Operation & Maintenance Manual WEAM007700 PC14R -2 HYDRAULIC EXCAVATOR SERIAL NUMBER PC14R -2 F00003 WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine.
FOREWORD 1.1 FOREWORD q This manual has been compiled by Komatsu Utility S.p.A. in order to supply customers with all the necessary information on the machine and on safety regulations, as well as the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
INFORMATION ON SAFETY 1.2 INFORMATION ON SAFETY Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations prescribed for the maintenance operations that must be performed on the machine. In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read and be sure to understand all the information and warnings contained in this manual and given on the plates applied onto the machine.
INFORMATION ON SAFETY DANGER q Before starting any maintenance operation, position the machine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and the controls, and stop the engine. DANGER q To make the information clearer, some illustrations in this manual represent the machine without safety guards.
INTRODUCTION 1.3 INTRODUCTION 1.3.1 INTENDED USE OF THE MACHINE The Komatsu machines described in this manual have been designed and constructed to be used mainly for EXCAVATION and EARTH-MOVING OPERATIONS. If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated in paragraph "6.1 AUTHORIZED OPTIONAL EQUIPMENT". 1.3.
INTRODUCTION 1.3.4 RUNNING-IN Every machine is scrupulously adjusted and tested before delivery. A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the various components. If the machine is subjected to excessive work load at the beginning of operation, its potential productivity and its functionality will be shortly and untimely reduced.
PRODUCT IDENTIFICATION 1.4 PRODUCT IDENTIFICATION The Komatsu excavator and its main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must be communicated to the Dealer when requiring assistance and ordering spare parts. 1.4.1 MACHINE SERIAL NUMBER The machine serial number is stamped on the front upper part of the main frame, on the left side. RKAB5040 1.4.
PRODUCT IDENTIFICATION 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE The engine serial number is stamped on the plate positioned on the engine itself. RKA16540 The exhaust gas emission plate is applied to the counterweight. RKA16550 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned inside the travel reduction gear and can be seen after removing the cover (1).
PRODUCT IDENTIFICATION 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned on the upper side of the swing motor.
PRODUCT IDENTIFICATION 1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS Machine no.° Model Product identification number (PIN) Engine no.° Travel reduction gear no.° Swing reduction gear no.° Dealer: Address: Tel.
TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD 1.1 FOREWORD.......................................................................................................................................... 1 1.2 INFORMATION ON SAFETY ................................................................................................................ 2 1.3 INTRODUCTION ................................................................................................................................... 1.3.
TABLE OF CONTENTS 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 2.4.1 STARTING THE ENGINE ....................................................................................................... 2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 2.4.3 HAND SIGNALS....................................................................................................................... 2.4.
TABLE OF CONTENTS 2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS................................................................................................................. 2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES....................................................................................................................... 56 56 THE MACHINE AND ITS OPERATIONS 3.1 MACHINE ILLUSTRATIONS ........................................
TABLE OF CONTENTS 3.3.14 CHANGING THE BUCKET ...................................................................................................... 3.3.15 PARKING THE MACHINE........................................................................................................ 3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK ...................................................... 3.3.16.1 BEFORE STOPPING THE ENGINE ....................................................................... 3.3.16.
TABLE OF CONTENTS 4.3 PARTS SUBJECT TO WEAR ............................................................................................................... 4.3.1 LIST OF THE PARTS SUBJECT TO WEAR............................................................................ 161 161 4.4 FUEL, COOLANT AND LUBRICANTS................................................................................................. 4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES............................
TABLE OF CONTENTS TECHNICAL SPECIFICATIONS 5.1 TECHNICAL DATA ............................................................................................................................... 202 5.2 LIFTING CAPACITIES .......................................................................................................................... 5.2.1 LIFTING CAPACITIES .............................................................................................................
PAGE INTENTIONALLY LEFT BLANK 16
SAFETY AND ACCIDENT PREVENTION 17
SAFETY, NOISE AND VIBRATION PLATES 2.1 SAFETY, NOISE AND VIBRATION PLATES 2.1.1 POSITION OF THE SAFETY PLATES q The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or grease, it is necessary to clean them with a solution made of water and detergent. Do not use fuel, petrol or solvents. q If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer.
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine include or are accompanied by pictograms. The staff in charge with the operation and maintenance of the machine must be perfectly familiar with the symbols contained in the pictograms; the following list illustrates what they look like and their respective meanings.
SAFETY, NOISE AND VIBRATION PLATES PLATFORM LIFTING SAFETY PLATE 22L-98-R2390 RKA01380 HYDRAULIC OIL TOPPING UP q (Only for machines in which synthetic biodegradable oil type HEES is used) BIO-OIL HYDRAULIC OIL TOPPING UP RWA00050 REFUELLING D RWA00040 ENGINE OIL FILTER RWA00080 20 RWA34380
SAFETY, NOISE AND VIBRATION PLATES FUEL FILTER D RWA00060 ENGINE AIR INTAKE FILTER RWA00090 ENGINE COOLANT RWA00130 ENGINE COOLANT PRESSURE RWA00110 HYDRAULIC OIL LEVEL RWA00100 HYDRAULIC OIL FILTER RWA00070 21
SAFETY, NOISE AND VIBRATION PLATES POWER OUTLET RWA00120 12 V ANCHORAGE POINT RWA00200 LIFTING POINT RWA04920 22
SAFETY, NOISE AND VIBRATION PLATES LIFTING CAPACITIES A B W=350mm kg 22 W A L L=880mm L=1130mm 1m 2m 3m MAX B 2m 1m 0 -1m 0 700kg 225kg 265kg 250kg 255kg 245kg 145kg 135kg 180kg 145kg 145kg 215kg 125kg > 20M-98-91510 RKA16530 23
SAFETY, NOISE AND VIBRATION PLATES 2.1.3 POSITION OF THE NOISE PLATES q The noise plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or grease, it is necessary to clean 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 Dealer.
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES q Only trained and authorized staff can use the machine and perform maintenance operations. q Follow all the safety rules, precautions and instructions when using the machine or performing maintenance operations.
GENERAL PRECAUTIONS 2.2.4 UNAUTHORIZED MODIFICATIONS q Any modification made without the authorization of Komatsu can involve hazards. q Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injury or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATOR SEAT q When leaving the operator seat, even if temporarily, make sure that the machine is in a safe position. (See "2.4.14 PARKING THE MACHINE").
GENERAL PRECAUTIONS 2.2.6 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 the tracks; get on and off the machine very carefully. q Do not hold or rest on the control levers. q Both when getting on and when getting off the machine, always maintain three points of contact (holding or resting points), in order to avoid losing your balance and falling down.
GENERAL PRECAUTIONS 2.2.7 PREVENTING 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 dangerous. q Keep any naked flame away from flammable fluids. q Stop the engine and do not smoke when refuelling. q Refuel and add oil only after stopping the engine and in well ventilated places. q Refuel and add oil in a well delimited area and do not allow unauthorized persons to approach.
GENERAL PRECAUTIONS 2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER q Inhaling asbestos powder is very dangerous. q If it is necessary to handle materials containing asbestos fibers, keep to the instructions given below: 1 - Do not use compressed air, but only aspirators to clean the machine and make sure that this operation is performed in a properly ventilated place. 2 - Use low-pressure water to abate dust when cleaning.
GENERAL PRECAUTIONS 2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT q Make sure that fire extinguishers have been provided and check their position. q Periodically make sure that the fire extinguishers are loaded and that you know how to use them. q Find out where the first aid kit has been placed. q Periodically make sure that the first aid kit contains the necessary disinfectants, bandages, medicins, etc. q It is necessary to know what to do in case of fire.
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.1 SAFETY AT THE WORK SITE q Before starting the engine, thoroughly check the area for any unusual condition of the ground due to which work may be dangerous. q Check the conditions of the ground at the work site and before starting the engine define the work plan and the best and safest operating procedure. q Make the ground surface as level as possible before carrying out any operation.
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.4 ROOM VENTILATION q Before starting the machine in confined or poorly ventilated places, provide for proper ventilation or connect the engine exhaust pipe to a suction duct. The engine exhaust gases can be deadly. RKA00420 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS q Remove any trace of dirt from the lights, in such a way as to ensure perfect visibility on the work area. q Make sure that the work lights have been correctly installed.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.1 STARTING THE ENGINE q Before getting on the machine, walk around it and check for people and objects that might be in the way. q Do not start the engine if warning plates have been attached to the control levers. q Before starting the engine, make sure that the controls are locked. q When starting the engine, sound the horn as an alert signal. q Start the engine only while seated with fastened seat belt.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.3 HAND SIGNALS WARNING q When it is necessary to position loads, make excavations or move the machine with reduced field of vision, the operator must be helped by another person standing on the ground and making signals to indicate the manoeuvres to be carried out, according to the specific signals defined by the relevant regulations.
