Komatsu PC14R-3, Operation & Maintence Manual

Page 1: ...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 cont...

Page 2: ......

Page 3: ...ntenance operations that have been carried out are important since they provide a clear report on the situation and say exactly what has been done and what has to be done after the next maintenance in...

Page 4: ...he use of this term must be limited to situations of extreme danger WARNING q Indicates a situation of potential danger that if not avoided may cause serious injury and even death CAUTION q Indicates...

Page 5: ...den to modify the setting of the hydraulic system safety valves Komatsu cannot be held liable for any damage to persons property or the machine if this has been tampered with by modifying the standard...

Page 6: ...necessary for the operation of such equipment are grouped in the final section of this manual Komatsu machines are constructed exclusively for the handling excavation and treatment of inert materials...

Page 7: ...tions and abrupt reversals SYNTHETIC BIODEGRADABLE OIL TYPE HEES For machines in which synthetic biodegradable oil type HEES is used perform the following operations in addition to the standard mainte...

Page 8: ...r is stamped on the front upper part of the main frame on the left side 1 4 2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER PIN The Komatsu excavators described in this manual are CE...

Page 9: ...is stamped on the plate positioned on the engine itself The exhaust gas emission plate is applied to the counterweight 1 4 4 TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the pla...

Page 10: ...SWING REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned on the upper side of the swing motor 1 4 6 CAB SERIAL NUMBER The serial number is stamped on the plate positione...

Page 11: ...ATION WEAM009300 9 1 4 7 SERIAL NUMBERS AND DEALER S ADDRESS Machine no Model Product identification number PIN Travel reduction gear no Swing reduction gear no Dealer Address Tel Contact person NOTES...

Page 12: ...dealer will be in charge of removing and installing the KOMTRAX equipment q Do not flatten or damage the cables or wires Do not pull the cables or wires hard Short circuits and disconnected cables can...

Page 13: ...2 PICTOGRAMS AND RELEVANT MEANINGS 19 2 1 3 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY 24 2 1 4 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB 25 2 1 5 VIBRATIONS TO WHICH THE OPERATOR I...

Page 14: ...7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE 49 2 8 PRECAUTIONS FOR MAINTENANCE 50 2 8 1 WARNING PLATES 50 2 8 2 TOOLS 50 2 8 3 MAINTENANCE STAFF 50 2 8 4 EQUIPMENT 51 2 8 5 WORKING UNDER THE MACHINE...

Page 15: ...IATOR COVER 87 3 2 8 BATTERY COVER 88 3 2 9 TILTING THE CAB FLOOR machines with canopy 89 3 2 10 TILTING THE CAB FLOOR machines with cab 92 3 2 11 FUSES 96 3 2 12 MAIN FUSE 97 3 2 13 TECHNICAL DOCUMEN...

Page 16: ...DING THE MACHINE 146 3 4 3 LIFTING THE MACHINE 152 3 5 USING THE MACHINE IN THE COLD SEASON 155 3 5 1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON 155 3 5 1 1 FUEL AND LUBRICANTS...

Page 17: ...TERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER 187 4 8 2 a CHANGING THE HYDRAULIC OIL FILTER 187 4 8 2 bCHANGING THE HYDRAULIC OIL187 4 9 MAINTENANCE PROCEDURES 188 4 9 1 WHEN REQUIRED 188 4 9 1 a CH...

Page 18: ...VE CLEARANCE 214 4 9 7 MAINTENANCE EVERY 2000 HOURS OF OPERATION 215 4 9 7 a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER 215 4 9 7 b CHANGING THE COOLANT 217 4 9 7 c CHECKING THE AL...

Page 19: ...SAFETY AND ACCIDENT PREVENTION 17...

Page 20: ...lean them with a solution made of water and detergent Do not use fuel petrol or solvents q If the plates are damaged ask for new ones to Komatsu or to your Komatsu Dealer q In case of replacement of a...

Page 21: ...hat they look like and their respective meanings WORK IN PROGRESS q Do not approach or stand within the equipment operating range when the boom and the bucket are raised DO NOT OPEN THE ENGINE HOOD q...

Page 22: ...that the front windshield is always locked HYDRAULIC OIL TOPPING UP q Only for machines in which synthetic biodegradable oil type HEES is used DANGER OF CRUSHING q Do not get close or touch the movin...

Page 23: ...NOISE AND VIBRATION PLATES WEAM009300 21 HYDRAULIC OIL TOPPING UP REFUELLING ENGINE OIL FILTER FUEL FILTER ENGINE AIR INTAKE FILTER ENGINE COOLANT RWA00050 D RWA00040 RWA00080 D RWA00060 RWA00090 RWA...

Page 24: ...LATES 22 WEAM009300 ENGINE COOLANT PRESSURE HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER POWER OUTLET ANCHORAGE POINT LIFTING POINT EMERGENCY EXIT machines with cab RWA00110 RWA00100 RWA00070 12 V RWA0012...

Page 25: ...1m 0 L 880mm L 1130mm 225kg 265kg 250kg 255kg 245kg 145kg 135kg 180kg 145kg 145kg 215kg 125kg A B 2m 3m MAX W 350mm kg 22 700kg 1m RKA22430 W W 350mm kg 22 L 2m 1m 0 1m 0 L 880mm L 1130mm A B 2m 3m M...

Page 26: ...solvents q If the plates are damaged ask for new ones to Komatsu or to your Komatsu Dealer q In case of replacement of a component provided with a noise plate make sure that such a plate is applied a...

Page 27: ...such a plate is applied also to the new part EXTERNAL NOISE q This value indicates the noise level outside the machine and refers to the noise perceived by persons in the vicinity of the work area NOI...

Page 28: ...ep them in good operating conditions q Any improper use of the safety devices may result in serious injury or even death 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS q Do not wear large or loose cloth...

