Page 1 Operation & Maintenance WEAM012101 Manual PC18MR HYDRAULIC EXCAVATOR SERIAL NUMBER PC18MR-3 20668 and up WARNING ORIGINAL INSTRUCTIONS 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.
Page 3: Foreword 1.1 Foreword
FOREWORD 1.1 FOREWORD This manual has been compiled by Komatsu Utility S.p.A. in order to supply customers with all the necessary in- formation 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.
Page 4: Information On Safety
Komatsu machines are manufactured and sold according to the rules or standards of the countries where they have to work. If the machines have to work in other countries, it is necessary to check that every safety devices and technical specifications are in compliance with the regulations in force;...
Page 5 WARNING It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be held liable for any damage to persons, property or the machine, if this has been tampered with by modi- fying the standard settings of the hydraulic system.
Page 6 INFORMATION ON SAFETY Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses “Safety labels using pictograms“ to indicate safety procedures. Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word.
Page 7: 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 EX- CAVATION and EARTH-MOVING OPERATIONS. If provided with suitable safety devices, they can be used with authorized optional equipment having the character- istics illustrated in paragraph "6.3.2 ATTACHMENT CONFIGURATION".
Page 8: Running-In
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.
Page 9: Positions And Directions Of The Machine
INTRODUCTION 1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE Forwards Right Backwards Operator seat Left Sprocket In this manual, the terms front/forward, rear/backward, left, and right refer to the travel direction as seen from the operator seat when it is facing the front and the sprocket is at the rear of the machine. WEAM012101...
Page 10: Product Identification
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 communi- cated to the Distributor when requiring assistance and ordering spare parts.
Page 11: Machine Serial Number Plate
SERIAL No. YEAR OF CONSTRUCTION OPERATING MASS ENGINE POWER Product Identification Number MANUFACTURER Manufactured by Komatsu Utility Europe S.p.A., Noventa Vicentina (VI), Italy for Komatsu Ltd., Tokyo, Japan 09601-00073 RKA28710 SERIAL NUMBER MACHINE DESIGNATION TYPE OPERATING MASS YEAR OF CONSTRUCTION...
Page 12: Engine Serial Number And Exhaust Gas Emission Plate
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 CAB SERIAL NUMBER The serial number is stamped on the plate positioned on the up- per left side.
Page 13: (For Machines Placed On The Market As From 29 December 2009)
PRODUCT IDENTIFICATION 1.4.6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: Komatsu Utility Europe S.p.A. Address: Via Atheste, 4 35042 Este (PD) Italy Authorized representative: Address: Distributor name: Address:...
Page 14: Komtrax System
1.5 KOMTRAX SYSTEM KOMTRAX is a system that uses wireless communication technology to monitor machines. The KOMTRAX system can be used only after contacting the Komatsu Distributor and having entered into a con- tract with him. As it is a wireless system, the KOMTRAX equipment uses radio waves; therefore, a due permit is required as well as compliance with the regulations in force in the country or territory where the machine is used.
Page 15 Even when the machine is outdoors, it cannot be used in areas where radio signals are weak or areas not cov- ered by the signal. Do not disconnect or tamper with the KOMTRAX communication terminal; consult the Komatsu dealer in case of failures.
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Page 17: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD FOREWORD............................INFORMATION ON SAFETY ........................ INTRODUCTION ........................... 1.3.1 INTENDED USE OF THE MACHINE ..................1.3.2 IMPROPER OR UNAUTHORIZED USES................1.3.3 MAIN CHARACTERISTICS...................... 1.3.4 RUNNING-IN ..........................1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE .............. PRODUCT IDENTIFICATION .......................
Page 18 TABLE OF CONTENTS 2.2.16 HOW TO BEHAVE IN CASE OF FIRE..................2.2.17 DETERGENT FOR THE WINDOWS..................2.2.18 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ............. 2.2.19 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........2.2.20 FIRE EXTINGUISHERS AND FIRST AID KIT ................. 2.2.21 PRECAUTIONS CONCERNING THE ROPS STRUCTURE............
Page 19 TABLE OF CONTENTS 2.8.12 BATTERY MAIN SWITCH PRECAUTIONS (if installed) ............2.8.13 SAFETY MEASURES TO OPEN (TILT) THE PLATFORM ............. 2.8.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL ........2.8.15 CHECKING THE COOLANT LEVEL IN THE RADIATOR ............2.8.16 USING LAMPS ........................
Page 20 TABLE OF CONTENTS 3.2.13 12V OUTLET FUSE........................3.2.14 TECHNICAL DOCUMENTATION COMPARTMENT ............... 3.2.15 TOOL BOX ..........................USE OF THE MACHINE AND RELATED CONTROLS................ 3.3.1 BEFORE STARTING THE ENGINE..................3.3.1.1 VISUAL CHECKS....................3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ....3.3.1.3 ADJUSTMENTS......................
Page 21 OIL .......................... 4.2.1.2 FUEL ........................4.2.1.3 COOLANT ....................... 4.2.1.4 GREASE ......................... 4.2.1.5 KOWA (KOMATSU OIL WEAR ANALYSIS) ............4.2.1.6 STORING OIL AND FUEL ..................4.2.1.7 FILTERS ......................... 4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM ........4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM........
Page 22 TABLE OF CONTENTS MAINTENANCE PLAN.......................... 4.8.1 MAINTENANCE PLAN ......................4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER....4.8.2.a CHANGING THE HYDRAULIC OIL FILTER .............. 4.8.2.b CHANGING THE HYDRAULIC OIL ................MAINTENANCE PROCEDURES ......................4.9.1 WHEN REQUIRED........................4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE....4.9.1.b BATTERY ELECTROLYTE LEVEL CHECK ..............
Page 23 TABLE OF CONTENTS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS ......................LIFTING CAPACITIES .......................... 5.2.1 LIFTING CAPACITIES PC18MR-3................... AUTHORIZED OPTIONAL EQUIPMENT GENERAL PRECAUTIONS FOR SAFETY ..................6.1.1 PRECAUTIONS WHEN SELECTING ..................6.1.2 READ THE INSTRUCTION MANUAL THOROUGHLY ............6.1.3 PRECAUTIONS WHEN REMOVING OR INSTALLING............
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Page 25: Safety And Accident Prevention
SAFETY AND ACCIDENT PREVENTION...
Page 26: Safety, Noise And Vibration Plates
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Distributor. In case of replacement of a component provided with a safety plate, make sure that such a plate is applied also to the new part.
Page 27: 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 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;...
Page 28 SAFETY, NOISE AND VIBRATION PLATES 4 - RISK OF ELECTROCUTION Minimum safety distances from overhead lines. Min. safety dis- Cable voltage tance 1.0 kV (distribution line) 6.6 kV (2–3 insulators) 5.2 m 33 kV (min. 3 insulators) 5.5 m 66 kV (min. 6 insulators) 154 kV (min.
Page 29 SAFETY, NOISE AND VIBRATION PLATES 7 - BATTERY AND ELECTRIC CABLES Risk of electric charges in case of work on the battery or the electric cables. 09808-A0881 RKA29640 8 - ADJUSTING THE TRACK TENSION The adjustment of the tracks involves the risk of injuries. Read manual regarding adjusting track for safe and proper han- dling.
Page 30 SAFETY, NOISE AND VIBRATION PLATES 11 - PLATFORM LIFTING SAFETY PLATE When the platform is open, make sure that the safety pin is cor- rectly inserted. 22F-98-33690 RKA28230 12 - HAZARDS DURING PLATFORM CLOSING When closing the platform, avoid body parts entering into the area under the platform, as there is danger of crushing.
Page 31 SAFETY, NOISE AND VIBRATION PLATES 15 - EMERGENCY EXIT (machine with cab) RKA25870 16 - BATTERY MAIN SWITCH (if installed) 22E-98-21140 RKA24350 17 - STARTER Start the engine only when correctly seated in the driving posi- tion. Do not attempt to run the starter motor by tampering with the starter motor terminals.
Page 32 SAFETY, NOISE AND VIBRATION PLATES CAUTION WHEN HANDLING BATTERIES Never smoke or use any naked flame near the batteries, no sparks. Always wear safety glasses when working with batteries. Keep children away from batteries. Caution - battery acid. WEAM012101...
Page 33 SAFETY, NOISE AND VIBRATION PLATES Read the operator’s manual before working with batteries. Caution - explosive gases. HYDRAULIC OIL TOPPING UP (Only for machines in which synthetic biodegradable oil type HEES is used) BIO-OIL RKA14710 HYDRAULIC OIL TOPPING UP 22F-98-33630 RKA28970 WEAM012101...
Page 34 SAFETY, NOISE AND VIBRATION PLATES ENGINE LUBRICATING OIL FILTER 22F-98-33640 RKA29000 FUEL FILTER 6217-71-6860 RKA29960 AF-NAC ENGINE COOLANT Fill Komatsu genuine engine coolant AF-NAC to prevent radia- tor damage by corrosion. AF-NAC 09642-A0480 RKA29010 HYDRAULIC OIL TOPPING UP 21D-98-11230 RKA29760...
Page 35 SAFETY, NOISE AND VIBRATION PLATES ENGINE OIL FILTER 21D-98-11190 RKA29770 FUEL FILTER 21D-98-11170 RKA29780 ENGINE AIR INTAKE FILTER 21D-98-11180 RKA30000 ENGINE COOLANT 21L-09-R4170 RKA29680 ENGINE COOLANT PRESSURE 21D-98-11150 RKA29790 WEAM012101...
