nthetic biodegradab le oil in the hydraulic sys tem, empty the system comp letely, dis-

connecting the cylinders and all the parts that may co ntain ordinary oil, an d replace the drain filt er with a new
one.
Start the engine and let it idl e withou t using the work equipm ent , wai t until the oil r eache s a tem perature of at
least 40°C, then start moving the equipment, so that al l the parts of t he system ar e filled with oi l. Stop the en­gine and check the oil level (see “4.7.3.e CHECKING THE HYDRAULIC SYSTEM OIL LEVEL”).

51

52

THE MACHINE AND
ITS OPERATIONS

SAFETY LOCKS

3.1 SAFETY LOCKS

DANGER

• If it is necessary to stop the machine, lower the equipment to the ground and always engage the safety

device by shifting the lever to the lock position. (See “3.3.5 pos. 8 MACHINE CONTROLS”).

• If the operator expects that he may need to sto p the machine with raised arms, he is responsible for

preparing and installing locks or safety devices that must ensure safety.

• During travel, position the upper structure so that it is directed towards the blade before engaging the

antirotation lock.

• Non-compliance with these rules may result in serious damage.

3.1.1 MACHINE LOCKS

• The machine is prov ided with an upper structure antirota tion

lock (1) that can be operated from the driving positio n; always
lock the upper structure rotation before leaving and when
transporting the machine.

• The other applications of the safety locks concern:

a) The engagement of the lock (2) on the boom swing control

pedal and of the lock (3) on the optional equipment control
pedal.

b) Th e loc k posi tion o f the s afety devi ce (4) for the lo cking of

the equipment, travel and boom swing controls.

1

RWA08800

2

RWA05540

54

3

4

RYA11960

RWA08810

3.2 GENERAL VIEWS

3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB

GENERAL VIEWS

5

6

7

4

3

2

8

1

1 - Bucket
2 - Bucket cylinder
3 - Arm
4 - Arm cylinder
5 - Boom
6 - Lifting cylinder
7 - Cab
8 - Sprocket
9 - Undercarriage

1314

10 - Revolving support
11 - Idler roller
12 - Track
13 - Blade
14 - Blade cylinder

12

11

9

10

RYA11970

55

GENERAL VIEWS

3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY

5

6

7

4

3

2

8

1

1 - Bucket
2 - Bucket cylinder
3 - Arm
4 - Arm cylinder
5 - Boom
6 - Lifting cylinder
7 - Canopy
8 - Sprocket
9 - Undercarriage

1314

10 - Revolving support
11 - Idler roller
12 - Track
13 - Blade
14 - Blade cylinder

12

11

9

10

RYA11980

56

3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT

GENERAL VIEWS

1

11

10

3 42

5

6

7

8

9

RYA11990

1 - Left safety lever
2 - Arm-upper structure rotation control
3 - Left track control lever
4 - Right track control lever
5 - Boom swing control pedal
6 - Bucket - boom lifting control
7 - Blade control
8 - Dashboard
9 - Accelerator control

10 - Speed increase control

11 - Optional equipment control pedal

12 - Rotation locking pin

2

6

1

12

RYA12000

RYA12010

57

INSTRUMENTS AND CONTROLS

3.3 INSTRUMENTS AND CONTROLS

3.3.1 INSTRUMENTS

1 - Hour meter
2 - Engine coolant temperature indicator
3 - Fuel level indicator

1

h

00

0

0

00

2

F

O

F

L

O

I

H

F

O

F

1

F

O

F

N

O

F

O

F

2

3

1 - HOUR METER

This instrument indicate s the total number of oper ating hours of
the engine. The count is continuous and the number is in­creased by 1 when the engine has run for one hour, independ­ently of its speed.
The hour meter keeps functioning even if the machine is not
travelling or working.
The reading is to be cons idered valid for the calculation of the
maintenance intervals.

RYA12020

RWA07100

58

2 - ENGINE COOLANT TEMPERATURE INDICA-

TOR

It indicates the temperatur e of the engine coolant, which must
normally be 80-85°C.
After the start, it is necessary to let the engine warm up before
beginni ng work.
If during operation the indicator exceeds the limit values and en­ters the overheating sector (red), let the engine idle until the indi­cator returns to the normal temperature sector (green).
When the indicator is in th e overhea ting sec tor (re d), the acou s­tic alarm sounds, too.
If this inconvenience occurs again, try to locate the fault (see

3.15.5.3 TROUBLE-SHOOTING - ENGINE).

3 - FUEL LEVEL INDICATORT

It indicates the fuel lev el in the ta nk; thi s inform ation is a vailabl e
only when the ignition key is in position «I» (see pos. 9).

INSTRUMENTS AND CONTROLS

RWA07140

RWA07110

59

INSTRUMENTS AND CONTROLS

3.3.2 WARNING LIGHTS

1 - Engine oil pressure warning light
2 - Generator warning light
3 - Pre-heating warning light

1

3

2

h

00

0

0

00

F

O

F

L

O

I

H

F

O

F

1

F

O

F

N

O

F

O

F

2

1 - ENGINE OIL PRESSURE WARNING LIGHT

This warning light comes on and makes the acoustic alarm
sound with engine at rest when the ignition circuit is operated,
then goes out as soon as the engine lubrication circuit is pressu­rized.
If this warning lig ht remai ns on or c omes on when the engine is
running, stop the machine immediately and try to locate the trou­ble.

