Komatsu PC110R-1 Manual

Operation & Maintenance
Manual
WEAM000402
HYDRAULIC EXCAVATOR
PC110R-1
SERIAL NUMBER
PC110R-1 2265010001 and up
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ingthismachine.
This manual should be kept inside the cab for refer-
ence and periodically reviewed by all personnel who
willcomeintocontactwiththemachine.
WARNING

FOREWORD
1
1.1 FOREWORD
•This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary in-
formation on the machine and the safety regulations related to it, together with the use and maintenance instruc-
tions 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 spare parts catalogue, is an integral part of the machine and must ac-
company it, even when it is resold, until its final disposal.
•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 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 Utility or your Komatsu Utility Dealer.
•The illustrations contained in this manual may represent machine configurations available on request.
The machines are constantly upgraded in order to increase their efficiency and reliability; this manual sums up
all the information regarding the state of technical progress at the moment in which the machine is launched on
the market.
Consult your Komatsu Utility Dealer for any updated information.
•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, it is advisable to consult either the Hour meter and the maintenance plan
frequently.
•Over the years Komatsu Utility Dealers have gathered considerable experience in customer service.
If more information is needed, do not hesitate to contact your Komatsu Utility 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 con-
form the machine to the safety standards and traffic rules.
Furthermore, Komatsu Utility Dealers also ensure their assistance for the supply of Komatsu Utility 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.
CAUTION
•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 using the machine or per-
forming 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
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 pre-
scribed 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 ap-
plied onto the machine.
To identify the messages regarding safety that are included in this manual and written on the machine plates, the
following words have been used.
• This word is used in the safety warnings in the manual and on the plates when
the situation is dangerous and it may possibly result in serious injuries or even
death.
These messages describe the safety precautions to be taken in order to avoid
any risk. Non-compliance with these instructions may also result in serious dam-
age to the machine.
• This word is used in the safety warnings in the manual and on the plates to signal
risks that may cause moderate damage or injuries.
The message can be used even to indicate the risk of damage to the machine on-
ly.
• This word is used when precautions are indicated, which must be taken to avoid
actions that may shorten the life of the machine.
Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op-
eration 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 all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity will work in total safety, with no risk of damaging the machine. In case of doubt regarding
the safety measures necessary for some procedures, contact Komatsu Utility or your local 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 en-
gine.
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 engine protection
casing is open, if this is not expressly prescribed for some specific maintenance operations.
DANGER
CAUTION
IMPORTANT
☞

INFORMATION ON SAFETY
3
DANGER
•It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility cannot
be held liable for any damage to persons, property or the machine, if this has been tampered with by
modifying the standard setting of the hydraulic system.
DANGER
•Before carrying out any electrical welding, disconnect the battery and the alternator (See “2.8.13 PRE-
CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR”).
DANGER
•Install only authorized additional equipment (See “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIP-
MENT”).

INTRODUCTION
4
1.3 INTRODUCTION
1.3.1 INTENDED USES
1.3.2 IMPROPER OR UNAUTHORIZED USE
The Komatsu Utility MACHINES described in this manual have been designed and constructed to be used by duly
trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the character-
istics 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 Utility 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 Utility, 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 Utility MACHINES are constructed exclusively for the handling, excavation and treatment of inert materi-
als; 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.
•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 variable displacement motors that operate epicyclic reduction
gears equipped with hydraulic brakes with negative control.
•Upper structure rotation achieved through an axial piston hydraulic motor acting on an epicyclic reduction gear.
•Lubrication of the ball-bearing ring toothing and of the pinion in grease bath.
•Main equipment servo levers ensuring also combined movements that can be modulated proportionally and con-
tinually.
•Boom swing and travel controls with servo assisted pedals that ensure proportional and continuous modulated
movements.
•Travel speed increase by means of a button.
•Servo controls also for the two-piece boom and the blade.
•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 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 - Change the oil in the swing reduction gear.
3 - Change the hydraulic circuit oil filter.
4 - 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 per-
formed 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 innner part to make sure that there are no depos-
its.
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 Utility EXCAVATOR and its main components are identified by serial numbers stamped on the iden-
tification 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.
RYA14760
The machine serial number is stamped on the front right part of
the main frame.
RYA14770
The Komatsu Utility EXCAVATORS described in this manual are
provided with the CE mark, which certifies that they are in compli-
ance with the CE harmonized standards.
The plate with the mark is applied onto the front wall of the main
frame, on the right side.

