Komatsu PC30MR-2, PC35MR-2 Maintenance Manual
WEAM006600
Operation & Maintenance
Manual
PC30MR-2
PC35MR-2
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC30MR-2 20001
PC35MR-2 5001
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or
maintaining this machine.
This manual should be kept inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
and up
and up
FOREWORD
1.1 FOREWORD
• This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine
efficient over time.
• The operation manual, together with the spare parts catalogue, is an integral part of the machine and must accompany it, even when it is resold, until its final disposal.
• The manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment inside the seat support, where also
the ownership documents and the logbook are usually kept.
• This manual must be given to the persons who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu Utility or your Komatsu Utility Dealer.
• The illustrations contained in this manual may represent machine configurations available on request.
Komatsu Utility machines are constantly improved in order to increase their efficiency and reliability; this manual
sums up all the information regarding the most recent techniques applied at the moment in which the machine is
marketed.
For any further and/or updated information, contact your Komatsu Utility Dealer.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important to
have a clear prospect of the situation and to know exactly what has been done and what has to be done after the
next maintenance interval. Therefore, it is advisable to consult either the hour meter and the maintenance plan
frequently.
• Over the years Komatsu Utility Dealers have gathered considerable experience in customer service.
If more information is needed, do not hesitate to contact your Komatsu Utility Dealer: he always knows how to
get the best performance from the machine, he can suggest the use of the equipment that is most suitable for
specific needs and can provide the technical assistance necessary for any change that may be required to con-
form 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 this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
• The incorrect use of the machine and inappropriate maintenance operations may cause serious injuries
and even death.
• Operators and maintenance personnel must carefully read this manual before using the machine or performing maintenance operations.
• Any serious accident that may occur during the use of the machine or during maintenance operations is
due to failure to comply with the instructions given herein.
• The procedures and precautions described in this manual are valid for application to the machine only
when it is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
1
INFORMATION ON SAFETY
1.2 INFORMATION ON SAFETY
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations pre-
scribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to understand all the information and warnings contained in this manual and given on the plates ap-
plied 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
• This word is used in the safety warnings in the manual and on the plates when the situation is danger-
ous 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.
CAUTION
• This word is used in the safety warnings in the manual and on the plates to signal risks that may cause
moderate damage or injuries.
The message can be used even to indicate the risk of damage to the machine only.
IMPORTANT
• This word is used when precautions are indicated, which must be taken to avoid actions that may shorten the life of the machine.
Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the operation or maintenance of the machine; for this reason, the safety messages included in this manual and applied
onto the machine may not include all possible safety precautions.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity can work in total safety, with no risk of damaging the machine. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu Utility or your local Dealer.
DANGER
• Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of either the equipment and the controls and stop the
engine.
DANGER
• To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the engine protection
casing is open, if this is not expressly prescribed for some specific maintenance operations.
2
INFORMATION ON SAFETY
DANGER
• It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility cannot
be held liable for any damage to persons, property or the machine, if this has been tampered with by
modifying the standard setting of the hydraulic system.
DANGER
• Before carrying out any electrical welding, disconnect the battery and the alternator (See "2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR").
DANGER
• Install only authorized additional equipment (See "6.1 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION").
3
INTRODUCTION
1.3 INTRODUCTION
1.3.1 INTENDED USES
The Komatsu Utility MACHINES described in this manual have been designed and constructed to be used mainly
for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point “6. AUTHORIZED OPTIONAL EQUIPMENT”.
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
• This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for particular applications, contact your Komatsu Utility Dealer before carrying out the work.
IMPORTANT
• The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu Utility, these publications are enclosed
to this manual.
• The instructions regarding the assembly of the authorized equipment, the controls requiring special arrangements on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.
Komatsu Utility MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials; therefore, the following uses are absolutely forbidden:
• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
• USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
• Simple and easy operation.
• Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
• Rotation of the upper structure achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear.
• Main equipment servolevers ensuring also combined movements that can be modulated proportionally and continually.
