Komatsu PC20R-8 Operation & Maintenance Manual Download

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TABLE OF CONTENTS

Page

3.7

PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1

PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.2

PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

TRANSPORTING THE MACHINE ON MOTOR VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1

LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.2

TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.10 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.1 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.11.4 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.13 USING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.13.1 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 106

3.13.3 DIGGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.13.4 CHANGING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.14 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.14.1 BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.14.2 DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

3.14.3 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

3.15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.15.1 OCCURRENCES THAT ARE NOT FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.15.2 HOW TO REMOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.15.3 AFTER THE FUEL HAS RUN OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.15.4 IF THE BATTERY IS DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.15.4.1

STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

3.15.5 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.15.5.1

ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.15.5.2

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.15.5.3

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Summary of Contents for PC20R-8

Page 1: ...03 and up 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...

Page 2: ......

Page 3: ...nance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval T...

Page 4: ...he message can be used even to indicate the risk of damage to the machine only This word is used when precautions are indicated which must be taken to avoid actions that may shorten the life of the ma...

Page 5: ...ns property or the machine if this has been tampered with by modifying the standard setting of the hydraulic system DANGER Before carrying out any electrical welding disconnect the battery and the alt...

Page 6: ...PORTANT The instructions regarding the authorized optional equipment are given in the relevant operation and maintenance manuals if the equipment is supplied by Komatsu Utility these publications are...

Page 7: ...ts potential yield and its func tionality will be shortly and untimely reduced Every new machine must be used carefully paying special attention to the following indications After the start let the en...

Page 8: ...harmonized standards of the European Community The plate provided with the mark is applied onto the front wall of the main frame on the left side kg kw kg kg MODELLO MODEL TYP MODELE MATRICOLA N SERI...

Page 9: ...e engine serial number is stamped on the plate positioned on the top of the engine cylinder head cover The exhaust gas emission plate is applied on the top of the en gine cylinder head cover RWAA10520...

Page 10: ...y 1 4 7 CAB SERIAL NUMBER RWA09980 The serial number of the swing reduction gear is stamped on the plate positioned on the swing motor head RWA09990 The serial number is stamped on the plate positione...

Page 11: ...CATION 9 1 4 8 SERIAL NUMBERS AND DEALER S ADDRESS Machine n Model Engine n Swing motor for PC20R only n Swing reduction gear for PC27R only n Cab n Dealer Address Tel Person to contact NOTES Travel r...

Page 12: ...10...

Page 13: ...1 4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY 27 2 1 5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 27 2 2 GENERAL PRECAUTIONS 28 2 2 1 GENERAL SAFETY RULES 28 2 2 2 SAFETY DEVICES AND GUA...

Page 14: ...EMOVAL 44 2 8 PRECAUTIONS FOR MAINTENANCE 45 2 8 1 WARNING PLATES 45 2 8 2 TOOLS 45 2 8 3 PERSONNEL 45 2 8 4 EQUIPMENT 46 2 8 5 WORKING UNDER THE MACHINE 46 2 8 6 CLEANING THE MACHINE 46 2 8 7 USE OF...

Page 15: ...EAT 78 3 5 1 ENGINE HOOD 78 3 5 2 RIGHT COUNTERWEIGHT 79 3 5 3 CANOPY 79 3 5 4 CAB 80 3 5 5 VENTILATION AND HEATING 83 3 5 6 SEAT 84 3 5 7 SAFETY BELT 84 3 5 8 EMERGENCY EXIT 85 3 5 9 TECHNICAL DOCUME...

Page 16: ...TAKEN IN THE WARM SEASON 104 3 13 USING THE WORK EQUIPMENT 105 3 13 1 ORGANIZING THE WORK AREA 105 3 13 2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS 106 3 13 3 DIGGING METHOD 107 3 13 4 CHANGING...

Page 17: ...THE FUEL TANK 137 4 7 1 c CHECKING THE ELECTRICAL SYSTEM 138 4 7 1 d CHECKING THE STEEL TRACK TENSION 138 4 7 1 e CHECKING THE RUBBER TRACKS 140 4 7 1 f CHECKING THE RUBBER TRACK TENSION 142 4 7 1 g...

Page 18: ...4 7 9 e DRAINING THE HYDRAULIC OIL TANK Only for machines in which the synthetic biodegradable oil type HEES is used 163 4 7 10 MAINTENANCE EVERY 1000 HOURS OF OPERATION 164 4 7 10 a CHANGING THE OIL...

