PDF Operation & Maintenance Manual Komatsu PC15R-8 Hydraulic Excavator - 1 MB
This Operation & Maintenance Manual is the complete guide for the Komatsu PC15R-8 Hydraulic Excavator (serial numbers F21803 and up).
It provides operators with detailed instructions on proper machine operation, safety protocols, and all scheduled maintenance tasks.
Following this manual is the best way to ensure the excavator's reliability and long service life.
It is an essential document for both new and experienced operators.
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--- Page 3 ---
CONTENTS
Page
CONTENTS
1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 INFORMATION ON SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 INTENDED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 IMPROPER OR UNAUTHORIZED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 MAIN CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.4 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.6 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 POSITION OF THE SAFETY PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.2 POSITION OF THE PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.1 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.2 SAFETY DEVICES AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.4 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2.5 LEAVING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2.6 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.8 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . 41
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.1 SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.2 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . 43
2.3.4 ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES . . . . . . . . 44
10
--- Page 4 ---
SAFETY PLATES
1.
• Warning Decal.
WARNING
Improper operation and main-
tenance can cause serious
injury or death.
Read manual and labels be-
fore operation and mainte-
nance.
Follow instructions and warn-
ings in manual and in labels
on machine.
Keep manual in machine cab
near operator.
Contact Komatsu distributor
for a replacement manual.
RWA16810
2.
• Height Decal DANGER
Hazardous voltage hazard.
Serious injury or death can
occur if machine or attach-
ments are not kept safe dis-
tance away from electrical
lines.
Line Voltage Safe Distance
6.6 kV At least 10ft (3m)
66.0 kV At least 16ft (5m)
275.0 kV At least 33ft (10m)
RWA24350
20
--- Page 5 ---
SAFETY PLATES
22.
• Lubricating diagram
2000 h
1000 h
250 h
100 h
50 h
10 h
RWA32680
23.
• Swing circle and swing pinion lubricating
RWA32690
30
--- Page 6 ---
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
• Do not jump on or off the machine, either when it is at rest and
when it is moving.
• When getting on or off the machine, always use the handles
and the tracks; get on and off the machine very carefully.
• Never hold or rest on the control levers.
• Either when getting on and when getting off the machine, al-
ways maintain three points of contact (holding or resting points),
in order to avoid losing your balance and falling down.
• Tighten the handle connection screws if they are loose and RWA05010
clean the handles and tracks if they are dirty with oil or grease.
Carefully clean the cab floor if it is dirty with oil, grease, mud or
rubble.
RWA05020
2.2.7 PREVENTING FIRES DUE TO FUEL
AND OIL
Fuel, oil and some types of antifreeze can be easily ignited if they
get in contact with a flame. Fuel is particularly flammable and
therefore extremely hazardous.
• Keep any naked flame away from flammable fluids.
• Stop the engine and do not smoke when refuelling.
• Top up with fuel and oil only after stopping the engine and in
well ventilated areas.
RWA00970
• Top up with fuel and oil in a well delimited area and do not allow
unauthorized persons to approach.
• 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 due to static electricity.
• After topping up, tighten the fuel and oil safety caps securely.
• Do not fill the tank completely, in order to leave room for the fuel
to expand.
• In case some fuel is spilled, wipe it up immediately.
RWA00980
40
--- Page 7 ---
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.9 VISIBILITY
• Switch on the working lights as soon as visibility decreases.
• If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the
weather to improve until visibility becomes acceptable.
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES
• If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sidewards, therefore
it is advisable to move at low speed and to avoid abrupt starts, stops or turns.
• When it has snowed heavily, the road shoulders and any obstacle are buried in the snow and are not visible,
therefore proceed with care when clearing the snow.
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
• When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the
height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.
2.4.12 WORKING ON LOOSE GROUND
• Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.
These areas may collapse, making the machine fall down or tip over and this could result in serious injuries or
death.
Remember that after heavy rain or earthquakes these dangerous conditions usually get worse.
• The earth laid near ditches is loose and can easily collapse due to the weight or vibrations of the machine.
Be extremely careful: always fasten the safety belt and close the cab door, if provided.
• In case of work in areas where stones or other material may fall on the machine, install the FOPS protection de-
vice.
