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Komatsu PC27R-8 Operation & Maintenance Manual

Hydraulic excavator
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Operation &
Maintenance Manual
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or
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.
PC20R
PC27R
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC20R
- F30791
-8
PC27R
- F31103
-8
WEAM000101
-8
-8
and up
and up

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Summary of Contents for Komatsu PC27R-8

  • Page 1 WEAM000101 Operation & Maintenance Manual PC20R PC27R HYDRAULIC EXCAVATOR SERIAL NUMBER PC20R - F30791 and up PC27R - F31103 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.

  • Page 3: Foreword

    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. Upper structure rotation achieved through an orbital hydraulic motor (for PC20R only). Upper structure rotation achieved through an axial piston hydraulic motor acting on an epicyclic reduction gear (for PC27R only) 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 top of the engine cylinder head cover. RWA08650 The exhaust gas emission plate is applied on the top of the en- gine cylinder head cover.

  • Page 10: Swing Motor Serial Number (For Pc20R Only)

    PRODUCT IDENTIFICATION 1.4.5 SWING MOTOR SERIAL NUMBER (for PC20R only) The serial number of the swing reduction gear is stamped on the plate positioned on the swing motor head. RWA09980 1.4.6 SWING REDUCTION GEAR SERIAL NUMBER (for PC27R only) The serial number is stamped on the plate positioned laterally on the reduction gear body.

  • Page 11: Serial Numbers And Dealer's Address

    PRODUCT IDENTIFICATION 1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS Machine n. Model Engine n. Travel reduction gear n. Swing motor (for PC20R only) n. Swing reduction gear (for PC27R only) 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 DESCRIPTION AND USE OF THE MACHINE 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 ............118 MAINTENANCE NOTES .
  • Page 18 TABLE OF CONTENTS Page 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION ....155 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION ......155 4.7.7.a ADJUSTING THE FAN BELT TENSION .
  • Page 19 TABLE OF CONTENTS Page AUTHORIZED OPTIONAL EQUIPMENT AUTHORIZED OPTIONAL EQUIPMENT ..........182 6.1.1 PRECAUTIONS REGARDING SAFETY .

  • 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 MACHINE WITH CANOPY RYA11890 RWA00030 RWA00020 RWA00010...

  • 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: Fuel Filter

    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 EMERGENCY EXIT RWA00190...

  • Page 27: Lifting Point

    SAFETY, NOISE AND VIBRATION PLATES LIFTING POINT RWA04920 DO NOT LIFT MORE THAN 1000 kg > 1000 Kg RWA00210...

  • 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: 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. 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 31: 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 When leaving the operator’s seat, even if temporarily, make...

  • Page 32: 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 33: 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. Before checking the coolant level, stop the engine and let the fluid cool down.

  • Page 34: Preventing Damage Caused By The Work Equipment

    If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator. Consult Komatsu Utility or your Komatsu Utility Dealer to have the cab structure and resistance checked in case of impact or damage.

  • Page 35: 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 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. When starting the engine, sound the horn as an alert signal.

  • Page 38: 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 39: 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 40: 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 41: 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 42: 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. 2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sidewards, there- fore it is advisable to move at low speed and to avoid abrupt starts, stops or turns.

  • Page 43: 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 44: 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 45: 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 46: 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. Incorrect manoeuvres may result in serious injuries or even death.

  • Page 47: 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 48: 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 49: 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 50: 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. Always tighten the fuel tank and the hydraulic circuit oil safety caps securely.

  • Page 51: 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 (+). At the end of the operation, reconnect first the positive ca- ble (+) and then the negative cable (–).

  • Page 52: 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 53: 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...

  • 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 pos. 8 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 GENERAL VIEW OF THE MACHINE WITH CAB RYA11970 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...

  • Page 58: General View Of The Machine With Canopy

    GENERAL VIEWS 3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY RYA11980 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 RYA11990 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 - Blade control 8 - Dashboard 9 - Accelerator control...

  • Page 60: Instruments And Controls

    INSTRUMENTS AND CONTROLS 3.3 INSTRUMENTS AND CONTROLS 3.3.1 INSTRUMENTS 1 - Hour meter 2 - Engine coolant temperature indicator 3 - Fuel level indicator RYA12020 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 INSTRUMENTS AND CONTROLS ENGINE COOLANT TEMPERATURE INDICA- It indicates the temperature of the engine coolant, which must normally be 80-85°C. After the start, it is necessary to let the engine warm up before beginning work. If during operation the indicator exceeds the limit values and en- ters the overheating sector (red), let the engine idle until the indi- cator returns to the normal temperature sector (green).

