Komatsu PC12R-8 Operation & Maintenance Manual Download Page 17

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TABLE OF CONTENTS

Page

MAINTENANCE

GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.2

MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.2.1

NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.2.1.1

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.2.1.2

COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.2.1.3

FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

4.2.2

NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

4.2.3

NOTES REGARDING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.2.4

NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.2.5

PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . 125

4.3

FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.3.1

HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS . . . . . . . . . . . . . . 128

4.4

DRIVING TORQUES FOR SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.4.1

STANDARD DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.4.2

SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.5

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.5.1

LUBRICATION DIAGRAM PC12R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.5.2

LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE) . . . . . . . . . . . . . . . . . 131

4.5.3

LUBRICATION DIAGRAM PC15R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.5.4

LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE) . . . . . . . . . . . . . . . . . 133

4.6

PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY . . . . . . . . . . . . . . 134

4.6.1

CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.7

MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.7.1

WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

4.7.1.a

WASHING THE COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

4.7.1.b

DRAINING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4.7.1.c

CHECKING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4.7.1.d

CHECKING THE STEEL TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

4.7.1.e

CHECKING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

4.7.1.f

CHECKING THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.7.1.g

CHANGING THE RUBBER TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.7.1.h

LUBRICATING THE ARTICULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

4.7.2

MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER
(BREAKER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.7.2.a

CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.7.2.b

CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.7.3

CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.7.3.a

VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.7.3.b

CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.7.3.c

CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

4.7.3.d

CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

4.7.3.e

CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . 155

4.7.4

MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 156

Summary of Contents for PC12R-8

Page 1: ...S F22262 and up Operation Maintenance Manual Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintain ing thi...

Page 2: ......

Page 3: ...nance 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 T...

Page 4: ...he message can be used even to indicate the risk of damage to the machine only This word is used when precautions are indicated which must be taken to avoid actions that may shorten the life of the ma...

Page 5: ...ns 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 alt...

Page 6: ...ORTANT 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 e...

Page 7: ...imely 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...

Page 8: ...ance with the CE harmonized standards The plate with the mark is applied onto the front wall of the main frame on the left side kg kw kg kg MODELLO MODEL TYP MODELE MATRICOLA N SERIAL N FABR NR SERIE...

Page 9: ...The engine serial number is stamped on the plate positioned on the front side of the tappet cover The exhaust gas emission plate is applied on the top of the en gine cylinder head cover RWAA10510 RWA...

Page 10: ...ON GEAR SERIAL NUMBER 1 4 6 CAB SERIAL NUMBER RWA04960 The serial number of the swing reduction gear is stamped on the plate positioned on the swing motor head RYAA0080 The cab serial number is stampe...

Page 11: ...PRODUCT IDENTIFICATION 9 1 4 7 SERIAL NUMBERS AND DEALER S ADDRESS Machine n Model Engine n Travel reduction gear n Swing reduction gear n Cab n Dealer Address Tel Person to contact NOTES...

Page 12: ...10...

Page 13: ...ON MACHINES WITH CANOPY 27 2 1 5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 28 2 2 GENERAL PRECAUTIONS 29 2 2 1 GENERAL SAFETY RULES 29 2 2 2 SAFETY DEVICES AND GUARDS 29 2 2 3 CLOTHING AND PERSON...

Page 14: ...EMOVAL 45 2 8 PRECAUTIONS FOR MAINTENANCE 46 2 8 1 WARNING PLATES 46 2 8 2 TOOLS 46 2 8 3 PERSONNEL 46 2 8 4 EQUIPMENT 47 2 8 5 WORKING UNDER THE MACHINE 47 2 8 6 CLEANING THE MACHINE 47 2 8 7 USE OF...

Page 15: ...3 2 FRONT OPENING WINDSHIELD 80 3 5 3 3 FRONT WINDSHIELD LOWER PART 81 3 5 3 4 SIDE OPENING WINDOW 82 3 5 4 VENTILATION AND HEATING 83 3 5 5 SEAT 83 3 5 6 SAFETY BELT 84 3 5 7 EMERGENCY EXIT 84 3 5 8...

Page 16: ...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 USING THE MACHINE WITH VARIABLE TRACK GAUGE 1...

Page 17: ...PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 134 4 6 1 CRITICAL PARTS FOR SAFETY 135 4 7 MAINTENANCE PLAN 138 4 7 1 WHEN REQUIRED 141 4 7 1 a WASHING THE COOLING CIRCUIT 141 4 7 1 b DRAI...