• Pedal controls for the boom swing and the optional equipment.
• Lever controls for travel and blade.
• Travel speed increase achieved through a pedal-operated push button.
• Complete series of instruments visible from the operating position.
• Lever accelerator.
• Easy maintenance with simplified intervals.
4
INTRODUCTION
1.3.4 RUNNING-IN
Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to excessive work load at the beginning of operation, its potential yield and its function-
ality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
• After the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
• Avoid operating the machine with the limit loads allowed or at high speed.
• Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
• After the first 250 hours, carry out the following operations, 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 synthetic biodegradable oil type HEES is used, the following operations are to be performed besides the standard maintenance operations:
• After the first 50 hours of operation, change the hydraulic circuit drain filter.
• After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
• When changing the oil filters (cartridges), check their inner part to make sure that there are no deposits.
If considerable deposits are observed, find out what may have caused them before starting the machine.
• The number of operating hours is indicated by the hour meter.
5
PRODUCT IDENTIFICATION
1.4 PRODUCT IDENTIFICATION
The Komatsu Utility EXCAVATOR and its main components are identified by serial numbers stamped on the iden-
tification plates.
The serial number and the identification numbers of the components are the only numbers that must be indicated
to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial number is stamped on the front upper part of
the main frame, on the left side.
RKA01330
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
The Komatsu Utility EXCAVATORS described in the present manual are provided with the CE mark, which certifies that they are in
compliance with the harmonized standards of the European Com-
munity.
The plate provided with the mark is applied onto the front wall of
the main frame, on the left side.
Product Identification Number
MANUFACTURER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
MODEL
Product Identification Number
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
RKA01331
kg
kw
22L-09-R1370
RWA39210
kg
kw
MANUFACTURER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
The serial number is stamped on the plate positioned on the upper side of the tappet cover.
The exhaust gas emission plates are positioned on the upper side
of the tappet cover and on the inner right side of the counterweight.
PRODUCT IDENTIFICATION
RKAA0350
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
The serial number is stamped on the plate positioned inside the
travel reduction gear and can be seen after removing the cover
(1).
RKAA0360
RKAA0370
1
RKAA0300
7
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
The serial number is stamped on the plate positioned on the upper side of the swing motor.
1.4.6 CAB SERIAL NUMBER
The CAB serial number is stamped on the plate positioned on the
top left side.
PRODUCT IDENTIFICATION
RKA01340
RKAA0310
8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine n. Model
Engine n.
Product identification number (PIN)
Travel reduction gear n.
Swing reduction gear n.
Cab n.
Dealer:
PRODUCT IDENTIFICATION
Address:
Person to contact:
NOTES:
Te l.
9
TABLE OF CONTENTS
TABLE OF CONTENTS
1. FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USES..................................................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES ................................................................................ 4
1.3.3 MAIN CHARACTERISTICS...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE SERIAL NUMBER .................................................................................................. 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE .................................. 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 7
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER ..................................................................... 8
1.4.6 CAB SERIAL NUMBER ........................................................................................................... 8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS ................................................................... 9
TABLE OF CONTENTS ........................................................................................................................ 10
2. SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 18
2.1.1 POSITION OF THE SAFETY PLATES..................................................................................... 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 19
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB ......................................... 24
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY .................................. 25
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED................................................. 25
2.2 GENERAL PRECAUTIONS .................................................................................................................. 26
2.2.1 GENERAL SAFETY RULES..................................................................................................... 26
2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 26
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 26
2.2.4 UNAUTHORIZED MODIFICATIONS........................................................................................ 27
2.2.5 LEAVING THE OPERATOR’S SEAT ...................................................................................... 27
2.2.6 GETTING ON AND OFF THE MACHINE................................................................................. 28
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL ...................................................................... 28
2.2.8 PREVENTING BURNS ............................................................................................................ 29
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ..................................................... 29
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 29
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT ......................................................................... 30
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 30
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 30
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 31
2.3.1 SAFETY ON THE WORK SITE ............................................................................................... 31
