Komatsu PC22MR-3 Operation & Maintenance Manual Download Page 237

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MAINTENANCE

MAINTENANCE PROCEDURES

4-29

Whenever possible, use an indicator to check electrolyte level

If an indicator can be used to check electrolyte level, proceed as indicated below.

Battery with charge indicator

A visual gauge indicates the battery charge level in different colours, according to the table positioned beside
the gauge:

Green: optimal charge

Gray: the battery needs recharging

White: the battery must be replaced.

WEAM014500

Summary of Contents for PC22MR-3

Page 1: ...his 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 refer...

Page 2: ......

Page 3: ...FOREWORD 11 WEAM014500...

Page 4: ...more information is needed do not hesitate to contact your Komatsu distributor he always knows how to get the best performance from the machine he can recommend the equipment that is most suitable fo...

Page 5: ...FOREWORD FOREWORD 1 3 Storage location for the Operation and Maintenance Manual WEAM014500...

Page 6: ...s reason ask Komatsu distributor before using the machine Terminology used in the signs The following words are used in the signs to inform the user that there is a potential hazard that may lead to p...

Page 7: ...n to modify the setting of the hydraulic system safety valves Komatsu cannot be held liable for any damage to persons property or the machine if this has been tampered with by modifying the standard s...

Page 8: ...hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual...

Page 9: ...se plate make sure that such a plate is applied also to the new part q Sound power level emitted by the machine measured according to ISO 6395 Dynamic test method simulated working cycle This is the g...

Page 10: ...te make sure that such a plate is applied also to the new part q Sound power level emitted by the machine measured according to ISO 6395 Dynamic test method simulated working cycle This is the guarant...

Page 11: ...chine to reduce the whole body vibration levels 1 Use the correct equipment and attachments 2 Maintain the machine according to this manual Q Tension of crawler for crawler machines Q Brake and steeri...

Page 12: ...rt machines long distances between worksites 8 The following guidelines can be effective to minimize risks of low back pain Q Operate the machine only when you are in good health Q Provide breaks to r...

Page 13: ...the assembly of the authorized equipment the controls requiring special arrangements on the machine and the hydraulic couplings necessary for the operation of such equipment are grouped in the final s...

Page 14: ...sy maintenance with simplified intervals RUNNING IN 1 All machines have been meticulously adjusted and tested before delivery However a new machine must be used with caution during the first 100 hours...

Page 15: ...l the terms front rear left and right refer to the travel direction as seen from the operator s seat when the operator s seat is facing the front and the sprocket F is at the rear of the machine A B C...

Page 16: ...to the distributor when requiring assistance and ordering spare parts MACHINE SERIAL NUMBER 1 The machine serial number is stamped on the front upper part of the main frame on the left side MACHINE ID...

Page 17: ...EMISSION PLATE 1 The engine serial number is stamped on the plate positioned on the engine itself The exhaust gas emission plate is on the left rear side of the cab chassis support A Serial number E M...

Page 18: ...ear and can be seen after removing the cover 1 SWING REDUCTION GEAR SERIAL NUMBER 1 The serial number is stamped on the plate positioned on the upper side of the swing motor CAB SERIAL NUMBER 1 The se...

Page 19: ...3 Fulfils all the relevant provisions of following EC Directive Machine serial No Engine serial No Product identification number PIN Manufacturers name Address Komatsu Utility Europe S p A Via Atheste...

Page 20: ...R PIN 1 14 MACHINE SERIAL NUMBER PLATE according directive 2006 42 EC 1 15 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE 1 15 TRAVEL REDUCTION GEAR SERIAL NUMBER 1 16 SWING REDUCTION GEAR SERIAL...

Page 21: ...ion 2 21 ROPS Cab specification 2 21 ATTACHMENT INSTALLATION 2 22 ATTACHMENT COMBINATIONS 2 22 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 2 22 CAB WINDOW GLASSES 2 22 UNAUTHORIZED MODIFICATIONS 2...

Page 22: ...R TOOLS 2 53 ACCUMULATOR GAS SPRING 2 53 PERSONNEL 2 53 ATTACHMENTS 2 53 WORK UNDER THE MACHINE 2 54 NOISE 2 54 WHEN USING HAMMER 2 54 WELDING WORKS 2 54 USING LAMPS 2 55 SAFETY FIRST WHEN USING HIGH...

Page 23: ...ng of lockable caps 3 31 Opening and closing the covers with lock 3 31 Cab door lock opening and closing 3 31 ENGINE HOOD 3 32 RADIATOR COVER 3 33 TANK COVER 3 34 TILTING THE CAB FLOOR 3 35 SUPPLEMENT...

Page 24: ...F MUD 3 83 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR 3 84 CHANGING THE BUCKET 3 86 PARKING THE MACHINE 3 87 CHECKS TO BE CARRIED OUT BEFORE STOPPING THE ENGINE 3 88 CHECKS TO BE CA...

Page 25: ...attery 3 114 Charging the battery 3 114 Starting with booster cables 3 115 OTHER TROUBLES 3 117 Electrical circuit 3 117 Frame 3 117 Engine 3 118 MAINTENANCE GUIDE TO MAINTENANCE 4 2 MAINTENANCE NOTES...

Page 26: ...USTING THE RUBBER TRACK TENSION 4 38 CHANGING THE RUBBER TRACKS 4 41 BUCKET TEETH REPLACEMENT 4 44 BLEEDING THE HYDRAULIC SYSTEM 4 45 CHECKING THE DETERGENT LEVEL IN THE WINDSIELD WASHER RESERVOIR 4 4...

Page 27: ...INAL DISPOSAL OF THE MACHINE 4 72 SPECIFICATIONS SPECIFICATIONS 5 2 OPERATING CHARACTERISTICS 5 3 LIFTING CAPACITIES 5 4 LIFTING CAPACITIES Canopy specification 5 4 LIFTING CAPACITIES Cab specificatio...

Page 28: ...6 13 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT 6 14 HYDRAULIC BREAKER 6 14 Main applications 6 14 How to use the breaker correctly 6 14 Always avoid the following incorrect uses 6 16 Greas...

Page 29: ...ake sure that the precautions outlined in this manual and the safety labels on the machine have been fully understood Always closely observed these safety measures when starting or performing assistan...

Page 30: ...lways keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off q There are also other labels in addition to the warning signs and safety labels...

Page 31: ...ithin the equipment operating radius when the boom and the bucket are raised 2 Do not open the hood Do not open or remove the hood when the engine is running 3 Consult the manual Carefully read the co...

Page 32: ...et too near the machine and do not stand within its operating radius 5 Platform lifting safety plate When the platform is open make sure that the safety pin is correctly inserted 6 Caution when standi...

Page 33: ...e tracks read the instructions in the manual 11 Lock the control levers Before standing up from the operator seat for example when opening or closing the front glass or when adjusting the operator sea...

Page 34: ...er the platform as there is danger of crushing 14 Risk of burns Do not open the radiator and the hydraulic oil tank when the engine is still hot Risk of explosion on the hydraulic accumulator and gas...

Page 35: ...use any naked flame near the batteries no sparks q When handling batteries always wear safety goggles q Keep children away from batteries q Caution battery acid q Read the operator s manual before wo...

