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TABLE OF CONTENTS

WEAM012101

MAINTENANCE PLAN..........................................................................................................................

209

4.8.1

MAINTENANCE PLAN .............................................................................................................

209

4.8.2

MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER...............

211

4.8.2.a CHANGING THE HYDRAULIC OIL FILTER ..............................................................

211

4.8.2.b CHANGING THE HYDRAULIC OIL ...........................................................................

211

4.9

MAINTENANCE PROCEDURES ..........................................................................................................

212

4.9.1

WHEN REQUIRED...................................................................................................................

212

4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE...............

212

4.9.1.b BATTERY ELECTROLYTE LEVEL CHECK ..............................................................

214

4.9.1.c CLEANING THE WATER SEPARATOR FILTER .....................................................

216

4.9.1.d DRAINING THE FUEL TANK .....................................................................................

217

4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION................................

217

4.9.1.f

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

220

4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION ............................

222

4.9.1.h CHANGING THE RUBBER TRACKS ........................................................................

224

4.9.1.i

CHECKING THE DETERGENT LEVEL IN THE WINDSIELD WASHER
RESERVOIR (machine with cab) ...............................................................................

227

4.9.1.j

LUBRICATION OF CAB DOOR HINGES (machines with cab) ................................

228

4.9.1.k CAB AIR FILTER CHECK AND CLEANING (machines with cab) ............................

228

4.9.1.l

CHECKING WINDSCREEN WIPER BLADE (machines with cab) ............................

229

4.9.1.m BLEEDING THE HYDRAULIC SYSTEM....................................................................

229

4.9.2

CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ...................................

230

4.9.3

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

230

4.9.4

MAINTENANCE EVERY 100 HOURS OF OPERATION .........................................................

231

4.9.4.a LUBRICATION ...........................................................................................................

231

4.9.5

MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used)..........................

233

4.9.6

MAINTENANCE EVERY 500 HOURS OF OPERATION .........................................................

234

4.9.6.a CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE ........

234

4.9.6.b CHANGING THE FUEL FILTER CARTRIDGE ..........................................................

235

4.9.6.c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS .........................

237

4.9.6.d CHECKING AND CLEANING THE FINS OF THE RADIATOR

AND OF THE EXCHANGER ......................................................................................

238

4.9.6.e CHECKING AND ADJUSTING THE FAN BELT TENSION .......................................

239

4.9.6.f

DRAINING THE HYDRAULIC OIL TANK
(Only for machines in which synthetic biodegradable oil type HEES is used)............

240

4.9.7

MAINTENANCE EVERY 1000 HOURS OF OPERATION .......................................................

241

4.9.7.a CHANGING THE HYDRAULIC OIL FILTER ..............................................................

241

4.9.7.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS .....................................

242

4.9.7.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ........................

242

4.9.8

MAINTENANCE EVERY 1500 HOURS OF OPERATION .......................................................

243

4.9.8.a FUEL INJECTION SYSTEM CHECK AND CLEANING .............................................

243

4.9.9

MAINTENANCE EVERY 2000 HOURS OF OPERATION .......................................................

244

4.9.9.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER ..

244

4.9.9.b CHANGING THE COOLANT......................................................................................

247

4.9.9.c CHECKING THE ALTERNATOR AND THE STARTER.............................................

248

4.9.9.d NITROGEN LOADING PRESSURE CHECK IN THE ACCUMULATOR

(FOR THE CONTROL CIRCUIT) ...............................................................................

249

4.10 END OF SERVICE LIFE........................................................................................................................

252

Содержание PC18MR-3

Страница 1: ...is 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 refere...

Страница 2: ......

Страница 3: ...ey provide a clear report on the situation and say exactly what has been done and what has to be done after the next maintenance interval Therefore it is advisable to consult both the hour meter and t...

Страница 4: ...the following words are used to express the potential level of the hazard DANGER q Indicates a situation of imminent danger that if not avoided may cause serious injury and even death The use of this...

Страница 5: ...o 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 modi fying the standard set...

Страница 6: ...icture to express a level of hazardous condition equivalent to the signal word These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of...

Страница 7: ...aulic couplings necessary for the operation of such equipment are grouped in the final section of this manual Komatsu machines are constructed exclusively for the handling excavation and treatment of...

Страница 8: ...tual operation q Avoid operating the machine with the limit loads allowed or at high speed q Avoid abrupt starts or accelerations useless sudden decelerations and abrupt reversals SYNTHETIC BIODEGRADA...

Страница 9: ...E In this manual the terms front forward rear backward left and right refer to the travel direction as seen from the operator seat when it is facing the front and the sprocket is at the rear of the ma...

Страница 10: ...Distributor when requiring assistance and ordering spare parts 1 4 1 MACHINE SERIAL NUMBER The machine serial number is stamped on the front upper part of the main frame on the left side 1 4 2 MACHIN...

Страница 11: ...OF CONSTRUCTION C PRODUCT IDENTIFICATION NUMBER G ENGINE POWER D MANUFACTURER MODEL SERIAL NUMBER MANUFACT YEAR MASS ENGINE POWER kg kW Product Identification Number MANUFACTURER Manufactured by Koma...

Страница 12: ...r is stamped on the plate positioned on the engine itself The exhaust gas emission plate is applied to the counterweight 1 4 4 CAB SERIAL NUMBER The serial number is stamped on the plate positioned on...

Страница 13: ...his machine PC18MR 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 Europ...

Страница 14: ...losive area or from an active electric exploder the cable harness must be disconnected from the module KOMTRAX Otherwise it may cause serious injuries or fatal accidents q This warning does not replac...

Страница 15: ...reless system it cannot be used inside tunnels undergrounds buildings or in mountainous areas where radio waves cannot be received Even when the machine is outdoors it cannot be used in areas where ra...

Страница 16: ...14 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...

Страница 17: ...SYSTEM 12 1 5 1 GENERAL PRECAUTIONS 12 SAFETY AND ACCIDENT PREVENTION 2 1 SAFETY NOISE AND VIBRATION PLATES 24 2 1 1 POSITION OF THE SAFETY PLATES 24 2 1 2 PICTOGRAMS AND RELEVANT MEANINGS 25 2 1 3 PO...

Страница 18: ...2 4 4 CHECKS FOR TRAVELLING IN REVERSE 54 2 4 5 MOVING THE MACHINE 54 2 4 6 MOVING ON SLOPES 55 2 4 7 WORKING ON SLOPES 56 2 4 8 UNAUTHORIZED OPERATIONS 56 2 4 9 PREVENTING ELECTROCUTION 58 2 4 10 VIS...

Страница 19: ...2 8 27 WASTE MATERIALS 74 2 8 28 COMPRESSED AIR 74 2 8 29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS 75 2 8 30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL T...

