Name: Komatsu PC22MR-3
Brand: Komatsu
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Operation & Maintenance

Manual

WEAM014500

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

Foreword6
Safety Information6
- Noise Levels9
  - Cab9
  - Canopy10
- Vibrations to Which the Operator Is Subjected11
  - Guide to Reduce Vibration Levels on Machine11
Introduction13
- Improper or Unauthorized Uses13
- Main Characteristics13
- Running-In14
- Directions of Machine15
Product Identification16
- Machine Serial Number16
- Machine Identification Plate and Product Identification Number (Pin)16
- Machine Serial Number Plate17
- (According Directive 2006/42/EC)17
- Engine Serial Number and Exhaust Gas Emission Plate17
- Travel Reduction Gear Serial Number18
- Swing Reduction Gear Serial Number18
- Cab Serial Number18
- Hour Counter Position18
- Declaration of Conformity19
- (For Machines Placed on the Market as from 29 December 2009)19
- Table to Enter Serial No. and Distributor19
- Table of Contents20
Safety29
Safety Labels30
- Location of Safety Labels30
- Safety Labels31
General Precautions42
- Safety Rules42
- If Problems Are Found42
- Working Wear and Personal Protective Items42
- Fire Extinguisher and First Aid Kit43
- Safety Equipment43
- Keep Machine Clean43
- Keep Operator's Compartment Clean44
- Leaving the Operator's Seat44
- Handrails and Steps45
- Mounting and Dismounting46
- Persons on Attachments46
- Do Not Get Caught in Articulated Portion46
- Burn Prevention47
- Fire Prevention and Explosion Prevention47
  - Fire Caused by Fuel or Oil47
  - Fire Caused by Accumulated Flammable Material48
  - Fire Starting from Electric Wiring48
  - Fire Coming from Hydraulic Line48
  - Explosion Caused by Lighting Equipment48
- Action if Fire Occurs48
- Windshield Washer Fluid48
- Falling Objects, Flying Objects and Intruding Objects Prevention49
- Cautions Related to Rops49
  - ROPS (Canopy Specification)49
  - ROPS (Cab Specification)49
- Attachment Installation50
- Attachment Combinations50
- Preventing Damage Caused by the Work Equipment50
- Cab Window Glasses50
- Unauthorized Modifications50
- Safety at Jobsite51
- Working on Loose Ground51
- Distance to High Voltage Cables52
- Ensure Good Visibility53
- Ventilation for Enclosed Area53
- Signalman's Signal and Signs54
  - Hand Signals54
- Emergency Exit from Operator's Cab59
- Asbestos Dust Hazard Prevention59
Safety Machine Operation60
- Starting Engine60
- Functioning63
Contents68
- Transporting the Machine70
  - Loading and Unloading70
  - Shipping the Machine70
- Battery71
  - Battery Hazard Prevention71
  - Starting Engine with Booster Cables72
- Towing73
  - Safety Rules for Towing73
- Lifting Objects with Bucket Link Lifting Device (Optional Equipment)74
  - Safety Rules for Lifting Objects74
- Lifting Objects with Bucket76
  - Safety Rules for Lifting Objects76
Safety Maintenance Information77
- Warning Tag77
- Keep Work Place Clean and Tidy77
- Appoint Leader When Working with Others77
- Stop Engine before Carrying out Maintenance78
- Cautions for Opening (Tilting) Floor79
- Maintenance with Engine Running80
- Proper Tools81
- Accumulator, Gas Spring81
- Personnel81
- Attachments81
- Work under the Machine82
- Noise82
- When Using Hammer82
- Welding Works82
- Using Lamps83
- Safety First When Using High-Pressure Grease to Adjust Track Tension83
- Do Not Disassemble Recoil Springs83
- Safety Rules for High-Pressure Oil84
- Safety Handling High-Pressure Hoses84
- Precautions for Maintenance Operations at High Temperatures and High Pressure84
- Waste Materials85
- Compressed Air85
- Periodic Replacement of Safety Critical Parts85
- Battery Main Switch Precautions85
- Precautions Concerning the Battery and the Alternator86
- Precautions Concerning the Starter86
- Chemical Hazard86
- Precautions to be Taken When Handling Technopolymers and Elastomers87
- Precautions for the Use of the Synthetic Biodegradable Oil Type Hees87
- Final Disposal of the Machine87
Functioning89
Machine Illustrations90
- Overall View of the Machine90
- Controls and Gauges91
Instruments and Controls92
- Warning Lights and Gauges92
- Switches and Push Buttons98
- Control Levers and Pedals104
Cab111
- Windshield111
- Door116
- Sliding Side Window117
- Emergency Exit Hammer118
Caps and Covers with Lock119
- Opening and Closing of Lockable Caps119
- Opening and Closing the Covers with Lock119
- Cab Door Lock Opening and Closing119
- Engine Hood120
- Radiator Cover121
- Tank Cover122
Tilting the Cab Floor123
Supplementary Power Supply128
- Power Outlet128
Fuses129
- Main Fuse130
- Outlet Fuse130
Storage Compartments131
- Technical Documentation Compartment131