  • Page 62: Warning Lights

    INSTRUMENTS AND CONTROLS 3.3.2 WARNING LIGHTS 1 - Engine oil pressure warning light 2 - Generator warning light 3 - Pre-heating warning light RYA12030 ENGINE OIL PRESSURE WARNING LIGHT This warning light comes on and makes the acoustic alarm sound with engine at rest when the ignition circuit is operated, then goes out as soon as the engine lubrication circuit is pressu- rized.
  • Page 63 INSTRUMENTS AND CONTROLS GENERATOR WARNING LIGHT This warning light comes on and makes the acoustic alarm sound when the ignition circuit is energized 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 bat- tery is not charged correctly.

  • Page 64: Switches And Push Buttons

    INSTRUMENTS AND CONTROLS 3.3.3 SWITCHES AND PUSH BUTTONS 1 - Fan switch (with cab only) 2 - Working light and instrument light switch 3 - Ignition switch 4 - Boom overload alarm switch (if installed) 5 - Revolving light switch (if installed) 6 - Horn RYA12040...

  • Page 65: Ignition Switch

    INSTRUMENTS AND CONTROLS WORKING LIGHT AND INSTRUMENT LIGHT SWITCH This is a rotary switch with three positions marked by the follow- ing symbols: (OFF - 1 - 2). 1) Enables the instrument light circuit 2) Enables the working light circuit RWA07180 IGNITION SWITCH This is a rotary key switch with four positions marked by the fol-...
  • Page 66 INSTRUMENTS AND CONTROLS 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. RWA20870...

  • Page 67: Electrical Accessories

    INSTRUMENTS AND CONTROLS 3.3.4 ELECTRICAL ACCESSORIES 1 - Engine acoustic alarm 2 - Windshield wiper / washer switch (with cab only) 3 - Overhead lamp (with cab only) 4 - Electric outlet RYA12070 RYA12080 RYA12090...
  • Page 68 INSTRUMENTS AND CONTROLS ENGINE ACOUSTIC ALARM This alarm starts sounding when the circuits are energized with the ignition key (rotation to position “I”) and is automatically dis- connected when the engine is started. If the alarm sounds during the use of the machine, it indicates: •...

  • Page 69: Machine Controls

    INSTRUMENTS AND CONTROLS 3.3.5 MACHINE CONTROLS RYA12100 1 - Left equipment control lever 2 - Right equipment control lever 3 - Left travel and steering control lever 4 - Right travel and steering control lever 5 - Boom swing control pedal 6 - Blade control lever 7 - Accelerator lever 8 - Left safety device control lever...
  • Page 70 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 71 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 72 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 73 INSTRUMENTS AND CONTROLS BLADE CONTROL LEVER RWA10010 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 B - Blade raising ACCELERATOR LEVER RYA12140...
  • Page 74 INSTRUMENTS AND CONTROLS 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 (8), which will automati- cally shift to the lock position.
  • Page 75 INSTRUMENTS AND CONTROLS SPEED INCREASE PUSH BUTTON This pedal makes it possible to increase the machine travel speed. By pressing it, you increase the speed; by releasing it, you return to the normal speed. IMPORTANT Do not use the speed increase pedal when changing di- rection or performing a counter-rotation.
  • Page 76 INSTRUMENTS AND CONTROLS 11 - 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: Main Fuse

    FUSES AND RELAYS 3.4.1.2 MAIN FUSE RWA09020 POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT – System main fuse...

  • Page 79: Relays

    FUSES AND RELAYS 3.4.2 RELAYS The horn relay is positioned inside the right control box, under the dashboard, while the other relays are grouped on a single base positioned inside the left control box. RWA10040 RWAA0890 RWA10050 RWA10060 POSITION DESCRIPTION Horn relay Engine acoustic alarm Preheating warning light timer...

  • Page 80: 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 81: Right Counterweight

    GUARDS AND DRIVER’S SEAT 3.5.2 RIGHT COUNTERWEIGHT DANGER Do not rotate the counterweight to the open position when the engine is running. Do not start the engine with the counterweight in open po- sition, if this is not expressly prescribed for the mainte- nance operations.