Page 19: ...ALLATION OF THE DEMOLITION HAMMER BREAKER 185 6 2 1 DESCRIPTION AND CONTROL 185 6 2 2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED 185 6 2 3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 189...

Page 20: ...18...

Page 21: ...SAFETY AND ACCIDENT PREVENTION...

Page 22: ...water and detergent 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 wi...

Page 23: ...SAFETY NOISE AND VIBRATION PLATES 21 MACHINE WITH CANOPY RWA00010 RWA00030 RWA00020 RYA11890...

Page 24: ...he operation and maintenance of the machine must know the symbols contained in the pictograms perfectly the following description illustrates what they look like and their respective meanings RWA00020...

Page 25: ...IC SYSTEM WITH OIL REFUELLING ENGINE LUBRICATING OIL FILTER FUEL FILTER ENGINE AIR SUCTION FILTER ENGINE COOLANT RWA34380 BIO OIL Only for machines in which the synthetic biodegradable oil type HEES i...

Page 26: ...TY NOISE AND VIBRATION PLATES 24 ENGINE COOLANT PRESSURE HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER ELECTRIC OUTLET ANCHORAGE POINT EMERGENCY EXIT RWA00110 RWA00100 RWA00070 12 V RWA00120 RWA00200 RWA00...

Page 27: ...SAFETY NOISE AND VIBRATION PLATES 25 LIFTING POINT DO NOT LIFT MORE THAN 1000 kg RWA04920 1000 Kg RWA00210...

Page 28: ...rol 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 plate make sure that this pl...

Page 29: ...your Komatsu Utility Dealer In case of replacement of a component provided with a noise plate make sure that this plate is applied also on the new piece RYA11940 LWA 89 514 CE 95 27 CE This value indi...

Page 30: ...t see 3 5 7 SAFETY BELT Do not remove the safety devices and always keep them in good operating conditions Any improper use of the safety devices may result in serious injuries or even death RWA00960...

Page 31: ...or s seat even if temporarily make sure that the machine is in a safe position See 2 4 13 PARK ING THE MACHINE Before leaving the operator s seat carry out the following oper ations in the sequence in...

Page 32: ...oor if it is dirty with oil grease mud or rubble RWA05020 RWA00970 RWA00980 Fuel oil and some types of antifreeze can be easily ignited if they get in contact with a flame Fuel is particularly flammab...

Page 33: ...ol down The hot oil that can be sprayed out of the tank may cause serious burns RWA01000 RWA01010 Asbestos powder can be hazardous to your health if it is in haled If you handle materials containing a...

Page 34: ...e neces sary disinfectants bandages medicins etc It is necessary to know what to do in case of fire Make sure that you have the phone numbers of the persons or structures you may need to contact in ca...

Page 35: ...der to find out their exact positions or to make them ineffective until the end of the operations Be care ful not to sever or damage any of these lines Check the depth and flow of water before operati...

Page 36: ...haust gases can be deadly Remove any trace of dirt from the lights in such a way as to ensure perfect visibility on the work area Make sure that the working lights are installed as prescribed Make als...

Page 37: ...s positioned on the back of the machine the oper ation of the travel levers is inverted In this condition take care not to mistake the travel move ments during the use of the machine See 3 6 5 HOW TO...

Page 38: ...vers must be used during travel avoid moving them abruptly sudden manoeuvres change the attitude of the machine and make driving difficult When travelling on rough ground keep the speed low and avoid...

Page 39: ...opes It is advisable to go down or up to a flat place to perform these operations Do not travel on wet grass or thick layers of leaves if the ma chine moves obliquely in these conditions it may slip D...

Page 40: ...n It is particularly dangerous to swing on slopes when the bucket is full If these operations must last longer accumulate soil in such a way as to create a horizontal platform on which the machine can...

Page 41: ...o be done first in case of electrocution 5 Keep the phone number of the electricity company and of the nearest first aid station at hand If the work equipment gets accidentally entangled in the cables...

Page 42: ...and are not visible therefore proceed with care when clearing the snow When working in tunnels galleries under electric cables or other ducts air telephone lines and wherever the height is limited pr...

Page 43: ...teeth into the ground 2 Stop the engine 3 Put wedges or safety blocks under the tracks Always rest the work equipment on the ground if it is neces sary to park with raised arms make sure that the saf...

