Komatsu PC22MR-3 Operation and Maintenance Manual (WEAM014501)

On a small excavator like the Komatsu PC22MR-3, you’re usually working in tight sites—utility trenches, residential foundations, landscaping—where downtime hurts fast. This Operation and Maintenance Manual is what I’d keep handy to set a solid service rhythm, so the machine starts every morning and tracks straight all day. If, for example, the swing feels slow or the controls get “spongy,” I’d use this book to trace through the basic checks in order before calling in heavier diagnostics.

Applications & Use Cases

Plan routine services so filters, belts, and wear parts are inspected and replaced before they cause unplanned stoppages.
Set a realistic maintenance schedule that matches how hard you’re actually working the machine, not just the calendar.
Walk an operator through daily and weekly inspections to catch leaks, loose hardware, and abnormal noises early.
Verify proper warm-up and shutdown habits to protect the engine, hydraulics, and undercarriage over the long term.
Use as a quick reference on site when a warning light appears or performance drops under load.

FAQ

Q: Can I keep this manual on a tablet in the cab?

A: Yes, as long as the file is readable offline and the screen is bright enough, it’s handy for quick checks on site.

Q: Is it still worth printing parts of it?

A: I’d print the inspection checklists and service charts, laminate them, and keep them in the job box or service truck.

Safety Note

Always follow the manual’s safety instructions before inspecting, adjusting, or servicing any part of the excavator.

📘 Show Index

Komatsu PC22MR-3 Index:

