Page 1 Operation & Maintenance WEAM009500 Manual PC26MR HYDRAULIC EXCAVATOR SERIAL NUMBER PC26MR F00003 and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine.
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
INFORMATION ON SAFETY 1.2 INFORMATION ON SAFETY Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations pre- scribed for the maintenance operations that must be performed on the machine. In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read and be sure to understand all the information and warnings contained in this manual and given on the plates ap- plied onto the machine.
Page 5 INFORMATION ON SAFETY DANGER Before starting any maintenance operation, position the machine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and the controls, and stop the en- gine. DANGER To make the information clearer, some illustrations in this manual represent the machine without safety guards.
Page 6: Introduction
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 "6.1 AUTHORISED TOOLS".
Page 7: 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 8: Product Identification
RKA01331 RKA01331 MODEL SERIAL No. MANUFACT.YEAR MASS MIN/MAX ENGINE POWER Product Identification Number MANUFACTURER KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN 22L-09-R1371 RKA18100 WEAM009500...
Page 9: 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. RKA18110 The exhaust gas emission plate is applied to the upper surface of the tappet cover and on the rear left side of the cab support frame.
Page 10: Swing Reduction Gear Serial Number
PRODUCT IDENTIFICATION 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned on the up- per side of the swing motor. RKAB2570 1.4.6 CAB SERIAL NUMBER The serial number is stamped on the plate positioned on the up- per left side.
Page 11: Serial Numbers And Dealer's Address
PRODUCT IDENTIFICATION 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS Machine no. Model Product identification number (PIN) Engine no. Travel reduction gear no. Swing reduction gear no. Cab No. Dealer: Address: Tel. Contact person: NOTES: WEAM009500...
Page 12: Komtrax System
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 dealer and having entered into a contract 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 13: 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 14 TABLE OF CONTENTS 2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT ............2.3.4 ROOM VENTILATION ......................2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ..............2.3.6 CLEANING THE WINDOWS AND CHECKING THE WINDSHIELD WIPER BLADES.... PRECAUTIONS TO BE TAKEN WHEN WORKING................2.4.1 STARTING THE ENGINE ......................
Page 15 TABLE OF CONTENTS 2.8.22 WASTE MATERIALS ......................2.8.23 COMPRESSED AIR ......................... 2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS 2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES ..........................THE MACHINE AND ITS OPERATIONS MACHINE ILLUSTRATIONS ........................ 3.1.1 OVERALL VIEW OF THE MACHINE ..................
Page 16 TABLE OF CONTENTS 3.3.6 SWINGING THE TURRET ....................... 3.3.7 WORK EQUIPMENT CONTROLS AND FUNCTIONS............. 3.3.8 UNAUTHORIZED OPERATIONS..................... 3.3.9 PRECAUTIONS FOR USE....................... 3.3.10 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES........3.3.11 GETTING THE MACHINE OUT OF MUD ................3.3.12 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR ..3.3.13 CHANGING THE BUCKET.......................
Page 17 TABLE OF CONTENTS MAINTENANCE GUIDE TO MAINTENANCE ........................MAINTENANCE NOTES ........................4.2.1 OIL, FUEL AND COOLANT...................... 4.2.1.1 OIL .......................... 4.2.1.2 FUEL ........................4.2.1.3 COOLANT ....................... 4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS) ............4.2.1.5 STORING OIL AND FUEL ..................4.2.1.6 FILTERS ......................... 4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM ........
Page 18 TABLE OF CONTENTS 4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION ............4.9.5.a LUBRICATION ......................4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE ..4.9.5.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)..4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS ...... 4.9.5.e CHANGING THE FUEL PUMP PREFILTER ............
Page 19: Safety And Accident Prevention
SAFETY AND ACCIDENT PREVENTION...
Page 20: Safety, Noise And Vibration Plates
SAFETY, NOISE AND VIBRATION PLATES 2.1 SAFETY, NOISE AND VIBRATION PLATES 2.1.1 POSITION OF THE SAFETY PLATES The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or grease, it is necessary to clean them with a solution made of water and detergent. Do not use fuel, petrol or solvents.
Page 21: Pictograms And Relevant Meanings
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine 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 22 SAFETY, NOISE AND VIBRATION PLATES PLATFORM LIFTING SAFETY PLATE When the platform is open, make sure that the safety pin is cor- rectly inserted. 22L-98-R2390 FRONT WINDSCREEN LOCKING (only with cab) Make sure that the front windshield is always locked. 09803-A0481 HYDRAULIC OIL TOPPING UP (Only for machines in which synthetic biodegradable oil type...
Page 23 SAFETY, NOISE AND VIBRATION PLATES REFUELLING RWA00040 ENGINE OIL FILTER RWA00080 FUEL FILTER RWA00060 ENGINE AIR INTAKE FILTER RWA00090 ENGINE COOLANT RWA00130 ENGINE COOLANT PRESSURE RWA00110 WEAM009500...
Page 24 SAFETY, NOISE AND VIBRATION PLATES HYDRAULIC OIL LEVEL RWA00100 HYDRAULIC OIL FILTER RWA00070 POWER OUTLET 12 V RWA00120 ANCHORAGE POINT RWA00200 EMERGENCY EXIT (machines with cab) RWA00190 LIFTING POINT RWA04920 WEAM009500...
Page 25 SAFETY, NOISE AND VIBRATION PLATES LIFTING CAPACITIES (PC26MR-3 WITH CANOPY) W=450mm kg 34 380kg 640kg 335kg 265kg L=1015mm 585kg 320kg 235kg 560kg 310kg 255kg 570kg 350kg L=1365mm 555kg 300kg 210kg > > 22K-98-R2110 LIFTING CAPACITIES (PC26MR-3 WITH CAB) W=450mm kg 34...
Page 26: Position Of The Noise Plates On Machines With Cab
SAFETY, NOISE AND VIBRATION PLATES 2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB The noise plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or grease, it is nec- essary to clean them with a solution made of water and deter- gent.
Page 27: Position Of The Noise Plates On Machines With Canopy
SAFETY, NOISE AND VIBRATION PLATES 2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY The noise plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or grease, it is nec- essary to clean them with a solution made of water and deter- gent.
