Komatsu PC35R-8 and PC45R-8 operation and maintenance manual

WEAM003202 Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Manual Manual Manual Manual PC35R-8 PC45R-8 HYDRAULIC EXCAVATOR SERIAL NUMBERS PC35R-8 F20932 and up PC45R-8 F21251 and up This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. Copyright 2002 Komatsu DataKom Publishing Division April 2002

FOREWORD 1 1.1 FOREWORD • This manual is provided by Komatsu in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time. • The operation manual, together with the parts book, is an integral part of the machine and must accompany it, even when it is resold, until the machines. • The manual must be handled with the greatest care and always kept on board the machine, so that it can be con- sulted at any moment; it must be placed in the appropriate compartment behind the seat, where also the owner- ship documents and the logbook are usually kept. • This manual must be given to the persons who use the machine and carry out the routine maintenance operations; they must read the contents carefully more than once, in such a way as to clearly understand what are the correct operating conditions and the dangerous conditions that must be avoided. In case of loss or damage of this manual, request a new copy to Komatsu or your Komatsu Dealer. • The illustrations contained in this manual may represent machine configurations available on request. Komatsu machines are constantly being improved in order to increase their efficiency and reliability; this manual sums up all the information regarding the most recent techniques applied at the moment in which the machine is marketed. For any further or updated information, contact your Komatsu Dealer. • Punctual periodic annotations regarding the maintenance 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. Therefore, consult the hour meter and the maintenance plan frequently. • Over the years Komatsu Dealers have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the best performance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules. Furthermore, Komatsu Dealers also ensure their assistance for the supply of Komatsu genuine spare parts, which alone guarantee safety and interchangeability. • The table included in this manual must be filled in with the machine data, which are the data that must always be indicated to the Dealer when requiring assistance and ordering spare parts. WARNING • Improper operation and maintenance of this machine may be hazardous and cause serious injuries and even death. • Operators and maintenance personnel must carefully read this manual before operating the machine or performing maintenance operations. • Some actions involved in the operation and maintenance of the machine may cause serious injuries or even death, if they are not performed in compliance with the instructions given herein. • The procedures and precautions described in this manual are valid for application to the machine only when it is used correctly. If the machine is used for any purpose or in any way other than those described herein, the operator is risking serious bodily injury or death. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

INFORMATION ON SAFETY 2 1.2 INFORMATION ON SAFETY Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations prescribed for the maintenance and operations of the machine. In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read and be sure to understand all the information and warnings contained in this manual and given on the labels applied onto the machine. To identify the messages regarding safety that are included in this manual and written on the machine labels, the following words have been used. • This word is used on safety messages and safety labels where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine. • This word is used on safety messages and safety labels where there is a poten- tially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine. • This word is used on safety messages and safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided. Failure to follow caution may also result in damage to the machine. • This word is used when precautions are indicated, which must be taken to avoid actions that may shorten the life of the machine. Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation or maintenance of the machine; for this reason, the safety messages included in this manual and applied onto the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. In case of doubt regarding the safety measures necessary for some procedures, contact your local Komatsu dealer. DANGER • Before starting any maintenance operation, position the machine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and of the controls and stop the engine. WARNING • To make the information clearer, some illustrations in this manual represent the machine without safety guards. Do not use the machine without guards and do not start the engine when the engine protection casing is open, if this is not expressly prescribed for some specific maintenance operations. DANGER WARNING CAUTION WARNING

INFORMATION ON SAFETY 3 WARNING • It is strictly forbidden 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 modi- fying the standard setting of the hydraulic system. IMPORTANT ☞ • Before carrying out any electrical welding, disconnect the battery and the alternator (See “2.8.13 PRE- CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR”). WARNING • Install only authorized additional equipment (See “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIP- MENT”). WARNING • Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual must be kept inside the cab for reference and periodically reviewed by all personnel who will come in contact or be working near the machine.