RYA12030

RWA07130

60

2 - GENERATOR WARNING LIGHT

IMPORTANT

☞

This warning light comes on and makes the acoustic alarm
sound when the ignitio n circuit is energize d and goes out when
the engine exceeds the idling speed; if this warning light remains
on even when the engine is running at the normal operating
speed, this means that the alternator does not work and the bat­tery is not charged correctly.

INSTRUMENTS AND CONTROLS

• If the warning light remains off when the ignition key is

turned to position «I», this means that the alternator is
faulty or broken.

3 - PRE-HEATING WARNING LIGHT

This warning light comes on when the ignition key is turned to
position «» to start the engine at low temperatures (see
“3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLI­MATES”).

RWA07150

RWA07160

61

INSTRUMENTS AND CONTROLS

3.3.3 SWITCHES AND PUSH BUTTONS

1 - Fan switch

(with cab only)
2 - Working light and instrument light switch
3 - Ignition switch
4 - Boom overload alarm switch

(if installed)
5 - Revolving light switch

(if installed)
6 - Horn

h

00

0

0

00

1

F

O

F

L

O

I

H

F

O

4

F

O

F

F

O

5

F

F

1

N

O

2

2

3

1 - FAN SWITCH (with cab only)

This is a two-speed switch that operates the fan motor. If operat­ed after the open ing of the tap i nstalled in the eng ine compart­ment, it ensures the circulation of warm air and serves as
heating switch. (See “3.3.5 VENTILATION AND HEATING”).

RYA12040

6

RYA12050

62

RWA07170

2 - WORKING LIGHT AND INSTRUMENT LIGHT

SWITCH

This is a rotary switc h with thr ee pos i tion s mark ed b y t he f oll ow­ing symbols: (OFF - 1 - 2).

1) Enables the instrument light circuit

2) Enables the working light circuit

3 - IGNITION SWITCH

This is a rotary key switch with four positions marked by the fol­lowing symbols: «» - (OFF) - I - «» (START).
For the use of this switch, see “3.6.2 STARTING THE ENGI NE”).

INSTRUMENTS AND CONTROLS

RWA07180

4 - BOOM OVERLOAD ALARM SWITCH

(if installed)

This is a rotary switch with two positions (OFF - ON) and, if oper­ated, makes it possible to define when the capacity limit has
been reached.

5 - REVOLVING LIGHT SWITCH

(if installed)

This is a tow-position rotary switch and, if pre ssed, oper ates the
revolving light.

RWA23290

RWA07200

RWA07210

63

INSTRUMENTS AND CONTROLS

6 - HORN

This push button i s posi tioned on the rig ht lev er gri p and serves
to warn the persons in the vicinity at the beginning of work and in
case of danger.

RWA20870

64

3.3.4 ELECTRICAL ACCESSORIES

1 - Engine acoustic alarm
2 - Windshield wiper / washer switch

(with cab only)

3 - Overhead lamp

(with cab only)

4 - Electric outlet

INSTRUMENTS AND CONTROLS

1

RYAA0010

2

RYA12070

3

RYA12080

4

RYA12090

65

INSTRUMENTS AND CONTROLS

1 - ENGINE ACOUSTIC ALARM

This alarm starts s ounding when the circuits are energiz ed with
the ignition key (rotation to pos ition “I”) and is au tomatica lly di s­connected when the engine is started.
If the alarm sounds during the use of the machine, it indicates:

• Engine oil low pressure.

• Overheating of the engine cooling circuit.

• Faulty alternator or worn out belt.

2 - WINDSHIELD WIPER / WASHER SWITCH

(only on machines with cab)

With the first click it operates the windshield wiper, while with the
second click (with automatic return to the first) it operates the
windshield washer.

RWA07200

3 - OVERHEAD LAMP

(only on machines with cab)

It is used to check the instruments and the inside of the cab
when visibility is insufficient.
To turn it on, press the switch to position ON.

4 - ELECTRIC OUTLET

An electric outle t is positioned on the front part of the m achine
for the connection of a lighting device for routine and mainte­nance operations.
It is a two-pole outlet and is in compliance with the I SO 4165­1979 standard.
Power supply 12V

RWA07230

RWA07240

66

RWA07250

3.3.5 MACHINE CONTROLS

INSTRUMENTS AND CONTROLS

8

10

3 41

5

2

6

7

1 - Left equipment control lever
2 - Right equipment control lever
3 - Left travel and steering control lever
4 - Right travel and steering control lever
5 - Boom swing control pedal
6 - Blade control lever
7 - Accelerator lever
8 - Left safety device control lever
9 - Speed increase push button

10 - Optional equipment control pedal

11 - Upper structure rotation locking lever

RYA12100

9

RYA12110

11

RYA12120

67

INSTRUMENTS AND CONTROLS

1-2 - EQUIPMENT CONTROL LEVERS

DANGER

• Before carrying out any manoeuvre with these levers, the operator must be seated in the work position

with fastened safety belt; before any manoeuvre he must perform the operations described in “3.13 US­ING THE WORK EQUIPMENT”).