Page 28: 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 29: Unauthorized Modifications
GENERAL PRECAUTIONS 2.2.4 UNAUTHORIZED MODIFICATIONS Any modification made without the authorization of Komatsu can involve hazards. Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injury or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATOR SEAT When leaving the operator seat, even if temporarily, make sure that the machine is in a safe position.
Page 30 GENERAL PRECAUTIONS 3 - Lock the equipment control by shifting the safety lever (1) to the “locked” position (L). 4 - Stop the engine. (See "3.3.3 STOPPING THE ENGINE"). 5 - If you have to go so far away that you will not be able to see the machine, extract the ignition key.
Page 31: Getting On And Off The Machine
GENERAL PRECAUTIONS 2.2.6 GETTING ON AND OFF THE MACHINE Do not jump on or off the machine, neither when it is at rest nor when it is moving. When getting on or off the machine, always use the handles and the tracks; get on and off the machine very carefully. Do not hold or rest on the control levers.
Page 32: Preventing Fires Due To Fuel And Oil
GENERAL PRECAUTIONS 2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL Fuel, oil and some types of antifreeze can easily ignite if they get in contact with a flame. Fuel is flammable and therefore very dan- gerous. Keep any naked flame away from flammable fluids. Stop the engine and do not smoke when refuelling.
Page 33: Preventing Damage Due To Asbestos Powder
GENERAL PRECAUTIONS 2.2.9 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 34: Fire Extinguishers And First Aid Kit
GENERAL PRECAUTIONS 2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT Make sure that fire extinguishers have been provided and check their position. Periodically make sure that the fire extinguishers are loaded and that you know how to use them. Find out where the first aid kit has been placed. Periodically make sure that the first aid kit contains the neces- sary disinfectants, bandages, medicins, etc.
Page 35: Precautions To Be Taken Before Starting The Engine
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.1 SAFETY AT THE WORK SITE Before starting the engine, thoroughly check the area for any unusual condition of the ground due to which work may be dan- gerous.
Page 36: 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 37: 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 38: 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 39 PRECAUTIONS TO BE TAKEN WHEN WORKING 3 - MOVE THE LOAD AWAY IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical posi- tion directed towards the load to be moved away, move the hand in the direction of the movement to be carried out. RKA15160 4 - BRING THE LOAD NEARER IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical posi-...
Page 40 PRECAUTIONS TO BE TAKEN WHEN WORKING 9 - FOLD THE ARM With both hands clasped, point the thumbs inwards. RKA15220 10 - EXTEND THE ARM With both hands clasped, point the thumbs outwards. RKA15230 11 - FOLD THE BUCKET Keep one hand still and closed. Rotate the other hand verti- cally with the thumb pointed towards the clasped hand.
Page 41 PRECAUTIONS TO BE TAKEN WHEN WORKING 15 - TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels. RKA15280 16 - TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels. RKA15290 17 - DISTANCE TO BE COVERED With the hands raised and facing inwards, move the hands laterally indicating the distance to be covered.
Page 42 PRECAUTIONS TO BE TAKEN WHEN WORKING 21 - STOP THE ENGINE Pass thumb or forefinger across the throat. RKA15340 WEAM009500...
Page 43: 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 44: 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 45: 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 turret, if possible, since this may cause the machine to lose balance and overturn.
Page 46 PRECAUTIONS TO BE TAKEN WHEN WORKING Do not carry out demolition work under the machine, since it may become unstable and tip over. When working on the top of buildings or other structures, check these structures and their strength before starting work. In fact, the buildings may collapse and cause serious injury or damag- RYA00600 When carrying out demolition work, do not position the machine...
Page 47: Preventing Electrocution
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.9 PREVENTING ELECTROCUTION Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution; for this reason, when working near overhead electric lines always respect the minimum safety dis- tances prescribed by the competent authorities and by the accident-prevention rules in force.
Page 48: Preventing Damage Caused By The Work Equipment
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage. 2.4.13 WORKING ON LOOSE GROUND Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.
Page 49: 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. Ramp Maintain a safety distance from the edges of ditches or from road sides.
Page 50: Battery
BATTERY 2.6 BATTERY 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY Electrolytic batteries contain sulphuric acid, which can cause burns. It can also corrode clothing and make holes in it. In case of contact with battery acid, immediately wash the affected part with plenty of water.
Page 51: 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 52: 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 53: Equipment
PRECAUTIONS FOR MAINTENANCE 2.8.4 EQUIPMENT The normal or special equipment that must be installed on the machine or that have been removed must be stored in a safe place and positioned in such a way as to prevent them from fall- ing down.
Page 54: Use Of The Engine During Maintenance
PRECAUTIONS FOR MAINTENANCE 2.8.7 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 55: Stop The Engine Before Carrying Out Any Maintenance Operation Or Inspection
PRECAUTIONS FOR MAINTENANCE 2.8.9 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 56: Rules To Be Followed When Refuelling Or Adding Oil
PRECAUTIONS FOR MAINTENANCE 2.8.10 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 57: Precautions To Be Taken When Handling The Battery And The Alternator
PRECAUTIONS FOR MAINTENANCE 2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR When repairing the electrical system, disconnect the battery or turn the battery main switch anticlockwise to shut off power. IMPORTANT • Disconnect first the negative earth cable (–) and then the positive cable (+).
Page 58: Handling High-Pressure Hoses
PRECAUTIONS FOR MAINTENANCE 2.8.15 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 59: Precautions To Be Taken When Using High-Pressure Grease To Adjust The Track Tension
PRECAUTIONS FOR MAINTENANCE 2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION The grease contained in the track tension adjustment device is pressurized. If the adjustment is not carried out according to the instructions given in the maintenance section, the grease valve (1) may be ejected due to the high pressure and this may be dangerous for the operator.
Page 60: Cooling Fan And Belt
PRECAUTIONS FOR MAINTENANCE 2.8.21 COOLING FAN AND BELT Be careful to the revolving parts and do not allow anyone to get too close to them, since clothes or limbs may get caught into them. If hands, clothes, or tools become entangled in the fan blades or the fan belt, they may be cut, torn or seriously injured/dam- aged;...
