Komatsu PC22MR-3 Manual

Operation & Maintenance
Manual
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HYDRAULIC EXCAVATOR
PC22MR-3
SERIAL NUMBER
PC22MR-3 F30001 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 inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
WARNING ORIGINAL INSTRUCTIONS

FOREWORD
11
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FOREWORD FOREWORD
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FOREWORD 1
qThis manual has been compiled by Komatsu Utility S.p.A. in order to supply customers with all the necessary
information on the machine and on safety regulations, as well as 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.
qThe operation manual, together with the spare parts catalogue, is an integral part of the machine and must
accompany it, even when it is resold, until its final disposal.
qThe illustrations contained in this manual may represent machine configurations available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual
sums up all the information regarding the most recent technology applied at the moment in which the machine
is launched.
For any further and/or updated information, contact your Komatsu distributor.
qPunctual periodic annotations regarding the maintenance 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 interval. Therefore, it is advisable to consult both the hour meter and the
maintenance plan frequently.
qOver the years Komatsu distributor have gathered considerable experience in customer service.
If more information is needed, do not hesitate to contact your Komatsu distributor: he always knows how to get
the best performance from the machine, he can recommend 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 distributor also offer assistance for the supply of Komatsu genuine spare parts, which
guarantee safety and interchangeability.
qThe table included in this manual must be filled in with the machine data, which are also the data that must be
communicated to the distributor when requiring assistance and ordering spare parts.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be
understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor
to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.
In this manual, measurements are expressed in international standard units (SI). As a reference, the units
of weight used in the past are shown in brackets ( ).
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FOREWORD FOREWORD
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Storage location for the Operation and Maintenance Manual:
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SAFETY INFORMATION FOREWORD
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SAFETY INFORMATION 1
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations
prescribed for the maintenance operations that must be performed on 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 plates
applied onto the machine. To enable the operator to use this machine safely, safety precautions are explained in
this manual and labels and warning plates are affixed to the machine to highlight situations involving potential
hazards and suggest how to avoid them.
Komatsu machines are manufactured and sold according to the rules or standards of the countries where they
have to work. If the machines have to work in other countries, it is necessary to check that every safety devices
and technical specifications are in compliance with the regulations in force; for this reason, ask Komatsu distributor
before using the machine.
Terminology used in the signs
The following words are used in the signs to inform the user that there is a potential hazard that may lead to
personal injury or damage to property.
In this manual, on the labels and on the plates, the following words are used to express the potential level of the
hazard.
DANGER
Indicates a situation of imminent danger that, if not avoided, may cause serious injury and even death. The use of
this term must be limited to situations of extreme danger.
WARNING
Indicates a situation of potential danger that, if not avoided, may cause serious injury and even death.
CAUTION
Indicates a situation of potential danger that, if not avoided, may cause moderate injury. This term can also be
used as a warning against dangerous interventions.
Other terms used in the signs
In addition to those indicated above, the following warning terms are used to recommend the precautions to be
taken to protect the machine or to supply useful information.
NOTICE
This term is used to indicate precautions that must be taken in order to avoid actions that may shorten the life of
the machine.
REMARK
This word is used to indicate a useful piece of information.
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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 the controls, and stop the engine.
DANGER
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 hood is open, unless
this is expressly prescribed for certain maintenance operations.
DANGER
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 modifying
the standard settings of the hydraulic system.
DANGER
Before carrying out any electric welding, disconnect the battery and the alternator. (See "PRECAUTIONS
CONCERNING THE BATTERY AND THE ALTERNATOR (2-58)").
DANGER
Install only optional tools or tools especially recommended and approved by Komatsu and that meet the
requirements included in section "EQUIPMENT CONFIGURATION (6-5)"
DANGER
It is absolutely forbidden to operate the machine while standing on the ground.
Every single manoeuvre must be carried out by the operator, correctly seated in driving position.
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SAFETY INFORMATION FOREWORD
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qSafety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using pictograms“ to indicate safety procedures.
Safety labels using pictogram
Safety pictograms use a picture to express a level of
hazardous condition equivalent to the signal word. These
safety pictograms use pictures in order to let the operator or
maintenance worker understand the level and type of
hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the
top or left side, and the method of avoiding the hazardous
condition at the bottom or right side. In addition, the type of
hazardous condition is displayed inside a triangle and the
method of avoiding the hazardous condition is shown inside a
circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety
precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Some illustrations may be different from the details of the machine in your possession: this is due to
the continuous improvements made to the machines. Consult Komatsu or your Komatsu distributor for the latest
available information of your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1J(1))
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NOISE LEVELS 1
CAB 1
qThe noise plates must always be legible and in good
conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean them with a solution made
of water and detergent. Do not use fuel, petrol or solvents.
qIf the plates are damaged, ask for new ones to Komatsu or
to your Komatsu distributor.
qIn case of replacement of a component provided with a
noise plate, make sure that such a plate is applied also to
the new part.
