Page 1 WEAM002702 Operation & Maintenance Manual PC12R PC12R -8 HS PC15R PC15R -8 HS HYDRAULIC EXCAVATOR SERIAL NUMBER PC12R - F31493 and up PC12R - F31493 -8 HS and up PC15R - F22262 and up PC15R - F22262 -8 HS and up WARNING Unsafe use of this machine may cause serious injury or death.
Page 3: Foreword
1.1 FOREWORD • This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance in- structions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
Page 4: Information On Safety
Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op- eration or maintenance of the machine; for this reason, the safety messages included in this manual and applied onto the machine may not include all possible safety precautions.
Page 5 INFORMATION ON SAFETY DANGER • It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility can- not be held liable for any damage to persons, property or the machine, if this has been tampered with by modifying the standard setting of the hydraulic system.
Page 6: Introduction
1.3 INTRODUCTION 1.3.1 INTENDED USES The Komatsu Utility MACHINES described in this manual have been designed and constructed to be used mainly for EXCAVATION and EARTH-MOVING OPERATIONS. If provided with suitable safety devices, they can be used with authorized optional equipment having the charac- teristics illustrated at point “6.1 AUTHORIZED OPTIONAL EQUIPMENT”.
Page 7: Main Characteristics
INTRODUCTION 1.3.3 MAIN CHARACTERISTICS • Simple and easy operation • Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears. • Revolving frame swing archieved by means of an orbital hydraulic motor. • Main equipment servolevers ensuring also combined movements that can be modulated proportionally and continually.
Page 8: Product Identification
PRODUCT IDENTIFICATION 1.4 PRODUCT IDENTIFICATION The Komatsu Utility EXCAVATOR and its main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must be indicated to the Dealer when requiring assistance and ordering spare parts.
Page 9: Engine Serial Number And Exhaust Gas Emission Plate
PRODUCT IDENTIFICATION 1.4.3 ENGINE SERIAL NUMBER AND EX- HAUST GAS EMISSION PLATE The engine serial number is stamped on the plate positioned on the front side of the tappet cover. RWA04950 The exhaust gas emission plate is applied on the top of the en- gine cylinder head cover.
Page 10: Swing Reduction Gear Serial Number
PRODUCT IDENTIFICATION 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER The serial number of the swing reduction gear is stamped on the plate positioned on the swing motor head. RWA04960 1.4.6 CAB SERIAL NUMBER The cab serial number is stamped on the plate positioned on the right side.
Page 11: Serial Numbers And Dealer's Address
PRODUCT IDENTIFICATION 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS Machine n. Model Engine n. Travel reduction gear n. Swing reduction gear n. Cab n. Dealer: Address: Tel. Person to contact: NOTES:...
Page 13: Table Of Contents
TABLE OF CONTENTS Page TABLE OF CONTENTS FOREWORD ..............INFORMATION ON SAFETY .
Page 14 TABLE OF CONTENTS Page PRECAUTIONS TO BE TAKEN WHEN WORKING ........2.4.1 STARTING THE ENGINE .
Page 15 TABLE OF CONTENTS Page THE MACHINE AND ITS OPERATIONS SAFETY LOCKS ..............3.1.1 MACHINE LOCKS .
Page 16 TABLE OF CONTENTS Page PARKING THE MACHINE ............3.7.1 PARKING ON LEVEL GROUND .
Page 17 TABLE OF CONTENTS Page MAINTENANCE GUIDE TO MAINTENANCE ............120 MAINTENANCE NOTES .
Page 18 TABLE OF CONTENTS Page 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION ......157 4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING .
Page 19 TABLE OF CONTENTS Page 5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) ............186 5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) .
Page 21: Safety And Accident Prevention
SAFETY AND ACCIDENT PREVENTION...
Page 22: Safety, Noise And Vibration Plates
Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on the new piece.
Page 23 SAFETY, NOISE AND VIBRATION PLATES RWA05440...
Page 24: Pictograms And Relevant Meanings
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine are accompanied or represented by pictograms. The personnel in charge with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly;...
Page 25 SAFETY, NOISE AND VIBRATION PLATES FILLING THE HYDRAULIC SYSTEM WITH (Only for machines in which the synthetic biodegradable oil type HEES is used) BIO-OIL RWA34380 REFUELLING RWA00040 ENGINE LUBRICATING OIL FILTER RWA00080 FUEL FILTER RWA00060 ENGINE AIR SUCTION FILTER RWA00090 ENGINE COOLANT RWA00130...
Page 26 SAFETY, NOISE AND VIBRATION PLATES ENGINE COOLANT PRESSURE RWA00110 HYDRAULIC OIL LEVEL RWA00100 HYDRAULIC OIL FILTER RWA00070 ELECTRIC OUTLET 12 V RWA00120 ANCHORAGE POINT RWA00200...
Page 27 SAFETY, NOISE AND VIBRATION PLATES EMERGENCY EXIT RWA00190 LIFTING POINT RWA04920...
Page 28: 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 Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a noise...
Page 29: 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 Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a noise...
Page 30: Vibrations To Which The Operator Is Subjected
SAFETY, NOISE AND VIBRATION PLATES 2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED • According to the results of the tests carried out to determine the vibrations transmitted to the operator by the machine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is subjected to vibrations lower than 0.5 m/sq.sec.
Page 31: General Precautions
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES • Only trained and authorized personnel can use the machine and perform maintenance operations. • Follow all the safety rules, precautions and instructions when using the machine or performing maintenance op- erations.
Page 32: Unauthorized Modifications
2.2.4 UNAUTHORIZED MODIFICATIONS • Any modification made without the authorization of Komatsu Utility can involve hazards. • Before making a modification, consult your Komatsu Utility Dealer. Komatsu Utility declines any responsibility for injuries or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATOR’S SEAT •...
Page 33: Getting On And Off The Machine
GENERAL PRECAUTIONS 2.2.6 GETTING ON AND OFF THE MA- CHINE • Do not jump on or off the machine, either when it is at rest and when it is moving. • When getting on or off the machine, always use the handles and the tracks;...
Page 34: Preventing Burns
GENERAL PRECAUTIONS 2.2.8 PREVENTING BURNS • If the engine coolant, the engine oil and the hydraulic oil are hot, use heavy cloths and wear gloves, heavy clothing and safety goggles before carrying out any check or touching the hot parts. •...
Page 35: Fire Extinguishers And First Aid Kit
• When installing and using optional equipment, carefully read the relevant instruction manual and keep to the in- dications given therein. • Do not use optional or special equipment without the authorization of Komatsu Utility or the Komatsu Utility Dealer.
Page 36: Precautions To Be Taken Before Starting The Engine
(earth, stones, etc.). • Check the safety belt and change it if it is broken or damaged. Replace any component only with homologated parts available at Komatsu Utility or its Dealers.
Page 37: 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 38: 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 39: Moving The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.4 MOVING THE MACHINE • When moving the machine, position the bucket at about 40÷50 cm from the ground; this position makes it possible to evaluate the space required for the movements more precisely and at the same time ensures the stability of the machine.
Page 40: Moving On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.5 MOVING ON SLOPES • Operations on slopes and on river or lake banks with damp ground may result in the tipping over or slipping of the ma- chine. • 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 41: Working On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 WORKING ON SLOPES WRONG • When working on slopes, if possible avoid rotating the upper structure, since the machine may lose balance and overturn. It is particularly dangerous to swing on slopes when the bucket is full.
Page 42: Preventing Electrocution
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.8 PREVENTING ELECTROCUTION • Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution; for this reason, when working near overhead electrical lines always respect the minimum safe- ty distances prescribed by the competent authorities and by the accident-prevention rules in force.