• Before leaving the operating position, lower the equipment to the ground and lock the safety device,

then stop the engine.

The control lever (1) is positioned on the operator’s left and con­trols the arm and the upper str ucture rotation, while the contro l
lever (2) is positioned at the operator’s left and controls the
boom and the bucket.

The following diagrams show the basic manoeuvres and the
possible combined manoeuvres.

1

2

LEVER 1 (BASIC MANOEUVRES)

N - Neutral
A - Arm opening
B - Rotation to the right
C - Arm folding
D - Rotation to the left

LEVER 2 (BASIC MANOEUVRES)

N - Neutral
A - Boom lowering
B - Bucket opening
C - Boom raising
D - Bucket folding

RYA12130

A

D

N

B

C

RWA07260

A

D

N

B

C

68

RWA07270

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

If the levers are operated in directions that are inclined wit h respect to the machine axis, s imultaneous move­ments proportional to the ang le of inclination ar e obtained, since the two hydraulic dist ributors corresp onding to
each single function are engaged at the same time.

LEVER 1 (COMBINED MANOEUVRES)

N - Neutral
A - Arm opening and rotation to the left
B - Arm opening and rotation to the right
C - Rotation to the right and arm folding
D - Rotation to the left and arm folding

A

D

B

N

C

RWA07280

LEVER 2 (COMBINED MANOEUVRES)

N - Neutral
A - Boom lowering and bucket folding
B - Boom lowering and bucket opening
C - Bucket opening and boom lifting
D - Bucket folding and boom lifting

• Before rotating the upper structure, make sure that the rotation locking pin is raised (released).

• The horn is positioned on the right lever grip and must be used to warn the persons in the vicinity at

the beginning of work and in case of danger.

• All movements are locked by shifting the safety device lever to the lock position (see pos. 8).

A

D

B

N

C

RWA07290

69

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

IMPORTANT

☞

3-4 - TRAVEL AND STEERING CONTROL LEVERS

DANGER

• Before carrying out any ma noeuvre w ith these le vers, the

operator must be seated in the work position with fas­tened safety belt.

• Before moving, make sure that the upper structure is di-

rected towards the blade and that all the safety devices
have been engaged; if the upper structure is turned by
180°, the controls are inverted.
(See “3.6.5 HOW TO MOVE THE MACHIN E”).

• Failure to comply wi th these rules may result in ser ious

accidents.

The levers (3) and (4) serve to operate the left and right travel
motors, respectively, and control the forward and the reverse
gear according to the movements indicated.

N - Neutral
A - Forward gear
B - Reverse gear

RWA07310

3

4

A

N

B

• All movements are locked by shifting the saf ety devi ce le-

ver to the lock position (see pos. 8).

5 - BOOM SWING CONTROL PEDAL

DANGER

• Always engage the safety dev ice (1) when the use of this

control pedal is not required, during travel and when park­ing the machine.
If this control pedal is inadvertently pressed, it may cause
serious accidents.

This pedal controls the boom swing to the right and to the left ac­cording to the movements indica ted.

N - Neutral
A - Swing to the left
B - Swing to the right

RWA07300

1

RWA05660

• All movements are locked by shifting the saf ety devi ce le-

ver to the lock position (see pos. 8).

• The boom swing is useful when it is necessary to dig be-

yond the track outline; do not use it during the work cycle.

70

RWA05650

INSTRUMENTS AND CONTROLS

DANGER

6 - BLADE CONTROL LEVER

• Before moving the machine, make sure that the blad e is

completely raised.

This lever controls the raising and lo wering of the blade accord­ing to the movements indicated.

N - Neutral
A - Blade lowering
B - Blade raising

RWA10010

A

N

B

7 - ACCELERATOR LEVER

This lever serves to adjust the speed and power of the engine.

• Idling position (1):

Lever pushed completely forward.

• Maximum speed position (2):

Lever pulled completely backward.

Use the accelerator lever with care, especially when the ma­chine is under strai n or is working in difficult conditions. Avoid
any useless acceleration, in order to reduce consum ption and
extend the life of either the engine and the machine.

RYA12140

1

2

71

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

8 - SAFETY DEVICE CONTROL LEVER

DANGER

• Before leaving the operating position, lower the equip-

ment to the ground and shift the safety device lever to the
lock position.

To lock the safety device, raise the lever (8), which will automati­cally shift to the lock position.
To unl ock the safety devi ce, push the lever (8) downwards unti l
engaging it in the check coupling.

RWA05370

• The movements of the equipment, the tr avel and t he boom

swing are locked when the safety device lever is in the
lock position.

8

RWA08930

8

RWA08940

72

9 - SPEED INCREASE PUSH BUTTON

IMPORTANT

☞

DANGER

This pedal makes it possible to increase the machine travel
speed.
By pressing it, you increase the speed; by releasing it, you return
to the normal speed.