2.3.2 FIRE PREVENTION ................................................................................................................ 31
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB.............................................. 31
2.3.4 ROOM VENTILATION ............................................................................................................. 32
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 32
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES .................. 32
10
TABLE OF CONTENTS
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 33
2.4.1 STARTING THE ENGINE .......................................................................................................33
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 33
2.4.3 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 34
2.4.4 MOVING THE MACHINE ........................................................................................................34
2.4.5 MOVING ON SLOPES ............................................................................................................ 35
2.4.6 WORKING ON SLOPES .........................................................................................................36
2.4.7 UNAUTHORIZED OPERATIONS ........................................................................................... 36
2.4.8 PREVENTING ELECTROCUTION .......................................................................................... 38
2.4.9 VISIBILITY ................................................................................................................................ 38
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES ........................................................ 38
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 39
2.4.12 WORKING ON LOOSE GROUND ........................................................................................... 39
2.4.13 PARKING THE MACHINE ....................................................................................................... 39
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES ................................................................ 40
2.5.1 LOADING AND UNLOADING ................................................................................................. 40
2.5.2 TRANSPORT ........................................................................................................................... 40
2.6 BATTERY .............................................................................................................................................. 41
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 41
2.6.2 STARTING WITH BOOSTER CABLES .................................................................................. 41
2.7 PRECAUTIONS FOR THE REMOVAL ................................................................................................ 42
2.8 PRECAUTIONS FOR MAINTENANCE................................................................................................. 43
2.8.1 WARNING PLATES ................................................................................................................ 43
2.8.2 TOOLS .................................................................................................................................... 43
2.8.3 PERSONNEL ........................................................................................................................... 43
2.8.4 EQUIPMENT ........................................................................................................................... 44
2.8.5 WORKING UNDER THE MACHINE ....................................................................................... 44
2.8.6 CLEANING THE MACHINE .................................................................................................... 44
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS .......................................... 45
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 45
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR
INSPECTION ........................................................................................................................... 45
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP ...................................... 46
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................................... 46
2.8.12 USING LAMPS ........................................................................................................................ 46
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR ......................... 47
2.8.14 PRECAUTIONS CONCERNING THE STARTER ................................................................... 47
2.8.15 HANDLING HIGH-PRESSURE PIPES .................................................................................... 47
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 48
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND
HIGH PRESSURE ................................................................................................................... 48
2.8.18 COOLING FAN AND BELT .....................................................................................................48
2.8.19 WASTE MATERIALS .............................................................................................................. 49
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES .................. 49
3. THE MACHINE AND ITS OPERATIONS
3.1 MACHINE VIEW ILLUSTRATIONS ...................................................................................................... 52
3.1.1 OVERALL MACHINE VIEW ..................................................................................................... 52
3.1.2 CONTROLS AND GAUGES ..................................................................................................... 53
3.2 DETAILED CONTROLS AND GAUGES .............................................................................................. 54
11
TABLE OF CONTENTS
3.2.1 MONITORING SYSTEM........................................................................................................... 54
3.2.1.1 EMERGENCY MONITORS..................................................................................... 55
3.2.1.2 METER DISPLAY PORTION .................................................................................. 57
3.2.1.3 PILOT LAMPS......................................................................................................... 59
3.2.1.4 MONITOR SWITCHES PORTION .......................................................................... 60
3.2.2 SWITCHES ............................................................................................................................... 62
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 65