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle).
This is the guaranteed value as specified in European
directive 2000/14/EC. This value includes an uncertainty-of
1.6 dB.
qSound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the
measured time-averaged A-weighted emission sound
pressure level at the operator’s position is 2.5 dB, in
accordance with ISO 11201.
ISO 6396
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CANOPY 1
qThe noise plates must always be legible and in good
conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean them with a solution made
of water and detergent. Do not use fuel, petrol or solvents.
qIf the plates are damaged, ask for new ones to Komatsu or
to your Komatsu distributor.
qIn case of replacement of a component provided with a
noise plate, make sure that such a plate is applied also to
the new part.
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle).
This is the guaranteed value as specified in European
directive 2000/14/EC. This value includes an uncertainty-of
1.6 dB.
qSound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the
measured time-averaged A-weighted emission sound
pressure level at the operator’s position is 2.5 dB, in
accordance with ISO 11201.
ISO 6396
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VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 1
When the earth moving machine is used for its intended purpose, the vibration levels transmitted from the
operator's seat are less than or equal to the vibration tested on the related class of machinery in accordance with
ISO7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s², the factor of uncertainty for
this vibration value is 1.2 m/s² according EN 12096: 1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s², the factor of uncertainty for this
vibration value is 0.2 m/s² according EN 12096: 1997.
These values were determined using a representative machine and measured during the typical operating
condition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
OPERATING CONDITION 1
Excavating (Digging-loading-rotating-unloading-rotating).
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE 1
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual.
QTension of crawler (for crawler machines).
QBrake and steering systems.
QControls, hydraulic system and linkages.
3. Keep the terrain where the machine is working and travelling in good condition.
QRemove any large rocks or obstacles.
QFill any ditches and holes.
QSite manager should provide machine operators with machine and schedule time to maintain terrain
conditions.
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted.
QAdjust the seat and suspension for the weight and size of the operator.
QWear seat belt.
QInspect and maintain the seat suspension and adjustment mechanisms.
5. Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly.
6. Adjust the machine speed and travel path to minimize the vibration level.
QWhen pushing with bucket or blade, avoid sudden loading; load gradually.
QDrive around obstacles and rough terrain conditions.
QSlow down when it is necessary to go over rough terrain.
QMake the curve radius of travelling path as large as possible.
QTravel at low speed when travelling around sharp curves.
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7. Minimize vibrations for long work cycle or long distance travelling.
QReduce speed to prevent bounce.
QTransport machines long distances between worksites.
8. The following guidelines can be effective to minimize risks of low back pain.
QOperate the machine only when you are in good health.
QProvide breaks to reduce long periods of sitting in the same posture.
QDo not jump down from the cab or machine.
QDo not repeatedly handle and lift loads.
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FOREWORD INTRODUCTION
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INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
qDigging work
qLeveling work
qDitching work
qLoading the machine
qDemolition work
See the section "OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR (3-84)" for
further details.
IMPROPER OR UNAUTHORIZED USES 1
CAUTION
This paragraph describes some of the improper or unauthorized uses of the machine; since it is
impossible to predict all the possible improper uses, if it is necessary to use the machine for particular
applications, contact your Komatsu distributor before carrying out the work.
NOTICE
qThe 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.
qThe instructions regarding the assembly of the authorized equipment, the controls requiring special
arrangements on the machine and the hydraulic couplings 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;
therefore, the following uses are absolutely forbidden:
qUse of the machine by minors or inexperienced persons.
qUse of the machine for the lifting of people
qTransport of containers with flammable or dangerous fluids.
qUse of the bucket for driving or extracting piles.
qUse of the machine for towing damaged vehicles.
MAIN CHARACTERISTICS 1
qSimple and easy operation.
qHydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
qRotation of the turret achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction
gear.
qMain equipment controlled through servo levers ensuring also combined movements that can be modulated
proportionally and continually.
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INTRODUCTION FOREWORD
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qBoom swing and optional equipment operated through foot pedal controls.
qTranslation and blade control levers.
qTravel speed selection push button.
qComplete series of instruments visible from the operating position.
qLever accelerator.
qEasy maintenance with simplified intervals.
RUNNING-IN 1
All machines have been meticulously adjusted and tested before delivery.
However, a new machine must be used with caution during the first 100 hours, for a correct running in of the
different components.