Page 43: Visibility
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.9 VISIBILITY • Switch on the working lights as soon as visibility decreases. • If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.
Page 44: Parking The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.13 PARKING THE MACHINE • Park the machine on firm and level ground. If this is not possi- ble and it is necessary to park on a slope, position the ma- chine with the bucket directed downwards and carry out the following operations: 1 - Rotate the bucket to the dumping position and lower the arms until thrusting the teeth into the ground.
Page 45: 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 • Loading and unloading the machine on/from a motor vehicle always involves potential hazards. Proceed with extreme care. Ramps • Perform loading and unloading on firm, level ground. Maintain a safety distance from the edges of ditches or from road sides.
Page 46: Battery
BATTERY 2.6 BATTERY 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY • Electrolytic batteries contain sulphuric acid that can quickly burn the skin and corrode clothes making holes in the fabric. If you spill acid on yourself, immediately rinse the involved area with plenty of water.
Page 47: Precautions For The Removal
PRECAUTIONS FOR THE REMOVAL 2.7 PRECAUTIONS FOR THE REMOVAL • The draw hook must be used only for the first aid and not for towing the machine. • Before moving the machine, make sure that all the controls are in neutral. •...
Page 48: 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, rest the equipment onto the ground, engage the safety locks of either the equipment and the controls and stop the engine.
Page 49: Equipment
• While cleaning the machine, keep the pressurized jet at a min- imum distance of approx. 60 cm in order not to damage the warning plates and the pictograms. If the plates are damaged, request Komatsu Utility or your Ko- matsu Utility Dealer to send you spare plates and change them.
Page 50: Use Of The Engine During Maintenance Operations
PRECAUTIONS FOR MAINTENANCE 2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS • During maintenance operations, let 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 51: Rules To Be Followed During Fuel Or Oil Topping Up
PRECAUTIONS FOR MAINTENANCE 2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP • Keep away from naked flames while refuelling or topping up oil. • Spilled fuel or oil make the ground slippery and may cause ac- cidents; clean any dirty area immediately and carefully. •...
Page 52: Precautions Concerning The Battery And The Alternator
PRECAUTIONS FOR MAINTENANCE 2.8.13 PRECAUTIONS CONCERNING THE REMOVAL BATTERY AND THE ALTERNATOR • When repairing the electrical system, disconnet the battery in order to stop the flow of current. IMPORTANT • Disconnect first the negative earth cable (–) and then the positive cable (+).
Page 53: Handling High-Pressure Pipes
PRECAUTIONS FOR MAINTENANCE 2.8.15 HANDLING HIGH-PRESSURE PIPES • Do not bend high-pressure pipes 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 54: Cooling Fan And Belt
PRECAUTIONS FOR MAINTENANCE 2.8.18 COOLING FAN AND BELT • Be careful to the revolving parts and do not allow anyone to get too close to these parts, since clothes or parts of the body may get caught into them. • If hands, clothes, or tools touch the fan blades or the belt, they may be cut, torn or seriously damaged;...
Page 55: The Machine And Its Operations
THE MACHINE AND ITS OPERATIONS...
Page 56: Safety Locks
SAFETY LOCKS 3.1 SAFETY LOCKS DANGER • If it is necessary to stop the machine, lower the equipment to the ground and always engage the safety device by shifting the lever to the lock position. (See “3.3.5 MACHINE CONTROLS”). • If the operator expects that he may need to stop the machine with raised arms, he is responsible for preparing and installing locks or safety devices that must ensure safety.
Page 57: General Views
GENERAL VIEWS 3.2 GENERAL VIEWS 3.2.1 FRONT GENERAL VIEW RWA05560 1 - Bucket 10 - Revolving support 2 - Bucket cylinder 11 - Idler roller 3 - Arm 12 - Track 4 - Arm cylinder 13 - Blade 5 - Boom 14 - Blade cylinder 6 - Lifting cylinder 7 - Cab...
Page 58: General View Of The Machine With Canopy
GENERAL VIEWS 3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY RWA05570 1 - Bucket 10 - Revolving support 2 - Bucket cylinder 11 - Idler roller 3 - Arm 12 - Track 4 - Arm cylinder 13 - Blade 5 - Boom 14 - Blade cylinder 6 - Lifting cylinder 7 - Canopy...
Page 59: General View Of The Driver's Seat
GENERAL VIEWS 3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT RYA12480 1 - Left safety lever 2 - Arm-upper structure rotation control 3 - Left track control lever 4 - Right track control lever 5 - Boom swing control pedal 6 - Bucket - boom lifting control 7 - Right safety lever (only for machines with canopy) 8 - Blade control...
Page 60: Instruments And Controls
INSTRUMENTS AND CONTROLS 3.3 INSTRUMENTS AND CONTROLS 3.3.1 INSTRUMENTS 1 - Hour meter 2 - Fuel level indicator RWA28790 HOUR METER This instrument indicates the total number of operating hours of the engine. The count is continuous and the number is in- creased by 1 when the engine has run for one hour, independ- ently of its speed.
Page 61: Warning Lights
INSTRUMENTS AND CONTROLS 3.3.2 WARNING LIGHTS 1 - Engine oil pressure warning light 2 - Engine coolant temperature warning light 3 - Generator warning light 4 - Pre-heating warning light RWA28800 ENGINE OIL PRESSURE WARNING LIGHT This warning light comes on with engine at rest when the ignition circuit is operated and goes out as soon as the engine lubrica- tion circuit is pressurized.
Page 62 INSTRUMENTS AND CONTROLS GENERATOR WARNING LIGHT This warning light comes on when the starting circuit is ener- gized and goes out when the engine 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 does not work and the battery is not charged correctly.
Page 63: Switches And Push Buttons
INSTRUMENTS AND CONTROLS 3.3.3 SWITCHES AND PUSH BUTTONS 1 - Fan switch 2 - Working light switch 3 - Ignition key 4 - Arm overload alarm switch (if installed) 5 - Revolving light switch (if installed) 6 - Horn 7 - Variable track gauge control push button (if provided) RWA28810 RWA28820...
Page 64 INSTRUMENTS AND CONTROLS FAN SWITCH This is a two-speed switch that operates the fan motor. If operat- ed after the opening of the tap installed in the engine compart- ment, it ensures the circulation of warm air and serves as heating switch.
Page 65 INSTRUMENTS AND CONTROLS REVOLVING LIGHT SWITCH (if installed) This is a tow-position rotary switch and, if pressed, operates the revolving light. RWA07210 HORN This push button is positioned on the right lever grip and serves to warn the persons in the vicinity at the beginning of work and in case of danger.
Page 66: Electrical Accessories
INSTRUMENTS AND CONTROLS 3.3.4 ELECTRICAL ACCESSORIES 1 - Windshield wiper / washer switch (with cab only) 2 - Overhead lamp (with cab only) 3 - Electric outlet RWAA9280 RWAA9290 RWA28850...
Page 67 INSTRUMENTS AND CONTROLS WINDSHIELD WIPER / WASHER SWITCH (only on machines with cab) With the first click it operates the windshield wiper, while with the second click (with automatic return to the first) it operates the windshield washer. RWA07230 OVERHEAD LAMP (only on machines with cab) It is used to check the instruments and the inside of the cab when visibility is insufficient.
Page 68: Machine Controls
INSTRUMENTS AND CONTROLS 3.3.5 MACHINE CONTROLS RYA12490 1 - Left equipment control lever 2 - Right equipment control lever 3 - Left travel control lever 4 - Right travel control lever 5 - Boom swing control pedal 6 - Blade control lever 7 - Accelerator lever 8 - Left safety device control lever 9 - Right safety device control lever...
Page 69 INSTRUMENTS AND CONTROLS 1-2 - EQUIPMENT CONTROL LEVERS DANGER • Before carrying out any manoeuvre with these levers, the operator must be seated in the work position with fastened safety belt; before any manoeuvre he must perform the operations described in “3.13 US- ING THE WORK EQUIPMENT”).
Page 70 INSTRUMENTS AND CONTROLS If the levers are operated in directions that are inclined with respect to the machine axis, simultaneous move- ments proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time. LEVER 1 (COMBINED MANOEUVRES) N - Neutral A - Arm opening and rotation to the left...