PRODUCT IDENTIFICATION
7
1.4.3 NGINE SERIAL NUMBER AND
EXHAUST GAS EMISSION PLATE
MODEL
SERIAL N
YEAR
TOTAL MAX WEIGHT
ENGINE POWER
MAX WEIGHT FRONT AXLE
MAX WEIGHT REAR AXLE
kg
kw
kg
kg
MODELLO - MODEL
TYP - MODELE
MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.
ANNO - YEAR
BAUJAHR - ANNEE
MASSA TOTALE MAX - TOTAL MAX WEIGHT
ZUL. GESAMTGEWICHT - POIDS TOTAL MAX
POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR
MASSA MAX ASSE ANT. - MAX WEIGHT FRONT AXLE
ZUL. ACHSLAST VORN - POIDS MAX ESSIEU AV
MASSA MAX ASSE POST. - MAX WEIGHT REAR AXLE
ZUL. ACHSLAST HINTEN - POIDS MAX ESSIEU AR
kg
kw
kg
kg
RWA34270
21D-98-12580
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) ITALY
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) ITALY
RWA18500
The engine serial number is stamped on the plate positioned on
the upper side of the tappet cover.
The exhaust gas emission plate is applied to the front side of the
tappet cover.
RWAA9550

PRODUCT IDENTIFICATION
8
1.4.4 TRAVEL REDUCTION GEAR SERIAL
NUMBER
1.4.5 SWING REDUCTION GEAR SERIAL
NUMBER
1.4.6 CAB SERIAL NUMBER
RWA18210
The serial number of the travel reduction gear is stamped on the
plate positioned on the outer side of the reduction gear cover.
The serial number of the swing reduction gear is stamped on the
plate positioned on the side of the reduction gear body.
RWAA11980
The cab serial number is stamped on the plate positioned on the
right side of the front base cross member.
RWA09430

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

CONTENTS
10
Page
CONTENTS
SAFETY AND ACCIDENT PREVENTION
1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 INFORMATION ON SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 INTENDED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 IMPROPER OR UNAUTHORIZED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 MAIN CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.4 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 PRODUCT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 NGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE . . . . . . . . . . . . . . . . . . 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.6 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.6 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.8 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . 29
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.1 SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.2 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB. . . . . . . . . . . . . . . . . . . . . . . 30
2.3.4 ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING
THE WINDSHIELD WIPER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CONTENTS
11
Page
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.1 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . 32
2.4.3 CHECKS FOR TRAVELLING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.4 MOVING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4.5 MOVING ON SLOPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.6 WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.7 UNAUTHORIZED OPERATIONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.8 PREVENTING ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.9 VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . 37
2.4.12 WORKING ON LOOSE GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.13 PARKING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5.2 SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6.2 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.1 WARNING PLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.2 TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.3 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.4 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.5 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.6 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.7 USE OF THE ENGINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY . . . . . . . . . . 44
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8.10 RULES FOR REFUELLING AND ADDING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.8.12 USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR . . . . . . . . . . . . . 46
2.8.14 PRECAUTIONS CONCERNING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . 47
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMSE . . . 47
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES
AND PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.8.18 COOLING FAN AND FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.8.19 WASTE MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL
TYPE HEES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