Page 44: ...and fas tened to the loading board and that they have the same length Position the ramps with a maximum inclination of 15 Make sure that the ramp surface is clean and there is no trace of grease oil s...

Page 45: ...rogen Hydrogen is highly explosive and can be easily ignited with small sparks or naked flames Before working with batteries stop the engine and remove the ignition key Avoid short circuiting the batt...

Page 46: ...chines or the cable Do not get astride the cable Remove the machine only as much as necessary to permit the required repairs Put wooden blocks between the towing cable and the machine body in order to...

Page 47: ...ditional warning tags also around the machine and in particular on the cab door handles RWA01310 RYA12300 1 Use only the tools provided with the machine and high quality tools suitable for the tasks t...

Page 48: ...ols or broken pieces are dan gerous because they may cause someone to slip or trip Al ways keep the machine and the work site clean and tidy To clean the machine use a pressurized jet of warm water or...

Page 49: ...ose clothes Periodically change the following parts which are important to prevent fires Fuel supply system fuel delivery and return pipes Hydraulic system main delivery pipes of the hydraulic pump Ev...

Page 50: ...oil tanks in properly ventilated place and avoid smoking When refuelling hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sparks du...

Page 51: ...he 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 If electrical welding operations are to be carried out o...

Page 52: ...pletely release the pres sures and the residual pressure present in the tank Small leakages from pipes under pressure and the resulting jets are extremely dangerous since they can perforate the skin a...

Page 53: ...e to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generated which are deposited on the filters and clog them...

Page 54: ...52...

Page 55: ...THE MACHINE AND ITS OPERATIONS...

Page 56: ...that it is directed towards the blade before engaging the antirotation lock Non compliance with these rules may result in serious damage The machine is provided with an upper structure antirotation lo...

Page 57: ...IEW OF THE MACHINE WITH CAB 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Lifting cylinder 7 Cab 8 Sprocket 9 Undercarriage 10 Revolving support 11 Idler roller 12 Track 13 Blade 14 Blade c...

Page 58: ...ACHINE WITH CANOPY 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Lifting cylinder 7 Canopy 8 Sprocket 9 Undercarriage 10 Revolving support 11 Idler roller 12 Track 13 Blade 14 Blade cylinde...

Page 59: ...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 1...

Page 60: ...0 h OFF OFF ON 1 2 3 RWA07100 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 hou...

Page 61: ...dicator 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 When the indicator is in the overheating...

Page 62: ...OFF LO HI 1 2 OFF 0 0 0 0 0 0 h OFF OFF ON 2 1 3 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...

Page 63: ...n 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 IMPORTANT If the warning light remains off when the ig...

Page 64: ...d alarm switch if installed 5 Revolving light switch if installed 6 Horn RYA12040 OFF LO HI 1 2 OFF 0 0 0 0 0 0 h OFF OFF ON 2 3 5 4 1 RYA12050 6 RWA07170 This is a two speed switch that operates the...

Page 65: ...Enables the instrument light circuit 2 Enables the working light circuit This is a rotary key switch with four positions marked by the fol lowing symbols OFF I START For the use of this switch see 3 6...

Page 66: ...64 INSTRUMENTS AND CONTROLS 6 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: ...ENTS 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 2 RYA12080 3 RYA12090 4 R...

Page 68: ...g of the engine cooling circuit Faulty alternator or worn out belt RWA07200 With the first click it operates the windshield wiper while with the second click with automatic return to the first it oper...

Page 69: ...ontrol 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: ...e equipment to the ground and lock the safety device then stop the engine The control lever 1 is positioned on the operator s left and con trols the arm and the upper structure rotation while the cont...

Page 71: ...ation to the right C Rotation to the right and arm folding D Rotation to the left and arm folding RWA07280 D A B C N N Neutral A Boom lowering and bucket folding B Boom lowering and bucket opening C B...

Page 72: ...nd the reverse gear according to the movements indicated N Neutral A Forward gear B Reverse gear IMPORTANT All movements are locked by shifting the safety device le ver to the lock position see pos 8...

Page 73: ...lowering B Blade raising RWA10010 A N B This lever serves to adjust the speed and power of the engine Idling position 1 Lever pushed completely forward Maximum speed position 2 Lever pulled completel...

Page 74: ...the lock position To lock the safety device raise the lever 8 which will automati cally shift to the lock position To unlock the safety device push the lever 8 downwards until engaging it in the check...