  • Page 82: Cab

    1 of the FOPS standard. If the cab is subjected to an impact, or if the ma- chine overturns, immediately contact your Komatsu Utility Dealer, who will check the stiffness of the cab and make sure that the operator’s safety is guaranteed.
  • Page 83 GUARDS AND DRIVER’S SEAT The front windshield (6) can be opened only after disengaging the couplings (7), by pulling and lifting the window. Open the windshield (6) by means of the opening handles (8), after disengaging the couplings (7). Move the windshield to the correct position: it will automatically fit in the upper locking seats.
  • Page 84 GUARDS AND DRIVER’S SEAT The side windows (12) and (13) positioned on the right side of the cab can be opened by sliding them; press the handle (14) and pull it. RWA09080 RWA09090...

  • Page 85: Ventilation And Heating

    GUARDS AND DRIVER’S SEAT 3.5.5 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: Seat

    GUARDS AND DRIVER’S SEAT 3.5.6 SEAT The seat can be adjusted as follows: a - Longitudinal position adjustment. b - Adjustment of the suspension degree, aimed at cushioning the inevitable vibrations and jerks as much as possible. The seat is installed on guides that slide longitudinally, can be moved forward or backward and the operator can choose the most comfortable driving position according to his physical struc- ture.

  • Page 87: Emergency Exit

    GUARDS AND DRIVER’S SEAT 3.5.8 EMERGENCY EXIT The machines with cab are provided with an emergency exit lo- cated in the rear window (1). Inside the cab you will find a hammer (2) to be used to break the window (1) in case of emergency. IMPORTANT Make sure that the hammer is always available and in the correct position inside the cab.

  • Page 88: Fire Extinguisher

    GUARDS AND DRIVER’S SEAT 3.5.10 FIRE EXTINGUISHER CAUTION The machine’s owner must provide for installing and fix- ing the fire extinguisher where prescribed. Periodically check the fire extinguisher support. Periodically make sure that the fire extinguisher is full. If the operator expects that he may need the fire extinguisher (1) RYA12170 on the machine, he must install it by fixing it on the rear compart- ment of the seat by means of the appropriate 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 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 you have to work in water, check that the maximum depth of immersion is lower than the centre of the top guide roller, and in any case that the engine cooling fan does not come into contact with the water;...

  • 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. Lower the blade and the work equipment to the ground.

  • 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. Park only with the bucket directed downwards.

  • 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. Block the means of transport by positioning wedges before and behind each wheel.

  • 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. If due to a sudden failure the machine stops with raised equipment, turn the ignition key to position «...

  • 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. Carry out all the possible movements and make sure that the control levers work properly. If visibility is not perfect or there are ducts or lines of any RWA09110 kind, work at reduced speed and ask the assistance of an-...

  • 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: Long Periods Of Inactivity

    LONG PERIODS OF INACTIVITY 3.14 LONG PERIODS OF INACTIVITY 3.14.1 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 112: 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 - Release the exhaust pipe and the fuel tank from the seals.

  • Page 113: Troubleshooting

    TROUBLESHOOTING 3.15 TROUBLESHOOTING 3.15.1 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 114: After The Fuel Has Run Out

    TROUBLESHOOTING 3.15.3 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 “4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION”. 3.15.4 IF THE BATTERY IS DOWN DANGER When checking or carrying out any operation on the bat-...

  • Page 115: Starting With Booster Cables

    TROUBLESHOOTING 3.15.4.1 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 (–). When starting the engine with booster cables, always wear safety goggles. Take care to avoid any contact between the machine to be started and the machine used as starting aid, in order to avoid sparks and therefore the explosion of the hydrogen produced by the batteries.

  • Page 116: Other Troubles

    3.15.5 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 117: Engine

    TROUBLESHOOTING 3.15.5.3 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. Steam comes out of radiator breather Fluid level low, fluid leakages.

  • Page 119: Maintenance

    MAINTENANCE...

  • Page 120: 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 121 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 Oils, filters, the coolant and the battery are considered special waste and must be collected and dis- posed of according to the regulations in force.

  • Page 122: 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: ITEM...

  • Page 123: Fuel

    0.52 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 124: Notes Regarding The Electrical System

    3 - check of the battery electrolyte level. Do not remove or eliminate any electric component installed on the machine and do not install any electric component with characteristics different from those specified and approved by Komatsu Utility. Be careful to keep the electric system dry.