Page 18: ...d CHANGING THE AIR CLEANER CARTRIDGE 169 4 7 9 e CLEANING THE OUTSIDE OF THE RADIATORS 169 4 7 9 f DRAINING THE HYDRAULIC OIL TANK Only for machines in which the synthetic biodegradable oil type HEES...

Page 19: ...ROWED 192 5 1 18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS VARIABLE TRACK GAUGE WIDENED 193 5 1 19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS VARIABLE TRACK GAUGE NARROWED 194 5 1 20 LIFTING CAPAC...

Page 20: ...18...

Page 21: ...SAFETY AND ACCIDENT PREVENTION...

Page 22: ...th 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...

Page 23: ...SAFETY NOISE AND VIBRATION PLATES 21 RWA05440...

Page 24: ...he 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 RWA00020...

Page 25: ...IC SYSTEM WITH OIL REFUELLING ENGINE LUBRICATING OIL FILTER FUEL FILTER ENGINE AIR SUCTION FILTER ENGINE COOLANT RWA34380 BIO OIL Only for machines in which the synthetic biodegradable oil type HEES i...

Page 26: ...SAFETY NOISE AND VIBRATION PLATES 24 ENGINE COOLANT PRESSURE HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER ELECTRIC OUTLET ANCHORAGE POINT RWA00110 RWA00100 RWA00070 12 V RWA00120 RWA00200...

Page 27: ...SAFETY NOISE AND VIBRATION PLATES 25 EMERGENCY EXIT LIFTING POINT RWA00190 RWA04920...

Page 28: ...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 RWA05460 LWA 89 514 CE 9...

Page 29: ...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...

Page 30: ...BJECTED According to the results of the tests carried out to determine the vibrations transmitted to the operator by the machine the upper limbs are subjected to vibrations lower than 2 5 m sq sec whi...

Page 31: ...t see 3 5 6 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 RWA00960...

Page 32: ...ing the operator s seat even if temporarily make sure that the machine is in a safe position See 2 4 13 PARK ING THE MACHINE Before leaving the operator s seat carry out the following oper ations in t...

Page 33: ...oor if it is dirty with oil grease mud or rubble RWA05020 RWA00970 RWA00980 Fuel oil and some types of antifreeze can be easily ignited if they get in contact with a flame Fuel is particularly flammab...

Page 34: ...asbestos fibers keep to the instructions given below 1 Do not use compressed air but only aspirators to clean the machine and make sure that the room in which you are working is properly ventilated 2...

Page 35: ...where maintenance opera tions are performed If the cab is inadvertently hit or the machine overturns during work the cab may be damaged with consequent reduction of its stiffness and of the safety th...

Page 36: ...der to find out their exact positions or to make them inneffective until the end of the operations Be careful not to sever or damage any of these lines Check the depth and flow of water before operati...

Page 37: ...haust gases can be deadly 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 als...

Page 38: ...check the position of the blade If the blade is positioned on the back side the travel levers must be operated in the opposite direction See 15 5 HOW TO MOVE THE MACHINE RWA06750 RWA06760 When operat...

Page 39: ...vers must be used during travel avoid moving them abruptly sudden manoeuvres change the attitude of the machine and make driving difficult When travelling on rough ground keep the speed low and avoid...

Page 40: ...opes It is advisable to go down or up to a flat place to perform these operations Do not travel on wet grass or thick layers of leaves if the ma chine moves obliquely in these conditions it may slip D...

Page 41: ...n It is particularly dangerous to swing on slopes when the bucket is full If these operations must last longer accumulate soil in such a way as to create a horizontal platform on which the machine can...

Page 42: ...o 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 equipment gets accidentally entangled in the cables...

Page 43: ...and are not visible therefore proceed with care when clearing the snow When working in tunnels galleries under electric cables or other ducts air telephone lines and wherever the height is limited pr...

Page 44: ...teeth into the ground 2 Stop the engine 3 Put wedges or safety blocks under the tracks Always rest the work equipment on the ground if it is neces sary to park with raised arms make sure that the saf...

Page 45: ...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 clean and there is no trace of grease oil s...

Page 46: ...rogen 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 Avoid short circuiting the batt...

Page 47: ...a 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...

Page 48: ...hine and in particular on the cab door handles RWA01310 RWA05400 Use only the tools provided with the machine and high quality tools suitable for the tasks to be performed Do not use worn damaged low...

Page 49: ...ols or broken pieces are dan gerous because they may cause someone to slip or trip Al ways keep the machine and the work site clean and tidy To clean the machine use a pressurized jet of warm water or...

Page 50: ...ose clothes 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 Ev...

Page 51: ...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 du...

Page 52: ...the negative earth cable and then the positive cable At the end of the operation reconnect first the positive ca ble and then the negative cable If electrical welding operations are to be carried out...