Page 61: Precautions To Be Taken When Handling Technopolymers And Elastomers
PRECAUTIONS FOR MAINTENANCE 2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLY- MERS AND ELASTOMERS DANGER Some components of the machine contain polymeric and elastomeric materials (Viton sealing rings, Te- flon rings, piston rings made of fluoroelastomers, electric cable insulating materials, etc.). At ambient temperature and up to approximately 200°C these materials can be handled without taking special precautions, since they are completely inert.
Page 62 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...
Page 63: The Machine And Its Operations
THE MACHINE AND ITS OPERATIONS...
Page 64: Machine Illustrations
MACHINE ILLUSTRATIONS 3.1 MACHINE ILLUSTRATIONS 3.1.1 OVERALL VIEW OF THE MACHINE RKA23420 Bucket Track Bucket cylinder Sprocket Undercarriage Arm cylinder (10) Idler roller Boom (11) Blade cylinder Boom cylinder (12) Blade WEAM009500...
Page 65: Controls And Gauges
MACHINE ILLUSTRATIONS 3.1.2 CONTROLS AND GAUGES RKA23430 (16) Blade control lever Operator seat (17) Warning lights and indicators display Working lights switch (18) Accelerator lever Revolving light switch (if installed) (19) Ignition switch Boom overload alarm switch (if installed) Control locking lever (left) (20) Cab floor locking lever Left work equipment control lever...
Page 66: 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 67: 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 68 INSTRUMENTS AND CONTROLS Battery 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 69: 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 70 INSTRUMENTS AND CONTROLS Fuel level indicator 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 4.5 litres, the indicator reaches the red reserve area (A) and the warning light (B) blinks.
Page 71: 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 72: Switches And Push Buttons
INSTRUMENTS AND CONTROLS 3.2.2 SWITCHES AND PUSH BUTTONS RKA23480 Ignition switch Cab heating and ventilation switch (machines with cab) Horn Windshield wiper switch (machines with cab) Travel speed selection switch Overhead light switch (machines with cab) Working lights switch (10) Power outlet (12V) Revolving light switch (if installed) (11)
Page 73 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 74 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 75 INSTRUMENTS AND CONTROLS Revolving light switch (if installed) It is an ON-OFF switch used to turn on the beacon light (LED on). RKA23550 Boom overload alarm switch (if installed) It is an ON-OFF switch that is pressed (LED on) to enable the boom overload device so that it indicates the moment when the load limit is reached.
Page 76 INSTRUMENTS AND CONTROLS Windshield wiper switch (machines with cab) Switch (8) 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 77 INSTRUMENTS AND CONTROLS 11. Battery main switch The battery main switch (11) is placed inside the engine compart- ment and the electrical current from the battery to the machine electrical system can be interrupted by turning the switch anti- clockwise. Always interrupt the electrical current before perform- ing any operation on the battery or the electrical system, and before any welding operations on the machine.
Page 78: Control Levers And Pedals
INSTRUMENTS AND CONTROLS 3.2.3 CONTROL LEVERS AND PEDALS RKA23580 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 control lever...
Page 79 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 and the control levers are touched by mistake, this may lead to serious injury.
Page 80 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 81 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 82 INSTRUMENTS AND CONTROLS Travel levers (with pedals) 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 83 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 84 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 85: Cab (If Provided)
INSTRUMENTS AND CONTROLS 3.2.4 CAB (if provided) WARNING The cab is a ROPS/FOPS safety element (Operator protec- tion in case of machine overturn or falling objects) accord- ing to current standards (ROPS/FOPS level 1). If there is a collision against the machine, or in case it turns over, have a Komatsu Dealer check that the cab complies with the stiffness and active safety standards the operator needs.
Page 86 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 87 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 (1) to the “locked” position (L). Release the windscreen by means of the upper lock (E) le- ver.
Page 88: 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 (1) to the locking position (L). If the con- trol levers are not locked and are inadvertently operated, there is the risk of serious accidents.
Page 89: 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 set the safety device lever (1) to locking position (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents.
Page 90: Caps And Covers With Lock
INSTRUMENTS AND CONTROLS 3.2.5 CAPS AND COVERS WITH LOCK Use the ignition key to open and close the caps and covers with lock. For details on the position of caps and covers with lock, see "3.3.17 LOCKING THE MACHINE". Introduce the key completely (6 mm from the point where the key narrows), then turn it.
Page 91: 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 92: 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 Open the engine cover (1) (for details, see paragraph "3.2.6 ENGINE HOOD").
Page 93: Tank Cover
INSTRUMENTS AND CONTROLS 3.2.8 TANK COVER WARNING Avoid climbing up the cover, since there is the risk of slipping and falling down. IMPORTANT Always keep the tank cover closed, unless expressly indi- cated otherwise for any maintenance operations. Carefully check the direction of the slot to make sure that the cap is locked.
Page 94: Tilting The Cab Floor
INSTRUMENTS AND CONTROLS 3.2.9 TILTING THE CAB FLOOR WARNING Always keep to the warnings when tilting or closing the cab floor. Any operation carried out incorrectly may cause serious injury. If possible, this operation should be carried out by two persons. Do not tilt or close the cab floor on slopes or if there is a strong wind.
Page 95 INSTRUMENTS AND CONTROLS Position blocks under the tracks in order to prevent the ma- chine from moving. 9 J A 0 5 4 6 6 Loosen the two screws (2) and remove the triangular cover (3). Open the engine hood (4) completely and make sure that it is kept open by the apposite rod (for further details, see "3.2.6 ENGINE HOOD").
Page 96 INSTRUMENTS AND CONTROLS Open the inspection door (7), pull the cab floor release lever (8) in the direction indicated by the arrow (backwards) with your left hand and at the same time push the handle (9) up- ward in the direction indicated by the arrow (approx. 45°). The canopy or cab are an integral part of the machine, as well as the cab floor, and they are all lifted together.
Page 97 INSTRUMENTS AND CONTROLS Closing the cab floor IMPORTANT Before closing the cab floor, check that there is no damage or anomaly in the wiring or piping located in the compart- ment under the floor. If any damage or anomaly is ob- served, have the necessary repairs carried out by your Komatsu Dealer.