Page 29: ...njury or damage caused by unauthorized modifications 2 2 5 LEAVING THE OPERATOR SEAT q When leaving the operator seat even if temporarily make sure that the machine is in a safe position See 2 4 14 PA...

Page 30: ...ontrol 4 Lock the equipment control by shifting the safety lever 1 to the locked position L 5 Stop the engine See 3 3 4 STOPPING THE ENGINE 6 If you have to go so far away that you will not be able to...

Page 31: ...e very carefully q Do not hold or rest on the control levers q Both when getting on and when getting off the machine always maintain three points of contact holding or resting points in order to avoid...

Page 32: ...r adding oil tighten the fuel or oil cap securely q Do not fill the tank completely in order to leave room for the fuel to expand q In case some fuel is spilled wipe it up immediately 2 2 8 PREVENTING...

Page 33: ...hen the arms are lifted if you are not sure that the safety locks have been duly engaged q Do not carry out any operation requiring the arms to be lifted if you are not sure that the locks are correct...

Page 34: ...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 Contact Komat...

Page 35: ...until the end of the operations Be careful not to sever or damage any of these lines q Check the depth and flow of water before operating in water or on river banks 2 3 2 FIRE PREVENTION q Completely...

Page 36: ...e lights in such a way as to ensure perfect visibility on the work area q Make sure that the work lights have been correctly installed Make also sure that they come on correctly 2 3 6 CLEANING THE WIN...

Page 37: ...engine only while seated with fastened seat belt q Do not allow anyone to get on the machine q Make sure that the platform fastening screws 1 are well tightened Incorrect tightening of the cab floor m...

Page 38: ...nly one person must be entrusted with making signals q The operator must make sure that the signalman is always within his field of vision and follow all his signals The use of hand signals serves to...

Page 39: ...rected towards the signalman move the hand in the direction of the movement to be carried out 5 LIFT THE BOOM With an arm extended in horizontal position and closed fingers point the thumb upwards 6 L...

Page 40: ...HE BUCKET Keep one hand still and open Rotate the other hand vertically with the thumb pointed towards the open hand 13 TRAVEL WHILE STEERING Lift the forearm corresponding to the inner steering side...

Page 41: ...ve the hands laterally indicating the distance to be covered 18 CARRY OUT THE MOVEMENTS SLOWLY One hand still in front of the hand that indicates the movement to be carried out The figure represents t...

Page 42: ...PRECAUTIONS TO BE TAKEN WHEN WORKING 40 WEAM009300 21 STOP THE ENGINE Pass thumb or forefinger across the throat RKA15340...

Page 43: ...possible to evaluate more precisely the space required for the movements and at the same time ensures the stability of the machine q Make sure that the driver seat is directed towards the blade Otherw...

Page 44: ...speed When travelling downhill position the machine with the turret rotated by 180 so that the sprocket 1 and the boom are in travelling direction as shown in the figure and proceed at low speed q Do...

Page 45: ...rations are going to last long accumulate soil in such a way as to create a horizontal platform on which the machine can be positioned 2 4 8 UNAUTHORIZED OPERATIONS q Do not carry out excavations unde...

Page 46: ...materials may damage the work equipment or even cause serious personal injury q As a general rule the machine is more liable to overturn when the work equipment is swung to one side than when it is a...

Page 47: ...carrying out this kind of operations warn everyone standing in the work area to keep a safety distance from the machine and the work equipment q Ask the electricity company in advance the voltage of...

Page 48: ...lt q In case of work in areas where stones or other material may fall on the machine install the FOPS protection device 2 4 14 PARKING THE MACHINE q Park the machine on firm and level ground If this i...

Page 49: ...th q Position the ramps with a maximum inclination of 15 q Make sure that the surface of the ramps is clean and there is no trace of grease oil soil or ice remove dirt from the tracks before loading t...

Page 50: ...attery stop the engine and remove the ignition key q Avoid short circuiting the battery terminals through any contact even if accidental with metal objects or tools or by inverting them q Tighten the...

Page 51: ...the cable q Move the machine only as far as necessary to allow the required repairs to be carried out q Put wooden blocks between the towing cable and the machine body in order to avoid wear or damage...

Page 52: ...he machine and in particular to the cab door handles 2 8 2 TOOLS q Use only the tools supplied together with the machine and high quality tools suitable for the tasks to be performed q Do not use worn...

Page 53: ...ase scattered tools or broken pieces are dangerous because they may cause someone to slip or trip Always keep the machine and the work site clean and tidy q To clean the machine use a pressurized jet...

Page 54: ...ires Fuel system fuel delivery and return pipes Hydraulic system main delivery pipes of the hydraulic pump q Even if they seem to be in good conditions these components must be periodically changed wi...

Page 55: ...lling hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sparks due to static electricity q Do not fill the tank completely in order t...

Page 56: ...nd also the alternator 2 8 14 PRECAUTIONS CONCERNING THE STARTER q Start the engine only when correctly seated in the driving position q Do not start the engine by tampering with the terminals of the...

Page 57: ...e the eyes For this reason always wear goggles and thick gloves during the inspections and use a piece of cardboard or a sheet of plywood to check for oil leakages If you are hit by a jet of high pres...

Page 58: ...ing spring with high preload in order to absorb the impacts of the front idler roller Do not attempt to remove the spring since this may lead to serious accidents and even death For any operation on t...

Page 59: ...fety goggles mask gloves and other protection items 2 8 24 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY q To ensure that the machine can be used as long as possible in total safety it i...

Page 60: ...es produced q In case of contact with the skin immediately rinse with a solution made of water and an alkaline detergent for about 30 minutes and then contact a poisoning treatment center without dela...

Page 61: ...THE MACHINE AND ITS OPERATIONS 59...