• Do not use the speed increase pedal when changing di-

rection or performing a counter-rotation.

INSTRUMENTS AND CONTROLS

RWA08970

10 - OPTIONAL EQUIPMENT CONTROL PEDAL

• Always engage the safety lock (1) when it is not necessary

to use this pedal, when the machine is travelling and
when it must be parked.
If the control pedal is inadvertently pressed, this may
cause serious accidents.

This pedal contro ls the de li ve ry an d return of the optiona l equ ip­ment oil, according to the movements indicated below.

N - Neutral (IDLE)
A - Left delivery
B - Right delivery

For the use of the pedal, see “6.1 AUTHORIZED OPTIONAL
EQUIPMENT”.

1

RWA08980

A

N

B

RWA08990

73

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

11 - UPPER STRUCTURE ROTATION LOCKING

LEVER

DANGER

• During travel and transport of the machine the rotation

locking lever must be shifted to the lock position; shift the
lever to the lock position after rotating the upper s tructure
so that it is parallel to the undercarriage.

• During travel, make sure that the upper structure is direct-

ed towards the blade; if th e upper structure is rotat ed by
180°, the controls are inverted.

When the lever is i n the lock p osition, it p revents the rotati on of
the upper structure.
To releas e the upper structure from the mechanica l constraint,
raise the lever and set it to the unlock position.

• Do not rotate the upper structure when the lever is in the

lock position.

RWA09000

RWA09010

74

FUSES AND RELAYS

IMPORTANT

☞

3.4 FUSES AND RELAYS

• When changing a fuse, make sure that the ignition key is in position «».

• If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses

having the same capacity.

• If the engine does not run when the ignition switch is turned to position ( ) (START), check the main

fuse and if necessary change it.

3.4.1 FUSES

The equipment fuses are grouped on a single base positioned on the left control box, while the main fuse is posi­tioned inside the battery compartment.

3.4.1.1 EQUIPMENT FUSES

1

2

9

10

67

5

RWAA0880

POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT

1 Green 30 Engine stop
2 Violet 3 Engine accosting alarm, start relay, instrument power supply
3 Light blue 15 Fan
4 Red 10 Arrangement for radio set installation
5 Brown 7,5 Revolving light, servocontrol solenoid valve

4

3

11

8

RWA10030

6 Red 10 Fuel pump, horn, TBG
7 Brown 7,5 Hammer solenoid valve
8 Brown 7,5 Outlet, cab

9 Brown 7,5 Alternator, speed increase solenoid valve
10 Brown 7,5 Engine stop solenoid
11 Brown 7,5 Working light

75

FUSES AND RELAYS

3.4.1.2 MAIN FUSE

1

RWA09020

POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT

1 – 60 System main fuse

76

FUSES AND RELAYS

3.4.2 RELAYS

The horn relay is positioned inside the right control box, under the dashboard, while the other relays are grouped
on a single base positioned inside the left control box.

RWA10040

1

RWAA0890

3

2

RWA10050

RWA10060

5

6

4

7

POSITION DESCRIPTION

1 Horn relay

2 Engine acoustic alarm

3 Preheating warning light timer

4 Preheating relay

5 Solenoid excitation timer (start)

6 Solenoid excitation relay (start)

7 Safety relay

77

GUARDS AND DRIVER’S SEAT

3.5 GUARDS AND DRIVER’S SEAT

3.5.1 ENGINE HOOD

DANGER

• Do not open the engine hood when the engine is running.

• Do not use the machine without engine hood and do not start the engine when the hood is open, unles s

this is expressly prescribed for certain maintenance operations.

• When carrying out an inspection or maintenance operation inside the engine hood, always engage the

hood in the safety coupling in order to keep it open.

• Non-compliance with these rules may result in serious accidents.

OPENING THE HOOD
After releasing the lock, pr ess the push bu tton (1) and raise the

engine hood (2) until engaging it in the safety coupling.

2

CLOSING THE HOOD
Pull the safety lev er (3) with a fin ger, lower the hood slow ly and

push it downwards until engaging the lock.
Lock the hood.

1

RWA05790

2

RWA05800

3

78

RWA05810

3.5.2 RIGHT COUNTERWEIGHT

DANGER

DANGER

GUARDS AND DRIVER’S SEAT

• Do not rotate the counterweight to the open position

when the engine is running.

• Do not start the engine with the counterweight in open po-

sition, if this is not express ly prescribed for the mainte­nance operations.

• The failure to comply with these rule s may result in seri-

ous damage.

The rotation of the counterwe ight to th e open p osition se rves to
permit inspection or maintenance operations on the radiator and
on the heat exchanger.

ROT ATING THE COUNTERWEIGHT TO THE OPEN POSITION
1 - Open the engine hood (see "3.5.1 ENGINE HOOD").
2 - Loosen and remove the screws (1).

Use a 22 mm hexagon spanner.

3 - Rotate the lateral counterweig ht (2) to the ma ximum open-

ing position and lock it with the safety pin (3).