PRECAUTIONS TO BE TAKEN WHEN WORKING 3 - MOVE THE LOAD AWAY IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical position directed towards the load to be moved away, move the hand in the direction of the movement to be carried out. RKA15160 4 - 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 be carried out.
PRECAUTIONS TO BE TAKEN WHEN WORKING 9 - FOLD THE ARM With both hands clasped, point the thumbs inwards. RKA15220 10 - EXTEND THE ARM With both hands clasped, point the thumbs outwards. RKA15230 11 - FOLD THE BUCKET Keep one hand still and closed. Rotate the other hand vertically with the thumb pointed towards the clasped hand. RKA15240 12 - OPEN THE BUCKET Keep one hand still and open. Rotate the other hand vertically with the thumb pointed towards the open hand.
PRECAUTIONS TO BE TAKEN WHEN WORKING 15 - TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels. RKA15280 16 - TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels. RKA15290 17 - DISTANCE TO BE COVERED With the hands raised and facing inwards, move the hands laterally indicating the distance to be covered.
PRECAUTIONS TO BE TAKEN WHEN WORKING 21 - STOP THE ENGINE Pass thumb or forefinger across the throat.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.4 CHECKS FOR TRAVELLING IN REVERSE q When operating in areas that may be hazardous or have poor visibility, designate a person to direct the movements of the machine and traffic on the work site. q Make sure that no unauthorized person is within the machine operating range or in its travel direction. If necessary, put up appropriate fences. q Before moving the machine, sound the horn in order to warn everyone close to the work area.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 MOVING ON SLOPES q Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip. q On hills, banks or slopes, keep the bucket very close to the ground (20-30 cm from the ground), and in case of emergency quickly lower it to the ground to help the machine stop.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.7 WORKING ON SLOPES q When working on slopes, if possible avoid rotating the turret, since the machine may lose its balance and overturn. It is particularly dangerous to swing the equipment on slopes when the bucket is full. If these operations are going to last long, accumulate soil in such a way as to create a horizontal platform on which the machine can be positioned. RYA00560 2.4.8 UNAUTHORIZED OPERATIONS q Do not carry out excavations under overhangs.
PRECAUTIONS TO BE TAKEN WHEN WORKING q Do not carry out demolition work under the machine, since it may become unstable and tip over. q When working on the top of buildings or other structures, check these structures and their strength before starting work. In fact, the buildings may collapse and cause serious injury or damages.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.9 PREVENTING ELECTROCUTION q Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution; for this reason, when working near overhead electric lines always respect the minimum safety distances prescribed by the competent authorities and by the accident-prevention rules in force.
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT q When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage. 2.4.13 WORKING ON LOOSE GROUND q Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.
TRANSPORTING THE MACHINE ON MOTOR VEHICLES 2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE q Loading and unloading the machine on/from a motor vehicle always involves potential hazards. Proceed with extreme care. q Perform loading and unloading operations on firm, level ground. Maintain a safety distance from the edges of ditches or from road sides.
BATTERY 2.6 BATTERY 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY q Electrolytic batteries contain sulphuric acid, which can cause burns. It can also corrode clothing and make holes in it. In case of contact with battery acid, immediately wash the affected part with plenty of water. q Battery acid may cause blindness if sprayed into the eyes. If acid gets accidentally into your eyes, flush them immediately with plenty of water and consult a doctor without delay.
PRECAUTIONS FOR THE REMOVAL OF THE MACHINE 2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE q Before removing the machine, make sure that all the controls are in neutral. q Incorrect manoeuvres may cause serious damage, personal injury and even death. q To move the machine, use properly dimensioned steel cables; do not use worn cables or cables with broken strands (A), deformed cables (B), twisted cables (C). q During the removal, no one can be allowed to get near the machines or the cable.
PRECAUTIONS FOR MAINTENANCE 2.8 PRECAUTIONS FOR MAINTENANCE 2.8.1 WARNING PLATES q Before starting any maintenance operation, position the machine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and the controls, and stop the engine. q If another person starts the engine and operates the control levers while the operator is servicing the machine, this may result in serious injury or even death.
PRECAUTIONS FOR MAINTENANCE 2.8.4 EQUIPMENT q The normal or special equipment that must be installed on the machine or that have been removed must be stored in a safe place and positioned in such a way as to prevent them from falling down. If they fall on someone, they may cause serious injury. q When assembling or removing any equipment, make sure that the ropes and the lifting hook are in good conditions and properly dimensioned for the load to be lifted. RKA00290 2.8.
PRECAUTIONS FOR MAINTENANCE 2.8.7 USE OF THE ENGINE DURING MAINTENANCE q During maintenance operations, make the engine run only when indispensable. If it is necessary to have the engine running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator should constantly remain in the cab, in order to be able to stop the engine whenever necessary.
PRECAUTIONS FOR MAINTENANCE 2.8.10 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL q Keep away from naked flames while refuelling or adding oil. q Spilled fuel or oil make the ground slippery and may cause accidents; clean any dirty area immediately and carefully. q Always tighten the safety caps of the fuel tank and of the hydraulic oil tank securely. q Do not use fuel to clean any part of the machine that is dirty with oil or dust.
PRECAUTIONS FOR MAINTENANCE 2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR q When repairing the electrical system, disconnet the battery in order to stop the flow of current. REMOVAL 1 2 IMPORTANT q Disconnect first the negative earth cable (–) and then the positive cable (+). At the end of the operation, reconnect first the positive cable (+) and then the negative cable (–).
PRECAUTIONS FOR MAINTENANCE 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL q Do not forget that the work equipment circuits are always under pressure; for this reason, when it is necessary to add or drain hydraulic oil or to perform maintenance operations or inspections on the hydraulic circuit, it is advisable to lower the equipment to the ground and completely release the pressures and the residual pressure present in the tank.
PRECAUTIONS FOR MAINTENANCE 2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION q The grease contained in the track tension adjustment device is pressurized. If the adjustment is not carried out according to the instructions given in the maintenance section, the grease valve (1) may be ejected due to the high pressure and this may be dangerous for the operator. q When loosening the valve (1) to reduce the track tension, do not give it more than one turn.
PRECAUTIONS FOR MAINTENANCE 2.8.21 COOLING FAN AND BELT q Be careful to the revolving parts and do not allow anyone to get too close to them, since clothes or limbs may get caught into them. q If hands, clothes, or tools become entangled in the fan blades or the fan belt, they may be cut, torn or seriously injured/ damaged; for this reason, avoid touching any revolving parts. RWA01660 2.8.22 WASTE MATERIALS q Do not dispose of used oil in the sewer system, rivers, etc.
PRECAUTIONS FOR MAINTENANCE 2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS DANGER q Some components of the machine contain polymeric and elastomeric materials (Viton sealing rings, Teflon rings, piston rings made of fluoroelastomers, electric cable insulating materials, etc.). At ambient temperature and up to approximately 200°C these materials can be handled without taking special precautions, since they are completely inert.
THE MACHINE AND ITS OPERATIONS 57
MACHINE ILLUSTRATIONS 3.1 MACHINE ILLUSTRATIONS 3.1.
MACHINE ILLUSTRATIONS 3.1.
INSTRUMENTS AND CONTROLS 3.2 INSTRUMENTS AND CONTROLS The following paragraphs describe the devices 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 information displayed. 3.2.
INSTRUMENTS AND CONTROLS 3.2.1.1 EMERGENCY WARNING LIGHTS CAUTION q If a warning light does not go out or comes on when the engine is running, stop the machine immediately and try to find the cause of the failure. (1) 1.
INSTRUMENTS AND CONTROLS 3.2.1.2 (1) 1. GAUGES Fuel gauge (2) Hour meter Fuel gauge It indicates the fuel level in the tank and functions only when the ignition key is in position ON (see "3.2.2 pos: 1. Ignition switch"). F: maximum level. E: minimum level. If the quantity of fuel in the tank is less than 3.3 litres, the indicator reaches the red reserve area (A). NOTE q If the indicator reaches the red reserve area (A) during use, stop the machine and provide for refuelling. 2.
INSTRUMENTS AND CONTROLS 3.2.1.3 (1) 1. WARNING LIGHTS Engine preheating warning light (2) (3) Travel speed increase warning light Engine coolant temperature warning light Engine preheating warning light This warning light comes on when the ignition key is turned to the preheating position (HEAT) to start the engine at low temperatures. It goes out automatically after approximately 10 seconds, when the preheating process has been completed. RWA07160 2.
