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Komatsu PC110R-1 Operation & Maintenance Manual

Hydraulic excavator
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Operation & Maintenance
Manual
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing this machine.
This manual should be kept inside the cab for refer-
ence and periodically reviewed by all personnel who
will come into contact with the machine.
PC110R
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC110R-1 2265010001
WEAM000402
-1
and up

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Summary of Contents for Komatsu PC110R-1

  • Page 1 WEAM000402 Operation & Maintenance Manual PC110R HYDRAULIC EXCAVATOR SERIAL NUMBER PC110R-1 2265010001 and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintain- ing this machine.

  • Page 3: Foreword

    1.1 FOREWORD • This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary in- formation on the machine and the safety regulations related to it, together with the use and maintenance instruc- tions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.

  • Page 4: Information On Safety

    Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op- eration or maintenance of the machine; for this reason, the safety messages included in this manual and applied onto the machine may not include all possible safety precautions.
  • Page 5 INFORMATION ON SAFETY DANGER • It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility cannot be held liable for any damage to persons, property or the machine, if this has been tampered with by modifying the standard setting of the hydraulic system.

  • Page 6: Introduction

    1.3 INTRODUCTION 1.3.1 INTENDED USES The Komatsu Utility MACHINES described in this manual have been designed and constructed to be used by duly trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS. If provided with suitable safety devices, they can be used with authorized optional equipment having the character- istics illustrated at point “6.1 AUTHORIZED OPTIONAL EQUIPMENT”.

  • Page 7: Main Characteristics

    INTRODUCTION 1.3.3 MAIN CHARACTERISTICS • Simple and easy operation. • Hydrostatic transmission obtained through two variable displacement motors that operate epicyclic reduction gears equipped with hydraulic brakes with negative control. • Upper structure rotation achieved through an axial piston hydraulic motor acting on an epicyclic reduction gear. •...

  • Page 8: Product Identification

    PRODUCT IDENTIFICATION 1.4 PRODUCT IDENTIFICATION The Komatsu Utility EXCAVATOR and its main components are identified by serial numbers stamped on the iden- tification plates. The serial number and the identification numbers of the components are the only numbers that must be indicated to the Dealer when requiring assistance and ordering spare parts.

  • Page 9: Ngine Serial Number And Exhaust Gas Emission Plate

    MASSA MAX ASSE ANT. - MAX WEIGHT FRONT AXLE ZUL. ACHSLAST VORN - POIDS MAX ESSIEU AV MASSA MAX ASSE POST. - MAX WEIGHT REAR AXLE ZUL. ACHSLAST HINTEN - POIDS MAX ESSIEU AR MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VICENTINA (VI) ITALY 21D-98-12580 RWA34270 MODEL...

  • Page 10: Travel Reduction Gear Serial Number

    PRODUCT IDENTIFICATION 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number of the travel reduction gear is stamped on the plate positioned on the outer side of the reduction gear cover. RWA18210 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER The serial number of the swing reduction gear is stamped on the plate positioned on the side of the reduction gear body.

  • Page 11: Serial Numbers And Dealer's Address

    PRODUCT IDENTIFICATION 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS Machine n. Model Engine n. Travel reduction gear n. Swing reduction gear n. Cab n. Dealer: Address Tel. Person to contact: NOTES:...

  • Page 12: Table Of Contents

    CONTENTS Page CONTENTS FOREWORD ..............INFORMATION ON SAFETY .
  • Page 13 CONTENTS Page PRECAUTIONS TO BE TAKEN WHEN WORKING ........2.4.1 STARTING THE ENGINE .
  • Page 14 CONTENTS Page DESCRIPTION AND USE OF THE MACHINE SAFETY LOCKS..............3.1.1 MACHINE LOCKS .
  • Page 15 CONTENTS Page PARKING THE MACHINE ............3.7.1 PARKING ON LEVEL GROUND .
  • Page 16 CONTENTS Page MAINTENANCE GUIDE TO MAINTENANCE ............MAINTENANCE NOTES .
  • Page 17 CONTENTS Page 4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION ......4.7.6.a CHECKING THE RADIATOR FLUID LEVEL ......4.7.6.b LUBRICATING THE SWING JOINT .
  • Page 18 CONTENTS Page TECHNICAL DATA TECHNICAL DATA..............5.1.1 STANDARD OVERALL DIMENSIONS .

  • Page 19: Safety And Accident Prevention

    SAFETY AND ACCIDENT PREVENTION...

  • Page 20: Safety, Noise And Vibration Plates

    Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on the new piece.

  • Page 21: Pictograms And Relevant Meanings

    SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine are accompanied or represented by pictograms. The personnel in charge with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly;...
  • Page 22 SAFETY, NOISE AND VIBRATION PLATES SAFETY DISTANCE • Do not get near or stand within the machine working area. RWA18280 FILLING THE HYDRAULIC SYSTEM WITH (Only for machines in which the synthetic biodegradable oil type HEES is used) BIO-OIL RWA34380 HYDRAULIC OIL TOPPING UP RWA00050 REFUELLING...
  • Page 23 SAFETY, NOISE AND VIBRATION PLATES FUEL FILTER RWA00060 ENGINE AIR SUCTION FILTER RWA00090 ENGINE COOLANT PRESSURE RWA00110 HYDRAULIC OIL LEVEL RYA12880 HYDRAULIC OIL FILTER RWA00070 ELECTRIC OUTLET 12 V RWA00120...
  • Page 24 SAFETY, NOISE AND VIBRATION PLATES ANCHORAGE POINT RWA00200 EMERGENCY EXIT RWA00190 DO NOT LIFT MORE THAN 1000 KG (Only for machine without overload warn- ing device) > 10 0 0 Kg RYA12890...

  • Page 25: Position Of The Noise Plates

    Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a noise plate, make sure that this plate is applied also on the new piece.

  • Page 26: Vibrations To Which The Operator Is Subjected

    SAFETY, NOISE AND VIBRATION PLATES 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED • According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma- chine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is subjected to vibrations lower than 0.5 m/sq.sec.

  • Page 27: General Precautions

    GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES • Only trained and authorized personnel can use the machine and perform maintenance operations. • Follow all the safety rules, precautions and instructions when using the machine or performing maintenance op- erations.

  • Page 28: Unauthorized Modifications

    2.2.4 UNAUTHORIZED MODIFICATIONS • Any modification made without the authorization of Komatsu Utility can involve hazards. • Before making a modification, consult your Komatsu Utility Dealer. Komatsu Utility declines any responsibility for injuries or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATOR’S SEAT •...

  • Page 29: Getting On And Off The Machine

    GENERAL PRECAUTIONS 2.2.6 GETTING ON AND OFF THE MA- CHINE • Do not jump on or off the machine, either when it is at rest and when it is moving. • When getting on or off the machine, always use the handles and the tracks;...

  • Page 30: Preventing Burns

    GENERAL PRECAUTIONS 2.2.8 PREVENTING BURNS • If the engine coolant, the engine oil and the hydraulic oil are hot, use heavy cloths and wear gloves, heavy clothing and safety goggles before carrying out any check or touching the hot parts. •...

  • Page 31: Preventing Damage Caused By The Work Equipment

    • When installing and using optional equipment, carefully read the relevant instruction manual and keep to the in- dications given therein. • Do not use optional or special equipment without the authorization of Komatsu Utility or the Komatsu Utility Deal- The installation and use of unauthorized equipment may create safety problems and adversely affect the effi- ciency and life of the machine.

  • Page 32: Precautions To Be Taken Before Starting The Engine

    (earth, stones, etc.). • Check the safety belt and change it if it is broken or damaged. Replace any component only with homologated parts available at Komatsu Utility or its Dealers.