ROTATING THE COUNTERWEIGHT TO THE CLOSED POSI­TION

1 - Remove the safety pin (3) and put it in the tool compart-

ment, rotate the counterweight (2) to the closed position
and put back the screws (1).

2 - Close the engine hood.

2

1

RWAA11040

2

RWAA11060

3

3.5.3 CANOPY

•The safety canopy is TOPS homologated in compliance

with the ISO EN474.5 standard and with level 1 of the
FOPS standard; if the canopy is subjected to an impact, or
if the machine overturns, immediately contact your Ko­matsu Utility Dealer, who will check the stiffness of the
canopy and make sure that the operator’s safety is guar­anteed.

RWAA11070

RWA07340

79

GUARDS AND DRIVER’S SEAT

3.5.4 CAB

DANGER

• The cab is TOPS homologated in compliance with the ISO

EN474.5 standard; if it is provided with an upper safety
protection, it also complies with level 1 of the FOPS
standard. If the cab is subjected to an impact, or if the ma­chine overturns, immediately contact your Komatsu Utility
Dealer, who will check the stiffness of the cab and make
sure that the operator’s safety is guaranteed.

The cab is provided with total opening of the door, while the front
upper windshield can be opened b y positionin g and fixi ng it un­der the cab roof. The lower windsh ield ca n be remo ved and ca n
be opened partially by sliding the windows to the right side.
These solutions are par ticu larly us eful durin g the su mmer, since
they ensure constant air circulation and therefore reduced stress
for the operator.
The small tank (1) contai ning the detergent for the front wind­shield is positioned inside the cab; make sure that this tank is al­ways filled with detergent

RYA12060

1

• The cab door (2) is a sli ding door and can be opened com-

pletely and kept open by the coupling s (3 ).
The coupling is automati c and takes place when the door (2)
hits against the retainer (4).
To release the door from the coupling (3), use the opening and
closing handle (5).

RWA10070

2

3

5

4

RWA09030

80

• The front windshield (6) c an b e o pene d o nly af ter dise ngaging

the couplings (7), by pulling and liftin g the windo w.
Open the windshield (6) by means of the opening ha ndles (8),
after disengaging the couplings (7).
Move the windshield to the correct position: it will automatically
fit in the upper locking seats.
To clos e the windshield, repeat the openin g procedure in the
reverse order.

GUARDS AND DRIVER’S SEAT

7

8

7

8

6

RWA09040

• With open front windshield , disengage the couplings (9) and

remove the lower windshield (10).
Position it behind the driver ’s seat and fasten it to the lockin g
seats (11) by means of the couplings.

7

RWA09050

9109

RWA09060

10 1111

RWA09070

81

GUARDS AND DRIVER’S SEAT

The side windows (12) and (1 3) positioned on the right side of
the cab can be opened by sliding them; press the handle (14)
and pull it.

13

12

RWA09080

14

RWA09090

82

3.5.5 VENTILATION AND HEATING

The ventilation and he ating of the cab ser ve to red uce the oper­ator’s stress either in the summer and in the winter ; these func­tions also serve to eliminate the condensate from the front
window, thus ensuring visibility during both work and travel.
Ventilation and air change are achieved by means of a 2-spee d
fan positioned inside the cab, under the seat support.
Air distribution is achieved by means of two fixed outlets (1) with
adjustable capacity for the in ner flow, while the flow that has the
function to defrost and defog the front window is achieved by
means of a fixed outlet (2) with adjustable capacity.
A radiator having the function to h eat the air conve yed into the
cab is installed be side the fa n; it is u sed in the cold sea son an d
receives the hot water nec essary for the heat exchang e direct ly
from the engine cooling circuit.
The water supply flow i s divided or excluded by m eans of a tap
(3) positioned inside the engine compartment.

GUARDS AND DRIVER’S SEAT

1

1

RYAA0020

2

RWA10200

3

RWAA0920

83

GUARDS AND DRIVER’S SEAT

j

3.5.6 SEAT

The seat can be adjusted as follows:

a - Longitudinal position adjustment.
b - Adjustment of the suspension degree, aimed at cushioning

the inevitable vibrations and jerks as much as possible.

The seat is instal led on guides that slide l ongitudinally, can be
moved forward or b ackward and the operator can choose the
most comfortable driving position according to his physical struc­ture.
The longitudinal a djustment of the seat is obtained by operatin g
the lever (1) and making the seat slide on the guides ; once the
desired position h as bee n fo und , r ele as e th e lev er and c arry o ut
slight movements , in order to ma ke sure tha t the lock pi n is en­gaged in its seat.

The adjustment of the degr ee of suspension is carried out with
the snap lever (2), according to the operator’s weight.
The suspension can b e stiffened or lightened according to the
operator’s need s; adjust the seat suspensi on with the lever (2)
after rotating its knob to position ( +) to stiffen the suspension or
to the opposite position (-) to lighten it.

RYAA0030

1

2

3.5.7 SAFETY BELT

DANGER

• Before starting the engine, fasten the safety belt.

