Galeo PC16R-2 Manual

Operation & Maintenance
Manual
WEAM007800
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
PC16R-2
HYDRAULIC EXCA ATOR
SERIAL NUMBER
PC16R-2 F00003 and up

FOREWORD
1
1.1 FOREWORD
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 manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment inside the seat support, where the
registration documents and the logbook are usually kept.
qThis manual must be given to the staff who have to 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, request a new copy to Komatsu or your Komatsu Dealer.
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 Dealer.
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 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 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 Dealers 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 Dealer when requiring assistance and ordering spare parts.
CAUTION
qThe incorrect use of the machine and inappropriate maintenance operations may cause serious injury
and even death.
qOperators and maintenance personnel must carefully read this manual before using the machine or
performing maintenance operations.
qAny serious accident that may occur during the use of the machine or during maintenance operations is
due to failure to comply with the instructions given herein.
qThe application of the procedures and precautions described in this manual will ensure safety only
provided that the machine is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.

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 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.
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
qIndicates 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
qIndicates a situation of potential danger that, if not avoided, may cause serious injury and even death.
CAUTION
qIndicates 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.
IMPORTANT
qThis term is used to indicate precautions that must be taken in order to avoid actions that may shorten
the life of the machine.
NOTE
qThis word is used to indicate a useful piece of information.
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 warnings included in this manual and applied onto the
machine may not include all possible safety precautions.
If all the instructions given in relation to this machine are kept to, the operators and anyone in the vicinity can work
in total safety, and do not run the risk of damaging the machine. In case of doubt regarding the safety measures
necessary for some procedures, contact Komatsu or your local Komatsu Dealer.

INFORMATION ON SAFETY
3
DANGER
qBefore 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
qTo 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.
WARNING
qIt 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.
WARNING
qBefore carrying out any electric welding, disconnect the battery and the alternator. (See "2.8.13
PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR").
WARNING
qInstall only authorized optional equipment (see "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
DANGER
qIt 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.

INTRODUCTION
4
1.3 INTRODUCTION
1.3.1 INTENDED USE OF THE MACHINE
The Komatsu machines described in this manual have been designed and constructed to be used mainly for
EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the
characteristics illustrated in paragraph "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
qThis 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 Dealer before carrying out the work.
IMPORTANT
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 LIFTING PERSONS OR OBJECTS.
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.
1.3.3 MAIN CHARACTERISTICS
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.
qBoom swing and optional equipment operated through foot pedal controls.
qTravel and blade operated through levers.
qTravel speed selection push button.
qHydraulic track gauge adjustment (optional).
qComplete series of instruments visible from the operating position.
qLever accelerator.
qEasy maintenance with simplified intervals.

INTRODUCTION
5
1.3.4 RUNNING-IN
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 productivity and its
functionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following instructions:
qAfter the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
qAvoid operating the machine with the limit loads allowed or at high speed.
qAvoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
For machines in which synthetic biodegradable oil type HEES is used, perform the following operations in addition
to the standard maintenance operations:
qAfter the first 50 hours of operation, change the hydraulic circuit drain filter.
qAfter the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
qWhen 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.
qThe number of operating hours is indicated by the hour meter.
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE
In this manual, the terms front/forward, rear/backward, left, and right refer to the travel direction as seen from the
operator seat when it is facing the front and the sprocket is at the rear of the machine.
Front
Operator's seat
Sprocket
Left Right
Rear
RYA00050

PRODUCT IDENTIFICATION
6
1.4 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 Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial number is stamped on the front upper part of
the main frame, on the left side.
1.4.2 MACHINE IDENTIFICATION PLATE
AND PRODUCT IDENTIFICATION
NUMBER (PIN)
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 right side.
RKAB5040
RKAB5050
RWA39210
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
kg
kw
Product Identification Number
MANUFACTURER
22L-09-R1370
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
kg
kw
Product Identification Number
MANUFACTURER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN

PRODUCT IDENTIFICATION
7
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
The engine serial number is stamped on the plate positioned on
the engine itself.
The exhaust gas emission plate is applied to the counterweight.
1.4.4 TRAVEL REDUCTION GEAR SERIAL
NUMBER
The serial number is stamped on the plate positioned inside the
travel reduction gear and can be seen after removing the cover
(1).
RKA16540
RKA16550
RKAB5060
1

PRODUCT IDENTIFICATION
8
1.4.5 SWING REDUCTION GEAR SERIAL
NUMBER
The serial number is stamped on the plate positioned on the
upper side of the swing motor.
RKAB5920

PRODUCT IDENTIFICATION
9
1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine no.° Model
Product identification number (PIN)
Travel reduction gear no.°
Swing reduction gear no.°
Dealer:
Address:
Tel.
Contact person:
NOTES:
Engine no.°

TABLE OF CONTENTS
10
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USE OF THE MACHINE ....................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES................................................................................ 4
1.3.3 MAIN CHARACTERISTICS...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE............................................................... 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE SERIAL NUMBER .................................................................................................. 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 7
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER ..................................................................... 8
1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS .................................................................... 9
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 18
2.1.1 POSITION OF THE SAFETY PLATES..................................................................................... 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 19
2.1.3 POSITION OF THE NOISE PLATES ...................................................................................... 24
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED................................................. 24
2.2 GENERAL PRECAUTIONS .................................................................................................................. 25
2.2.1 GENERAL SAFETY RULES..................................................................................................... 25
2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 25
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 25
2.2.4 UNAUTHORIZED MODIFICATIONS........................................................................................ 26
2.2.5 LEAVING THE OPERATOR SEAT ......................................................................................... 26
2.2.6 GETTING ON AND OFF THE MACHINE................................................................................. 27
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL ...................................................................... 28
2.2.8 PREVENTING BURNS ............................................................................................................ 28
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ..................................................... 29
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 29
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT ......................................................................... 30
2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE.................................................... 30
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 30
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 31
2.3.1 SAFETY AT THE WORK SITE................................................................................................. 31
2.3.2 FIRE PREVENTION ................................................................................................................ 31
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT ...................................................... 31
2.3.4 ROOM VENTILATION ............................................................................................................. 32
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 32
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 33
2.4.1 STARTING THE ENGINE ........................................................................................................ 33
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 33

TABLE OF CONTENTS
11
2.4.3 HAND SIGNALS....................................................................................................................... 34
2.4.4 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 39
2.4.5 MOVING THE MACHINE ........................................................................................................39
2.4.6 MOVING ON SLOPES ............................................................................................................ 40
2.4.7 WORKING ON SLOPES .........................................................................................................41
2.4.8 UNAUTHORIZED OPERATIONS ........................................................................................... 41
2.4.9 PREVENTING ELECTROCUTION .......................................................................................... 43
2.4.10 VISIBILITY................................................................................................................................ 43
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES ........................................................ 43
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 44
2.4.13 WORKING ON LOOSE GROUND ........................................................................................... 44
2.4.14 PARKING THE MACHINE........................................................................................................ 44
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES ................................................................ 45
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 45
2.5.2 TRANSPORTING THE MACHINE ........................................................................................... 45
2.6 BATTERY .............................................................................................................................................. 46
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 46
2.6.2 STARTING WITH BOOSTER CABLES .................................................................................. 46
2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE................................................................. 47
2.8 PRECAUTIONS FOR MAINTENANCE................................................................................................. 48
2.8.1 WARNING PLATES ................................................................................................................ 48
2.8.2 TOOLS .................................................................................................................................... 48
2.8.3 MAINTENANCE STAFF ........................................................................................................... 48
2.8.4 EQUIPMENT ........................................................................................................................... 49
2.8.5 WORKING UNDER THE MACHINE ....................................................................................... 49
2.8.6 CLEANING THE MACHINE .................................................................................................... 49
2.8.7 USE OF THE ENGINE DURING MAINTENANCE................................................................... 50
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 50
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 50
2.8.10 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL ..................................... 51
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................................... 51
2.8.12 USING LAMPS ........................................................................................................................ 51
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY
AND THE ALTERNATOR......................................................................................................... 52
2.8.14 PRECAUTIONS CONCERNING THE STARTER .................................................................... 52
2.8.15 HANDLING HIGH-PRESSURE HOSES .................................................................................. 52
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 53
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH
TEMPERATURES AND HIGH PRESSURE............................................................................. 53
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE
GREASE TO ADJUST THE TRACK TENSION ...................................................................... 54
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE
SHOCK ABSORBER UNIT ...................................................................................................... 54
2.8.20 HYDRAULIC ACCUMULATOR ............................................................................................... 54
2.8.21 COOLING FAN AND BELT .....................................................................................................55
2.8.22 WASTE MATERIALS .............................................................................................................. 55
2.8.23 COMPRESSED AIR ................................................................................................................. 55
2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS
AND ELASTOMERS ................................................................................................................ 56
2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE
OIL TYPE HEES....................................................................................................................... 56