  • Page 125: 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 126: 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 50°C filling Change 104 122°F SAE 10W SAE 20W-20 API CD (PC20R) (PC20R) SAE 30 Engine oil pan SAE 40 (PC27R) (PC27R)
  • Page 127 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 128: 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 129: 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 130: Lubrication

    LUBRICATION 4.5 LUBRICATION 4.5.1 LUBRICATION DIAGRAM IMPORTANT For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. The type of lubricant to be used is indicated in the lubricant table (See “4.3 FUEL, COOLANT AND LU- BRICANTS”). 2000 h 1000 h 250 h 100 h...

  • Page 131: Periodical Change Of The Components That Are Connected With Safety

    PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY 4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY To ensure safety at any moment while driving and using the machine, the operator must carry out all the periodic maintenance operations prescribed.

  • Page 132: Critical Parts For Safety

    PERIODICAL CHANGE OF THE COMPONENTS THAT ARE 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 Fuel pipe (Fuel filter –...
  • Page 133 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY HYDRAULIC SYSTEM Components related to safety that periodically need changing Change interval Hydraulic pipe (Main pump delivery) Hydraulic pipe (Secondary pump delivery) Hydraulic pipe (Load Sensing signal) Every 2 years or 4000 hours, whichever oc- Hydraulic pipe (Boom cylinder) curs first...
  • Page 134 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY RWA33940 OPERATOR’S SAFETY Components related to safety that periodically Q.ty Change interval need changing Safety belt Every 4 years...

  • Page 135: 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 Air cleaner Check, clean or change...

  • Page 136: Maintenance Every 100 Hours Of Operation

    MAINTENANCE PLAN 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION PART OPERATION PAGE Joint and ball-bearing ring articulations Lubricate 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...

  • Page 137: Maintenance Every 1000 Hours Of Operation

    MAINTENANCE PLAN 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION PART OPERATION PAGE Travel reduction gears Change the oil 4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION PART OPERATION PAGE Hydraulic oil and suction filter Change the oil and clean the filter Coolant Change Engine valves...

  • Page 138: 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 139: Draining The Fuel Tank

    MAINTENANCE PLAN 11 - Rotate the lateral counterweight to the closed position and close the engine hood. IMPORTANT The circuit must be washed more frequently if the water used contains a high quantity of calcium salts, that is, if the water is very hard. RWA09300 4.7.1.b DRAINING THE FUEL TANK RWA10110...

  • Page 140: Checking The Electrical System

    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 141 It is therefore necessary to turn or change the pins and bush- ings. RWA09320 For any change or repair, contact your Komatsu Utility Deal- To reduce the tension 1 - Gradually loosen the greasing valve (1) to let the grease out;...

  • Page 142: 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 143 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 144: 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. The shoe tension must be checked with the frame lifted from the ground.
  • Page 145 6 - If the rubber track tension is not sufficient even after the in- jection 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 146: 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 147 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 148: Checking, Cleaning Or Changing The Air Cleaner Cartridge

    MAINTENANCE PLAN 4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE DANGER Remove the air cleaner only after stopping the engine and do not start the engine if the air cleaner is open. Wear safety goggles during the cleaning operations. IMPORTANT When the red piston of the clogging indicator (1) is visible through the gauge, clean or change the air cleaner car-...

  • Page 149: 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 150: 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 151: 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 152: 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 153: Checking The Air Cleaner Clogging Indicator

    MAINTENANCE PLAN 4.7.3.f CHECKING THE AIR CLEANER CLOG- GING INDICATOR The clogging indicator is installed on the air cleaner and can be reached by opening the engine hood. When the air cleaner is clogged, the red piston of the indicator (1) visible through the gauge indicates that maintenance is re- quired.

  • Page 154: 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 155: 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 156 MAINTENANCE PLAN EQUIPMENT LUBRICATION POINTS RWA09930 6 - Boom swing fulcrum pin (for PC20R only) (2 points) 6 - Boom swing fulcrum pin (for PC27R only) (1 point) 7 - Boom fulcrum pin (1 point) (1 point) 8 - Lifting cylinder base pin (1 point) 9 - Lifting cylinder head pin (1 point)

  • Page 157: Maintenance After The First 250 Hours Of Operation

    For further details on the various maintenance operations, see the sections “4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION” and “4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION”. For the inspection and adjustment, contact your Komatsu Utility Dealer. 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION 4.7.7.a...

