Komatsu PC16R-3 Manual

Operation & Maintenance
Manual
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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-3HS
HYDRAULIC XCAVATOR
SERIAL NUMBER
PC16R-3 F60241 and up
PC16R-3
PC16R-3HS F72480 and up
ORIGINAL INSTRUCTIONS

FOREWORD
1
1.1 FOREWORD
q This manual has been compiled by Komatsu 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.
q 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.
q The 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.
q This manual must be given to the staff who have to use the machine and carry out the routine maintenance op-
erations; 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 Distributor.
q The illustrations contained in this manual may represent machine configurations available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums
up all the information regarding the most recent technology applied at the moment in which the machine is
launched.
For any further and/or updated information, contact your Komatsu Distributor.
q Punctual 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 mainte-
nance plan frequently.
q Over the years Komatsu Distributors have gathered considerable experience in customer service.
If more information is needed, do not hesitate to contact your Komatsu Distributor: he always knows how to get
the best performance from the machine, he can recommend the equipment that is most suitable for specific
needs and can provide the technical assistance necessary for any change that may be required to conform the
machine to the safety standards and traffic rules.
Furthermore, Komatsu Distributors also offer assistance for the supply of Komatsu genuine spare parts, which
guarantee safety and interchangeability.
q The table included in this manual must be filled in with the machine data, which are also the data that must be
communicated to the Distributor when requiring assistance and ordering spare parts.
CAUTION
q In this manual, the units of measurement of SI system are used, the similarities to English units of meas-
urements are indicated ( ).
q The incorrect use of the machine and inappropriate maintenance operations may cause serious injury
and even death.
q Operators and maintenance personnel must carefully read this manual before using the machine or per-
forming maintenance operations.
q Any 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.
q The application of the procedures and precautions described in this manual will ensure safety only pro-
vided 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.
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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 work and 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 enable the operator to use this machine safely, safety precautions are explained in this
manual and labels and warning plates are affixed to the machine to highlight situations involving potential hazards
and suggest how to avoid them.
Komatsu machines are manufactured and sold according to the rules or standards of the countries where they
have to work. If the machines have to work in other countries, it is necessary to check that every safety devices
and technical specifications are in compliance with the regulations in force; for this reason, ask Komatsu Distribu-
tor before using the machine.
Terminology used in the signs
The following words are used in the signs to inform the user that there is a potential hazard that may lead to per-
sonal 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
q Indicates a situation of imminent danger that, if not avoided, may cause serious injury and even death.
The use of this term must be limited to situations of extreme danger.
WARNING
q Indicates a situation of potential danger that, if not avoided, may cause serious injury and even death.
CAUTION
q Indicates a situation of potential danger that, if not avoided, may cause moderate injury. This term can
also be used as a warning against dangerous interventions.
Other terms used in the signs
In addition to those indicated above, the following warning terms are used to recommend the precautions to be
taken to protect the machine or to supply useful information.
IMPORTANT
q This term is used to indicate precautions that must be taken in order to avoid actions that may shorten
the life of the machine.
NOTE
q This 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 Distributor.
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INFORMATION ON SAFETY
3
DANGER
q Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of the equipment and the controls, and stop the en-
gine.
DANGER
q To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the hood is open, un-
less this is expressly prescribed for certain maintenance operations.
WARNING
q It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be
held liable for any damage to persons, property or the machine, if this has been tampered with by modi-
fying the standard settings of the hydraulic system.
WARNING
q Before carrying out any electric welding, disconnect the battery and the alternator. (See "2.8.16 PRE-
CAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR").
WARNING
q Install only optional tools or tools especially recommended and approved by Komatsu and that meet the
requirements included in section "6.3 ATTACHMENT GUIDE".
DANGER
q It is absolutely forbidden to operate the machine while standing on the ground.
Every single manoeuvre must be carried out by the operator, correctly seated in driving position.