Page 53: ...pletely release the pres sures 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 a...

Page 54: ...e to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generated which are deposited on the filters and clog them...

Page 55: ...THE MACHINE AND ITS OPERATIONS...

Page 56: ...ition 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 The machine is provided with an up...

Page 57: ...FRONT GENERAL VIEW 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Lifting cylinder 7 Cab 8 Sprocket 9 Undercarriage 10 Revolving support 11 Idler roller 12 Track 13 Blade 14 Blade cylinder R...

Page 58: ...ACHINE WITH CANOPY 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Lifting cylinder 7 Canopy 8 Sprocket 9 Undercarriage 10 Revolving support 11 Idler roller 12 Track 13 Blade 14 Blade cylinde...

Page 59: ...ntrol 3 Left track control lever 4 Right track control lever 5 Boom swing control pedal 6 Bucket boom lifting control 7 Right safety lever only for machines with canopy 8 Blade control 9 Dashboard 10...

Page 60: ...operating hours of the engine The count is continuous and the number is in creased by 1 when the engine has run for one hour independ ently of its speed The hour meter keeps functioning even if the m...

Page 61: ...perated and goes out as soon as the engine lubrica tion circuit is pressurized If this warning light remains on or comes on with the engine run ning stop the machine immediately and try to locate the...

Page 62: ...is running at the normal operating speed this means that the alternator does not work and the battery is not charged correctly IMPORTANT If the warning light remains off when the ignition key is turn...

Page 63: ...rking light switch 3 Ignition key 4 Arm overload alarm switch if installed 5 Revolving light switch if installed 6 Horn 7 Variable track gauge control push button if provided OFF LO HI 1 2 OFF 0 0 0 0...

Page 64: ...es as heating switch See 3 5 4 VENTILATION AND HEATING RWA07180 This is a rotary switch with three positions marked by the follow ing symbols OFF 1 2 1 Enables the instrument light circuit 2 Enables t...

Page 65: ...o warn the persons in the vicinity at the beginning of work and in case of danger RWA20870 This button is positioned on the left joystick lever and when pressed it enables the hydraulic circuit of the...

Page 66: ...64 INSTRUMENTS AND CONTROLS 3 3 4 ELECTRICAL ACCESSORIES 1 Windshield wiper washer switch with cab only 2 Overhead lamp with cab only 3 Electric outlet RWAA9280 1 RWAA9290 2 RWA28850 3...

Page 67: ...o the first it operates the windshield washer RWA07230 RWA07240 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...

Page 68: ...control lever 4 Right travel control lever 5 Boom swing control pedal 6 Blade control lever 7 Accelerator lever 8 Left safety device control lever 9 Right safety device control lever only on machines...

Page 69: ...e 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 con trols the arm and the upper structure rotation while the cont...

Page 70: ...the left and arm folding RWA07280 D A B C N 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 RWA0729...

Page 71: ...the reverse gear according to the movements indicated N Neutral A Forward gear B Reverse gear IMPORTANT All movements are locked by shifting the safety device le ver to the lock position see pos 8 9...

Page 72: ...opera tions with the machine resting on firm and level ground and with the tracks raised from the ground in order to avoid damaging the shoes and the hydraulic motors With pressed button the lever co...

Page 73: ...to the lock position To lock the safety device raise the lever 1 which will automati cally move to the lock position To unlock the safety device push the lever 1 downwards until engaging it in the che...

Page 74: ...func tion To lock the safety device raise the lever 1 which will automati cally move to the lock position To unlock the safety device push the lever 1 downwards until engaging it in the check couplin...

Page 75: ...ional oil flow and the other for the control of an unidirectional flow BIDIRECTIONAL CONTROL 1 If the pedal is pressed in A high pressure oil is delivered from the opening C and conveyed to the equipm...

Page 76: ...allel to the undercarriage During travel make sure that the upper structure is direct ed towards the blade if the upper structure is rotated by 180 the controls are inverted When the lever is in the l...

Page 77: ...wn 7 5 Fuel pump speed increase 11 Brown 7 5 Solenoid excitation power supply 12 Red 50 General circuit of the system IMPORTANT When changing a fuse make sure that the ignition key is in position If t...

Page 78: ...1 Preheating warning light timer 2 Solenoid excitation timer 3 Solenoid excitation relay 4 Safety relay 5 Generator warning light relay 6 Current limiter All the relays are grouped on a single base po...

Page 79: ...ing 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 accid...

Page 80: ...If the cab is subjected to an impact or if the ma chine overturns immediately contact your Komatsu Utili ty Dealer who will check the stiffness of the cab and make sure that the operator s safety is g...