Page 71 INSTRUMENTS AND CONTROLS 3-4 - TRAVEL AND STEERING CONTROL LEVERS DANGER • Before carrying out any manoeuvre with these levers, the operator must be seated in the work position with fas- tened safety belt. • Before moving, make sure that the upper structure is di- rected towards the blade and that all the safety devices have been engaged;...
Page 72 INSTRUMENTS AND CONTROLS BLADE CONTROL LEVER DANGER • Before moving the machine, make sure that the blade is completely raised. This lever controls the raising and lowering of the blade accord- ing to the movements indicated. N - Neutral A - Blade lowering RWA07320 B - Blade raising CAUTION...
Page 73 INSTRUMENTS AND CONTROLS LEFT SAFETY DEVICE CONTROL LEVER DANGER • Before leaving the operating position, lower the equip- ment to the ground and shift the safety device lever to the lock position. To lock the safety device, raise the lever (1), which will automati- cally move to the lock position.
Page 74 INSTRUMENTS AND CONTROLS RIGHT SAFETY DEVICE CONTROL LEVER (only on machines with canopy) DANGER • Before leaving the operating position, lower the equip- ment to the ground and shift the safety device lever to the lock position. The machines with canopy are provided with two levers for the control of the safety device, each one of which operates inde- RWA05690 pendently of the other, even if both of them have the same func-...
Page 75 INSTRUMENTS AND CONTROLS 11 - OPTIONAL EQUIPMENT CONTROL PEDAL A - (STANDARD PEDAL) This pedal controls the oil flow delivered to the optional equip- ment and can be used only for equipment with unidirectional oil flow (demolition hammer). If the pedal is pressed in (A), high-pressure oil is delivered from the opening (C) and conveyed to the equipment through the left pipe.
Page 76 INSTRUMENTS AND CONTROLS 12 - UPPER STRUCTURE ROTATION LOCKING LEVER DANGER • During travel and transport of the machine the rotation locking lever must be shifted to the lock position; shift the lever to the lock position after rotating the upper structure so that it is parallel to the undercarriage.
Page 77: Fuses And Relays
FUSES AND RELAYS 3.4 FUSES AND RELAYS IMPORTANT • When changing a fuse, make sure that the ignition key is in position « ». • If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 78: Relays
FUSES AND RELAYS 3.4.2 RELAYS All the relays are grouped on a single base positioned inside the seat support. RWA06720 POSITION DESCRIPTION Preheating warning light timer Solenoid excitation timer Solenoid excitation relay Safety relay Generator warning light relay Current limiter...
Page 79: Guards And Driver's Seat
GUARDS AND DRIVER’S SEAT 3.5 GUARDS AND DRIVER’S SEAT 3.5.1 ENGINE HOOD DANGER • Do not open the engine hood when the engine is running. • Do not use the machine without engine hood and do not start the engine when the hood is open, unless this is expressly prescribed for certain maintenance operations.
Page 80: Canopy
1 of the FOPS standard. If the cab is subjected to an impact, or if the ma- chine overturns, immediately contact your Komatsu Utili- ty Dealer, who will check the stiffness of the cab and make sure that the operator’s safety is guaranteed.
Page 81: Sliding Door
GUARDS AND DRIVER’S SEAT 3.5.3.1 SLIDING DOOR CAUTION • Make sure that the sliding door is locked either when open and when closed. • Open or close the sliding door only when the machine is positioned on level ground. • Avoid opening the sliding door on slopes, since the effort required for this operation may change suddenly.
Page 82: Front Opening Windshield
GUARDS AND DRIVER’S SEAT 3.5.3.2 FRONT OPENING WINDSHIELD CAUTION • When opening or closing the front windshield, be careful not to crush your hands. Always hold the handles firmly with both hands until the windshield is completely opened or closed. •...
Page 83: Front Windshield (Lower Part)
GUARDS AND DRIVER’S SEAT 3.5.3.3 FRONT WINDSHIELD (LOWER PART) • With open front windshield, release the couplings (13) and re- move the lower part of the windshield (12). Position it at the back of the cab, behind the driver’s seat and secure it to the seats (14) with the couplings (13).
Page 84: Side Opening Window
GUARDS AND DRIVER’S SEAT 3.5.3.4 SIDE OPENING WINDOW • The side windows (15) positioned on the right side of the cab can be slided open; press the handle (16) and pull it. RWAA9420 RWAA9430...
Page 85: Ventilation And Heating
GUARDS AND DRIVER’S SEAT 3.5.4 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the oper- ator’s stress either in the summer and in the winter; these func- tions also serve to eliminate the condensate from the front window, thus ensuring visibility during both work and travel.
Page 86: Safety Belt
GUARDS AND DRIVER’S SEAT 3.5.6 SAFETY BELT DANGER • Before starting the engine, fasten the safety belt. • The safety belt must be changed when it is frayed, dam- aged or worn and in any case every 4 years. The safety belt (1) is of the type with two coupling points and ad- justable length (2);...
Page 87: Technical Documentation Case
GUARDS AND DRIVER’S SEAT 3.5.8 TECHNICAL DOCUMENTATION CASE CAUTION • The operation manual and the spare parts catalogue are integral parts of the machine and must accompany it even in case of resale. The technical documentation case is positioned centrally inside the seat support.
Page 89: Use Of The Machine
• Dirt, oil and fuel in the engine compartment near its hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your Komatsu Utility Dealer. Before starting the engine, check around and under the machine to verify: 1 - if there are loose screws or nuts;...
Page 90: Operational Checks
USE OF THE MACHINE 3.6.1.3 OPERATIONAL CHECKS DANGER • All the checks must be carried out by the operator while seated, with fastened safety belt. • If the machine has been stopped after use or in order to carry out maintenance operations, the safety devices may have been disconnected;...
Page 91: Starting The Engine
USE OF THE MACHINE 3.6.2 STARTING THE ENGINE DANGER • Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls. From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non-compliance with the safety regulations and the rule of the road.
Page 92: Starting With Cold Engine Or In Cold Climates
USE OF THE MACHINE 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES DANGER • Do not use any fluid or product that facilitate the cold starting of the engine, since these are ether-based and may cause explosions. 1 - Pull the accelerator lever until reaching half of its stroke and turn the ignition key to the preheating position «...
Page 93: Warming The Engine
USE OF THE MACHINE 3.6.3 WARMING THE ENGINE 1 - After starting the engine, let it warm up before starting work. 2 - The ideal warming up of the engine is achieved with the engine running at idling speed, which is obtained with the hand accelerator.
Page 94 USE OF THE MACHINE Before moving the machine, check the instruments, warm up the engine and the hydraulic oil, make sure that the rotation lock is engaged, that the safety device is released, that the blade is raised and that the work equipment is at least at 40÷50 cm from the ground;...
Page 95: Steering (Changing Direction)
USE OF THE MACHINE 3.6.5.1 STEERING (CHANGING DIRECTION) DANGER • When the blade is directed backward, the operation of the travel levers is inverted; before operating the travel levers, check the position of the blade. • If possible, avoid any abrupt change of direction. Counter-rotations should be carried out with the ma- chine at rest.
Page 96: Moving On Slopes
USE OF THE MACHINE 3.6.5.2 MOVING ON SLOPES DANGER • Do not work on slopes with inclination exceeding 30°, since in these conditions the machine may overturn. • When moving on slopes, do not use the travel speed in- crease pedal. When working on slopes some precautions should be taken to avoid risks for the operator and anyone in the vicinity;...
Page 97: Maximum Immersion Depth
USE OF THE MACHINE 3.6.5.3 MAXIMUM IMMERSION DEPTH DANGER • If it is necessary to work with the machine immersed in water on on river banks or sea shores, always check the water depth and the current flow. • Make sure that the surface on which you are working is sufficiently firm. If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not ex- ceed the upper structure rotation ball-bearing ring and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.
Page 98: Parking The Machine
PARKING THE MACHINE 3.7 PARKING THE MACHINE 3.7.1 PARKING ON LEVEL GROUND DANGER • Park the machine on firm and level ground, in a sufficient- ly wide space, so that the checks, the daily lubrication and the refuelling can be carried out without problems. •...