INSTRUMENTS AND CONTROLS 3. Engine coolant temperature warning light This warning light comes on when the engine coolant exceeds the maximum temperature allowed; in this case, reduce the engine speed until the warning light goes out. If this inconvenience occurs again, make sure that the radiator is clean.
INSTRUMENTS AND CONTROLS 3.2.2 SWITCHES AND PUSH BUTTONS RKA16590 (1) (2) (3) Ignition switch Horn Light switch (4) (5) (6) 1. Travel speed selection switch (if provided) Blade/adjustable track gauge selection switch (if provided) Power outlet Ignition switch This is a four-position rotary switch and is used to switch the engine on and off. q Position OFF When the switch is in this position, the ignition key can be inserted and removed.
INSTRUMENTS AND CONTROLS 2. Horn This button is positioned at the centre of the right lever knob and serves to send out a warning signal at the beginning of work and in case of danger. RKA10590 3. Light switch This is a two-position (ON-OFF) switch and is used to turn the lights on and to light up the warning lights and gauges display. Position ON (A):Lights on and warning lights and gauges display lit up Position OFF (B):Lights and display off. 4.
INSTRUMENTS AND CONTROLS 5. Blade/adjustable track gauge selection switch (if provided) WARNING q Use the narrow track gauge only when it is necessary to go through narrow passages or when there is no other choice. For normal applications and digging operations, always select the wide track gauge. q Avoid adjusting the track gauge when the machine is working on a slope: the machine may lose stability and overturn. Always adjust the track gauge on level surfaces.
INSTRUMENTS AND CONTROLS 3.2.
INSTRUMENTS AND CONTROLS 1. Safety lever (control locking lever) WARNING q Before leaving the driver seat, lower the equipment to the ground and shift the safety lever to the “locked” position (L). If the safety lever is not in the “locked” position and the control levers are touched by mistake, this may lead to serious injury. q If the safety lever is not in the “locked” position, the control levers may move, causing accidents or serious injury.
INSTRUMENTS AND CONTROLS 2. - 3. Work equipment control levers WARNING q Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt. q Before leaving the driver seat, lower the equipment to the ground, lock the controls with the safety lever and stop the engine. RKA14330 IMPORTANT q The horn push button is positioned on the right lever grip and must be used to warn all the people in the vicinity before starting work and in case of danger.
INSTRUMENTS AND CONTROLS 4. Accelerator lever This lever is used to control the engine speed 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 difficult conditions. Avoiding useless accelerations means reducing consumption and extending the service life of both the engine and the machine. RKA16460 5.
INSTRUMENTS AND CONTROLS 6. Travel levers WARNING q Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt. q Before moving the machine, make sure that the sprocket (A) is positioned at the rear of the machine and that the safety locks are engaged; if the turret is rotated by 180°, the controls are inverted (see "3.3.5 HOW TO MOVE THE MACHINE" e "3.3.6 STEERING THE MACHINE").
INSTRUMENTS AND CONTROLS 7. Boom swing control pedal locking device WARNING q F Always shift the safety lever to position (L) when the boom swing is not required, during travel and when parking the machine. If the control pedal is inadvertently pressed, this may cause serious accidents. This device is used to lock the movements of the boom swing control pedal and has two positions. L (F): free 9JA05440 (L): locked 8.
INSTRUMENTS AND CONTROLS 10. Pedal locking device (for the optional equipment control pedal) WARNING q 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 inadvertently pressed, this may cause serious accidents. The safety device is used to lock the optional equipment control pedal. RKA10550 11.
INSTRUMENTS AND CONTROLS 3.2.4 COVERSWITH LOCK Use the ignition key to open and close the covers with lock. For details on the position of the covers with lock, see "3.3.17 LOCKING THE 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. RYA01680 OPENING AND CLOSING THE COVERS WITH LOCK Opening 1 - Insert the key into the lock.
INSTRUMENTS AND CONTROLS 3.2.5 ENGINE HOOD WARNING q Do not open the engine hood when the engine is running. q Do not use the machine without engine hood and do not start the engine when the hood is open, unless this is expressly prescribed for certain maintenance operations. q When carrying out an inspection or maintenance operation inside the engine hood, always open it completely and make sure that it is kept open by the apposite rod.
INSTRUMENTS AND CONTROLS 3.2.6 RADIATOR COVER WARNING q When carrying out an inspection or maintenance operation inside the radiator cover, always open it completely and make sure that it is kept open by the apposite rod. OPENING THE BATTERY COVER 1. Release the radiator COVERSWITH LOCK"). cover lock (1) (see "3.2.4 2. Pull the radiator cover (2) and open it completely. The cover (2) is kept open by the apposite rod (3). CLOSING THE COVER 1.
INSTRUMENTS AND CONTROLS 3.2.7 BATTERY COVER WARNING q When carrying out an inspection or maintenance operation inside the battery cover, always open it completely and make sure that it is kept open by the apposite rod. OPENING THE BATTERY COVER 1. Release the battery cover lock (1) (see "3.2.4 COVERSWITH LOCK"). 2. Pull the battery cover (2) and open it completely. The cover (2) is kept open by the apposite rod (3). CLOSING THE COVER 1.
INSTRUMENTS AND CONTROLS 3.2.8 TILTING THE CAB FLOOR WARNING q Always keep to the warnings when tilting or closing the cab floor. Any operation carried out incorrectly may cause serious injury. q Do not tilt or close the cab floor on slopes or if there is a strong wind. q Do not get too near the cab floor tilting or closing area and do not enter the cab when the cab floor is tilted. q Do not start the engine when the cab floor is tilted.
INSTRUMENTS AND CONTROLS 7. Raise the mat (4), pull the cab floor release lever (5) in the direction indicated by the arrow and at the same time push the handle (6) upwards in the direction indicated by the arrow (approx. 45°). IMPORTANT q If the cab floor does not tilt, pull the handle (6) downwards and repeat the procedure described above. q When tilting or closing the cab floor, be extremely careful, and keep away from the area under the cab floor.
INSTRUMENTS AND CONTROLS Closing the cab floor IMPORTANT q Before closing the cab floor, check that there is no damage or anomaly in the wiring or piping located in the compartment under the floor. If any damage or anomaly is observed, have the necessary repairs carried out by your Komatsu Dealer. 1. Remove the safety pin (10) and store it into the apposite hole (13). NOTE q If the safety pin (10) does not come out, try again by pushing the handle (6) at the same time. 2.
INSTRUMENTS AND CONTROLS 3.2.9 FUSES IMPORTANT q When changing a fuse, make sure that the ignition key is in position OFF. 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 protect the electrical equipment and wiring from burning out. If a fuse is corroded, covered with white powder, or loose in the fuse holder, change it. Replace the fuse with a new one having the same capacity.
INSTRUMENTS AND CONTROLS 3.2.10 MAIN FUSE IMPORTANT q When changing a fuse, make sure that the ignition key is in position OFF. If the starter does not run when the ignition switch is turned to position ON, the fuse (1) may have blown. Open the cover on the left side of the machine to check the fuse and change it if necessary. The main fuse is positioned on the battery. For further details on how to open and close the cover on the left side of the machine, see "3.2.7 BATTERY COVER".
USE OF THE MACHINE AND RELATED CONTROLS 3.3 USE OF THE MACHINE AND RELATED CONTROLS 3.3.1 BEFORE STARTING THE ENGINE 3.3.1.1 VISUAL CHECKS Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, oil, fuel or coolant leakages, and check the conditions of the work equipment and the hydraulic system. Check also for loose wires, excessive gaps, and accumulation of dust in places that reach high temperatures.
USE OF THE MACHINE AND RELATED CONTROLS 8. Check the seat belt and the relevant couplings. If there is any damage or anomaly, change them with new ones. 9. Check the cab floor fastening screws. • Open the engine hood and make sure that the two fastening screws of the cab floor (1) are correctly tightened. If there are loose screws, tighten them. If any anomaly is observed, carry out the necessary repairs or have them carried out by your Komatsu Dealer. 3.3.1.
USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE ENGINE OIL LEVEL AND TOPPING UP WARNING q Soon after the machine has been stopped the engine is very hot and may cause burns; let the engine cool down to 40-45°C before carrying out any check. CAUTION q When carrying out an inspection or maintenance operation inside the engine hood, always open it completely and make sure that it is kept open by the apposite rod.
USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE FUEL LEVEL AND REFUELLING WARNING q When refuelling, avoid spilling fuel, since this may cause a fire hazard. If fuel is spilled, wipe it up immediately. q Fuel is highly flammable; do not use naked flames and do not smoke when refuelling. Hold the fuel gun constantly in contact with the filler. 1. Insert the key in the ignition switch (1) and turn it to position ON. 2. Check the fuel level on the fuel gauge (2).
USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP WARNING q Carry out this check when the oil is cold, with the machine positioned on level ground, bucket and arm cylinders retracted and bucket teeth resting on the ground. q Before topping up, stop the engine and eliminate the residual pressure from the equipment circuits (by shifting the controls more than once) and from the tank by slowly loosening the filling cap. 1.
USE OF THE MACHINE AND RELATED CONTROLS 4. Extend the boom, arm and bucket cylinders completely, as shown in the diagram on the right, and remove the filler cap. Put back the cap and pressurize the tank, lowering the equipment to the ground. IMPORTANT q If a constant or abnormal decrease in the oil level is observed, 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.
USE OF THE MACHINE AND RELATED CONTROLS CHECKING AND CLEANING THE WATER SEPARATOR WARNING q Fuel is flammable; do not use naked flames and do not smoke while draining the water separator. q If fuel is spilled, wipe it up immediately. If the red ring (1) of the water separator is on the bottom of the casing (2), this means that there is no water. If the ring (1) is floating, this means that there is water up to its lower surface, therefore drain the water by proceeding as follows.
USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE HORN 1. Turn the ignition switch to position ON. 2. Press the button positioned on the right lever and make sure that the horn functions correctly. If the horn does not sound, contact your Komatsu Dealer, who will carry out the necessary repairs.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.3 ADJUSTMENTS WARNING q Adjust the position of the seat before starting work or when taking the place of another operator. q Adjust the seat so that the control levers and the switches can be easily used by the operator seated with his back against the backrest.
USE OF THE MACHINE AND RELATED CONTROLS SEAT BELT WARNING q Before fastening the seat belt, make sure that the fastening brackets or the belt itself do not show any anomaly. If there are damaged or worn parts, change the belt. q In any case, change the seat belt every 3 years, even if it seems to be in good conditions. The date of manufacture is indicated on the reverse side of the belt. q Adjust and fasten the seat belt before operating the machine.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE 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 started, the work equipment may move suddenly and cause serious accidents. 1. Make sure that the safety lever (1) is in the “locked” position (L).
USE OF THE MACHINE AND RELATED CONTROLS 2) Press the light switch (6) and make sure that the work light functions correctly. If it does not function, this may be due to a faulty bulb, or to an interruption in the wirings, therefore it is advisable to contact a Komatsu Dealer, who will provide for the necessary repairs. 3) Press the horn button (7) to make sure that the horn functions correctly.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2 STARTING THE ENGINE 3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES WARNING q Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. From the moment at which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and noncompliance with the safety regulations and the rule of the road..
USE OF THE MACHINE AND RELATED CONTROLS 3. Turn the ignition key (3) to position START to start the engine. RYA17360 4. As soon as the engine starts, release the key (3), which will automatically return to position ON.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES WARNING q Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. From the moment at which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and noncompliance with the safety regulations and the rule of the road..
USE OF THE MACHINE AND RELATED CONTROLS 3. Turn the ignition key (3) to the preheating position (HEAT) and make sure that the preheating warning light (4) comes on. After approximately 10 seconds, the warning light (4) goes out, indicating that the preheating phase has been completed. RKA16310 4. When the preheating warning light (4) goes out, turn the ignition key (3) directly to position START to start the engine. RKA16320 5.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.3 AFTER STARTING THE ENGINE WARNING q Emergency stop If a failure has occurred or an anomaly has been observed, turn the ignition key to position OFF. q If the work equipment is operated without warming up the engine sufficiently, the response of the work equipment to the movements of the control lever will be slow, and the work equipment may not move as desired by the operator, so always carry out the warming up procedure.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.3.2 WARMING-UP OPERATIONS IMPORTANT q Do not carry out any operation and do not shift the levers suddenly when the hydraulic oil temperature is too low. Always carry out the warming up operations. 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 minutes without interruption.
USE OF THE MACHINE AND RELATED CONTROLS 3. Operate the right work equipment control lever (3) slowly, stop the bucket, and hold it in the stop position for 5 minutes. RKA10840 4. After carrying out the warming-up operations, make sure that the warning lights and gauges are in the conditions described below. If any anomaly is observed, carry out the necessary maintenance operations and repairs.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.4 STOPPING THE ENGINE IMPORTANT q The sudden stop of the engine while it is running shortens its life. q Do not stop the engine suddenly, except in case of 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, in order to allow it to cool down gradually before stopping it. 1.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.5 HOW TO MOVE THE MACHINE WARNING q Before moving the machine, make sure that you perfectly know the control functions and all the relevant safety regulations. q The operator must be seated in the driving position with fastened seat belt. q Before operating the travel levers, check the direction of the undercarriage. If the sprocket is at the front, the operation of the travel levers is inverted.
USE OF THE MACHINE AND RELATED CONTROLS • When the sprocket (A) is at the rear of the machine, push the levers (3) slowly forward to move the machine off. • When the sprocket (A) is at the front of the machine, pull the levers (3) slowly backward to move the machine off. Machine with speed increase function 4. Switch over the travel speed by proceeding as follows. • Press the travel speed selection switch (4) to change over from high (A) to low (B) speed and vice versa.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.5.3 MOVING THE MACHINE IN REVERSE 1. Shift the safety lever (2) to the “free” position (F), then raise the work equipment 40-50 cm from the ground. 2. Lift the blade. 3. Opearate both travel levers (3) as explained below. RKA01610 • When the sprocket (A) is at the rear of the machine, pull the levers (3) slowly backward to start moving in reverse.
USE OF THE MACHINE AND RELATED CONTROLS • 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 TECHNICAL DATA" NOTE q When the engine is started, the low speed is automatically selected. When the machine travels at high speed on soft ground or up a slope and the load increases, the low speed is automatically selected, but the travel speed increase warning light remains on.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.6 STEERING THE MACHINE 3.3.6.1 STEERING (CHANGING DIRECTION) WARNING q Before operating the travel control levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levers is inverted. q Avoid abrupt changes of direction as much as possible. Carry out counter rotations with the machine at rest. q Due to the strong friction generated by changes of direction, do not use the travel speed increase control.
USE OF THE MACHINE AND RELATED CONTROLS STEERING (CHANGING DIRECTION) When steering to the left: If the left travel lever is shifted back to the neutral position, the machine will steer to the left. NOTE q To steer to the right, operate the right travel lever in the same way. RYA02170 HOW TO CARRY OUT COUNTER-ROTATIONS (SPIN TURN) To carry out a counter-rotation to the left, pull the left travel lever backward and push the right travel lever forward.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.7 SWINGING THE TURRET WARNING q Before swinging the turret, make sure that the area around the machine is safe. 1. 2. To swing the turret, use the left work equipment control lever (1). 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.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS The work equipment is controlled by means of the right and left work equipment control levers. The left lever controls the arm and the turret swing, while the right lever controls the boom and the bucket. When the levers are released, they automatically return to the neutral position and the work equipment remain in the position where they stopped.
USE OF THE MACHINE AND RELATED CONTROLS q Boom swing control To swing the boom, use the boom swing control pedal. q Blade control Select the use of the blade with the blade/adjustable track gauge selection switch. To operate the blade, shift the lever positioned to the right of the operator seat forward or backward.
USE OF THE MACHINE AND RELATED CONTROLS q Track gauge adjustment control (version with adjustable track gauge) WARNING q Select the narrow track gauge only when the machine must travel in small spaces. For normal applications and digging operations, always select the wide track gauge. q Adjusting the track gauge on slopes is dangerous, since this may affect the lateral stability of the machine. Therefore, it is advisable to adjust the track gauge on level surfaces.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.9 UNAUTHORIZED OPERATIONS WARNING q If it is necessary to operate the work equipment control levers while the machine is moving, carry out this operation with the maximum care. q PERATIONS FOR WHICH IT IS NOT ALLOWED TO EXPLOIT THE TURRET SWING Do not use the turret swing force to compact soil or break earth mounds or walls. When swinging the turret, do not dig the bucket teeth into the ground. These operations will damage the work equipment.
USE OF THE MACHINE AND RELATED CONTROLS q OPERATIONS FOR WHICH IT IS NOT ALLOWED TO EXPLOIT THE DROPPING FORCE OF THE BUCKET Do not exploit the dropping force of the bucket to use it as a pickaxe, breaker, or pile driver. This may considerably reduce the life of the machine. RYA02400 q OPERATIONS FOR WHICH IT IS NOT ALLOWED TO EXPLOIT THE FORCE OF GRAVITY OF THE MACHINE Do not use the force of gravity of the machine to carry out digging operations.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.10 PRECAUTIONS FOR USE q q TRAVELLING Travelling on big stones, logs or other obstacles subjects the frame and in particular the tracks to considerable strain, which damages the machine. For this reason, it is always advisable to remove any obstacles or to avoid them, if possible.