Page 36 SAFETY, NOISE AND VIBRATION PLATES HYDRAULIC OIL LEVEL 21D-98-12030 RKA29800 HYDRAULIC OIL FILTER 21D-98-12050 RKA29810 POWER OUTLET 12 V 21D-98-12040 RKA30060 ANCHORAGE POINT 21D-98-11860 RKA28810 LIFTING POINT RKA28830 WEAM012101...
Page 37 SAFETY, NOISE AND VIBRATION PLATES LIFTING CAPACITIES W=400mm kg 23 150kg 235kg 135kg 215kg 265kg 420kg 140kg 230kg 110kg 185kg L=965mm 240kg 395kg 135kg 220kg 115kg 190kg 245kg 400kg 150kg 245kg L=1215mm 240kg 395kg 135kg 220kg 100kg 165kg > 22J-98-25721 RKA25920 WEAM012101...
Page 38: Position Of The Noise Plates On Machines With Cab
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Distributor. In case of replacement of a component provided with a noise...
Page 39: Position Of The Noise Plates On Machines With Canopy
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Distributor. In case of replacement of a component provided with a noise...
Page 40: Vibrations To Which The Operator Is Subjected
SAFETY, NOISE AND VIBRATION PLATES 2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera- tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 41 SAFETY, NOISE AND VIBRATION PLATES The following guidelines can be effective to minimize risks of low back pain. • Operate the machine only when you are in good health. • Provide breaks to reduce long periods of sitting in the same posture. •...
Page 42: General Precautions
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES Only trained and authorized staff 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. When working with other operators or when the work site is often occupied by other operators, make sure that everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as to be able to see the machine and to be visible to the operator.
Page 43: Unauthorized Modifications
GENERAL PRECAUTIONS 2.2.5 UNAUTHORIZED MODIFICATIONS Any modification made without the authorization of Komatsu can involve hazards. Before making a modification, consult your Komatsu Distributor. Komatsu declines any responsibility for injury or damage caused by unauthorized modifications. 2.2.6 LEAVING THE OPERATOR SEAT When leaving the operator seat, even if temporarily, make sure that the machine is in a safe position.
Page 44: Emergency Exit
GENERAL PRECAUTIONS 2.2.7 EMERGENCY EXIT In the even of an emergency where the cab door cannot be opened, use the hammer provided to break the win- dow and escape through the window, taking care to avoid injury cause by broken glass. For more details, see "3.2.4.4 EMERGENCY EXIT HAMMER (machines with cab)".
Page 45: Is Forbidden To Climb On The Equipment
GENERAL PRECAUTIONS 2.2.9 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT Do not allow anyone to climb on the bucket, the grapple forks, or other equipment. There is the risk of falling down and be seriously injured. 2.2.10 ARTICULATED PARTS The free space around the work equipment changes depending on the movement of the articulated parts.
Page 46: Preventing Burns
GENERAL PRECAUTIONS 2.2.13 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. Before checking the coolant level, stop the engine and let the fluid cool down.
Page 47: Preventing Damage Due To Asbestos Powder
GENERAL PRECAUTIONS 2.2.18 PREVENTING DAMAGE DUE TO ASBESTOS POWDER Inhaling asbestos powder is very dangerous. If the material to be handled contains asbestos fibres, it is com- pulsory to make sure that all the laws and safety regulations in this regard are respected. If the regulations in force concerning work in environments con- taminated by asbestos fibres are not complied with, it is forbid- den to use the machine.
Page 48: Precautions Concerning The Rops Structure
If the canopy is inadvertently hit or the machine overturns during work, the ROPS structure may be damaged, which consequently reduces its stiffness and the operator’s safety. In case of impact or damage, contact Komatsu or a Komatsu Distributor to have the canopy structure and resist- ance checked Do not remove the ROPS canopy for any reason whatsoever and avoid using the machine without canopy.
Page 49: Precautions To Be Taken Before Starting The Engine
(earth, stones, etc.). Check the seat belt and change it if it is broken or damaged. Replace any component only with homologated parts available at Komatsu or its Distributors. WEAM012101...
Page 50: 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 51: 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 52: Hand Signals
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.3 HAND SIGNALS WARNING When it is necessary to position loads, make excavations or move the machine with reduced field of vi- sion, the operator must be helped by another person standing on the ground and making signals to indi- cate the manoeuvres to be carried out, according to the specific signals defined by the relevant regulations.
Page 53 PRECAUTIONS TO BE TAKEN WHEN WORKING 4 - BRING THE LOAD NEARER IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical posi- tion directed towards the signalman, move the hand in the di- rection of the movement to be carried out. RKA15170 5 - LIFT THE BOOM With an arm extended in horizontal position and closed fin-...
Page 54 PRECAUTIONS TO BE TAKEN WHEN WORKING 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 verti- cally with the thumb pointed towards the clasped hand. RKA15240 12 - OPEN THE BUCKET Keep one hand still and open.
Page 55 PRECAUTIONS TO BE TAKEN WHEN WORKING 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. RKA15300 18 - CARRY OUT THE MOVEMENTS SLOWLY One hand still in front of the hand that indicates the move-...
Page 56: Checks For Travelling In Reverse
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.4 CHECKS FOR TRAVELLING IN REVERSE When operating in areas that may be hazardous or have poor visibility, designate a person to direct the movements of the ma- chine and traffic on the work site. Make sure that no unauthorized person is within the machine operating range or in its travel direction.
Page 57: Moving On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 MOVING ON SLOPES Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip. 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 58: Working On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.7 WORKING ON SLOPES Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip. When working on slopes (max. inclination 10°), avoid turning the revolving frame, if possible, since this may cause the ma- chine to lose balance and overturn.
Page 59 PRECAUTIONS TO BE TAKEN WHEN WORKING To make it easier to escape from the machine in case of emer- gency, set the tracks at right angles to the road shoulder or coast, with the sprocket at the rear, when carrying out digging operations.
Page 60: Preventing Electrocution
PRECAUTIONS TO BE TAKEN WHEN WORKING When using a breaker or other heavy-duty equipment, the machine may lose its balance and overturn. Both when operating on flat ground and when operating on slopes, keep to the following instructions: 1 - Do not lower, swing, or stop the work equipment suddenly. 2 - Do not extend or retract the boom cylinder suddenly, since the impact may cause the machine to overturn.
Page 61: Visibility
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.10 VISIBILITY Make sure that there are no people or obstacles in the area surrounding the machine and check the conditions of the worksite to ensure that all operations and movements can be carried out safely. Switch on the work lights as soon as visibility decreases.
Page 62: Parking The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.14 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 op- erations: 1 - Rotate the bucket to the dumping position and lower the arms until thrusting the teeth into the ground.
Page 63: Transporting The Machine On Motor Vehicles
TRANSPORTING THE MACHINE ON MOTOR VEHICLES 2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE Loading and unloading the machine on/from a motor vehicle al- ways involves potential hazards. Proceed with extreme care. Perform loading and unloading operations on firm, level ground. Maintain a safety distance from the edges of ditches or from road sides.
Page 64: Battery
BATTERY 2.6 BATTERY 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY Electrolytic batteries contain lead and 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 af- fected part with plenty of water.
Page 65: Starting With Booster Cables
BATTERY 2.6.2 STARTING WITH BOOSTER CABLES When starting the machine with booster cables, always wear safety goggles. When starting the engine by means of another machine, avoid any contact between the two machines. Before connecting the additional cables, make sure that both the starter key and the battery main switch are turned to OFF.
Page 66: Precautions For The Removal Of The Machine
PRECAUTIONS FOR THE REMOVAL OF THE MACHINE 2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE Before removing the machine, make sure that all the controls are in neutral. Incorrect manoeuvres may cause serious damage, personal in- jury and even death. To move the machine, use properly dimensioned steel cables;...
Page 67: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE 2.8 PRECAUTIONS FOR MAINTENANCE 2.8.1 WARNING PLATES Before starting any maintenance operation, position the ma- chine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and the con- trols, and stop the engine.
Page 68: Equipment
60 cm, in order not to damage the warning plates and the pictograms. If the plates are damaged, request Komatsu or your Komatsu Distributor 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 69: Use Of The Engine During Maintenance
PRECAUTIONS FOR MAINTENANCE 2.8.8 USE OF THE ENGINE DURING MAINTENANCE During maintenance operations, make the engine run only when indispensable. If it is necessary to have the en- gine 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 70: Stop The Engine Before Carrying Out Any Maintenance Operation Or Inspection
PRECAUTIONS FOR MAINTENANCE 2.8.11 STOP THE ENGINE BEFORE CARRY- ING OUT ANY MAINTENANCE OPER- ATION OR INSPECTION Stop the machine only on firm and level ground and stop the en- gine before carrying out any maintenance operation or inspec- tion. If it is necessary to have the engine running during mainte- nance, shift the safety lever (1) to the “locked”...
Page 71: Safety Measures To Open (Tilt) The Platform
PRECAUTIONS FOR MAINTENANCE 2.8.13 SAFETY MEASURES TO OPEN (TILT) THE PLATFORM To open (tip) the platform, see "3.2.9 TILTING THE CAB FLOOR". Safety measures to park the machine Park the machine on a firm and level surface. Select a place with no risks of landslide, falling objects or floods.
Page 72: Rules To Be Followed When Refuelling Or Adding Oil
PRECAUTIONS FOR MAINTENANCE 2.8.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING 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. Always tighten the safety caps of the fuel tank and of the hy- draulic oil tank securely.