Page 62: ...AM009300 3 1 MACHINE ILLUSTRATIONS 3 1 1 OVERALL VIEW OF THE MACHINE RKA22480 1 2 3 4 5 6 Bucket Bucket cylinder Arm Arm cylinder Boom Boom cylinder 7 8 9 10 11 12 Track Sprocket Undercarriage Idler r...

Page 63: ...ntrol right lever Scraper control lever variable width Indicators and warning lights display Accelerator lever Start up switch 16 17 18 19 20 21 22 23 24 25 26 27 Hour counter Translation speed increa...

Page 64: ...ices that are necessary for correct operation of the machine To perform the required operations correctly and safely it is important to understand the equipment operating methods and the meaning of th...

Page 65: ...ne is running stop the machine immediately and try to find the cause of the failure see 3 7 6 OTHER TROUBLES 2 Charge level warning light This warning light comes on together with the acoustic alarm w...

Page 66: ...stop the machine and provide for refuelling 2 Hour meter This instrument indicates the total number of operating hours of the engine The count is continuous and the hour number is increased by 0 1 wh...

Page 67: ...arning light This warning light comes on when the travel speed selection switch is in high speed position see 3 2 2 pos 4 Travel speed selection switch if provided When the speed selection switch in l...

Page 68: ...ature warning light This warning light comes on when the engine coolant exceeds the maximum temperature allowed in this case reduce the engine speed until the warning light goes out If this inconvenie...

Page 69: ...ll automatically return to position ON q Position HEAT preheating When starting the engine in cold weather turn the key to position HEAT for approximately 10 seconds until the corresponding warning li...

Page 70: ...e travel speed is switched over from high to low when the machine is travelling the machine may deviate to one side even if it is travelling straight Stop the machine before changing speed This is a t...

Page 71: ...the track gauge and pay the utmost attention during travel q Before using the blade adjustable track gauge lever check the position of the switch This is a two position switch and allows the operator...

Page 72: ...q When the windshield washer is in operation pay attention to the following Do not keep the switch pressed in spraying position for more than 10 consecutive seconds Do not press the switch to spray d...

Page 73: ...witch 10 is placed inside the engine compartment and the electrical current from the battery to the machine electrical system can be interrupted by turning the switch anticlockwise Always interrupt th...

Page 74: ...r Right work equipment control lever Accelerator lever Blade adjustable track gauge lever if provided Travel levers 7 8 9 10 11 12 1st boom swing control pedal locking device 1st boom swing control pe...

Page 75: ...fting the safety lever take care to avoid touching the equipment control levers This lever operates the safety device that locks the work equipment the swing and travel functions and the attachments W...

Page 76: ...g work and in case of danger q When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety lever control locking lever The control lever 2 is positioned on t...

Page 77: ...track gauge when the machine is working on a slope This may affect the lateral stability of the machine q Widen or narrow the track gauge with the machine resting on a firm and level surface and the...

Page 78: ...carrying out steering manoeuvres use the pedals with the maximum care q When leaving the operator seat always rotate the pedals to the rest position in order to avoid pressing them by mistake These l...

Page 79: ...g control pedal and has two positions F free L locked 8 Boom swing control pedal This pedal controls the boom swing to the right and to the left according to the movements indicated below a swing to t...

Page 80: ...e locked even if the lever is at the locking position To unlock tower rotation pull the lever fully up and turn it downwards IMPORTANT q Do not turn the upper tower when the lever is at the locking po...

Page 81: ...use serious injury Do not tilt or close the cab floor on slopes or if there is a strong wind To tilt or close the cab floor pull the lever to the free position F After tilting or closing the cab floor...

Page 82: ...4 1 WINDSCREEN machines with cab WARNING q When the upper windscreen or the cab door is opened or closed always take the safety device lever to the locking position L If the control levers are not lo...

Page 83: ...at the right or left top of the front windscreen and push the locking levers B down to release the windscreen 5 Seize the handles C and D pull up the windscreen and push it until the lock E is trippe...

Page 84: ...ground then stop the engine 2 Shift the safety lever to the locked position 3 Release the windscreen by means of the upper lock E lever 4 Seize the handles C and D push the windscreen forwards and lo...

Page 85: ...on a slope the operating effort may change suddenly Do not open or close the door on slopes q Be careful to your hands in order to prevent them from being caught between the door and the front or cen...

Page 86: ...lose the window release and draw the handle 1 to slide the window 3 2 4 4 EMERGENCY EXIT HAMMER machines with cab WARNING q When it is necessary to break the window with the hammer pay attention not t...

Page 87: ...nserted only partially into the lock it may break OPENING AND CLOSING THE COVERS WITH LOCK Opening 1 Insert the key into the lock 2 Turn the key counterclockwise and open the cover Closing 1 Close the...

Page 88: ...etely and make sure that it is kept open by the apposite rod q Non compliance with these rules may lead to serious accidents IMPORTANT q If it is not necessary to open the cover always keep it locked...

Page 89: ...tions are required inside the radiators compartment always open it completely OPENING THE BATTERY COVER 1 Release the radiator cover lock 1 see 3 2 5 COVERSWITH LOCK 2 Pull the radiator cover 2 and op...

Page 90: ...COVER When inspections and maintenance operations are required inside the battery housing remove the fixing screws 1 and completely remove the housing 2 After the inspections or maintenance operation...

Page 91: ...fter lifting the platform always attach the safety stop q Do not carry out any operation on the machine without having first attach the safety stop q If there is something wrong in the locking functio...

Page 92: ...in the direction of the arrow approximately 45 IMPORTANT q When tilting or closing the cab floor be extremely careful and keep away from the area under the cab floor NOTE q The cab floor tilts thanks...

Page 93: ...Pull the platform 5 downwards in the direction of the arrow approximately 45 IMPORTANT q Lower the cab floor slowly and make sure that the wires and pipes located under it are neither damaged nor twi...

Page 94: ...ter lifting the platform always attach the safety stop q Do not carry out any operation on the machine without having first attach the safety stop q If there is something wrong in the locking function...