50
--- Page 8 ---
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.15 HANDLING HIGH-PRESSURE PIPES
• Do not bend high-pressure pipes or rub them with abrasive or cutting objects.
Do not use any bent or cracked pipes or hoses that were previously rejected because of leaks or fastening de-
fects, since they may burst during use.
• Always repair or replace any loose or faulty fuel or oil pipe. Any leakage of fuel or oil may cause fires.
2.8.16 PRECAUTIONS TO BE TAKEN WHEN DANGEROUS!
HANDLING HIGH-PRESSURE OIL
• Do not forget that the work equipment circuits are always under
pressure; for this reason, when it is necessary to add or drain
hydraulic oil or to perform maintenance operations or inspec-
tions on the hydraulic circuit, it is advisable to lower the equip-
ment to the ground and completely release the pressures 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 and
penetrate in the blood circulation or injure the eyes. RWA01480
For this reason, always wear goggles and thick gloves during
the inspections and use a piece of cardboard or a sheet of ply-
wood to check for oil leakages. CORRECT
If you are hit by a jet of high-pressure oil or are injured, even if
slightly, immediately consult a doctor.
RWA01580
2.8.17 PRECAUTIONS FOR MAINTENANCE
OPERATIONS AT HIGH TEMPERA-
TURES AND HIGH PRESSURE
• When the machine is stopped at the end of operations, the en-
gine coolant, the oil and all the components are hot and the hy-
dralic circuits are under pressure.
In these conditions, if the coolant, the hydraulic oil and the en-
gine oil are to be drained in order to change them or the filters,
there are serious risks of damage and burns.
Wait for the temperature to lower within the normal operating
range 40-45°C (104-113°F) before carrying out the mainte- RWA00990
nance operations in accordance with the procedures indicated
in the relevant sections of this manual).
60
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INSTRUMENTS AND CONTROLS
3- GENERATOR WARNING LIGHT
This warning light comes on when the starting circuit is ener-
gized and goes out when the engine exceeds the idling speed; if
this warning light remains on even when the engine is running at
the normal operating speed, this means that the alternator does
not work and the battery is not charged correctly.
☞ IMPORTANT
• If the warning light remains off when the ignition key is
turned to position «I», this means that the alternator is
RWA07150
faulty or broken.
4- PREHEATING WARNING LIGHT
This warning light comes on when the ignition key is turned to
position « » to start the engine at low temperatures.
(See “3.6.2.2 Starting with cold engine or in cold climates”).
RWA07160
70
--- Page 10 ---
INSTRUMENTS AND CONTROLS
6- BLADE CONTROL LEVER
WARNING
• Before moving the machine, make sure that the blade is
completely raised. A
This lever controls the raising and lowering of the blade accord- N
ing to the movements indicated.
N - Neutral B
A - Blade lowering RWA07320
B - Blade raising
CAUTION
• On machines with variable track gauge this lever is used
also to widen or narrow the track gauge.
The control is enabled by means of the push button posi-
tioned on the left joystick lever.
For its use, see ”3.3.3 pos. 7 VARIABLE TRACK GAUGE
CONTROL PUSH BUTTON”. A
• Carry out the track gauge widening or narrowing opera-
tions with the machine resting on firm and level ground N
and with the tracks raised from the ground, in order to
avoid damaging the shoes and the hydraulic motors. B
RWA28860
With pressed button, the lever controls the widening and narrow-
ing of the track gauge according to the movements indicated.
N - Neutral
A - Track gauge widening
B - Track gauge narrowing
7- ACCELERATOR LEVER
This lever serves to adjust the speed and power of the engine.
• Idling position (1):
Lever pushed completely forward. 1
• Maximum speed position (2):
Lever pulled completely backward.
Use the accelerator lever with care, especially when the ma- 2
chine is under strain or is working in difficult conditions. Avoid
any useless acceleration, in order to reduce consumption and
extend the life of either the engine and the machine. RWA07330
80
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GUARDS AND DRIVER’S SEAT
3.5.3.2 FRONT OPENING WINDSHIELD
8
CAUTION
• When opening or closing the front windshield, be careful
9
not to crush your hands. 7
Always hold the handles firmly with both hands until the
windshield is completely opened or closed. 9
• When the front windshield is open, make sure that the
lock engages with the rear coupling. 10
• When closing the front windshield, seize the handles with RWAA9320
both hands and move it slowly until the lock engages.