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INFORMATION ON SAFETY
4
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using pictograms“ to indicate safety procedures.
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the
top or left side, and the method of avoiding the hazardous condi-
tion at the bottom or right side. In addition, the type of hazardous
condition is displayed inside a triangle and the method of avoiding
the hazardous condition is shown inside a circle.
09653-A0361
RKA28890
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INTRODUCTION
5
1.3 INTRODUCTION
1.3.1 INTENDED USE OF THE MACHINE
This Komatsu machine is designed to be used mainly for the following work:
q Digging work
q Leveling work
q Ditching work
q Loading
See the section "3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR" for
further details.
1.3.2 DEMOLITION WORK
WARNING
• A demolition machine is a machine based on earth moving
machinery (see EN ISO 6165) and including equipment and
attachment (working tool - e.g. processor or breaker) spe-
cifically designed to demolish, cut, loosen, separate, pick
up, transport and distribute component parts of buildings
or civil engineering structures.
q This machine is not prepared for use in Demolition.
q Using this machine in demolition work gives an increased
risk of serious injury or death.
q All Komatsu machinery that have been specifically de-
signed for, and can be used in, demolition work, will dis-
play the Komatsu demolition decal.
q If the machine does not display this decal and it is neces-
sary to carry out demolition work, contact your distributor
for information on demolition machinery compliant with
the applicable standards.
1.3.3 IMPROPER OR UNAUTHORIZED USES
CAUTION
q 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 it is necessary to use the machine for particular appli-
cations, contact your Komatsu Distributor before carrying out the work.
IMPORTANT
q The 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.
q 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 such equipment
are grouped in the final section of this manual.
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INTRODUCTION
6
Komatsu machines are constructed exclusively for the handling, excavation and treatment of inert materials; there-
fore, the following uses are absolutely forbidden:
q USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
q USE OF THE MACHINE FOR THE LIFTING OF PEOPLE.
q TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
q USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
q USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.4 MAIN CHARACTERISTICS
q Simple and easy operation.
q Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
q Rotation of the turret achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear.
q Main equipment controlled through servo levers ensuring also combined movements that can be modulated pro-
portionally and continually.
q Boom swing and optional equipment operated through foot pedal controls.
q Travel and blade operated through levers.
q Travel speed selection push button.
q Hydraulic track gauge adjustment (optional).
q Complete series of instruments visible from the operating position.
q Lever accelerator.
q Easy maintenance with simplified intervals.
1.3.5 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:
q After the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
q Avoid operating the machine with the limit loads allowed or at high speed.
q Avoid 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:
q After the first 50 hours of operation, change the hydraulic circuit drain filter.
q After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
q When 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.
q The number of operating hours is indicated by the hour meter.
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INTRODUCTION
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1.3.6 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.
(A) Forwards (D) Right
(B) Backwards (E) Operator seat
(C) Left (F) Sprocket
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PRODUCT IDENTIFICATION
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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 Distributor 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
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PRODUCT IDENTIFICATION
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1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
A SERIAL NUMBER E MACHINE DESIGNATION TYPE
B OPERATING MASS F YEAR OF CONSTRUCTION
CPRODUCT IDENTIFICATION NUMBER G ENGINE POWER
D MANUFACTURER
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PRODUCT IDENTIFICATION
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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
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PRODUCT IDENTIFICATION
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1.4.5 SWING REDUCTION GEAR SERIAL
NUMBER
The serial number is stamped on the plate positioned on the up-
per side of the swing motor.
1.4.6 CAB SERIAL NUMBER
The serial number is stamped on the plate positioned on the up-
per left side.
RKAB5920
RKAB8240
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PRODUCT IDENTIFICATION
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1.4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
1.4.8 DECLARATION OF CONFORMITY
(for machines placed on the market as from 29 December 2009)
The manufacturer:
Komatsu Italia Manufacturing S.p.A.