Page 98: Fuses
INSTRUMENTS AND CONTROLS 3.2.10 FUSES IMPORTANT When changing a fuse, make sure that the ignition key is in position OFF. If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 99: Main Fuse
INSTRUMENTS AND CONTROLS 3.2.11 MAIN FUSE IMPORTANT When changing a fuse, make sure that the ignition key is in position OFF. If the engine does not start when the start-up key is set to START, check the mains fuse and replace it, if necessary. If the starter does not run when the ignition switch is turned to po- sition START, the fuse (1) may have blown.
Page 100: Technical Documentation Compartment
INSTRUMENTS AND CONTROLS 3.2.13 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 101: Use Of The Machine And Related Controls
USE OF THE MACHINE AND RELATED CONTROLS 3.3 USE OF THE MACHINE AND RELATED CONTROLS 3.3.1 BEFORE STARTING THE ENGINE 3.3.1.1 VISUAL CHECKS Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, oil, fu- el or coolant leakages, and check the conditions of the work equipment and the hydraulic system.
Page 102 USE OF THE MACHINE AND RELATED CONTROLS Make sure that there are no faults in the gauges and the warning lights. If any anomaly is observed, provide for the necessary re- pairs. Clean any dirty surface. Check the seat belt and the relevant couplings. If there is any damage or anomaly, change them with new ones.
Page 103: 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 104 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 105 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 106 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 retracted and bucket teeth resting on the ground. Before topping up, stop the engine and eliminate the residual pressure from the equipment circuits (by shifting the controls more than once) and from the tank by slowly loosening the filling cap.
Page 107 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 If a constant or abnormal decrease in the oil level is ob- served, thoroughly check the hydraulic circuit, the pistons...
Page 108 USE OF THE MACHINE AND RELATED CONTROLS CHECKING AND CLEANING THE FILTERING ELEMENT 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 red ring (1) of the water separator is on the bottom of the casing (2), this means that there is no water.
Page 109 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE WIRING SYSTEM WARNING If the fuses are corroded, oxidized or not perfectly held in their seat, replace them only with fuses having the same capacity; before changing a fuse, make sure that the ignition key is in position OFF. If the wirings show traces of short circuits, contact your Komatsu Dealer, who will locate the fault and carry out any necessary repairs.
Page 110: 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 111 USE OF THE MACHINE AND RELATED CONTROLS REAR-VIEW MIRRORS Adjust the inclination of the rear-view mirrors, so that the area behind the cab is well visible. Machine equipped with canopy RKA23720 Machine equipped with cab RKA23730 WEAM009500...
Page 112 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. In any case, change the seat belt every 3 years, even if it seems to be in good conditions.
Page 113: Operations To Be Carried Out Before Starting The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE WARNING When starting the engine, make sure that the safety lever is in the “locked” position. If the control levers are not locked and are inadvertently touched when the engine is started, the work equipment may move suddenly and cause serious accidents.
Page 114 USE OF THE MACHINE AND RELATED CONTROLS 2 - Press the light switch (10) and make sure that the working headlamp on the boom turns on. If it does not turn on, contact a Komatsu Dealer, who will carry out all the nec- essary repair operations.
Page 115: 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 116 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 117 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). RKA23840 Turn the ignition key (3) to the preheating position (HEAT) and make sure that the preheating warning light (4) comes After approximately 18 seconds, the warning light (4) goes out, indicating that the preheating phase has been completed.
Page 118: After Starting The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2 AFTER STARTING THE ENGINE WARNING Emergency stop If a failure has occurred or an anomaly has been observed, turn the ignition key to position OFF. If the work equipment is operated without warming up the engine sufficiently, the response of the work equipment to the movements of the control lever will be slow, and the work equipment may not move as desired by the operator, so always carry out the warming up procedure.
Page 119: Warming The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2.2 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 120 USE OF THE MACHINE AND RELATED CONTROLS Operate the right work equipment control lever (3) slowly, stop the bucket, and hold it in the stop position for 5 minutes. RKA23880 After carrying out the warming-up operations, make sure that the warning lights and gauges are in the conditions described below.
Page 121: 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 122: 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 123 USE OF THE MACHINE AND RELATED CONTROLS When the sprocket (A) is at the rear of the machine, push the levers (3) slowly forward to move the machine off. When the sprocket (A) is at the front of the machine, pull the levers (3) slowly backward to move the machine off.
Page 124: 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 RKA01610 When the sprocket (A) is at the rear of the machine, pull the...
Page 125: Stopping The Machine
USE OF THE MACHINE AND RELATED CONTROLS • When the machine is travelling at high speed, the travel speed increase warning light (5) comes on. For details on the travel speed, see paragraph ."5.1 TECH- NICAL DATA". NOTE When the engine is started, the low speed is automatically selected. When the machine travels at high speed on soft ground or up a slope and the load increases, the low speed is automatically selected, but the travel speed increase warning light remains on.
Page 126: 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 127 USE OF THE MACHINE AND RELATED CONTROLS STEERING (CHANGING DIRECTION) When steering to the left: If the left travel lever is shifted back to the neutral position, the machine will steer to the left. NOTE To steer to the right, operate the right travel lever in the same way.
Page 128: Swinging The Turret
USE OF THE MACHINE AND RELATED CONTROLS 3.3.6 SWINGING THE TURRET WARNING Before swinging the turret, make sure that the area around the machine is safe. To swing the turret, use the left work equipment control lever (1). When the swing function is not used, shift the left lever (1) to the neutral position (N).
Page 129: 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 turret swing, while the right lever controls the boom and the bucket. When the levers are released, they automatically return to the neutral position and the work equipment remain in the position where they stopped.
Page 130 USE OF THE MACHINE AND RELATED CONTROLS Boom swing control To swing the boom, use the boom swing control pedal. Blade control Shift the lever positioned to the right of the operator seat forward or backward to operate the blade. RKA23950 WEAM009500...
Page 131: Unauthorized Operations
USE OF THE MACHINE AND RELATED CONTROLS 3.3.8 UNAUTHORIZED OPERATIONS WARNING If it is necessary to operate the work equipment control levers while the machine is moving, carry out this operation with the maximum care. PERATIONS FOR WHICH IT IS NOT ALLOWED TO EXPLOIT THE TURRET SWING Do not use the turret swing force to compact soil or break earth mounds or walls.