  • Page 33: Room Ventilation

    PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.4 ROOM VENTILATION • Before starting the machine in confined or poorly ventilated places, provide for proper ventilation or connect the engine ex- haust pipe to a suction duct. The engine exhaust gases can be deadly.

  • Page 34: Precautions To Be Taken When Working

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.1 STARTING THE ENGINE • Before getting on the machine, walk around it and check for people and objects that might be in the way. • Do not start the engine if warning plates have been attached to the control levers. •...

  • Page 35: Moving The Machine

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.4 MOVING THE MACHINE • When moving the machine, position the front bucket at about 40-50 cm from the ground; this position makes it possible to evaluate the space required for the movements more precisely and at the same time ensures the stability of the machine.

  • Page 36: Moving On Slopes

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.5 MOVING ON SLOPES • Operations on slopes and on river or lake banks with damp ground may result in the tipping over or slipping of the machine. • 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.

  • Page 37: Working On Slopes

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 WORKING ON SLOPES WRONG • When working on slopes, if possible avoid rotating the upper structure, since the machine may lose balance and overturn. It is particularly dangerous to swing on slopes when the bucket is full.

  • Page 38: Preventing Electrocution

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.8 PREVENTING ELECTROCUTION • 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 electrical lines always respect the minimum safety distances prescribed by the competent authorities and by the accident-prevention rules in force.

  • Page 39: Visibility

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.9 VISIBILITY • Switch on the working lights as soon as visibility decreases. • If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.

  • Page 40: Parking The Machine

    PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.13 PARKING THE MACHINE • Park the machine on firm and level ground. If this is not possible and it is necessary to park on a slope, position the machine with the bucket directed downwards and carry out the following oper- ations: 1 - Rotate the bucket to the dumping position and lower the arms until thrusting the teeth into the ground.

  • Page 41: Transporting The Machine On Other Vehicles

    TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE • Loading and unloading the machine on/from another vehicle al- Ramps ways involve potential hazards. Proceed with extreme care. • Perform loading and unloading on firm, level ground. Maintain a safety distance from the edges of ditches or from road sides.

  • Page 42: Battery

    BATTERY 2.6 BATTERY 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES • Electrolytic batteries contain sulphuric acid which can cause burns. It can also corrode clothing and make holes in it. If you get splashed with battery acid, immediately wash the affected part with plenty of water.

  • Page 43: Precautions For Emergency Recovery

    PRECAUTIONS FOR EMERGENCY RECOVERY 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY • Before moving the machine, make sure that all the controls are in neutral. • Incorrect manoeuvres may result in serious injuries or even death. • To move the machine, use properly dimensioned steel cables; do not use worn cables or cables with broken strands (A), twist- ed cables (B), deformed cables (C).

  • Page 44: Precautions To Be Taken During Maintenance

    PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.1 WARNING PLATES • Before starting any maintenance operation, position the ma- chine on a firm and level surface, rest the equipment onto the ground, engage the safety locks of either the equipment and the controls and stop the engine.

  • Page 45: Equipment

    60 cm in order not to damage the warning plates and the pictograms. If the plates are damaged, request Komatsu Utility or your Ko- matsu Utility Dealer to send you spare plates and change them. • Water into the electrical system provokes the oxidation of the contacts and may hinder the start of the machine or even make it start suddenly and abruptly.

  • Page 46: Use Of The Engine During Maintenance

    PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.7 USE OF THE ENGINE DURING MAINTENANCE • During maintenance operations, run the engine 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.

  • Page 47: Rules For Refuelling And Adding Oil

    PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.10 RULES FOR REFUELLING AND ADD- ING OIL • Keep away from naked flames while refuelling or adding oil. • Spilled fuel or oil make the ground slippery and may cause acci- dents; clean any dirty area immediately and carefully. •...

  • Page 48: Precautions Concerning The Battery And The Alternator

    PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.13 PRECAUTIONS CONCERNING THE REMOVAL BATTERY AND THE ALTERNATOR • When repairing the electrical system, disconnet the battery in order to stop the flow of current. IMPORTANT • Disconnect first the negative earth cable (-) and then the positive cable (+).

  • Page 49: Precautions Concerning High-Pressure Hoses

    PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES • Do not bend high-pressure hoses or rub them with sharp or abrasive objects. Do not use bent or cracked pipes or hoses that were previously rejected because of leaks or fastening defects, since they may burst during use.

  • Page 50: Cooling Fan And Fan Belt

    PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.18 COOLING FAN AND FAN BELT • Be careful to the rotating parts and do not allow anyone to get too close to these parts, since clothes or parts of the body may get caught into them. •...
  • Page 51 THE MACHINE AND ITS OPERATIONS...

  • Page 52: Safety Locks

    SAFETY LOCKS 3.1 SAFETY LOCKS DANGER • If it is necessary to stop the machine, lower the equipment to the ground and always engage the safety device by shifting the lever to the lock position. (See “3.3.5 pos. 1 MACHINE CONTROLS). •...

  • Page 53: General Views

    GENERAL VIEWS 3.2 GENERAL VIEWS 3.2.1 FRONT GENERAL VIEW (MONOBOOM) RYA15420 1 - Bucket 10 - Track 2 - Bucket cylinder 11 - Blade cylinder 3 - Arm 12 - Idler roller 4 - Arm cylinder 13 - Blade 5 - Boom 14 - Boom swing cylinder 6 - Revolving support 15 - Lifting cylinder...

  • Page 54: Front General View (Two-Piece Boom)

    GENERAL VIEWS 3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM) RYA15430 1 - Bucket 10 - Sprocket 2 - Bucket cylinder 11 - Undercarriage 3 - Arm 12 - Track 4 - Arm cylinder 13 - Blade cylinder 5 - Two-piece boom - upper part 14 - Idler roller 6 - Two-piece boom cylinder 15 - Blade...

  • Page 55: Cab Inside General View

    GENERAL VIEWS 3.2.3 CAB INSIDE GENERAL VIEW 1 - Safety lever 2 - Arm - rotation control 3 - Lifting - bucket control 4 - Left track control pedal 5 - Right track control pedal 6 - Boom swing control pedal 7 - Hydraulic hammer control 8 - Optional equipment control pedal RWA18760...
  • Page 56 GENERAL VIEWS 9 - Instrument panel 10 - Switch panel 11 - Blade control 12 - Accelerator control 13 - Rotation locking pin RYA15460 RWA18650...

  • Page 57: Instruments And Controls

    INSTRUMENTS AND CONTROLS 3.3 INSTRUMENTS AND CONTROLS 3.3.1 INSTRUMENTS 00000 RYA15470 1 - Hour meter 2 - Engine coolant temperature indicator 3 - Fuel level indicator HOUR METER This instrument indicates the total number of operating hours of the engine. The count is continuous and the number is increased by 1 when the engine has run for one hour, independently of its speed.
  • Page 58 INSTRUMENTS AND CONTROLS ENGINE COOLANT TEMPERATURE INDICA- This instrument indicates the temperature of the engine coolant, which in normal conditions should be 80-85°C. After starting the engine and before starting work, let it warm up until the temperature indicator reaches the green range. If the indicator exceeds the limit values while the engine is run- ning and reaches the overheating red range, let the engine idle until the indicator returns to the normal temperature green range.

  • Page 59: Warning Lights

    INSTRUMENTS AND CONTROLS 3.3.2 WARNING LIGHTS 00000 RYA15480 1 - Generator warning light 2 - Pre-heating warning light 3 - Engine oil pressure warning light 4 - Air cleaner clogging warning light GENERATOR WARNING LIGHT This warning light comes on and activates the acoustic alarm when the starting circuit is energized and goes out when the en- gine exceeds the idling speed;...
  • Page 60 INSTRUMENTS AND CONTROLS PREHEATING WARNING LIGHT This warning light comes on when the ignition key is turned to po- sition « » to start the engine at low temperatures. (See “3.6.2.2 Starting with cold engine or in cold climates”). RWA07160 ENGINE OIL PRESSURE WARNING LIGHT This warning light comes on and activates the acoustic alarm with engine at rest when the starting circuit is energized and goes out...