• The safety belt must be changed if it is broken, damaged

or worn, and in any case it must be changed every 4
years.

The safety belt (1) is of the type with two coupling points and ad-

ustable length (2 ); i t m us t b e w ell t igh tene d and ho ld the opera­tor’s hips, while lea ving the upper part of the body completely
free.

RYAA0040

2 1

RWA05950

84

3.5.8 EMERGENCY EXIT

IMPORTANT

☞

CAUTION

The machines wit h cab are provided with an emergency exit lo­cated in the rear window (1).
Inside the cab you will find a hammer (2) to be used to break the
window (1) in case of emergency.

• Make sure that the h ammer is a lways availab le and in the

correct position inside the cab.

GUARDS AND DRIVER’S SEAT

1

2

RYA12150

1

3.5.9 TECHNICAL DOCUMENTATION CASE

• The operation manual and the spare parts catalogue are

integral parts of the machine and must accompany it even
in case of resale.

The technical docume ntation case is positione d in the appropri­ate container (1) inside the seat support.
Keep the use and maintenance manual in this place, so that you
can consult it at any moment.

RWA05970

1

RYA12160

85

GUARDS AND DRIVER’S SEAT

3.5.10 FIRE EXTINGUISHER

CAUTION

• The machine’s owner must provide for installing and fix-

ing the fire extinguisher where prescribed.

• Periodically check the fire extinguisher support.

• Periodically make sure that the fire extinguisher is full.

If the operator expects that he may need the fire extinguisher (1)
on the machine, he must install it by fixing it on the rear compart­ment of the seat by means of the appropriate support.

3.5.11 FIRST AID KIT

CAUTION

• Periodically make sure that the first aid kit contains the

necessary disinfectants, bandages, medicins, etc. and
check their conditions and expiry date.

1

RYA12170

The first aid kit must be inst alled by the owner of the machine
and positioned in side the s eat su pport , wher e also th e t echni cal
documentation is usually kept.

RWA11110

86

USE OF THE MACHINE

DANGER

DANGER

IMPORTANT

☞

3.6 USE OF THE MACHINE

3.6.1 CHECKS BEFORE STARTING THE ENGINE

3.6.1.1 VISUAL CHECKS

• Dirt, oil and fuel in the engine compartment near its hot parts may damage the machine and even cause

fires.
Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your Komatsu Utility
Dealer.

Before starting the engine, check around and under the machine to verify:

1 - if there are loose screws or nuts;
2 - if there are oil, fuel or coolant leakages;
3 - the wear of the work equipment;
4 - the fastening of the electrical connections;
5 - the fastening of the engine exhaust pipe and manifold;
6 - the track tension and the fastening of the sprockets;
7 - if the safety and warning plates are sufficiently clean;
8 - if the handles of the operator’s cab are clean.

Any leak or anomaly must immediately be repaired/eliminated and any trace of oil or grease must be removed.
Further visual checks concern:

9 - the condition of the safety belt;

10 - the efficiency of the instruments and of the dashboard;

11 - the condition of the cab windows and the efficiency of the working lights.

3.6.1.2 DAILY CHECKS

• Do not smoke while refuelling or topping up the oils and do not use naked flames or non-homologated

lighting means to check the fuel and oil levels, in order not to cause fires.

• If fuel, oil, or lubricant are spilled while filling the tanks, clean the dirty areas immediately.

Before starting any operation, check the engine coolant, engine oil and hydraulic circuit oil levels.
At the end of work, provide for refu ell in g, in or der to a vo id th e forma t io n of con dens at e, al way s che ckin g the fuel
level on the indicator provided on the dashboard.

• Avoid filling the tank completely, in order to leave room for the gas oil to expand.

• After refuelling, put back the fillercap, making sure that the bleed hole is completely open.

• Check the engine oil level with the machine in horizontal position and th e hydra ulic circuit oil level with

the arm and bucket cylinders retracted and the bucket teeth on the ground.

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3.6.1.3 OPERA TI ONAL CHECKS

DANGER

• All the checks must be carried out by the oper ator while

seated, with fastened safety belt.

• If the machine has been stopped after use or in order to

carry out maintenance operations, the safety devic es may
have been disconnected; when the operator gets o n the
cab, he must make sure that all the safety locks of the
equipment controls are in the correct position and there­fore that the equipment cannot move suddenly and cause
accidents.

The checks concern:

1 - the lock position of the safety device;
2 - the accelerator idling position;
3 - the neutral position of the controls.

The following check is car ried out by turning the ignition key to
position «» to apply voltage to the c ontrol pane l and check th e
functionality of the acoustic alarm, the fuel level indicator and the
engine oil pressure, generator and preheating warning lights.

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USE OF THE MACHINE

DANGER

IMPORTANT

☞

3.6.2 STARTING THE ENGINE

• Before starting the engine, carefully read the instru ctions and information regardin g safety given in

this manual and make sure that you know the controls.
From the moment in which the engine is started, the operator is directly responsible for any damage
that may be caused by wrong manoeuvres and non-compliance w ith the s afety regula tions and the rule
of the road.