• Before opening the front windshield (7), disconnect the wind-
shield wiper connector (10) positioned on the right inner side
of the cab.
☞ IMPORTANT
• If the front windshield is opened without disconnecting
the connector (10), the wiring that supplies power to the 10
windshield wiper motor will certainly be torn.
• After pressing the lever (8), open the windshield (7) with the RWAA9460
handles (9) while pulling and lifting the windshield.
Move the windshield (7) to the correct position, so that it auto-
matically couples with the upper retaining seats.
To close the windshield, carry out the same operations in the
reverse order, after pressing the lever (11).
8
RWAA9390
11
RWAA9380
90
--- Page 13 ---
USE OF THE MACHINE
3.6.2.2 STARTING WITH COLD ENGINE OR IN
COLD CLIMATES
WARNING
• Do not use any fluid or product that facilitate the cold
starting of the engine, since these are ether-based and
may cause explosions.
1 - Pull the accelerator lever until reaching half of its stroke and
turn the ignition key to the preheating position « » for maxi- RWA06010
mum 15 seconds in the coldest weather.
The preheating time is determined 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 - Turn the ignition key to position « » (START) until the en-
gine starts and for maximum 15 seconds.
4 - As soon as the engine starts, release the ignition key, which
will automatically return to position « » and reduce the speed
to idling.
☞ IMPORTANT RWA01990
• If the engine does not start at the first attempt, repeat the
operations 1 and 2 after waiting for at least 1 minute, in or-
der not to overload the battery.
RWA01970
RWA07360
100
--- Page 14 ---
TRANSPORTING THE MACHINE ON OTHER VEHICLES
3.9.2 TRANSPORT
1 - Check the overall dimensions; the height, width and weight of the means of transport - machine included -
must be compatible with the road and any tunnel, subway, bridge, electric or telephone line that may be found
on the way.
2 - Keep to the regulations in force regarding signals, speed limits, road traffic, authorizations, etc.
110
--- Page 15 ---
USING THE MACHINE WITH VARIABLE TRACK GAUGE
3.14.2 ADJUSTING THE BLADE
1
The machine with variable track gauge is equipped with adjust-
able blade and the positions available are two:
A -Standard position
Blade width: 1000 mm (40 in)
1000 (3'3")
RWA32870
B -Max. extension position: 1
Blade width: 1320 mm (52 in)
1320 (4'4")
RWA32880
The blade width can be modified by proceeding as follows:
1 - Stop the machine on a level surface, lower the equipment to
the ground and stop the engine.
2 - Remove the bolts (1) that fasten the extensions positioned at
the blade ends.
3 - Invert their positions, right extension on the left side and left
extension on the right side, put back the fastening bolts and
tighten according to the prescribed driving torque (see ”4.4.1
STANDARD DRIVING TORQUES”).
RWAA9330
1
1
RWAA9340
120
--- Page 16 ---
GUIDE TO MAINTENANCE
4.1 GUIDE TO MAINTENANCE
• Before opening the engine hood, engage all the safety locks and stop the engine.
• If it is necessary to check the oil level in the hydraulic tank, retract the bucket and arm cylinders completely and
lower the bucket teeth to the ground.
• Carry out any operation on firm and level ground.
• Use Komatsu genuine oils and greases; choose oils suitable for the ambient temperature.
• Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils
and greases.
• Always keep the machine clean. This makes it easier to find out any part causing troubles.
In particular, keep the grease nipples, the breathers and the areas near the openings for the level checks clean
and prevent any impurities from getting into/on them.
• Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down
until reaching at least 40-50° C (104-122°F).
• When changing the oils or the filters, check if metal particles are present. If you find large quantities of metal
particles, contact your Komatsu Dealer.
• Check and change the oil in a clean place and prevent any impurities from getting into the tank.
• Before carrying out any maintenance operation, hang the warning plates on the ignition switch, the control le-
vers and the cab door, if the machine is provided with cab, in order to prevent anyone from starting the engine
by mistake.
• When performing maintenance operations, always take the precautions indicated on the safety plates 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 not apply more than 200V continuously.