Page 95: ...release lever 5 in the direction indicated by the arrow and at the same time push the handle 6 upwards in the direction indicated by the arrow approx 45 IMPORTANT q If the cab floor does not tilt pull...

Page 96: ...ng pin 7 is inserted in the groove 9 of the locking plate 8 9 Insert the safety pin 10 into the hole 11 from the outside 10 Turn until the coupling at the end of the safety pin 10 is completely engage...

Page 97: ...e same time 2 Pull the cab floor release lever 5 in the direction shown by the arrow and at the same time pull the handle 6 downwards in the direction indicated by the arrow approximately 45 IMPORTANT...

Page 98: ...g the same capacity Fuse capacity and circuits involved F1 F5 F6 F9 F10 F11 F7 F8 F2 F3 F4 RKA16520 RKA22790 POSITION COLOUR CAPACITY A CIRCUIT INVOLVED F1 Red 10 Radio power supply F2 Green 30 Supply...

Page 99: ...chine see 3 2 8 BATTERY COVER NOTE q The main fuse is the high capacity fuse installed to protect the electric components and the wiring 3 2 13 TECHNICAL DOCUMENTATION COMPARTMENT CAUTION q The use an...

Page 100: ...re starting the engine 1 Check the work equipment the cylinders the articulations and the pipes for damage wear excessive play If any anomaly is observed provide for the necessary repairs 2 Remove dir...

Page 101: ...bsolutely necessary Before checking the coolant level wait for the engine to cool down and check the expansion tank q Immediately after the engine has stopped the coolant is very hot and under pressur...

Page 102: ...fore checking the engine oil level wait approximately 15 minutes in order to allow the engine to cool down 1 Open the engine hood For details see paragraph 3 2 6 ENGINE HOOD 2 Remove the dipstick G an...

Page 103: ...gauge 2 If the fuel level is low open the engine hood 3 for details see 3 2 6 ENGINE HOOD remove the cap and refuel through the filler F While refuelling check the fuel level on the sight gauge G Tan...

Page 104: ...hat the oil level is included between the H and L marks on the sight gauge G IMPORTANT q Do not exceed the max level mark H This would damage the hydraulic circuit and cause the oil to overflow q If t...

Page 105: ...mp for leaks CHECKING THE AIR FILTER CLOGGING INDICATOR 1 Open the engine hood For further details see paragraph 3 2 6 ENGINE HOOD 2 Check if the red piston is visible in the transparent portion of th...

Page 106: ...er details see 4 9 1 d DRAINING THE FUEL TANK CHECKING THE WIRING SYSTEM WARNING q If the fuses are corroded oxidized or not perfectly held in their seat replace them only with fuses having the same c...

Page 107: ...CKING THE HORN 1 Turn the ignition switch to position ON 2 Press the button positioned on the right lever and make sure that the horn functions correctly If the horn does not sound contact your Komats...

Page 108: ...en carrying out deep digging operations make the seat slide forward to improve visibility on the lower area in front of the machine B Suspension In order to adjust the suspension turn the handwheel 2...

Page 109: ...apply a tightening torque of 24 5 4 9 Nm 2 5 0 5 kgfm If the surface of the belt is damaged or if the couplings are broken or deformed change the belt assembly Fastening and unfastening the seat belt...

Page 110: ...ition L NOTE q If the safety lever is in working position F the engine does not start up 2 Check the position of each lever 3 Turn the ignition key 2 to position ON and carry out the following checks...

Page 111: ...work light functions correctly If it does not function this may be due to a faulty bulb or to an interruption in the wirings therefore it is advisable to contact a Komatsu Dealer who will provide for...

Page 112: ...inals of the starter This may cause serious injury or even fires q Start the engine only while seated with fastened seat belt q Before starting the engine make sure that there is no one within the ope...

Page 113: ...NE AND RELATED CONTROLS WEAM009300 111 3 Turn the ignition key 3 to position START to start the engine 4 As soon as the engine starts release the key 3 which will automatically return to position ON R...

Page 114: ...ngine only while seated with fastened seat belt q Before starting the engine make sure that there is no one within the operating range of the machine and sound the horn q Never use starting aid fluids...

Page 115: ...omes on After approximately 10 seconds the warning light 4 goes out indicating that the preheating phase has been completed 4 When the preheating warning light 4 goes out turn the ignition key 3 direc...

Page 116: ...e warming up procedure correctly 3 3 3 1 RUNNING IN A NEW MACHINE CAUTION q Komatsu machines are adjusted and tested completely before shipment However operating the machine under severe conditions at...

Page 117: ...o let the engine idle accelerate every now and then or increase the speed up to an intermediate value After starting the engine let it warm up before starting work Carry out the operations and checks...

Page 118: ...warning light 7 warning light off 5 Make sure that the colour of the exhaust gases is normal and that there are no strange noises or vibrations If any anomaly is observed contact your Komatsu Dealer 6...

Page 119: ...recommended not to stop the engine suddenly if it has been running for a long period and is still hot in this case let the engine run at low idling speed for about 5 minutes in order to allow it to c...

Page 120: ...and make sure that there are no persons other equipment or obstacles in the way q Avoid any travel manoeuvre or change of direction with the accelerator at maximum speed since manoeuvres carried out...

Page 121: ...A to low B speed and vice versa The changeover from high to low speed or vice versa takes place whenever the switch is pressed When the machine is travelling at high speed the travel speed increase wa...

Page 122: ...the rear of the machine pull the levers 3 slowly backward to start moving in reverse When the sprocket A is at the front of the machine push the levers 3 slowly forward to start moving in reverse Mach...

Page 123: ...hine travels at high speed on soft ground or up a slope and the load increases the low speed is automatically selected but the travel speed increase warning light remains on When the load is reduced t...