• Before starting the engi ne, make sure that t here is no one with in the operating rad ius of the machine

and sound the horn.

• Before starting the engine, turn the ignition key to position «» to operate the automatic check and

make sure that the acoustic alarm and the warning lights are working correctly.

3.6.2.1 STARTING WITH WARM ENGINE OR IN

TEMPERATE CLIMATE S

1 - Turn the ignition key directly to position «» (START).
2 -As soon as the engin e starts, relea se the igni tion key, which

will automatically return to position «».

• If the engine does not start within 15 sec ond s , rele ase th e

key, which will automatically return to position «» and
wait for 15 seconds before trying again.

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RWA01980

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USE OF THE MACHINE

IMPORTANT

☞

3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES

DANGER

• Do not use any fluid or product that facilitate the cold

starting of the engine, since these are ether-based and
may cause explosions.

1 -Pull the accelerator l ever until r eaching half of its stroke an d

turn the ignition key to the pr ehea tin g pos i tio n «» for maxi­mum 15 seconds in the coldest weather.
The preheating time i s determined according to the outside
temperature and the recom mended ratio is approximately 1
second for each degree below zero.
The preheating is signalled by the warning light positioned on
the dashboard.

2 - Turn the ignition ke y to position «» (START) until the en-

gine starts and for maximum 15 seconds.

3 -As soon as the engin e starts, relea se the igni tion key, which

will automatically return to position «» and reduce the speed
to idling.

RYA12180

• If the engine does not start at the first attempt, repeat the

operations 1 and 2 after at least 30 seconds, in order not
to overload the battery.

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RWA01970

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USE OF THE MACHINE

IMPORTANT

☞

DANGER

3.6.3 WARMING THE ENGINE

1 - After starting the engine, let it warm up before starting work.
2 - The ideal warming up of the engine is achieved with the engine running at idling speed, which is obtained with

the hand accelerator.

• Do not accelerate completely or abruptly until the coolant temperature has reached at least 60°C.

3 - To reduce the time necessary to warm up the engine, accelerate now and then.
4 - During the warming up of the eng ine, ch eck the colour of the exhaust gases and verify i f abnormal noises or

vibrations can be noticed; any anomaly must be verified and its cause must be eliminated.

3.6.4 HEATING THE HYDRAULIC OIL

When warming up the engine, especially in the cold season, it is advisable to heat also the hydraulic system oil.
For this reason, when the coolant temperature has reached approximately 60°C, proceed as follows:

1 - Release the safety device of the controls (See “3.1 SAFETY LOCKS”).
2 - Slowly extend and retract the arm and the bucket completely for several times.
3 - Lower the bucket to the ground and lock the safety device again.

3.6.5 HOW TO MOVE THE MACHINE

• Before moving the machi ne, ma ke sure that yo u kn ow the c ontrol functi ons and all t he relev ant safe ty

regulations perfectly.

• Make sure that the upper structure is directed towards the blade and lock it in this position by means of

the rotation lock.

• The operator must be sitting in the driving position with fastened safety belt.

• Before moving the machine, make sure that ther e is no one within the o peratin g radius of the mac hine

and that there are no obstacles in the surrounding area.

• Be extremely careful when enga ging the reverse and make sure that there are no persons, wor king

means or obstacles in the way.

• Avoid manoeuvres or changes of dire ct ion wh en t ra vell ing at f ull s p eed, sin ce the mano euv res ca rried

out in these conditions cause abrupt movements.

• Do not use the speed increase pedal when changing direction or carrying out a counter-rotation.

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Before moving the machine, check the instruments, warm up the engine and the hydraulic oil, make sure that the
rotation lock is engaged, that the safety device is released, that the blade is raised and that the work equipment is
at least at 40÷50 cm from the ground; the control levers must be in the neutral position.

1 - Pull the acceler ato r lev er and se t the engi ne ru nning a t idlin g

speed.

RYA12200

2 - Operate the l evers (right and left) at the same time, shiftin g

them forward to make the machine advance or backward to
make it move in reverse.

F

F

3 - Press the speed increa se peda l to increas e the speed of th e

machine.

N

R

R

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RWA08970

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DANGER

IMPORTANT

☞

IMPORTANT

☞

IMPORTANT

☞

3.6.5.1 STEERING (CHANGING DIRECTION)

• When the blade is directed backward, the operation of the travel levers is inverted; before operating the

travel levers, check the position of the blade.

• If possible, avoid any abrupt change of direction. Counter-rotations should be carried out with the ma-

chine at rest.

• Due to the considerabl e friction create d when changing direction, it i s advisable no t to use the spe ed

increase pedal.

CHANGING DIRECTION WHEN THE MACHINE IS
NOT MOVING

To turn to the left, operate the RIGHT travel lever as indicated
below. To move FORWARD, push the lever. To move BACK­WARD, pull the lever.

• To turn to the right, operate the LEFT travel lever in the

same way.

CHANGING DIRECTION WHEN THE MACHINE IS
MOVING (the left and right travel levers are in the
same position)

To tu rn to the left, shift the L EFT travel lever back to th e neut ral
position; the machine will turn to the left.