TABLE OF CONTENTS
12
THE MACHINE AND ITS OPERATIONS
3.1 MACHINE ILLUSTRATIONS ................................................................................................................ 58
3.1.1 OVERALL VIEW OF THE MACHINE ....................................................................................... 58
3.1.2 CONTROLS AND GAUGES..................................................................................................... 59
3.2 INSTRUMENTS AND CONTROLS ....................................................................................................... 60
3.2.1 WARNING LIGHTS AND GAUGES ......................................................................................... 60
3.2.1.1 EMERGENCY WARNING LIGHTS ......................................................................... 61
3.2.1.2 GAUGES ................................................................................................................. 62
3.2.1.3 WARNING LIGHTS ................................................................................................. 63
3.2.2 SWITCHES AND PUSH BUTTONS ......................................................................................... 65
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 68
3.2.4 COVERSWITH LOCK............................................................................................................... 75
3.2.5 ENGINE HOOD ........................................................................................................................ 76
3.2.6 RADIATOR COVER ................................................................................................................. 77
3.2.7 BATTERY COVER ................................................................................................................... 78
3.2.8 TILTING THE CAB FLOOR ......................................................................................................79
3.2.9 FUSES...................................................................................................................................... 82
3.2.10 MAIN FUSE .............................................................................................................................. 83
3.2.11 TECHNICAL DOCUMENTATION COMPARTMENT ............................................................... 83
3.2.12 TOOL BOX ............................................................................................................................... 83
3.3 USE OF THE MACHINE AND RELATED CONTROLS........................................................................ 84
3.3.1 BEFORE STARTING THE ENGINE......................................................................................... 84
3.3.1.1 VISUAL CHECKS.................................................................................................... 84
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE .................. 85
3.3.1.3 ADJUSTMENTS ...................................................................................................... 92
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ......... 94
3.3.2 STARTING THE ENGINE......................................................................................................... 96
3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES............................... 96
3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES ................................. 98
3.3.3 AFTER STARTING THE ENGINE............................................................................................ 100
3.3.3.1 RUNNING IN A NEW MACHINE............................................................................. 100
3.3.3.2 WARMING-UP OPERATIONS ................................................................................ 101
3.3.4 STOPPING THE ENGINE ........................................................................................................103
3.3.5 HOW TO MOVE THE MACHINE.............................................................................................. 104
3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE
MOVING THE MACHINE ........................................................................................ 104
3.3.5.2 MOVING THE MACHINE FORWARD .................................................................... 104
3.3.5.3 MOVING THE MACHINE IN REVERSE ................................................................. 106
3.3.5.4 STOPPING THE MACHINE .................................................................................... 107
3.3.6 STEERING THE MACHINE...................................................................................................... 108
3.3.6.1 STEERING (CHANGING DIRECTION) .................................................................. 108
3.3.7 SWINGING THE TURRET ....................................................................................................... 110
3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS............................................................. 111
3.3.9 UNAUTHORIZED OPERATIONS............................................................................................. 114
3.3.10 PRECAUTIONS FOR USE.......................................................................................................116
3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES...................................... 118
3.3.12 GETTING THE MACHINE OUT OF MUD ................................................................................ 120
3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR .......... 121
3.3.14 CHANGING THE BUCKET.......................................................................................................123
3.3.15 PARKING THE MACHINE........................................................................................................ 124
3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK ...................................................... 126
3.3.16.1 BEFORE STOPPING THE ENGINE ....................................................................... 126
3.3.16.2 AFTER STOPPING THE ENGINE .......................................................................... 126