USE OF THE MACHINE AND RELATED CONTROLS q MAXIMUM WATER DEPTH CAUTION q When driving the machine out of water, if the inclination of the machine exceeds 15°, the rear of the turret will be submerged, and this may cause the cooling fan to break. Be extremely careful when driving the machine out of water. Do not immerse the machine in water beyond the permissible depth (under the carrier roller (1)).
USE OF THE MACHINE AND RELATED CONTROLS 3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES WARNING q Swinging or using the work equipment on slopes may cause the machine to lose stability and overturn, therefore it is advisable to avoid these operations. It is particularly dangerous to swing the turret when the machine is travelling downhill with full bucket. If these operations cannot be avoided, create a sort of platform by heaping some ground, so that the machine can work in horizontal position.
USE OF THE MACHINE AND RELATED CONTROLS 2. When travelling uphill on a slope whose inclination exceeds 15°, position the work equipment as shown in the diagram on the right. 20 ~ 30 cm RYA17700 BRAKING WHEN TRAVELLING DOWNHILL To brake when travelling downhill, shift the travel levers to the neutral position. This will automatically engage the brakes.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.12 GETTING THE MACHINE OUT OF MUD Always proceed carefully to avoid getting stuck in mud. However, if the machine gets stuck in mud, proceed as indicated below. WHEN ONE SIDE ONLY GETS STUCK IMPORTANT q When using the boom or arm to raise the machine, always place the bottom of the bucket in contact with the ground. (Never push with the bucket teeth.) The angle between the boom and the arm should be included between 90° and 110°.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR In addition to those indicated below, many other applications are possible, thanks to the use of various attachments.
USE OF THE MACHINE AND RELATED CONTROLS LEVELLING OPERATIONS Use the blade to fill excavations and level the ground surface. For refilling operations, widen the track gauge and the blade. SIDE DITCHING WORK RYA02570 It is possible to use the machine for side ditching work in limited spaces, by combining the turret and the boom swing.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.14 CHANGING THE BUCKET WARNING q When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet. q The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during work. q Avoid using your fingers to align the holes, since they may be cut off in case of sudden or uncontrolled movements.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.15 PARKING THE MACHINE WARNING q Avoid stopping the machine abruptly. Always calculate a sufficient safety distance when stopping. q Park the machine on firm and level ground. Avoid parking the machine on slopes. If it is absolutely necessary to park the machine on a slope, put blocks under the tracks and thrust the work equipment into the ground to prevent the machine from moving.
USE OF THE MACHINE AND RELATED CONTROLS 3. Lower the bucket keeping it in horizontal position, until its bottom touches the ground. 4. Lower the blade to the ground. RYA17850 5. Shift the safety lever (3) to the “locked” position (L).
USE OF THE MACHINE AND RELATED CONTROLS 3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK 3.3.16.1 BEFORE STOPPING THE ENGINE At the end of work, before stopping the engine, check the engine coolant temperature warning light (1), the engine oil pressure warning light (2) and the fuel level on the gauge (3). 3.3.16.2 AFTER STOPPING THE ENGINE 1. Walk around the machine, check the work equipment, the outside of the machine and the undercarriage, and make sure that there are no oil or coolant leakages.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only) 3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS Rubber tracks have exceptional characteristics that cannot be found in steel tracks. However, if they are used in the same way as steel tracks, the advantages they offer cannot be fully exploited. Operate without subjecting the rubber tracks to excessive stress, trying to adapt to the conditions of the job site and to the work being carried out.
USE OF THE MACHINE AND RELATED CONTROLS 3.3.18.3 USE OF THE RUBBER TRACKS UNAUTHORIZED USES Keep to the following instructions. q Avoid performing rotations or other operations on broken rocks, very hard rocks, steel bars, scraps, or near the edges of steel plates, since this may damage the rubber tracks. q In places like river beds, where there is a great quantity of large and small stones, these may get stuck in the tracks, and damage them or cause them to come off.
USE OF THE MACHINE AND RELATED CONTROLS 1. Avoid steering when moving on kerbs, rocks or areas with considerable differences in height (more than 20 cm). When the machine moves in these conditions, always position it perpendicular to the obstacles. RYA02770 2. When travelling up slopes in reverse, avoid steering at the beginning of the slope. If it is necessary to steer on a slope, carry out this manoeuvre gradually. RYA02780 3.
USE OF THE MACHINE AND RELATED CONTROLS Detachment of the rubber track from the track frame 5. When the machine moves over an obstacle, a gap forms between the carrier roller and the rubber track. In these conditions, the rubber track may come off. RYA02800 6. Furthermore, if the machine travels in reverse, a gap forms between the carrier roller, the idler roller, and the rubber track.
USE OF THE MACHINE AND RELATED CONTROLS q If the machine travels in reverse in these conditions, the rubber track will come off. RYA02820 q If the machine steers in these conditions, the rubber track will come off.
TRANSPORTING THE MACHINE 3.4 TRANSPORTING THE MACHINE When transporting the machine, observe all the laws and regulations in force, paying special attention to safety. 3.4.1 TRANSPORT PROCEDURE As a general rule, the machine must be transported on a trailer. Choose the trailer according to the weight and size of the machine, as indicated in paragraph "5.
TRANSPORTING THE MACHINE During the loading and unloading operations, always use ramps or a platform and proceed as indicated below. LOADING THE MACHINE NOTE q Load and unload the machine on/from the trailer on firm and level ground only, and widen the track gauge. Keep a safety distance from the edge of the road. 1. 2. Engage the trailer brakes and place safety blocks under the trailer wheels to prevent it from moving.
TRANSPORTING THE MACHINE 4. Position the work equipment at the front and the blade at the rear, with the turret and the undercarriage parallel to each other. 5. Move the machine towards the ramps and lower the work equipment as much as possible, taking care to prevent them from touching the trailer. 6. Make sure that the machine is in line with the ramps and that the centerline of the machine corresponds to the centerline of the trailer. 7.
TRANSPORTING THE MACHINE SECURING THE MACHINE ON THE MEANS OF TRANSPORT After positioning the machine on the trailer, it is necessary to secure it by proceeding as indicated below. IMPORTANT q To avoid damaging the machine during transport, place wooden blocks under the end of the bucket cylinder, in such a way as to prevent it from touching the ground. 1. Lower the blade. 2. Extend the bucket cylinder and the arm cylinder completely, and lower the boom slowly. 3.
TRANSPORTING THE MACHINE UNLOADING THE MACHINE NOTE q Load and unload the machine on/from the trailer on firm and level ground only, and widen the track gauge. Keep a safety distance from the edge of the road. 1. Engage the trailer brakes and place safety blocks under the trailer wheels to prevent it from moving. The distance between the ramps and their alignment must be adapted to the wheelbase of the trailer and the track gauge. Make sure that the two sides are at the same distance.
TRANSPORTING THE MACHINE 6. Run the engine at low speed. (A): Idling 7. Lift the blade. RKA16490 8. Lift the work equipment, make sure that the travel direction is in line with the ramps and start travelling slowly. Lower the work equipment as much as possible, without causing interferences. When the machine is on the ramps, do not use any control lever apart from the travel levers.
TRANSPORTING THE MACHINE 3.4.3 LIFTING THE MACHINE WARNING q Do not lift the machine if the operator is still on board. q Always make sure that the metal cable used to lift the machine is sufficiently strong for the weight being lifted. q Do not lift the machine with the turret swung laterally. Before lifting the machine, swing the work equipment to the sprocket side, then position the undercarriage and the turret parallel to each other.
TRANSPORTING THE MACHINE 7. Install shackles in the lifting holes on both ends of the blade (2 points), then pass the metal cables through them. NOTE q On machines with adjustable track gauge, set the blade in the narrow configuration. RKA16690 RKA16680 8. Install one shackle in the lifting hole provided in the boom, then pass the metal cable through it. IMPORTANT q Always use the three coupling points provided for lifting the machine. Do not lift the machine with swung boom or turret.
USING THE MACHINE IN THE COLD SEASON 3.5 USING THE MACHINE IN THE COLD SEASON 3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON During the cold season or in areas where temperatures are particularly low, especially during the night, it is necessary to take some countermeasures meant to limit any damage deriving from low temperatures. 3.5.1.1 FUEL AND LUBRICANTS Change fuel and oil with low viscosity products for all components. For details on the required viscosity, see "4.
USING THE MACHINE IN THE COLD SEASON 3.5.1.3 BATTERY WARNING q The battery produces flammable gas, therefore keep flames and sparks away from it. q The battery electrolyte is dangerous. In case of contact with the eyes or the skin, wash with plenty of running water and consult a doctor without delay. q The battery electrolyte melts paint. In case of contact with the machine body, wash immediately with water.