Страница 20: ...HE REVOLVING FRAME 145 3 3 7 WORK EQUIPMENT CONTROLS AND FUNCTIONS 146 3 3 8 UNAUTHORIZED OPERATIONS 149 3 3 9 PRECAUTIONS FOR USE 151 3 3 10 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES 153 3 3...

Страница 21: ...CTRICAL SYSTEM 187 3 7 6 2 FRAME 188 3 7 6 3 ENGINE 188 MAINTENANCE 4 1 GUIDE TO MAINTENANCE 192 4 2 MAINTENANCE NOTES 194 4 2 1 OIL FUEL AND COOLANT 194 4 2 1 1 OIL 194 4 2 1 2 FUEL 195 4 2 1 3 COOLA...

Страница 22: ...e oil type HEES is used 230 4 9 4 MAINTENANCE EVERY 100 HOURS OF OPERATION 231 4 9 4 a LUBRICATION 231 4 9 5 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION Only for machines in which synthetic bio...

Страница 23: ...TACHMENT GUIDE 265 6 3 1 COMBINATIONS OF WORK EQUIPMENT 265 6 3 2 ATTACHMENT CONFIGURATION 265 6 4 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 267 6 4 1 POSITION OF THE DEVICES 267 6 4 2...

Страница 24: ...22 PAGE INTENTIONALLY LEFT BLANK...

Страница 25: ...SAFETY AND ACCIDENT PREVENTION 23...

Страница 26: ...n them with a solution made of water and detergent Do not use fuel petrol or solvents q If the plates are damaged ask for new ones to Komatsu or to your Komatsu Distributor q In case of replacement of...

Страница 27: ...ist illustrates what they look like and their respective meanings 1 CONSULT THE MANUAL q Carefully read the contents of the manual before using the ma chine or performing maintenance operations 2 SAFE...

Страница 28: ...nt when it is lifted and under load 6 RISK OF BURNS q Do not open the radiator and the hydraulic oil tank when the en gine is still hot Cable voltage Min safety dis tance 1 0 kV distribution line 5 m...

Страница 29: ...ment of the tracks involves the risk of injuries q Read manual regarding adjusting track for safe and proper han dling 9 DO NOT OPEN THE ENGINE HOOD q Do not open or remove the hood when the engine is...

Страница 30: ...ger of crushing 13 LATERAL STABILITY q When the gauge is fully retracted the lateral stability is reduced In jobsites where there is danger of the machine turning over extend the gauge and be extremel...

Страница 31: ...he starter motor by tampering with the starter motor terminals 18 THE LOCK IS OPERATED WITH THE LOCK LEVER 19 PRECAUTIONS WITH THE KOMTRAX SYSTEM q The signal indicates danger of explosion caused by a...

Страница 32: ...S 30 WEAM012101 CAUTION WHEN HANDLING BATTERIES q Never smoke or use any naked flame near the batteries no sparks q Always wear safety glasses when working with batteries q Keep children away from bat...

Страница 33: ...Read the operator s manual before working with batteries q Caution explosive gases HYDRAULIC OIL TOPPING UP q Only for machines in which synthetic biodegradable oil type HEES is used HYDRAULIC OIL TO...

Страница 34: ...R FUEL FILTER AF NAC ENGINE COOLANT q Fill Komatsu genuine engine coolant AF NAC to prevent radia tor damage by corrosion HYDRAULIC OIL TOPPING UP REFUELLING 22F 98 33640 RKA29000 6217 71 6860 RKA2996...

Страница 35: ...PLATES WEAM012101 33 ENGINE OIL FILTER FUEL FILTER ENGINE AIR INTAKE FILTER ENGINE COOLANT ENGINE COOLANT PRESSURE 21D 98 11190 RKA29770 21D 98 11170 RKA29780 21D 98 11180 RKA30000 21L 09 R4170 RKA29...

Страница 36: ...PLATES 34 WEAM012101 HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER POWER OUTLET ANCHORAGE POINT LIFTING POINT 21D 98 12030 RKA29800 21D 98 12050 RKA29810 21D 98 12040 RKA30060 12 V 21D 98 11860 RKA28810 RK...

Страница 37: ...CAPACITIES RKA25920 L W A B 22J 98 25721 2m 1m 0 1m 0 L 965mm L 1215mm A B 2m 3m MAX W 400mm kg 23 235kg 135kg 215kg 265kg 420kg 140kg 230kg 110kg 185kg 240kg 395kg 135kg 220kg 115kg 190kg 245kg 400k...

Страница 38: ...oise plate make sure that such a plate is applied also to the new part EXTERNAL NOISE q Sound power level emitted by the machine measured accord ing to ISO 6395 Dynamic test method simulated working c...

Страница 39: ...se plate make sure that such a plate is applied also to the new part EXTERNAL NOISE q Sound power level emitted by the machine measured accord ing to ISO 6395 Dynamic test method simulated working cy...

Страница 40: ...1 Use the correct equipment and attachments 2 Maintain the machine according to this manual Tension of crawler for crawler machines Brake and steering systems Controls hydraulic system and linkages 3...

Страница 41: ...uidelines can be effective to minimize risks of low back pain Operate the machine only when you are in good health Provide breaks to reduce long periods of sitting in the same posture Do not jump down...

Страница 42: ...or remove the guards when the engine is running q Always use the proper safety devices to lock the machine when parking and use the seat belt correctly q Do not remove the safety devices and always ke...

Страница 43: ...en if temporarily make sure that the machine is in a safe position See 2 4 14 PARKING THE MACHINE q Before leaving the operator seat carry out the following opera tions in the sequence indicated below...

Страница 44: ...n the ground 2 2 8 GETTING ON AND OFF THE MACHINE q Do not jump on or off the machine neither when it is at rest nor when it is moving q When getting on or off the machine always use the handles and t...

Страница 45: ...TING FIRES DUE TO FUEL AND OIL Fuel oil and some types of antifreeze can easily ignite if they get in contact with a flame Fuel is flammable and therefore very dan gerous q Keep any naked flame away f...

Страница 46: ...or inside the lower housing panels q To prevent ignition caused by sparks released by other sources of flame remove ant inflammable material such as dry leaves detritus pieces of paper soot etc accum...

Страница 47: ...when the arms are lifted if you are not sure that the safety locks have been duly engaged q Do not carry out any operation requiring the arms to be lifted if you are not sure that the locks are correc...

Страница 48: ...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 that must be guaranteed to the operator Contact Komat...

Страница 49: ...il the end of the operations Be careful not to sever or damage any of these lines q Check the depth and flow of water before operating in water or on river banks 2 3 2 FIRE PREVENTION q Completely rem...