  • Page 61: Switches And Push Buttons

    INSTRUMENTS AND CONTROLS 3.3.3 SWITCHES AND PUSH BUTTONS 1 - Fan switch 2 - Air conditioner switch (if provided) 3 - Working light and instrument light switch 4 - Horn 5 - Clamshell bucket anticlockwise rotation control button 6 - Clamshell bucket clockwise rotation control button RYA13720 RYA15490...
  • Page 62 INSTRUMENTS AND CONTROLS 7 - Starting switch 8 - Revolving light switch (if installed) 9 - Speed increase selection push-button 10 - WORKING MODE selector 11 - Boom overload alarm switch 12 - Optional equipment control selection switch 13 - Hydraulic pliers use enabling switch 14 - Demolition hammer control button 15 - Windshield wiper / washer switch RYA15500...
  • Page 63 INSTRUMENTS AND CONTROLS FAN SWITCH This is a three-speed switch that operates the fan motor. Turn the switch clockwise to increase the ventilation intensity. If operated after the tap installed on the heater has been opened, this switch ensures the circulation of warm air and serves as heat- ing switch (see “3.5.4 VENTILATION AND HEATING”).
  • Page 64 INSTRUMENTS AND CONTROLS CLAMSHELL BUCKET ANTICLOCKWISE RO- TATION CONTROL BUTTON This is a single-function button and permits the anticlockwise rota- tion of the clamshell bucket. When it is released, the bucket stops. For further details on its use, see “6.3.1 CLAMSHELL BUCKET CONTROL”.
  • Page 65 INSTRUMENTS AND CONTROLS IGNITION SWITCH This is a rotary key switch with four positions marked by the fol- lowing symbols: « » - (OFF) - I - « » (START). For further details on the use of this switch, see “3.6.2 STARTING THE ENGINE”.
  • Page 66 INSTRUMENTS AND CONTROLS 10 - WORKING MODE SELECTOR This switch is used to select the power of the work equipment and has two positions: Position “P” (LED off) for normal applications. Position “E” (LED on) for light-duty applications. IMPORTANT • When the engine is stopped, the selector is always in posi- tion “P”...
  • Page 67 INSTRUMENTS AND CONTROLS 12 - OPTIONAL EQUIPMENT CONTROL SELEC- TION SWITCH CAUTION • This switch must be used only for equipment that requires continuous and prolonged operation (for example, the bush cutter). This switch changes the function of the control positioned on the right joystick lever (see “3.3.3 pos.
  • Page 68 INSTRUMENTS AND CONTROLS 14 - DEMOLITION HAMMER CONTROL BUTTON When pressed, this button operates the demolition hammer; when the button is released, the hammer stops. For further details on its use, see “6.2.1 DEMOLITION HAMMER CONTROL”. RWA20040 15 - WINDSHIELD WIPER / WASHER SWITCH With the first click it operates the windshield wiper, while with the second click (with automatic return to the first) it operates the windshield washer.

  • Page 69: Electrical Accessories

    INSTRUMENTS AND CONTROLS 3.3.4 ELECTRICAL ACCESSORIES 1 - Engine acoustic alarm 2 - Overhead lamp 3 - Electric outlet RYA15540 RYA15550 RYA12630...
  • Page 70 INSTRUMENTS AND CONTROLS ENGINE ACOUSTIC ALARM The acoustic alarm is operated when the circuits are energized with the ignition key (rotation to position «I») and is automatically disconnected after the automatic check on the warning lights. The sounding of the alarm during operation signals: •...

  • Page 71: Machine Controls

    INSTRUMENTS AND CONTROLS 3.3.5 MACHINE CONTROLS 1 - Safety device control lever 2 - Left equipment control lever 3 - Right equipment control lever 4 - Two-piece boom control pedal 5 - Left travel and steering control lever 6 - Right travel and steering control lever 7 - Boom swing control pedal RWA18760 RYA15560...
  • Page 72 INSTRUMENTS AND CONTROLS 8 - Blade control lever 9 - Hand accelerator 10 - Upper structure rotation locking lever RYA15580 RWA18710...
  • Page 73 INSTRUMENTS AND CONTROLS SAFETY DEVICE CONTROL LEVER DANGER • Before leaving the operating position, lower the equipment to the ground and lock the safety device. To lock the safety device, raise the lever (8), which will automati- cally move to the lock position. To release the safety device, push the lever (8) downwards until it engages the check coupling.
  • Page 74 INSTRUMENTS AND CONTROLS 2-3 - EQUIPMENT CONTROL LEVERS DANGER • Before carrying out any manoeuvre with these levers, the operator must be seated in the work position with fastened safety belt; before any manoeuvre he must perform the operations described in “3.12 US- ING THE WORK EQUIPMENT”.
  • Page 75 INSTRUMENTS AND CONTROLS If the levers are operated in directions that are inclined with respect to the machine axis, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each sin- gle function are engaged at the same time. LEVER 2 (COMBINED MANOEUVRES) N - Neutral A - Arm opening and rotation to the left...
  • Page 76 INSTRUMENTS AND CONTROLS TWO-PIECE BOOM CONTROL PEDAL (IF PROVIDED) This pedal controls the opening and folding of the two-piece boom according to the movements indicated. N - Neutral A - Boom opening B - Boom folding IMPORTANT • All movements are locked by shifting the safety device le- RYA12640 ver to the lock position (see pos.
  • Page 77 INSTRUMENTS AND CONTROLS BOOM SWING CONTROL PEDAL DANGER • Always engage the safety device (1) when the use of this control pedal is not required, during travel and when park- ing the machine. If this control pedal is inadvertently pressed, it may cause serious accidents.
  • Page 78 INSTRUMENTS AND CONTROLS HAND ACCELERATOR This lever serves to adjust the speed and power of the engine. • Idling position (A): push the lever completely forward. • Maximum speed position (B): pull the lever completely backward. Use the accelerator lever with care, especially when the machine is under strain or is working in difficult conditions.

  • Page 79: Fuses And Relays

    FUSES AND RELAYS 3.4 FUSES AND RELAYS IMPORTANT • When changing a fuse, make sure that the ignition key is in position « ». • If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.

  • Page 80: Central Unit Fuses

    FUSES AND RELAYS 3.4.1.1 CENTRAL UNIT FUSES 11 12 RYA15680 POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT Low beam (56B) Light blue High beam (56A) Brown Outlet, radio, overhead lamp Brown Revolving light Brown Working light Light blue Heating Brown Alternator Orange Instrument board power supply Brown...

  • Page 81: Central Unit Relays

    FUSES AND RELAYS 3.4.1.2 CENTRAL UNIT RELAYS RYA15690 POSITION DESCRIPTION (RL1) Horn relay (RL2) Relay for working light on the boom...

  • Page 82: Engine Line Fuses And Relays

    FUSES AND RELAYS 3.4.2 ENGINE LINE FUSES AND RELAYS The fuses and relays are grouped on a single base positioned in- side the engine compartment and can be reached by removing the cover (1). RWAA11990 RWAA12000 3.4.2.1 ENGINE LINE FUSES RWA20010 POSITION COLOUR...

  • Page 83: Engine Line Relays

    FUSES AND RELAYS 3.4.2.2 ENGINE LINE RELAYS RYA15700 POSITION DESCRIPTION Solenoid pull timer (1") Plug preheating relay Solenoid pull relay Start consent relay, against repeated starting POWER MODE resistance Start consent diode...