CONTENTS
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Page
DESCRIPTION AND USE OF THE MACHINE
3.1 SAFETY LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1.1 MACHINE LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2 GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.1 FRONT GENERAL VIEW (MONOBOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2.3 CAB INSIDE GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.1 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.2 WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.3 SWITCHES AND PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.4 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.3.5 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.1 CENTRAL UNIT FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.1.1 CENTRAL UNIT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4.1.2 CENTRAL UNIT RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.4.2 ENGINE LINE FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.2.1 ENGINE LINE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.2.2 ENGINE LINE RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provided) . . . . . . . . . . . . 82
3.5 GUARDS AND DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.5.1 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.5.2 SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.5.3 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.5.4 VENTILATION AND HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.5.5 AIR CONDITIONER (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.5.6 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.5.7 SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.8 EMERGENCY EXIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.9 TECHNICAL DOCUMENTATION CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.5.10 FIRE EXTINGUISHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.5.11 FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.6 USE OF THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1 CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1.1 VISUAL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1.2 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1.3 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.6.2 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES . . . . . . . . . 97
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES . . . . . . . . . . . . . . . . 98
3.6.3 WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.6.4 HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.6.5 HOW TO MOVE THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.6.5.1 STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.6.5.2 MOVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.6.5.3 MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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3.7 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.7.1 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.7.2 PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.8 STOPPING THE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.9.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.9.2 TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10.1 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10.3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.10.4 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.12 USING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.12.1 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT. . . . . . 112
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . 113
3.12.4 DIGGING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.12.5 CHANGING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.13 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.13.1 BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.13.2 DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.13.3 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.14 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.14.1 HOW TO REMOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.14.3 IF THE BATTERY IS DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.14.3.1 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.14.4 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.14.4.1 ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.14.4.2 HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.14.4.3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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MAINTENANCE
4.1 GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1 NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1.1 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1.3 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2.4 NOTES REGARDING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . 131
4.3 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS. . . . . . . . . . . . . . . 134
4.4 DRIVING TORQUES FOR SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.4.1 STANDARD DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.4.2 SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.5.1 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY . . . . . . . . . . . . . . . 137
4.6.1 CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.7 MAINTENANCE PLAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.7.1 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE . . . 145
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . 147
4.7.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.7.1.d CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.7.1.e CHECKING THE STEEL TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.7.1.f CHECKING THE SHOE FASTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER . . . . . . . 153
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.7.2.b CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.7.3 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.7.3.a VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.7.3.b CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.7.3.c CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.3.d CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . 156
4.7.3.f DRAINING THE WATER SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.7.4.a LUBRICATING THE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 161

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4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.7.6.b LUBRICATING THE SWING JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7.6.c CHECKING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.7.7.a LUBRICATING THE BALL-BEARING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . 164
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.7.9.a ADJUSTING THE FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . 166
4.7.9.d CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS . . . . . . . . . 166
4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR . . . . . . . . . . . 167
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 168
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER . . . . . . . . . . . . . . . . . . . . . 168
4.7.11.b CHANGING THE SERVO CONTROL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.7.11.c CHANGING THE ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.7.11.d CHANGING THE ENGINE OIL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.7.11.e CHANGING THE FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.7.11.f DRAINING THE FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . 174
4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . 175
4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL . . . . . . . . 176
4.7.11.k DRAINING THE HYDRAULIC OIL TANK (Only for machines in which
the synthetic biodegradable oil type HEES is used) . . . . . . . . . . . . . . . . . . . . . . . 176
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.7.12.a CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE . . . . . . . . . . 178
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS . . . . . . . . . . . . . . . 179
4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR . . . . . . . . . . . . . . . . . 180
4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.7.13.d CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.7.13.e CHANGING THE BALL-BEARING RING PINION LUBRICANT . . . . . . . . . . . . . 185
4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER . . . . . . . . . . . . . . . . . . . . 185
4.7.13.g CHECKING THE A/C COOLING GAS QUANTITY
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.7.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.7.14.a CHANGING THE A/C DEHYDRATOR FILTER
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.7.14.b CHECKING THE CORRECT OPERATION OF THE A/C COMPRESSOR
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 187

CONTENTS
16
Page
TECHNICAL DATA
AUTHORIZED OPTIONAL EQUIPMENT
5.1 TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.1.1 STANDARD OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.1.2 TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.1.3 LIFTING CAPACITIES
(Only for machines with overload alarm device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.1.3.1 LIFTING CAPACITY TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.1.3.2 LIFTING CAPACITY WITH MONOBOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.1.3.3 LIFTING CAPACITY WITH TWO-PIECE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . 195
6.1 AUTHORIZED OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1.1 PRECAUTIONS REGARDING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . 199
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER . . . . . . . . . . . . . . . 201
6.2.1 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED. . . . . . . . . . . . . . . 201
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER . . . . . . . . . . . . . . . . . . . . . . . 205
6.2.3.1 INSTALLING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.2.3.2 REMOVING THE HAMMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.2.4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.3 CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.3.1 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.3.2 INSTALLING THE CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
6.3.3 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

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SAFETY AND
ACCIDENT PREVENTION

SAFETY, NOISE AND VIBRATION PLATES
18
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
•The 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.
•If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer.
•In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on
the new piece.
•The 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.
RYA14780