Page 99: Parking On Slopes
PARKING THE MACHINE 3.7.2 PARKING ON SLOPES DANGER • The movement of the machine when the operator is not on board may cause serious accidents and even death; to prevent this, carry out the operations described below. • Park on slopes only when it is absolutely necessary. •...
Page 100: Stopping The Engine
STOPPING THE ENGINE 3.8 STOPPING THE ENGINE MIN. IMPORTANT • The sudden stop of the engine while it is running short- ens its life. Do not stop the engine suddenly, except in case of emergency. • It is likewise recommended not to stop the engine sud- denly if it has been running for a long period and is still hot;...
Page 101: Transporting The Machine On Motor Vehicles
TRANSPORTING THE MACHINE ON MOTOR VEHICLES 3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 3.9.1 LOADING AND UNLOADING THE MACHINE DANGER • The loading and unloading of the machine on/from the means of transport must be carried out on a flat surface and at a safety distance from the edges of ditches or from the road side.
Page 102: Transport
TRANSPORTING THE MACHINE ON MOTOR VEHICLES 3.9.2 TRANSPORT 1 - Check the overall dimensions; the height, width and weight of the means of transport - machine included - must be compatible with the road and any tunnel, subway, bridge, electric or telephone line that may be found on the way.
Page 103: Lifting The Machine
LIFTING THE MACHINE 3.10 LIFTING THE MACHINE DANGER • To lift the machine, the cables and the upper lifting bar used must be properly sized; do not use worn cables or cables with broken strands. • Do not lift the machine before the operator has got off and make sure that there is no one around before lifting it.
Page 104: Precautions To Be Taken In The Cold Season
PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON During the cold season or in areas where the temperature is particularly low, especially during the night, it is nec- essary to take some countermeasures meant to limit the damage deriving from low temperatures. 3.11.1 FUEL AND LUBRICANTS 1 - Change the fuel and use the winter fuel ASTM D975 N.
Page 105: Other Precautions
PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 1 - When the ambient temperature decreases, the battery capacity decreases accordingly and, if the battery charge is low, the electrolyte may freeze. Keep the battery completely charged and insulate it to protect it against low temperatures, so that the machine can be started without problems the following day.
Page 106: Precautions To Be Taken In The Warm Season
PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 1 - At the end of the cold season, change the lubricants, the coolant and the fuel. IMPORTANT • The coolant must be changed only if it is not permanent. For the relevant specifications, see “4.3 FUEL, COOLANT AND LUBRICANTS”.
Page 107: Using The Work Equipment
USING THE WORK EQUIPMENT 3.13 USING THE WORK EQUIPMENT DANGER • Always fasten the safety belt before any manoeuvre. • Before starting work, warn the persons in the vicinity by means of the horn positioned on the right le- ver. •...
Page 108: Positioning The Machine For Digging Operations
USING THE WORK EQUIPMENT 3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS DANGER • Before moving the equipment, make sure that no one is standing in the work area. • When working on a slope, position the machine horizon- tally on a firm and compact surface. •...
Page 109: Digging Method
USING THE WORK EQUIPMENT 3.13.3 DIGGING METHOD DANGER • The geometry of the rotation fulcrum of the arms and the bucket make it possible to dig even beyond the stabilizer line, which makes the ground give way. Do not dig beyond the boom fulcrum line, since the ground may collapse and cause the machine to overturn.
Page 110: Changing The Bucket
USING THE WORK EQUIPMENT 3.13.4 CHANGING THE BUCKET DANGER • When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet. • The change of the equipment must be carried out by two persons, who must decide together the words and signals to use during operations.
Page 111: Using The Machine With Variable Track Gauge
USING THE MACHINE WITH VARIABLE TRACK GAUGE 3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE The machine with variable track gauge makes it is easier to pass through narrow spaces and increases safety when carrying out side digging operations. It is possible to adjust the track gauge as desired within the fol- lowing range: Track gauge width: Max.
Page 112: Adjusting The Blade
USING THE MACHINE WITH VARIABLE TRACK GAUGE 3.14.2 ADJUSTING THE BLADE The machine with variable track gauge is equipped with adjusta- ble blade and the positions available are two: A -Standard position Blade width: 1000 mm RWA29040 B -Max. extension position: Blade width: 1320 mm RWA29050 The blade width can be modified by proceeding as follows:...
Page 113: Long Periods Of Inactivity
LONG PERIODS OF INACTIVITY 3.15 LONG PERIODS OF INACTIVITY 3.15.1 BEFORE THE PERIOD OF INACTIVI- DANGER • When draining the fuel, do not smoke or bring naked flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading around.
Page 114: During The Period Of Inactivity
IMPORTANT • If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your Komatsu Utility Dealer. When using the machine after a long period of inactivity, proceed as follows: 1 - Free the exhaust pipe and the fuel tank from the seals.
Page 115: Troubleshooting
TROUBLESHOOTING 3.16 TROUBLESHOOTING 3.16.1 OCCURRENCES THAT ARE NOT FAILURES The following occurrences are not failures: 1 - When the boom is retracted, the movement speed decreases temporarily, according to the position of the boom (more or less vertical. 2 - The boom speed decreases temporarily according to the po- sition of the bucket teeth (more or less horizontal).
Page 116: After The Fuel Has Run Out
TROUBLESHOOTING 3.16.3 AFTER THE FUEL HAS RUN OUT Before starting the engine, when the fuel has run out and therefore air has entered the fuel supply circuit, it is necessary to bleed the fuel supply circuit. For the necessary operations, see “4.7.7 MAINTENANCE EVERY 500 HOURS OF OPERATION”. 3.16.4 IF THE BATTERY IS DOWN DANGER •...
Page 117: Starting With Booster Cables
TROUBLESHOOTING 3.16.4.1 STARTING WITH BOOSTER CABLES DANGER • When starting the engine with the aid of another machine, connect the batteries in parallel. • When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (–). •...
Page 118: Other Troubles
(•): Always contact your Komatsu Utility Dealer when you have to carry out this operation. • : If the anomaly or its cause are not included in the failures indicated below, contact your Komatsu Utility Deal- er for the necessary repair.
Page 119: Engine
TROUBLESHOOTING 3.16.5.3 ENGINE TROUBLE CAUSE REMEDY • • Oil pressure warning light remains on Oil level in oil pan too low. Top up. • • even with engine at high speed: Oil filter clogged. Change filter. • • Oil unsuitable for the season. Change.
Page 121: Maintenance
MAINTENANCE...
Page 122: Guide To Maintenance
• Carry out any operation on firm and level ground. • Use Komatsu Utility genuine oils and greases; choose oils suitable for the ambient temperature. • Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils and greases.
Page 123 GUIDE TO MAINTENANCE • Never mix oils of different brands. Do not top up with any oil different from the oil used in the machine. If necessary, drain all the oil and fill the tank with the oil of the new brand. DANGER •...
Page 124: Maintenance Notes
• Use only Komatsu Utility genuine spare parts. • Do not mix different types of oil. • Unless specified otherwise, the oils and the coolant used by Komatsu Utility to fill the tanks before the delivery of the machine are the following:...
Page 125: Fuel
1.75 • Use drinkable water and in any case soft water. • Do not use corrosion inhibitors containing soluble oil, since they damage the rubber couplings. • In case of doubt, contact your Komatsu Utility Dealer. 4.2.1.3 FUEL • Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or re- duce its power.
Page 126: Notes Regarding The Electrical System
• Do not remove or eliminate any electric component installed on the machine and do not install any electric com- ponent with characteristics different from those specified and approved by Komatsu Utility. • Be careful to keep the electric system dry.
Page 127: Parts Subject To Wear That Periodically Need Changing