5 - Connect the earth cable within 1 m from the point in which the welding must be carried out.
6 - Avoid placing gaskets and bearings between the welding area and the earth cable.
• Do not use flammable fluids to clean the machine parts. Keep naked flames or lit cigarettes away from these
fluids.
• When O-rings and gaskets are removed, clean the sealing surfaces thoroughly and replace the O-rings and
gaskets with new ones. Fit the O-rings and gaskets correctly when reassembling.
• Avoid keeping loose objects or tools in your pockets: they may fall out and drop into the machine, especially
when you open covers and work on the machine while bending over it.
• When washing the machine, do not direct the high-pressure water jet onto the radiator and the heat exchanger.
• When washing the machine, protect the electric system connectors and avoid wetting the ignition switch.
• Before starting work in mud, under the rain, on seashores or river banks, carry out a general lubrication.
Wash the machine immediately after work to protect the components from rust. Lubricate the equipment joints
more frequently than usual.
• When working at dusty work sites, proceed as follows:
1 - Check the air cleaner for any clogging and clean it more frequently than usual.
2 - Clean the radiator and the heat exchanger frequently, to avoid any clogging of the fins.
3 - Change the diesel oil filter more frequently than usual.
4 - Clean the electrical components, especially the starter and the alternator, to avoid any accumulation of dust.
130
--- Page 17 ---
NUT AND BOLT TIGHTENING TORQUES
4.4 NUT AND BOLT TIGHTENING TORQUES
4.4.1 STANDARD TIGHTENING TORQUES
★ Nm (Newton metre): 1 Nm = 0.102 kgm (0.738 lb ft)
Thread wrench 8.8 10.9
Pitch
diameter size
(mm)
(mm) (mm) kgm Nm lb ft kgm Nm lb ft
6 1 10 0.96 ± 0.1 9.5 ± 1 7 ± 0.74 1.3 ± 0.15 13.5 ± 1.5 10 ± 1
8 1.25 13 2.3 ± 0.2 23 ± 2 17 ± 1.5 3.2 ± 0.3 32.2 ± 3.5 24 ± 2.6
10 1.5 17 4.6 ± 0.5 45 ± 4.9 32 ± 3.6 6.5 ± 0.6 63 ± 6.5 47 ± 4.8
12 1.75 19 7.8 ± 0.8 77 ± 8 57 ± 5.9 11 ± 1 108 ± 11 80 ± 8
14 2 22 12.5 ± 1 122 ± 13 90 ± 9.6 17.5 ± 2 172 ± 18 127 ± 13
16 2 24 19.5 ± 2 191 ± 21 141 ± 15 27 ± 3 268 ± 29 198 ± 22
18 2.5 27 27 ± 3 262 ± 28 194 ± 21 37 ± 4 366 ± 36 270 ± 26
20 2.5 30 38 ± 4 372 ± 40 275 ± 30 53 ± 6 524 ± 57 387 ± 42
22 2.5 32 52 ± 6 511 ± 57 377 ± 42 73 ± 8 719 ± 80 531 ± 59
24 3 36 66 ± 7 644 ± 70 475 ± 52 92 ± 10 905 ± 98 668 ± 72
27 3 41 96 ± 10 945 ± 100 698 ± 74 135 ± 15 1329 ± 140 980 ± 103
30 3.5 46 131 ± 14 1287 ± 140 950 ± 103 184 ± 20 1810 ± 190 1336 ± 140
☞ IMPORTANT
• This driving torque table is not valid for screws or nuts that must lock nylon parts or alike onto washers
or components made of nylon or nonferrous materials.
4.4.2 SPECIFIC TIGHTENING TORQUES
ITEM DESCRIPTION kgm Nm lb ft
Engine Front support central screw 5.5± 0.5 54 ± 5 40 ±3.6
Rear support central screw 5.5 ± 0.5 54 ± 5 40 ±3.6
Engine supports Screws for fastening to the engine 6.5± 0.5 64 ± 5 47 ±3.6
140
--- Page 18 ---
MAINTENANCE PLAN
4.7.1.b DRAINING THE FUEL TANK
1
WARNING
• When draining the fuel tank, avoid spilling fuel, since this
may cause fires.