Page 75: ...or performing a counter rotation RWA08970 DANGER Always engage the safety lock 1 when it is not necessary to use this pedal when the machine is travelling and when it must be parked If the control ped...

Page 76: ...allel to the undercarriage During travel make sure that the upper structure is direct ed towards the blade if the upper structure is rotated by 180 the controls are inverted When the lever is in the l...

Page 77: ...5 Alternator speed increase solenoid valve 10 Brown 7 5 Engine stop solenoid 11 Brown 7 5 Working light IMPORTANT When changing a fuse make sure that the ignition key is in position If the fuses are...

Page 78: ...76 FUSES AND RELAYS 3 4 1 2 MAIN FUSE POSITION COLOUR CAPACITY A INVOLVED CIRCUIT 1 60 System main fuse RWA09020 1...

Page 79: ...r 4 Preheating relay 5 Solenoid excitation timer start 6 Solenoid excitation relay start 7 Safety relay The horn relay is positioned inside the right control box under the dashboard while the other re...

Page 80: ...ing out an inspection or maintenance operation inside the engine hood always engage the hood in the safety coupling in order to keep it open Non compliance with these rules may result in serious accid...

Page 81: ...5 1 ENGINE HOOD 2 Loosen and remove the screws 1 Use a 22 mm hexagon spanner 3 Rotate the lateral counterweight 2 to the maximum open ing position and lock it with the safety pin 3 ROTATING THE COUNTE...

Page 82: ...g and fixing it un der the cab roof The lower windshield can be removed and can be opened partially by sliding the windows to the right side These solutions are particularly useful during the summer s...

Page 83: ...7 Move the windshield to the correct position it will automatically fit in the upper locking seats To close the windshield repeat the opening procedure in the reverse order RWA09040 6 8 7 7 8 RWA09050...

Page 84: ...82 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 13 12 RWA09090 14...

Page 85: ...ort Air distribution is achieved by means of two fixed outlets 1 with adjustable capacity for the inner flow while the flow that has the function to defrost and defog the front window is achieved by m...

Page 86: ...slight movements in order to make sure that the lock pin is en gaged in its seat The adjustment of the degree of suspension is carried out with the snap lever 2 according to the operator s weight The...

Page 87: ...IMPORTANT Make sure that the hammer is always available and in the correct position inside the cab RYA12150 1 2 RWA05970 1 CAUTION The operation manual and the spare parts catalogue are integral parts...

Page 88: ...expects that he may need the fire extinguisher 1 on the machine he must install it by fixing it on the rear compart ment of the seat by means of the appropriate support RYA12170 1 CAUTION Periodicall...

Page 89: ...Further visual checks concern 9 the condition of the safety belt 10 the efficiency of the instruments and of the dashboard 11 the condition of the cab windows and the efficiency of the working lights...

Page 90: ...the safety locks of the equipment controls are in the correct position and there fore that the equipment cannot move suddenly and cause accidents The checks concern 1 the lock position of the safety d...

Page 91: ...s and the rule of the road Before starting the engine make sure that there is no one within the operating radius of the machine and sound the horn Before starting the engine turn the ignition key to p...

Page 92: ...ed according to the outside temperature and the recommended ratio is approximately 1 second for each degree below zero The preheating is signalled by the warning light positioned on the dashboard 2 Tu...

Page 93: ...ed as follows 1 Release the safety device of the controls See 3 1 SAFETY LOCKS 2 Slowly extend and retract the arm and the bucket completely for several times 3 Lower the bucket to the ground and lock...

Page 94: ...work equipment is at least at 40 50 cm from the ground the control levers must be in the neutral position 1 Pull the accelerator lever and set the engine running at idling speed RYA12200 2 Operate th...

Page 95: ...onsiderable friction created when changing direction it is advisable not to use the speed increase pedal To turn to the left operate the RIGHT travel lever as indicated below To move FORWARD push the...

Page 96: ...ing that may suddenly modify the work con ditions and the stability of the machine 2 When it is necessary to travel downhill the bucket must al ways be directed downwards in the position indicated in...

Page 97: ...rking 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...

Page 98: ...provided 1 Park the machine on firm and level ground in a sufficiently wide space 2 Lower the blade and the bucket to the ground if there is not enough space the work equipment must be folded and se c...

Page 99: ...absence of natural obstacles rotate the bucket in the dumping position and thrust the teeth into the ground 2 Lower the blade to the ground 3 Engage the safety lock of the boom swing control of the o...