FOREWORD
- FOREWORD
- SAFETY INFORMATION
  - NOISE LEVELS
  - VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
- INTRODUCTION
  - IMPROPER OR UNAUTHORIZED USES
  - MAIN CHARACTERISTICS
  - RUNNING-IN
  - DIRECTIONS OF MACHINE
- PRODUCT IDENTIFICATION
  - MACHINE SERIAL NUMBER
  - MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
  - MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
  - ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
  - TRAVEL REDUCTION GEAR SERIAL NUMBER
  - SWING REDUCTION GEAR SERIAL NUMBER
  - CAB SERIAL NUMBER
  - HOUR COUNTER POSITION
  - TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
  - DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)
  - FOREWORD
  - SAFETY
  - FUNCTIONING
  - MAINTENANCE
  - SPECIFICATIONS
  - OPTIONAL EQUIPMENT
SAFETY
- SAFETY LABELS
  - LOCATION OF SAFETY LABELS
  - SAFETY LABELS
- GENERAL PRECAUTIONS
  - SAFETY RULES
  - IF PROBLEMS ARE FOUND
  - WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
  - FIRE EXTINGUISHER AND FIRST AID KIT
  - SAFETY EQUIPMENT
  - KEEP MACHINE CLEAN
  - KEEP OPERATOR’S COMPARTMENT CLEAN
  - LEAVING THE OPERATOR’S SEAT
  - HANDRAILS AND STEPS
  - MOUNTING AND DISMOUNTING
  - NO PERSONS ON ATTACHMENTS
  - DO NOT GET CAUGHT IN ARTICULATED PORTION
  - BURN PREVENTION
  - FIRE PREVENTION AND EXPLOSION PREVENTION
  - ACTION IF FIRE OCCURS
  - WINDSHIELD WASHER FLUID
  - FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION
  - CAUTIONS RELATED TO ROPS
  - ATTACHMENT INSTALLATION
  - ATTACHMENT COMBINATIONS
  - PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  - CAB WINDOW GLASSES
  - UNAUTHORIZED MODIFICATIONS
  - SAFETY AT JOBSITE
  - WORKING ON LOOSE GROUND
  - DISTANCE TO HIGH VOLTAGE CABLES
  - ENSURE GOOD VISIBILITY
  - VENTILATION FOR ENCLOSED AREA
  - SIGNALMAN’S SIGNAL AND SIGNS
  - EMERGENCY EXIT FROM OPERATOR’S CAB
  - ASBESTOS DUST HAZARD PREVENTION
- SAFETY MACHINE OPERATION
  - STARTING ENGINE
  - FUNCTIONING
  - TRANSPORTING THE MACHINE
  - BATTERY
  - TOWING
  - LIFTING OBJECTS WITH LIFTING DEVICE (OPTIONAL EQUIPMENT)
- SAFETY MAINTENANCE INFORMATION
  - WARNING TAG
  - KEEP WORK PLACE CLEAN AND TIDY
  - APPOINT LEADER WHEN WORKING WITH OTHERS
  - STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
  - CAUTIONS FOR OPENING (TILTING) FLOOR
  - MAINTENANCE WITH ENGINE RUNNING
  - PROPER TOOLS
  - ACCUMULATOR, GAS SPRING
  - PERSONNEL
  - ATTACHMENTS
  - WORK UNDER THE MACHINE
  - NOISE
  - WHEN USING HAMMER
  - WELDING WORKS
  - USING LAMPS
  - SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
  - DO NOT DISASSEMBLE RECOIL SPRINGS
  - SAFETY RULES FOR HIGH-PRESSURE OIL
  - SAFETY HANDLING HIGH-PRESSURE HOSES
  - PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
  - WASTE MATERIALS
  - COMPRESSED AIR
  - PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
  - BATTERY MAIN SWITCH PRECAUTIONS
  - PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
  - PRECAUTIONS CONCERNING THE STARTER
  - CHEMICAL HAZARD
  - PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
  - PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES
  - FINAL DISPOSAL OF THE MACHINE
FUNCTIONING
- MACHINE ILLUSTRATIONS
  - OVERALL VIEW OF THE MACHINE
  - CONTROLS AND GAUGES
- INSTRUMENTS AND CONTROLS
  - WARNING LIGHTS AND GAUGES
  - SWITCHES AND PUSH BUTTONS
  - CONTROL LEVERS AND PEDALS
- CAB
  - WINDSHIELD
  - DOOR
  - SLIDING SIDE WINDOW
  - EMERGENCY EXIT HAMMER
- CAPS AND COVERS WITH LOCK
  - Opening and closing of lockable caps
  - Opening and closing the covers with lock
  - Cab door lock opening and closing
  - ENGINE HOOD
  - RADIATOR COVER
  - TANK COVER
- TILTING THE CAB FLOOR
- SUPPLEMENTARY POWER SUPPLY
  - POWER OUTLET
- FUSES
  - MAIN FUSE
  - 12V OUTLET FUSE
- STORAGE COMPARTMENTS
  - TECHNICAL DOCUMENTATION COMPARTMENT
  - TOOL BOX
  - PUMP SUPPORT FOR GREASING