Via Atheste, 4
35042 Este (PD) Italy
Declares that this machine:
PC16R-3
PC16R-3HS
Fulfils all the relevant provisions of following EC Directive:
Machine serial No.
Engine serial No.
Product identification number
(PIN)
Manufacturers name:
Address:
Komatsu Italia Manufacturing S.p.A.
Via Atheste, 4
35042 Este (PD) Italy
Authorized representative:
Address:

Distributor name:
Address:
Service Personnel
Phone/Fax
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC until 19 April 2016
2014/30/EU after 20 April 2016
Outdoor Noise Directive 2000/14/EC amended 2005/88/EC
Radio Equipment and Telecommunications Termi-
nal Equipment Directive 1999/5/EC until 12 June 2016
Radio Equipment Directive 2014/53/EU after 13 June 2016
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KOMTRAX SYSTEM
13
1.5 KOMTRAX SYSTEM
q KOMTRAX is a system that uses wireless communication technology to monitor machines.
q The KOMTRAX system can be used only after contacting the Komatsu Distributor and having entered into a con-
tract with him.
q As it is a wireless system, the KOMTRAX equipment uses radio waves; therefore, a due permit is required as
well as compliance with the regulations in force in the country or territory where the machine is used.
Contact a Komatsu Distributor before selling or exporting any machine fitted with a KOMTRAX equipment.
q The KOMTRAX system can be removed or disabled by the Komatsu Distributor as required, in case the machine
is sold or exported.
q Komatsu and its authorised Distributor shall not be liable for any problems or damage resulting from the nonob-
servance of the safety precautions described herein.
1.5.1 GENERAL PRECAUTIONS
WARNING
q Do not remove, repair, modify or move the communication terminal, the aerial or the cables as this may
lead to failures or short-circuits in the KOMTRAX equipment or the machine itself.
The Komatsu Distributor will be in charge of removing and installing the KOMTRAX equipment.
q Do not flatten or damage the cables or wires. Do not pull the cables or wires hard.
Short-circuits and disconnected cables can cause failures or fire in the KOMTRAX equipment or the ma-
chine.
q This machine is equipped with a two-way radio communication device KOMTRAX. Keep away from any
explosive area. If the machine must operate within 12 metres from an explosive area or from an active
electric exploder, the cable harness must be disconnected from the module KOMTRAX. Otherwise, it
may cause serious injuries or fatal accidents.
q This warning does not replace the requirements or regulations in force in the area or country where this
machine is operating. The following specifications are supplied in order to guarantee compliance with
all the applicable requirements and regulations.
q The transmission rated power for the Komtrax transmitter is 5 - 10 watt.
q The frequency operation interval for the Komtrax module is 148 - 150 MHz.
q If you have a pacemaker, make sure that the communication aerial is placed at least 22 cm from the
pacemaker as radio waves can adversely affect the pacemaker operation.
IMPORTANT
q Even if the starter key is turned to OFF, the KOMTRAX system can absorb a minimum quantity of energy.
In case the machine is not used for a long time, strictly follow the instructions contained in section "3.6
LONG PERIODS OF INACTIVITY". If the machine is not used for a long time, stop the engine, wait at least
one minute, and afterwards turn the battery main switch to OFF and extract the specific key.
Remember that when the battery main switch is turned to OFF, the KOMTRAX system does not work.
q Contact the Komatsu Distributor before installing protections or any other covering accessory onto the
opening roof.
q Be careful not to let water deposit on the communication terminals or their cables.
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14
NOTE
q As KOMTRAX is a wireless system, it cannot be used inside tunnels, undergrounds, buildings or in
mountainous areas where radio waves cannot be received.
Even when the machine is outdoors, it cannot be used in areas where radio signals are weak or areas
not covered by the signal.
q Do not disconnect or tamper with the KOMTRAX communication terminal; consult the Komatsu Distrib-
utor in case of failures.