Page 100: ...en running for a long period and is still hot in this case let the engine idle for about 5 minutes in order to allow it to cool down gradually before stopping it Before stopping the engine proceed as...

Page 101: ...e between the ramps must be suitable for the machine gauge Position the ramps with a maximum inclination of 15 Remove any trace of oil grease or ice from the ramps and the loading board Do not change...

Page 102: ...ons 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 2 Keep...

Page 103: ...ion and engage the con trol pedal safety device 3 Shift the safety device lever to the lock position and stop the engine 4 Insert a metal or nylon rope in the two holes provided on the blade ends and...

Page 104: ...this mixture only during the winter and when changing the coolant in autumn or spring wash the cooling circuit see 4 7 1 WHEN REQUIRED 2 When it is necessary to calculate the antifreeze water ratio r...

Page 105: ...27 75 1 23 1 24 1 25 1 26 1 Before using the machine in normal operating conditions carry out some slow movements either forward and in reverse and operate all the work equipment cylinders slowly mor...

Page 106: ...PORTANT The coolant must be changed only if it is not permanent For the relevant specifications see 4 3 FUEL COOLANT AND LUBRICANTS 2 Make sure that the cooling fan belt is in good conditions 3 Make s...

Page 107: ...nd exploitment of the machine the operator must get to know the controls the described operating method and learn how to organize work in a free area while seated in the driving position If after a fi...

Page 108: ...e of an other operator 1 Center the machine with respect to the digging line IMPORTANT If this is not possible because it is necessary to dig along walls or banks swing the boom sidewards and position...

Page 109: ...ilitate the filling of the bucket and therefore increase productivity 4 he removal depth must be correct and suitable for the type of ground excessive depth may lock the move ments overload the engine...

Page 110: ...s The described procedures are valid also for the coupling of the mechanical constraints of the optional equipment 1 Position the bucket on a level surface directing it so that the flat part of its ba...

Page 111: ...les 3 Change all the filtering elements air cleaner engine oil filter hydraulic circuit filters diesel oil filter 4 Drain the coolant and replace it with a corrosion inhibitor permanent fluid 5 Drain...

Page 112: ...ed as follows 1 Release the exhaust pipe and the fuel tank from the seals 2 Check all the levels engine oil coolant fuel hydraulic circuit oil 3 Make sure that the battery is charged and install it on...

Page 113: ...tion of the bucket teeth more or less horizontal 3 When travelling down a steep slope at low speed a noise coming from the travel motor may be heard RWA06050 RWA06060 DANGER When removing the machine...

Page 114: ...e is made of diluted sulphuric acid that may corrode the clothes and even the skin in case of contact with this fluid immediately rinse the involved part with plenty of water If the acid gets into the...

Page 115: ...urrent load that must be transferred The battery to be used for the starting must have greater capacity or at least the same capacity as the battery of the machine to be started Make sure that the cab...

Page 116: ...repair Charge battery Change Starter pinion engages and then dis engages Battery charge insufficient Charge battery Starter makes engine run slowly Battery charge insufficient Faulty starter Charge ba...

Page 117: ...end of the scale Faulty instrument Change Engine coolant temperature indicator always on the left end of the scale Faulty thermostat Faulty instrument Change Change Engine does not start with starter...

Page 118: ...116...

Page 119: ...MAINTENANCE...

Page 120: ...s applied onto the machine Instructions for arc welding 1 Turn the ignition key to position 2 Disconnect the battery first the negative pole and then the positive pole 3 Disconnect the alternator 4 Do...

Page 121: ...nk 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 The combustib...

Page 122: ...ion gear oil for PC27R only SAE 10W API classification CD Fuel With ambient temperature over 10 C ASTM D975 no 2 diesel oil With ambient temperature under 10 C ASTM D975 no 1 diesel oil Radiator Perma...

Page 123: ...e work day When refuelling make sure that there is no water on the fuel drum cover and take care not to draw the conden sate from the drum bottom If fuel runs out or if the fuel filter has been replac...

Page 124: ...optional device to the fuses ignition switch battery relays etc for the installation of any optional equipment contact your Komatsu Utility Dealer If any electric welding operation has to be carried o...

Page 125: ...the machine Use only Komatsu Utility genuine parts which alone can guarantee excellent quality and interchangeability ITEM CODE DESCRIPTION Q TY CHANGE INTERVAL Hydraulic oil filter 848101172 Cartrid...