Page 36: ...ETY LABELS SAFETY 2 8 q Caution explosive gases Hydraulic oil topping up Only for machines in which the synthetic biodegradable oil type HEES is used Hydraulic oil topping up Engine oil filter WEAM014...

Page 37: ...Y SAFETY LABELS 2 9 Fuel filter Engine coolant AF NAC q Fill Komatsu genuine engine coolant AF NAC to prevent radiator damage by corrosion Hydraulic oil topping up Refuelling Engine oil filter D WEAM0...

Page 38: ...SAFETY LABELS SAFETY 2 10 Fuel filter Engine air suction filter Engine coolant Engine coolant pressure Hydraulic oil level 215 98 28970 WEAM014500...

Page 39: ...SAFETY SAFETY LABELS 2 11 Hydraulic oil filter Electrical outlet Anchorage point Lifting point WEAM014500...

Page 40: ...SAFETY LABELS SAFETY 2 12 Anchorage point Lifting point Emergency exit Cab specification 09960 01201 WEAM014500...

Page 41: ...SAFETY SAFETY LABELS 2 13 Lifting capacities Canopy specification Lifting capacities Cab specification WEAM014500...

Page 42: ...gauges smoke oil leakage etc or any abnormal display on the warning devices or monitor report to the person in charge and have the necessary action taken Do not operate the machine until the problem...

Page 43: ...s and covers changed or repaired if damaged Neither use the machine without guards nor remove the guards when the engine is running q Always use the proper safety devices to lock the machine when park...

Page 44: ...s act as lenses and can cause a fire q Do not use cellular telephones inside the operator s compartment when driving or operating the machine q Never carry dangerous objects such as for example flamma...

Page 45: ...o so far away that you will not be able to see the machine extract the ignition key HANDRAILS AND STEPS 2 To prevent personal injury caused by slipping or falling off the machine always do as follows...

Page 46: ...e wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts q Do not get on or off the machine while holding tools in your hand MOUNTING AND DISMOUNTING 2 q N...

Page 47: ...plug FIRE PREVENTION AND EXPLOSION PREVENTION 2 FIRE CAUSED BY FUEL OR OIL 2 Fuel oil antifreeze and window washer liquid are particularly flammable and can be hazardous To prevent fire always observ...

Page 48: ...not cleaned there is danger of fire FIRE COMING FROM HYDRAULIC LINE 2 q Check that all the hose and tube clamps guards and cushions are securely fixed in position q If they are loose they may vibrate...

Page 49: ...structure designed to protect an operator who is wearing a seatbelt if the machine should roll over It supports the weight of the machine when it rolls over and also absorbs the impact energy q If RO...

Page 50: ...USED BY THE WORK EQUIPMENT 2 q Do not stand within or approach the operating radius of the work equipment even when the operator is on board the machine and the engine is running q Do not stand or wor...

Page 51: ...you need to operate on a road protect pedestrian and cars by designating a person for worksite traffic duty or by installing fences around the worksite q When traveling or operating in shallow water o...

Page 52: ...risk are the following q Wear shoes with thick rubber or leather soles q Request the aid of another person who can warn you if the machine gets too close to the electric line q Operate at low speed q...

Page 53: ...the working lamp and front lamps installed to the machine and set up additional lighting in the work area if necessary q Stop operations if the visibility is poor such as in mist snow rain or dust VEN...

Page 54: ...signalman before starting the job q Only one person must be entrusted with making signals q The operator must make sure that the signalman is always within his field of vision and follow all his signa...

Page 55: ...ed out q BRING THE LOAD NEARER IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical position directed towards the signalman move the hand in the direction of the movement to...

Page 56: ...sped point the thumbs inwards q EXTEND THE ARM With both hands clasped point the thumbs outwards q FOLD THE BUCKET Keep one hand still and closed Rotate the other hand vertically with the thumb pointe...

Page 57: ...ched fist Rotate the other fist vertically indicating the wheel s turning direction q TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels q DISTANCE TO BE...

Page 58: ...gure represents the lift slowly control q STOP With one arm extended laterally open the hand facing downwards and move the arm forwards and backwards q EMERGENCY STOP With both arms extended in horizo...

Page 59: ...e lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste Always observe the following q Spray water to ke...

Page 60: ...hts are functioning correctly q Clean the floor of the cockpit and the controls pedals and levers from any oil and grease and excessive dirt on the floor earth stones etc q Check fluid levels coolant...

Page 61: ...q Canopy specification q Cab specification q Open the triangular trunk the engine bonnet and the tank housing and make sure that the fixing screws n 4 1 from platform are properly fixed q If any anoma...

Page 62: ...COLD WEATHER 2 q Carry out the warming up operation thoroughly If the machine is not thoroughly warmed up before the control levers are operated the reaction of the machine will be slow and this may...

Page 63: ...ation of the lever front and rear travel is reversed left and right steering is reversed Be extremely careful when operating the machine in this situation q Before travelling check again that there is...

Page 64: ...over obstacles which make the machine tilt strongly to one side q When traveling or carrying out operations always keep a safe distance from people structures or other machines to avoid coming into c...

Page 65: ...al position and travel at low speed When travelling downhill position the machine with the turret rotated by 180 so that the sprocket 1 and the boom are in travelling direction as shown in the figure...

Page 66: ...ne has to be used on a slope pile the soil A to make a platform that will keep the machine as horizontal as possible q Do not work on a slope covered with the steel plates Even with slight slopes ther...

Page 67: ...uipment or a hazard of serious personal injury being caused by flying pieces of broken materials or of the machine tipping over due to reaction from the impact q Generally speaking the machine is more...

Page 68: ...is a hazard that it may tip over or become buried in the snow Be careful not to leave the road shoulder or to get trapped in a snow drift q When clearing snow the road shoulder and objects placed besi...

Page 69: ...OPERATION 2 41 q If the machine needs to be parked on a ravine do so as follows q Set the bucket on the downhill side then dig it into the ground q Put blocks under the track to prevent the machine f...

Page 70: ...s again q When on the ramps do not operate any lever except for the travel lever q The center of gravity of the machine will change suddenly at the joint between the ramps and the track or trailer and...

Page 71: ...tteries turn the starting switch to the OFF position As there is a hazard that sparks will be generated always do as follows q Do not let tools or other metal objects make any contact between the batt...

Page 72: ...ry main switch are turned to OFF q Be sure to connect the positive cable first and then the negative or earth cable when connecting the booster cables Disconnect first the negative or earth cable and...

Page 73: ...sudden loads on the steel cables q Never use a wire rope which has cut strands A reduced diameter B or kinks C There is danger that the rope may break during the towing operation q Always check caref...

Page 74: ...e as the lifting capacity of the machine Always be sure to lift within the relevant lifting limits q The lifting link RLL Rated Lifting Load and part number A are stamped on the link as shown below q...

Page 75: ...visually for damage or deformation before use to ensure that they are not damaged or worn Any damaged deformed or worn parts should not be used and must be replaced q Where possible the lifting opera...

Page 76: ...ne eg chains shackles etc must be rated correctly for the load to be lifted q It is dangerous if the raised load hits any person or structure When swinging or operating the work equipment check carefu...