Page 124: ...speed and the load increases the low speed is automatically selected and the machine slows down When the load is reduced the travel system automatically changes over to high speed Use the travel leve...

Page 125: ...o the left NOTE q To steer to the right operate the right travel lever in the same way HOW TO CARRY OUT COUNTER ROTATIONS SPIN TURN To carry out a counter rotation to the left pull the left travel lev...

Page 126: ...en the bucket is full pay the utmost attention and avoid abrupt movements 3 When the rotation function is not used place the tower parallel to the lower car then take the rotation locking lever 1 to t...

Page 127: ...to the neutral position and the work equipment remain in the position where they stopped The movements of the levers and the corresponding movements of the equipment are shown in the diagrams below q...

Page 128: ...ing control To swing the boom use the boom swing control pedal q Blade control Select the use of the blade with the blade adjustable track gauge selection switch To operate the blade shift the lever p...

Page 129: ...de adjustable track gauge switch to the track gauge adjustment position To adjust the track gauge shift the lever positioned to the right of the operator seat forward or backward IMPORTANT q If there...

Page 130: ...VEL FORCE OF THE MACHINE Do not dig the bucket into the ground and do not use the travel force to carry out digging operations This may damage the machine or the work equipment q PRECAUTIONS TO BE TAK...

Page 131: ...IT IS NOT ALLOWED TO EXPLOIT THE FORCE OF GRAVITY OF THE MACHINE Do not use the force of gravity of the machine to carry out digging operations When working on hard rocky surfaces use some other metho...

Page 132: ...right or to the left if one of the rubber tracks passes over obstacles such as big stones or logs or gets into a ditch or a hole In these cases lower the speed and take care to keep the machine balanc...

Page 133: ...the turret will be submerged and this may cause the cooling fan to break Be extremely careful when driving the machine out of water Do not immerse the machine in water beyond the permissible depth un...

Page 134: ...ravel lift the machine at about 20 30 cm from the ground Do not travel downhill in reverse q Do not change direction on slopes side movements must be carried out on level ground or with inclination no...

Page 135: ...will automatically engage the brakes WHEN THE ENGINE STOPS ON A SLOPE If the engine stops when the machine is travelling uphill shift the travel levers to the neutral position lower the bucket to the...

Page 136: ...et teeth The angle between the boom and the arm should be included between 90 and 110 When only one side gets stuck in mud use the bucket to raise the track then lay boards or logs under the track and...

Page 137: ...rom the machine to a 30 angle towards the machine There may be some differences depending on the digging depth but it is advisable to try to keep within the above range rather than operate with the cy...

Page 138: ...se the blade to fill excavations and level the ground surface For refilling operations widen the track gauge and the blade SIDE DITCHING WORK It is possible to use the machine for side ditching work i...

Page 139: ...ements q The described procedures are valid also for the coupling of the mechanical connections of the optional equipment 1 Position the bucket on level ground directing it so that the flat part of it...

Page 140: ...and thrust the work equipment into the ground to prevent the machine from moving q If the control levers are inadvertently touched the work equipment or the machine may move suddenly and cause seriou...

Page 141: ...RELATED CONTROLS WEAM009300 139 3 Lower the bucket keeping it in horizontal position until its bottom touches the ground 4 Lower the blade to the ground 5 Shift the safety lever 3 to the locked positi...

Page 142: ...and the undercarriage and make sure that there are no oil or coolant leakages If any anomaly is observed provide for the necessary repairs 2 Fill the fuel tank 3 Check the engine compartment for paper...

Page 143: ...s to take the necessary precautions for use and to avoid performing operations that are not allowed This will increase the life of the rubber tracks and will allow their characteristics to be fully ex...

Page 144: ...ith considerable differences in height When moving on obstacles or surfaces with considerable differences in height position the machine perpendicular to the obstacle to prevent the tracks from coming...

Page 145: ...ry to steer on a slope carry out this manoeuvre gradually 3 Do not proceed along the edges of a slope or on uneven ground keeping one track in horizontal position and the other inclined or partially r...

Page 146: ...re if the machine travels in reverse a gap forms between the carrier roller the idler roller and the rubber track The rubber track may come off also in the following conditions q When the machine stee...

Page 147: ...E AND RELATED CONTROLS WEAM009300 145 q If the machine travels in reverse in these conditions the rubber track will come off q If the machine steers in these conditions the rubber track will come off...

Page 148: ...d surface from collapsing q Before loading the machine remove any trace of mud and dirt from the tracks in such a way as to prevent the machine from slipping when it is on the ramps Make sure that the...

Page 149: ...ks under the trailer wheels to prevent it from moving The distance between the ramps and their alignment must be adapted to the wheelbase of the trailer and the track gauge Make sure that the two side...

Page 150: ...ing care to prevent them from touching the trailer 6 Make sure that the machine is in line with the ramps and that the centerline of the machine corresponds to the centerline of the trailer 7 Load the...

Page 151: ...nd remove the ignition key 4 Shift the safety lever to the locked position L 5 Lock the sliding door machines with cab and the covers with lock see paragraph See paragraph 3 2 5 COVERSWITH LOCK IMPORT...

Page 152: ...to the wheelbase of the trailer and the track gauge Make sure that the two sides are at the same distance The inclination of the ramps must not exceed 15 2 Remove the chains and the metal cables with...

Page 153: ...de 8 Lift the work equipment make sure that the travel direction is in line with the ramps and start travelling slowly Lower the work equipment as much as possible without causing interferences When t...

Page 154: ...machine using the holes provided in the undercarriage since these must be used only for transporting the machine This would damage the undercarriage IMPORTANT q For details on the weight of the machin...

Page 155: ...e sure that the space around the operator seat is clear then get off the machine 7 Install shackles in the lifting holes on both ends of the blade 2 points then pass the metal cables through them NOTE...

Page 156: ...g the machine Do not lift the machine with swung boom or turret q Pay attention to the pipes and take care that they do not get caught 9 During the lifting operations the angle between the metal cable...