  • Page 84: Fuses And Relays Of The Air Conditioning System (If Provided)

    FUSES AND RELAYS 3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provid- The fuses and relays of the air conditioning electric system are fixed to the machine in two different positions. A first group is fixed inside the air recirculation filter casing and can be reached after removing the cover (1).
  • Page 85 FUSES AND RELAYS A second group is gathered in a container (2) positioned beside the battery and can be reached after opening the side cover (see “3.5.2 SIDE COVER”). RWAA12350 RWAA12360 FUSES POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT Green System general fuse Light blue Electric fan (25) Light blue...

  • Page 86: Guards And Driver's Seat

    GUARDS AND DRIVER’S SEAT 3.5 GUARDS AND DRIVER’S SEAT 3.5.1 ENGINE HOOD DANGER • Do not open the engine hood when the engine is running. • Do not use the machine without engine hood and do not start the engine when the hood is open, unless this is ex- pressly prescribed for certain maintenance operations.

  • Page 87: Cab

    3.5.3 CAB DANGER • If the cab is subjected to an impact, or if the machine overturns, immediately contact your Komatsu Util- ity Dealer, who will check the stiffness of the cab and make sure that the operator’s safety is guaranteed.
  • Page 88 GUARDS AND DRIVER’S SEAT • The cab door (2) can be opened completely and held in position by the coupling (3). The coupling is automatic and is engaged when the door (2) strikes against the retainer (4). To release the door from the coupling (3), pull the lever (5) posi- tioned on the left post of the cab upwards.
  • Page 89 GUARDS AND DRIVER’S SEAT • With open upper windshield, disengage the couplings (9) and remove the lower windshield (10). Position it behind the driver’s seat and fasten it to the locking seats (11). RWA18910 RWA19020 RWA18920 • The roof (12) can be snapped open partially or completely. In any case, force the pushing handles (13) upwards to open it.
  • Page 90 GUARDS AND DRIVER’S SEAT • The side windows (14) and (15) positioned on the right side of the cab can be opened by sliding them; press the handle (16) and pull it. RYA15720 RWA18890...

  • Page 91: Ventilation And Heating

    GUARDS AND DRIVER’S SEAT 3.5.4 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the opera- tor’s stress either in summer and in winter; these functions also serve to eliminate the condensate from the front window, thus en- suring visibility during both work and travel.

  • Page 92: Air Conditioner (If Provided)

    GUARDS AND DRIVER’S SEAT 3.5.5 AIR CONDITIONER (if provided) DANGER • The coolant contained in the air conditioning system is very dangerous. If some sprays should get into the eyes or come in contact with the skin, immediately wash with plenty of water and consult a doctor. To avoid possible explosions, do not cause sparks and do not use naked flames near the system.
  • Page 93 GUARDS AND DRIVER’S SEAT Air distribution is achieved by means of a series of orientable out- lets (5) with adjustable capacity for the inner flow and for the flow that has the function to defog the windows. IMPORTANT • At the beginning of the hot season and before using the air conditioning, clean the suction filters (see “4.7.1.b CAB AIR FILTER”...

  • Page 94: Seat

    GUARDS AND DRIVER’S SEAT 3.5.6 SEAT The seat is extremely comfortable, offering several adjustment options: a - longitudinal adjustment; b - back inclination adjustment; c - adjustment of the suspension, aimed at dampening the inev- itable vibrations and jerks as much as possible; d - seat cushion inclination adjustment;...

  • Page 95: Safety Belt

    GUARDS AND DRIVER’S SEAT 3.5.7 SAFETY BELT DANGER • Before starting the engine, fasten the safety belt. • The safety belt must be changed when it is frayed, dam- aged or worn and in any case every 4 years. The safety belt (1) is of the type with two coupling points and ad- justable length (2);...

  • Page 96: Technical Documentation Case

    GUARDS AND DRIVER’S SEAT 3.5.9 TECHNICAL DOCUMENTATION CASE CAUTION • The operation manual and the spare parts catalogue are in- tegral parts of the machine and must accompany it even in case of resale. The technical documentation case is positioned behind the seat, and it usually contains also the ownership documents.

  • Page 97: Use Of The Machine

    • Dirt, oil and fuel in the engine compartment near its hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your Komatsu Utility Dealer. Before starting the engine, check around and under the machine to verify: 1 - if there are loose screws or nuts;...

  • Page 98: Operational Checks

    USE OF THE MACHINE 3.6.1.3 OPERATIONAL CHECKS DANGER • All the checks must be carried out by the operator while seated, with fastened safety belt. • If the machine has been stopped after use or in order to carry out maintenance operations, the safety devices may have been disconnected;...

  • Page 99: Starting The Engine

    USE OF THE MACHINE 3.6.2 STARTING THE ENGINE DANGER • Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls. From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non-compliance with the safety regulations in force.

  • Page 100: Starting With Cold Engine Or In Cold Climates

    USE OF THE MACHINE 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES DANGER • Do not use any fluid or product that facilitate the cold start- ing of the engine, since these are ether-based and may cause explosions. 1 - Pull the accelerator lever until reaching half of its stroke and turn the ignition key to the preheating positio «...

  • Page 101: Warming The Engine

    USE OF THE MACHINE 3.6.3 WARMING THE ENGINE 1 - After starting the engine, let it warm up before starting work. 2 - The ideal warming up of the engine is achieved by making the engine run at idling speed by means of the hand accelerator.
  • Page 102 USE OF THE MACHINE Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the rotation lock is engaged, the safety device is released, the blade is raised and the work equipment is at least at 40÷50 cm from the ground;...

  • Page 103: Steering (Changing Direction)

    USE OF THE MACHINE 3.6.5.1 STEERING (CHANGING DIRECTION) DANGER • When the blade is directed backward, the operation of the travel levers is inverted; before operating the travel levers, check the position of the blade. • If possible, avoid any abrupt change of direction. Counter-rotations should be carried out with the ma- chine at rest.

  • Page 104: Moving On Slopes

    USE OF THE MACHINE 3.6.5.2 MOVING ON SLOPES DANGER • Do not work on slopes with inclination exceeding 30°, since in these conditions the machine may overturn. • When moving on slopes, do not use the travel speed in- crease function. When working on slopes some precautions should be taken to avoid risks for the operator and anyone in the vicinity;...

  • Page 105: Maximum Immersion Depth

    USE OF THE MACHINE 3.6.5.3 MAXIMUM IMMERSION DEPTH DANGER • If it is necessary to work with the machine immersed in water on on river banks or sea shores, always check the water depth and the current flow. • Make sure that the surface on which you are working is sufficiently firm. If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not exceed the center line of the upper roller and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break...

  • Page 106: Parking The Machine

    PARKING THE MACHINE 3.7 PARKING THE MACHINE 3.7.1 PARKING ON LEVEL GROUND DANGER • Park the machine on firm and level ground, in a sufficiently wide space, so that the checks, the daily lubrication and the refuelling can be carried out without problems. •...

  • Page 107: Parking On Slopes

    PARKING THE MACHINE 3.7.2 PARKING ON SLOPES DANGER • The movement of the machine when the operator is not on board may cause serious accidents and even death; to pre- vent this, carry out the operations described below. • Park on slopes only when it is absolutely necessary. •...

  • Page 108: Stopping The Engine

    STOPPING THE ENGINE 3.8 STOPPING THE ENGINE MIN. IMPORTANT • The sudden stop of the engine while it is running shortens its life. 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;...

  • Page 109: Transporting The Machine On Other Vehicles

    TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9.1 LOADING AND UNLOADING THE MACHINE DANGER • The loading and unloading of the machine on-off the means of transport must be carried out on a flat surface and at a safety distance from the edges of ditches or from the road side.