Page 77: ...erator is providing for service this may result in serious injuries or even death KEEP WORK PLACE CLEAN AND TIDY 2 q Do not leave hammers or other tools around the working area Wipe up all grease oil...

Page 78: ...Select a place where there is no hazard of landslides falling rocks or flooding q Lower the work equipment and blade completely to the ground q When leaving the machine set lock lever 1 to the LOCK p...

Page 79: ...when there is strong wind This may lead to serious personal injury q Never open the floor when the engine is running or when the door on the cab specification machine is open or when the lock lever i...

Page 80: ...lever 1 to the LOCK position L then stop the engine q Canopy specification q Cab specification q When carrying out operations near the fan fan belt or other rotating parts there is a hazard of being c...

Page 81: ...emble the accumulator q Do not bring it near flame or dispose of it in fire q Do not make holes in it weld it or use a cutting torch q Do not hit or roll the accumulator or subject it to any impact q...

Page 82: ...king If the noise from the machine is too loud it may cause temporary or permanent hearing problems WHEN USING HAMMER 2 When using a hammer pins may fly out or metal particles may be scattered This ma...

Page 83: ...ment grease drain plug 1 may fly out and cause serious injury or property damage q When loosening grease drain plug 1 to loosen the track tension never loosen it more than one turn Loosen the grease d...

Page 84: ...OSES 2 q If oil or fuel leaks from high pressure hoses it may cause fire or defective operation which may lead to serious injury If any loose bolts are found stop work and tighten to the specified tor...

Page 85: ...cement of safety critical parts See SAFETY RELATED PARTS 4 20 q The material of these components naturally changes over time and repeated use causes deterioration wear and fatigue As a result there is...

Page 86: ...f the machine controllers PRECAUTIONS CONCERNING THE STARTER 2 q Start the engine only when correctly seated in the driving position q Do not start the engine by tampering with the terminals of the st...

Page 87: ...in immediately rinse with a solution made of water and an alkaline detergent for about 30 minutes and then contact a poisoning treatment center without delay PRECAUTIONS FOR THE USE OF THE SYNTHETIC B...

Page 88: ...SAFETY MAINTENANCE INFORMATION SAFETY 2 60 WEAM014500...

Page 89: ...FUNCTIONING 13 WARNING Before reading this section make sure you have read and understood the section on safety WEAM014500...

Page 90: ...TIONING 3 2 MACHINE ILLUSTRATIONS 3 OVERALL VIEW OF THE MACHINE 3 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Boom cylinder 7 Track 8 Sprocket 9 Undercarriage 10 Idler roller 11 Blade cyl...

Page 91: ...h pedal 10 Boom swing control pedal 11 Pedal locking device 12 Horn 13 Right work equipment control lever 14 Control locking lever right Canopy specification 15 Travel speed selection switch 16 Blade...

Page 92: ...that are necessary for correct operation of the machine To perform the required operations correctly and safely it is important to understand the equipment operating methods and the meaning of the inf...

Page 93: ...unction comes on and the acoustic alarm starts sounding Carry out the necessary repairs immediately 1 Engine oil pressure warning light This warning light comes on together with the acoustic alarm whe...

Page 94: ...en the engine exceeds the idling speed If this indicator light stays on when the engine is running at full operating speed this signals that the alternator is not working and therefore the battery is...

Page 95: ...exceeds the set values during operation and reaches the red overheating area B let the engine idle until the indicator returns within the normal operating range A When the indicator reaches the red ov...

Page 96: ...d the warning light B blinks REMARK If the indicator reaches the red reserve area A during use stop the engine and provide for refuelling 3 Hour meter This instrument indicates the total number of ope...

Page 97: ...speed increase warning light This warning light comes on when the travel speed selection switch is in high speed position see Travel speed selection switch 3 12 When the selector switch is in normal p...

Page 98: ...speed selection switch 4 Working lights switch 5 Revolving light switch if installed 6 Boom overload alarm switch if installed 7 Cab heating and ventilation switch Cab specification 8 Windshield wipe...

Page 99: ...e starter run As soon as the engine starts release the key which will automatically return to position ON Position HEAT preheating D When starting the engine in cold weather turn the key to position H...

Page 100: ...gh to low or vice versa When high speed is selected the speed increase warning light is lit on the indicators and warning lights display see WARNING LIGHTS AND GAUGES 3 4 When low speed is selected th...

Page 101: ...ration is disabled 7 Cab heating and ventilation switch Cab specification It is a three speed switch and operates the fan motor Turn the switch 7 clockwise to increase the fan speed If operated after...

Page 102: ...asher When the windshield wiper washer is in operation and the switch which is in position B is pressed the detergent is sprayed out Upon release of the switch only the windshield wiper works REMARK W...

Page 103: ...arting the engine NOTICE q The battery main switch must always be set to ON except in the following cases Q When the machine is not going to be used for a long period or when the machine is prepared f...

Page 104: ...nt control lever 3 Right work equipment control lever 4 Accelerator lever 5 Blade control lever 6 Travel levers equipped with pedal 7 Boom swing control pedal locking device 8 Boom swing control pedal...

Page 105: ...ion the translation and the optional equipment When the lever is pulled up it is set to LOCK position L The safety device is hydraulic so even if the control levers and pedals are moved the movements...

Page 106: ...ver seat lower the equipment to the ground lock the controls with the safety lever and stop the engine NOTICE q The horn push button is positioned on the right lever grip and must be used to warn all...

Page 107: ...eed and power a Minimum push the lever completely forward b Maximum pull the lever completely backward Use the accelerator with care especially when the machine is under strain or is working in diffic...

Page 108: ...eering manoeuvres use the pedals with the maximum care q When leaving the operator seat always rotate the pedals to the rest position in order to avoid pressing them by mistake These levers are used t...

Page 109: ...swing control pedal and has two positions F free L locked 8 Boom swing control pedal This pedal controls the boom swing to the right and to the left according to the movements indicated below a swing...

Page 110: ...e cab floor see TILTING THE CAB FLOOR 3 35 10 Optional tools control pedal locking device WARNING Always lock the optional equipment control pedal when the use of this control is not required during t...

Page 111: ...protects the operator against psychophysical strain WINDSHIELD 3 WARNING q When the upper windscreen or the cab door is opened or closed always take the safety device lever 1 to the locking position...

Page 112: ...o the locked position L 3 Make sure that the windshield wiper is positioned correctly 4 4 Seize the handles A at the right or left top of the front windscreen and push the locking levers B down to rel...

Page 113: ...FUNCTIONING CAB 3 25 5 Seize the handles C and D pull up the windscreen and push it until the lock E is tripped WEAM014500...

Page 114: ...1 Stop the machine on a level surface lower the equipment completely to the ground then stop the engine 2 Shift the safety lever 1 to the locked position L 3 Release the windscreen by means of the upp...

Page 115: ...FUNCTIONING CAB 3 27 5 When the windscreen lower part reaches the upper part of the lower glass push the windscreen upper section forwards against the locking catches G WEAM014500...

Page 116: ...lope the operating effort may change suddenly Do not open or close the door on slopes q Be careful to your hands in order to prevent them from being caught between the door and the front or centre pil...

Page 117: ...rs are not locked and are inadvertently operated there is the risk of serious accidents q Keep hands and head must remain inside the cab window during translation or when digging operations are carrie...