Page 73: Precautions To Be Taken When Handling The Battery And The Alternator
PRECAUTIONS FOR MAINTENANCE 2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR When the electrical system is being repaired or when electric welds are made, turn the battery main switch to OFF (O) to in- terrupt the current (see "3.2.2 pos: 9. Battery main switch (if in- stalled)").
Page 74: Handling High-Pressure Hoses
PRECAUTIONS FOR MAINTENANCE 2.8.19 HANDLING HIGH-PRESSURE HOSES Do not bend high-pressure hoses or rub them with abrasive or cutting objects. Do not use any bent or cracked pipes or hoses that were previously rejected because of leaks or fastening de- fects, since they may burst during use.
Page 75: Precautions To Be Taken When Using High-Pressure Grease To Adjust The Track Tension
Do not attempt to remove the spring, since this may lead to serious accidents and even death. For any operation on the shock absorber unit, contact your Komatsu Distributor. 2.8.24 HYDRAULIC ACCUMULATOR AND GAS SPRING The hydraulic accumulator and gas springs contain high pressure nitrogen.
Page 76: Cooling Fan And Belt
2.8.26 CHEMICAL HAZARD During maintenance or dismalting operations, where there is a risk of contact with hazardous chemical substanc- es, relevant safety precautions should be taken. If any doubt exists, contact your Komatsu distributor. See also disposal of "2.8.27 WASTE MATERIALS".
Page 77: Precautions To Be Taken When Handling Technopolymers And Elastomers
CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE" - " CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP"). 2.8.31 FINAL DISPOSAL OF THE MACHINE At the end of the working life of the machine, ask Komatsu Distributor for the final disposal. WEAM012101...
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Page 79: The Machine And Its Operations
THE MACHINE AND ITS OPERATIONS...
Page 80: Machine Illustrations
MACHINE ILLUSTRATIONS 3.1 MACHINE ILLUSTRATIONS 3.1.1 OVERALL VIEW OF THE MACHINE RKA22480 Bucket Track Bucket cylinder Sprocket Undercarriage Arm cylinder (10) Idler roller Boom (11) Blade cylinder Boom cylinder (12) Blade WEAM012101...
Page 81: Controls And Gauges
MACHINE ILLUSTRATIONS 3.1.2 CONTROLS AND GAUGES RKA27870 (15) Warning lights and indicators display Operator seat Blade/adjustable track gauge selection switch (16) Accelerator lever Working lights switch (17) Ignition switch Left hand arm rest (18) Cab floor locking lever Control locking lever (safety lever) (19) Electrical system control warning light (optional) Left work equipment control lever...
Page 82: Instruments And Controls
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. 3.2.1 WARNING LIGHTS AND GAUGES RKA23440 Emergency lights...
Page 83: Emergency Warning Lights
INSTRUMENTS AND CONTROLS 3.2.1.1 EMERGENCY WARNING LIGHTS CAUTION If a warning light comes on or the acoustic alarm sounds while the engine is running, stop the engine immediately and try to locate the cause of the failure. These warning lights must always be checked while the engine is running. If any anomaly occurs, the warning light corresponding to the faulty function comes on and the acoustic alarm starts sounding.
Page 84 INSTRUMENTS AND CONTROLS Charge level warning light This warning light comes on, together with the acoustic alarm, when the starting circuit is energized and goes out when the en- gine exceeds the idling speed; if this warning light remains on even when the engine is running at the normal operating speed, this means that the alternator is not working and the battery is not charged correctly.
Page 85: Gauges
INSTRUMENTS AND CONTROLS 3.2.1.2 GAUGES RKA23460 Hour meter Engine coolant temperature indicator Fuel level indicator Engine coolant temperature indicator It indicates the engine coolant temperature, which should normal- ly be approximately 80–85°C. After starting the engine, let it warm up before starting work. If the indicator exceeds the set values during operation and reaches the red overheating area (B), let the engine idle until the indicator returns within the normal operating range (A).
Page 86 INSTRUMENTS AND CONTROLS 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 6.0 litres, the indicator reaches the red reserve area (A) and the warning light (B) blinks.
Page 87: Warning Lights
INSTRUMENTS AND CONTROLS 3.2.1.3 WARNING LIGHTS RKA23470 Engine preheating warning light Travel speed increase 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 tempera- tures.
Page 88: Switches And Push Buttons
INSTRUMENTS AND CONTROLS 3.2.2 SWITCHES AND PUSH BUTTONS RKA27880 Ignition switch Windshield wiper switch (machines with cab) Horn Ventilation and heating switch (machines with cab) Working lights switch Overhead light (machines with cab) Travel speed selection switch Battery main switch (if installed) Blade/adjustable track gauge selection switch WEAM012101...
Page 89 INSTRUMENTS AND CONTROLS Ignition switch This is a four-position rotary switch and is used to switch the en- gine on and off. Position OFF When the switch is in this position, the ignition key can be in- serted and removed. When the key is turned to this position, the power supply to the electric circuit is interrupted and the engine stops.
Page 90 INSTRUMENTS AND CONTROLS Travel speed selection switch WARNING When loading or unloading the machine on/from a trailer, always travel at low speed. Never operate the travel speed selection switch during the loading or unloading operation. If the translation speed shifts from high to low while the machine is moving, the latter may swerve to one side even if moving straight on.
Page 91 INSTRUMENTS AND CONTROLS Blade/adjustable track gauge selection switch WARNING 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 se- lect the wide track gauge. Avoid adjusting the track gauge when the machine is work- ing on a slope: the machine may lose stability and over- turn.
Page 92 INSTRUMENTS AND CONTROLS Windshield wiper switch (machines with cab) Switch (6) activates the front windscreen wiper and it is also used as windscreen washer switch. The switch functions as described below: Windshield wiper only Press the switch to position (B) to start the windshield wiper. Position (A): windshield wiper off.
Page 93 INSTRUMENTS AND CONTROLS Battery main switch (if installed) The battery main switch is located inside the engine compartment and can be reached by opening the engine bonnet (see "3.2.6 ENGINE HOOD"). Turn the key anticlockwise, to (O) OFF, to interrupt the current supplied by the battery to the electrical system;...
Page 94: Control Levers And Pedals
INSTRUMENTS AND CONTROLS 3.2.3 CONTROL LEVERS AND PEDALS RKA27900 Safety device control lever (control locking) Boom swing control pedal locking device Left work equipment control lever Boom swing control pedal Right work equipment control lever Cab floor locking lever Accelerator lever (10) Control pedal locking device optional tools Blade/adjustable track gauge lever...
Page 95 INSTRUMENTS AND CONTROLS Safety lever (control locking lever) WARNING 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 (L) and the control levers are touched by mistake, this may lead to serious injury.
Page 96 INSTRUMENTS AND CONTROLS 2. - 3. Work equipment control levers WARNING Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt. Before leaving the driver seat, lower the equipment to the ground, lock the controls with the safety lever and stop the engine.
Page 97 INSTRUMENTS AND CONTROLS 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 un- der strain or is working in difficult conditions.
Page 98 INSTRUMENTS AND CONTROLS Travel levers WARNING Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt. 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;...
Page 99 INSTRUMENTS AND CONTROLS Boom swing control pedal locking device WARNING 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.
Page 100 INSTRUMENTS AND CONTROLS 10. Control pedal locking device optional tools WARNING Always lock the optional equipment control pedal when the use of this control is not required, during travel and when parking the machine. If the control pedal is inadvertently pressed, this may cause serious accidents.
Page 101: Cab (If Provided)
(ROPS/FOPS level 1). If there is a collision against the machine, or in case it turns over, have a Komatsu Distributor check that the cab complies with the stiffness and active safety standards the operator needs.
Page 102 INSTRUMENTS AND CONTROLS Seize the handles (A) at the right or left top of the front wind- screen and push the locking levers (B) down to release the windscreen. RKAB9680 RKAB9690 Seize the handles (C) and (D), pull up the windscreen and push it until the lock (E) is tripped.
Page 103 INSTRUMENTS AND CONTROLS Closing WARNING When closing the windshield, lower it slowly and pay atten- tion to your hands. Stop the machine on a level surface, lower the equipment completely to the ground, then stop the engine. Shift the safety lever to the “locked” position. Release the windscreen by means of the upper lock (E) le- ver.
Page 104: Door (Machines With Cab)
INSTRUMENTS AND CONTROLS 3.2.4.2 DOOR (machines with cab) WARNING When the cab door is opened or closed, always take the safety device lever to the locking position (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents.
Page 105: Side Sliding Window (Machines With Cab)
INSTRUMENTS AND CONTROLS 3.2.4.3 SIDE SLIDING WINDOW (machines with cab) WARNING When opening or closing the side window, always shift the safety lever to position “lock” (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents.
Page 106: Covers With Lock
INSTRUMENTS AND CONTROLS 3.2.5 COVERS WITH LOCK OPENING AND CLOSING THE COVERS WITH LOCK Use the start-up key to open or close the cases with locks. For details regarding the position of the cases with locks, see section "3.3.17 LOCKING THE MACHINE". Introduce the key completely (6 mm from the point where the key narrows), then turn it.
Page 107: Engine Hood
INSTRUMENTS AND CONTROLS 3.2.6 ENGINE HOOD WARNING 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 expressly prescribed for certain maintenance operations. When carrying out an inspection or maintenance operation inside the engine hood, always open it com- pletely and make sure that it is kept open by the apposite rod.