3.2.4 WINDSHIELD (Machines equipped with cab) .......................................................................... 71
3.2.5 SLIDING DOOR (Machines equipped with cab) ....................................................................... 75
3.2.6 SLIDING WINDOW (Machines equipped with cab).................................................................. 75
3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab) ......................................... 76
3.2.8 COVER WITH LOCK ................................................................................................................ 77
3.2.9 ENGINE REAR COVER ........................................................................................................... 78
3.2.10 COOLING COVER ................................................................................................................... 79
3.2.11 MUD COVER............................................................................................................................ 80
3.2.12 METHOD OF OPENING (TILTING) FLOOR ............................................................................ 81
3.2.13 FUSE ........................................................................................................................................ 86
3.2.14 BLOCK FUSE ........................................................................................................................... 86
3.2.15 OPERATION MANUAL STORAGE.......................................................................................... 87
3.2.16 TOOL BOX ............................................................................................................................... 87
3.2.17 GREASE GUN HOLDER .......................................................................................................... 87
3.2.18 ASHTRAY (Machines equipped with cab) ................................................................................ 87
3.3 MACHINE OPERATIONS AND CONTROLS ....................................................................................... 88
3.3.1 BEFORE STARTING ENGINE................................................................................................. 88
3.3.1.1 WALK-AROUND CHECKS ..................................................................................... 88
3.3.1.2 CHECKS BEFORE STARTING .............................................................................. 90
3.3.1.3 ADJUSTMENT ........................................................................................................ 96
3.3.1.4 OPERATIONS BEFORE STARTING ENGINE ....................................................... 99
3.3.1.5 STARTING ENGINE ............................................................................................... 101
3.3.2 AFTER STARTING ENGINE.................................................................................................... 104
3.3.2.1 BREAKING-IN THE NEW MACHINE...................................................................... 104
3.3.2.2 WARMING-UP OPERATION .................................................................................. 104
3.3.3 STOPPING THE ENGINE ........................................................................................................106
3.3.4 MACHINE OPERATION........................................................................................................... 107
3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF .......................................... 107
3.3.4.2 MOVING MACHINE FORWARD............................................................................. 107
3.3.4.3 MOVING MACHINE BACKWARD .......................................................................... 109
3.3.4.4 STOPPING MACHINE ............................................................................................ 110
3.3.5 STEERING THE MACHINE...................................................................................................... 111
3.3.5.1 STEERING.............................................................................................................. 111
3.3.6 SWINGING ............................................................................................................................... 113
3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS .......................................................... 114
3.3.8 PROHIBITED OPERATIONS ................................................................................................... 116
3.3.9 GENERAL OPERATION INFORMATION ................................................................................ 118
3.3.10 TRAVELING ON SLOPES........................................................................................................ 120
3.3.11 ESCAPE FROM MUD .............................................................................................................. 122
3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR ....................................... 123
3.3.13 CHANGING THE BUCKET.......................................................................................................125
3.3.14 PARKING MACHINE ................................................................................................................ 126
3.3.15 CHECK AFTER SHUT OFF ENGINE....................................................................................... 127
3.3.16 MACHINE INSPECTION AFTER DAILY WORK...................................................................... 127
3.3.17 LOCKING.................................................................................................................................. 127
3.3.18 RUBBER SHOES AND ROAD LINERS (Machine equipped with rubber shoe or road liner)... 128
3.3.18.1 RUBBER SHOES AND ROAD LINERS INFORMATION........................................ 128
12
TABLE OF CONTENTS
3.3.18.2 WARRANTY FOR RUBBER SHOES AND ROAD LINERS.................................... 128
3.3.18.3 USING RUBBER SHOES AND ROAD LINERS ..................................................... 128
3.4 TRANSPORTATION ............................................................................................................................. 132
3.4.1 TRANSPORTATION PROCEDURE ........................................................................................ 132
3.4.2 LOADING AND UNLOADING WITH TRAILER ........................................................................ 132
3.4.3 LIFTING MACHINE .................................................................................................................. 138
3.5 COLD WEATHER OPERATION ........................................................................................................... 140