  • Page 110: Transport

    TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9.2 TRANSPORT 1 - Check the overall dimensions; the height, width and weight of the means of transport - machine included - must be compatible with the road and any tunnel, underpass, bridge, electric or telephone line that may be found on the way.

  • Page 111: Precautions To Be Taken In The Cold Season

    PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON During the cold season or in areas where the temperature is particularly low, especially during the night, it is nec- essary to take some countermeasures meant to limit the damage deriving from low temperatures. 3.10.1 FUEL AND LUBRICANTS 1 - Change the fuel and use the winter fuel ASTM D975 N.

  • Page 112: Battery

    PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 3.10.3 BATTERY DANGER • To avoid explosions due to the presence of gas, do not provoke sparks and do not use naked flames near the battery. • The battery electrolyte is dangerous. If it comes in contact with the eyes or the skin, immediately rinse with plenty of water and consult a doctor immediately.

  • Page 113: Precautions To Be Taken In The Warm Season

    PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 1 - At the end of the cold season, change the lubricants, the coolant and the fuel. IMPORTANT • The coolant must be changed only if it is not permanent. For the relevant specifications, see “4.3 FUEL, COOLANT AND LUBRICANTS”.

  • Page 114: Using The Work Equipment

    USING THE WORK EQUIPMENT 3.12 USING THE WORK EQUIPMENT DANGER • Always fasten the safety belt before any manoeuvre. • Before starting work, warn the persons in the vicinity by means of the horn positioned on the right lever. • If due to a sudden failure the machine stops with raised equipment, turn the ignition key to position « », release the safety device, gradually operate the boom lowering control lever until the bucket rests on the ground and release any residual pressure.

  • Page 115: Positioning The Machine For Digging Operations

    USING THE WORK EQUIPMENT 3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS DANGER • Before moving the equipment, make sure that no one is standing in the work area. • When working on a slope, position the machine horizontal- ly on a firm and compact surface. •...

  • Page 116: Digging Method

    USING THE WORK EQUIPMENT 3.12.4 DIGGING METHOD DANGER • The geometry of the rotation fulcra of the arms and the bucket make it possible to dig even beyond the track line, which makes the ground give way. Never dig beyond the boom fulcrum line, since the ground may collapse and cause the machine to overturn.

  • Page 117: Changing The Bucket

    USING THE WORK EQUIPMENT 3.12.5 CHANGING THE BUCKET DANGER • When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet. • The change of the equipment must be carried out by two persons, who must decide together the words and signals to use during operations.

  • Page 118: Long Periods Of Inactivity

    LONG PERIODS OF INACTIVITY 3.13 LONG PERIODS OF INACTIVITY 3.13.1 BEFORE THE PERIOD OF INACTIVI- DANGER • When draining the fuel, do not smoke or bring naked flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading around.

  • Page 119: During The Period Of Inactivity

    IMPORTANT • If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your Komatsu Utility Dealer. When using the machine after a long period of inactivity, proceed as follows: 1 - Free the exhaust pipe and the fuel tank from the seals.

  • Page 120: Troubleshooting

    TROUBLESHOOTING 3.14 TROUBLESHOOTING 3.14.1 HOW TO REMOVE THE MACHINE DANGER • When removing the machine, use a wire rope suitable for the weight of the machine to be removed. If the machine gets stuck in mud and cannot get out using only its motive power, or in case of breakdown, use a wire rope as shown in the figure on the right.

  • Page 121: If The Battery Is Depleted

    TROUBLESHOOTING 3.14.3 IF THE BATTERY IS DEPLETED DANGER • When checking or carrying out any operation on the bat- tery, stop the engine and make sure that the ignition key is in position « » • The battery produces hydrogen, which may explode. Do not use naked flames and do not smoke near the battery, and avoid producing sparks.

  • Page 122: Starting With Booster Cables

    TROUBLESHOOTING 3.14.3.1 STARTING WITH BOOSTER CABLES DANGER • When starting the engine with the aid of another machine, connect the batteries in parallel. • When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (-). •...

  • Page 123: Other Troubles

    (•): Always contact your Komatsu Utility Dealer when you have to carry out this operation. • : If the anomaly or its cause are not included in the failures indicated below, contact your Komatsu Utility Dealer for the necessary repair.

  • Page 124: Hydraulic System

    TROUBLESHOOTING 3.14.4.2 HYDRAULIC SYSTEM TROUBLE CAUSE REMEDY • • Pump emits an abnormal noise: No oil in the tank. Repair or change. • (•) Faulty pump. Repair or change. • • Hydraulic oil unsuitable for the tem- Change. perature. • (•) Equipment control levers do not return Broken return spring or seized ele-...

  • Page 125: Engine

    TROUBLESHOOTING 3.14.4.3 ENGINE TROUBLE CAUSE REMEDY • • Oil pressure warning light remains on Oil level in oil pan too low. Top up. • • even with engine at high speed: Oil filter clogged. Change filter. • • Oil unsuitable for the season Change.
  • Page 126 PAGE INTENTIONALLY LEFT BLANK...

  • Page 127: Maintenance

    MAINTENANCE...

  • Page 128: Guide To Maintenance

    • Carry out any operation on firm and level ground. • Use Komatsu Utility genuine oils and greases; choose oils suitable for the ambient temperature. • Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils and greases.
  • Page 129 GUIDE TO MAINTENANCE • Never mix oils of different brands. Do not top up with any oil different from the oil used in the machine. If necessary, drain all the oil and fill the tank with the oil of the new brand. DANGER •...

  • Page 130: Maintenance Notes

    • Use only Komatsu Utility genuine spare parts. • Do not mix different types of oil. • Unless specified otherwise, the oils and the coolant used by Komatsu Utility to fill the tanks before the delivery of the machine are the following:...

  • Page 131: Fuel

    • The required standards for permanent antifreeze are the following: SAE-J1034 and FEDERAL STANDARD O-A- 548D. In case of doubt regarding the compliance of the antifreeze used with the standards, contact your Komatsu Utility Dealer and ask for precise information.

  • Page 132: Notes Regarding The Electrical System

    • Do not remove or eliminate any electric component installed on the machine and do not install any electric com- ponent with characteristics different from those specified and approved by Komatsu Utility. • Be careful to keep the electric system dry.

  • Page 133: Parts Subject To Wear That Periodically Need Changing

    The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic mainte- nance intervals prescribed or when they reach the wear limit. The timely change of these parts ensures an economic use of the machine. Use only Komatsu Utility genuine parts, which alone can guarantee excellent quality and interchangeability. ITEM CODE DESCRIPTION Q.TY...

  • Page 134: Fuel, Coolant And Lubricants

    FUEL, COOLANT AND LUBRICANTS 4.3 FUEL, COOLANT AND LUBRICANTS PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE AMBIENT TEMPERATURE CAPACITY (l) RESERVOIR FLUID -30 -20 -10 50°C filling Change 86 104 122°F SAE 10W SAE 30 Engine oil pan 12.5 12.5 SAE 40 API CD SAE 15W-30...
  • Page 135 • Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half. • Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine, in the work equipment hydraulic circuit and in the reduction gears.

  • Page 136: Homologated Hees Synthetic Biodegradable Lubricants

    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 HEES SYNTHETIC BIODEGRADABLE OIL KOMATSU BO 46 G4 (KES 07.872) AGIP —...

  • Page 137: Driving Torques For Screws And Nuts

    DRIVING TORQUES FOR SCREWS AND NUTS 4.4 DRIVING TORQUES FOR SCREWS AND NUTS 4.4.1 STANDARD DRIVING TORQUES Nm (Newton metro): 1 Nm = 0.102 kgm 10.9 Thread Pitch Spanner size diameter (mm) (mm) (mm) 0.96 ± 0.1 9.5 ± 1 1.3 ±...