Page 157: ...r the skin In case of contact with the eyes or the skin wash with plenty of running water and consult a doctor without delay q The coolant containing antifreeze is flammable do not smoke and do not us...

Page 158: ...ity of the battery decreases accordingly If the battery charge is low the electrolyte may freeze Keep the battery charge level as high as possible and insulate the battery against excessively low temp...

Page 159: ...the fan there is a radiator that transfers heat to the air sent into the cab it is used during the cold season and receives the hot water necessary for exchange heat directly from the engine cooling...

Page 160: ...osition it on wooden boards to prevent the tracks from freezing on the ground which would make it extremely difficult to start the machine the following morning q Open the drain valve and drain the wa...

Page 161: ...hments 3 6 2 DURING A PERIOD OF INACTIVITY WARNING q If it is necessary to carry out a rust prevention treatment while the machine is kept indoors open doors and windows to increase ventilation and av...

Page 162: ...t used for a long period more than 1 month strictly observe the following instructions q Disconnect the terminal from the battery negative lead and cover the battery or turn the battery main switch an...

Page 163: ...ered with no load the bucket speed drops momentarily according to the more or less horizontal position of the bucket teeth q When the swing is operated or locked the brake valve emits a noise q When t...

Page 164: ...o not smoke and avoid producing sparks near the battery q The battery electrolyte is made of diluted sulphuric acid that may corrode clothes and even the skin in case of contact with this fluid immedi...

Page 165: ...attery from the machine position it in a well ventilated place and remove the caps before proceeding q Immediately change any damaged caps q Set the voltage of the battery charger so that it correspon...

Page 166: ...he clamps with each other or with the machine frame IMPORTANT q The booster cables and the clamps must be sized according to the dimensions of the battery q The battery to be used to start the engine...

Page 167: ...OOSTER CABLES When the engine has started remove the cables in the reverse order with respect to their connection 1 Remove the clamp of booster cable B from the engine block of the machine to be start...

Page 168: ...o out even with engine running Faulty alternator Faulty cables Change Check and repair Alternator emits abnormal noise Faulty alternator Change Starter does not turn with ignition switch in position O...

Page 169: ...l pressure warning light comes on Oil level in oil pan too low air sucked in Oil filter clogged Oil leakage due to damage or incorrect tightening of oil pipes or joints Engine oil pressure sensor faul...

Page 170: ...EM Adjust valve clearance Exhaust gases white or light blue Too much oil in oil pan Unsuitable fuel Restore level See CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE Change with fuel in compliance...

Page 171: ...MAINTENANCE 169...

Page 172: ...nd changing filters soon after work is dangerous wait for the engine to cool down to a safe temperature of 40 45 C If it is necessary to drain the oil when it is cold warm it up to a suitable temperat...

Page 173: ...roethylene to clean it Trichloroethylene reduces the resistance and duration of the tank q Before starting work on muddy ground under rain or snow on seashores or river banks check the tightening of v...

Page 174: ...k of the degree of pollution of the oil 3 periodical change q When changing the oil change also the filters q It is advisable to have the oil periodically analysed in order to check the conditions of...

Page 175: ...ation according to the mini mum atmospheric temperature For concentration see 4 4 1 COOLANT q The coolant containing antifreeze is flammable do not use naked flames near the coolant and do not smoke w...

Page 176: ...many problems KOWA ANALYSIS STAGES q Analysis of metal particles In this stage a ICP Inductively Coupled Plasma analyser is used to measure the density of the metal particles present in the oil q Meas...

Page 177: ...vent any impurities from getting into the oil fuel or in the air circuits thus avoiding problems to important components of the machine Periodically change all the filters For further information see...

Page 178: ...ntenance operations required for the hydraulic system are the following 1 Daily check of the oil level in the tank 2 Periodical change of the oil filter 3 Periodical change of the oil and cleaning of...

Page 179: ...ate also the machine serial number to the Komatsu Dealer in or der to receive the most updated version of the component required 4 3 1 LIST OF THE PARTS SUBJECT TO WEAR The parts between parenthesis m...

Page 180: ...Y l 1st filling Change Engine oil pan OIL API CD 3 6 3 3 Travel reduction gears 0 3 0 3 Hydraulic system 23 8 15 2 e Hydraulic system with biodegrada ble oil See par 4 4 1 23 8 15 2 Fuel tank DIESEL O...

Page 181: ...pes Oil change quantity quantity of oil necessary to fill the system or unit during the normal inspection and mainte nance operations ASTM American Society of Testing and Materials SAE Society of Auto...

Page 182: ...engine the trans missions the braking system etc q Before introducing biodegradable oil in the hydraulic system drain the system completely disconnect ing the cylinders and all the parts that may con...

Page 183: ...TANT q This tightening torque table is not valid for screws or nuts that must fasten parts made of nylon or simi lar materials onto washers or components made of nylon or nonferrous metals or requirin...

Page 184: ...a hose always use Komatsu original spare parts having the same size of the part to be replaced a Nm Newton metre 1 Nm 0 102 kgm RKA12600 a Thread diameter a Wrench size mm TIGHTENING TORQUE kgm Nm 9...

Page 185: ...E PLAN q The type of lubricant to be used is indicated in the lubricant table see 4 4 FUEL COOLANT AND LUBRI CANTS 1 10 9 8 2 7 6 5 4 3 15 16 17 18 21 12 11 13 500 h 1 22 1 2 10 h 2000 h 13 1000 h 14...

Page 186: ...the time interval prescribed for their change has not elapsed yet If the pipe clamps show signs of deterioration like deformations or cracks provide for changing them together with the pipes In additi...

Page 187: ...el pipe fuel pump fuel filter 1 4 Fuel pipe fuel filter injection pump 1 5 Fuel pipe fuel filter fuel tank 1 6 Fuel return pipe fuel filter injection pump 1 7 Fuel return pipe between the nozzles 2 8...