Page 118: ...remove any glass fragments from the window edges and take care not to injure yourself Be careful not to slip on the glass fragments scattered on the ground On machines equipped with cab the emergency...

Page 119: ...urn the key anticlockwise and open the cap Closing 1 Tighten the cap thoroughly and insert the key into the lock 2 Turn the key clockwise and extract it Opening and closing the covers with lock 3 Open...

Page 120: ...ly and make sure that it is kept open by the apposite rod q Non compliance with these rules may lead to serious accidents NOTICE q If it is not necessary to open the cover always keep it locked q When...

Page 121: ...1 Open the engine hood 1 For details see paragraph ENGINE HOOD 3 32 2 Pull the lever 2 that opens the radiator cover 3 3 Open the cover 3 completely and make sure that it is kept open by the apposite...

Page 122: ...nance operations q Carefully check the direction of the slot to make sure that the cap is locked 1 Release the lock of the cap 1 and remove it then remove the gasket 2 For further details see CAPS AND...

Page 123: ...d q Do not start the engine when the cab floor is tilted q If there is something wrong in the locking function when the cab floor is tilted interrupt work and have the necessary repairs carried out by...

Page 124: ...Canopy specification q Cab specification 4 Place safety blocks under the tracks to prevent the machine from moving 5 Loosen the two screws 2 and remove the triangular cover 3 6 Open the engine hood 4...

Page 125: ...ted together NOTICE q If the cab floor cannot be lifted this means that the release lever 8 isn t in the correct release position Pull the handle 9 backwards with your right hand then repeat the proce...

Page 126: ...by pushing the handle 9 at the same time 2 Pull the cab floor release lever 8 in the direction shown by the arrow backwards with your left hand and at the same time pull the handle 9 downward in the...

Page 127: ...FUNCTIONING TILTING THE CAB FLOOR 3 39 4 Close the radiator cover 5 and the engine hood 4 5 Install the triangular cover 3 WEAM014500...

Page 128: ...T 3 A power outlet is positioned on the front part of the machine for the connection of a lamp for routine and maintenance operations It is a two pole outlet and is in compliance with the ISO 4165 197...

Page 129: ...loose in the fuse holder change it Replace the fuse with a new one having the same capacity Fuse capacity and circuits involved POSITION CAPACITY CIRCUIT INVOLVED F1 10A Working headlamp on boom 25A W...

Page 130: ...f the machine to check the fuse and change it if necessary The mains fuse 50A is located above the battery For details on how to open and close the right cover see RADIATOR COVER 3 33 REMARK The main...

Page 131: ...TOOL BOX 3 The tool box is positioned inside the seat support and can be reached by opening the front panel PUMP SUPPORT FOR GREASING 3 WARNING Soon after the engine has stopped the temperature of th...

Page 132: ...the machine q This machine is equipped with a two way radio communication device KOMTRAX Keep away from any explosive area If the machine must operate within 12 metres from an explosive area or from a...

Page 133: ...ommunication terminal consult the Komatsu distributor in case of failures REMARK As KOMTRAX is a wireless system it cannot be used inside tunnels undergrounds buildings or in mountainous areas where r...

Page 134: ...linders the articulations and the pipes for damage wear excessive play If any anomaly is observed provide for the necessary repairs 2 Remove dust and dirt from the areas around the engine battery and...

Page 135: ...ne 3 Carry out the checks listed below every day before starting the engine Check the coolant level and top up WARNING q Do not remove the radiator cap unless such operation is absolutely necessary Be...

Page 136: ...cluded between the FULL and LOW marks on the expansion tank 1 If the level is low top up through the filler neck of the tank 1 until reaching the FULL mark 3 Put back the cap after topping up 4 If the...

Page 137: ...ine cover For details see paragraph ENGINE HOOD 3 32 2 Remove the dipstick G and wipe it with a cloth 3 Insert the dipstick completely into the oil filler pipe then remove it and check the oil level 4...

Page 138: ...he fuel level on the fuel gauge 2 If the level is low unlock the lock remove the cap and top up through the filler F While refuelling check the fuel level on the sight gauge G q Tank capacity 28 l 3 A...

Page 139: ...e hood and the radiator cover For details see paragraph RADIATOR COVER 3 33 3 Make sure that the oil level is included between the H and L marks on the sight gauge G NOTICE q Do not exceed the max lev...

Page 140: ...s pressurised to prevent the pump from sucking in air Check the filter clogging indicator 1 Open the engine hood For further details see paragraph ENGINE HOOD 3 32 2 Check if the red piston is visible...

Page 141: ...the fuel tank For further details see DRAINING THE FUEL TANK 4 32 Checking the wiring system WARNING q If fuses are corroded rusted or do not hold well in place replace them with fuses featuring the...

Page 142: ...udinal adjustment allowed 140 mm Adjust the position of the operator seat according to the job to be carried out For example when it is necessary to carry out deep digging operations make the seat sli...

Page 143: ...op the engine immediately and fix or replace them Adjust the inclination of the rear view mirrors so that the area behind the cab is well visible q Canopy specification q Cab specification Mirror A Lo...

Page 144: ...n the seat belt before operating the machine q Always fasten the seat belt when working with the machine q Make sure that none of the two parts of the belt is twisted Make sure that the screws that fa...

Page 145: ...ng the engine 3 WARNING q When starting the engine make sure that the safety lever is in the locked position q If the control levers are not locked and are inadvertently touched when the engine is sta...

Page 146: ...q Fuel level warning light 8 q Travel speed increase warning light 9 If a warning light or indicator does not turn on or the sound alarm does not go on contact a Komatsu distributor who will carry out...

Page 147: ...of the starter This may cause serious injury or even fires q Start the engine only while seated with fastened seat belt q Before starting the engine make sure that there is no one within the operatin...

Page 148: ...Pull the accelerator lever 2 midway between the idling position A and the maximum speed position B 3 Turn the ignition key 3 to position START to start the engine 4 As soon as the engine starts releas...

Page 149: ...fore starting the engine make sure that there is no one within the operating range of the machine and sound the horn q Never use starting aid fluids as they may cause explosions q Exhaust gas is toxic...

Page 150: ...approximately 18 seconds the warning light 4 goes out indicating that the preheating phase has been completed REMARK The indicator light 4 lights even when the starter key is in the preheating HEAT p...

Page 151: ...such a way as to warm it up gradually before actual operation q Avoid operating the machine with the limit loads allowed or at high speed q Immediately after starting the engine avoid sudden starts s...

Page 152: ...This will lengthen the life of the machine q Do not accelerate abruptly before completing the warming up operations Do not let the engine run at low idling or high idling speed for more than 20 minut...

Page 153: ...il pressure warning light 6 warning light off q Battery charge level warning light 7 warning light off 5 Make sure that the colour of the exhaust gases is normal and that there are no strange noises o...

Page 154: ...emergency It is likewise recommended not to stop the engine suddenly if it has been running for a long period and is still hot in this case let the engine run at low idling speed for about 5 minutes...

Page 155: ...operating range and that there are no obstacles in the surrounding area q Be extremely careful when reversing and make sure that there are no persons other equipment or obstacles in the way q Avoid an...