Page 108: Radiator Cover
INSTRUMENTS AND CONTROLS 3.2.7 RADIATOR COVER WARNING 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 Release the radiator cover lock (1) (see "3.2.5 COVERS WITH LOCK").
Page 109: Battery Cover
INSTRUMENTS AND CONTROLS 3.2.8 BATTERY COVER WARNING When carrying out an inspection or maintenance operation inside the battery cover, always open it com- pletely and make sure that it is kept open by the apposite rod. OPENING THE BATTERY COVER Release the battery cover lock (1) (see "3.2.5 COVERS WITH LOCK").
Page 110: Tilting The Cab Floor
If there is something wrong in the locking function when the cab floor is tilted, interrupt work and have the necessary repairs carried out by your Komatsu Distributor. Always fasten the platform fixing screws to the torque in compliance with the values included in the sec- tion "4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS".
Page 111 INSTRUMENTS AND CONTROLS Position blocks under the tracks in order to prevent the ma- chine from moving. 9JA05466 Open the engine hood (2) completely and make sure that it is kept open by the apposite rod (for further details, see "3.2.6 ENGINE HOOD").
Page 112 INSTRUMENTS AND CONTROLS After tilting the floor open, make sure that the locking pin (8) is inserted in the groove (10) of the locking plate (9). 10. Insert the safety pin (11) into the hole (12) from the outside. 11. Turn until the coupling at the end of the safety pin (11) is completely engaged with the pin (13).
Page 113 Tighten the cab floor fastening screws (3) applying the re- quired torque. Tightening torque: 156.8 to 196 Nm NOTE If any screw is damaged, replace it with an original Komatsu part having the same size. Close the engine hood (2). WEAM012101...
Page 114: Machines With Cab
INSTRUMENTS AND CONTROLS 3.2.9.2 MACHINES WITH CAB Tilting the cab floor Lower the blade. Extend the bucket and arm cylinders completely, then lower the boom slowly. Shift the safety lever (1) to the “locked” position (L), then stop the engine. RKA22440 Position blocks under the tracks in order to prevent the ma- chine from moving.
Page 115 INSTRUMENTS AND CONTROLS Raise the mat (4), pull the cab floor release lever (5) in the di- rection indicated by the arrow and at the same time push the handle (6) upwards in the direction indicated by the arrow (approx. 45°). IMPORTANT If the cab floor does not tilt, pull the handle (6) downwards and repeat the procedure described above.
Page 116 Tighten the cab floor fastening screws (3) applying the re- quired torque. Tightening torque: 156.8 to 196 Nm NOTE If any screw is damaged, replace it with an original Komatsu part having the same size. Close the engine hood (2). WEAM012101...
Page 117: Auxiliary Power Outlet
INSTRUMENTS AND CONTROLS 3.2.10 AUXILIARY POWER OUTLET Power outlet 12V A power outlet (1) is positioned on the front part of the machine for the connection of a lamp for routine and maintenance opera- tions. It is a two-pole outlet and is in compliance with the ISO 4165- 1979 standard.
Page 118: Main Fuse
INSTRUMENTS AND CONTROLS 3.2.12 MAIN FUSE IMPORTANT Before replacing fuses, be sure to first turn the starting switch to the OFF position, wait for over one minute, then switch the battery disconnect switch to OFF and take out the battery disconnect switch key. If the engine does not start when the start-up key is set to START, check the mains fuse and replace it, if necessary.
Page 119: Technical Documentation Compartment
INSTRUMENTS AND CONTROLS 3.2.14 TECHNICAL DOCUMENTATION COMPARTMENT CAUTION The use and maintenance manual is an integral part of the machine and must accompany it even in case of resale. The use and maintenance manual must be stored with care and always kept on board the machine, so that it can be consulted at any moment;...
Page 120: Use Of The Machine And Related Controls
Always perform thorough checks and carry out the necessary repairs; if any fault oc- curs repeatedly, contact your Komatsu Distributor. Ensure that the platform is fastened with screws (1) and, on versions with roof, also with screws (2). If it is not secured properly, it may cause serious injury.
Page 121 (1) are securely tightened. On machines with roof, also check that the fastener screws (2) are tightened correctly. Every time there are abnormal situations related to platform, re- store the correct conditions proceeding personally or contact your Komatsu Distributor for repairs. RKA26040 WEAM012101...
Page 122: Checks To Be Carried Out Before Starting The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE Carry out the checks listed below every day before starting the engine. CHECKING THE COOLANT LEVEL AND TOPPING UP WARNING Do not remove the radiator cap, unless such operation is absolutely necessary. Before checking the coolant level, wait for the engine to cool down and check the expansion tank.
Page 123 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE ENGINE OIL LEVEL AND TOPPING UP WARNING 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 When carrying out an inspection or maintenance operation inside the engine hood, always open it com- pletely and make sure that it is kept open by the apposite rod.
Page 124 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE FUEL LEVEL AND REFUELLING WARNING When refuelling, avoid spilling fuel, since this may cause a fire hazard. If fuel is spilled, wipe it up imme- diately. 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.
Page 125 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP WARNING Carry out this check when the oil is cold, with the machine positioned on level ground, bucket and arm cylinders re- tracted and bucket teeth resting on the ground.
Page 126 USE OF THE MACHINE AND RELATED CONTROLS 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 equip- ment to the ground. IMPORTANT Make sure that the hydraulic tank is pressurized.
Page 127 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE WATER SEPARATOR WARNING Fuel is flammable; do not use naked flames and do not smoke while draining the water separator. If fuel is spilled, wipe it up immediately. If the decanting device red ring (1) is at the bottom of the contain- er (2), it means that there is no water.
Page 128 OFF. If the wirings show traces of short circuits, contact your Komatsu Distributor, who will locate the fault and carry out any necessary repairs.
Page 129: Adjustments
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.3 ADJUSTMENTS WARNING Adjust the position of the seat before starting work or when taking the place of another operator. 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.
Page 130 USE OF THE MACHINE AND RELATED CONTROLS REAR-VIEW MIRRORS WARNING Always check the cleaning and correct orientation of the rear-view mirrors before starting to work; they must allow to control the rear area control without moving the log in relation to the normal working posi- tion.
Page 131 USE OF THE MACHINE AND RELATED CONTROLS SEAT BELT WARNING 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. The safety belt can be replaced also if there are not failures or wear signs according to the following program.
Page 132: Operations To Be Carried Out Before Starting The Engine
Travel speed increase warning light (9) If a warning light or indicator does not turn on, or the sound alarm does not go on, contact a Komatsu Distributor, who will carry out all the necessary repair operations. After approximately 3 seconds, only the following warning lights remain on.
Page 133 USE OF THE MACHINE AND RELATED CONTROLS 2 - Press the light switch (10) and ensure that the working headlamp switches on. If it does not turn on, contact a Ko- matsu Distributor, who will carry out all the necessary re- pair operations.
Page 134: Starting The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.5 STARTING THE ENGINE Start-up with hot engine or mild weather WARNING Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. Once the engine is started, the Operator is absolutely responsible for the damages deriving from false manoeuvres or failure to observe safety regulations..
Page 135 USE OF THE MACHINE AND RELATED CONTROLS As soon as the engine starts, release the key (3), which will automatically return to position ON. RYA17370 Starting with cold engine or in cold climates WARNING Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls.
Page 136 USE OF THE MACHINE AND RELATED CONTROLS Pull the accelerator lever (2) completely, from the idling posi- tion (A) to the maximum speed position (B). RKA10820 RKA23840 Turn the start-up key (3) to HEAT and make sure that the preheat warning light (4) is on. After about 18 seconds, once the preheating is complete, the warning light (4) turns off and the sound alarm goes on.
Page 137: After Starting The Engine
In such case, contact your Komatsu Dis- tributor as soon as possible to have the engine checked.
Page 138: Warming The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2.4 WARMING THE ENGINE IMPORTANT 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. Do not accelerate abruptly before completing the warming-up operations.
Page 139 RKA23890 that there are no strange noises or vibrations. If any anomaly is observed, contact your Komatsu Distributor. Shift the safety lever (2) to the “locked” position (L), then make sure that the machine does not move even when the levers and pedals are operated.
Page 140: Stopping The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.3 STOPPING THE ENGINE 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 141: How To Move The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.4 HOW TO MOVE THE MACHINE WARNING Before moving the machine, make sure that you perfectly know the control functions and all the relevant safety regulations. The operator must be seated in the driving position with fastened seat belt. Before operating the travel levers, check the direction of the undercarriage.
Page 142 When the load is reduced, the travel system automatically changes over to high speed. On machines with translation warning alarm, check that the alarm works correctly. If the alarm does not sound, contact your Komatsu Distributor for repairs. WEAM012101...
Page 143: Moving The Machine In Reverse
USE OF THE MACHINE AND RELATED CONTROLS 3.3.4.3 MOVING THE MACHINE IN REVERSE Move the safety lever (2) to working position (F), then lift the working tools 40-50 cm off the ground. Lift the blade. 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.
Page 144: Stopping The Machine
When the load is reduced, the travel system automatically changes over to high speed. On machines with translation warning alarm, check that the alarm works correctly. If the alarm does not sound, contact your Komatsu Distributor for repairs. 3.3.4.4 STOPPING THE MACHINE WARNING Avoid stopping the machine abruptly.
Page 145: Steering The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.5 STEERING THE MACHINE 3.3.5.1 STEERING (CHANGING DIRECTION) WARNING 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. Avoid abrupt changes of direction as much as possible.