- Tool Box131
- Pump Support for Greasing131
Komtrax System132
- General Precautions132
Use of the Machine and Related Controls134
- Before Starting the Engine134
Contents145
- After Starting the Engine151
- Stopping the Engine154
- How to Move the Machine155
- Steering the Machine160
  - Steering (Changing Direction)160
- Turret Rotation162
- Work Equipment Controls and Functions163
- Unauthorized Operations165
- Precautions for Use167
- Precautions to be Taken When Travelling on Slopes169
- Getting the Machine out of Mud171
- Operations that Can be Performed with the Hydraulic Excavator172
- Changing the Bucket174
- Parking the Machine175
- Checks to be Carried out before Stopping the Engine176
- Checks to be Carried out after Work177
- Locking the Machine177
- Rubber Tracks (Machines with Rubber Tracks)178
Transportation183
- Transport Procedure183
- Loading and Unloading the Machine184
- Lifting the Machine189
Using the Machine in the Cold Season192
- Precautions to be Taken When Using the Machine in the Cold Season192
- Cab Ventilation and Cooling194
  - Cab Ventilation194
  - Cab Heating194
- Precautions to be Taken Every Day at the End of Work195
- How to Proceed at the End of the Cold Season195
Long Periods of Inactivity196
- Before a Period of Inactivity196
- During a Period of Inactivity196
- After a Period of Inactivity197
- Recommendations for Machines Equipped with Komtrax System During Long Periods of Inactivity197
- Allowed Ambient Temperature Range During the Operation and Storage of the Machine for a Long Time198
Troubleshooting199
- If Fuel Runs out Completely199
- Occurrences that Are Not Failures199
- Removing the Machine200
- Precautions to be Taken When Working in Particular Conditions200
- If the Battery Is down201
- Other Troubles205
Guide to Maintenance210
- Maintenance Notes213
- Oil, Fuel, Coolant and Grease213
- Kowa (Komatsu Oil Wear Analysis)216
  - KOWA Analysis Stages216
  - Oil Sampling216
- Storing Oil and Fuel217
- Filters217
- Notes on the Maintenance of the Electrical System217
- Notes on the Maintenance of the Hydraulic System218
- Maintenance Notes Regarding Lubrication218
Parts Subject to Wear219
- List of the Parts Subject to Wear219
Fuel, Coolant and Lubricants220
- Recommended Brands, Quality Recommended for Products Different than Original Komatsu Oil221
- Approved Synthetic Biodegradable Lubricants Type Hees222
Contents223
Tightening Torques223
- Standard Tightening Torques for Screws and Nuts223
- Standard Tightening Torques for Flexible Hoses (Orfs)224
Lubrication225
- Lubrication Diagram225
- Ball-Bearing Ring Greasing Points226
Periodical Change of Safety-Related Components227
- Safety-Related Parts228
Maintenance Plan229
- Checks to be Carried out before Starting the Engine229
- Maintenance Plan230
- Maintenance Intervals in Case of Use of the Hydraulic Breaker231
Maintenance Procedures232
- When Required232
- Checks to be Carried out before Starting the Engine256
- Maintenance after the First 50 Hours of Operation256
Biodegradable Oil Type HEES Is Used)257
- Maintenance Every 100 Hours of Operation257
  - Lubrication257
- Maintenance after the First 500 Hours of Operation259
- Maintenance Every 500 Hours of Operation260
- Maintenance Every 1000 Hours of Operation267
- Maintenance Every 1500 Hours of Operation270
  - Fuel Injection System Check and Cleaning270
  - Engine Casing Breather Pipe Check270
- Maintenance Every 2000 Hours of Operation271
Final Disposal of the Machine280
Specifications281
Operating Characteristics283
Lifting Capacities284
- LIFTING CAPACITIES (Canopy Specification)284
- LIFTING CAPACITIES (Cab Specification)287
Optional Equipment291
General Precautions for Safety292
- Precautions When Selecting292
- Read the Instruction Manual Thoroughly292
- Precautions When Removing or Installing292
- Precautions When Using293
Specifications294
- Arm-Pin Information294
Equipment Use Guide295
- Combinations of Work Equipment295
- Equipment Configuration295
Machine Configuration for the Installation of Attachments297
- Position of the Devices297
- Hydraulic Circuit300
- Operating the Equipment302
  - Using the Hydraulic Breaker302
  - Use of Generic Equipment such as the Crusher303
Contents303
- Long Periods of Inactivity303
Precautions to be Taken When Using Optional Equipment304
- Hydraulic Breaker304
Bucket with Hook309
- Hook Condition309
- Unauthorized Operations309

Brand	Komatsu
Model	PC22MR-3
Category	Excavators
Language	English

Komatsu PC22MR-3 User Manual

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Komatsu PC22MR-3 Specifications

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