  • Page 138: Lubrication

    LUBRICATION 4.5 LUBRICATION 4.5.1 LUBRICATION DIAGRAM IMPORTANT • For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. • The type of lubricant to be used is indicated in the lubricant table (See “4.3 FUEL, COOLANT AND LU- BRICANTS”).

  • Page 139: Periodical Change Of The Components Connected With Safety

    PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY To ensure safety at any moment while driving and using the machine, the operator must carry out all the periodic maintenance operations prescribed. Furthermore, the operator must periodically change the components indicat- ed in the table in the following page, which are especially related to safety and fire-prevention rules.

  • Page 140: Critical Parts For Safety

    PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6.1 CRITICAL PARTS FOR SAFETY FUEL SUPPLY SYSTEM Components related to safety that periodically need changing Q.ty Change interval Fuel pipe (Fuel tank – precleaner) Fuel pipe (Precleaner - fuel pump) Fuel pipe (Fuel pump - fuel filter) Fuel pipe (Fuel filter –...
  • Page 141 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY HYDRAULIC SYSTEM Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Main pump delivery) Hydraulic pipe (Secondary pump delivery) Every 2 years or Hydraulic pipe (Boom cylinder) 4000 hours, which- ever occurs first Hydraulic pipe (Arm cylinder) Hydraulic pipe (Bucket cylinder)
  • Page 142 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY RWA20320 OPERATOR’S SAFETY Components related to safety that periodically Q.ty Change interval need changing Safety belt Every 4 years RWAA5380...

  • Page 143: Maintenance Plan

    MAINTENANCE PLAN 4.7 MAINTENANCE PLAN 4.7.1 WHEN REQUIRED PART OPERATION PAGE Air cleaner Check, clean or change Cab filter Check and clean A/C air recirculation filter Check and clean (only for machines with air conditioner) Water separator Clean Tracks Check and adjust tension Tracks Check shoe fastening 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION...
  • Page 144 MAINTENANCE PLAN 4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used) (Operations to be carried out together with those prescribed at point“4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION”) PART OPERATION PAGE...
  • Page 145 MAINTENANCE PLAN 4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION PART OPERATION PAGE Fan belt Check fan belt condition and tension A/C compressor belt Check fan belt condition and tension (only for machines with air conditioner) Battery Check electrolyte level Travel reduction gears Check levels (n.
  • Page 146 MAINTENANCE PLAN 4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION PART OPERATION PAGE Engine valves Check clearance 4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION PART OPERATION PAGE Travel reduction gears Change oil Swing reduction gear Change oil Hydraulic oil and suction filter Change oil and clean filter Coolant Change...

  • Page 147: When Required

    MAINTENANCE PLAN 4.7.1 WHEN REQUIRED 4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE DANGER • Remove the air cleaner only after stopping the engine and do not start the engine if the air cleaner is open. • Always wear goggles while cleaning the filter. IMPORTANT •...
  • Page 148 MAINTENANCE PLAN 7 - Put back the cover (2) and rotate it clockwise, making sure that the ejector (5) is positioned vertically and at the bottom. 8 - Lock the cover by means of the yellow safety device (1). IMPORTANT •...

  • Page 149: Checking And Cleaning The Cab Air Filter

    MAINTENANCE PLAN 4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER DANGER • Always wear goggles while cleaning the filter. Air suction for the ventilation of the cab is protected by means of a filter positioned on the right side of the cab. This filter holds all the impurities contained in the air and must be cleaned whenever a decrease in the air circulation is noticed.

  • Page 150: Checking And Cleaning The Air Recirculation Filter (Only For Machines Equipped With Air Conditioner)

    MAINTENANCE PLAN 4.7.1.c CHECKING AND CLEANING THE AIR RE- CIRCULATION FILTER (only for machines equipped with air conditioner) DANGER • Always wear goggles while cleaning the filter. On machines equipped with air conditioning system, the inner air recirculation is protected by means of a filter that holds all the im- purities contained in the air and must be cleaned whenever a de- RWAA12110 crease in the air circulation is noticed.

  • Page 151: Cleaning The Water Separator

    MAINTENANCE PLAN 4.7.1.d CLEANING THE WATER SEPARATOR The water separator can be reached after opening the engine hood (see “3.5.1 ENGINE HOOD”). To clean the water separator, proceed as follows: 1 - Loosen the screw (1) and drain the fuel contained in the wa- ter separator, collecting it into a container with suitable ca- pacity.

  • Page 152: Checking The Steel Track Tension

    MAINTENANCE PLAN 4.7.1.e CHECKING THE STEEL TRACK TENSION DANGER • This operation must be carried out by two operators. One operator must be seated in the cab and oper- ate the machine according to the instructions of the operator who carries out the check and the adjust- ment.
  • Page 153 MAINTENANCE PLAN ADJUSTMENT DANGER • The grease contained in the hydraulic cylinder is under pressure. For this reason, do not loosen the greasing valve (1) giving it more than one turn; if the valve is loosened ex- cessively, it may be pushed out due to the grease pressure and this is very dangerous for the operator.

  • Page 154: Checking The Shoe Fastening

    MAINTENANCE PLAN 4.7.1.f CHECKING THE SHOE FASTENING DANGER • To make up for the inevitable settling movements, it is absolutely necessary to check the driving torque of the screws (1) after the first 30 hours of operation. A successive check must be carried out after the first 100 hours of running-in and repeated after 200 hours of operation if a considerable decrease in the screw fastening is observed.

  • Page 155: Maintenance Intervals In Case Of Use Of The Demolition Hammer

    MAINTENANCE PLAN 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER The hydraulic oil used in the machines provided with demolition hammer deteriorates more quickly than the oil used in normal digging machines, therefore it is advisable to respect the following maintenance plan. 4.7.2.a CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100÷150 hours of...

  • Page 156: Checks Before Starting

    • Dirt, oil and fuel spread in the engine compartment near the hot areas may cause fires and damage the machine. Check if there are leakages frequently and carry out the necessary repairs immediately; if this occurs re- peatedly, contact your Komatsu Utility Dealer. Before starting the engine, check: 1. if there are loose screws or nuts;...

  • Page 157: Checking The Fuel Level

    MAINTENANCE PLAN 4.7.3.c CHECKING THE FUEL LEVEL DANGER • When refuelling, avoid spilling fuel to prevent any risk of fire. If some fuel should inadvertently be spilled, clean the dirty area immediately. • Fuel is flammable; neither use naked flames, nor smoke while refuelling.

  • Page 158: Checking The Oil Level In The Hydraulic Circuit

    MAINTENANCE PLAN 4.7.3.e CHECKING THE OIL LEVEL IN THE HY- DRAULIC CIRCUIT DANGER • The oil level in the hydraulic circuit must be checked with cold oil and the machine positioned on level ground, with retracted bucket and arm cylinders, cylinders of the two- piece boom extended and bucket teeth resting on the ground.

  • Page 159: Draining The Water Separator

    MAINTENANCE PLAN 4.7.3.f DRAINING THE WATER SEPARATOR DANGER • Fuel is flammable; neither use naked flames, nor smoke while draining the water separator. • If some fuel should inadvertently be spilled, clean the dirty area immediately. This operation serves to drain the condensate water and must be RWAA5500 carried out with full tank, in order to prevent air from entering the fuel supply circuit.