Page 81: ...operation may change suddenly Always use the handle to open or close the door The cab door 2 is a sliding door and it can be opened com pletely and held in position by the couplings 3 The coupling is...

Page 82: ...the front windshield 7 disconnect the wind shield wiper connector 10 positioned on the right inner side of the cab IMPORTANT If the front windshield is opened without disconnecting the connector 10 t...

Page 83: ...ART With open front windshield release the couplings 13 and re move the lower part of the windshield 12 Position it at the back of the cab behind the driver s seat and secure it to the seats 14 with t...

Page 84: ...82 GUARDS AND DRIVER S SEAT 3 5 3 4 SIDE OPENING WINDOW The side windows 15 positioned on the right side of the cab can be slided open press the handle 16 and pull it RWAA9420 15 16 RWAA9430 16...

Page 85: ...e cab is installed beside the fan it is used in the cold season and receives the hot water necessary for the heat exchange directly from the engine cooling circuit The water supply flow is divided or...

Page 86: ...ling points and ad justable length 2 it must be well tightened and hold the opera tor s hips while leaving the upper part of the body completely free RWA05950 2 1 The machines with cab are provided wi...

Page 87: ...he 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...

Page 88: ...86...

Page 89: ...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...

Page 90: ...l the safety locks of the equipment controls are in the correct position and there fore that the equipment cannot move suddenly and cause accidents The checks concern 1 the lock position of the safety...

Page 91: ...egulations and the rule of the road Before starting the engine make sure that there is no one within the operating radius of the machine and sound the horn Before starting the engine turn the ignition...

Page 92: ...cording to the outside temperature and the recommended ratio is approximately 1 second for each degree below zero The preheating is signalled by the warning light positioned on the dashboard 2 Turn th...

Page 93: ...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 t...

Page 94: ...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 accelerator lever and set the engine running at idling speed RYA12200...

Page 95: ...onsiderable friction created when changing direction it is advisable not to use the speed increase pedal To turn to the left operate the RIGHT travel lever as indicated below To move FORWARD push the...

Page 96: ...ing that may suddenly modify the work con ditions 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...

Page 97: ...fficiently firm If it is necessary to work with the machine immersed in water make sure that the maximum depth does not ex ceed the upper structure rotation ball bearing ring and in any case that the...

Page 98: ...d lock the cab if provided 1 Park the machine on firm and level ground in a sufficiently wide space 2 Lower the blade and the bucket to the ground if there is not enough space the work equipment must...

Page 99: ...ossible due to the absence of natural obstacles rotate the bucket in the dumping position and thrust the teeth into the ground 2 Lower the blade to the ground 3 Engage the safety lock of the boom swin...

Page 100: ...en 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...

Page 101: ...e between the ramps must be suitable for the machine gauge Position the ramps with a maximum inclination of 15 Remove any trace of oil grease or ice from the ramps and the loading board Do not change...

Page 102: ...ons the height width and weight of the means of transport machine included must be compatible with the road and any tunnel subway bridge electric or telephone line that may be found on the way 2 Keep...

Page 103: ...sert a metal or nylon rope in the four upper holes Fix the ropes with the appropriate locks or with safety pins 5 Connect the ropes to the lifting hook as indicated in the fig ure IMPORTANT Always use...

Page 104: ...this mixture only during the winter and when changing the coolant in autumn or spring wash the cooling circuit see 4 7 1 WHEN REQUIRED 2 When it is necessary to calculate the antifreeze water ratio r...

Page 105: ...27 75 1 23 1 24 1 25 1 26 1 Before using the machine in normal operating conditions carry out some slow movements either forward and in reverse and operate all the work equipment cylinders slowly mor...

Page 106: ...PORTANT The coolant must be changed only if it is not permanent For the relevant specifications see 4 3 FUEL COOLANT AND LUBRICANTS 2 Make sure that the cooling fan belt is in good conditions 3 Make s...

Page 107: ...method and learn how to organize work in a free area while seated in the driving position If after a first inspection the area results to be uneven encumbered with big obstacles or characterized by co...

Page 108: ...k at reduced speed and ask the assistance of an other operator 1 Center the machine with respect to the digging line IMPORTANT If this is not possible because it is necessary to dig along walls or ban...

Page 109: ...ilitate the filling of the bucket and therefore increase productivity 4 he removal depth must be correct and suitable for the type of ground excessive depth may lock the move ments overload the engine...

Page 110: ...s The described procedures are valid also for the coupling of the mechanical constraints of the optional equipment 1 Position the bucket on a level surface directing it so that the flat part of its ba...