Page 156: ...bucket from the ground q Canopy specification q Cab specification 2 Lift the working equipment 40 50 cm from the ground 3 Lift the blade 4 Activate both translation levers 3 or pedals 4 as described...

Page 157: ...ravel speed increase warning light 6 comes on For details on the travel speed see paragraph SPECIFICATIONS 5 2 REMARK q When the engine is started the low speed is automatically selected q When the ma...

Page 158: ...rs 3 or pedals 4 slowly backward to start reversing q When the driving wheel A is at the front of the machine push the levers 3 or the pedals 4 slowly forward to start reversing 5 Switch over the trav...

Page 159: ...increases the low speed is automatically selected but the travel speed increase warning light remains on When the load is reduced the travel system automatically changes over to high speed 6 Make sure...

Page 160: ...load increases the low speed is automatically selected and the machine slows down When the load is reduced the travel system automatically changes over to high speed Use the travel levers to change d...

Page 161: ...ward left B Back left REMARK To steer to the right operate the right travel lever in the same way Counter rotation rotation of the machine on itself To carry out a counter rotation to the left pull th...

Page 162: ...ol lever 1 2 When the swing function is not used shift the left lever 1 to the neutral position N With the lever in this position the swing lock is automatically engaged A Swing to the left B Swing to...

Page 163: ...ically return to a neutral position and the working tools remain in the position in which they were stopped The movement of the levers and the corresponding movement of the tools are illustrated in th...

Page 164: ...st boom q Blade control Move the lever on the right of the operator s seat forward or backward to operate the blade q Optional equipment control Press the pedal located on the left of the translation...

Page 165: ...the travel force to carry out digging operations This may damage the machine or the work equipment Precautions when using the hydraulic cylinders at the end of stroke When the hydraulic cylinders are...

Page 166: ...ions for which it is not allowed to exploit the dropping force of the machine It is prohibited to carry out digging operations using the dropping force of the machine When excavating hard rock bed use...

Page 167: ...sible to the ground and try to move the machine keeping the obstacle equidistant from the tracks Closure of the working equipment When folding the work equipment to the travel or transport position be...

Page 168: ...t will be submerged and this can cause the cooling fan break For this reason pay special attention when the machine is coming out the water Do not immerse the machine in water beyond the permissible d...

Page 169: ...position q Do not travel up or down steep slopes since the machine may overturn q During travel lift the machine at about 20 30 cm from the ground Do not travel downhill in reverse q Do not change dir...

Page 170: ...slope If the engine stops when the machine is travelling uphill shift the travel levers to the neutral position lower the bucket to the ground stop the machine then start the engine again Precautions...

Page 171: ...h with the bucket teeth The angle between the 1st and the 2nd boom must be within 90 and 110 When only one side gets stuck in mud use the bucket to raise the track then lay boards or logs under the tr...

Page 172: ...rom a 45 angle away from the machine to a 30 angle towards the machine There may be some differences depending on the digging depth but it is advisable to try to keep within the above range rather tha...

Page 173: ...3 85 Filling levelling operations Use the blade to refill after excavation or to level the ground surface Side ditching work The machine can be used for side ditching in confined spaces by combining t...

Page 174: ...quipment 1 Position the bucket on level ground directing it so that the flat part of its back rests on the ground REMARK Make sure the bucket is resting on the ground slightly to make the removal of t...

Page 175: ...tracks and thrust the work equipment into the ground to prevent the machine from moving q If the control levers are inadvertently touched the work equipment or the machine may move suddenly and cause...

Page 176: ...Shift the safety lever 3 to the locked position L q Canopy specification q Cab specification CHECKS TO BE CARRIED OUT BEFORE STOPPING THE ENGINE 3 At the end of the working day before turning the engi...

Page 177: ...repairs 2 Fill the fuel tank 3 Check the engine compartment for paper and debris Remove any paper and debris to avoid a fire hazard 4 Remove any mud that may be attached to the undercarriage LOCKING T...

Page 178: ...any damage due to the incorrect use of the machine Use of the rubber tracks 3 Prohibited Operations Keep to the following instructions q Avoid performing rotations or other operations on broken rocks...

Page 179: ...t affects the adhesion of the steel core q Always repair the tracks before use When handling materials like salt sugar flour or soy seeds the presence of deep cuts in the rubber tracks may cause the i...

Page 180: ...ation exceeding 10 and with the other track on flat ground To avoid damaging the rubber tracks always proceed with both tracks resting on the same horizontal plane 4 If the machine is operated in the...

Page 181: ...Furthermore if the machine travels in reverse a gap is formed between the carrier roller the idler roller and the track The rubber track may come off also in the following conditions q When turning i...

Page 182: ...INE AND RELATED CONTROLS FUNCTIONING 3 94 q If the machine travels in reverse in these conditions the rubber track will come off q If the machine steers in these conditions the rubber track will come...

Page 183: ...As a general rule the machine must be transported on a trailer Select the trailer based on the weight and size of the machine as described in paragraph SPECIFICATIONS 5 2 It is important to remember...

Page 184: ...ce grease or oil q Do not change direction when the machine is already on the ramps since it may overturn If necessary move the machine down the ramps find the correct direction and go up again q It i...

Page 185: ...sides 2 in such a way that they are parallel and there is the same distance from the centre 3 of the trailer The installation angle 4 must be 15 max If the ramps bend excessively under the weight of t...

Page 186: ...ible without causing any interference When the machine is on the ramps operate only the travel levers Do not operate any other lever 6 Stop the machine where requested then slowly rotate the turret of...

Page 187: ...in or metal cable use the hole in the rear part of the undercarriage and the hole in the blade side plate Release 1 Load and unload the machine on from the trailer on firm and level ground only and wi...

Page 188: ...ess the translation speed selector switch located on the blade control lever grip The warning light turns off and low travel speed is selected 7 Place the safety locking lever 1 in the working positio...

Page 189: ...ercarriage and the turret parallel to each other q Always keep the machine in horizontal position during the lifting operations q Do not stand under the machine when this is suspended q Do not attempt...

Page 190: ...If the boom is swing to the left or to the right operate the boom swing pedal to position the boom parallel to the undercarriage then lock the pedal safety device 5 Place the safety locking lever 1 in...

Page 191: ...e with swing boom or turret q Pay attention to the pipes and take care that they do not get caught 10 Lift the machine slowly until the ropes are tense and check that the clamps are correct before com...

Page 192: ...f the fluid in the drainage channels or on the ground q The coolant containing antifreeze is flammable do not smoke and do not use naked flames during the checks and when preparing the mixture 1 Use o...

Page 193: ...lant weight density and check the battery charge percentage using the following table Since the capacity of the battery decreases considerably at low temperatures cover the battery or remove it from t...

Page 194: ...used for de icing and anti fogging of the glass Together with the fan there is a radiator that transfers heat to the air sent into the cab it is used during the cold season and receives the hot water...

Page 195: ...ion it on wooden boards to prevent the tracks from freezing on the ground which would make it extremely difficult to start the machine the following morning q Open the drain valve and drain the water...

Page 196: ...ng off the engine wait a minute then turn the battery switch to OFF and remove it Cover up the battery during long periods of inactivity q Lock all the control levers and pedals with the safety lever...