Страница 50: ...INDOWS q If a cab window breaks on the side facing the work equipment this may hit the operator Therefore it is advisa ble to stop the machine immediately and to replace the broken glass q Check the l...

Страница 51: ...he engine only while seated with fastened seat belt q Do not allow anyone to get on the machine q Make sure that the platform fastening screws 1 are well tight ened Incorrect tightening of the cab flo...

Страница 52: ...thin his field of vision and follow all his sig nals The use of hand signals serves to direct the lifting handling and positioning of the loads lifted by the work equip ment Hand signals can also be u...

Страница 53: ...al position and closed fin gers point the thumb upwards 6 LOWER THE BOOM With an arm extended in horizontal position and closed fin gers point the thumb downwards 7 SWING THE BOOM With an arm extended...

Страница 54: ...thumb pointed towards the open hand 13 TRAVEL WHILE STEERING Lift the forearm corresponding to the inner steering side with clenched fist Rotate the other fist vertically indicating the wheel s turnin...

Страница 55: ...MENTS SLOWLY One hand still in front of the hand that indicates the move ment to be carried out The figure represents the lift slowly control 19 STOP With one arm extended laterally open the hand faci...

Страница 56: ...sible to evaluate more precisely the space required for the movements and at the same time ensures the stability of the machine q Make sure that the driver seat is directed towards the blade Otherwise...

Страница 57: ...d When travelling downhill position the machine with the revolv ing frame rotated by 180 so that the sprocket 1 and the boom are in travelling direction as shown in the figure and proceed at low speed...

Страница 58: ...in such a way as to create a horizontal platform on which the ma chine can be positioned 2 4 8 UNAUTHORIZED OPERATIONS q It is dangerous to use the bucket or lift arm for crane operations so do not c...

Страница 59: ...efore starting work In fact the buildings may collapse and cause serious injury or damag es q When carrying out demolition work do not position the machine under the structure being demolished since b...

Страница 60: ...accident prevention rules in force q As far as underground long distance lines are concerned the minimum distance depends on the covering of the ducts in which the cables are laid q The basic safety...

Страница 61: ...d heavily the road shoulders and any obstacle are buried in the snow and are not visible therefore proceed with care when clearing the snow 2 4 12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT q When...

Страница 62: ...ground 2 Stop the engine 3 Put wedges or safety blocks under the tracks q Always lower the work equipment to the ground if it is neces sary to park with raised arms make sure that the safety locks ar...

Страница 63: ...the ramps with a maximum inclination of 15 q Make sure that the surface of the ramps is clean and there is no trace of grease oil soil or ice remove dirt from the tracks be fore loading the machine on...

Страница 64: ...ation on the battery or before disconnecting the cables stop the engine wait at least one minute and after wards turn the battery main switch to OFF and extract the spe cific key q When disconnecting...

Страница 65: ...g the booster cables make sure to connect the positive cable first and then the negative or earth cable After the start disconnect first the negative or earth cable and then the positive cable q Conne...

Страница 66: ...tride the cable q Move the machine only as far as necessary to allow the re quired repairs to be carried out q Put wooden blocks between the towing cable and the machine body in order to avoid wear or...

Страница 67: ...the machine and high quality tools suitable for the tasks to be performed q Do not use worn damaged low quality tools or tools that are not suitable for the tasks to be performed in order to avoid an...

Страница 68: ...e scattered tools 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 q To clean the machine use a pressurized jet...

Страница 69: ...onents like pipes and belts must be periodically changed For the replacement of the parts that are critical for safety see 4 7 PERIODICAL CHANGE OF SAFETY RE LATED COMPONENTS q The material used for m...

Страница 70: ...used during the operation must be agreed upon in advance q The person who carries out the maintenance operation must be very careful not to touch any moving part of the engine 2 8 12 BATTERY MAIN SWIT...

Страница 71: ...t open the platform when the machine is on a slope or if there is strong wind This may cause serious personal injuries q Do not open or close the platform with the engine running or if the safety devi...

Страница 72: ...lling hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sparks due to static electricity q Do not fill the tank completely in order t...

Страница 73: ...tch if in stalled q If electric welds are necessary for the machine besides discon necting the battery disconnect the alternator and the KOM TRAX system control unit 2 8 18 PRECAUTIONS CONCERNING THE...

Страница 74: ...nt in the tank Small leakages from pipes under pressure and the resulting jets are extremely dangerous since they can perforate the skin and penetrate in the blood circulation or injure the eyes For t...

Страница 75: ...m pacts of the front idler roller Do not attempt to remove the spring since this may lead to serious accidents and even death For any operation on the shock absorber unit contact your Komatsu Distribu...

Страница 76: ...y precautions should be taken If any doubt exists contact your Komatsu distributor See also disposal of 2 8 27 WASTE MATERIALS 2 8 27 WASTE MATERIALS q Do not dispose of used oil in the sewer system r...

Страница 77: ...diately rinse with a solu tion made of water and an alkaline detergent for about 30 min utes and then contact a poisoning treatment center without delay 2 8 30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTH...

Страница 78: ...76 PAGE INTENTIONALLY LEFT BLANK...

Страница 79: ...THE MACHINE AND ITS OPERATIONS 77...

Страница 80: ...AM012101 3 1 MACHINE ILLUSTRATIONS 3 1 1 OVERALL VIEW OF THE MACHINE RKA22480 1 Bucket 7 Track 2 Bucket cylinder 8 Sprocket 3 Arm 9 Undercarriage 4 Arm cylinder 10 Idler roller 5 Boom 11 Blade cylinde...

Страница 81: ...warning light optional 6 Left work equipment control lever 20 Engine oil pressure warning light 7 Travel levers 21 Battery charge level warning light 8 Boom swing control pedal 22 Travel speed increa...

Страница 82: ...ices 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 th...

Страница 83: ...function comes on and the acoustic alarm starts sounding Carry out the necessary re pairs immediately 1 Engine oil pressure warning light This warning light comes on together with the acoustic alarm...

Страница 84: ...es out when the en gine exceeds the idling speed if this warning light remains on even when the engine is running at the normal operating speed this means that the alternator is not working and the ba...

Страница 85: ...xceeds 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 ove...

Страница 86: ...nks NOTE q If the indicator reaches the red reserve area A during use stop the machine and provide for refuelling 3 Hour meter This instrument indicates the total number of operating hours of the engi...

Страница 87: ...increase warning light This warning light comes on when the travel speed selection switch is in high speed position see 3 2 2 pos 4 Travel speed selection switch When the selector switch is in normal...

Страница 88: ...ion switch 6 Windshield wiper switch machines with cab 2 Horn 7 Ventilation and heating switch machines with cab 3 Working lights switch 8 Overhead light machines with cab 4 Travel speed selection swi...