TABLE OF CONTENTS
13
3.3.17 LOCKING THE MACHINE........................................................................................................ 126
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only) ........................................... 127
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS .......................................................... 127
3.3.18.2 WARRANTY ON RUBBER TRACKS...................................................................... 127
3.3.18.3 USE OF THE RUBBER TRACKS ........................................................................... 128
3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME ................................ 128
3.4 TRANSPORTING THE MACHINE ........................................................................................................ 132
3.4.1 TRANSPORT PROCEDURE ................................................................................................... 132
3.4.2 LOADING AND UNLOADING THE MACHINE......................................................................... 132
3.4.3 LIFTING THE MACHINE .......................................................................................................... 138
3.5 USING THE MACHINE IN THE COLD SEASON ................................................................................. 140
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON ..... 140
3.5.1.1 FUEL AND LUBRICANTS....................................................................................... 140
3.5.1.2 COOLANT ............................................................................................................... 140
3.5.1.3 BATTERY................................................................................................................ 141
3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK................................. 142
3.5.3 HOW TO PROCEED AT THE END OF THE COLD SEASON ................................................ 142
3.6 LONG PERIODS OF INACTIVITY ........................................................................................................ 143
3.6.1 BEFORE A PERIOD OF INACTIVITY...................................................................................... 143
3.6.2 DURING A PERIOD OF INACTIVITY ...................................................................................... 143
3.6.3 AFTER A PERIOD OF INACTIVITY ......................................................................................... 143
3.7 TROUBLESHOOTING .......................................................................................................................... 144
3.7.1 IF FUEL RUNS OUT COMPLETELY ....................................................................................... 144
3.7.2 OCCURRENCES THAT ARE NOT FAILURES ....................................................................... 144
3.7.3 REMOVING THE MACHINE .................................................................................................... 144
3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS ............ 145
3.7.5 IF THE BATTERY IS DOWN.................................................................................................... 145
3.7.5.1 REMOVING AND INSTALLING THE BATTERY .................................................... 146
3.7.5.2 CHARGING THE BATTERY ................................................................................... 146
3.7.5.3 STARTING WITH BOOSTER CABLES .................................................................. 147
3.7.6 OTHER TROUBLES................................................................................................................. 149
3.7.6.1 ELECTRICAL CIRCUIT........................................................................................... 149
3.7.6.2 FRAME.................................................................................................................... 150
3.7.6.3 ENGINE .................................................................................................................. 150
MAINTENANCE
4.1 GUIDE TO MAINTENANCE .................................................................................................................. 154
4.2 MAINTENANCE NOTES ....................................................................................................................... 156
4.2.1 OIL, FUEL AND COOLANT...................................................................................................... 156
4.2.1.1 OIL .......................................................................................................................... 156
4.2.1.2 FUEL ....................................................................................................................... 157
4.2.1.3 COOLANT ............................................................................................................... 157
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)........................................................... 158
4.2.1.5 STORING OIL AND FUEL ...................................................................................... 159
4.2.1.6 FILTERS ................................................................................................................. 159
4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM ...................................... 160
4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM........................................ 160
4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION .......................................................... 160
4.3 PARTS SUBJECT TO WEAR ............................................................................................................... 161
4.3.1 LIST OF THE PARTS SUBJECT TO WEAR............................................................................ 161