Page 146 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. (A): Left forward steering (B): Left reverse steering NOTE To steer to the right, operate the right travel lever in the same way.
Page 147: Swinging The Revolving Frame
USE OF THE MACHINE AND RELATED CONTROLS 3.3.6 SWINGING THE REVOLVING FRAME WARNING Before swinging the revolving frame, make sure that the area around the machine is safe. To swing the revolving frame, 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).
Page 148: Work Equipment Controls And Functions
USE OF THE MACHINE AND RELATED CONTROLS 3.3.7 WORK EQUIPMENT CONTROLS AND FUNCTIONS Working tools are controlled by the levers positioned to the Operator's right and left. The left lever controls the arm and the revolving frame swing, while the right lever controls the boom and the bucket. When the levers are re- leased, they automatically return to the neutral position and the work equipment remain in the position where they stopped.
Page 149 USE OF THE MACHINE AND RELATED CONTROLS Boom swing control To swing the boom, use the boom swing control pedal. Blade control WARNING The scraper control is not locked, even if the safety device lever is in locking position. Therefore, do not touch the control lever if no operations are being carried out with the scraper.
Page 150 USE OF THE MACHINE AND RELATED CONTROLS Track gauge adjustment control WARNING Select the narrow track gauge only when the machine must travel in small spaces. For normal applica- tions and digging operations, always select the wide track gauge. Adjusting the track gauge on slopes is dangerous, since this may affect the lateral stability of the ma- chine.
Page 151: Unauthorized Operations
USE OF THE MACHINE AND RELATED CONTROLS 3.3.8 UNAUTHORIZED OPERATIONS WARNING Do not attempt to operate the work equipment control levers during travel. If it is necessary to operate the work equipment control levers while the machine is moving, carry out this operation with the maximum care.
Page 152 USE OF THE MACHINE AND RELATED CONTROLS OPERATIONS FOR WHICH IT IS NOT ALLOWED TO EX- PLOIT 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.
Page 153: Precautions For Use
USE OF THE MACHINE AND RELATED CONTROLS 3.3.9 PRECAUTIONS FOR USE TRAVEL Travelling over boulders, tree stumps, or other obstacles means submitting the frame (and in particular the tracks) to considera- ble stress, and this may damage the machine. For this reason, it is advisable to remove any obstacles or to avoid passing over them.
Page 154 USE OF THE MACHINE AND RELATED CONTROLS MAXIMUM WATER DEPTH CAUTION When driving the machine out of water, if the inclination of the machine exceeds 15°, the rear of the revolving frame will be submerged, and this may cause the cooling fan to break.
Page 155: Precautions To Be Taken When Travelling On Slopes
USE OF THE MACHINE AND RELATED CONTROLS 3.3.10 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES WARNING When travelling downhill on steep slopes, slow down using the travel levers and the hand accelerator. Do not travel downhill on slopes whose inclination exceeds 15°.
Page 156 USE OF THE MACHINE AND RELATED CONTROLS When travelling uphill on a slope, position the work equip- ment as shown in the diagram on the right. 20-30 cm 15˚max. RKA17480 BRAKING WHEN TRAVELLING DOWNHILL To brake when travelling downhill, shift the travel levers to the neutral position. This will automatically engage the brakes.
Page 157: Getting The Machine Out Of Mud
USE OF THE MACHINE AND RELATED CONTROLS 3.3.11 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 in- dicated below. WHEN ONE SIDE ONLY GETS STUCK IMPORTANT When using the boom or arm to raise the machine, always place the bottom of the bucket in contact with the ground.
Page 158: Possible Applications Of The Hydraulic Excavator
USE OF THE MACHINE AND RELATED CONTROLS 3.3.12 POSSIBLE APPLICATIONS OF THE HYDRAULIC EXCAVATOR In addition to those indicated below, many other applications are possible, thanks to the use of various attach- ments. DIGGING WITH REVERSED BUCKET The excavator is suitable for carrying out digging operations in a lower position with respect to the machine.
Page 159 USE OF THE MACHINE AND RELATED CONTROLS FILLING/LEVELLING OPERATIONS Use the blade to refill after excavation or to level the ground sur- face. SIDE DITCHING WORK The machine can be used for side ditching in confined spaces by combining the revolving frame swing and boom swing functions. WEAM012101...
Page 160: Changing The Bucket
USE OF THE MACHINE AND RELATED CONTROLS 3.3.13 CHANGING THE BUCKET WARNING 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 operators, who must decide together the words and signals to be used during work.
Page 161: Parking The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.14 PARKING THE MACHINE WARNING Avoid stopping the machine abruptly. Always calculate a sufficient safety distance when stopping. 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.
Page 162: Checks To Be Carried Out Before Stopping The Engine
USE OF THE MACHINE AND RELATED CONTROLS Lower the bucket horizontally until its bottom touches the ground. Lower the blade to the ground. Shift the safety lever (3) to the “locked” position (L). RKA22990 3.3.15 CHECKS TO BE CARRIED OUT BEFORE STOPPING THE ENGINE At the end of the working day, before turning the engine off, check the engine water temperature in the indicator (1), the engine oil...
Page 163: Locking The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.17 LOCKING THE MACHINE Always lock the following parts: (1) Engine hood (2) Tank cover (3) Battery cover (4) Document and tool compartment cover. (5) Cab door (machines with cab) Always close the windows. For further details, see paragraph "3.2.5 COVERS WITH LOCK".
Page 164: Rubber Tracks (Machines Equipped With Rubber Tracks Only)
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 as steel shoes, their advantages cannot be fully exploited.
Page 165 USE OF THE MACHINE AND RELATED CONTROLS When stored for long periods (3 months or more), keep the machine in a closed room protected from direct sun- light and rain. Do not use the machine in areas characterised by high temperatures, for example, in presence of burning woods, scorching steel plates or surfaces in asphalting process.
Page 166 USE OF THE MACHINE AND RELATED CONTROLS Avoid steering when travelling over curbs, rocks, or places where there is a considerable difference in height (more than 20 cm). If this cannot be avoided, always proceed perpendic- ularly to the obstacles. RYA02770 RYA02770 When travelling uphill in reverse, avoid steering at the begin-...
Page 167 USE OF THE MACHINE AND RELATED CONTROLS Removal mechanism of the rubber shoe from the track When the machine moves over an obstacle, a gap forms be- tween the carrier roller and the rubber track. In these condi- tions, the track may come off. RYA02800 Furthermore, if the machine travels in reverse, a gap is formed between the carrier roller, the idler roller and the...
Page 168 USE OF THE MACHINE AND RELATED CONTROLS If the machine travels in reverse in these conditions, the rubber track will come off. RYA02820 If the machine steers in these conditions, the rubber track will come off. RYA02830 WEAM012101...
Page 169: Transporting The Machine
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 "5.1 TECHNICAL SPECIFICATIONS".
Page 170 TRANSPORTING THE MACHINE During the loading and unloading operations, always use ramps or a platform and proceed as indicated below. LOADING THE MACHINE 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.
Page 171 TRANSPORTING THE MACHINE When loading, set the work equipment at the front and the blade at the back, with the undercarriage and the revolving frame parallel. Before getting on the ramps, 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.
Page 172 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 To avoid damaging the bucket cylinder during transport, position a wooden block at one end of the cylinder to prevent it from touching the ground.
Page 173 TRANSPORTING THE MACHINE UNLOADING THE MACHINE 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. Operate the trailer brake and fit chocks (1) under the wheels to prevent the trailer from moving.
Page 174 TRANSPORTING THE MACHINE Set the safety device lever to working position (F). RKA22540 Run the engine at low speed. (A): Idling Lift the blade. RKA23970 Raise the work equipment, make sure that the travelling di- rection of the machine corresponds to the direction of the ramps, and proceed slowly.
Page 175: Lifting The Machine
The lifting method varies depending on the accessories and tools that are actually installed. In case of machines with different specifications, contact your Komatsu Distrib- utor for more detailed information. When lifting the machine, carry out the operation on a level sur- face, proceeding as indicated below.
Page 176 TRANSPORTING THE MACHINE Shift the safety lever (2) to the “locked” position (L). Stop the engine, make sure there is nothing inside the operator's cab, and then get off the machine. If the machine is fitted with cab, close the door and the front windscreen.
Page 177 TRANSPORTING THE MACHINE Connect the ropes to the upper lifting bar as indicated in the figure. IMPORTANT Always use the three coupling points provided for lifting the machine. Do not lift the machine with swing boom or re- volving frame. Pay attention to the pipes and take care that they do not get caught.
Page 178: Using The Machine In The Cold Season
The coolant containing antifreeze is flammable; do not smoke and do not use naked flames during the checks and when preparing the mixture. 1 - Use only Komatsu original coolant antifreeze (AF-NAC) to dilute according to the minimum atmospheric tem- perature indicated in the table in section "4.4.1 COOLANT".
Page 179: Battery
USING THE MACHINE IN THE COLD SEASON 3.5.1.3 BATTERY WARNING The battery produces flammable gas, therefore keep flames and sparks away from it. 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.
Page 180: Ventilation And Heating
USING THE MACHINE IN THE COLD SEASON 3.5.2 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the opera- tor’s stress both in summer and in winter; these functions also serve to eliminate condensate from the front windshield, thus en- suring visibility during both work and travel.
Page 181: Precautions To Be Taken Every Day At The End Of Work
USING THE MACHINE IN THE COLD SEASON 3.5.3 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK WARNING Making the tracks turn idly is dangerous, therefore it is advisable to keep away from the tracks when car- rying 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.