Page 197: ...ethylene may damage the tank RECOMMENDATIONS FOR MACHINES EQUIPPED WITH KOMTRAX SYSTEM DURING LONG PERIODS OF INACTIVITY 3 Even if the starter key is turned to OFF the KOMTRAX system can absorb a mini...

Page 198: ...ND STORAGE OF THE MACHINE FOR A LONG TIME 3 The recommended ambient temperature range for operation and long term storage is 20 C to 45 C If the machine is used in environments with temperature lower...

Page 199: ...failures q When the arm is retracted and the work equipment is lowered with no load the arm speed drops momentarily according to the more or less vertical position of the arm itself q When the bucket...

Page 200: ...the right Position wooden blocks between the wire cables and the machine body in order to prevent the cables from damaging the body itself PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS...

Page 201: ...a doctor without delay q When working on the battery always wear goggles and rubber gloves q When removing the battery disconnect the earth cable first When installing the battery connect the positiv...

Page 202: ...ammable and may explode therefore for this operation it is necessary to remove the battery from the machine position it in a well ventilated place and remove the caps before proceeding q Immediately c...

Page 203: ...the cable as far from the battery as possible In any case avoid the attachments since they are poor conductors q When removing the booster cables take care to avoid any contact of the clamps with eac...

Page 204: ...o turret E of the machine to be started Starting the engine CAUTION Make sure that the safety levers of both machines are in the locked position Also make sure that all the control levers are in NEUTR...

Page 205: ...mits abnormal noise q Faulty alternator q Change Starter does not turn with ignition switch in position ON q Faulty cables q Battery charge insufficient q Faulty fuse q Battery main switch turned to O...

Page 206: ...faulty q Restore level See Checks to be carried out before starting the engine q Replace cartridge See Every 500 hours q Check and repair q Change Steam comes out of radiator top pressure valve q Flu...

Page 207: ...clearance Exhaust gases white or light blue q Too much oil in oil pan q Unsuitable fuel q Restore level See Checks to be carried out before starting the engine q Change with fuel in compliance with s...

Page 208: ...TROUBLESHOOTING FUNCTIONING 3 120 WEAM014500...

Page 209: ...MAINTENANCE 1T n 24 WARNING Before reading this section make sure you have read and understood the section on safety WEAM014500...

Page 210: ...o do this could result in serious injury or death q Guards are installed in the area of the engine to protect personnel from moving parts These guards should only be removed by a Komatsu service engin...

Page 211: ...ank Instructions for arc welding q Before any welding operation on the machine stop the engine wait at least one minute and afterwards turn the battery main switch to OFF and extract the specific key...

Page 212: ...ntenance If you forget to perform the checks after inspection and maintenance unexpected problems may occur and this may lead to serious injury or property damage Always do the following q Checks afte...

Page 213: ...il q Do not mix different types or brands of oil q Maintain the prescribed levels when topping up the oil Too much or too little oil can cause malfunctions q If the oil in the working equipment is not...

Page 214: ...ted to this machine uses an injection device at high pressure This device needs that components and lubrication have high precision characteristics therefore its working life may be considerably reduc...

Page 215: ...ommended in this manual q The greased parts not covered by the maintenance section must be lubricated during servicing therefore they need to be lubricated Add grease if any part becomes stiff after b...

Page 216: ...allows customers to save money and avoid many problems KOWA analysis stages 4 q Analysis of metal particles In this stage a ICP Inductively Coupled Plasma analyser is used to measure the density of t...

Page 217: ...re present If you find large quantities of metal particles contact your Komatsu distributor q Do not open the spare filter packages before using them q Always use Komatsu original spare parts NOTES ON...

Page 218: ...circuit by proceeding as follows Q Start the engine and let it idle Q Extend all cylinders 4 5 times stopping them at approx 100 mm from the end of stroke Q Slowly make all cylinders reach the end of...

Page 219: ...e therefore the serial number of the machine should be given to the Komatsu distributor in order to receive the latest version of the component LIST OF THE PARTS SUBJECT TO WEAR 4 The parts between pa...

Page 220: ...draulic system with biodegradable oil See pag 4 14 20 40 PANOLIN HLP SYNTH 46 Articulation greasing Super white grease note 2 20 50 G2 T G2 TE Grease EPlithium based 20 50 G2 LI Engine cooling system...

Page 221: ...portant function to prevent corrosion as well as freezing In the areas where freezing is not a problem it is essential to use of an antifreeze coolant All Komatsu equipment are supplied with Komatsu S...

Page 222: ...tem it cannot be used for the engine the transmissions the braking system etc q Before introducing biodegradable oil in the hydraulic system drain the system completely disconnecting the cylinders and...

Page 223: ...ing torque table is not valid for screws or nuts that must fasten parts made of nylon or similar materials onto washers or components made of nylon or nonferrous metals or requiring specific tightenin...

Page 224: ...a hose always use Komatsu original spare parts having the same size of the part to be replaced q Nm Newton metre 1 Nm 0 102 kgm Thread diameter a mm Wrench size b mm Driving torque Standard value Use...

Page 225: ...The type of lubricant to be used is indicated in the lubricant table see 4 FUEL COOLANT AND LUBRICANTS Z 22K 98 31511 PC22MR 3 10h 100h 500h 1000h 2000h Z Grease Engine oil level Final reduction gear...

Page 226: ...LUBRICATION MAINTENANCE 4 18 BALL BEARING RING GREASING POINTS 4 Grease WEAM014500...

Page 227: ...psed yet If the pipe clamps show signs of deterioration like deformations or cracks provide for changing them together with the pipes In addition to the periodical change of the components listed in t...

Page 228: ...5 Fuel pipe fuel filter fuel tank 1 6 Fuel return pipe fuel filter injection pump 1 7 Fuel return pipe between the nozzles 2 8 Fuel return pipe nozzles injection pump 1 9 Fuel return cap 1 10 Hydraul...

Page 229: ...GINE 4 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE 4 48 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION Only for machines in which synthetic biodegradable oil type HEES is used CHANGING THE...

Page 230: ...NANCE EVERY 1500 HOURS OF OPERATION FUEL INJECTION SYSTEM CHECK AND CLEANING 4 62 ENGINE CASING BREATHER PIPE CHECK 4 62 MAINTENANCE EVERY 2000 HOURS OF OPERATION CHANGING THE OIL IN THE HYDRAULIC TAN...

Page 231: ...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 operation A Hydraulic fluid filter replacement interval X De...

Page 232: ...details see ENGINE HOOD 3 32 2 If the red piston of the filter clogging indicator 1 is visible clean the air filter cartridge NOTICE q Do not clean the cartridge if the red piston of the filter clogg...

Page 233: ...dge is damaged change it 7 Remove the cloth or adhesive tape used to cover the air connector inside the filter body 8 Install the cleaned cartridge 4 or a new cartridge 9 Position the cap 3 with the d...

Page 234: ...ed every time air circulation is reduced The filter can be accessed from outside the cab after overturning the platform see TILTING THE CAB FLOOR 3 35 Carry out the following operations to clean the e...

Page 235: ...ic acid diluted until the concentration suitable for the room temperature is obtained see Battery 3 104 q Check that the terminals and connection cables are not rusted if necessary clean and protect t...

Page 236: ...ve the vinyl protection placed on the battery 3 Remove the plug 1 of the battery look through the filler opening 2 and check the electrolyte surface If the electrolyte does not reach the sleeve 3 add...