Страница 89: ...When starting the engine in cold weather turn the key to posi tion HEAT for approximately 18 seconds until the correspond ing warning light goes out Release the key which will automatically return to...

Страница 90: ...lever knob centre and is used to select the translation speed Each time the switch is pressed the translation speed shifts from high to low or vice ver sa When high speed is selected the speed increas...

Страница 91: ...ays widen the track gauge and pay the utmost attention during travel q The control of the scraper and the adjustable track is not locked even if the safety device lever is in locking position Therefor...

Страница 92: ...wing Do not keep the switch pressed in spraying position for more than 10 consecutive seconds Do not press the switch to spray detergent if the reservoir is empty 7 Overhead light switch machines with...

Страница 93: ...before starting the engine IMPORTANT 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...

Страница 94: ...7 Boom swing control pedal locking device 2 Left work equipment control lever 8 Boom swing control pedal 3 Right work equipment control lever 9 Cab floor locking lever 4 Accelerator lever 10 Control...

Страница 95: ...le track is not locked q When shifting the safety lever take care to avoid touching the equipment control levers The lever activates the safety device to lock the working tools rotation travel and acc...

Страница 96: ...When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety lever control locking lever A Version with canopy B Version with cab The control lever 2 is posi...

Страница 97: ...ks slightly raised from the ground in order to avoid damaging the tracks and the hydraulic motors q This lever is not locked even if the safety device lever is in locking position Therefore do not tou...

Страница 98: ...d by 180 the controls are inverted see 3 3 4 HOW TO MOVE THE MACHINE e 3 3 5 STEERING THE MACHINE q Non compliance with these rules may lead to serious acci dents These levers are used to operate the...

Страница 99: ...When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety lever control locking lever q The boom swing is useful to displace the digging line be yond the t...

Страница 100: ...s inadvertently pressed this may cause serious accidents The safety device is used to lock the optional equipment control pedal 11 Optional equipment control pedal The pedal controls oil delivery to a...

Страница 101: ...2 4 1 WINDSCREEN machines with cab WARNING q When the upper windscreen or the cab door is opened or closed always take the safety device lever to the locking position L If the control levers are not...

Страница 102: ...at the right or left top of the front wind screen and push the locking levers B down to release the windscreen 5 Seize the handles C and D pull up the windscreen and push it until the lock E is tripp...

Страница 103: ...ground then stop the engine 2 Shift the safety lever to the locked position 3 Release the windscreen by means of the upper lock E le ver 4 Seize the handles C and D push the windscreen forwards and l...

Страница 104: ...on a slope the operating ef fort may change suddenly Do not open or close the door on slopes q Be careful to your hands in order to prevent them from be ing caught between the door and the front or c...

Страница 105: ...lose the window release and draw the handle 1 to slide the window 3 2 4 4 EMERGENCY EXIT HAMMER machines with cab WARNING q When it is necessary to break the window with the hammer pay attention not t...

Страница 106: ...E MACHINE Introduce the key completely 6 mm from the point where the key narrows then turn it If the key is turned when it is inserted only partially into the lock it may break LOCKED COVERS AND CAB D...

Страница 107: ...etely and make sure that it is kept open by the apposite rod q Non compliance with these rules may lead to serious accidents IMPORTANT q If it is not necessary to open the cover always keep it locked...

Страница 108: ...hat it is kept open by the apposite rod OPENING THE BATTERY COVER 1 Release the radiator cover lock 1 see 3 2 5 COVERS WITH LOCK 2 Pull the radiator cover 2 and open it completely The cover 2 is kept...

Страница 109: ...t it is kept open by the apposite rod OPENING THE BATTERY COVER 1 Release the battery cover lock 1 see 3 2 5 COVERS WITH LOCK 2 Pull the battery cover 2 and open it completely The cover 2 is kept open...

Страница 110: ...s attach the safety stop q Do not carry out any operation on the machine without having first attach the safety stop q If there is something wrong in the locking function when the cab floor is tilted...

Страница 111: ...the screws 4 fastening the roof to the rear ballast 8 Lift the mat 5 pull the release lever 6 in the direction indi cated by the arrow and simultaneously push the platform 7 upward in the direction in...

Страница 112: ...s inserted in the groove 10 of the locking plate 9 10 Insert the safety pin 11 into the hole 12 from the outside 11 Turn until the coupling at the end of the safety pin 11 is completely engaged with t...

Страница 113: ...e direction indicated by the arrow and simultaneously pull the platform 7 downward in the direction indicated by the arrow by approx 45 IMPORTANT q Lower the cab floor slowly and make sure that the wi...

Страница 114: ...he boom slowly 3 Shift the safety lever 1 to the locked position L then stop the engine 4 Position blocks under the tracks in order to prevent the ma chine from moving 5 Open the engine hood 2 complet...

Страница 115: ...b floor be extremely careful and keep away from the area under the cab floor NOTE q The cab floor tilts thanks to the operation of a gas cylinder so when the ambient temperature is low the operating e...

Страница 116: ...the same time 2 Pull the cab floor release lever 5 in the direction shown by the arrow and at the same time pull the handle 6 down wards in the direction indicated by the arrow approximately 45 IMPORT...

Страница 117: ...switch key q If the fuses are oxidized corroded or do not fit perfectly in their seat replace them only with new fuses having the same capacity The fuses are bundled on a unique base placed inside th...

Страница 118: ...check the fuse and replace if necessary The mains fuse 45A is located above the battery For instructions for opening and closing the battery cover see 3 2 8 BATTERY COVER NOTE q The main fuse is the...

Страница 119: ...accompany it even in case of resale The use and maintenance manual must be stored with care and always kept on board the machine so that it can be consulted at any moment it must be placed in the tech...

Страница 120: ...out this check with the machine parked on level ground If the machine is inclined position it horizontally before carrying out the check Carry out the following inspection and cleaning operations eve...

Страница 121: ...loosened bolt 8 Make sure that there are no faults in the gauges and the warning lights If any anomaly is observed provide for the necessary repairs Clean any dirty surface 9 Check the seat belt and t...

Страница 122: ...Removing the cap in these conditions to check the coolant level may cause a burn hazard Before removing the cap wait until temperature is reduced and loosen the cap slowly to release the remaining pre...

Страница 123: ...d before checking the engine oil level wait approximately 15 minutes in order to allow the engine to cool down 1 Open the engine hood For details see paragraph 3 2 6 EN GINE HOOD 2 Remove the dipstick...

Страница 124: ...on the fuel gauge 2 If the fuel level is low open the engine hood 3 for details see 3 2 6 EN GINE HOOD remove the cap and refuel through the filler F While refuelling check the fuel level on the sigh...

Страница 125: ...e sure that the oil level is included between the H and L marks on the sight gauge G IMPORTANT q Do not exceed the max level mark H This would damage the hydraulic circuit and cause the oil to overflo...