The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic mainte- nance intervals prescribed or when they reach the wear limit. The timely change of these parts ensures an economic use of the machine. Use only Komatsu Utility genuine parts, which alone can guarantee excellent quality and interchangeability. ITEM CODE DESCRIPTION Q.TY...
Page 128: Fuel, Coolant And Lubricants
FUEL, COOLANT AND LUBRICANTS 4.3 FUEL, COOLANT AND LUBRICANTS PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE CAPACITY (l) AMBIENT TEMPERATURE RESERVOIR FLUID 30°C filling Change SAE 10W SAE 20W-20 Engine oil pan • API CD SAE 30 SAE 40 Hydraulic system SAE 10W •...
Page 129 • Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half. • Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine, in the equipment hydraulic circuit and in the reduction gears.
Page 130: Homologated Hees Synthetic Biodegradable Lubricants
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended : SUPPLIER HEES SYNTHETIC BIODEGRADABLE OIL KOMATSU BO 46 G4 (KES 07.872) AGIP —...
Page 131: Driving Torques For Screws And Nuts
DRIVING TORQUES FOR SCREWS AND NUTS 4.4 DRIVING TORQUES FOR SCREWS AND NUTS 4.4.1 STANDARD DRIVING TORQUES Nm (Newton metre): 1 Nm = 0.102 kgm 10.9 Thread Pitch Spanner size diameter (mm) (mm) (mm) 0.96 ± 0.1 9.5 ± 1 1.3 ±...
Page 132: Lubrication
LUBRICATION 4.5 LUBRICATION 4.5.1 LUBRICATION DIAGRAM PC12R IMPORTANT • For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. • The type of lubricant to be used is indicated in the lubricant table (See “4.3 FUEL, COOLANT AND LU- BRICANTS”).
Page 133: Lubrication Diagram Pc12R Hs (Variable Track Gauge)
LUBRICATION 4.5.2 LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE) IMPORTANT • For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. • The type of lubricant to be used is indicated in the lubricant table (See “4.3 FUEL, COOLANT AND LU- BRICANTS”).
Page 134: Lubrication Diagram Pc15R
LUBRICATION 4.5.3 LUBRICATION DIAGRAM PC15R IMPORTANT • For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. • The type of lubricant to be used is indicated in the lubricant table (See “4.3 FUEL, COOLANT AND LU- BRICANTS”). 2000 h 1000 h 250 h...
Page 135: Lubrication Diagram Pc15R Hs (Variable Track Gauge)
LUBRICATION 4.5.4 LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE) IMPORTANT • For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. • The type of lubricant to be used is indicated in the lubricant table (See “4.3 FUEL, COOLANT AND LU- BRICANTS”).
Page 136: Periodical Change Of The Components Connected With Safety
PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECT- ED WITH SAFETY To ensure safety at any moment while driving and using the machine, the operator must carry out all the periodic maintenance operations prescribed. Furthermore, the operator must periodically change the components indicat- ed in the table in the following page, which are especially related to safety and accident-prevention rules.
Page 137: Critical Parts For Safety
PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6.1 CRITICAL PARTS FOR SAFETY FUEL SUPPLY SYSTEM Components related to safety that periodically need changing Change interval Fuel pipe (Fuel tank - precleaner) Fuel pipe (Precleaner - fuel pump) Fuel pipe (Fuel pump - fuel filter) Every 2 years or 4000 hours, whichever oc- Fuel pipe (Fuel filter - injection pump)
Page 138 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY HYDRAULIC SYSTEM PC12R-PC12R HS Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Main pump delivery to distributor) Every 2 years or 4000 hours, which- Hydraulic pipe (Pump delivery to swing unit) ever occurs first Hydraulic pipe (Pump delivery to servo controls) •...
Page 139 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY HYDRAULIC SYSTEM PC15R-PC15R HS Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Main pump delivery to distributor) Every 2 years or 4000 hours, which- Hydraulic pipe (Load Sensing signal) ever occurs first Hydraulic pipe (Pump delivery to servo controls) •...
Page 140: Maintenance Plan
MAINTENANCE PLAN 4.7 MAINTENANCE PLAN 4.7.1 WHEN REQUIRED PART OPERATION PAGE Cooling circuit Wash Fuel tank Drain the condensate Electrical system Check Steel tracks Check and adjust the tension Rubber tracks Check Rubber tracks Check and adjust the tension Rubber tracks Change Articulation points Lubricate...
Page 141 MAINTENANCE PLAN 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION PART OPERATION PAGE Joint and ball-bearing ring articulations Lubricate Variable track gauge sliding guides Lubrication Air cleaner Clean the cartridge 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION (Operations to be carried out together with those prescribed at point “4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION”) PART OPERATION...
Page 142 MAINTENANCE PLAN 4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION PART OPERATION PAGE Engine oil filter Change Fuel filter Change Fuel pump precleaner Change Air cleaner Change the cartridge Radiators Clean the outside Hydraulic oil tank Drain condensate (Only for machines with synthetic biodegrad- able oil) 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION PART...
Page 143: When Required
MAINTENANCE PLAN 4.7.1 WHEN REQUIRED 4.7.1.a WASHING THE COOLING CIRCUIT DANGER • Be extremely careful when carrying out this maintenance operation, since the engine must be running; one operator must remain on the machine and the operators must decide the words and signals to be used in advance.
Page 144: Draining The Fuel Tank
• If there are signs of short circuit on the cables, find out the cause and repair them; always contact your Komatsu Utility Dealer for the troubleshooting. Make sure that there are no disconnected cables or signs of short circuit in the electrical system.
Page 145: Checking The Steel Track Tension
MAINTENANCE PLAN 4.7.1.d CHECKING THE STEEL TRACK TENSION DANGER • This operation must be carried out by two operators. One operator must be seated in the cab and oper- ate the machine according to the instructions of the operator who carries out the check and the adjust- ment.
Page 146 It is therefore necessary to turn or change the pins and bush- RWA06540 ings. For any change or repair, contact your Komatsu Utility Deal- To reduce the tension 1 - After removing the cover that gives access to the adjustment point, gradually loosen the greasing valve (3) to let the grease out;...
Page 147: Checking The Rubber Tracks
MAINTENANCE PLAN 4.7.1.e CHECKING THE RUBBER TRACKS Change the rubber tracks when they reach the prescribed wear limits. 1 - When the height “A” of the rubber claw is lower than 5 mm; if the height of the claw is below 5 mm, the risk of track slipping increases and the advance power will decrease accordingly.
Page 148 IMPORTANT • If the break length (2) is inferior to 30 mm, or its depth is inferior to 10 mm, the track does not need repairing. • For any change or repair, contact your Komatsu Utility Dealer. RWA06600...
Page 149: Checking The Rubber Track Tension
MAINTENANCE PLAN 4.7.1.f CHECKING THE RUBBER TRACK TENSION DANGER • This operation must be carried out by two persons. One operator must sit in the cab and move the ma- chine according to the signals of the operator who carries out the check and the adjustment. •...
Page 150 7 - If the rubber track tension is not sufficient even after the injec- tion of grease, change the track or the idler seals. For these operations, contact your Komatsu Utility Dealer. IMPORTANT • The wear of the rubber tracks varies according to the work conditions and to the characteristics of the ground on which the machine is operated.
Page 151: Changing The Rubber Track
• During the check, do not remove any part except the shoe to be changed. • If the shoe tension cannot be loosened by proceeding as indicated below, contact your Komatsu Utility Dealer, who will carry out the necessary repairs.
Page 152 MAINTENANCE PLAN INSTALLING THE RUBBER TRACK 1 - Raise the undercarriage by means of boom and arm and make sure that the grease contained in the cylinder has been removed. When carrying out this operation, move the control levers slowly. RWA06380 2 - Install the rubber tracks on the sprocket, inserting the drive blocks.
Page 153: Lubricating The Articulations
MAINTENANCE PLAN 4.7.1.h LUBRICATING THE ARTICULATIONS IMPORTANT • Clean the grease nozzles before applying the greasing pump. • After lubrication, remove any excess grease. • As a general rule, it is important to consider that each cylinder is provided with two greasers posi- tioned on the coupling eyelets and that each pin serving as fulcrum for a movement is provided with at least one greaser.