USING THE MACHINE IN THE COLD SEASON 3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK WARNING q Making the tracks turn idly is dangerous, therefore it is advisable to keep away from the tracks when carrying out this operation. To prevent the mud and water present on the undercarriage from freezing, thus making it impossible to move the machine the following morning, always take the following precautions. q Remove any mud and water that may be present on the machine body.
LONG PERIODS OF INACTIVITY 3.6 LONG PERIODS OF INACTIVITY 3.6.1 BEFORE A PERIOD OF INACTIVITY IMPORTANT q To protect the hydraulic cylinder rods while the machine is not used, position the work equipment as shown in the figure on the right. (This prevents the cylinder rods from rusting). If the machine is going to remain unused for a long period (more than one month), proceed as indicated below. q Clean and wash all the machine components, then store the machine indoors.
TROUBLESHOOTING 3.7 TROUBLESHOOTING 3.7.1 IF FUEL RUNS OUT COMPLETELY Before starting the engine after running out of fuel, refuel and bleed the fuel system. For details on the bleeding procedure, see "4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE" - " BLEEDING THE FUEL CIRCUIT". 3.7.
TROUBLESHOOTING 3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS q When carrying out digging operations in water, if water gets on the pins of the work equipment, always add grease to the bucket articulations (1), (2), (3), (4) and (5) before work. q When carrying out heavy duty digging and deep digging operations, always add grease to the bucket articulations (1), (2), (3), (4) and (5) (total: 5 points) before work.
TROUBLESHOOTING 3.7.5.1 REMOVING AND INSTALLING THE BATTERY q Before removing the battery, disconnect the earth cable (-). If a tool touches the positive terminal and the frame of the machine at the same time, sparks may be generated. q When installing the battery, connect the earth cable (-) last. q Install the battery correctly. During this operation, take care to prevent the clamps from touching the terminals.
TROUBLESHOOTING 3.7.5.3 STARTING WITH BOOSTER CABLES When starting the engine with booster cables, proceed as indicated below. CONNECTING AND DISCONNECTING THE BOOSTER CABLES WARNING q When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (–). q When starting the engine with booster cables, always wear safety goggles.
TROUBLESHOOTING STARTING THE ENGINE CAUTION q Make sure that the safety levers of both machines are in the “locked” position. Also make sure that all the control levers are in NEUTRAL. 1. Make sure that the clamps hold the battery terminals firmly. 2. Start the engine of the machine used as starting aid and run it at high rpm. 3. Start the engine of the machine to be started (see "3.3.2 STARTING THE ENGINE").
TROUBLESHOOTING 3.7.6 OTHER TROUBLES q Always contact your Komatsu Dealer when you have to carry out this operation. q If the anomaly or its cause is not included in the table below, contact your Komatsu Dealer for the necessary repair. 3.7.6.1 ELECTRICAL CIRCUIT TROUBLE CAUSE Lights do not work satisfactorily even with engine running at high speed. (•) Faulty cables SOLUTION (•) Blown fuse (•) Check and repair any loose terminals and connections. • Adjust fan belt tension.
TROUBLESHOOTING 3.7.6.2 FRAME TROUBLE Travel speed, swing, boom, arm, bucket slow. Pump does not work correctly. Hydraulic oil temperature increases excessively. CAUSE SOLUTION • No hydraulic oil. • Restore level. See "CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE". • Foreign body in the hydraulic tank filter. • Clean. See "Every 2000 hours OF OPERATION". • No hydraulic oil. • Restore level. See"CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE". • Adjust fan belt tension.
TROUBLESHOOTING TROUBLE CAUSE • No fuel. • Air in fuel system. • Water in fuel system. • Pump or fuel injection nozzle faulty. Engine does not start with starter running. • Starter makes engine run slowly. • See "ELECTRICAL SYSTEM". • Excessive valve clearance. (•) Adjust valve clearance. • Too much oil in oil pan. • Restore level. See "CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE". • Change with fuel in compliance with standards. • Unsuitable fuel. • Air filter clogged.
THIS PAGE WAS INTENTIONALLY LEFT EMPTY 152
. MAINTENANCE 153
GUIDE TO MAINTENANCE 4.1 GUIDE TO MAINTENANCE WARNING q Oils, filters, coolant, gaskets, electric cables, and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. q The combustible material of some components may become extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale its fumes.
GUIDE TO MAINTENANCE q Avoid keeping loose objects or tools in your pockets: they may fall out and drop into the machine, especially when you open covers and work on the machine while bending over it. q When working on rocky areas, make sure that the undercarriage is not damaged and that there are no breakages, damages, worn parts, or loose or damaged nuts or bolts. q When washing the machine, do not direct the high-pressure water jet onto the radiator.
MAINTENANCE NOTES 4.2 MAINTENANCE NOTES q Use only Komatsu genuine spare parts. q Do not mix different types of oil.
MAINTENANCE NOTES 4.2.1.2 FUEL q Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or reduce its power. q Always refuel at the end of the workday. q When refuelling, make sure that there is no water on the fuel drum cover and take care not to draw condensate from the drum bottom. q If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit. 4.2.1.
MAINTENANCE NOTES 4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS) This system requires that oil samples be periodically collected and analysed. This is a preventive maintenance service, which makes it possible to identify faulty parts or worn machine components timely. It also allows many failures to be prevented and machine downtime to be reduced. Many years of experience and the availability of countless data and information allow Komatsu to accurately determine the conditions of the machine.
MAINTENANCE NOTES 4.2.1.5 STORING OIL AND FUEL q Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting into them. q When storing drums for a long period, position them on one side, so that the opening is lateral. This prevents moisture from being sucked in through the drum filling opening. If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.
MAINTENANCE NOTES 4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM q If the cables are wet or their insulating material is damaged, the electrical system leaks and this may result in malfunctions of the machine. q The maintenance operations required for the electrical system are the following: 1 - Check of the alternator belt tension. 2 - Check of the alternator belt for damage or breakages. 3 - Check of the battery charge level.
PARTS SUBJECT TO WEAR 4.3 PARTS SUBJECT TO WEAR The parts subject to wear like filters, bucket teeth, etc. must be changed when periodical maintenance is carried out or when they reach the wear limits. The timely change of these parts ensures an economic use of the machine. Use only Komatsu genuine parts, which alone can guarantee excellent quality and interchangeability.
FUEL, COOLANT AND LUBRICANTS 4.4 FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE ITEM / TANK / SYSTEM FLUID -30 -22 -20 -4 -10 14 0 32 10 50 20 68 30 86 CAPACITY (l) 40 50°C 104 122°F 1st filling Change 3,6 3,3 0,3 0,3 23,8 15,2 23,8 15,2 19 — 3,1 — SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 Travel gears OIL API CD reduction SAE 30 SAE 10W Hydraulic system SAE 10W-30 SAE 15W-40 Hydraulic system with biodegradable oil • See par. “4.4.1” a.
FUEL, COOLANT AND LUBRICANTS IMPORTANT q When the diesel sulphur content is less than 0,5%, change the engine oil according to the periodic maintenance intervals indicated in the operation and maintenance manual. If the sulphur content exceeds 0.5%, change the engine oil according to the following table: Sulphur content Engine oil change interval from 0.5 to 1.0% 1/2 of regular interval over 1.
FUEL, COOLANT AND LUBRICANTS 4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended: SUPPLIER KOMATSU SYNTHETIC BIODEGRADABLE OIL TYPE “HEES” BO 46 G4 (KES 07.
TIGHTENING TORQUES 4.5 TIGHTENING TORQUES 4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS CAUTION q If screws, nuts or other parts are not tightened with the required torque, they may become loose or damage the components with which they cooperate, and this may cause machine failures or operation problems. Always pay the utmost attention when carrying out tightening operations. If not specified otherwise, tighten the screws and nuts applying the torques specified in the table.
TIGHTENING TORQUES 4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS If not specified otherwise, tighten the nuts of the hoses applying the torque specified in 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 a Nm (Newton metre): 1 Nm = 0.
LUBRICATION 4.6 LUBRICATION 4.6.1 LUBRICATION DIAGRAM IMPORTANT q For details on how to lubricate specific parts, see "4.8 MAINTENANCE PLAN". q The type of lubricant to be used is indicated in the lubricant table (see "4.4 FUEL, COOLANT AND LUBRICANTS").
PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS 4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS To ensure safety at any moment while driving and using the machine, the operator must carry out all the routine maintenance operations prescribed. Furthermore, the operator must periodically change the components indicated in the table in the following page, which are especially related to safety and fire-prevention rules.
PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS 4.7.1 SAFETY-RELATED PARTS No. Safety-related components that periodically need changing Q.
MAINTENANCE PLAN 4.8 MAINTENANCE PLAN If the machine is equipped with hydraulic breaker, the maintenance schedule for some components will be different. For further details, see "4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER". 4.8.1 MAINTENANCE PLAN WHEN REQUIRED a. b. c. d. e. f. g. h. i. CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE..................................................................... CHECKING THE BATTERY CHARGE LEVEL .....................................
MAINTENANCE PLAN 4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER In machines equipped with breaker hydraulic oil deteriorates more rapidly than in machines equipped with standard equipment. When using the breaker, always keep to the following maintenance plan. 4.8.2.a CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100÷150 hours of operation and for the successive changes keep to the indications given in the table on the right.
MAINTENANCE PROCEDURES 4.9 MAINTENANCE PROCEDURES 4.9.1 WHEN REQUIRED 4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE WARNING q Remove the air filter only after stopping the engine and do not start the engine if the air filter is open. q When compressed air is used to clean the filter, dust may get into the eyes. Wear safety goggles and a dust mask during the cleaning operations. Checking the cartridge 1. Open the engine hood. For paragraph"3.2.5 ENGINE HOOD".
MAINTENANCE PROCEDURES 5. Slightly strike the filtering element (4) on the palm of your hand, in such a way as to remove the dust, and blow compressed air on the inner surface, keeping the air jet at a distance of approximately 15 cm and the pressure below 4-5 bars. 6. After the cleaning operations, inspect the filtering surface for damage by introducing a lamp into it and carefully check the front gaskets. If the cartridge is damaged, change it. 7.
MAINTENANCE PROCEDURES 4.9.1.b CHECKING THE BATTERY CHARGE LEVEL WARNING q Check the charge level only with the engine at rest. q To prevent gas explosions, do not use naked flames, do not smoke and avoid producing sparks due to short circuits. q The battery electrolyte is dangerous; in case of contact with the eyes or skin, rinse with plenty of water and consult a doctor without delay. The battery is maintenance-free.
MAINTENANCE PROCEDURES 4.9.1.c CLEANING THE WATER SEPARATOR FILTER WARNING q Change the filter after work, when the engine has cooled down to 40÷45°C. q During these operations some fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire. 1. Open the radiator cover. For further details, see "3.2.6 RADIATOR COVER". 2. Turn the valve (1) of the water separator to the closed position (A). 3.
MAINTENANCE PROCEDURES 4.9.1.d DRAINING THE FUEL TANK WARNING q When draining the fuel tank, avoid spilling fuel, since this may cause fires. q If some fuel is accidentally spilled, clean the dirty area immediately, in order to prevent it from getting slippery and to avoid fires. 1. Swing the turret so that the drain valve (1) is positioned between the tracks. 2. Open the radiator cover. For details, see paragraph "3.2.6 RADIATOR COVER". 3.
MAINTENANCE PROCEDURES ADJUSTMENT DANGER q The grease contained in the hydraulic cylinder is pressurized. For this reason, do not give the grease valve (1) more than one turn when loosening it; in fact, if the valve is loosened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator.. Do not loose any component apart from the valve (1). If the track tension does not decrease after this operation, contact your Komatsu Dealer.
MAINTENANCE PROCEDURES To reduce the track tension, proceed as follows: DANGER q It is extremely dangerous to let the grease out following any procedure different from those illustrated below. q If the track tension cannot be reduced with this operation, contact your Komatsu Dealer, 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.
MAINTENANCE PROCEDURES 3. When more than half of the steel core cords at the centre of the track are cut. RYA07520 4. When one or more steel cores have come off the track or are pushed out due to excessive tension. RYA03240 5. If the rubber track cannot be tensioned correctly through the injection of grease, check the track tensioner gaskets and if necessary change them or even the track. (See "4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION").
MAINTENANCE PROCEDURES 4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION The rubber tracks wear out to different degrees, depending on the work conditions and on the characteristics of the surface on which the machine is working. Therefore, it is necessary to check the track wear and tension frequently, in order to keep the tracks correctly tensioned. IMPORTANT q To carry out the check and the corresponding maintenance operation, stop the machine on firm and level ground. Check both tracks.
MAINTENANCE PROCEDURES To increase the track tension, proceed as follows: IMPORTANT q The standard adjustment value is low, therefore take care to avoid increasing the rubber track tension excessively. 1. 2. Carefully clean the grease valve (1) and inject grease through the grease nipple (2) until reaching the desired tension. If the rubber track cannot be tensioned enough by injecting grease, it is necessary to change the track or the track tensioner gaskets.
MAINTENANCE PROCEDURES 4.9.1.h CHANGING THE RUBBER TRACKS WARNING q This operation must be carried out by two persons. One operator must be seated in the cab and manoeuvre the machine following the signals of the other operator who carries out the change and the adjustment. q The track must be changed with the frame raised from the ground; be careful not to shift any control lever while the operator is working. q During the change do not remove any component apart from the track.
MAINTENANCE PROCEDURES Stop the machine on a firm and level surface and lower the equipment to the ground. 1. Raise the undercarriage using boom and arm. Carry out this operation shifting the control levers very slowly. 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 a short distance. 4.
MAINTENANCE PROCEDURES INSTALLING THE RUBBER TRACKS 1. Raise the undercarriage using boom and arm and make sure that the grease contained in the cylinder has been eliminated. Carry out this operation shifting the control levers very slowly. 2. Install the rubber tracks on the sprocket by fitting the driving blocks. 3. Turn the sprocket (1) as if in reverse, then push the track towards the turret. RYA05230 4. Using a steel tube (2), position the track and turn the sprocket again. 5.
MAINTENANCE PROCEDURES 4.9.1.i BLEEDING THE HYDRAULIC SYSTEM 1. Start the engine and let it idle for approximately 10 minutes (see "3.3.2 STARTING THE ENGINE"). 2. Extend all cylinders 4-5 times, stopping them at approx. 100 mm from the end of stroke. IMPORTANT q 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. 3.
MAINTENANCE PROCEDURES 4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE WARNING q Dirt, oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires. Check frequently and repair any leakage immediately; if they occur repeatedly, contact your Komatsu Dealer. For details on the following items, see "3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE".
MAINTENANCE PROCEDURES 4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION 4.9.5.a LUBRICATION IMPORTANT q Clean the grease nipples before applying the greasing pump. q After lubrication, remove all the contaminated grease that may have spread out of the nipples. q If the machine is used in difficult conditions, carry out this operation more frequently than usual.
MAINTENANCE PROCEDURES (1) Bucket-link connection pins (1 point) (2) Arm–bucket connection pin (1 point) (3) Arm–link connection pin (1 point) (4) Bucket cylinder rod end (1 point) (5) Link connection pin (1 point) (6) Boom swing bracket pin (1 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 (1 point) (11) Boom cylinder rod end (1 point) (12) Boom–arm connection pins (1 point) (13) Bucket cylinder base pin (1 point)
MAINTENANCE PROCEDURES 4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE WARNING q Change the oil with the machine parked on a level surface and the work equipment resting on the ground. q Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40÷45°C before draining the oil.
MAINTENANCE PROCEDURES 4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE WARNING q Change the filtering element after work, when the engine has cooled down to 40÷45°C. q During these operations some fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire. q Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of according to the regulations in force. FUEL FILTER 1. Open the engine hood.
MAINTENANCE PROCEDURES 4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS WARNING q Soon after the machine has been stopped, the engine oil is very hot and may cause burns; let the oil cool down to 40÷45° C before carrying out any check. q Loosen the cap slowly to release any residual pressure. 1. The check must be carried out on each reduction gear, with the drain plug (P) in low position and perpendicular to the ground.
MAINTENANCE PROCEDURES 4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION WARNING q Soon after the machine has been stopped, the engine is very hot and may cause burns; let the engine cool down before carrying out any check. q To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instructions given in paragraph "3.2.8 TILTING THE CAB FLOOR" or have this operation carried out by your Komatsu Dealer.
MAINTENANCE PROCEDURES 4.9.5.g DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used) WARNING q To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instructions given in paragraph "3.2.8 TILTING THE CAB FLOOR" or have this operation carried out by your Komatsu Dealer.
MAINTENANCE PROCEDURES 4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS. 4.9.6.a CHANGING THE HYDRAULIC OIL FILTER WARNING q To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instructions given in paragraph "3.2.8 TILTING THE CAB FLOOR" or have this operation carried out by your Komatsu Dealer.
MAINTENANCE PROCEDURES Extend the boom, arm and bucket cylinders completely, as shown in the figure, and remove the filler cap (F). Put back the cap and pressurize the tank by lowering the equipment to the ground. IMPORTANT q In machines equipped with breaker hydraulic oil deteriorates more rapidly than in machines used for simple digging operations.