Page 188: ...which synthetic biodegradable oil type HEES is used a CHANGING THE HYDRAULIC OIL FILTER 212 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION Only for machines in which synthetic biodegradable oil ty...

Page 189: ...ns given in the table on the right If the machine contains synthetic biodegradable oil type HEES the filter must be changed after the first 50 hours of operation 4 8 2 b CHANGING THE HYDRAULIC OIL Cha...

Page 190: ...tails see para graph 3 2 6 ENGINE HOOD 2 If the red piston of the filter clogging indicator 1 is visible clean the air filter cartridge IMPORTANT q Do not clean the cartridge if the red piston of the...

Page 191: ...tridge is damaged change it 7 Remove the cloth or adhesive tape used to cover the air connector inside the filter body 8 Install the cleaned cartridge 4 or a new cartridge 9 Position the cap 3 with th...

Page 192: ...g the battery housing see 3 2 8 BATTERY COVER A visual indicator 2 signals with different colours the battery charge level according to the table next to the indicator Green optimal charge Gray the ba...

Page 193: ...ighten the metal ring 2 7 Turn the valve 1 of the water separator to the open position B and bleed the air by proceeding as indicated below IMPORTANT q When removing the water separator take care not...

Page 194: ...t be drained before refuelling q Never use trichloroethylene to wash the inside of the tank Use exclusively diesel oil 4 9 1 e CHECKING AND ADJUSTING THE STEEL TRACK TENSION The pins and bushings of t...

Page 195: ...ct your Komatsu Dealer WARNING q If the resistance met when injecting the grease is excessive move the machine forward and backward covering a short distance To increase the track tension proceed as f...

Page 196: ...q The degree of wear of pins and bushings varies depending on the work conditions and on the characteristics of the ground It is therefore necessary to check the track tension fre quently in order to...

Page 197: ...RUBBER TRACK TENSION IMPORTANT q If the track tension is such that the track may come off its seat the track may be lengthened and the track tensioner cylinder damaged 6 If the broken area between th...

Page 198: ...e the machine forward of a distance corresponding to the length of the track on the ground then lower the equipment to the ground and stop the engine 2 Choose a perfectly flat rod 3 long enough to cov...

Page 199: ...operation contact your Komatsu Dealer who will pro vide for the necessary repairs 1 Gradually loosen the grease valve 1 to let the grease out do not give the valve more than one turn 2 If the grease d...

Page 200: ...ck absorber of the idler roller This operation can be performed only by specialized personnel at any Komatsu Dealer REMOVING THE RUBBER TRACK DANGER q The grease contained in the hydraulic cylinder is...

Page 201: ...2 Gradually loosen the grease valve 1 to let the grease out do not give the valve more than one turn 3 If the grease does not come out smoothly move the machine slowly forward and backward covering a...

Page 202: ...locks 3 Turn the sprocket 1 as if in reverse then push the track to wards the turret 4 Using a steel tube 2 position the track and turn the sprock et again 5 Make sure that the track is correctly inst...

Page 203: ...ul to prevent dust from getting into the reservoir IMPORTANT q To fill the reservoir use only non flammable detergent of the type used for cars q Do not use the antifreezes used in engine cooling syst...

Page 204: ...ion for the ventilation of the cab is protected by a filter positioned on the right side of the cab This filter blocks all the impurities contained in the air and must be cleaned whenever a decrease i...

Page 205: ...ce it more often if you work in fairly critical environmental conditions It is also advis able to clean the windscreen regularly to remove any dirt grease or residue of any kind since they can hamper...

Page 206: ...indicator q Check the water separator q Check the wiring systems q Check the functionality of the horn 4 9 3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION Only for machines in which synthetic bio...

Page 207: ...THE COMPONENTS OF THE SWING SYSTEM NOTE q When injecting grease to lubricate the swing pinion and the ball bearing ring swing the turret slowly and grease every 90 1 Carefully clean the grease nipple...

Page 208: ...in 1 point 4 Bucket cylinder rod end 1 point 5 Link connection pin 1 point 6 Boom swing bracket pin 1 point 7 Boom base pin 1 point 8 Boom cylinder base pin 1 point 9 Boom cylinder rod end 1 point 10...

Page 209: ...oil that flows out of it into a container with suitable capacity While the oil flows out remove the filler cap F so that the oil can flow out freely 3 Screw the plug P onto the engine oil pan 4 Using...

Page 210: ...seal 6 Give the metal ring a further 2 3 turn IMPORTANT If the casing is tightened excessively the seal may be dam aged and cause fuel leakages Fuel leakages may also be due to insufficient tightenin...

Page 211: ...RICANTS 4 9 5 e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND OF THE EXCHANGER WARNING q If compressed air steam or water hit someone they may cause serious injury Always wear a visor and safety...

Page 212: ...ing the cab floor see 3 2 9 TILTING THE CAB FLOOR machines with canopy 1 The check is manual press the belt with a thumb on the intermediate point between the drive shaft pulley and the fan pulley wit...

Page 213: ...ollected and dis posed of according to the regulations in force 1 Turn the turret so that the lower part of the hydraulic oil tank is not covered by the tracks 2 Retract the arm and bucket cylinders c...

Page 214: ...is posed of according to the regulations in force CAUTION q On machines containing synthetic biodegradable oil type HEES this must be changed for the first time after the first 50 hours of operation a...

Page 215: ...MPORTANT q In machines equipped with breaker hydraulic oil deterio rates more rapidly than in machines used for simple dig ging operations On new machines change the filter after the first 100 150 hou...

Page 216: ...the elimination of any suspended solid particles 1 Move the machine until the drain plug P is in low position and perpendicular to the ground 2 Remove the drain plug P and let the used oil flow out co...