Page 154: Maintenance Intervals In Case Of Use Of The Demolition Hammer (Breaker)
MAINTENANCE PLAN 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (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. 4.7.2.a CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100÷150 hours...
Page 155: Checks Before Starting
• Dirt, oil and fuel spread in the engine compartment near the hot areas may cause fires and damage the machine. Check if there are leakages frequently and carry out the necessary repairs immediately; if this occurs repeatedly, contact your Komatsu Utility Dealer. Before starting the engine, check: 1. if there are loose screws or nuts;...
Page 156: Checking The Fuel Level
MAINTENANCE PLAN 4.7.3.c CHECKING THE FUEL LEVEL DANGER • When refuelling, avoid spilling fuel to prevent any risk of fire. If some fuel should inadvertently be spilled, clean the dirty area immediately. • Fuel is flammable; neither use naked flames, nor smoke while refuelling.
Page 157: Checking The Oil Level In The Hydraulic Circuit
MAINTENANCE PLAN 4.7.3.e CHECKING THE OIL LEVEL IN THE HY- DRAULIC CIRCUIT DANGER • The oil level in the hydraulic circuit must be checked with cold oil and the machine positioned on level ground, with retracted bucket and arm cylinders and the bucket teeth resting on the ground;...
Page 158: Maintenance After The First 50 Hours Of Operation
MAINTENANCE PLAN 4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used) The following maintenance operation must be carried out after the first 50 hours of operation. • HYDRAULIC OIL DRAIN FILTER CHANGE For further details on the various maintenance operations, see section “EVERY 250 HOURS”.
Page 159: Maintenance Every 100 Hours Of Operation
MAINTENANCE PLAN 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION 4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING IMPORTANT • Clean the grease nozzles before applying the greasing pump. • After lubrication, remove any excess grease. • If the machine is used in difficult conditions, perform this maintenance operation more frequently. These maintenace operations must be carried out with the equipment completely extended and resting on the ground.
Page 160 MAINTENANCE PLAN (FOR PC12R ONLY) RWA06140 5 - Blade cylinder base pin (for PC12R only) (1 point) 6 - Blade cylinder head pin (for PC12R only) (1 point) 7 - Blade fulcrum pin (for PC12R only) (2 points)
Page 161: Lubricating The Variable Track Gauge Sliding Guides (Pc12R Hs - Pc15R Hs)
MAINTENANCE PLAN 4.7.5.b LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (PC12R HS – PC15R HS) IMPORTANT • Carefully clean the sliding guides before applying grease. • If the machine is used in difficult conditions, carry out this maintenance operation more frequently. This operation must be carried out with the machine resting on RWAA9350 level ground and the track gauge widened as much as possible...
Page 162: Cleaning The Air Cleaner Cartridge
MAINTENANCE PLAN 4.7.5.c CLEANING THE AIR CLEANER CAR- TRIDGE DANGER • Remove the air cleaner only after stopping the engine and do not start the engine if the air cleaner is open. • Always wear safety goggles during the cleaning opera- tions.
Page 163: Maintenance After The First 250 Hours Of Operation
• CHECK AND ADJUST THE ENGINE VALVE CLEARANCE For details on the various maintenance operations, see the sections “EVERY 1000 HOURS” and “EVERY 2000 HOURS”. For the inspection and adjustment, contact your Komatsu Utility Dealer. 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION 4.7.7.a...
Page 164: Checking The Battery Electrolyte Level
MAINTENANCE PLAN 4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL DANGER • Check the level only after stopping the engine and if necessary add distilled water only before starting work. • Always wear safety goggles and waterproof gloves. • To prevent gas explosions, do not use naked flames, do not smoke and avoid producing sparks due to short circuits.
Page 165: Checking The Oil Level In The Travel Reduction Gears
MAINTENANCE PLAN 4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS DANGER • As soon as the machine has been stopped the oil is very hot; let it cool down until it reaches 40÷50°C before carry- ing out the check. This check must be carried out on each reduction gear posi- tioned with the level plugs (1) on the horizontal axis and the drain plug (2) downward.
Page 166: Changing The Hydraulic System Oil Filter
MAINTENANCE PLAN 4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER DANGER • Soon after the machine has been stopped the hydraulic oil is very hot; let it cool down until it reaches a tempera- ture of 40÷45°C before changing it. • The hydraulic system is pressurized; loosen the filling cap slowly to release the residual pressure.
Page 167: Changing The Engine Oil
MAINTENANCE PLAN 4.7.7.e CHANGING THE ENGINE OIL MAX. DANGER MIN. • 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 168: Maintenance After The First 500 Hours Of Operation
MAINTENANCE PLAN 4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used) The following maintenance operation must be carried out after the first 500 hours of operation, together with the maintenance operations to be carried out “EVERY 500 HOURS”.
Page 169: Changing The Fuel Filter
MAINTENANCE PLAN 4.7.9.b CHANGING THE FUEL FILTER DANGER • Change the filtering element after work, when the engine has cooled down to 40÷45°C. • When these operations are carried out, fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire.
Page 170: Changing The Fuel Pump Precleaner
MAINTENANCE PLAN 4.7.9.c CHANGING THE FUEL PUMP PRECLEANER DANGER • Change the precleaner after work, when the engine has cooled down to 40÷45°C. • When these operations are carried out, fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire.
Page 171: Changing The Air Cleaner Cartridge
MAINTENANCE PLAN 4.7.9.d CHANGING THE AIR CLEANER CAR- TRIDGE DANGER • Remove the air cleaner (1) only after stopping the engine and do not start the engine if the air cleaner casing is open. For this operation, it is necessary to remove the filtering element as described at point 3.7.5.c for the periodical cleaning opera- RWA06290 tions to be carried out every 100 hours.
Page 172: Draining The Hydraulic Oil Tank (Only For Machines In Which The Synthetic Biodegradable Oil Type Hees Is Used)
MAINTENANCE PLAN 4.7.9.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthet- ic biodegradable oil type HEES is used) DANGER • Retract the bucket and arm cylinder completely, lower the bucket teeth to the ground and, after stopping the engine, release the residual pressures from the work equipment circuits (by operating the controls more than once) and from the tank (by slowly loosening the filling cap).
Page 173: Maintenance Every 1000 Hours Of Operation
MAINTENANCE PLAN 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION These operations must be carried out together with those to be carried out every 100, 250, 500 HOURS. 4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS DANGER • Soon after the machine has been stopped the engine oil is very hot; let the engine cool down until it reaches a temperature of 40÷45°C before changing the oil.
Page 174: Maintenance Every 2000 Hours Of Operation
MAINTENANCE PLAN 4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 100, 250, 500 and 1000 HOURS. 4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FIL- CAUTION • On machines containing synthetic biodegradable hydrau- lic oil type HEES, carry out the change after the first 500 hours of operation and successively every 2000 hours, and in any case at least once a year.
Page 175 MAINTENANCE PLAN IMPORTANT • Carefully check the filtering element grid and if it is not in perfect conditions, change it. 7 - Put back the drain plug (2), the lower flange (5), making sure that the gasket is in good conditions, and the clamp (3) of the suction pipe.
Page 176: Changing The Coolant
Komatsu Utility Dealer. 4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER For any inspection and/or repair, contact your Komatsu Utility Dealer. If the engine is started frequently, have an inspection carried out every 1000 hours of operation.
Page 177: Technical Specifications
TECHNICAL SPECIFICATIONS...
Page 178: Technical Data
TECHNICAL DATA 5.1 TECHNICAL DATA 5.1.1 STANDARD OVERALL DIMENSIONS PC12R WITH CAB 1020 1000 1070 3495 RWA29090 WITH CANOPY 1020 1000 1070 3495 RWA29100 IMPORTANT • If the machine is equipped with the long arm instead of the standard arm, or with steel tracks instead of rubber tracks, the overall dimensions indicated in the drawing remain unchanged.