Страница 126: ...ob served thoroughly check the hydraulic circuit the pistons and the pump for leaks CHECKING THE AIR FILTER CLOGGING INDICATOR 1 Open the engine hood For further details see paragraph 3 2 6 ENGINE HO...

Страница 127: ...t means that there is water up to the ring low er surface therefore it is necessary to drain water following the procedure below 1 Open the radiator cover For details see paragraph 3 2 7 RADIATOR COVE...

Страница 128: ...ke sure that the charge level warning light is always visi ble Make sure that the fuses are not damaged that fuses with the required capacity are used that there are no dis connected broken or short c...

Страница 129: ...arried out For example when it is necessary to carry out deep digging operations make the seat slide forward in order to in crease visibility on the area in front of the machine B Inclination Pull the...

Страница 130: ...f the machine incautious people who may have entered into the working zone may be run down or fixed obstacles or motor vehicles may be crashed during operation q If rear view mirrors shall be moved or...

Страница 131: ...se If necessary apply a tightening torque of 24 5 4 9 Nm 2 5 0 5 kgfm If the surface of the belt is damaged or if the couplings are broken or deformed change the belt assembly Fastening and unfastenin...

Страница 132: ...arning lights are on for about 3 seconds q Pre heating warning light 3 q Battery charge level warning light 4 q Engine oil low pressure warning light 5 q Electrical system control warning light 6 opti...

Страница 133: ...the light switch 10 and ensure that the working headlamp switches on If it does not turn on contact a Ko matsu Distributor who will carry out all the necessary re pair operations 3 Press the horn but...

Страница 134: ...tarting the engine make sure that there is no one within the operating range of the machine and sound the horn q Exhaust gas is toxic When starting the engine in closed places make sure that there is...

Страница 135: ...gine only while seated with fastened seat belt q Before 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...

Страница 136: ...t the preheat warning light 4 is on After about 18 seconds once the preheating is complete the warning light 4 turns off and the sound alarm goes on 4 When the preheating warning light 4 goes out turn...

Страница 137: ...elerations unnecessary sudden stops and sudden changes in direction 3 3 2 2 ENGINE STARTING CAPACITY AND NOISE LEVEL CHECK When the engine is started check that this does not cause abnormal noise and...

Страница 138: ...let the engine idle accelerate every now and then or increase the speed up to an intermediate value After starting the engine let it warm up before starting work Carry out the operations and checks in...

Страница 139: ...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 or vibrations If any anomaly is observed contact your Komatsu D...

Страница 140: ...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 in order to allow it to c...

Страница 141: ...emely careful when reversing and make sure that there are no persons other equipment or ob stacles in the way q Avoid any travel manoeuvre or change of direction with the accelerator at maximum speed...

Страница 142: ...ersa takes place whenever the switch is pressed q When the machine is travelling at high speed the travel speed increase warning light 5 comes on For details on the travel speed see paragraph 5 1 TECH...

Страница 143: ...ear of the machine pull the levers 3 slowly backward to start moving in reverse q When the sprocket A is at the front of the machine push the levers 3 slowly forward to start moving in reverse 4 Chang...

Страница 144: ...oad increases the low speed is automatically se lected but the travel speed increase warning light remains on When the load is reduced the travel system automatically changes over to high speed 5 On m...

Страница 145: ...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 directi...

Страница 146: ...ft forward steering B Left reverse steering NOTE q To steer to the right operate the right travel lever in the same way HOW TO CARRY OUT COUNTER ROTATIONS SPIN TURN To carry out a counter rotation to...

Страница 147: ...tral position N With the lever in this position the swing lock is automatically engaged A Swing to the left b Swing to the right NOTE q When the revolving frame swing function is used on a slope let t...

Страница 148: ...ly return to the neutral position and the work equipment remain in the position where they stopped The movements of the levers and the corresponding movements of the equipment are shown in the diagram...

Страница 149: ...r control is not locked even if the safety device lever is in locking position Therefore do not touch the control lever if no operations are being carried out with the scraper q Select the use of the...

Страница 150: ...er if no operations are being carried out with the adjustable track q Before using the blade adjustable track gauge lever check the position of the switch q Set the blade adjustable track gauge switch...

Страница 151: ...E MACHINE Do not dig the bucket into the ground and do not use the travel force to carry out digging operations This may damage the ma chine or the work equipment q PRECAUTIONS WHEN USING HYDRAULIC CY...

Страница 152: ...T IS NOT ALLOWED TO EX PLOIT THE FORCE OF GRAVITY OF THE MACHINE Do not use the force of gravity of the machine to carry out dig ging operations When working on hard rocky surfaces use some other meth...

Страница 153: ...so that the obstacle is positioned in line with the mid point of the track gauge q FOLDING THE WORK EQUIPMENT When folding the work equipment to the travel or transport posi tion be careful to preven...

Страница 154: ...revolving frame will be submerged and this may cause the cooling fan to break Be extremely careful when driving the machine out of wa ter Do not immerse the machine in water beyond the permissible dep...

Страница 155: ...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 direction on slopes side mo...

Страница 156: ...ine 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 TO BE TAKEN ON S...

Страница 157: ...sh with the bucket teeth The angle between the boom and the arm should be included between 90 and 110 When only one side gets stuck in mud use the bucket to raise the track then lay boards or logs und...

Страница 158: ...positions available for digging with the arm range from a 45 angle away from the machine to a 30 angle towards the ma chine There may be some differences depending on the digging depth but it is advi...

Страница 159: ...157 FILLING LEVELLING OPERATIONS Use the blade to refill after excavation or to level the ground sur face SIDE DITCHING WORK The machine can be used for side ditching in confined spaces by combining...

Страница 160: ...hat you do not place your feet below the bucket while you stand next to the machine to carry out the job q Avoid using your fingers to align the holes since they may be cut off in case of sudden or un...

Страница 161: ...he 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 cau...

Страница 162: ...e in the indicator 1 the engine oil pressure warning light 2 and the fuel level in the indicator 3 3 3 16 CHECKS TO BE CARRIED OUT AFTER WORK 1 Walk around the machine check the work equipment the out...

Страница 163: ...k the following parts 1 Engine hood 2 Tank cover 3 Battery cover 4 Document and tool compartment cover 5 Cab door machines with cab Always close the windows For further details see paragraph 3 2 5 COV...

Страница 164: ...not be used in working places where they may get damaged for example steel plate corners or edges U shaped grooves attachment fittings pointed stones or crushed rocks steel rods or iron scraps The wa...

Страница 165: ...when crushed soya seeds corn remaining vegeta bles etc If the machine is used for transporting such products wash it after use q Do not transport materials that can corrode the steel core such as sal...