Page 111: ...When the track gauge is reduced as much as possible the lateral stability of the machine is reduced as well In working sites where the machine may overturn widen the track gauge and be careful during...

Page 112: ...dth can be modified by proceeding as follows 1 Stop the machine on a level surface lower the equipment to the ground and stop the engine 2 Remove the bolts 1 that fasten the extensions positioned at t...

Page 113: ...les 3 Change all the filtering elements air cleaner engine oil filter hydrulic circuit filters diesel oil filter 4 Drain the coolant and replace it with a corrosion inhibitor permanent fluid 5 Drain t...

Page 114: ...follows 1 Free the exhaust pipe and the fuel tank from the seals 2 Check all the levels engine oil coolant fuel hydraulic circuit oil 3 Make sure that the battery is charged and install it on the mach...

Page 115: ...the po sition of the bucket teeth more or less horizontal 3 When travelling down a steep slope at low speed a noise coming from the travel motor may be heard RWA06050 DANGER When removing the machine...

Page 116: ...e is made of diluted sulphuric acid that may corrode the clothes and even the skin in case of contact with this fluid immediately rinse the involved part with plenty of water If the acid gets into the...

Page 117: ...urrent load that must be transferred The battery to be used for the starting must have greater capacity or at least the same capacity as the battery of the machine to be started Make sure that the cab...

Page 118: ...repair Charge battery Change Starter pinion engages and then dis engages Battery charge insufficient Charge battery Starter makes engine run slowly Battery charge insufficient Faulty starter Charge ba...

Page 119: ...es on with engine running Coolant insufficient Faulty thermostat Add coolant Change Engine does not start with starter run ning No fuel Air in fuel system Compression defect valves with wrong clearanc...

Page 120: ...118...

Page 121: ...MAINTENANCE...

Page 122: ...s applied onto the machine Instructions for arc welding 1 Turn the ignition key to position 2 Disconnect the battery first the negative pole and then the positive pole 3 Disconnect the alternator 4 Do...

Page 123: ...nk with the oil of the new brand DANGER Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force The combustib...

Page 124: ...E 10W API classification CD Fuel Ambient temperature above 10 C ASTM D975 no 2 diesel oil Ambient temperature below 10 C ASTM D975 no 1 diesel oil Radiator Permanent ethylene glycol based antifreeze w...

Page 125: ...d take care not to draw the conden sate from the drum bottom If fuel runs out or if the fuel filter has been replaced it is necessary to bleed the circuit Be extremely careful when performing maintena...

Page 126: ...optional device to the fuses ignition switch battery relays etc for the installation of any optional equipment contact your Komatsu Utility Dealer If any electric welding operation has to be carried...

Page 127: ...he machine Use only Komatsu Utility genuine parts which alone can guarantee excellent quality and interchangeability ITEM CODE DESCRIPTION Q TY CHANGE INTERVAL Hydraulic oil filter 848101172 Cartridge...

Page 128: ...aulic system with biodegradable oil SEE 4 3 1 24 22 Travel reduction gears ea OIL API CD 0 4 0 4 Fuel tank DIESEL OIL 20 Engine cooling system WATER ANTIFREEZE 3 2 WATER 3 2 PERMANENT COOLANT 3 2 LUBR...

Page 129: ...classification is used reduce the engine oil change interval by a half Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine...

Page 130: ...r the en dothermic motor the transmissions the braking system etc Before introducing the synthetic biodegradable oil in the hydraulic system empty the system com pletely disconnecting the cylinders an...

Page 131: ...gm Nm 6 8 10 12 14 1 1 25 1 5 1 75 2 10 13 17 19 22 0 96 0 1 2 3 0 2 4 6 0 5 7 8 0 8 12 5 1 9 5 1 23 2 45 4 9 77 8 122 13 1 3 0 15 3 2 0 3 6 5 0 6 11 1 17 5 2 13 5 1 5 32 2 3 5 63 6 5 108 11 172 18 16...

Page 132: ...r the lubrication procedures for the single points see 4 7 MAINTENANCE PLAN The type of lubricant to be used is indicated in the lubricant table See 4 3 FUEL COOLANT AND LU BRICANTS 2000 h 1000 h 250...

Page 133: ...or the lubrication procedures for the single points see 4 7 MAINTENANCE PLAN The type of lubricant to be used is indicated in the lubricant table See 4 3 FUEL COOLANT AND LU BRICANTS 2000 h 1000 h 250...

Page 134: ...brication procedures for the single points see 4 7 MAINTENANCE PLAN The type of lubricant to be used is indicated in the lubricant table See 4 3 FUEL COOLANT AND LU BRICANTS 2000 h 1000 h 250 h 100 h...