3.5.1 COLD WEATHER OPERATION INFORMATION .................................................................... 140
3.5.1.1 FUEL AND LUBRICANTS....................................................................................... 140
3.5.1.2 COOLING SYSTEM COOLANT.............................................................................. 140
3.5.1.3 BATTERY................................................................................................................ 141
3.5.2 CAB HEATER IN COLD WEATHER (Machines equipped with cab) ....................................... 141
3.5.3 AFTER DAILY WORK COMPLETION ..................................................................................... 142
3.5.4 AFTER COLD WEATHER SEASON........................................................................................ 142
3.6 LONG TERM STORAGE....................................................................................................................... 143
3.6.1 BEFORE STORAGE ................................................................................................................ 143
3.6.2 DURING STORAGE ................................................................................................................. 143
3.6.3 AFTER STORAGE ................................................................................................................... 143
3.7 TROUBLES AND ACTIONS ................................................................................................................. 144
3.7.1 RUNNING OUT OF FUEL ........................................................................................................ 144
3.7.2 PHENOMENA THAT ARE NOT FAILURES ............................................................................ 144
3.7.3 TOWING THE MACHINE ......................................................................................................... 144
3.7.4 SEVERE JOB CONDITION ...................................................................................................... 145
3.7.5 DISCHARGED BATTERY ........................................................................................................ 145
3.7.5.1 BATTERY REMOVAL AND INSTALLATION .......................................................... 146
3.7.5.2 BATTERY CHARGES............................................................................................. 146
3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES ................................................... 147
3.7.6 OTHER TROUBLE ................................................................................................................... 149
3.7.6.1 ELECTRICAL SYSTEM .......................................................................................... 149
3.7.6.2 CHASSIS ................................................................................................................ 150
3.7.6.3 ENGINE .................................................................................................................. 150
4. MAINTENANCE
4.1 MAINTENANCE INFORMATION .......................................................................................................... 154
4.2 LUBRICANTS, COOLANT AND FILTERS ........................................................................................... 157
4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ................................... 157
4.2.1.1 OIL .......................................................................................................................... 157
4.2.1.2 FUEL ....................................................................................................................... 157
4.2.1.3 COOLING SYSTEM COOLANT.............................................................................. 158
4.2.1.4 GREASE ................................................................................................................. 158
4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) .............................. 159
4.2.1.6 OIL AND FUEL STORAGE ..................................................................................... 160
4.2.1.7 FILTERS ................................................................................................................. 160
4.2.2 ELECTRIC SYSTEM MAINTENANCE ..................................................................................... 161
4.2.3 HANDLING HYDRAULIC SYSTEM ......................................................................................... 161
4.3 WEAR PARTS....................................................................................................................................... 162
4.3.1 WEAR PARTS LIST ................................................................................................................. 162
4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS ................................................................. 163
4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS.............................. 167
4.5 TIGHTENING TORQUE SPECIFICATIONS ......................................................................................... 168
4.5.1 TIGHTENING TORQUE LIST .................................................................................................. 168
13
TABLE OF CONTENTS
4.6 LUBRICATION ...................................................................................................................................... 169
4.6.1 LUBRICATION DIAGRAM........................................................................................................169
4.7 SAFETY CRITICAL PARTS .................................................................................................................. 170
4.7.1 SAFETY CRITICAL PARTS LIST............................................................................................. 170
4.8 MAINTENANCE SCHEDULE................................................................................................................ 171
4.8.1 MAINTENANCE SCHEDULE CHART...................................................................................... 171
4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER .................................................... 172
4.9 MAINTENANCE PROCEDURE ............................................................................................................ 173
4.9.1 WHEN REQUIRED................................................................................................................... 173
4.9.1.a CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ................................ 173
4.9.1.b CLEAN INSIDE OF COOLING SYSTEM ................................................................ 175
4.9.1.c CHECK LEVEL OF BATTERY ELECTROLYTE ..................................................... 177