• If some fuel is accidentally spilled, clean the dirty area im-
mediately, in order to prevent it from getting slippery and
to avoid fires.
This operation serves to let all the impurities and the condensate RWA06360
flow out of the tank; open the cock (1) at the base of the tank and
wait until clean fuel flows out.
☞ IMPORTANT
• The tank must be drained before starting the engine, with
temperatures exceeding 0°C (32°F); when the temperature
is below 0°C (32°F), the tank must be drained at the end of
work or in any case with the machine at operating temper- 1
ature, to prevent the condensate from freezing.
• The condensate and the impurities that may have accu-
mulated inside the tank must be eliminated before refuel-
RWA06370
ling.
4.7.1.c CHECKING THE ELECTRICAL SYSTEM
WARNING
• If the fuses are corroded, oxidized or not perfectly held in their seat, replace them only with fuses hav-
ing the same capacity; before changing a fuse, make sure that the ignition key is in position « ».
• If there are signs of short circuit on the cables, find out the cause and repair them; always contact your
Komatsu Dealer for the troubleshooting.
Make sure that there are no disconnected cables or signs of short circuit in the electrical system.
Make sure that all the cables are well tightened in the relevant terminals; tighten any loose cables.
In particular, check:
1. Battery
2. Starter
3. Alternator
150
--- Page 19 ---
MAINTENANCE PLAN
4.7.3 CHECKS BEFORE STARTING
4.7.3.a VARIOUS CHECKS
WARNING
• Dirt, oil and fuel spread in the engine compartment near the hot areas may cause fires and damage the
machine.
Check if there are leakages frequently and carry out the necessary repairs immediately; if this occurs
repeatedly, contact your Komatsu Dealer.
Before starting the engine, check:
1. if there are loose screws or nuts;
2. if there are oil, fuel or coolant leakages;
3. if the work equipment is worn;
4. the track tension and wear;
5. the conditions and efficiency of the instruments and warning lights on the dashboard, of the working lights and
of the horn.
The other general checks concern safety, and precisely:
6. soundness of the safety belt;
7. soundness and legibility of the warning plates;
8. cleanliness of the handles used to reach the driver’s seat, cleanliness inside the driver’s cab.
4.7.3.b CHECKING THE COOLANT LEVEL
WARNING 1
• Do not remove the radiator cap; the coolant must be
checked with cold engine, through the compensation
tank.
The coolant tank (1) can be reached after opening the engine
hood: the coolant level in the tank must be included between the
MINIMUM and MAXIMUM marks.
If necessary, add water or coolant and, if a constant and consid-
erable decrease in the coolant level can be noticed, check the
tightness of the radiator-engine unit and of the radiator casing.
RWA06080
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MAINTENANCE PLAN
4.7.6.e CHANGING THE ENGINE OIL
MAX.
WARNING
MIN.
• Soon after the machine has been stopped the engine oil is
very hot and may cause burns; let the engine cool down
until it reaches a temperature of 40-45°C (104-113°F) be-
fore draining the oil.
• The oil that may be spilled during the change makes the 3
ground slippery, therefore, use anti-slip shoes and imme-
diately remove any trace of oil from the floor. 1 2 RWA06250
• Oils, filters, the coolant and the battery are considered
special waste and must be collected and disposed of ac-
cording to the anti-pollution regulations 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. (Use
a 19 mm spanner).
While the oil flows out, remove the filling cap (2), so that the
oil can flow freely.
3 - Tighten the plug (1) onto the pan and pour the prescribed
quantity of new oil, using the dipstick (3) to make sure that
the oil reaches the MAX. level.
To top up, use oil suitable for the ambient temperature (See
“4.3 FUEL, COOLANT AND LUBRICANTS”).
4 - Put back the filling cap (2), start the engine, let it run for 5
minutes and then stop it.
Check the level again and top up if necessary.
5 - Close the engine hood.
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TECHNICAL DATA
5.1 TECHNICAL DATA
5.1.1 STANDARD OVERALL DIMENSIONS
WITH CAB
2360 (7'9")
1225 (4')
220 (8.7")
435 (1'5")
250 (9.8")
230 (9") 1020 (3'4")
1000 (3'3") 1145 (3'9") 1070 (3'6")
3535 (11'7")