Page 217: ...lic oil is very hot and may cause burns let it cool down to 40 45 C before carrying out this maintenance operation q Immediately clean any area dirty with oil q Oils filters the coolant and the batter...

Page 218: ...lower flange 6 with the filter 7 checking the soundness of the gasket and the suction pipe 4 with the clamps 3 12 Fill with prescribed oil until reaching the level G Use only oil of the prescribed ty...

Page 219: ...eaches approximately 40 45 C before changing the coolant q Slowly loosen the radiator cap in order to release any residual pressure q Oils filters the coolant and the battery are considered special wa...

Page 220: ...radiator with new fluid see 4 4 FUEL COOLANT AND LUBRICANTS 6 Start the engine and let it run at high idling speed for a few minutes check the level again and top up before putting back the upper cap...

Page 221: ...TECHNICAL SPECIFICATIONS 219...

Page 222: ...kg 1590 Bucket capacity m3 0 044 Engine Komatsu 3D67E 2A diesel engine Engine power KW HP rpm 11 2 15 2600 A Total length mm 3380 B Total height mm 2320 C Total width mm 1000 D Track width mm 230 E S...

Page 223: ...gging depth mm 2000 C Max digging height mm 3285 D Max vertical wall digging depth mm 1450 E Max dumping height mm 2295 F Work equipment min swing radius mm 1485 Work equipment min swing radius with b...

Page 224: ...xceed 87 of the hydraulic lifting capacity or 78 of the tipping limit Load limited by the hydraulic lifting capacity and not by the tipping limit ROPS CANOPY STANDARD ARM STANDARD COUNTERWEIGHT LOWERE...

Page 225: ...180 0 5 m 970 864 579 452 389 300 270 221 234 203 1 0 m 698 698 434 434 293 293 227 227 1 5 m ROPS CANOPY STANDARD ARM ADDITIONAL COUNTERWEIGHT RAISED BLADE Unit kg 1 m 1 5 m 2 m 2 5 m 3 m 3 5 m Max...

Page 226: ...3 0 m 2 5 m 182 182 187 187 2 0 m 178 178 184 183 1 5 m 220 220 199 199 187 176 185 162 1 0 m 302 302 235 229 201 173 189 152 0 5 m 377 304 270 222 214 169 194 150 0 m 679 440 413 295 290 216 218 166...

Page 227: ...254 182 202 141 0 5 m 970 750 539 380 349 258 254 182 228 162 1 0 m 698 698 434 390 293 261 227 203 1 5 m ROPS CAB STANDARD ARM ADDITIONAL COUNTERWEIGHT LOWERED BLADE Unit kg 1 m 1 5 m 2 m 2 5 m 3 m...

Page 228: ...85 735 527 380 340 252 246 187 194 139 1 0 m 977 748 518 386 341 254 226 184 208 170 1 5 m 310 310 191 191 ROPS CAB LONG ARM ADDITIONAL COUNTERWEIGHT LOWERED BLADE Unit kg 1 m 1 5 m 2 m 2 5 m 3 m 3 5...

Page 229: ...AUTHORISED OPTIONAL EQUIPMENT 227...

Page 230: ...ling any equipment take the following precautions and be careful to ensure that operations are carried out in total safety q Carry out installation and removal on a firm and flat surface q When the op...

Page 231: ...g operations since they are particularly dangerous 1 Travelling downhill with lifted equipment 2 Crossing slopes transversally 3 Swinging the turret on slopes q When work equipment with overall dimens...

Page 232: ...the tool diameter q Measure referred to the tool length NOTE q Tools total weight with loaded material and any quick attachment should not exceed the value of the lifting capacity Total weight Bucket...

Page 233: ...NTS WEAM009300 231 6 2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6 2 1 POSITION OF THE DEVICES RKA23120 1 2 Quick couplers Selection valve 3 4 Optional equipment control pedal Pedal lo...

Page 234: ...iring the use of the hydraulic breaker Spool A completely rotated clockwise Width across face of square portion of spool A 9 mm 3 Optional equipment control pedal The pedal 3 controls oil delivery to...

Page 235: ...s 1 Stop the engine and move the hydraulic controls in all directions in order to release the residual pressures present in the circuits of the machine 2 Press the optional equipment control pedal to...

Page 236: ...fter starting the air sucked in by the cylinders may damage the piston gaskets 3 Slowly make all cylinders reach the end of stroke for 3 4 times 4 Press the optional equipment control pedal a dozen ti...

Page 237: ...g the breaker make sure that the spool of the selection valve 1 is completely rotated clockwise and resting against its retainer position b q When using the breaker shift the accelerator almost to max...

Page 238: ...pool of the selection valve 1 is completely rotated counterclockwise and resting against its retainer position a q For further details and other precautions to be taken when handling the equipment car...

Page 239: ...ORISED TOOLS CHARACTERISTICS 6 4 1 HYDRAULIC BREAKER WARNING q The hydraulic breaker is very noisy therefore always wear ear muffs when using it MAIN APPLICATIONS q Crushing rocks q Demolition work q...

Page 240: ...undercarriage more than necessary 3 When working on very hard materials it is important to avoid hitting the same point for more than 30 seconds Hit the same point for a few seconds and change positi...

Page 241: ...work do not use the hydraulic breaker with the bucket cylinder at the end of stroke but always leave a minimum space of 5 cm 1 Gathering or moving stones with the hydraulic breaker 2 Swinging the turr...

Page 242: ...009300 5 Levering with the tool after driving it into the material to be broken 6 Hitting the ground with the breaker bit 7 Lifting the machine by levering on the breaker bit with the bucket cylinder...

Page 243: ...with the breaker in the wrong position the breaker circuit will receive more grease than necessary As a result soil and sand may get into the hydraulic circuit and damage the hydraulic components whil...

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Page 246: ...2007 KOMATSU UTILITY EUROPE S p A All Rights Reserved Printed in Europe 12 2007...