4.9.1.d CLEAN WATER SEPARATOR ELEMENT ............................................................. 179
4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK........................................... 179
4.9.1.f CHECK AND TIGHTEN TRACK SHOE BOLTS
(Machine equipped with road liner, steel shoe)....................................................... 180
4.9.1.g CHECK AND ADJUST TRACK TENSION
(Machine equipped with road liner, steel shoe)....................................................... 180
4.9.1.h CHECK, RUBBER SHOES OR ROAD LINERS
(Machine equipped with rubber shoes, road liner) .................................................. 182
4.9.1.i CHECK AND ADJUST RUBBER SHOE TENSION
(Machine equipped with rubber shoes) ................................................................... 184
4.9.1.j REPLACE RUBBER SHOES
(Machine equipped with rubber shoes) ................................................................... 186
4.9.1.k REPLACE ROAD LINERS
(Machine equipped with road liner) ......................................................................... 188
4.9.1.l CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
(Machine equipped with cab) .................................................................................. 188
4.9.1.m CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER
(Machine equipped with cab) .................................................................................. 189
4.9.1.n LUBRICATING ........................................................................................................ 189
4.9.1.o BLEEDING AIR FROM HYDRAULIC SYSTEM ...................................................... 190
4.9.2 CHECK BEFORE STARTING .................................................................................................. 191
4.9.3 EVERY 500 HOURS MAINTENANCE ..................................................................................... 192
4.9.3.a LUBRICATING ........................................................................................................ 192
4.9.3.b CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ... 194
4.9.3.c REPLACE FUEL FILTER CARTRIDGE .................................................................. 195
4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................... 196
4.9.3.e CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS...................... 196
4.9.3.f CHECK AND ADJUST COOLING FAN BELT TENSION ....................................... 197
4.9.4 EVERY 1000 HOURS MAINTENANCE ................................................................................... 198
4.9.4.a REPLACE HYDRAULIC OIL FILTER ELEMENT.................................................... 198
4.9.4.b CHANGE OIL IN FINAL DRIVE CASE.................................................................... 200
4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST ................................................. 200
4.9.5 EVERY 2000 HOURS MAINTENANCE ................................................................................... 201
4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER .................................... 201
4.9.5.b CHECK ALTERNATOR, STARTING MOTOR ........................................................ 202
5. TECHNICAL SPECIFICATIONS
5.1 SPECIFICATIONS ................................................................................................................................. 204
5.2 LIFTING CAPACITIES .......................................................................................................................... 206
5.2.1 LIFTING CAPACITIES PC30MR-2 (WITH CANOPY) .............................................................. 206
5.2.2 LIFTING CAPACITIES PC30MR-2 (WITH CABIN) .................................................................. 209
5.2.3 LIFTING CAPACITIES PC35MR-2 (WITH CANOPY) .............................................................. 212
5.2.4 LIFTING CAPACITIES PC35MR-2 (WITH CABIN) .................................................................. 215
14
TABLE OF CONTENTS
6. AUTHORIZED OPTIONAL EQUIPMENT
6.1 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION .......................................................... 220
6.1.1 SAFETY FIRST ........................................................................................................................ 220
6.1.2 ATTACHMENT INSTALLATION .............................................................................................. 221
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT ........................................................ 222
6.1.3.1 FOR MODEL PC30MR-2 ONLY ............................................................................. 222
6.1.3.2 FOR MODEL PC35MR-2 ONLY ............................................................................. 222
6.2 MACHINE READY FOR ATTACHMENT .............................................................................................. 223
6.2.1 LOCATIONS ............................................................................................................................. 223
6.2.2 HYDRAULIC CIRCUIT ............................................................................................................. 225
6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT ...................................... 225
6.2.2.2 MAINTENANCE ...................................................................................................... 226
6.2.2.3 BLEEDING AIR ....................................................................................................... 226
6.3 ATTACHMENT OPERATIONS ............................................................................................................. 227
6.3.1 LONG TERM STORAGE.......................................................................................................... 228
6.3.2 SPECIFICATIONS.................................................................................................................... 228
6.4 ATTACHMENT GUIDE.......................................................................................................................... 229
6.4.1 ATTACHMENT COMBINATIONS ............................................................................................ 229
6.5 RECOMMENDED ATTACHMENT OPERATIONS ............................................................................... 230
6.5.1 HYDRAULIC BREAKER........................................................................................................... 230
15
TABLE OF CONTENTS
PAGE INTENTIONALLY LEFT BLANK
16
SAFETY AND
ACCIDENT PREVENTION
17
SAFETY, NOISE AND VIBRATION PLATES
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
• The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean them with a solution made of water and detergent.