- KOMTRAX SYSTEM
  - GENERAL PRECAUTIONS
- USE OF THE MACHINE AND RELATED CONTROLS
  - BEFORE STARTING THE ENGINE
  - AFTER STARTING THE ENGINE
  - STOPPING THE ENGINE
  - HOW TO MOVE THE MACHINE
  - STEERING THE MACHINE
  - TURRET ROTATION
  - WORK EQUIPMENT CONTROLS AND FUNCTIONS
  - UNAUTHORIZED OPERATIONS
  - PRECAUTIONS FOR USE
  - PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES
  - GETTING THE MACHINE OUT OF MUD
  - OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR
  - LIFTING OBJECTS WITH LIFTING DEVICE
  - LIFTING CAPACITIES TABLES
  - CHANGING THE BUCKET
  - PARKING THE MACHINE
  - CHECKS TO BE CARRIED OUT BEFORE STOPPING THE ENGINE
  - CHECKS TO BE CARRIED OUT AFTER WORK
  - LOCKING THE MACHINE
  - RUBBER TRACKS (MACHINES WITH RUBBER TRACKS)
- TRANSPORTATION
  - TRANSPORT PROCEDURE
  - LOADING AND UNLOADING THE MACHINE
  - LIFTING THE MACHINE
- USING THE MACHINE IN THE COLD SEASON
  - PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON
  - CAB VENTILATION AND COOLING
  - PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK
  - HOW TO PROCEED AT THE END OF THE COLD SEASON
- LONG PERIODS OF INACTIVITY
  - BEFORE A PERIOD OF INACTIVITY
  - DURING A PERIOD OF INACTIVITY
  - AFTER A PERIOD OF INACTIVITY
  - RECOMMENDATIONS FOR MACHINES EQUIPPED WITH KOMTRAX SYSTEM DURING LONG PERIODS OF INACTIVITY
  - ALLOWED AMBIENT TEMPERATURE RANGE DURING THE OPERATION AND STORAGE OF THE MACHINE FOR A LONG TIME
- TROUBLESHOOTING
  - IF FUEL RUNS OUT COMPLETELY
  - OCCURRENCES THAT ARE NOT FAILURES
  - REMOVING THE MACHINE
  - PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS
  - IF THE BATTERY IS DOWN
  - OTHER TROUBLES
MAINTENANCE
- GUIDE TO MAINTENANCE
  - MAINTENANCE NOTES
  - OIL, FUEL, COOLANT AND GREASE
  - KOWA (KOMATSU OIL WEAR ANALYSIS)
  - STORING OIL AND FUEL
  - FILTERS
  - NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM
  - NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM
  - MAINTENANCE NOTES REGARDING LUBRICATION
- PARTS SUBJECT TO WEAR
  - LIST OF THE PARTS SUBJECT TO WEAR
- FUEL, COOLANT AND LUBRICANTS
  - RECOMMENDED BRANDS, QUALITY RECOMMENDED FOR PRODUCTS DIFFERENT THAN ORIGINAL KOMATSU OIL
  - APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES
- TIGHTENING TORQUES
  - STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS
  - STANDARD TIGHTENING TORQUES FOR FLEXIBLE HOSES (ORFS)
- LUBRICATION
  - LUBRICATION DIAGRAM
  - BALL-BEARING RING GREASING POINTS
- PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS
  - SAFETY-RELATED PARTS
- MAINTENANCE PLAN
  - MAINTENANCE PLAN
  - MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER
- MAINTENANCE PROCEDURES
  - WHEN REQUIRED
  - CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
  - MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
  - MAINTENANCE EVERY 100 HOURS OF OPERATION
  - MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
  - MAINTENANCE EVERY 500 HOURS OF OPERATION
  - MAINTENANCE EVERY 1000 HOURS OF OPERATION
  - MAINTENANCE EVERY 1500 HOURS OF OPERATION
  - MAINTENANCE EVERY 2000 HOURS OF OPERATION
- FINAL DISPOSAL OF THE MACHINE
SPECIFICATIONS
- SPECIFICATIONS
- OPERATING CHARACTERISTICS
- LIFTING CAPACITIES
  - LIFTING CAPACITIES (Canopy specification)
  - LIFTING CAPACITIES (Cab specification)
OPTIONAL EQUIPMENT
- GENERAL PRECAUTIONS FOR SAFETY
  - PRECAUTIONS WHEN SELECTING
  - READ THE INSTRUCTION MANUAL THOROUGHLY
  - PRECAUTIONS WHEN REMOVING OR INSTALLING
  - PRECAUTIONS WHEN USING
- SPECIFICATIONS
  - ARM-PIN INFORMATION
- EQUIPMENT USE GUIDE
  - COMBINATIONS OF WORK EQUIPMENT
  - EQUIPMENT CONFIGURATION
- MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS
  - POSITION OF THE DEVICES
  - HYDRAULIC CIRCUIT
  - OPERATING THE EQUIPMENT
  - LONG PERIODS OF INACTIVITY
- PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT
  - HYDRAULIC BREAKER