Страница 166: ...this is absolutely necessary carry out the manoeuvre grad ually 3 Avoid traveling along the edge of slopes or on rough ground with one track raised machine inclination exceeding 10 and with the other...

Страница 167: ...rack may come off 6 Furthermore if the machine travels in reverse a gap is formed between the carrier roller the idler roller and the track q When turning in a condition where the rubber track cannot...

Страница 168: ...E AND RELATED CONTROLS 166 WEAM012101 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 off...

Страница 169: ...en using piled soil compact it to prevent the inclined surface from collapsing q Before loading the machine remove any trace of mud and dirt from the tracks in such a way as to prevent the ma chine fr...

Страница 170: ...dge of the road 2 Operate the trailer brake and fit chocks 1 under the wheels to prevent the trailer from moving Fit the ramps 2 with a maximum gradient of 15 3 and spaced equally from both sides of t...

Страница 171: ...e ramps and that the centerline of the machine corresponds to the centerline of the trailer The machine must move slowly and its travelling direction must correspond to the direction of the ramps Lowe...

Страница 172: ...engine and remove the ignition key 4 Shift the safety lever 1 to the locked position L 5 Lock the cab door and cases with lock see section 3 2 5 COVERS WITH LOCK IMPORTANT q Do not use the hole in the...

Страница 173: ...trailer from moving Fit the ramps 2 with a maximum gradient of 15 3 and spaced equally from both sides of the trailer 3 Remove the chains and the metal cables with which the machine has been secured 4...

Страница 174: ...de 9 Raise the work equipment make sure that the travelling di rection of the machine corresponds to the direction of the ramps and proceed slowly Lower the work equipment as much possible without cau...

Страница 175: ...q It is prohibited to lift the machine using the holes provided in the undercarriage since these must be used only for transporting the machine This would damage the under carriage IMPORTANT q For det...

Страница 176: ...he machine If the machine is fitted with cab close the door and the front windscreen 7 Shift the extended portion of the blade to the narrow position install shackles in the lifting holes 2 points on...

Страница 177: ...Pay attention to the pipes and take care that they do not get caught 10 Lift the machine slowly until the ropes are stretched and make sure that the fastenings are correct before lifting the machine...

Страница 178: ...r carry out operations with coolant containing antifreeze fluid drained during ra diator repair please contact your Komatsu Distributor or a company specialised in this kind of opera tion Antifreeze f...

Страница 179: ...city of the battery decreases accordingly If the battery charge is low the electrolyte may freeze Keep the battery charge level as high as possible and insulate the battery against excessively low tem...

Страница 180: ...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 re ceives the hot water necessary for exchange heat directly from the e...

Страница 181: ...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...

Страница 182: ...raulic cylinder piston rod with grease q After shutting off the engine wait over one minute then turn the battery disconnect switch to the OFF position and take out the battery disconnect switch key P...

Страница 183: ...e of trichloroethylene may damage the tank 3 6 4 RECOMMENDATIONS FOR MACHINES EQUIPPED WITH KOMTRAX SYSTEM DURING LONG PERIODS OF INACTIVITY Even if the starter key is turned to OFF the KOMTRAX system...

Страница 184: ...with no load the bucket speed drops momentarily according to the more or less horizontal position of the bucket teeth q When the swing is operated or locked the brake valve emits a noise q When the m...

Страница 185: ...s hydrogen which may explode Do not smoke and avoid producing sparks near the battery q The battery electrolyte is made of diluted sulphuric acid that may corrode clothes and even the skin in case of...

Страница 186: ...d as indicated below q During recharge the battery produces hydrogen which is flam mable and may explode therefore for this operation it is neces sary to remove the battery from the machine position i...

Страница 187: ...con nect the cable as far from the battery as possible In any case avoid the attachments since they are poor conduc tors q When removing the booster cables take care to avoid any contact of the clamp...

Страница 188: ...hine to be started STARTING THE ENGINE CAUTION q Make sure that the safety levers 1 of both machines are in the locked position L Also make sure that all the con trol levers are in NEUTRAL 1 Make sure...

Страница 189: ...engine running Faulty alternator Faulty cables Change Check and repair Alternator emits abnormal noise Faulty alternator Change Starter does not turn with ignition switch in position ON Faulty cables...

Страница 190: ...joints Engine oil pressure sensor faulty Restore level See CHECKS TO BE CARRIED OUT BEFORE START ING THE ENGINE Replace cartridge See Every 500 hours OF OPERATION Check and repair Change Steam comes...

Страница 191: ...YSTEM Adjust valve clearance Exhaust gases white or light blue Too much oil in oil pan Unsuitable fuel Restore level See CHECKS TO BE CARRIED OUT BEFORE START ING THE ENGINE Change with fuel in compli...

Страница 192: ...190 PAGE INTENTIONALLY LEFT BLANK...

Страница 193: ...MAINTENANCE 191...

Страница 194: ...e oil and grease containers clean and prevent any foreign matter from get ting into them q Keep the machine thoroughly clean this facilitates troubleshooting In particular grease nozzles breather hole...

Страница 195: ...ic therefore avoid using trichloroethylene to clean it Trichloroethylene reduces the resistance and duration of the tank q Before starting work on muddy ground under rain or snow on seashores or river...

Страница 196: ...lution of the oil 3 periodical change q When changing the oil change also the filters q It is advisable to have the oil periodically analysed in order to check the conditions of the machine The analys...

Страница 197: ...ntifreeze is flammable do not use naked flames near the coolant and do not smoke while topping up q Use only Komatsu original permanent antifreeze coolant AF NAC an ethylene glycol based solution with...

Страница 198: ...ful and allows customers to save money and avoid many problems KOWA ANALYSIS STAGES q Analysis of metal particles In this stage a ICP Inductively Coupled Plasma analyser is used to measure the density...

Страница 199: ...q Filters are very important components for safety They prevent any impurities from getting into the oil fuel or in the air circuits thus avoiding problems to important components of the machine Peri...

Страница 200: ...oon after work the oil is very hot The circuit is pressurized not only during work but also at the end of work q The maintenance operations required for the hydraulic system are the following 1 Daily...

Страница 201: ...advisable to indicate also the machine serial number to the Komatsu Distributor in order to receive the most updated version of the component required 4 3 1 LIST OF THE PARTS SUBJECT TO WEAR The parts...

Страница 202: ...e transmissions cooling circuit and or other components q Lubricant additives available in the market may work but they may also damage the machine Komatsu recom mends any additive for lubricants norm...

Страница 203: ...OLIN HLP SYNTH 46 Articulation greasing Grease super white Note 2 G2 T G2 TE Grease EP lithium based G2 LI Engine cooling system Supercoolant AF NAC Note 3 AF NAC Fuel tank Fuel oil Note 4 ASTM No 2 D...