Page 237: ...be used to check electrolyte level proceed as indicated below Battery with charge indicator q A visual gauge indicates the battery charge level in different colours according to the table positioned b...

Page 238: ...h a filter wrench and remove the casing 3 and the filtering element 5 Take care not to lose the red ring 4 that is positioned inside the casing 4 Wash the inside of the casing 3 and the filtering elem...

Page 239: ...wait approximately 15 20 seconds in such a way as to allow the fuel system to be automatically bled 3 Turn the ignition key to position START and start the engine NOTICE q If the engine starts regula...

Page 240: ...sediments and water collected at the bottom together with the fuel Collect fuel and sediments into a container with suitable capacity 4 When clean fuel flows out close the drain valve 1 NOTICE q The...

Page 241: ...s 1 become loose and are not tightened at the required torque the useful life of the tracks will be shorter q After tightening make sure that the nut and the track are in contact with the surface of t...

Page 242: ...d Check both tracks Checking the cartridge 1 With the engine idling move the machine forward of a distance corresponding to the length of the track on the ground then lower the equipment to the ground...

Page 243: ...omatsu distributor WARNING If the resistance met when injecting the grease is excessive move the machine forward and backward covering a short distance To increase the track tension proceed as follows...

Page 244: ...ort distance 3 Tighten the valve and remove any trace of grease 4 Move the machine forward and backward then stop it and make sure that the track tension is correct NOTICE q The degree of wear of pins...

Page 245: ...ck 3 When more than half of the steel core cords at the centre of the track are cut 4 When one or more steel cores have come off the track or are pushed out due to excessive tension 5 If the rubber tr...

Page 246: ...l ground Check both tracks q In particular on new machines or after the installation of new tracks it is advisable to carry out a first check after 10 hours of operation q Adjusting the track tension...

Page 247: ...t your Komatsu distributor WARNING If the resistance met when injecting the grease is excessive move the machine forward and backward covering a short distance To increase the track tension proceed as...

Page 248: ...owly forward and backward covering a short distance 3 Tighten the valve and remove any trace of grease 4 Move the machine forward and backward then stop it and make sure that the track tension is corr...

Page 249: ...be performed only by specialized personnel at any Komatsu distributor Installing the rubber tracks DANGER q The grease contained in the hydraulic cylinder is pressurized For this reason do not give th...

Page 250: ...moothly move the machine slowly forward and backward covering a short distance 4 Introduce the steel tubes 2 in the track turn the sprocket as if in reverse 3 so that the steel tubes move with the tra...

Page 251: ...el tube 2 position the track and turn the sprocket again 5 Make sure that the track is correctly installed on the sprocket and the idler roller 6 Adjust the track tension For details see CHECKING AND...

Page 252: ...ower surface of the bucket on a block make sure the working tools are in a stable position afterwards set the safety device lever to locking L Place the bucket in such a way that its bottom surface is...

Page 253: ...of stroke 2 Then activate each cylinder 3 or 4 times up to the end of stroke 3 Finally activate each cylinder 4 or 5 times up to the end of stroke to fully remove the air 4 Purge the air from the equi...

Page 254: ...To fill the reservoir use only non flammable detergent an ethyl alcohol based of the type used for cars q Do not use methyl alcohol based detergents may irritate the eyes q Do not use the antifreezes...

Page 255: ...aning of the wiper carried out with the washer in function If after cleaning there are scratches it means that the scrapping blade is deteriorated and it is necessary to replace the wiper NOTICE For b...

Page 256: ...el and top up q Check the oil level in the oil pan and top up q Check the fuel level and top up q Check the oil level in the hydraulic tank and top up q Check the air filter clogging indicator q Check...

Page 257: ...ponents of the swing system REMARK When grease is injected to lubricate the swing pinion and fifth wheel turn the turret slowly to change the position for greasing 1 Carefully clean the grease nipples...

Page 258: ...inder base pin 1 point 7 Blade cylinder rod end 1 point 8 Blade base pin 2 points 9 1st boom rotation bracket pin 2 points 10 Boom base pin 2 point 11 Boom cylinder base pin 1 point 12 2nd boom cylind...

Page 259: ...odegradable oil HEES is used The following maintenance operation must be carried out after the first 500 hours of operation together with the maintenance operations to be carried out every 500 hours q...

Page 260: ...the used oil that flows out of it into a container with suitable capacity While the oil flows out remove the filler cap F so that the oil can flow out freely 3 Screw the plug P onto the engine oil pan...

Page 261: ...e cover For details see ENGINE HOOD 3 32 2 Turn the valve 1 of the filter to the closed position A 3 Using a filter wrench loosen the metal ring of the filter and remove the casing 2 4 Clean the head...

Page 262: ...wait approximately 15 20 seconds in such a way as to allow the fuel system to be automatically bled 3 Turn the ignition key to position START and start the engine NOTICE q If the engine starts regula...

Page 263: ...60 and using the oil prescribed in the lubricant chart see FUEL COOLANT AND LUBRICANTS 4 12 CHANGING THE FUEL PUMP PREFILTER 4 WARNING q After work has ended clean the prefilter after the engine has...

Page 264: ...washing cycle the specific products available on the market can be used provided that the instructions given on the package are followed and that the washed parts are carefully dried NOTICE q Do not u...

Page 265: ...umb on the intermediate point between the drive shaft pulley and the fan pulley with a force equal to 98 Nm 10 kg the resulting deflection must be approximately 9 13 mm 2 If the deflection exceeds thi...

Page 266: ...the tracks 2 Retract the arm and bucket cylinders completely and lower the boom until the bucket teeth rest on the ground 3 Lower the blade to the ground 4 Stop the engine and eliminate the residual p...

Page 267: ...000 hours The filter is positioned on the hydraulic system drain outlet and it holds the metal particles that come off the various components due to wear The filter can be reached after removing the t...

Page 268: ...d special waste and must be collected and disposed of according to the regulations in force This operation must be carried out on each reduction gear with the machine parked on level ground and at a t...

Page 269: ...OCEDURES 4 61 CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE 4 Since these checks and adjustments require the use of special tools have them carried out by qualified personnel supplied by your Koma...

Page 270: ...and cleaning Given that special tools are needed for these operations it is advisable to commission your Komatsu distributor to perform them ENGINE CASING BREATHER PIPE CHECK 4 To ensure that emissio...

Page 271: ...p q Soon after the machine has been stopped the hydraulic oil is very hot and may cause burns let it cool down to 40 45 C before carrying out this maintenance operation q Immediately clean any area di...

Page 272: ...idual pressure from the tank 8 Remove the drain plug P and let the oil flow out gathering it into a container with suitable capacity 9 Tilt the cab floor see TILTING THE CAB FLOOR 3 35 10 Loosen the c...

Page 273: ...tank by lowering the equipment to the ground 16 Make sure that all control levers are in neutral position and run the engine at idle for 2 3 minutes before activating the working tools Move piston man...

Page 274: ...preventing both corrosion and freezing Komatsu machines are supplied with Supercoolant Komatsu AF NAC The Supercoolant Komatsu AF NAC has high anticorrosion antifreeze and coolant properties so it ca...