If the machine is subjected to excessive work load at the beginning of operation, its potential productivity and its
functionality will be shortly and untimely reduced. For more details, see "Running-in (3-63)".
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DIRECTIONS OF MACHINE 1
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket (F) is at the rear of the machine.
(A)
(B)
(C)
(D)
Front
Rear
Left
Right
(E)
(F)
Operator's seat
Sprocket
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PRODUCT IDENTIFICATION FOREWORD
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PRODUCT IDENTIFICATION
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
communicated to the distributor when requiring assistance and ordering spare parts.
MACHINE SERIAL NUMBER 1
The machine serial number is stamped on the front upper part
of the main frame, on the left side.
MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION
NUMBER (PIN) 1
The Komatsu excavators described in this manual are CE
marked, in fact they are in compliance with the EU harmonised
standards.
The plate with the CE marking is applied to the front wall of the
main frame, on the left side.
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FOREWORD PRODUCT IDENTIFICATION
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MACHINE SERIAL NUMBER PLATE
(according directive 2006/42/EC) 1
ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE 1
The engine serial number is stamped on the plate positioned
on the engine itself.
The exhaust gas emission plate is on the left rear side of the
cab chassis support.
(A) Serial number (E) Machine designation type
(B) Operating mass (F) Year of manufacture
(C) Product identification number (G) Engine power
(D) Manufacturer
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PRODUCT IDENTIFICATION FOREWORD
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TRAVEL REDUCTION GEAR SERIAL NUMBER 1
The serial number is stamped on the plate positioned inside the
travel reduction gear and can be seen after removing the cover
(1).
SWING REDUCTION GEAR SERIAL NUMBER 1
The serial number is stamped on the plate positioned on the
upper side of the swing motor.
CAB SERIAL NUMBER 1
The serial number is stamped on the plate positioned on the
upper left side.
HOUR COUNTER POSITION 1
The hour counter is positioned on the machine panel.
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TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
DECLARATION OF CONFORMITY
(for machines placed on the market as from 29 December 2009) 1
The Manufacturer:
Komatsu Utility Europe S.p.A.
Via Atheste, 4
35042 Este (PD) Italy
Declares that this machine:
PC22MR-3
Fulfils all the relevant provisions of following EC Directive:
Machine serial No.
Engine serial No.
Productidentificationnumber
(PIN)
Manufacturers name:
Address:
Komatsu Utility Europe S.p.A.
Via Atheste, 4
35042 Este (PD) Italy
Authorised Representative:
Address:
Distributor name
Address:
Service Personnel
Phone/Fax
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Noise emission in the environment directive 2000/14/EC amended by 2005/88/EC
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CONTENTS
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CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION......................................................................................................................................1-4
NOISE LEVELS..........................................................................................................................................1-7
CAB ...................................................................................................................................................1-7
CANOPY............................................................................................................................................1-8
VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...................................................................1-9
OPERATING CONDITION ................................................................................................................1-9
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............................................................1-9
INTRODUCTION.................................................................................................................................................1-11
IMPROPER OR UNAUTHORIZED USES................................................................................................1-11
MAIN CHARACTERISTICS......................................................................................................................1-11
RUNNING-IN ............................................................................................................................................1-12
DIRECTIONS OF MACHINE ....................................................................................................................1-13
PRODUCT IDENTIFICATION.............................................................................................................................1-14
MACHINE SERIAL NUMBER...................................................................................................................1-14
MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN).....................1-14
MACHINE SERIAL NUMBER PLATE
(according directive 2006/42/EC)..............................................................................................................1-15
ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....................................................1-15
TRAVEL REDUCTION GEAR SERIAL NUMBER....................................................................................1-16
SWING REDUCTION GEAR SERIAL NUMBER......................................................................................1-16
CAB SERIAL NUMBER............................................................................................................................1-16
HOUR COUNTER POSITION ..................................................................................................................1-16
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................1-17
DECLARATION OF CONFORMITY
(for machines placed on the market as from 29 December 2009)............................................................1-17
SAFETY
SAFETY LABELS.................................................................................................................................................2-2
LOCATION OF SAFETY LABELS..............................................................................................................2-2
SAFETY LABELS .......................................................................................................................................2-3
GENERAL PRECAUTIONS ...............................................................................................................................2-14
SAFETY RULES.......................................................................................................................................2-14
IF PROBLEMS ARE FOUND....................................................................................................................2-14
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ...................................................................2-14
FIRE EXTINGUISHER AND FIRST AID KIT ............................................................................................2-15
SAFETY EQUIPMENT..............................................................................................................................2-15
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