MAINTENANCE PROCEDURES 4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS WARNING q As soon as the machine has been stopped the oil is very hot and may cause burns; let the oil cool down until reaching 40÷45°C before changing it. q Loosen the cap slowly to release any residual pressure. q Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of according to the regulations in force.
MAINTENANCE PROCEDURES 4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS and every 1000 HOURS. 4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER WARNING q To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instructions given in paragraph "3.2.8 TILTING THE CAB FLOOR" or have this operation carried out by your Komatsu Dealer.
MAINTENANCE PROCEDURES 7. Loosen the screws (1), remove the plate (2) and slowly loosen the filler cap (F) to release the residual pressure from the tank. 8. Remove the drain plug (2) and let the oil flow out, gathering it into a container with suitable capacity. 9. Loosen the clamps (3), remove the suction pipe (4) and let the oil that is still in the tank flow out. 10. Remove the screws (5), remove the flange (6) and clean the air intake filter (7).
MAINTENANCE PROCEDURES IMPORTANT q In machines equipped with breaker hydraulic oil deteriorates more rapidly than in machines used for simple digging operations. Change the oil following the instructions given in the table. Replacement interval for hydraulic oil Replacement interval (H) 2000 1500 1000 500 0 20 40 60 80 100 Breaker operating ratio (%) RWA07630 4.9.7.
MAINTENANCE PROCEDURES 3. Loosen and remove the upper cap (2) of the radiator. 4. Open the radiator drain valve (3), remove the drain plug (4) on the engine block and let the fluid flow out, gathering it in a container with suitable capacity. Drain the coolant tank (5) while the fluid flows out. 5. Close the drain valve (3), put back the plug (4) on the engine block and fill the radiator with new fluid (see "4.4 FUEL, COOLANT AND LUBRICANTS"). 6.
TECHNICAL SPECIFICATIONS 201
TECHNICAL DATA 5.1 TECHNICAL DATA Unit of measurement PC14R-2 Operating weight (Operator included: 80 kg) (kg) 1480 Bucket capacity (m3) 0,044 - Komatsu 3D67E-1A diesel engine KW (HP)/rpm 11,2(15)/2600 Engine Engine power 202 A Total length mm 3380 B Total height mm 2310 C Total width mm 1000 D Track width mm 230 E Swing radius mm 825 F Total length of the tracks mm 1370 G Tumbler distance mm 1015 Min.
TECHNICAL DATA Operating characteristics Unit of measurement PC14R-2 A Max. digging outreach mm 3635 B Max. digging depth mm 2000 C Max. digging height mm 3285 D Max. vertical wall digging depth mm 1450 E Max. dumping height mm 2295 F Work equipment min. swing radius mm 1485 Work equipment min. swing radius (with boom swing) mm 1085 G Max. outreach at ground level mm 3545 H Max. blade lifting height mm 280 I Max.
LIFTING CAPACITIES 5.2 LIFTING CAPACITIES 5.2.1 LIFTING CAPACITIES DANGER q According to the harmonized standard EN474-5 (§ 4.1.7.5), the 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. NOTE q The load does not exceed 87% of the hydraulic lifting capacity or 78% of the tipping limit.
LIFTING CAPACITIES ROPS CANOPY + STANDARD ARM + STANDARD COUNTERWEIGHT + RAISED BLADE 1m A- 1.5 m 2m 2.5 m Unit: kg 3m 3.5 m Max. B 3.0 m 2.5 m 2.0 m 1.5 m 1.0 m 0.5 m 0m - 0.5 m - 1.0 m - 1.
LIFTING CAPACITIES ROPS CANOPY + LONG ARM + STANDARD COUNTERWEIGHT + RAISED BLADE A- 1m 1.5 m 2m 2.5 m Unit: kg 3m 3.5 m Max. B 3.0 m 2.5 m 2.0 m 1.5 m 1.0 m 0.5 m 0m - 0.5 m - 1.0 m - 1.
AUTHORISED OPTIONAL EQUIPMENT 207
AUTHORIZED OPTIONAL EQUIPMENT 6.1 AUTHORIZED OPTIONAL EQUIPMENT CAUTION q When installing and using optional equipment, carefully read the relevant manual and keep to the instructions given therein. q Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated (see "6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT").
AUTHORIZED OPTIONAL EQUIPMENT 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT WARNING q The installation of long or heavy work equipment may affect the stability of the machine. Therefore, be particularly careful when moving down a steep slope or when swinging the equipment on a slope, since the machine may lose its balance and overturn. q Avoid carrying out the following operations, since they are particularly dangerous. 1. Travelling downhill with lifted equipment. 20 ~ 30 cm 2.
AUTHORIZED OPTIONAL EQUIPMENT 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT 6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT (Specific weight of the handled material = 1.8 t/cu m) Height (mm) MAX. CAPACITY SAE (m3) MAX. OPERATING PRESSURE (bar) MAX. FLOW RATE (l/min.) 400 – 0,055 – – 24 1000 – 0,040 – – Ditch-digging bucket 24 800 – 0,045 – – Clamshell bucket 60 250 900 0,020 150 20 Hydraulic breaker 90 – 815 – 110 25 Drill 75 a 200 q 1000 – 150 25 MAX.
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2.1 POSITION OF THE DEVICES (1) (2) 1. Quick couplers Selection valve (3) (4) Optional equipment control pedal Pedal locking device (for the optional equipment control pedal) Quick couplers The quick couplers (1) are used to connect the pipes to the ends of the equipment. When removing the equipment, protect the quick couplers with the plugs (A).
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 2. Selection valve The selection valve (2) regulates the flow of the hydraulic oil and has two positions. q Position (a): for applications requiring the use of the generic equipment. Spool (A) completely rotated counterclockwise. q Position (b): for applications requiring the use of the hydraulic breaker. Spool (A) completely rotated clockwise. Width across face of square portion of spool (A): 9 mm 3.
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2.2 HYDRAULIC CIRCUIT 6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT WARNING q The machine must be parked on a level surface, with the equipment resting on the ground. q When the connecting pins are removed or installed, chips may come off; always wear gloves, safety goggles and helmet. q The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during work.
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2.2.3 BLEEDING 1. After connecting the pipes, start the engine and let it idle for approximately 10 minutes (see "3.3.2 STARTING THE ENGINE"). 2. Extend all cylinders 4-5 times, stopping them at approx. 100 mm from the end of stroke. IMPORTANT q 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. 3.
OPERATING THE EQUIPMENT 6.3 OPERATING THE EQUIPMENT WARNING q 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 inadvertently pressed, this may cause serious accidents. USING THE HYDRAULIC BREAKER The breaker is operated by pressing the lower part of the equipment control pedal (B). NOTE q If it is necessary to adjust the oil flow, have this operation carried out by your Komatsu Dealer.
OPERATING THE EQUIPMENT USE OF GENERIC EQUIPMENT SUCH AS THE CRUSHER Generic equipment is operated by pressing the equipment control pedal as indicated below. A Upper part (A) pressed: the oil flows to right side of the arm (hydraulic tank side). Lower part (B) pressed: the oil flows to the left side of the arm (operator seat side). NOTE q If it is necessary to adjust the oil flow, have this operation carried out by your Komatsu Dealer.
PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT 6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT The instructions given below must be strictly followed when the hydraulic excavator is fitted with a piece of equipment. IMPORTANT q Choose the type of equipment that is most suitable to the hydraulic excavator on which it must be installed. q Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated (see "6.1.
PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT 2. It is absolutely necessary to keep the pressure of excavator on the breaker constant as the bit penetrates ground. Always accompany the breaker as it penetrates and use excavator arms to obtain such a pressure as to keep undercarriage lifted approx. 5 cm from the ground. Avoid lifting the undercarriage more than necessary. the the the the RYA03850 3.
PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT ALWAYS AVOID THE FOLLOWING INCORRECT USES: To ensure long machine life and safe work, the following operations should be avoided. IMPORTANT q 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 breaker. RYA03890 2. Swinging the turret while using the breaker. RYA03900 3.
PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT 5. Levering with the tool after driving it into the material to be broken. RYA03930 6. Hitting the ground with the breaker bit. RYA03940 7. Lifting the machine by levering on the breaker bit with the bucket cylinder completely extended.
PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT GREASING Supply grease in the correct position. RYA05800 IMPORTANT q If grease is injected 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 components while the breaker is being used. Therefore, make sure to carry out the greasing operation with the breaker in the correct position.
THIS PAGE WAS INTENTIONALLY LEFT EMPTY 222
© 2005 KOMATSU UTILITY EUROPE S.p.A.