Page 126: ...tem OIL API CD 48 29 Hydraulic system with biodegrada ble oil SEE 4 3 1 48 29 Travel reduction gears ea OIL API CD 0 7 0 7 Fuel tank DIESEL OIL 35 Engine cooling system WATER ANTIFREEZE 4 WATER 4 PERM...

Page 127: ...ssification 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 t...

Page 128: ...r the en dothermic motor the transmissions the braking system etc Before introducing the synthetic biodegradable oil in the hydraulic system empty the system com pletely disconnecting the cylinders an...

Page 129: ...75 2 10 13 17 19 22 0 96 0 1 2 3 0 2 4 6 0 5 7 8 0 8 12 5 1 9 5 1 23 2 45 4 9 77 8 122 13 1 3 0 15 3 2 0 3 6 5 0 6 11 1 17 5 2 13 5 1 5 32 2 3 5 63 6 5 108 11 172 18 16 18 20 22 24 2 2 5 2 5 2 5 3 24...

Page 130: ...r 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...

Page 131: ...onents immediately in case of failures or anomalies even if the time interval prescribed for their change has not elapsed yet If the pipe clamps show signs of deterioration like deformations or cracks...

Page 132: ...always change the O rings the gaskets and analogous components No Components related to safety that periodically need changing Qty Change interval 1 Fuel pipe Fuel tank precleaner 1 Every 2 years or...

Page 133: ...be pe riodically changed When changing pipes always change the O rings the gaskets and analogous components No Components related to safety that periodically need changing Qty Change interval 1 Hydra...

Page 134: ...CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY 6 5 4 RWA33940 OPERATOR S SAFETY No Components related to safety that periodically need changing Q ty Change interval 1 Safety belt 1 Every 4 ye...

Page 135: ...djust the tension 138 e Rubber tracks Check 140 f Rubber tracks Check and adjust the tension 142 g Rubber tracks Change 144 h Air cleaner Check clean or change 146 N PART OPERATION PAGE a Hydraulic oi...

Page 136: ...RT OPERATION PAGE a Joint and ball bearing ring articulations Lubricate 153 N PART OPERATION PAGE a Travel reduction gears Change the oil 164 b Engine valves Check the clearance 169 N PART OPERATION P...

Page 137: ...EVERY 2000 HOURS OF OPERATION N PART OPERATION PAGE a Travel reduction gears Change the oil 164 N PART OPERATION PAGE a Hydraulic oil and suction filter Change the oil and clean the filter 165 b Coola...

Page 138: ...otate the right counterweight to the open position see 3 5 2 RIGHT COUNTERWEIGHT 3 With the fluid still warm open the drain cock 2 of the radi ator remove the drain plug 3 positioned on the engine blo...

Page 139: ...m mediately in order to prevent it from getting slippery and to avoid fires This operation serves to let all the impurities and the condensate flow out of the tank open the cock 1 at the base of the t...

Page 140: ...or who carries out the check and the adjust ment The track tension must be checked with the frame lifted from the ground be careful not to move any control lever while the operator is carrying out the...

Page 141: ...or change the pins and bush ings For any change or repair contact your Komatsu Utility Deal er To reduce the tension 1 Gradually loosen the greasing valve 1 to let the grease out do not give the valve...

Page 142: ...lipping increases and the advance power will decrease accordingly 1 Roller 2 Rubber track 2 When the steel reinforcement 3 can be seen on two or more points on the track 3 When more than a half of the...

Page 143: ...seat the track may be lengthened and the idler cyl inder may be damaged too 6 If the break between the support claws of the rubber tracks reaches a length 1 of approximately 60 mm the track must be r...

Page 144: ...k and the second roll er starting from the sprocket If the distance is included between 10 and 15 mm the ten sion is normal If the clearance exceeds the standard value adjust the ten sion and restore...

Page 145: ...valve 1 to let the grease out do not give the valve more than one turn Use a 19 mm hexagon spanner 3 If the grease does not flow out freely move the machine slowly forward and backward for a short di...

Page 146: ...due to the grease pressure and this is very dangerous for the operator Do not loosen any other component apart from the valve 1 When assembling or removing the track before rotating the sprocket make...

Page 147: ...rocket as if in reverse 1 pushing the outer edge of the track towards the upper structure 4 By means of a steel tube 2 position the track and rotate the sprocket again 5 Make sure that the rubber trac...