Page 132 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 133: Precautions For Use
USE OF THE MACHINE AND RELATED CONTROLS 3.3.9 PRECAUTIONS FOR USE TRAVELLING Travelling on big stones, logs or other obstacles subjects the frame and in particular the tracks to considerable strain, which damages the machine. For this reason, it is always advisable to remove any obstacles or to avoid them, if possible.
Page 134 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 turret will be sub- merged, and this may cause the cooling fan to break. Be extremely careful when driving the machine out of wa- ter.
Page 135: 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 136 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 137: 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 138: Operations That Can Be Performed With The Hydraulic Excavator
USE OF THE MACHINE AND RELATED CONTROLS 3.3.12 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR In addition to those indicated below, many other applications are possible, thanks to the use of various attach- ments. DIGGING WITH REVERSED BUCKET When the machine is in the position shown in the diagram on the right, the maximum digging force and thrusting force of the single cylinders is obtained when the bucket cylinder and the relevant...
Page 139 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 turret swing and boom swing functions. WEAM009500...
Page 140: 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 sig- nals to be used during work.
Page 141: 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 142: 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). NOTE On machines with cab, there is a single safety lever located to the left of the Operator.
Page 143: Locking The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.17 LOCKING THE MACHINE Always lock the following parts: (1) Cab door (machines with cab) Always close the windows. (2) Engine hood (3) Fuel filler cap (4) Document and tool compartment cover. For further details, see paragraph "3.2.5 CAPS AND COVERS WITH LOCK".
Page 144: 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 USE OF THE RUBBER TRACKS Rubber tracks have exceptional characteristics that cannot be found in steel tracks. However, if they are used in the same way as steel tracks, the advantages they offer cannot be fully exploited.
Page 145: Use Of The Rubber Tracks
USE OF THE MACHINE AND RELATED CONTROLS 3.3.18.3 USE OF THE RUBBER TRACKS UNAUTHORIZED USES Keep to the following instructions. Avoid performing rotations or other operations on broken rocks, very hard rocks, steel bars, scraps, or near the edges of steel plates, since this may damage the rubber tracks. In places like river beds, where there is a great quantity of large and small stones, these may get stuck in the tracks, and damage them or cause them to come off.
Page 146 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 When travelling uphill in reverse, avoid steering at the begin- ning of the slope.
Page 147 USE OF THE MACHINE AND RELATED CONTROLS Detachment of the rubber track from the track frame When the machine moves over an obstacle, a gap forms be- tween the carrier roller and the rubber track. In these condi- tions, the rubber 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 148 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 WEAM009500...
Page 149: 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 DATA".
Page 150 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 151 TRANSPORTING THE MACHINE When loading, set the work equipment at the front and the blade at the back, with the undercarriage and the turret 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 152 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 153 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. Activate the trailer brakes and position safety blocks under the wheels so that the trailer does not move.
Page 154 TRANSPORTING THE MACHINE Set the safety device lever to working position (F). NOTE On machines with cab, there is a single safety lever located to the left of the Operator. RKA23860 RKA23870 Run the engine at low speed. (A): Idling Lift the blade.
Page 155: Lifting The Machine
TRANSPORTING THE MACHINE 3.4.3 LIFTING THE MACHINE WARNING The operator who carries out lifting operations with the crane must be properly qualified. Do not lift the machine if the operator is still on board. Always make sure that the metal cable used to lift the machine is sufficiently strong for the weight being lifted.
Page 156 TRANSPORTING THE MACHINE Shift the safety lever to the “locked” position (L). NOTE On machines with cab, there is a single safety lever located to the left of the Operator. Stop the engine, make sure there is nothing inside the operator's cab, and then get off the machine.
Page 157: Using The Machine In The Cold Season
USING THE MACHINE IN THE COLD SEASON 3.5 USING THE MACHINE IN THE COLD SEASON 3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON During the cold season or in areas where temperatures are particularly low, especially during the night, it is neces- sary to take some countermeasures meant to limit any damage deriving from low temperatures.
Page 158: 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 159: Cab Ventilation And Cooling
USING THE MACHINE IN THE COLD SEASON 3.5.2 CAB VENTILATION AND COOLING 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 160: 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 161: 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 162: 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 "4.9.5.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)" - " BLEEDING THE FUEL CIRCUIT". 3.7.2 OCCURRENCES THAT ARE NOT FAILURES Pay attention to the following occurrences, that are not consid- ered failures:...
Page 163: 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 (A), (B), (C), (D) and (E) before work. When carrying out heavy duty digging and deep digging opera- tions, always add grease to the bucket articulations (A), (B), (C), (D) and (E) (total: 5 points) before work.
Page 164: Removing And Installing The Battery
TROUBLESHOOTING 3.7.5.1 REMOVING AND INSTALLING THE BATTERY Before removing the battery, disconnect the earth cable (-). If a tool touches the positive terminal and the frame of the machine at the same time, sparks may be generated. When installing the battery, connect the earth cable (-) last. Install the battery correctly.
Page 165: 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 166 TROUBLESHOOTING STARTING THE ENGINE CAUTION Make sure that the safety levers of both machines are in the “locked” position. Also make sure that all the control levers are in NEUTRAL. Make sure that the clamps hold the battery terminals firmly. Start the engine of the machine used as starting aid and run it at high rpm.
Page 167: Other Troubles
TROUBLESHOOTING 3.7.6 OTHER TROUBLES Always contact your Komatsu Dealer when you have to carry out this operation. If the anomaly or its cause is not included in the table below, contact your Komatsu Dealer for the necessary re- pair. 3.7.6.1 ELECTRICAL CIRCUIT TROUBLE CAUSE...
Page 168: Frame
TROUBLESHOOTING 3.7.6.2 FRAME TROUBLE CAUSE SOLUTION Travel speed, swing, boom, arm, • No hydraulic oil. • Restore level. See "CHECKS TO BE CARRIED OUT BEFORE START- bucket slow. ING THE ENGINE". Pump does not work correctly. • Foreign body in the hydraulic tank fil- •...