Page 135: ...or the lubrication procedures for the single points see 4 7 MAINTENANCE PLAN The type of lubricant to be used is indicated in the lubricant table See 4 3 FUEL COOLANT AND LU BRICANTS 2000 h 1000 h 250...

Page 136: ...ately in case of failures or anomalies even if the time interval prescribed for their change has not elapsed yet If the pipe clamps show signs of deterioration like deformations or cracks provide for...

Page 137: ...riodically changed When changing pipes always change O rings gaskets and analogous components No Components related to safety that periodically need changing Qty Change interval 1 Fuel pipe Fuel tank...

Page 138: ...onnected with safety and the components that must be pe riodically changed When changing pipes always change O rings gaskets and analogous components No Components related to safety that periodically...

Page 139: ...hanged When changing pipes always change O rings gaskets and analogous components No Components related to safety that periodically need changing Q ty Change interval 1 Hydraulic pipe Main pump delive...

Page 140: ...Check 142 d Steel tracks Check and adjust the tension 143 e Rubber tracks Check 145 f Rubber tracks Check and adjust the tension 147 g Rubber tracks Change 149 h Articulation points Lubricate 151 N PA...

Page 141: ...7 9 MAINTENANCE EVERY 500 HOURS OF OPERATION N PART OPERATION PAGE a Joint and ball bearing ring articulations Lubricate 157 b Variable track gauge sliding guides Lubrication 159 c Air cleaner Clean...

Page 142: ...ump precleaner Change 168 d Air cleaner Change the cartridge 169 e Radiators Clean the outside 169 f Hydraulic oil tank Only for machines with synthetic biodegrad able oil Drain condensate 170 N PART...

Page 143: ...2 of the radi ator remove the drain plug 3 positioned on the engine block and the radiator cap 1 Use a 17 mm hexagon spanner 3 Let all the fluid flow out put back the plug 3 on the engine block and c...

Page 144: ...k or in any case with the machine at operating temperature to prevent the condensate from freezing The condensate and the impurities that may have accu mulated inside the tank must be eliminated befor...

Page 145: ...ontrol levers slowly during this operation 2 Measure the distance between the track and the second roll er starting from the sprocket If the distance is included be tween 10 and 20 mm the tension is n...

Page 146: ...3 to let the grease out do not give the valve more than one turn Use a 19 mm hexagon spanner 2 If the grease does not flow out freely move the machine slowly forward and backward for a short distance...

Page 147: ...lipping increases and the advance power will decrease accordingly 1 Roller 2 Rubber track 2 When the steel reinforcement 3 can be seen on two or more points on the track 3 When more than a half of the...

Page 148: ...engthened and the idler cyl inder may be damaged too 6 If the break between the support claws of the rubber tracks reaches a length 1 of approximately 60 mm the track must be repaired It must be immed...

Page 149: ...n the up per part of the track mid way between the two axes 2 Lift each track by means of boom and arm When carrying out this operation move the control levers slowly 3 On model PC12R measure the dist...

Page 150: ...To reduce the tension gradually loosen the greasing valve 3 to let the grease out do not give the valve more than one turn Use a 19 mm hexagon spanner 4 If the grease does not flow out freely move th...

Page 151: ...or the operator Do not loosen any other component in addition to the valve 2 When assembling or removing the track before rotating the sprocket make sure that the grease contained in the cylinder has...

Page 152: ...rocket as if in reverse 1 pushing the outer edge of the track towards the upper structure 4 By means of a steel tube 2 position the track and rotate the sprocket again 5 Make sure that the rubber trac...

Page 153: ...enance operation must be performed only when the articulations require lubrication For the lubrica tion extend the equipment completely and lower it the ground use a syringe to apply the prescribed gr...

Page 154: ...successive changes keep to the indica tions given in the table on the right If the machine contains synthetic biodegradable oil type HEES the filter must be changed after the first 50 hours of operat...

Page 155: ...he instruments and warning lights on the dashboard of the working lights and of the horn The other general checks concern safety and precisely 6 soundness of the safety belt 7 soundness and legibility...

Page 156: ...horoughly and lock the tank RWA06090 1 2 RWA07480 OFF LO HI 1 2 OFF 0 0 0 0 0 0 h CHECK CAUTION 2 DANGER Soon after the machine has been stopped the engine is very hot and may cause burns let the engi...

Page 157: ...level must be visible through the gauge 1 positioned on the tank and must be included between the MIN and MAX marks To top up use the suitable hydraulic oil See 4 3 FUEL COOLANT AND LUBRICANTS If a c...