Page 182: Long Periods Of Inactivity
LONG PERIODS OF INACTIVITY 3.6 LONG PERIODS OF INACTIVITY 3.6.1 BEFORE A PERIOD OF INACTIVITY IMPORTANT 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).
Page 183: After A Period Of Inactivity
IMPORTANT If the machine has been stored without carrying out the monthly rust-prevention treatment, have mainte- nance performed by your Komatsu Distributor. Before using the machine after a long period of inactivity, carry out the operations listed below. Recharge the battery and install it on the machine.
Page 184: Troubleshooting
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 "4.9.6.b CHANGING THE FUEL FILTER CARTRIDGE" - " BLEEDING THE FUEL CIRCUIT".
Page 185: Precautions To Be Taken When Working In Particular Conditions
TROUBLESHOOTING 3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDI- TIONS When carrying out digging operations in water, if water gets on the pins of the work equipment, always add grease to the buck- et articulations (1), (2), (3), (4) and (5) before work. When carrying out heavy duty digging and deep digging opera- tions, always add grease to the bucket articulations (1), (2), (3), (4) and (5) (total: 5 points) before work.
Page 186: Removing And Installing The Battery
TROUBLESHOOTING 3.7.5.1 REMOVING AND INSTALLING THE BATTERY IMPORTANT After securing the battery, make sure that it does not move. If it does move, tighten it adequately again. Before removing the battery, stop the engine, wait at least one minute, and afterwards turn the battery main switch to OFF and extract the specific key.
Page 187: Starting With Booster Cables
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 When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (–). When starting the engine with booster cables, always wear safety goggles.
Page 188 TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Before connecting the batteries via additional cables, make sure that the starter key of both the machines and the battery main switch of the machine to be started are turned to OFF. Connect the additional cables as instructed below and observing the number order in the diagram.
Page 189: Other Troubles
(•) Always contact your Komatsu Distributor when you have to carry out this operation. • In case of anomalies or problems that are not listed here below, contact your Komatsu Distributor, who will pro- vide for the necessary repairs. 3.7.6.1...
Page 190: Frame
TROUBLESHOOTING 3.7.6.2 FRAME TROUBLE CAUSE SOLUTION • No hydraulic oil. • Restore level. See "CHECKS TO BE Travel speed, swing, boom, arm, CARRIED OUT BEFORE START- bucket slow. ING THE ENGINE". • Foreign body in the hydraulic tank fil- • Clean. See "Every 2000 hours OF Pump does not work correctly.
Page 191 TROUBLESHOOTING TROUBLE CAUSE SOLUTION • No fuel. • Restore level. See "CHECKS TO BE CARRIED OUT BEFORE START- ING THE ENGINE". • Air in fuel system. • Repair the point where air is sucked in, see "EVERY 500 HOURS OF OPERATION".
Page 192 PAGE INTENTIONALLY LEFT BLANK...
Page 193 MAINTENANCE...
Page 194: Guide To Maintenance
Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu service engineer unless specific instructions are given in this manual. If any doubt exists, contact your Komatsu Distributor.
Page 195 GUIDE TO MAINTENANCE Do not use flammable fluids to clean any parts of the machine. Keep naked flames away from these fluids and avoid smoking. When O rings and gaskets are removed, clean the sealing surfaces thoroughly and replace the O rings and gas- kets with new ones.
Page 196: Maintenance Notes
Use only Komatsu genuine spare parts. Do not mix different types of oil. Unless specified otherwise, the oils and the coolant used by Komatsu to fill the tanks before the delivery of the machine are the following: ITEM / TANK / SYSTEM SPECIFICATIONS •...
Page 197: Fuel
Do not use corrosion inhibitors containing soluble oil, since they damage the rubber couplings. In case of doubt regarding the applicable standards for the use of coolant, contact your Komatsu Distributor, who will supply you with exhaustive and precise information.
Page 198: Kowa (Komatsu Oil Wear Analysis)
Many years of experience and the availability of countless data and information allow Komatsu to accurately deter- mine the conditions of the machine. This also allows us to locate troubles and suggest the most suitable and fast repair solutions.
Page 199: Storing Oil And Fuel
When changing the oil filters, check if metal particles are present. If you find large quantities of metal particles, contact your Komatsu Distributor. Do not open the spare filter packages before using them. Always use Komatsu original spare parts. WEAM012101...
Page 200: Notes On The Maintenance Of The Electrical System
External electromagnetic interference may cause a malfunction of the controller of the control system; before in- stalling a radio receiver or any other wireless tools, contact your Komatsu Distributor. Do not connect any optional device to the fuses, ignition switch, battery, relays, etc.; for the installation of any op- tional equipment, contact your Komatsu Distributor.
Page 201: Parts Subject To Wear
Due to our constant efforts aimed at improving product quality, the spare parts codes may be changed, therefore when ordering spare parts it is advisable to indicate also the machine serial number to the Komatsu Distributor, in order to receive the most updated version of the component required.
Page 202: Fuel, Coolant And Lubricants
FUEL, COOLANT AND LUBRICANTS 4.4 FUEL, COOLANT AND LUBRICANTS Original Komatsu oils have been designed to ensure reliability and long life of the Komatsu construction equip- ment and their components. To keep machinery in the best conditions for a long time, it is essential to observe the instructions indicated in this user and maintenance manual.
Page 203 FUEL, COOLANT AND LUBRICANTS CORRECT SELECTION ACCORDING TO ROOM TEMPERATURE Room Temperature Fluid Topping up Fluid type recommended by 50°C Komatsu 104 122°F Komatsu SAE 10W30DH EO10W30DH Komatsu Engine oil pan Engine oil SAE 15W40DH EO15W40DH Komatsu SAE 30DH EO30DH...
Page 204: Coolant
0.93 1.12 1.27 1.43 1.55 1.68 1.80 Coolant quantity Water quantity litres 2.17 1.98 1.83 1.67 1.55 1.42 1.30 Volume percentage NOTE The percentage of original Komatsu coolant (AF-NAC) should never be below 30% in order to avoid corrosion. WEAM012101...
Page 205: 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 SYNTHETIC BIODEGRADABLE OIL TYPE “HEES” KOMATSU BO 46 G4 (KES 07.872) AGIP —...
Page 206: Tightening Torques
If not specified otherwise, tighten the screws and nuts applying the torques specified in the table. If it is necessary to replace a screw or a nut, always use Komatsu original spare parts having the same size of the part to be re- placed.
Page 207: Standard Tightening Torques For Flexible Hoses
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.
Page 208: Lubrication
IMPORTANT For details on how to lubricate specific parts, see "4.9.4.a LUBRICATION". The type of lubricant to be used is indicated in the lubricant table (see "4.4 FUEL, COOLANT AND LUBRI- CANTS"). Grease PC18MR-3 PC18MR-3 Fuel filter 2000h 1000h 500h...
Page 209: Periodical Change Of Safety-Related Components
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 indicat- ed in the table in the following page, which are especially related to safety and fire-prevention rules.
Page 210: Safety-Related Parts
PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS 4.7.1 SAFETY-RELATED PARTS Safety-related components that periodically need changing Q.ty Change interval Fuel pipe (fuel tank - water separator) Fuel pipe (water separator – fuel pump) Fuel pipe (fuel pump - fuel filter) Fuel pipe (fuel filter - injection pump) Fuel pipe (fuel filter –...
Page 211: Maintenance Plan
MAINTENANCE PLAN 4.8 MAINTENANCE PLAN If the machine is equipped with hydraulic breaker, the maintenance schedule for some components will be differ- ent. For further details, see "4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAK- ER", in order to be able to provide for correct maintenance. 4.8.1 MAINTENANCE PLAN WHEN REQUIRED CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE ..........
Page 212 MAINTENANCE PLAN MAINTENANCE EVERY 1000 HOURS OF OPERATION CHANGING THE HYDRAULIC OIL FILTER .................... 241 CHANGING THE OIL IN THE FINAL REDUCTION GEARS..............242 CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE............242 MAINTENANCE EVERY 1500 HOURS OF OPERATION FUEL INJECTION SYSTEM CHECK AND CLEANING ................243 MAINTENANCE EVERY 2000 HOURS OF OPERATION CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER .........
Page 213: Maintenance Intervals In Case Of Use Of The Hydraulic Breaker
MAINTENANCE PLAN 4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER 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. 4.8.2.a CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100÷150 hours of...
Page 214: Maintenance Procedures
MAINTENANCE PROCEDURES 4.9 MAINTENANCE PROCEDURES 4.9.1 WHEN REQUIRED 4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE WARNING Remove the air filter only after stopping the engine and do not start the engine if the air filter is open. 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.
Page 215 MAINTENANCE PROCEDURES 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.
Page 216: Battery Electrolyte Level Check
MAINTENANCE PROCEDURES 4.9.1.b BATTERY ELECTROLYTE LEVEL CHECK WARNING Carry out this check with the machine parked on level ground. Check the level only when the engine is stopped and, if necessary, add distilled water only before start- ing the operations. Always wear protective goggles and waterproof gloves.
Page 217 Komatsu Distributor or the battery manufacturer. WHENEVER ELECTROLYTE LEVEL CANNOT BE CHECKED ON THE BATTERY SIDE If electrolyte level cannot be checked on the battery side, or if the MAXIMUM level is not indicated, check following the steps below.