Page 169 TROUBLESHOOTING TROUBLE CAUSE SOLUTION Engine does not start with starter run- • No fuel. • Restore level. See "CHECKS TO BE CARRIED OUT BEFORE START- ning. ING THE ENGINE". • Air in fuel system. • Repair the point where air is sucked in, see "EVERY 500 HOURS OF •...
Page 170 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...
Page 171: Maintenance
MAINTENANCE...
Page 172: Guide To Maintenance
GUIDE TO MAINTENANCE 4.1 GUIDE TO MAINTENANCE WARNING Oils, filters, coolant, gaskets, electric cables, and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. The combustible material of some components may become extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale its fumes.
Page 173 GUIDE TO MAINTENANCE 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 gaskets with new ones. Fit the O rings and gaskets correctly when reassembling.
Page 174: Maintenance Notes
MAINTENANCE NOTES 4.2 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 175: Fuel
MAINTENANCE NOTES 4.2.1.2 FUEL Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or re- duce its power. Always refuel at the end of the workday. When refuelling, make sure that there is no water on the fuel drum cover and take care not to draw condensate from the drum bottom.
Page 176: Kowa (Komatsu Oil Wear Analysis)
MAINTENANCE NOTES 4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS) This system requires that oil samples be periodically collected and analysed. This is a preventive maintenance service, which makes it possible to identify faulty parts or worn machine components timely. It also allows many failures to be prevented and machine downtime to be reduced.
Page 177: Storing Oil And Fuel
MAINTENANCE NOTES 4.2.1.5 STORING OIL AND FUEL Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting into them. When storing drums for a long period, position them on one side, so that the opening is lateral. This prevents moisture from being sucked in through the drum filling opening.
Page 178: Notes On The Maintenance Of The Electrical System
MAINTENANCE NOTES 4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM If the cables are wet or their insulating material is damaged, the electrical system leaks and this may result in malfunctions of the machine. The maintenance operations required for the electrical system are the following: 1 - Check of the alternator belt tension.
Page 179: Parts Subject To Wear
PARTS SUBJECT TO WEAR 4.3 PARTS SUBJECT TO WEAR The parts subject to wear like filters, bucket teeth, etc. must be changed when periodical maintenance is carried out or when they reach the wear limits. The timely change of these parts ensures an economic use of the machine. Use only Komatsu genuine parts, which alone can guarantee excellent quality and interchangeability.
Page 180: Fuel, Coolant And Lubricants
FUEL, COOLANT AND LUBRICANTS 4.4 FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY (l) ITEM / TANK / FLUID 50°C SYSTEM filling Change 104 122°F SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 Travel reduction API CD SAE 30 gears SAE 10W SAE 10W-30...
Page 181: Coolant
FUEL, COOLANT AND LUBRICANTS IMPORTANT When the diesel sulphur content is less than 0,5%, change the engine oil according to the periodic main- tenance intervals indicated in the operation and maintenance manual. If the sulphur content exceeds 0.5%, change the engine oil according to the following table: Sulphur content Engine oil change interval from 0.5 to 1.0%...
Page 182: Approved Synthetic Biodegradable Lubricants Type Hees
FUEL, COOLANT AND LUBRICANTS 4.4.2 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”...
Page 183: Tightening Torques
TIGHTENING TORQUES 4.5 TIGHTENING TORQUES 4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS CAUTION If screws, nuts or other parts are not tightened with the required torque, they may become loose or dam- age the components with which they cooperate, and this may cause machine failures or operation prob- lems.
Page 184: Standard Tightening Torques For Hoses With Orfs
TIGHTENING TORQUES 4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS If not specified otherwise, tighten the nuts of the hoses applying the torque specified in the table. If it is necessary to replace a hose, always use Komatsu original spare parts having the same size of the part to be replaced. RKA12600 a Nm (Newton metre): 1 Nm = 0.102 kgm TIGHTENING TORQUE...
Page 185: Lubrication
IMPORTANT For details on how to lubricate specific parts, see "4.9.5.a LUBRICATION". The type of lubricant to be used is indicated in the lubricant table (see "4.4 FUEL, COOLANT AND LUBRI- CANTS"). Grease PC26MR-3 Filter 10 h 2,10 500 h...
Page 186: 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 187: 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 - prefilter) Fuel pipe (prefilter - fuel pump) Fuel pipe (fuel pump - fuel filter) Fuel pipe (fuel filter - injection pump) Fuel pipe (fuel filter –...
Page 188: 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 BREAKER". 4.8.1 MAINTENANCE PLAN WHEN REQUIRED CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE ..........
Page 189 MAINTENANCE PLAN MAINTENANCE EVERY 1000 HOURS OF OPERATION CHANGING THE HYDRAULIC OIL FILTER ....................216 CHANGING THE OIL IN THE FINAL REDUCTION GEARS............... 218 CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ............218 MAINTENANCE EVERY 2000 HOURS OF OPERATION CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER........219 CHANGING THE COOLANT ........................
Page 190: 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 191: 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 192 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 193: Cab Air Filter Check And Cleaning (Machines With Cab)
MAINTENANCE PROCEDURES 4.9.1.b CAB AIR FILTER CHECK AND CLEANING (machines with cab) 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 Dealer.
Page 194: Checking The Battery Charge Level
MAINTENANCE PROCEDURES 4.9.1.c CHECKING THE BATTERY CHARGE LEVEL WARNING Check the charge level only with the engine at rest. To prevent gas explosions, do not use naked flames, do not smoke and avoid producing sparks due to short circuits. The battery electrolyte is dangerous; in case of contact with the eyes or skin, rinse with plenty of water and consult a doctor without delay.
Page 195: Cleaning The Fuel Filter (With Water Separator)
MAINTENANCE PROCEDURES 4.9.1.d CLEANING THE FUEL FILTER (WITH WATER SEPARATOR) 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.
Page 196: Draining The Fuel Tank
MAINTENANCE PROCEDURES 4.9.1.e 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 turret so that the drain valve (1) is positioned between the tracks.