Страница 204: ...problem it is essential to use of an antifreeze coolant All Komatsu equipment are supplied with Komatsu Supercoolant coolant AF NAC Komatsu Supercoolant coolant AF NAC has excellent anticorrosive ant...

Страница 205: ...s missions the braking system etc q Before introducing the biodegradable oil in the hydraulic system empty the system completely discon necting the cylinders and all the parts that may contain ordinar...

Страница 206: ...tightening torque table is not valid for screws or nuts that must fasten parts made of nylon or simi lar materials onto washers or components made of nylon or nonferrous metals or requiring specific t...

Страница 207: ...the table If it is necessary to replace a hose always use Komatsu original spare parts having the same size of the part to be replaced a Nm Newton metre 1 Nm 0 102 kgm Thread diameter a Wrench size b...

Страница 208: ...ype of lubricant to be used is indicated in the lubricant table see 4 4 FUEL COOLANT AND LUBRI CANTS Grease Z Z Z Z Y Y Y Y PC18MR 3 PC18MR 3 22J 98 35910 2000h 1000h 500h 100h 10h RKA30750 Fuel filte...

Страница 209: ...t elapsed 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...

Страница 210: ...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 Hydraulic pipe...

Страница 211: ...NDSCREEN WIPER BLADE machines with cab 229 m BLEEDING THE HYDRAULIC SYSTEM 229 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION Only for machines i...

Страница 212: ...NG THE ENGINE VALVE CLEARANCE 242 MAINTENANCE EVERY 1500 HOURS OF OPERATION a FUEL INJECTION SYSTEM CHECK AND CLEANING 243 MAINTENANCE EVERY 2000 HOURS OF OPERATION a CHANGING THE OIL IN THE HYDRAULIC...

Страница 213: ...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 Demolition hammer use pe...

Страница 214: ...tails see para graph 3 2 6 ENGINE HOOD 2 If the red piston of the filter clogging indicator 1 is visible clean the air filter cartridge IMPORTANT q Do not clean the cartridge if the red piston of the...

Страница 215: ...tridge 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 th...

Страница 216: ...her holes are not clogged q Restore the level adding only distilled water If the level is low because the liquid has spilled add sul phuric acid diluted until the concentration suitable for the room t...

Страница 217: ...r see 3 2 8 BATTERY COVER 2 Remove the plug 1 of the battery look through the filler opening 2 and check the electrolyte surface If the electro lyte does not reach the sleeve 3 add distilled water unt...

Страница 218: ...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 element 5 with diesel or flushing oil 5 After washing...

Страница 219: ...e tank must be drained before refuelling q Never use trichloroethylene to wash the inside of the tank Use exclusively diesel oil 4 9 1 e CHECKING AND ADJUSTING THE STEEL TRACK TENSION The pins and bus...

Страница 220: ...contact your Komatsu Distributor WARNING q If the resistance met when injecting the grease is excessive move the machine forward and backward covering a short distance INCREASING THE TRACK TENSION 1 C...

Страница 221: ...tance 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 IMPORTANT q The degree of wear of pins and...

Страница 222: ...s 1 When the height A of the rubber claw is less than 5 mm in this case in fact the track may slip and its traction force be reduced 1 Roller 2 Rubber track 2 When the steel core is visible in two or...

Страница 223: ...he track tension is such that the track may come off its seat the track may be lengthened and the track tensioner cylinder damaged 6 If the broken area between the rubber track claws reaches a length...

Страница 224: ...e machine forward of a distance corresponding to the length of the track on the ground then lower the equipment to the ground and stop the engine 2 Choose a perfectly flat rod 3 long enough to cover t...

Страница 225: ...our Komatsu Distributor who will provide for the necessary repairs 1 Gradually loosen the grease valve 1 to let the grease out do not give the valve more than one turn 2 If the grease does not come ou...

Страница 226: ...shock absorber adjusted This operation can be performed only by specialized personnel at any Komatsu Distributor REMOVING THE RUBBER TRACK DANGER q The grease contained in the hydraulic cylinder is pr...

Страница 227: ...ly 2 Gradually loosen the grease valve 1 to let the grease out do not give the valve more than one turn 3 If the grease does not come out smoothly move the machine slowly forward and backward covering...

Страница 228: ...cks 3 Turn the sprocket as if in reverse then push the track to wards the revolving frame 4 Using a steel tube position the track and turn the sprocket again 5 Make sure that the track is correctly in...

Страница 229: ...e reservoir IMPORTANT q 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...

Страница 230: ...k during the cleaning operations The air suction for the ventilation of the cab is protected by a filter positioned on the right side of the cab This filter blocks all the impurities contained in the...

Страница 231: ...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 gaskets 1 Run the engine at idle ext...

Страница 232: ...ck the coolant level 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...

Страница 233: ...tion LUBRICATING THE COMPONENTS OF THE SWING SYSTEM NOTE q When grease is injected to lubricate the swing pinion and fifth wheel turn the revolving frame slowly to change the position for greasing 1 C...

Страница 234: ...linder rod end 1 point 5 Link connection pin 1 point 6 Boom swing bracket pin 2 point 7 Boom base pin 1 point 8 Boom cylinder base pin 1 point 9 Boom cylinder rod end 1 point 10 Boom cylinder base pin...

Страница 235: ...synthetic biodegradable oil type 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...

Страница 236: ...e 3 2 6 ENGINE HOOD 2 Remove the drain plug P of the engine oil pan gathering the used oil that flows out of it into a container with suitable capacity While the oil flows out remove the filler cap F...

Страница 237: ...OOD 2 Place a container under the filter to collect any spilt fuel 3 Turn the valve 1 of the filter to the closed position A 4 Using a filter wrench loosen the metal ring of the filter and remove the...

Страница 238: ...roximately 10 15 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 IMPORTANT q If the engine starts regularly an...

Страница 239: ...ied out on each reduction gear with the drain plug P in low position and perpendicular to the ground If necessary move the machine slightly until reach ing the specified position which is indispensabl...

Страница 240: ...ing cycle the specific products available on the market can be used provided that the instructions giv en on the package are followed and that the washed parts are carefully dried IMPORTANT q Do not u...

Страница 241: ...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 this value adjust by proceeding as indicated below IMPORTANT q Guar...

Страница 242: ...dis posed of according to the regulations in force 1 Turn the revolving frame so that the lower part of the hydrau lic oil tank is not covered by the tracks 2 Retract the arm and bucket cylinders com...

Страница 243: ...ype HEES this must be changed for the first time after the first 50 hours of operation and successively every 1000 hours IMPORTANT q If the machine is equipped with demolition hammer the hydraulic oil...