TABLE OF CONTENTS
14
4.4 FUEL, COOLANT AND LUBRICANTS.................................................................................................162
4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES............................ 164
4.5 TIGHTENING TORQUES ...................................................................................................................... 165
4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS ....................................... 165
4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS......................................... 166
4.6 LUBRICATION ...................................................................................................................................... 167
4.6.1 LUBRICATION DIAGRAM........................................................................................................167
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS ...................................................... 168
4.7.1 SAFETY-RELATED PARTS ..................................................................................................... 169
4.8 MAINTENANCE PLAN.......................................................................................................................... 170
4.8.1 MAINTENANCE PLAN ............................................................................................................. 170
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER............... 171
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER........................................................... 171
4.8.2.b CHANGING THE HYDRAULIC OIL ........................................................................ 171
4.9 MAINTENANCE PROCEDURES .......................................................................................................... 172
4.9.1 WHEN REQUIRED................................................................................................................... 172
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE............ 172
4.9.1.b CHECKING THE BATTERY CHARGE LEVEL ....................................................... 174
4.9.1.c CLEANING THE WATER SEPARATOR FILTER .................................................. 175
4.9.1.d DRAINING THE FUEL TANK.................................................................................. 176
4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION............................. 176
4.9.1.f CHECKING THE RUBBER TRACKS...................................................................... 178
4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION ......................... 180
4.9.1.h CHANGING THE RUBBER TRACKS ..................................................................... 182
4.9.1.i BLEEDING THE HYDRAULIC SYSTEM ................................................................ 185
4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ................................... 186
4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used).......................... 186
4.9.4 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used).......................... 186
4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION ......................................................... 187
4.9.5.a LUBRICATION ........................................................................................................ 187
4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE ..... 189
4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE ....................................................... 190
4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS ...................... 191
4.9.5.e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND
OF THE EXCHANGER ........................................................................................... 191
4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION .................................... 192
4.9.5.g DRAINING THE HYDRAULIC OIL TANK
(Only for machines in which synthetic biodegradable oil type HEES is used) ........ 193
4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION ....................................................... 194
4.9.6.a CHANGING THE HYDRAULIC OIL FILTER........................................................... 194
4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS .................................. 196
4.9.6.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ..................... 196
4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION ....................................................... 197
4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER 197
4.9.7.b CHANGING THE COOLANT .................................................................................. 199
4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER ......................................... 200

TABLE OF CONTENTS
15
TECHNICAL SPECIFICATIONS
5.1 TECHNICAL DATA ............................................................................................................................... 202
5.2 LIFTING CAPACITIES .......................................................................................................................... 204
5.2.1 LIFTING CAPACITIES ............................................................................................................. 204
AUTHORIZED OPTIONAL EQUIPMENT
6.1 AUTHORIZED OPTIONAL EQUIPMENT ............................................................................................. 208
6.1.1 PRECAUTIONS REGARDING SAFETY.................................................................................. 208
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................. 209
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT........................................................ 210
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....................................... 210
6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS ................................ 211
6.2.1 POSITION OF THE DEVICES ................................................................................................. 211
6.2.2 HYDRAULIC CIRCUIT ............................................................................................................. 213
6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT ........................................... 213
6.2.2.2 MAINTENANCE ...................................................................................................... 213
6.2.2.3 BLEEDING .............................................................................................................. 214
6.3 OPERATING THE EQUIPMENT ........................................................................................................... 215
6.3.1 LONG PERIODS OF INACTIVITY ........................................................................................... 216
6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT ......................................... 217
6.4.1 HYDRAULIC BREAKER........................................................................................................... 217

16
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SAFETY AND
ACCIDENT PREVENTION
17

SAFETY, NOISE AND VIBRATION PLATES
18
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
qThe safety 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 Dealer.
qIn case of replacement of a component provided with a safety plate, make sure that such a plate is applied also
to the new part.
qThe machine can be provided with other plates in addition to those indicated below; keep also to the instructions
given in the additional plates, in any case.
RKA16560