Page 197: Shoe Fixing Screws Check And Tightening
MAINTENANCE PROCEDURES 4.9.1.f SHOE FIXING SCREWS CHECK AND TIGHTENING (Machines equipped with steel tracks, road liners) WARNING To compensate for the inevitable settling movements, it is indispensable to check the tightening torque of the screws (1) after the first 30 hours of operation. Carry out another check after the first 100 hours of run- ning-in and, if the screws have become loose again, repeat the check after 200 hours of operation.
Page 198 MAINTENANCE PROCEDURES ADJUSTMENT DANGER The grease contained in the hydraulic cylinder is pressurized. For this reason, do not give the grease valve (1) more than one turn when loosening it; in fact, if the valve is loosened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator..
Page 199: Checking The Rubber Tracks
MAINTENANCE PROCEDURES REDUCING THE TRACK TENSION DANGER 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 Dealer, who will pro- vide for the necessary repairs.
Page 200 MAINTENANCE PROCEDURES When more than half of the steel core cords at the centre of the track are cut. RYA07520 When one or more steel cores have come off the track or are pushed out due to excessive tension. RYA03240 If the rubber track cannot be tensioned correctly through the injection of grease, check the track tensioner gaskets and if necessary change them or even the track.
Page 201: Checking And Adjusting The Rubber Track Tension
MAINTENANCE PROCEDURES 4.9.1.i CHECKING AND ADJUSTING THE RUBBER TRACK TENSION The rubber tracks wear out to different degrees, depending on the work conditions and on the characteristics of the surface on which the machine is working. Therefore, it is necessary to check the track wear and tension fre- quently, in order to keep the tracks correctly tensioned.
Page 202 MAINTENANCE PROCEDURES INCREASING THE TRACK TENSION IMPORTANT The standard adjustment value is low, therefore take care to avoid increasing the rubber track tension excessively. Carefully clean the grease valve (1) and inject grease through the grease nipple (2) until reaching the desired ten- sion.
Page 203: Changing The Rubber Tracks
MAINTENANCE PROCEDURES 4.9.1.j CHANGING THE RUBBER TRACKS WARNING This operation must be carried out by two persons. One operator must be seated in the cab and ma- noeuvre the machine following the signals of the other operator who carries out the change and the ad- justment.
Page 204 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 205 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 206: Checking The Detergent Level In The Windsield Washer Reservoir (Machine With Cab)
MAINTENANCE PROCEDURES 4.9.1.k CHECKING THE DETERGENT LEVEL IN THE WINDSIELD WASHER RESERVOIR (machine with cab) The reservoir (1) is positioned inside the radiator compartment and contains detergent for the front windshield; make sure that the reservoir is always filled with detergent. If necessary, add non- flammable detergent of the type used for cars.
Page 207: Lubrication Of Cab Door Hinges (Machines With Cab)
MAINTENANCE PROCEDURES 4.9.1.l 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 208: Checks To Be Carried Out Before Starting The Engine
MAINTENANCE PROCEDURES 4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE WARNING Dirt, oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires. Check frequently and repair any leakage immediately; if they occur repeatedly, contact your Komatsu Dealer.
Page 209: Maintenance Every 500 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION 4.9.5.a LUBRICATION IMPORTANT Clean the grease nipples before applying the greasing pump. After lubrication, remove all the contaminated grease that may have spread out of the nipples. If the machine is used in difficult conditions, carry out this operation more frequently than usual. As a general rule, it is important to consider that each cylinder is provided with two grease nipples posi- tioned on the couplings and that each pin serving as fulcrum point for a movement is provided with at least one grease nipple.
Page 210 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) Blade cylinder base pin (1 point) (7) Blade cylinder rod end (1 point) (8) Blade base pin (2 points) (9) Boom swing bracket pin (2 point)
Page 211 MAINTENANCE PROCEDURES (14) Boom cylinder rod end (1 point) (15) Boom–arm connection pins (1 point) (16) Bucket cylinder base pin (1 point) RKA24060 WEAM009500...
Page 212: Changing The Engine Oil And The Engine Oil Filter Cartridge
MAINTENANCE PROCEDURES 4.9.5.b 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; let the engine cool down until it reaches a temperature of 40÷45°C before draining the oil.
Page 213: Changing The Fuel Filter Element (With Water Separator)
MAINTENANCE PROCEDURES 4.9.5.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR) 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 214: Checking The Oil Level In The Final Reduction Gears
MAINTENANCE PROCEDURES 4.9.5.d 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 215: Checking And Cleaning The Fins Of The Radiator And Of The Exchanger
MAINTENANCE PROCEDURES 4.9.5.f 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 216: Checking And Adjusting The Fan Belt Tension
MAINTENANCE PROCEDURES 4.9.5.g CHECKING AND ADJUSTING THE FAN BELT TENSION WARNING Soon after the machine has been stopped, the engine is very hot and may cause burns; let the engine cool down before carrying out any check. 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 217: Draining The Hydraulic Oil Tank (Only For Machines In Which Synthetic Biodegradable Oil Type Hees Is Used)
MAINTENANCE PROCEDURES 4.9.5.h DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used) WARNING Retract the arm and bucket cylinders completely, rest the bucket teeth on the ground and, after stopping the engine, eliminate the residual pressures from the equipment (by shifting the controls more than once) and from the tank (by slowly loosening the filler cap).
Page 218: Maintenance Every 1000 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS. 4.9.6.a CHANGING THE HYDRAULIC OIL FILTER WARNING Soon after the machine has been stopped, the hydraulic oil is very hot and may cause burns; let it cool down to 40÷45°...
Page 219 MAINTENANCE PROCEDURES Extend the boom, arm and bucket cylinders completely, as shown in the figure, and remove the filler cap (F). Put back the cap and pressurize the tank by lowering the equipment to the ground. Put back the tank cover (1). IMPORTANT In machines equipped with breaker hydraulic oil deterio- rates more rapidly than in machines used for simple dig-...
Page 220: Changing The Oil In The Final Reduction Gears
MAINTENANCE PROCEDURES 4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS WARNING As soon as the machine has been stopped the oil is very hot and may cause burns; let the oil cool down until reaching 40÷45°C before changing it. Loosen the cap slowly to release any residual pressure.