Do not use fuel, petrol or solvents.
• If the plates are damaged, ask for new ones to Komatsu 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 plates in addition to those indicated below; keep also to the instructions
given in the additional plates, in any case.
18
RKA01360
SAFETY, NOISE AND VIBRATION PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
The warning and danger plates applied onto the machine are accompanied or represented by pictograms.
The personnel in charge with the operation and maintenance of the machine must know the symbols contained in
the pictograms perfectly; the following description illustrates what they look like and their respective meanings.
DANGER IN THE WORK AREA
• Do not approach or stand within the equipment operating radius
when the boom and the bucket are raised.
DO NOT OPEN THE HOOD
• Do not open or remove the hood when the engine is running.
CONSULT THE MANUAL
• Carefully read the contents of the manual before using the machine or performing maintenance operations.
3F05B2612
3F30B2612
RWA00020
RWA00010
SAFETY DISTANCE
• Do not get too near the machine and do not stand within its operating radius.
09651-A0481
RWA00030
22L-98-22270
19
CAB LIFTING SAFETY LOCK
FILLING THE HYDRAULIC SYSTEM WITH OIL
• (Only for machines in which the synthetic biodegradable
oil type HEES is used)
SAFETY, NOISE AND VIBRATION PLATES
22L-98-R2390
RKA01380
HYDRAULIC OIL TOPPING UP
REFUELLING
BIO-OIL
RWA00050
D
RWA00040
RWA34380
ENGINE LUBRICATING OIL FILTER
20
RWA00080
FUEL FILTER
ENGINE AIR SUCTION FILTER
ENGINE COOLANT
SAFETY, NOISE AND VIBRATION PLATES
D
RWA00060
RWA00090
ENGINE COOLANT PRESSURE
HYDRAULIC OIL LEVEL
RWA00130
RWA00110
RWA00100
HYDRAULIC OIL FILTER
RWA00070
21
ELECTRIC OUTLET
SAFETY, NOISE AND VIBRATION PLATES
ANCHORAGE POINT
EMERGENCY EXIT
RWA00120
12 V
RWA00200
RWA00190
LIFTING POINT
RWA04920
22
LIFTING CAPACITIES (PC30MR-2)
SAFETY, NOISE AND VIBRATION PLATES
LIFTING CAPACITIES (PC35MR-2)
23
2.1.3 POSITION OF THE NOISE PLATES
ON MACHINES WITH CAB
• The noise plates must always be legible and in good conditions;
for this reason, if they are dirty with dust, oil or grease, it is nec
essary to clean them with a solution made of water and deter-
gent.
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 noise
plate, make sure that this plate is applied also on the new piece.
SAFETY, NOISE AND VIBRATION PLATES
-
RKA01410
RKA01530
NOISE OUTSIDE THE CAB
• This value indicates the noise level outside the machine and refers to the noise perceived by persons in the vicinity of the work area.
PC30MR-2
RKA01500
2000/14/EC
PC35MR-2
RKA01510
2000/14/EC
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.
24
PC30MR-2
RKA01390
ISO 6396
PC35MR-2
RKA01520
ISO 6396
SAFETY, NOISE AND VIBRATION PLATES
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY
• The noise plates must always be legible and in good conditions;
for this reason, if they are dirty with dust, oil or grease, it is nec
essary to clean them with a solution made of water and deter-
gent.
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 noise
plate, make sure that this plate is applied also on the new piece.
EXTERNAL NOISE
• This value indicates the noise level outside the machine and refers to the noise perceived by persons in the vici-
nity of the work area.