• To turn to the right, op erate the RIGHT travel le ver in the

same way.

HOW TO CARRY OUT A COUNTER-ROTATION
(with the machine not moving)

To turn to the left, pull the LE FT travel lever backward and push
the RIGHT travel lever forward.

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RWA07390

• To carry out a counter-rotation to the right, pull the RIGHT

travel lever backward and push the LEFT travel lever for­ward.

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3.6.5.2 MOVING ON SLOPES

DANGER

• Do not work on slopes with inclination exceeding 30°,

since in these conditions the machine may overturn.

• When moving on slopes, do not use the travel speed in-

crease pedal.

When working on slopes some precautions should b e taken to
avoid risks for the operator and anyone in the vicinity; the checks
and operations to be carried out are the following:

1 - Always check the work area for snow, landslips, gravel, loose

ground and anything that may suddenly modify the work con­ditions and the stability of the machine.

2 - When it is necessary to travel downhill, the bucket must al-

ways be directed downwards, in the position indicated in the
figure.

3 - When travelling uphill, the bucket must always be directed

upward.

4 - When moving the machine during work, always lower the

bucket.

5 - Carry out any lateral movement on a flat surface at the begin-

ning or at the end of the slop e; if this is not possible, move
obliquely, keeping the machine axis as paral lel to the slope
directrix as possible.
Do not move too obliquely or, even worse, with the machin e
axis rotated by 90° with respect to the slope directrix.

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DANGER

CAUTION

3.6.5.3 MAXIMUM IMMERSION DEPTH

• If it is necessary to work with the machine immersed in water on river banks or sea sh ores, always

check the water depth and the current flow.

• Make sure that the surface on which you are working is sufficiently firm.

If you have to work in water, check that the maximum depth of immersion is lower than the centre of the top guide
roller, and in any case that the engine c ooling fan does not c ome into contact with th e water; otherwise it m ay
break or be damaged.

RWA10190

• When working in water or on muddy ground, lubricate the articulations more frequently than usual.

• After work, remove any dirt or mud and lubricate the articulations.

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PARKING THE MACHINE

3.7 PARKING THE MACHINE

3.7.1 PARKING ON LEVEL GROUND

DANGER

• Park the machine on firm and level ground, in a sufficient-

ly wide space, so that the checks, the daily lubrication and
the refuelling can be carried out without problems.

• Lower the blade and the work equipment to the ground.

• Keep to all the safety rules, in order to avoid any move-

ment of the machine when the operator is absent.

• When leaving the machine, remo ve the ignition key, use

the handles and lock the cab, if provided.

1 - Park the machine on firm and level gr ound, in a sufficiently

wide space.

2 - Lower the blade and the bucket to the ground ; if there is not

enough space, the work equipm ent must be folded and se­cured with the appropriate locks.

3 - Engage the safety lock of the boom swing control, of th e op-

tional equipment co ntrol and of the upper structu re rotation
and shift the safety device lever to the lock position.

4 - Stop the engine following the procedure indicated in para-

graph “3.8 STOPPING THE ENGINE”.
5 - Leave the driving position using the tracks and the handles.
6 - Refuel, taking the necessary precautions.
7 - Remove the ignition key and lock the cab, if provided.

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RWA02000

3.7.2 PARKING ON SLOPES

DANGER

• The movement of the machine when the operator is not on

board may cause serious accidents and even death; to
prevent this, carry out the operations described below.

• Park on slopes only when it is absolutely necessary.

• Park only with the bucket directed downwards.

PARKING THE MACHINE

1 - Pa rk the machine with the bucke t directed downwards and

resting against an obstacle.
If this is not possible due to the absence of natural obstacles,
rotate the bucket in the dumping posi tio n and thr us t the tee th

into the ground.
2 - Lower the blade to the ground.
3 - Engage the safety lo ck of the b oom swing con trol, of the op-

tional equipment co ntrol and of the upper structu re rotation

and shift the safety device lever to the lock position.
4 - Stop the engine following the procedure indicated in para-

graph “3.8 STOPPING THE ENGINE”.
5 - Leave the driving position using the tracks and the handles.
6 - Put wedges under the tracks.
7 - Refuel, taking the necessary precautions.
8 - Remove the ignition key and lock the cab, if provided.

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RWA09000

RYA11740

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STOPPING THE ENGINE

IMPORTANT

☞

3.8 STOPPING THE ENGINE

• The sudden stop of the engine while it is running short-

ens its life. Do not stop the engine suddenly, except in
case of emergency.

• It is likewise recommended not to stop the engine sud-

denly if it has been running for a long period and is still
hot; in this case, let the engine idle for about 5 minutes, in
order to allow it to cool down gradually before stopping it.

Before stopping the engine, proceed as follows:
1 - Rest the work equipment onto the ground.
2 - Shift the levers to the neutral pos ition and connect the sa fety

devices.

3 - Shift the accelerator lever to the idling position.
Stop the engine by turning the ignition key to position «» (OFF).

MIN.

RYA12210

RWA02000

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