Page 148: ...ly strike the filtering element on the palm of your hand to remove the dust and blow compressed air on the inner sur face keeping the air jet at a distance of approximately 15 cm and making sure that...

Page 149: ...successive changes keep to the indica tions 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 operat...

Page 150: ...instruments and warning lights on the dashboard of the acoustic alarm of the working lights and of the horn The other general checks concern safety and precisely 6 soundness of the safety belt 7 soun...

Page 151: ...sate After refuelling tighten the filler cap 3 thoroughly and lock the tank RWA09890 OFF LO HI 1 2 OFF 0 0 0 0 0 0 h OFF ON 1 RWA09150 3 2 DANGER Soon after the machine has been stopped the engine is...

Page 152: ...en the MIN and MAX marks If the level is near the MIN mark top up by adding the pre scribed hydraulic oil see 4 3 FUEL COOLANT AND LUBRI CANTS through the filler 2 then put back the fillercap Use a 24...

Page 153: ...ay and do not smoke while draining the fuel If some fuel is accidentally spilt clean the dirty area im mediately The check can be carried out by means of the red ring 1 in stalled in the filter When t...

Page 154: ...r 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 Fo...

Page 155: ...syringe and the prescribed grease See 4 3 FUEL COOLANT AND LUBRICANTS IMPORTANT As a general rule it is important to consider that each cylinder is provided with two greasers posi tioned on the coupli...

Page 156: ...er head pin 1 point 10 Arm cylinder base pin 1 point 11 Arm cylinder head pin 1 point 12 Arm fulcrum pin 1 point 13 Bucket cylinder base pin 1 point 14 Lever fulcrum pin 1 point 15 Bucket cylinder hea...

Page 157: ...S OF OPERATION For the inspection and adjustment contact your Komatsu Utility Dealer The fan belt can be reached by opening the engine hood See 3 5 1 ENGINE HOOD The check is manual press the belt wit...

Page 158: ...mbient temperature See 3 11 3 BATTERY IMPORTANT It is advisable to add distilled water before starting work in order to prevent it from freezing Before putting back the cell plugs make sure that the b...

Page 159: ...rovided and throw it away 3 Clean the contact surface between the seal and the filter sup port lubricate the seal of the new filter and screw it until it touches the support 4 Give another half turn b...

Page 160: ...ulations in force Proceed as follows 1 Open the engine hood See 3 5 1 ENGINE HOOD 2 Remove the drain plug 1 of the oil pan gathering the used oil that flows out into a container with suitable capacity...

Page 161: ...oil The oil that may be spilled during the change makes the ground slippery therefore use anti slip shoes and immediately remove any trace of oil from the floor Oils filters the coolant and the batte...

Page 162: ...ean the sealing surface of the cover 4 and install the new filter in the container 3 install the O ring of the cover and smear it with some grease 4 Reassemble the whole unit open the fuel tap 1 and b...

Page 163: ...ng to the anti pollution regulations in force 1 Place a container under the precleaner 1 to gather the fuel 2 Shift the accelerator lever to the idling position 3 Remove the precleaner from the clamp...

Page 164: ...washing cycle the specific products available on the mar ket can be certainly used provided that the instructions given on the package are followed and that the washed parts are carefully dried at the...

Page 165: ...rm cylinder completely and lower the boom until the bucket teeth touch the ground 3 Lower the blade to the ground 4 Stop the engine and eliminate the residual pressures present in the equipment by mov...

Page 166: ...the machine on level ground at a temperature of 40 45 C so that the oil is more fluid and can be drained easily together with the suspended solid par ticles 1 Move the machine until the drain plug 1...

Page 167: ...e oil cool down until it reaches 4045 C before carry ing out any maintenance operation Immediately clean any area dirty with oil Oils filters the coolant and the battery are considered special waste a...

Page 168: ...ion pipe are in good conditions 9 Fill with the prescribed oil until reaching the correct level 7 Use oil of the prescribed type only See 26 FUEL COOL ANT AND LUBRICANTS 10 Open the engine hood and lo...

Page 169: ...n more than once in order to deaerate the system check the level again and top up if necessary CAUTION Do not start the engine with empty tank since this would certainly damage the pump IMPORTANT The...

Page 170: ...o eliminate any encrus tation See 4 7 1 a WASHING THE COOLING CIRCUIT 1 Open the engine hood See 3 5 1 ENGINE HOOD 2 Rotate the right counterweight to the open position see 3 5 2 RIGHT COUNTERWEIGHT 3...