Page 218: Cleaning The Water Separator Filter
MAINTENANCE PROCEDURES 4.9.1.c CLEANING THE WATER SEPARATOR FILTER WARNING Change the filter after work, when the engine has cooled down to 40÷45°C. During these operations some fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire. Open the radiator cover.
Page 219: Draining The Fuel Tank
MAINTENANCE PROCEDURES 4.9.1.d DRAINING THE FUEL TANK WARNING When draining the fuel tank, avoid spilling fuel, since this may cause fires. If some fuel is accidentally spilled, clean the dirty area immediately, in order to prevent it from getting slippery and to avoid fires. Swing the revolving frame so that the drain valve (1) is positioned between the tracks.
Page 220 «S» of 0 mm and the track is not suffi- ciently stretched, this means that the pins and bushings are excessively worn. Therefore, it is necessary to exchange or replace the pins and bushings. For any replacement or repair, contact your Komatsu Distrib- utor. WEAM012101...
Page 221 It is extremely dangerous to let the grease out following any procedure different from those illustrated below. If the track tension cannot be reduced with this operation, contact your Komatsu Distributor, who will provide for the necessary repairs. Gradually loosen the grease valve (1) to let the grease out;...
Page 222: Checking The Rubber Tracks
MAINTENANCE PROCEDURES 4.9.1.f CHECKING THE RUBBER TRACKS Change the rubber tracks when they reach the indicated wear limits. When the height “A” of the rubber claw is less than 5 mm: in this case, in fact, the track may slip and its traction force be reduced..
Page 223 If the length of the broken area is less then 30 mm or its depth is less than 10 mm, it is not necessary to repair the track. For any repair or replacement, contact your Komatsu Dis- tributor. RAY07530 WEAM012101...
Page 224: Checking And Adjusting The Rubber Track Tension
Do not loose any component apart from the valve (1). If the track tension does not decrease after this operation, con- tact your Komatsu Distributor. WARNING If the resistance met when injecting the grease is exces- sive, move the machine forward and backward covering a short distance.
Page 225 It is extremely dangerous to let the grease out following any procedure different from those illustrated below. If the track tension cannot be reduced with this operation, contact your Komatsu Distributor, who will provide for the necessary repairs. Gradually loosen the grease valve (1) to let the grease out;...
Page 226: Changing The Rubber Tracks
Do not loose any component apart from the valve (1). If the track tension does not decrease after this operation, con- tact your Komatsu Distributor. It is extremely dangerous to let the grease out following any procedure different from the one indicated below.
Page 227 MAINTENANCE PROCEDURES Stop the machine on a firm and level surface and lower the equip- ment to the ground. Raise the undercarriage using boom and arm. Carry out this operation shifting the control levers very slowly. Gradually loosen the grease valve (1) to let the grease out; do not give the valve more than one turn.
Page 228 MAINTENANCE PROCEDURES INSTALLING THE RUBBER TRACKS Raise the undercarriage using boom and arm and make sure that the grease contained in the cylinder has been eliminat- Carry out this operation shifting the control levers very slowly. Install the rubber tracks on the sprocket by fitting the driving blocks.
Page 229: Checking The Detergent Level In The Windsield Washer Reservoir (Machine With Cab)
MAINTENANCE PROCEDURES 4.9.1.i CHECKING THE DETERGENT LEVEL IN THE WINDSIELD WASHER RESERVOIR (machine with cab) The tank (1) is located under the driving cab and can be accessed after opening the sliding door. The tank holds liquid detergent used for cleaning the front windscreen; make sure that the reser- voir is always full.
Page 230: Lubrication Of Cab Door Hinges (Machines With Cab)
MAINTENANCE PROCEDURES 4.9.1.j LUBRICATION OF CAB DOOR HINGES (machines with cab) Lubricate when the cab door squeaks when it is opened or closed, or when there are oxidation traces around the shoulder washers or their pivots. Lubrication consists in filling the grease nipples placed on the hinge axis with grease.
Page 231: Checking Windscreen Wiper Blade (Machines With Cab)
MAINTENANCE PROCEDURES 4.9.1.l CHECKING WINDSCREEN WIPER BLADE (machines with cab) Check only after the windscreen wiper mechanism has been activated. Checking consists in detecting the faulty cleaning of the wiper carried out with the washer in function. If after cleaning, there are scratches, it means that the scrapping blade is deteriorated and it is necessary to replace the wiper.
Page 232: Checks To Be Carried Out Before Starting The Engine
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 Distributor. For details on the following items, see "3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE EN- GINE".
Page 233: Maintenance Every 100 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.4 MAINTENANCE EVERY 100 HOURS OF OPERATION 4.9.4.a LUBRICATION WARNING Do not turn the revolving frame during fifth wheel and swing pinion lubrication. IMPORTANT Clean the grease nipples before using the grease gun and clean dirty grease leakage after lubrication. If the machine is used in difficult conditions, carry out this operation more frequently than usual.
Page 234 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 (2 point) (7) Boom base pin (1 point) (8) Boom cylinder base pin (1 point) (9) Boom cylinder rod end (1 point)
Page 235: Maintenance After The First 500 Hours Of Operation (Only For Machines In Which Synthetic Biodegradable Oil Type Hees Is Used)
MAINTENANCE PROCEDURES 4.9.5 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which 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 236: Maintenance Every 500 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.6 MAINTENANCE EVERY 500 HOURS OF OPERATION 4.9.6.a CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE WARNING Change the oil with the machine parked on a level surface and the work equipment resting on the ground. Soon after the machine has been stopped the engine oil is very hot and may cause burns;...
Page 237: Changing The Fuel Filter Cartridge
MAINTENANCE PROCEDURES 4.9.6.b CHANGING THE FUEL FILTER CARTRIDGE WARNING Change the filtering element after work, when the engine has cooled down to 40÷45°C. During these operations some fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire.
Page 238 MAINTENANCE PROCEDURES BLEEDING THE FUEL CIRCUIT WARNING The engine may start during the bleeding operations; make sure that there is no one near the machine. After filling the fuel tank, ensure that the filter valve (1) is in the open position (B). Turn the ignition key to position ON and wait approximately 10-15 seconds, in such a way as to allow the fuel system to be automatically bled.
Page 239: Checking The Oil Level In The Final Reduction Gears
MAINTENANCE PROCEDURES 4.9.6.c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS WARNING 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. Loosen the cap slowly to release any residual pressure.
Page 240: Checking And Cleaning The Fins Of The Radiator And Of The Exchanger
MAINTENANCE PROCEDURES 4.9.6.d CHECKING AND CLEANING THE FINS OF THE RADIATOR AND OF THE EXCHANGER WARNING If compressed air, steam or water hit someone, they may cause serious injury. Always wear a visor and safety shoes. Open the radiator cover. For details, see paragraph "3.2.7 RADIATOR COVER"...
Page 241: Checking And Adjusting The Fan Belt Tension
IMPORTANT Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu serv- ice engineer unless specific instructions are given in this manual. ADJUSTMENT Lift the platform, see "3.2.9 TILTING THE CAB FLOOR".
Page 242: Draining The Hydraulic Oil Tank (Only For Machines In Which Synthetic Biodegradable Oil Type Hees Is Used)
MAINTENANCE PROCEDURES 4.9.6.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used) WARNING To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instruc- tions given in paragraph "3.2.9 TILTING THE CAB FLOOR" or have this operation carried out by your Ko- matsu Distributor.
Page 243: Maintenance Every 1000 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.7 MAINTENANCE EVERY 1000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS. 4.9.7.a CHANGING THE HYDRAULIC OIL FILTER WARNING To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instruc- tions given in paragraph "3.2.9 TILTING THE CAB FLOOR"...
Page 244: Changing The Oil In The Final Reduction Gears
Always use oil of the prescribed type (see "4.4 FUEL, COOLANT AND LUBRICANTS"). 4.9.7.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE Since these checks and adjustments require the use of special tools, have them carried out by qualified personnel supplied by your Komatsu Distributor. WEAM012101...
Page 245: Maintenance Every 1500 Hours Of Operation
To obtain the best engine performance, the fuel injection valves must operate perfectly. Then, it is necessary to carry out the fuel injection valves check and cleaning. Given that special tools are needed for these operations, it is advisable to commission your Komatsu Distributor to perform them. WEAM012101...
Page 246: Maintenance Every 2000 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.9 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS and every 1000 HOURS. 4.9.9.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER WARNING To carry out this maintenance operation it is necessary to tilt the cab floor. Carefully follow the instruc- tions given in paragraph "3.2.9 TILTING THE CAB FLOOR"...
Page 247 MAINTENANCE PROCEDURES Shift the safety lever to the “locked” position (L). Tilt the cab floor (see "3.2.9 TILTING THE CAB FLOOR"). RKA23010 Loosen the screws (1), remove the plate (2) and slowly loos- en the filler cap (F) to release the residual pressure from the tank.
Page 248 MAINTENANCE PROCEDURES 14. 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. NOTE Make sure the hydraulic tank is pressurised. If it is not pressu- rised, the pump will suck air, affecting tool operation.
Page 249: Changing The Coolant
MAINTENANCE PROCEDURES 4.9.9.b CHANGING THE COOLANT CAUTION The coolant must be changed every 2000 hours of operation or every 2 years, whichever occurs first. WARNING Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns;...
Page 250: Checking The Alternator And The Starter
4.9.9.c CHECKING THE ALTERNATOR AND THE STARTER The brush may be worn or the bearing may be without grease. Contact the Komatsu Distributor for check or repair operations. If the engine is frequently started, carry out checks every 1000 hours.