Page 179: Technical Characteristics Pc12R
Komatsu diesel engine model ........
Page 180: Standard Overall Dimensions Pc12R Hs (Variable Track Gauge)
TECHNICAL DATA 5.1.3 STANDARD OVERALL DIMENSIONS PC12R HS (VARIABLE TRACK GAUGE) WITH CAB 1020 1000 1070 1320 3495 RWA29110 WITH CANOPY 1020 1000 1070 1320 3495 RWA29120 IMPORTANT • If the machine is equipped with the long arm instead of the standard arm, or with steel tracks instead of rubber tracks, the overall dimensions indicated in the drawing remain unchanged.
Page 181: Technical Characteristics Pc12R Hs (Variable Track Gauge)
Komatsu diesel engine model ........
Page 182: Standard Overall Dimensions Pc15R
TECHNICAL DATA 5.1.5 STANDARD OVERALL DIMENSIONS PC15R WITH CAB 1020 1000 1145 1070 3535 RWA29130 WITH CANOPY 1020 1000 1145 1070 3535 RWA29140 IMPORTANT • If the machine is equipped with the long arm instead of the standard arm, or with steel tracks instead of rubber tracks, the overall dimensions indicated in the drawing remain unchanged.
Page 183: Technical Characteristics Pc15R
Komatsu diesel engine model ........
Page 184: Standard Overall Dimensions Pc15R Hs (Variable Track Gauge)
TECHNICAL DATA 5.1.7 STANDARD OVERALL DIMENSIONS PC15R HS (VARIABLE TRACK GAUGE) WITH CAB 1020 1000 1145 1070 1320 3535 RWA29150 WITH CANOPY 1020 1000 1145 1070 1320 3535 RWA29160 IMPORTANT • If the machine is equipped with the long arm instead of the standard arm, or with steel tracks instead of rubber tracks, the overall dimensions indicated in the drawing remain unchanged.
Page 185: Technical Characteristics Pc15R Hs (Variable Track Gauge)
Komatsu diesel engine model ........
Page 186: Lifting Capacity With Raised Blade Pc12R
TECHNICAL DATA 5.1.9 LIFTING CAPACITY WITH RAISED BLADE PC12R CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. RWA08090 : Rating over front : Rating over side : Load is limited by hydraulic capacity rather than tipping Bucket width L= 350 mm Bucket weight kg 24...
Page 187: Lifting Capacity With Lowered Blade Pc12R
TECHNICAL DATA 5.1.10 LIFTING CAPACITY WITH LOWERED BLADE PC12R CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. • Carry out the lifting operations only with the blade equipped with the appropriate safety device. RWA29330 : Raiting over front : Raiting over side...
Page 188: Lifting Capacity With Raised Blade Pc12R Hs (Variable Track Gauge Narrowed)
TECHNICAL DATA 5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. RWA29440 : Raiting over front : Raiting over side : Load is limited by hydraulic capacity rather than tipping Bucket width L= 350 mm...
Page 189: Lifting Capacity With Raised Blade Pc12R Hs
TECHNICAL DATA 5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. RWA29550 : Raiting over front : Raiting over side : Load is limited by hydraulic capacity rather than tipping Bucket width L= 350 mm...
Page 190: Lifting Capacity With Lowered Blade Pc12R Hs
TECHNICAL DATA 5.1.13 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. • Carry out the lifting operations only with the blade equipped with the appropriate safety device. RWA29660 : Raiting over front : Raiting over side...
Page 191: Lifting Capacity With Lowered Blade Pc12R Hs
TECHNICAL DATA 5.1.14 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. • Carry out the lifting operations only with the blade equipped with the appropriate safety device. RWA29770 : Raiting over front : Raiting over side...
Page 192: Lifting Capacity With Raised Blade Pc15R
TECHNICAL DATA 5.1.15 LIFTING CAPACITY WITH RAISED BLADE PC15R CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. RWA08310 : Rating over front : Rating over side : Load is limited by hydraulic capacity rather than tipping Bucket width L= 400 mm Bucket weight kg 25...
Page 193: Lifting Capacity Lowered Blade Pc15R
TECHNICAL DATA 5.1.16 LIFTING CAPACITY LOWERED BLADE PC15R CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. • Carry out the lifting operations only with the blade equipped with the appropriate safety device. RWA29880 : Raiting over front : Raiting over side...
Page 194: Lifting Capacity With Raised Blade Pc15R Hs
TECHNICAL DATA 5.1.17 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. RWA29990 : Raiting over front : Raiting over side : Load is limited by hydraulic capacity rather than tipping Bucket width L= 350 mm...
Page 195: Lifting Capacity With Raised Blade Pc15R Hs
TECHNICAL DATA 5.1.18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. RWA30100 : Raiting over front : Raiting over side : Load is limited by hydraulic capacity rather than tipping Bucket width L= 350 mm...
Page 196: Lifting Capacity With Lowered Blade Pc15R Hs
TECHNICAL DATA 5.1.19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. • Carry out the lifting operations only with the blade equipped with the appropriate safety device. RWA30210 : Raiting over front : Raiting over side...
Page 197: Lifting Capacity With Lowered Blade Pc15R Hs
TECHNICAL DATA 5.1.20 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED) CAUTION • Carry out the lifting operations only with the machine resting on firm and level ground. • Carry out the lifting operations only with the blade equipped with the appropriate safety device. RWA30320 : Raiting over front : Raiting over side...
Page 199 AUTHORISED OPTIONAL EQUIPMENT...
Page 200: Authorized Optional Equipment
The installation of optional accessories and equipment other than those authorized by Komatsu Utility negatively affects the life of the machine, but can also cause problems concerning safety. It is advisable to contact a Komatsu Utility Dealer before installing any accessory not indicated in this operation and maintenance manual.
Page 201: Precautions Regarding The Installation Of Equipment
• Always keep to the correct procedure when installing the boom and arm. Failure to carry out the cor- rect procedure may result in grave risks, therefore it is advisable to contact a Komatsu Utility Dealer before the installation.
Page 202: Characteristics Of The Optional Equipment
AUTHORIZED OPTIONAL EQUIPMENT 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT (PC12R-PC12R HS) (Specific weight of the handled material = 1.8 t/cu.m.) MAX. DIMENSIONS MAX. MAX. SAE MAX. OPERATING MAX. FLOW WEIGHT CAPACITY PRESSURE RATE EQUIPMENT Width Height (kg) (bar) (l/min.) (mm) (mm) Bucket —...
Page 203: Arrangement For The Installation Of The Demolition Hammer (Breaker)
ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLI- TION HAMMER (BREAKER) DANGER • For the characteristics of the hammer, see “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT”. • The demolition hammer is very noisy, therefore always wear headphones when using it. 6.2.1 DESCRIPTION AND CONTROL The machine can be fitted for the application of a demolition hammer;...
Page 204 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 2 - Keep the pressure of the excavator on the hammer constant as the bit penetrates in the material. Always follow the hammer in the penetration phase and oper- ate the excavator arms in order to obtain a pressure sufficient to keep the undercarriage raised at about 5 mm from the ground.
Page 205 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) IMPORTANT • During work, do not use the demolition hammer with the bucket cylinder at the end of its stroke, but al- ways leave a minimum space of 5 cm. ALWAYS AVOID THE FOLLOWING INCORRECT USES: 1 - Gathering or moving stones with the demolition hammer.
Page 206 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 4 - Working with the hammer in horizontal position or even with greater inclination. RWA06490 5 - Lever with the tool after thrusting it into the material to be bro- ken. RWA06500 6 - Hitting the ground with the hammer bit.
Page 207: Installing And Removing The Demolition Hammer
ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 6.2.3.1 INSTALLING THE HAMMER DANGER • The machine must be parked on a level surface, with the equipment resting on the ground. • For the installation, the hammer must be positioned horizontally, with the bit directed towards the ma- chine.
Page 208: Removing The Hammer
ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 6.2.3.2 REMOVING THE HAMMER To remove the hammer, proceed as follows: 1 - Stop the engine and move the hydraulic controls in all directions, in order to completely release the residual pressures present in the circuits of the machine.