  • Page 158: 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 159: 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 temperature of 40÷45°C before changing it. The hydraulic system is pressurized; loosen the filling cap slowly to release the residual pressure. Oils, filters, the coolant and the battery are considered special waste and must be collected and dis- posed of according to the anti-pollution regulations in force.

  • Page 160: Changing The Engine Oil

    MAINTENANCE PLAN 4.7.7.e CHANGING THE ENGINE OIL DANGER Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40÷45°C before draining the oil. The oil that may be spilled during the change makes the ground slippery, therefore, use anti-slip shoes and imme- diately remove any trace of oil from the floor.

  • Page 161: 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 162: 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. Oils, filters, the coolant and the battery are considered special waste and must be collected and dis- posed of according to the anti-pollution regulations in force.

  • Page 163: 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. Oils, filters, the coolant and the battery are considered special waste and must be collected and dis- posed of according to the anti-pollution regulations in force.

  • Page 164: Cleaning The Outside Of The Radiators

    MAINTENANCE PLAN 4.7.9.d CLEANING THE OUTSIDE OF THE RADI- ATORS DANGER If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield and safety shoes. The radiator and the heat exchanger can be reached after open- ing the engine hood (see "3.5.1 ENGINE HOOD") and the lateral RWA06300 counterweight (see "3.5.2 RIGHT COUNTERWEIGHT").

  • Page 165: Draining The Hydraulic Oil Tank (Only For Machines In Which The Synthetic Biodegradable Oil Type Hees Is Used)

    MAINTENANCE PLAN 4.7.9.e 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 166: 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 167: 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 168 MAINTENANCE PLAN 7 - Loosen the clamp (3) that holds the suction pipe and remove the screws (4). Remove the flange (5) and clean the suction filter (6). Use a 13 mm hexagon spanner. IMPORTANT Carefully check the filtering element grid and if it is not in perfect conditions, change it.
  • Page 169 MAINTENANCE PLAN 11-Extend the boom, arm and bucket cylinders completely as in- dicated in the figure and remove the filling cap (1). Put back the cap and pressurize the inside of the tank lower- ing the equipment to the ground. 12-Make sure that all the control levers are in neutral and let the engine idle for 2÷3 minutes before operating the work equip- ment.

  • Page 170: Changing The Coolant

    MAINTENANCE PLAN 4.7.11.b CHANGING THE COOLANT DANGER Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns; let the engine cool down until it reaches approxi- mately 40÷45°C before changing the coolant. Slowly loosen the radiator cap, in order to release the re- sidual pressure.

  • Page 171: Checking And Adjusting The Engine Valve Clearance

    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 173: Technical Specifications

    TECHNICAL SPECIFICATIONS...

  • Page 174: Technical Data

    TECHNICAL DATA 5.1 TECHNICAL DATA 5.1.1 STANDARD OVERALL DIMENSIONS (for model PC20R only) MACHINE WITH CAB 300 / 1340 1120 1210 1240 1430 4250 (4320) RWA08760 ( ) Dimensions with long digging arm (L=1320 mm) Steel tracks Rubber tracks MACHINE WITH CANOPY 300 / 1340 1120...

  • Page 175: Technical Characteristics Pc20R

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

  • Page 176: Standard Overall Dimensions (For Model Pc27R Only)

    TECHNICAL DATA 5.1.3 STANDARD OVERALL DIMENSIONS (for model PC27R only) MACHINE WITH CAB 1485 1200 1510 1240 1500 4525 (4655) RWA08780 ( ) Dimensions with long digging arm (L=1500 mm) Steel tracks Rubber tracks MACHINE WITH CANOPY 1485 1200 1510 1240 1500 4525 (4655)

  • Page 177: Technical Characteristics Pc27R

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

  • Page 178: Lifting Capacity With Cab (For Model Pc20R Only)

    TECHNICAL DATA 5.1.5 LIFTING CAPACITY WITH CAB (for model PC20R only) CAUTION According to the standard EN474-5 (§ 4.1.7.5), this machine if not equipped with suitable devices is not allowed to lift more than 1000 kg. Do not attempt to lift loads unless the machine is standing on firm, level ground. RWA09450 : Rating over front : Rating over side...