-
RKA01420
PC30MR-2
RKA01500
2000/14/EC
PC35MR-2
RKA01510
2000/14/EC
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma-
chine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is
subjected to vibrations lower than 0.5 m/sq.sec.
25
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
• Only trained and authorized personnel can use the machine and perform maintenance operations.
• Follow all the safety rules, precautions and instructions when using the machine or performing maintenance operations.
• When working with other operators or when the work site is often occupied by other operators, make sure that
everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as
to be able to see the machine and to be visible to the operator.
2.2.2 SAFETY DEVICES AND GUARDS
• Make sure that all the guards and covers are in the correct position. Have guards and covers changed or repaired if damaged. Neither use the machine without guards, nor remove the guards when the engine is running.
• Always use the proper safety devices to lock the machine when parking and fasten the safety belt.
• Do not remove the safety devices and always keep them in good operating conditions.
• Any improper use of the safety devices may result in serious injuries or even death.
2.2.3 CLOTHING AND PERSONAL
PROTECTION ITEMS
• Do not wear large or loose clothes, rings and watches and do
not approach the machine with loose long hair, since they can
get entagled in the moving parts of the machine and cause seri
ous injuries or damage.
Avoid also wearing clothes dirty with oil or fuel, since they are
flammable.
• Wear a hard hat, goggles, safety shoes, mask, gloves and
headphones when operating the machine or performing mainte
nance operations.
• Always wear safety goggles, a hard hat and heavy gloves if
your job involves scattering metal chips or minute materials;
these precautions are particularly useful when driving the equip
ment connection pins with a hammer and when blowing com-
pressed air into the air filter and the radiator to clean them.
During these operations, make also sure that no one is standing
or working near the machine without the necessary protections.
• When working for 8 hours with a noise level exceeding 90 dBA,
it is necessary to use headphones or ear plugs and be particu
larly careful, especially at the end of the work shift.
-
-
-
-
RKA00510
26
GENERAL PRECAUTIONS
2.2.4 UNAUTHORIZED MODIFICATIONS
• Any modification made without the authorization of Komatsu Utility can involve hazards.
• Before making a modification, consult your Komatsu Utility Dealer. Komatsu Utility declines any responsibility for
injuries or damage caused by unauthorized modifications.
2.2.5 LEAVING THE OPERATOR’S SEAT
• When leaving the operator’s seat, even if temporarily, make
sure that the machine is in a safe position. (See
ING THE MACHINE").
• Before leaving the operator’s seat, carry out the following operations in the sequence indicated below:
1 - Rest the equipment onto the ground.
2 - Connect the safety devices of the boom swing, optional
equipment and upper structure rotation controls.
"2.4.13 PARK-
3 - Lock the equipment control by shifting the safety device le-
ver to the lock position.
4 - Stop the engine (See "3.3.3 STOPPING THE ENGINE").
5 - If you have to go so far away that you will not be able to
see the machine, extract the ignition key.
CABIN
CANOPY
27
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
• Do not jump on or off the machine, either when it is at rest and
when it is moving.
• When getting on or off the machine, always use the handles
and the tracks; get on and off the machine very carefully.
• Never hold or rest on the control levers.
• Either when getting on and when getting off the machine, al-
ways maintain three points of contact (holding or resting points),
in order to avoid losing your balance and falling down.
• Tighten the handle connection screws if they are loose and
clean the handles and tracks if they are dirty with oil or grease.
Carefully clean the cab floor if it is dirty with oil, grease, mud or
rubble.
CANOPY
CABIN
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
Fuel, oil and some types of antifreeze can be easily ignited if they
get in contact 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 with fuel and oil only after stopping the engine and in
well ventilated areas.
• Top up with fuel and oil in a well delimited area and do not allow
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.
• After topping up, tighten the fuel and oil safety caps securely.
• Do not fill the tank completely, in order to leave room for the fuel
to expand.
• In case some fuel is spilled, wipe it up immediately.
RKA00480
RKA00490
28
Loading...