Page 158: ...r machines in which the synthetic biodegradable oil type HEES is used The following maintenance operation must be carried out after the first 50 hours of operation HYDRAULIC OIL DRAIN FILTER CHANGE Fo...

Page 159: ...more frequently These maintenace operations must be carried out with the equipment completely extended and resting on the ground For the lubrication use a syringe and the prescribed grease See 4 3 FU...

Page 160: ...MAINTENANCE PLAN 158 FOR PC12R ONLY 5 Blade cylinder base pin for PC12R only 1 point 6 Blade cylinder head pin for PC12R only 1 point 7 Blade fulcrum pin for PC12R only 2 points RWA06140 6 7 5 7...

Page 161: ...lt conditions carry out this maintenance operation more frequently This operation must be carried out with the machine resting on level ground and the track gauge widened as much as possible see 3 14...

Page 162: ...lows a Remove the coupling 2 and release the filter from its sup port b Remove the couplings 3 and the cover 4 and extract the filtering element 5 c Hit the element slightly on the palm of your hand t...

Page 163: ...adjustment contact your Komatsu Utility Dealer The fan belt can be reached after opening the engine hood See 3 5 1 ENGINE HOOD The control is manual press the belt 1 with your thumb on the indicated p...

Page 164: ...ched after raising the mat on the left side and opening the door 2 The electrolyte level in each cell must be about 6 mm above the plate edge if necessary top up with distilled water only If on the co...

Page 165: ...arried out on each reduction gear posi tioned with the level plugs 1 on the horizontal axis and the drain plug 2 downward If necessary move the machine slightly until reaching the re quired position w...

Page 166: ...ed and throw it away 4 Clean the contact surface between the seal and the filter sup port lubricate the seal of the new filter and screw it until it touches the support 5 Give another half turn by han...

Page 167: ...lution regulations in force Proceed as follows 1 Open the engine hood See 3 5 1 ENGINE HOOD 2 Remove the drain plug 1 of the oil pan gathering the used oil that flows out into a container with suitabl...

Page 168: ...oil The oil that may be spilled during the change makes the ground slippery therefore use anti slip shoes and immediately remove any trace of oil from the floor Oils filters the coolant and the batte...

Page 169: ...lement 3 Clean the sealing surface of the cover 3 and install the new filter in the pan 2 install the O ring and smear it with some grease 4 Reassemble the whole unit open the fuel tap 1 and bleed the...

Page 170: ...to the anti pollution regulations in force 1 Place a container under the precleaner 1 to gather the fuel 2 Shift the hand accelerator lever to the idling position 3 Remove the precleaner from the cla...

Page 171: ...ty shoes The outside of the radiators must be cleaned with a jet of com pressed air and if necessary with a low pressure water or steam washing cycle the specific products available on the mar ket can...

Page 172: ...th touch the ground 2 Lower the blade to the ground 3 Stop the engine and eliminate the residual pressures present in the equipment by moving the controls several times 4 Slowly loosen the filling cap...

Page 173: ...th the machine on level ground at a temperature of 40 45 C so that the oil is more fluid and can be drained easily together with the suspended solid par ticles 1 Move the machine until the drain plug...

Page 174: ...reaches 4045 C before carry ing out any maintenance operation Immediately clean any area dirty with oil Oils filters the coolant and the battery are considered special waste and must be collected and...

Page 175: ...ated in the figure and remove the filling cap 1 Put back the cap and pressurize the inside of the tank low ering the equipment to the ground 11 Make sure that all the control levers are in neutral and...

Page 176: ...iminate any encrus tation See 4 7 1 a WASHING THE COOLING CIRCUIT 1 Open the engine hood See 3 5 1 ENGINE HOOD 2 Loosen and remove the upper cap 1 of the radiator 3 Open the drain cock 2 of the radiat...

Page 177: ...TECHNICAL SPECIFICATIONS...

Page 178: ...00 1225 2360 1000 230 435 1070 3495 220 250 RWA29090 RWA29100 1020 900 1225 2290 1000 230 435 1070 3495 220 250 IMPORTANT If the machine is equipped with the long arm instead of the standard arm or wi...

Page 179: ...04 ENGINE Komatsu diesel engine model 3D68 N3FAE Maximum power 2450 rpm EEC 80 1269 kW 10 3 Maximum torque 1800 rpm EEC 80 1269 Nm 49 ELECTRICAL SYSTEM Alternator 12V Electrical output 20 A Earthing...

Page 180: ...1225 2360 1000 1320 230 435 1070 3495 220 250 RWA29110 RWA29120 1020 900 1225 2290 1000 230 435 1070 3495 250 1320 220 IMPORTANT If the machine is equipped with the long arm instead of the standard ar...