Page 251: Nitrogen Loading Pressure Check In The Accumulator (For The Control Circuit)
Do not make holes in the accumulator, do not weld or use oxyhydrogen flames. Do not hit or press the accumulator. The gas must be released when disposing of the accumulator. Refer to your Komatsu Distributor to have this operation carried out.
Page 252 MAINTENANCE PROCEDURES ACCUMULATOR OPERATION CHECK CAUTION Before starting check operations, make sure that no person or other obstacles are in the surrounding ar- Check nitrogen loading pressure as follows. Stop the machine on a solid and flat surface. Place the working tool as extended as possible (fully extend- ed boom and bucket in discharge position) and keep it 1.5 m (A) away from the ground..
Page 253 If the tool does not descend or stops at the middle of the course, the accumulator pressure is not enough. Refer to your Komatsu Distributor for check operations. When the check is completed, take the safety device lever back to the locking position (L) and turn the start-up key to OFF.
Page 254: End Of Service Life
END OF SERVICE LIFE 4.10 END OF SERVICE LIFE For safe dismantling of the machine at end of service life, please contact your local Komatsu Distributor. WEAM012101...
Page 255 TECHNICAL SPECIFICATIONS...
Page 256: Technical Specifications
TECHNICAL SPECIFICATIONS 5.1 TECHNICAL SPECIFICATIONS Unit of measurement PC18MR-3 (kg) 1910 Operating mass (ISO 6016) Bucket capacity (ISO 7451) 0,044 Komatsu Engine 3D67E-2 diesel engine Engine power (ISO 14396: 2002) KW (HP)/rpm 11.8(16.0)/2600 Total length 3650 With canopy 2320 Total height (Min/Max)
Page 257 TECHNICAL SPECIFICATIONS Unit of PC18MR-3 Operating characteristics measurement Max. digging outreach 4025 Max. digging depth 2160 With canopy 3615 Max. digging height With cab 3615 Max. vertical wall digging depth 1785 With canopy 2610 Max. dumping height With cab 2610 Work equipment min.
Page 258: Lifting Capacities
LIFTING CAPACITIES 5.2 LIFTING CAPACITIES 5.2.1 LIFTING CAPACITIES PC18MR-3 DANGER 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. Carry out lifting operations only with the machine positioned on firm and flat ground.
Page 259 LIFTING CAPACITIES STANDARD ARM 965mm + STANDARD COUNTERWEIGHT + LOWERED BLADE + WIDE TRACK GAUGE Unit: kg 2.5 m 3.5 m Max. 3.0 m *355 2.5 m *305 *322 2.0 m *318 *314 *318 1.5 m *460 *373 *333 *319 1.0 m *653 *454...
Page 260 LIFTING CAPACITIES STANDARD ARM 965 mm + ADDITIONAL COUNTERWEIGHT + LOWERED BLADE + WIDE TRACK GAUGE Unit: kg 2.5 m 3.5 m Max. 3.0 m *355 *355 2.5 m *305 *305 *322 2.0 m *318 *318 *314 *318 1.5 m *460 *373 *333...
Page 261 LIFTING CAPACITIES LONG ARM 1215 mm + STANDARD COUNTERWEIGHT + LOWERED BLADE + WIDE TRACK GAUGE Unit: kg 2.5 m 3.5 m Max. 3.0 m *279 *294 2.5 m *239 *239 *270 *281 2.0 m *257 *257 *268 *280 1.5 m *318 *294 *283...
Page 262 LIFTING CAPACITIES LONG ARM 1215 mm + ADDITIONAL COUNTERWEIGHT + LOWERED BLADE + WIDE TRACK GAUGE Unit: kg 2.5 m 3.5 m Max. 3.0 m *279 *279 *294 *294 2.5 m *239 *239 *270 *281 2.0 m *257 *257 *268 *280 1.5 m *318...
Page 263: Authorized Optional Equipment
AUTHORISED OPTIONAL EQUIPMENT...
Page 264: General Precautions For Safety
When installing attachments or options to the machine, it is necessary to pay attention to safety. Please obey the following precautions strictly when selecting, installing, or using attachments or options. For attachment items other than those described in this operation manual please refer to your Komatsu Distributor. 6.1.1 PRECAUTIONS WHEN SELECTING Please consult your Komatsu distributor before installing attachments or options to the machine.
Page 265: Precautions When Using
When calculating the allowable mass of attachments, the mass of the bucket, see the explanation of lift- ing capacity chart PC18MR-3 ("5.2.1 LIFTING CAPACITIES PC18MR-3"). For an attachment not intended to bear a load, for example a breaker, it should not exceed the minimum lift capacity of the machine as shown on the related lift capacity charts (see "5.2.1 LIFTING CAPACITIES...
Page 266: Specifications
SPECIFICATIONS 6.2 SPECIFICATIONS Hydraulic specifications Max. Service valve flow (1st attachment) 35 litres/min Standard Service valve working pressure (1st attachment) 23 MPa (230 bar) Optional Safety service valve working pressure (1st attachment) — MPa ( — bar) Standard Service valve safety pressure (1st attachment) 27.9 MPa (279 bar) 6.2.1 ARM-PIN INFORMATION A - A B - B...
Page 267: Attachment Guide
When installing any attachment or option, there may be problems with safety, so please contact your Ko- matsu distributor before installing. Installing attachments or options without consulting your Komatsu distributor may not only cause prob- lems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment.
Page 268 For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durability and high wear resistance be employed. Machine layout: Equipments characteristics (to be managed only by Komatsu or Komatsu Distributor) Working Working...
Page 269: Machine Configuration For The Installation Of Attachments
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4.1 POSITION OF THE DEVICES RKA23120 Quick couplers Optional tools control pedal Selection valve Optional tools control pedal locking device WEAM012101...
Page 270 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS Quick couplers The quick coupling (1) is used to connect the pipes equipped with quick coupling to the ends of the equipment. NOTE When the tools are removed, fit the cap (A) in the quick cou- pling.
Page 271: Hydraulic Circuit
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4.2 HYDRAULIC CIRCUIT 6.4.2.1 INSTALLING AND CONNECTING THE EQUIPMENT WARNING The machine must be parked on a level surface, with the equipment resting on the ground. When the connecting pins are removed or installed, chips may come off; always wear gloves, safety goggles and helmet.
Page 272: Bleeding
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4.2.3 BLEEDING After connecting the pipes, start the engine and let it idle for approximately 10 minutes (see "3.3.2 AFTER STARTING THE ENGINE" ). Extend all cylinders 4-5 times, stopping them at approx. 100 mm from the end of stroke. IMPORTANT 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.
Page 273: Operating The Equipment
The breaker is operated by pressing the lower part of the equip- ment control pedal (B). NOTE If it is necessary to adjust the oil flow, have this operation car- ried out by your Komatsu Distributor. RKA16510 Precautions for use Before using the breaker, make sure that the spool of the selection valve (1) is completely rotated counterclockwise and resting against its retainer, position (a).
Page 274: Long Periods Of Inactivity
Lower part (B) pressed: the oil flows to the left side of the arm (op- erator seat side). NOTE If it is necessary to adjust the oil flow, have this operation car- ried out by your Komatsu Distributor. RKA16500 Precautions for use Before using a crusher or other generic equipment, make sure that the spool of the selection valve (1) is completely rotated clockwise and resting against its retainer, position (a).
Page 275: Modifying The Machine Control Pattern (Only On Machines With Pattern Change Valve)
MODIFYING THE MACHINE CONTROL PATTERN (ONLY ON MACHINES WITH PATTERN CHANGE VALVE) 6.6 MODIFYING THE MACHINE CONTROL PATTERN (ONLY ON MACHINES WITH PATTERN CHANGE VALVE) WARNING Before using the pattern change lever to modify the control pattern of the machine, lower the tools to the ground, stop the engine an ensure that the safety device lever is in the locked position.
Page 276: Machine Control Diagrams
MODIFYING THE MACHINE CONTROL PATTERN (ONLY ON MACHINES WITH PATTERN CHANGE VALVE) 6.6.2 MACHINE CONTROL DIAGRAMS WARNING After having changed the operation diagrams, always re- place the relevant card in the operator compartment. RKA26180 ISO PATTERN control system BACKHOE PATTERN control system WEAM012101...
Page 277: Precautions To Be Taken When Using Optional Equipment
Choose the type of equipment that is most suitable to the hydraulic excavator on which it must be in- stalled. Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated (see "6.3.2 ATTACHMENT CONFIGURATION").
Page 278 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT It is absolutely necessary to keep the pressure of the excava- tor on the breaker constant as the bit penetrates the ground. Always accompany the breaker as it penetrates and use the excavator arms to obtain such a pressure as to keep the un- dercarriage lifted approx.
Page 279 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 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.
Page 280 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT Levering with the tool after driving it into the material to be broken. RYA03930 Hitting the ground with the breaker bit. RYA03940 Lifting the machine by levering on the breaker bit with the bucket cylinder completely extended.
Page 281 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT GREASING Supply grease in the correct position. RYA05800 IMPORTANT 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.
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Komatsu PC18MR-3 Operation & Maintenance Manual

Foreword 1.1 Foreword

Safety and Accident Prevention

The Machine and Its Operations

Maintenance

(Operations to be Carried out Together with those Prescribed in Paragraph "4.9.6 MAIN-

Technical Specifications

Authorized Optional Equipment

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Summary of Contents for Komatsu PC18MR-3