  • Page 160: Maintenance Every 10 Hours Of Operation

    MAINTENANCE PLAN 4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION 4.7.4.a LUBRICATING THE JOINTS IMPORTANT • Clean the grease nozzles before applying the greasing pump. • After lubrication, remove any excess grease. • If the machine is used in difficult conditions, perform these maintenance operations more frequently. These maintenance operations must be carried out with the equipment completely extended and resting on the ground.
  • Page 161 MAINTENANCE PLAN EQUIPMENT LUBRICATION POINTS (MONOBOOM) RYA15860 1 - Tie rod-bucket coupling pin (1 point) 2 - Tie rod-lever coupling pin (1 point) 3 - Bucket cylinder head pin (1 point) 4 - Bucket fulcrum pin (1 point) 5 - Lever fulcrum pin (1 point) 6 - Bucket cylinder base pin (1 point)
  • Page 162 MAINTENANCE PLAN EQUIPMENT LUBRICATION POINTS (TWO-PIECE BOOM) RYA15870 1- Tie rod-bucket coupling pin (1 point) 2 - Tie rod-lever coupling pin (1 point) 3 - Bucket cylinder head pin (1 point) 4 - Bucket fulcrum pin (1 point) 5 - Lever fulcrum pin (1 point) 6 - Bucket cylinder base pin (1 point)

  • Page 163: Maintenance After The First 50 Hours Of Operation

    • If the fluid level in the radiator is low and the expansion tank is full of coolant, check the tightness and make sure that there are no air leaks from the coupling that connects the radiator and the expansion tank. If the problem persists, contact your Komatsu Utility Deal-...

  • Page 164: Lubricating The Swing Joint

    • If there are signs of short circuit on the cables, find out the cause and repair them; always contact your Komatsu Utility Dealer for the troubleshooting. Make sure that there are no disconnected cables or signs of short circuit in the electrical system.

  • Page 165: Maintenance Every 100 Hours Of Operation

    MAINTENANCE PLAN 4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION These operations must be carried out together with the operations to be performed EVERY 50 HOURS. 4.7.7.a LUBRICATING THE BALL-BEARING RING The lubrication of the ball-bearing ring must be performed after carefully cleaning the grease nipples (1), applying the prescribed grease by means of the the greasing pump supplied with the ma- chine.

  • Page 166: Maintenance After The First 250 Hours Of Operation

    • CHECK AND ADJUST THE ENGINE VALVE CLEARANCE For details on the various maintenance operations, see the sections “4.7.11 MAINTENANCE EVERY 500 HOURS” and “4.7.13 MAINTENANCE EVERY 2000 HOURS”. For the inspection and adjustment, contact your Komatsu Utility Dealer. 4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION 4.7.9.a...

  • Page 167: Adjusting The Tension Of The A/Ccompressor Belt (Only For Machines Equipped With Air Conditioner)

    MAINTENANCE PLAN 4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT (only for machines equipped with air conditioner) DANGER • The coolant contained in the air conditioning system is very dangerous. If some sprays get into the eyes or come in contact with the skin, they may cause blindness or con- gelation.

  • Page 168: Checking The Battery Electrolyte Level

    MAINTENANCE PLAN 4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL DANGER • Check the level only after stopping the engine and if necessary add distilled water only before starting work. • Always wear safety goggles and waterproof gloves. • To prevent gas explosions, do not use naked flames, do not smoke and avoid producing sparks due to short circuits.

  • Page 169: Checking The Oil Level In The Swing Reduction Gear

    MAINTENANCE PLAN 4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR DANGER • As soon as the machine has been stopped the oil is very hot; let it cool down until it reaches 40-45°C before carrying out the check. MAX.

  • Page 170: Maintenance After The First 500 Hours Of Operation

    MAINTENANCE PLAN 4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the 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 “EVERY 500 HOURS”.
  • Page 171 MAINTENANCE PLAN 2 - Remove the screws (2) that hold the filter cover (3), remove the cartridge (4) and the filter casing (5). Use a 13 mm spanner. 3 - Carefully clean the filter casing (5), making sure that the filter gasket (7) and the container gasket (8) are in perfect condi- tions.

  • Page 172: Changing The Servo Control Filter

    MAINTENANCE PLAN 4.7.11.b CHANGING THE SERVO CONTROL FIL- DANGER • Soon after the machine has been stopped the hydraulic oil is very hot; let it cool down until it reaches a temperature of 40-45°C before changing it. • The hydraulic system is pressurized; after stopping the en- gine, move the control levers more than once in all direc- tions to release the residual pressure.

  • Page 173: Changing The Engine Oil

    MAINTENANCE PLAN 4.7.11.c CHANGING THE ENGINE OIL DANGER • 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.

  • Page 174: Changing The Engine Oil Filter

    MAINTENANCE PLAN 4.7.11.d CHANGING THE ENGINE OIL FILTER DANGER • 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.

  • Page 175: Changing The Fuel Filter

    MAINTENANCE PLAN 4.7.11.e CHANGING THE FUEL FILTER DANGER • Change the filtering element after work, when the engine has cooled down to 40-45°C. • When these operations are carried out, fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire.

  • Page 176: Draining The Fuel Tank

    MAINTENANCE PLAN 4.7.11.f DRAINING THE FUEL TANK DANGER • When draining the fuel tank, avoid spilling fuel, since this may cause fires. • If some fuel is accidentally spilled, clean the dirty area im- mediately, in order to prevent it from getting slippery and to avoid fires.

  • Page 177: Cleaning The Outside Of The A/Ccondenser (Only For Machines Equipped With Air Conditioner)

    MAINTENANCE PLAN 4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines equipped with air conditioner) DANGER • If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield, a dust mask and safety shoes. RWAA12280 The condenser (1) can be reached after removing the cover (2).

  • Page 178: Checking The Ball-Bearing Ring Pinion Lubricant Level

    MAINTENANCE PLAN 4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL IMPORTANT • Carry out this check with the machine at rest and at the end of work, that is, with the machine at operating temperature. This check is visual and serves to verify the level of the grease 100 mm contained in the tank (1) that encloses the pinion (2) and the ball- bearing ring (3).
  • Page 179 MAINTENANCE PLAN 5 - Open the right side cover (see “3.5.2 SIDE COVER”) and slowly loosen the filling cap (1) to release the residual pres- sure. 6 - Remove the lower cover and loosen the drain plug (2) until all the condensate has flown out.

  • Page 180: Maintenance Every 1000 Hours Of Operation

    • On new machines, adjust the engine valve clearance after the first 250 hours of operation and succes- sively every 1000 hours. Since the check and adjustment of the engine valve clearance require the use of special tools, have these opera- tions carried out by your Komatsu Utility Dealer.

  • Page 181: Maintenance Every 2000 Hours Of Operation

    MAINTENANCE PLAN 4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed EVERY 50, 100, 250, 500 and 1000 HOURS. 4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS DANGER • Soon after the machine has been stopped the oil is very hot; let the oil cool down until it reaches a tem- perature of 40-45°C before changing it.

  • Page 182: Changing The Oil In The Swing Reduction Gear

    MAINTENANCE PLAN 4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR DANGER • Soon after the machine has been stopped the oil is very hot; let the oil cool down until it reaches a tem- perature of 40-45°C before changing it. •...
  • Page 183 MAINTENANCE PLAN 4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER CAUTION • On machines containing synthetic biodegradable hydraulic oil type HEES, carry out the change after the first 500 hours of operation and successively every 2000 hours, and in any case at least once a year.

  • Page 184: Filter

    MAINTENANCE PLAN 6 - Remove the lower cover, remove the drain plug (2) and let the oil flow out, gathering it into a container with suitable capacity. Use 17 and 27 mm spanners. 7 - Remove the upper flange (3) of the tank and change the filter (see “4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER”).
  • Page 185 MAINTENANCE PLAN 10 - Fill with the prescribed oil until reaching the correct level (8). Use oil of the prescribed type only (see “4.3 FUEL, COOL- ANT AND LUBRICANTS”). 11 - Open the engine hood (see “3.5.1 ENGINE HOOD”) and loosen the drain screw (9) positioned on the hydraulic pump until no air bubbles can be noticed in the oil flowing out of the screw.