Page 275: ...2 Check that the cooling water temperature has decreased enough to allow the radiator cap 1 to be unscrewed to the stop in order to relieve the pressure 3 Press the radiator cap 1 unscrew until it st...

Page 276: ...vel FULL 10 Close the covers CHECKING THE ALTERNATOR AND THE STARTER 4 The brush may be worn or the bearing may be without grease Contact your Komatsu distributor for the necessary inspection or repai...

Page 277: ...it or press the accumulator q The gas must be released when disposing of the accumulator Refer to your Komatsu distributor to have this operation carried out q If the nitrogen loading pressure in the...

Page 278: ...g tool as extended as possible fully extended boom and bucket in discharge position and keep it 1 5 m A away from the ground REMARK Carry out the operations described in points 3 5 within 15 seconds P...

Page 279: ...ool descends because of its own weight and touches the ground the accumulator is correct If the tool does not descend or stops at the middle of the course the accumulator pressure is not enough Refer...

Page 280: ...FINAL DISPOSAL OF THE MACHINE MAINTENANCE 4 72 FINAL DISPOSAL OF THE MACHINE 4 At the end of the working life of the machine ask Komatsu distributor for the final disposal WEAM014500...

Page 281: ...SPECIFICATIONS 15 WEAM014500...

Page 282: ...SO 14396 2002 KW HP rpm 15 5 21 2500 A Total length mm 3750 B Total height mm 2485 C Total width mm 1450 D Track width mm 250 E Swing radius without ballast mm 720 Swing radius with ballast 810 F Tota...

Page 283: ...x digging depth mm 2280 C Max digging height mm 4000 D Max vertical wall digging depth mm 1860 E Max dumping height mm 2720 F Work equipment min swing radius mm 1790 Work equipment min swing radius wi...

Page 284: ...machine cannot lift weights exceeding 1000 kg unless it is provided with appropriate equipment q Carry out lifting operations only with the machine positioned on firm and flat ground REMARK The load...

Page 285: ...Unit of measurement kg 2 m 3 m Max 3 0 m 265 2 0 m 250 180 1 0 m 440 235 160 0 m 410 220 170 1 0 m 420 235 Long arm Raised blade Unit of measurement kg 2 m 3 m Max 3 0 m 200 2 0 m 255 205 150 1 0 m 6...

Page 286: ...25 445 245 1 0 m 1195 570 665 310 480 220 0 m 1570 540 810 295 605 235 1 0 m 1395 550 755 320 Long arm counterweight raised blade Unit of measurement kg 2 m 3 m Max 3 0 m 325 325 350 270 2 0 m 365 330...

Page 287: ...not lift weights exceeding 1000 kg unless it is provided with appropriate equipment q Carry out lifting operations only with the machine positioned on firm and flat ground REMARK The load does not exc...

Page 288: ...Unit of measurement kg 2 m 3 m Max 3 0 m 275 2 0 m 265 190 1 0 m 460 245 170 0 m 430 235 180 1 0 m 440 245 Long arm Raised blade Unit of measurement kg 2 m 3 m Max 3 0 m 215 2 0 m 265 215 160 1 0 m 6...

Page 289: ...40 445 255 1 0 m 1195 590 665 320 480 230 0 m 1570 560 810 310 605 245 1 0 m 1395 570 755 330 Long arm counterweight raised blade Unit of measurement kg 2 m 3 m Max 3 0 m 325 325 350 285 2 0 m 365 340...

Page 290: ...LIFTING CAPACITIES SPECIFICATIONS 5 10 WEAM014500...

Page 291: ...OPTIONAL EQUIPMENT 1 26 WARNING Before reading this section make sure you have read and understood the section on safety WEAM014500...

Page 292: ...you thoroughly read and understand the instruction manuals for the machine and the attachment or option q If you lose the instruction manual or it is damaged always obtain an new copy from the attachm...

Page 293: ...verrun is miscalculated so allow extra space to the swing position when swinging Q The hydraulic drift of the work equipment the amount of the work equipment moves down under its own weight when it is...

Page 294: ...res min q Standard service valve working pressure 1st equipment 24 5 MPa 245 bar q Optional safety service valve working pressure 1st equipment MPa bar q Standard service valve safety pressure equipme...

Page 295: ...distributor as well as causing safety problems may also adversely affect the operation of the machine and the durability of the equipment q Komatsu is not liable for injuries accidents or damage resu...

Page 296: ...iption Category Weigt h Working pressure Working flow Main dimension ISO capacity Lifting capacity Height Width kg Mpa l min mm mm m3 kg 1 Core machine 2065 2 Work Equipment Arm 1810 mm Equipments 111...

Page 297: ...N OF ATTACHMENTS 6 POSITION OF THE DEVICES 6 1 Quick couplers The quick coupling is used to connect the pipes equipped with quick coupling to the ends of the equipment 1 Quick couplers 2 Selection val...

Page 298: ...ns requiring the use of the generic equipment Spool C completely rotated clockwise q Position b for applications requiring the use of the hydraulic breaker Spool C completely rotated counterclockwise...

Page 299: ...ment control pedal WARNING Always lock the optional equipment control pedal when the use of this control is not required during travel and when parking the machine If the control pedal is inadvertentl...

Page 300: ...e hydraulic connections using the pipes provided After connecting the mechanical constraints carry out the hydraulic connections by proceeding as follows 1 Stop the engine and move the hydraulic contr...

Page 301: ...from the end of stroke NOTICE If the engine runs at maximum rpm or if the cylinders are brought to the end of stroke soon after starting the air sucked in by the cylinders may damage the piston gasket...

Page 302: ...or use q Before using the breaker make sure that the spool of the selection valve 1 is completely rotated counterclockwise and resting against its retainer position a q When using the breaker shift th...

Page 303: ...ric equipment make sure that the spool of the selection valve 1 is completely rotated clockwise and resting against its retainer position a q For further details and other precautions to be taken when...

Page 304: ...irements indicated see EQUIPMENT CONFIGURATION 6 5 HYDRAULIC BREAKER 6 WARNING The hydraulic breaker is very noisy therefore always wear ear muffs when using it Main applications 6 q Crushing rocks q...

Page 305: ...Avoid lifting the undercarriage more than necessary 3 When working on very hard materials it is important to avoid hitting the same point for more than 30 seconds Hit the same point for a few seconds...

Page 306: ...e avoided NOTICE During work do not use the hydraulic breaker with the bucket cylinder at the end of stroke but always leave a minimum space of 5 cm 1 Gathering or moving stones with the hydraulic bre...

Page 307: ...17 5 Levering with the tool after driving it into the material to be broken 6 Hitting the ground with the breaker bit 7 Lifting the machine by levering on the breaker bit with the bucket cylinder comp...

Page 308: ...er in the wrong position the breaker circuit will receive more grease than necessary As a result soil and sand may get into the hydraulic circuit and damage the hydraulic components while the breaker...

Page 309: ...l attention to the angle of the hook q Never travel the machine while lifting a load q If the bucket with hook is turned and used for operations it will hit the arm during dumping operations be carefu...

Page 310: ...BUCKET WITH HOOK OPTIONAL EQUIPMENT 6 20 WEAM014500...

Page 311: ......

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Komatsu PC22MR-3, Operation & Maintenance Manual

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