Page 181: ...ity SAE m3 0 04 ENGINE Komatsu diesel engine model 3D68 N3FAE Maximum power 2450 rpm EEC 80 1269 kW 10 3 Maximum torque 1800 rpm EEC 80 1269 Nm 49 ELECTRICAL SYSTEM Alternator 12V Electrical output 20...

Page 182: ...60 1000 230 435 1070 3535 220 250 RWA29130 RWA29140 1020 1145 1225 2290 1000 230 435 1070 3535 220 250 IMPORTANT If the machine is equipped with the long arm instead of the standard arm or with steel...

Page 183: ...SAE m3 0 04 ENGINE Komatsu diesel engine model 3D68 N3FBE Maximum power 2600 rpm EEC 80 1269 kW 11 2 Maximum torque 1800 rpm EEC 80 1269 Nm 49 ELECTRICAL SYSTEM Alternator 12V Electrical output 20 A E...

Page 184: ...1225 2360 1000 230 435 1070 3535 250 RWA29150 1320 220 RWA29160 1020 1145 1225 2290 1000 230 435 1070 3535 250 1320 220 IMPORTANT If the machine is equipped with the long arm instead of the standard a...

Page 185: ...TY Capacity SAE m3 0 04 ENGINE Komatsu diesel engine model 3D68 N3FBE Maximum power 2600 rpm EEC 80 1269 kW 11 2 Maximum torque 1800 rpm EEC 80 1269 Nm 49 ELECTRICAL SYSTEM Alternator 12V Electrical o...

Page 186: ...nd Rating over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2 m 2m 1m 0 1m 240 245 145 195 260 345 130 170 25...

Page 187: ...e blade equipped with the appropriate safety device Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A...

Page 188: ...and level ground Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2 m 2m 1m 0 1m 240 245 145 195 260...

Page 189: ...nd level ground Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2 m 2m 1m 0 1m 260 260 160 200 280...

Page 190: ...s only with the blade equipped with the appropriate safety device Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting...

Page 191: ...only with the blade equipped with the appropriate safety device Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting c...

Page 192: ...und Rating over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2 m 2m 1m 0 1m 265 270 160 175 320 360 140 150 2...

Page 193: ...lade equipped with the appropriate safety device Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2...

Page 194: ...and level ground Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2 m 2m 1m 0 1m 265 270 160 175 320...

Page 195: ...nd level ground Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 2 m 2m 1m 0 1m 280 270 180 190 340...

Page 196: ...s only with the blade equipped with the appropriate safety device Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting...

Page 197: ...only with the blade equipped with the appropriate safety device Raiting over front Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting c...

Page 198: ...196...

Page 199: ...AUTHORISED OPTIONAL EQUIPMENT...

Page 200: ...lure to comply with this rule Komatsu Utility declines any responsibility for accidents or damage DANGER When removing or installing any equipment take the following precautions and be careful to the...

Page 201: ...ot to perform them 1 Travelling downhill with raised work equipment 2 Transversal crossing of slopes 3 Rotation of the upper structure on slopes RWA07850 WRONG RWA05150 WRONG WRONG RWA06820 When insta...

Page 202: ...ing bucket 24 1000 0 040 Ditch digging bucket 24 800 0 045 Clamshell bucket 60 250 900 0 020 150 20 Hydraulic hammer 90 815 110 25 Drill 75 200 1000 150 25 Specific weight of the handled material 1 8...

Page 203: ...e since pressurized oil is thus introduced in the delivery circuit left side the oil flow is interrupted and therefore the hammer is stopped by releasing the pedal See 3 3 5 pos 11 OPTIONAL EQUIPMENT...

Page 204: ...dercarriage more than necessary 3 When working on very hard materials it is important not to keep hitting the same point for more than 30 seconds Hit the same point for a few seconds and change positi...

Page 205: ...ork do not use the demolition hammer with the bucket cylinder at the end of its stroke but al ways leave a minimum space of 5 cm 1 Gathering or moving stones with the demolition hammer 2 Rotating the...

Page 206: ...tal position or even with greater inclination 5 Lever with the tool after thrusting it into the material to be bro ken 6 Hitting the ground with the hammer bit 7 Lifting the machine by levering on the...

Page 207: ...ical constraints carry out the hydraulic connections by proceeding as fol lows 1 Stop the engine and move the hydraulic controls in all direc tions in order to completely release the residual pressure...

Page 208: ...the residual pressure present in the hammer delivery pipe 3 Slowly loosen the hydraulic oil filling cap to release the residual pressure from the tank 4 Disconnect the hammer feeding and draining pip...

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Komatsu PC12R-8, Operation & Maintenance Manual

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