  • Page 186: Changing The Coolant

    MAINTENANCE PLAN 4.7.13.d CHANGING THE COOLANT DANGER • Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns; let the engine cool down until it reaches approxi- mately 40-45°C before changing the coolant. •...

  • Page 187: Changing The Ball-Bearing Ring Pinion Lubricant

    RWA19370 4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER For any inspection and/or repair, contact your Komatsu Utility Dealer. If the engine is started frequently, the alternator and the starter should be inspected every 1000 hours of operation.

  • Page 188: Checking The A/C Cooling Gas Quantity (Only For Machines Equipped With Air Conditioner)

    • The air conditioning system must be serviced only by qualified personnel. To check the cooling gas it is necessary to use specific equipment: have this operation carried out only by special- ized personnel, contacting your Komatsu Utility Dealer.

  • Page 189: Maintenance Every 4000 Hours Of Operation

    • Have the dehydrator filter changed only by qualified personnel, contacting your Komatsu Utility Dealer. The filter (1) must be changed after 4000 hours of operation or every 2 years, whichever occurs first.
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  • Page 191 TECHNICAL SPECIFICATIONS...

  • Page 192: Technical Data

    TECHNICAL DATA 5.1 TECHNICAL DATA 5.1.1 STANDARD OVERALL DIMENSIONS OVERALL DIMENSIONS WITH MONOBOOM 2120 6470 2420 1580 1950 4890 2400 RYA16160 OVERALL DIMENSIONS WITH TWO-PIECE BOOM 2120 6030 2420 1950 1580 4450 2400 RYA16170...

  • Page 193: Technical Characteristics

    Komatsu diesel engine model ........

  • Page 194: Lifting Capacities

    TECHNICAL DATA 5.1.3 LIFTING CAPACITIES (Only for machines with overload alarm device) CAUTION • According to the harmonized standard EN474-5 (§ 4.1.7.5), the machine cannot lift weights exceeding 1000 kg, unless it is provided with suitable devices. DANGER • Carry out lifting operations only with the machine positioned on firm and level ground. •...
  • Page 195 TECHNICAL DATA Z (m) X (m) Z (m) X (m) RWA21330 RWA21340 I - Side lifting L - Standard operating mass P - Lifting capacity Z - Lifting point-ground distance X - Distance between the upper structure rotation axis and the bucket lifting point •...

  • Page 196: Lifting Capacity With Monoboom

    TECHNICAL DATA 5.1.3.2 LIFTING CAPACITY WITH MONOBOOM RWA21320 30 MPa (300 bar) 900 mm kg 300 500 mm kg 10980 Z (m) X (m) 3150 mm 4,5 m 4,5 m P(kg) P(kg) P(kg) P(kg) P(kg) P(kg) P(kg) P(kg) — — 3800 1150 2300...

  • Page 197: Lifting Capacity With Two-Piece Boom

    TECHNICAL DATA 5.1.3.3 LIFTING CAPACITY WITH TWO-PIECE BOOM RWA21310 30 MPa (300 bar) 900 mm kg 300 500 mm kg 10980 Z (m) X (m) 3864 mm 4,5 m 4,5 m P(kg) P(kg) P(kg) P(kg) P(kg) P(kg) P(kg) P(kg) — —...
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  • Page 199 AUTHORISED OPTIONAL EQUIPMENT...

  • Page 200: Authorized Optional Equipment

    The installation of optional accessories and equipment other than those authorized by Komatsu Utility shortens the life of the machine and may also cause problems concerning safety. It is advisable to contact a Komatsu Utility Dealer before installing any accessory not indicated in this operation and maintenance manual.

  • Page 201: Precautions Regarding The Installation Of Equipment

    • Always keep to the correct procedure when installing the boom and arm. Failure to carry out the correct procedure may result in grave risks, therefore it is advisable to contact a Komatsu Utility18 Dealer before installation.

  • Page 202: Characteristics Of The Optional Equipment

    AUTHORIZED OPTIONAL EQUIPMENT 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT (Specific weight of the handled material = 1.8 t/m MAX. DIMENSIONS MAX. MAX. MAX. SAE MAX. OPERATING FLOW EQUIPMENT WEIGHT CAPACITY PRESSURE Width Height RATE . (kg) (cu.m.) (bar) (mm) (mm) (l/min.) Bucket 1000...

  • Page 203: Arrangement For The Installation Of The Demolition Hammer

    ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLI- TION HAMMER DANGER • For the characteristics of the hammer, see “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT”. • The demolition hammer is very noisy, therefore always wear headphones when using it. 6.2.1 DESCRIPTION AND OPERATION The machine can be fitted for the application of a demolition ham- mer instead of the standard bucket on the arm.
  • Page 204 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 2 - Keep the pressure of the excavator on the hammer constant as the bit penetrates in the material. Always follow the hammer in the penetration phase and oper- ate the excavator arms in order to obtain a pressure sufficient to keep the undercarriage raised at about 5 mm from the ground.
  • Page 205 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER IMPORTANT • During work, do not use the demolition hammer with the bucket cylinder at the end of its stroke, but al- ways leave a minimum space of 5 cm. ALWAYS AVOID THE FOLLOWING INCORRECT USES: 1 - Gathering or moving stones with the demolition hammer.
  • Page 206 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 4 - Working with the hammer in horizontal position or even with greater inclination. RWA06490 5 - Lever with the tool after thrusting it into the material to be bro- ken. RWA06500 6 - Hitting the ground with the hammer bit.

  • Page 207: Installing And Removing The Demolition Hammer

    ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 6.2.3.1 INSTALLING THE HAMMER DANGER • The machine must be parked on a level surface, with the equipment resting on the ground. • For the installation, the hammer must be positioned hori- zontally, with the bit directed towards the machine.

  • Page 208: Removing The Hammer

    ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6 - Rotate the lever of the selection valve (3) completely anticlock- wise. 7 - Start the machine and raise the demolition hammer position- ing it vertically. 8 - Stop the machine again and lubricate the arm connection joints (See “4.7.4.a LUBRICATING THE JOINTS”) and the hammer (see the specific operation and maintenance manu- al).

  • Page 209: Clamshell Bucket

    CLAMSHELL BUCKET 6.3 CLAMSHELL BUCKET DANGER • For the characteristics of the clamshell bucket, see “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT”. • The bucket can oscillate on the arm coupling; during use, keep in consideration the increased overall dimensions due to the swinging. •...

  • Page 210: Installing The Clamshell Bucket

    CLAMSHELL BUCKET 6.3.2 INSTALLING THE CLAMSHELL BUCKET DANGER • The machine must be parked on a level surface, with the equipment lowered to the ground. • When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet.
  • Page 211 CLAMSHELL BUCKET CAUTION • During the following phases, take care to prevent any im- purity from getting into the pipes. 9 - Remove the sealing plugs of the machine pipes and of the clamshell bucket hoses. Use 36, 41 and 50 mm spanners. 10 - Connect the pipes for the opening and curling of the clam- shell bucket to the couplings (2 and 3) and the pipes for the rotation to the couplings (4 and 5), making sure that the char-...

  • Page 212: Maintenance

    CLAMSHELL BUCKET 11 - Rotate the lever of the selection valve (6) completely clock- wise. 12 - Lubricate the arm connection joints (see “4.7.4.a LUBRICAT- ING THE JOINTS”) and the clamshell bucket (see the specif- ic use and maintenance manual). 13 - Start the machine and lift the clamshell bucket of a few centi- metres.

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