Page 171: ...R Since the check and adjustment of the engine valve clearance require the use of special tools have these opera tions carried out by your Komatsu Utility Dealer For any inspection and or repair conta...

Page 172: ...170...

Page 173: ...TECHNICAL SPECIFICATIONS...

Page 174: ...HINE WITH CANOPY Dimensions with long digging arm L 1320 mm Steel tracks Rubber tracks 1340 1210 1400 2450 1430 1120 545 1240 4250 4320 290 RWA08760 300 310 300 250 Dimensions with long digging arm L...

Page 175: ...acity SAE m3 0 07 ENGINE Komatsu diesel engine model 3D78A 3FAE Maximum power 2600 rpm EEC 80 1269 kW 17 Maximum torque 1600 rpm EEC 80 1269 Nm 72 5 ELECTRICAL SYSTEM Alternator 12V Electrical output...

Page 176: ...WITH CANOPY Dimensions with long digging arm L 1500 mm Steel tracks Rubber tracks 1485 1510 1440 2490 1500 1200 300 585 1240 4525 4655 315 RWA08780 330 340 Dimensions with long digging arm L 1500 mm S...

Page 177: ...acity SAE m3 0 08 ENGINE Komatsu diesel engine model 3D82A 3FAE Maximum power 2600 rpm EEC 80 1269 kW 19 Maximum torque 1600 rpm EEC 80 1269 Nm 81 5 ELECTRICAL SYSTEM Alternator 12V Electrical output...

Page 178: ...n firm level ground Rating over front Rating at maximum reach Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 3 m 2 m...

Page 179: ...on firm level ground Rating over front Rating at maximum reach Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity C B A 3 m 2 m...

Page 180: ...t Rating at maximum reach Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity Rating over side C B A kg L Bucket width L 400mm B...

Page 181: ...nt Rating at maximum reach Load is limited by hydraulic capacity rather than tipping A Reach from swing center B Bucket hook height C Lifting capacity Rating over side C B A kg L Bucket width L 400mm...

Page 182: ...180...

Page 183: ...AUTHORISED OPTIONAL EQUIPMENT...

Page 184: ...ilure to comply with this rule Komastu Utility declines any responsibility for accidents or damage DANGER When removing or installing any equipment take the following precautions and be careful to the...

Page 185: ...ot to perform them 1 Travelling downhill with raised work equipment 2 Transversal crossing of slopes 3 Rotation of the upper structure on slopes RWA07850 WRONG RWA05150 WRONG RWA06820 WRONG When insta...

Page 186: ...eaning bucket 40 1300 0 050 Ditch digging bucket 55 950 0 075 Clamshell bucket 70 275 1000 0 025 210 24 Hydraulic hammer 150 950 140 35 Drill 90 250 1500 210 35 Specific weight of the handled material...

Page 187: ...delivery circuit left side the oil flow is interrupted and the hammer is thus stopped by releasing the pedal To use the demolition hammer make sure that the control of the selection valve 2 is complet...

Page 188: ...dercarriage more than necessary 3 When working on very hard materials it is important not to keep hitting the same point for more than 30 seconds Hit the same point for a few seconds and change positi...

Page 189: ...ork 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 1 Gathering or moving stones with the demolition hammer 2 Rotating the...

Page 190: ...tal position or even with greater inclination 5 Lever with the tool after thrusting it into the material to be bro ken 6 Hitting the ground with the hammer bit 7 Lifting the machine by levering on the...

Page 191: ...ints of the bucket as described in 3 13 4 CHANGING THE BUCKET and to carry out the hy draulic connections using the pipes provided After connecting the mechanical constraints carry out the hydraulic c...

Page 192: ...in all directions in order to completely release the residual pressures present in the circuits of the machine 2 Press the hammer control pedal to release the residual pressure present in the hammer...

Page 193: ...e oil necessary for the opera tion of the equipment are also provided as a fixed installation and reach the coupling RYA12280 1 RWA09400 2 This is a three way valve and is used to change the direction...

Page 194: ...the pedal is pressed in B with the selection valve 1 con trol in B high pressure oil is conveyed to the equipment through the right piping 4 3 If the circuit is arranged for the use of equipment with...

Page 195: ...traints carry out the hy draulic connections by proceeding as follows 1 Stop the engine and move the hydraulic controls in all direc tions in order to completely release the residual pressures present...

Page 196: ...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...

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Komatsu PC20R-8, Operation & Maintenance Manual

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