  • Page 179: Lifting Capacity With Canopy (For Model Pc20R Only)

    TECHNICAL DATA 5.1.6 LIFTING CAPACITY WITH CANOPY (for model PC20R only) CAUTION According to the standard EN474-5 (§ 4.1.7.5), this machine if not equipped with suitable devices is not allowed to lift more than 1000 kg. Do not attempt to lift loads unless the machine is standing on firm, level ground. RWA09560 : Rating over front : Rating over side...

  • Page 180: Lifting Capacity With Cab (For Model Pc27R Only)

    TECHNICAL DATA 5.1.7 LIFTING CAPACITY WITH CAB (for model PC27R only) CAUTION According to the standard EN474-5 (§ 4.1.7.5), this machine if not equipped with suitable devices is not allowed to lift more than 1000 kg. Do not attempt to lift loads unless the machine is standing on firm, level ground. RWA09670 : Rating over front : Rating over side...

  • Page 181: Lifting Capacity With Canopy (For Model Pc27R Only)

    TECHNICAL DATA 5.1.8 LIFTING CAPACITY WITH CANOPY (for model PC27R only) CAUTION According to the standard EN474-5 (§ 4.1.7.5), this machine if not equipped with suitable devices is not allowed to lift more than 1000 kg. Do not attempt to lift loads unless the machine is standing on firm, level ground. RWA09780 : Rating over front : Rating over side...
  • Page 183 AUTHORISED OPTIONAL EQUIPMENT...

  • Page 184: Authorized Optional Equipment

    AUTHORIZED OPTIONAL EQUIPMENT 6.1 AUTHORIZED OPTIONAL EQUIPMENT CAUTION Komastu Utility machines can be supplied with optional equipment in addition to the standard equip- ment; if optional equipment is installed and used, carefully read the relevant operation manual and keep to the instructions given therein. Use exclusively optional or special equipment recommended and approved by Komastu Utility and complying with the requisites indicated in the table (See “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT”).

  • Page 185: Precautions Regarding The Installation Of Equipment

    AUTHORIZED OPTIONAL EQUIPMENT 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT DANGER The use of lengthened work equipment reduces the stability of the machine. If it is necessary to rotate the upper structure on a slope or to travel downhill, be particularly careful, since the machine may lose its balance and overturn.

  • Page 186: Characteristics Of The Optional Equipment

    AUTHORIZED OPTIONAL EQUIPMENT 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT (FOR MODEL PC20R ONLY) (Specific weight of the handled material = 1.8 t/cu.m.) MAX. DIMENSIONS MAX. MAX. MAX. SAE MAX. OPERATING FLOW WEIGHT CAPACITY PRESSURE EQUIPMENT Width Height RATE (kg) (bar) (mm) (mm) (l/min.)

  • Page 187: 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 EQUIP- MENT”. The demolition hammer is very noisy, therefore always wear headphones when using it. 6.2.1 DESCRIPTION AND CONTROL The machine is fitted for the application of a demolition hammer;...
  • Page 188 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 189 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 190 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. RWA06510 6 - Hitting the ground with the hammer bit.

  • Page 191: 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 hori- zontally, with the bit directed towards the machine.

  • Page 192: Removing The Hammer

    ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 8 - Stop the machine again and lubricate the joints (See “4.5 LUBRICATION”) and the hammer (See the specific use and maintenance manual). 9 - Before starting work, check the seals. DANGER Always wear thick gloves and safety goggles during this check.

  • Page 193: Arrangement For The Operation Of Optional Equipment

    ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT 6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT The machine is equipped with an independent hydraulic circuit for the operation of optional equipment that can be installed in- stead of the standard bucket. The oil flow in the circuit is controlled by a selection valve (1) and a pedal (2) that controls the additional distributor provided for the operation of the equipment.

  • Page 194: Control Pedal (2)

    ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT 6.3.2 CONTROL PEDAL (2) This pedal controls the delivery and return of the oil to the op- tional equipment. 1 - If the pedal is pressed in (A), high-pressure oil is conveyed to the equipment through the left piping (3).

  • Page 195: Assemblying And Connecting The Equipment

    ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT 6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT DANGER The machine must be parked on a level surface, with the equipment resting on the ground. When the coupling pins are removed or installed, chips may come off; always wear gloves, safety gog- gles and helmet.

  • Page 196: Maintenance

    ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT 6.3.4 MAINTENANCE The hydraulic system does not require any maintenance operation and inspection other than those prescribed for the machine. For the maintenance operations required for the equipment, see the specific operation manuals.

This manual is also suitable for:

Pc20r-8

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