Page 221: Maintenance Every 2000 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 500 HOURS and every 1000 HOURS. 4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER WARNING 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 222 MAINTENANCE PROCEDURES Open the engine hood and the radiator cover (1). For details, see paragraph "3.2.7 RADIATOR COVER" Loosen the screws (2), remove the plate (3) and slowly loos- en the filler cap (F) to release the residual pressure from the tank.
Page 223 MAINTENANCE PROCEDURES 15. 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. 16. Make sure that all the control levers are in neutral position and let the engine idle for at least 2÷3 minutes before operat- ing the work equipment.
Page 224: Changing The Coolant
MAINTENANCE PROCEDURES 4.9.7.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 225: Checking The Alternator And The Starter
MAINTENANCE PROCEDURES Fill the tank (4) until reaching the maximum level (FULL). Close the covers. 4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER The brush may be worn or the bearing may be without grease. Contact your Komatsu Dealer for the necessary in- spection or repair.
Page 226 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...
Page 227: Technical Specifications
TECHNICAL SPECIFICATIONS...
Page 228: Technical Data
TECHNICAL DATA 5.1 TECHNICAL DATA Unit PC26MR-3 of measurement With TOPS FOPS canopy and rubber tracks 2470 With TOPS FOPS canopy and steel tracks 2590 Operating weight (kg) 2630 With TOPS FOPS cab and rubber tracks With TOPS FOPS cab and steel tracks...
Page 229 TECHNICAL DATA Unit PC26MR-3 Operating characteristics of measurement Max. digging outreach 4440 Max. digging depth 2460 4250 With canopy Max. digging height 4250 With cab Max. vertical wall digging depth 1860 2980 With canopy Max. dumping height 2980 With cab Work equipment min.
Page 230: Lifting Capacities
LIFTING CAPACITIES 5.2 LIFTING CAPACITIES 5.2.1 LIFTING CAPACITIES (WITH CANOPY) 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. NOTE The load does not exceed 87% of the hydraulic lifting capacity or 78% of the tipping limit.
Page 231 LIFTING CAPACITIES STANDARD ARM + COUNTERWEIGHT + LOWERED BLADE Unit of measurement: (kg) Max. 3.0 m *590 *580 2.0 m *660 *660 *590 *540 1.0 m *900 *740 *520 *1260 *780 *600 -1.0 m *1000 *740 *620 STANDARD ARM + COUNTERWEIGHT + RAISED BLADE Unit of measurement: (kg) Max.
Page 232: Lifting Capacities (With Cab)
LIFTING CAPACITIES 5.2.2 LIFTING CAPACITIES (WITH CAB) 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. NOTE The load does not exceed 87% of the hydraulic lifting capacity or 78% of the tipping limit.
Page 233 LIFTING CAPACITIES STANDARD ARM + COUNTERWEIGHT + LOWERED BLADE Unit of measurement: (kg) Max. 3.0 m *560 *570 2.0 m *640 *640 *570 *540 1.0 m *900 *740 *530 *1260 *780 *600 -1.0 m *1000 *740 *620 STANDARD ARM + COUNTERWEIGHT + RAISED BLADE Unit of measurement: (kg) Max.
Page 234 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...
Page 235 AUTHORISED EQUIPMENT...
Page 236: Authorised Tools
AUTHORISED TOOLS 6.1 AUTHORISED TOOLS CAUTION When installing and using optional equipment, carefully read the relevant manual and keep to the in- structions given therein. Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated (see "6.1.3 AUTHORISED TOOLS CHARACTERISTICS"). Komatsu cannot be held liable for any injury, damage or product failure resulting from the installation and use of unauthorized equipment.
Page 237: Precautions Regarding The Installation Of Equipment
AUTHORISED TOOLS 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT WARNING The installation of long or heavy work equipment may affect the stability of the machine. Therefore, be particularly careful when moving down a steep slope or when swinging the equipment on a slope, since the machine may lose its balance and overturn.
Page 238: Authorised Tools Characteristics
AUTHORISED TOOLS CAUTION Only use tools authorised by Komatsu. Pay special attention to the safety standards and, before starting operations, carry out a test (in a safe place) to check the operative range of the tool and its centre of gravity. Some tools, when completely retracted, can interfere with some parts of the machine (specially with the operator's cab).
Page 239: Machine Configuration For The Installation Of Attachments
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2.1 POSITION OF THE DEVICES RKA24070 Quick couplers Optional equipment control pedal Selection valve Pedal locking device (for the optional equipment control pedal) Quick couplers The quick coupling (1) is used to connect the pipes equipped with quick coupling to the ends of the equipment.
Page 240 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS Selection valve The selection valve (2) regulates the flow of the hydraulic oil and has two positions. Position (a): for applications requiring the use of the hydraulic breaker. Spool (A) completely rotated counterclockwise. Position (b): for applications requiring the use of the generic equipment.
Page 241: Hydraulic Circuit
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2.2 HYDRAULIC CIRCUIT 6.2.2.1 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 242: Maintenance
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.2.2.2 MAINTENANCE The hydraulic system does not require any operation and inspection other than those prescribed for the routine maintenance of the machine. Regarding the maintenance operations required for the equipment, see the specific operation manuals.
Page 243: Operating The Equipment
OPERATING THE EQUIPMENT 6.3 OPERATING THE EQUIPMENT 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 seri- ous accidents.
Page 244: Long Periods Of Inactivity
OPERATING THE EQUIPMENT USE OF GENERIC EQUIPMENT SUCH AS THE CRUSHER Generic equipment is operated by pressing the equipment control pedal as indicated below. Upper part (A) pressed: the oil flows to right side of the arm (hy- draulic tank side). Lower part (B) pressed: the oil flows to the left side of the arm (op- erator seat side).
Page 245: Precautions To Be Taken When Using Optional Equipment
PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT 6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT The instructions given below must be strictly followed when the hydraulic excavator is fitted with a piece of equip- ment. IMPORTANT Choose the type of equipment that is most suitable to the hydraulic excavator on which it must be in- stalled.
Page 246 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 247 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 248 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 249 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.
Page 250 THIS PAGE WAS INTENTIONALLY LEFT EMPTY...

Komatsu Utility PC26MR-3 Operation & Maintenance Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Komatsu Utility PC26MR-3

Summary of Contents for Komatsu Utility PC26MR-3