Страница 244: ...rried out on each reduction gear with the machine parked on level ground and at a tem perature of 40 45 C so that the oil becomes fluid and can be drained easily which facilitates the elimination of a...

Страница 245: ...500 HOURS 4 9 8 a FUEL INJECTION SYSTEM CHECK AND CLEANING To obtain the best engine performance the fuel injection valves must operate perfectly Then it is necessary to carry out the fuel injection...

Страница 246: ...re carrying out this maintenance operation q Immediately clean any area dirty with oil q Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of ac...

Страница 247: ...e the suction pipe 4 and let the oil that is still in the tank flow out 10 Take out screws 5 and remove the flange with filter 6 11 Remove any dirt from the filter 6 then wash it with clean diesel oil...

Страница 248: ...ssurised If it is not pressu rised the pump will suck air affecting tool operation 15 Close the cab floor see 3 2 9 TILTING THE CAB FLOOR 16 Make sure that all the control levers are in neutral positi...

Страница 249: ...permanent coolant does not require any washing cycle for descaling the circuit 1 Remove the screws 1 and remove the radiator cap guard located on the right hand side of the machine 2 Open the engine h...

Страница 250: ...rd on the right hand side of the machine and close the covers 4 9 9 c CHECKING THE ALTERNATOR AND THE STARTER The brush may be worn or the bearing may be without grease Contact the Komatsu Distributor...

Страница 251: ...t 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 IMPORTANT q If the nitrogen loading pressur...

Страница 252: ...tool as extended as possible fully extend ed boom and bucket in discharge position and keep it 1 5 m A away from the ground Carry out the operations described in points 3 5 within 15 sec onds Pressur...

Страница 253: ...the tool 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 R...

Страница 254: ...END OF SERVICE LIFE 252 WEAM012101 4 10 END OF SERVICE LIFE For safe dismantling of the machine at end of service life please contact your local Komatsu Distributor...

Страница 255: ...TECHNICAL SPECIFICATIONS 253...

Страница 256: ...engine Engine power ISO 14396 2002 KW HP rpm 11 8 16 0 2600 A Total length mm 3650 B Total height Min Max With canopy mm 2320 With cab 2410 C Total width mm 980 1300 D Track width mm 230 E Swing radi...

Страница 257: ...x digging height With canopy mm 3615 With cab mm 3615 D Max vertical wall digging depth mm 1785 E Max dumping height With canopy mm 2610 With cab mm 2610 F Work equipment min swing radius mm 1670 Work...

Страница 258: ...ne 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 NOTE q The load does n...

Страница 259: ...1 136 412 102 338 84 0 5 m 752 188 531 134 386 101 345 94 1 0 m 635 193 446 137 342 116 1 5 m 394 203 309 174 STANDARD ARM 965mm STANDARD COUNTERWEIGHT RAISED BLADE WIDE TRACK GAUGE Unit kg 2 m 2 5 m...

Страница 260: ...174 412 133 338 111 0 5 m 752 238 531 173 386 132 345 123 1 0 m 635 243 446 176 342 149 1 5 m 394 253 309 219 STANDARD ARM 965 mm ADDITIONAL COUNTERWEIGHT RAISED BLADE WIDE TRACK GAUGE Unit kg 2 m 2 5...

Страница 261: ...300 71 0 5 m 783 183 543 131 403 98 306 77 1 0 m 704 185 493 131 350 99 310 93 1 5 m 535 192 357 137 301 127 LONG ARM 1215 mm STANDARD COUNTERWEIGHT RAISED BLADE WIDE TRACK GAUGE Unit kg 2 m 2 5 m 3...

Страница 262: ...96 0 5 m 783 233 543 169 403 129 306 104 1 0 m 704 235 493 170 350 130 310 122 1 5 m 535 242 357 176 301 162 LONG ARM 1215 mm ADDITIONAL COUNTERWEIGHT RAISED BLADE WIDE TRACK GAUGE Unit kg 2 m 2 5 m...

Страница 263: ...AUTHORISED OPTIONAL EQUIPMENT 261...

Страница 264: ...u thoroughly read and understand the in struction 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 attachme...

Страница 265: ...alculated 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 stopped in a...

Страница 266: ...d Service valve working pressure 1st attachment 23 MPa 230 bar q Optional Safety service valve working pressure 1st attachment MPa bar q Standard Service valve safety pressure 1st attachment 27 9 MPa...

Страница 267: ...prob lems with safety but may also have an adverse effect on the operation of the machine and the life of the equipment q Any injuries accidents or damage resulting from the use of unauthorized attach...

Страница 268: ...scription Category Weigth Working pressure Working flow Main dimension ISO capacity Lift capacity Height Width kg Mpa l min mm mm m3 kg 1 Core machine 1660 2 Work Equipment Boom 1760 mm Equipment 82 2...

Страница 269: ...OF ATTACHMENTS WEAM012101 267 6 4 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6 4 1 POSITION OF THE DEVICES RKA23120 1 2 Quick couplers Selection valve 3 4 Optional tools control pedal O...

Страница 270: ...pplications requiring the use of the generic equipment Spool A completely rotated clockwise Width across face of square portion of spool A 9 mm 3 Optional equipment control pedal The pedal 3 controls...

Страница 271: ...onnections by proceeding as follows 1 Stop the engine and move the hydraulic controls in all direc tions in order to release the residual pressures present in the circuits of the machine 2 Press the o...

Страница 272: ...n after starting the air sucked in by the cylinders may damage the piston gaskets 3 Slowly make all cylinders reach the end of stroke for 3 4 times 4 Press the optional equipment control pedal a dozen...

Страница 273: ...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 the accelerator almost...

Страница 274: ...t 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 han dling the equipment ca...

Страница 275: ...chine 6 6 1 PROCEDURE FOR MODIFYING CON TROL PATTERN 1 Park the machine on stable even ground set the safety de vice lever to the locked position and stop the engine 2 Open the cover on the right hand...

Страница 276: ...TH PATTERN CHANGE VALVE 274 WEAM012101 6 6 2 MACHINE CONTROL DIAGRAMS WARNING q After having changed the operation diagrams always re place the relevant card in the operator compartment q ISO PATTERN...

Страница 277: ...icated see 6 3 2 ATTACHMENT CONFIGURATION 6 7 1 HYDRAULIC BREAKER WARNING q The hydraulic breaker is very noisy therefore always wear ear muffs when using it MAIN APPLICATIONS q Crushing rocks q Demol...

Страница 278: ...g 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 and change p...

Страница 279: ...ing 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 breaker 2 Swinging the...

Страница 280: ...278 WEAM012101 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 c...

Страница 281: ...njected with the breaker 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 compone...

Страница 282: ...280 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...

Страница 283: ......

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Komatsu PC18MR-3, Руководство по эксплуатации и техническому обслуживанию

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