INTRODUCTION 4 1.3 INTRODUCTION 1.3.1 INTENDED USES 1.3.2 IMPROPER OR UNAUTHORIZED USES The Komatsu HYDRAULIC EXCAVATOR described in this manual have been designed and constructed to be used mainly for the following functions: • DIGGING WORKS • SMOOTHING WORKS • DITCHING WORKS • SIDE DITCHING WORKS • LOADING WORKS If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point “6.1 AUTHORIZED OPTIONAL EQUIPMENT”. CAUTION • This paragraph describes some of the improper or unauthorized uses of the machine; since it is impos- sible to predict all the possible improper uses, if the machine happens to be used for particular applica- tions, contact your Komatsu Dealer before carrying out the work. IMPORTANT ☞ • The instructions regarding the authorized optional equipment are given in the relevant operation and maintenance manuals; if the equipment is supplied by Komatsu, these publications are enclosed to this manual. • The instructions regarding the assembly of the authorized equipment, the controls requiring special ar- rangements on the machine and the hydraulic couplings necessary for the operation of the equipment are grouped in the final section of this manual. Komatsu MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials; therefore, the following uses are absolutely forbidden: • USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS. • USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS. • USE OF THE MACHINE FOR TRANSPORTING PERSONS. • TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS. • USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES. • USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.

INTRODUCTION 5 1.3.3 MAIN CHARACTERISTICS 1.3.4 RUNNING-IN • Simple and easy operation. • Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears. • Revolving frame swing achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear. • Main equipment servolevers ensuring also combined movements that can be modulated proportionally and con- tinually. • Pedal controls for the boom swing and the optional equipment. • Lever controls for travel and blade. • Travel speed increase achieved through a pedal-operated push button. • Complete series of instruments visible from the operating position. • Lever accelerator. • Easy maintenance with simplified intervals. Every machine is scrupulously adjusted and tested before delivery. A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the various components. If the machine is subjected to excessive work load at the beginning of operation, its potential yield and its function- ality 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 engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation. • Avoid operating the machine with the limit loads allowed or at high speed. • Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals. • After the first 250 hours, carry out the following operations, in addition to those to be performed every 250 hours: 1 - Change the oil in the travel reduction gears. 2 - Check and adjust the engine valve clearance. SYNTHETIC BIODEGRADABLE OIL TYPE HEES On machines in which the synthetic biodegradable oil type HEES is used, the following operations are to be performed besides the standard maintenance operations: • After the first 50 hours of operation, change the hydraulic circuit drain filter. • After the first 500 hours of operation, change the hydraulic circuit oil. IMPORTANT ☞ • When changing the oil filters (cartridges), check their inner part to make sure that there are no deposits. If considerable deposits are observed, find out what may have caused them before starting the machine. • The number of operating hours is indicated by the hour meter.

PRODUCT IDENTIFICATION 6 1.4 PRODUCT IDENTIFICATION 1.4.1 MACHINE SERIAL NUMBER 1.4.2 MACHINE IDENTIFICATION PLATE The Komatsu EXCAVATOR and its main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must be indicated to the Dealer when requiring assistance and ordering spare parts. RYA12420 The machine serial number is stamped on the front upper part of the main frame, on the left side. RYA12430 The Komatsu EXCAVATORS described in the present manual are provided with the CE mark, which certifies that they are in compliance with the 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. MODEL SERIAL No. MANUFACTURING YEAR MASS ENGINE POWER MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VICENTINA (VI) ITALY UNDER LICENSE FROM KOMATSU LTD kg kw RYA11860 20T-98-RB26451

PRODUCT IDENTIFICATION 7 1.4.3 ENGINE SERIAL NUMBER AND EMIS- SION LABEL 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER RWA10340 The engine serial number is stamped on the plate positioned on the top of the engine cylinder head cover. The emission label is applied on the top of the engine cylinder head cover.  RWA11060 The serial number of the travel reduction gear is stamped on the plate positioned on the outer side of the reduction gear cover.

PRODUCT IDENTIFICATION 8 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER 1.4.6 CAB SERIAL NUMBER RWA09990 The serial number is stamped on the plate positioned laterally on the reduction gear body.  The CAB serial number is stamped on the plate positioned on the top left side.

PRODUCT IDENTIFICATION 9 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS Machine n. Model Engine n. Swing reduction gear n. Cab n. Dealer: Address: Tel. Person to contact: NOTES: Travel reduction gear n.

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Komatsu PC35R-8 and PC45R-8 operation and maintenance manual

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