This manual is also suitable for:

Pc12r-8 hs Pc15r-8 Pc15r-8 hs

Komatsu PC12R-8 Operation & Maintenance Manual

Foreword

Information on Safety

Introduction

Product Identification

Safety and Accident Prevention

Safety, Noise and Vibration Plates

General Precautions

Precautions to be Taken before Starting the Engine

Precautions to be Taken When Working

Transporting the Machine on Motor Vehicles

Battery

Precautions for the Removal

Precautions for Maintenance

The Machine and Its Operations

Safety Locks

General Views

Instruments and Controls

Fuses and Relays

Guards and Driver's Seat

Use of the Machine

Parking the Machine

Stopping the Engine

Transporting the Machine on Motor Vehicles

Lifting the Machine

Precautions to be Taken in the Cold Season

Precautions to be Taken in the Warm Season

Using the Work Equipment

Using the Machine with Variable Track Gauge

Long Periods of Inactivity

Troubleshooting

Maintenance

Guide to Maintenance

Maintenance Notes

Fuel, Coolant and Lubricants

Driving Torques for Screws and Nuts

Lubrication

Periodical Change of the Components Connected with Safety

Maintenance Plan

Technical Specifications

Technical Data

6.1 Authorized Optional Equipment

Authorized Optional Equipment

Arrangement for the Installation of the Demolition Hammer (Breaker)

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Summary of Contents for Komatsu PC12R-8