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TABLE OF CONTENTS
15
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 5
1.3.1 INTENDED USE OF THE MACHINE ....................................................................................... 5
1.3.2 DEMOLITION WORK ............................................................................................................... 5
1.3.3 IMPROPER OR UNAUTHORIZED USES................................................................................ 5
1.3.4 MAIN CHARACTERISTICS......................................................................................................6
1.3.5 RUNNING-IN ............................................................................................................................ 6
1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE .............................................................. 7
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 8
1.4.1 MACHINE SERIAL NUMBER .................................................................................................. 8
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 8
1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)................ 9
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 10
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 10
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER .................................................................... 11
1.4.6 CAB SERIAL NUMBER ............................................................................................................ 11
1.4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ........................................................... 12
1.4.8 DECLARATION OF CONFORMITY
(for machines placed on the market as from 29 December 2009) ........................................... 12
1.5 KOMTRAX SYSTEM ............................................................................................................................. 13
1.5.1 GENERAL PRECAUTIONS ..................................................................................................... 13
TABLE OF CONTENTS ........................................................................................................................ 15
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 24
2.1.1 POSITION OF THE SAFETY PLATES .................................................................................... 24
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 25
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY ................................. 35
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB .......................................... 36
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ................................................ 37
2.2 GENERAL PRECAUTIONS .................................................................................................................. 39
2.2.1 GENERAL SAFETY RULES .................................................................................................... 39
2.2.2 HOW TO BEHAVE IN CASE OF ANOMALIES ........................................................................ 39
2.2.3 SAFETY DEVICES AND GUARDS .......................................................................................... 39
2.2.4 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 39
2.2.5 UNAUTHORIZED MODIFICATIONS ....................................................................................... 40
2.2.6 LEAVING THE OPERATOR SEAT ......................................................................................... 40
2.2.7 EMERGENCY EXIT ................................................................................................................. 41
2.2.8 GETTING ON AND OFF THE MACHINE................................................................................. 42
2.2.9 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT ............................................................. 43
2.2.10 ARTICULATED PARTS............................................................................................................ 43
2.2.11 LIFTING OF PERSONNEL PROHIBITED................................................................................ 43
2.2.12 PREVENTING FIRES DUE TO FUEL AND OIL ..................................................................... 43
2.2.13 PREVENTING BURNS ............................................................................................................ 44
2.2.14 PREVENTING FIRES CAUSED BY ACCUMULATED INFLAMMABLE MATERIAL ............... 44
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2.2.15 FIRES CAUSED BY ELECTRICAL WIRING............................................................................ 44
2.2.16 HOW TO BEHAVE IN CASE OF FIRE..................................................................................... 44
2.2.17 DETERGENT FOR THE WINDOWS........................................................................................ 44
2.2.18 ASBESTOS DUST HAZARD PREVENTION ........................................................................... 45
2.2.19 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 45
2.2.20 FIRE EXTINGUISHERS AND FIRST AID KIT ......................................................................... 45
2.2.21 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION ......... 46
2.2.22 CAUTIONS RELATED TO ROPS ............................................................................................ 47
2.2.22.1 ROPS (Canopy specification).................................................................................. 47
2.2.22.2 ROPS (Cab specification) ....................................................................................... 47
2.2.23 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 47
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 48
2.3.1 SAFETY AT THE WORK SITE................................................................................................. 48
2.3.2 FIRE PREVENTION ................................................................................................................ 48
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT ...................................................... 48
2.3.4 ROOM VENTILATION ............................................................................................................. 49
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 49
2.3.6 CAB WINDOWS ....................................................................................................................... 49
2.3.7 CLEANING THE WINDOWS AND CHECKING THE WINDSHIELD WIPER BLADES............ 49
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 50
2.4.1 STARTING THE ENGINE ........................................................................................................ 50
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 50
2.4.3 HAND SIGNALS ....................................................................................................................... 51
2.4.4 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 56
2.4.5 MOVING THE MACHINE ........................................................................................................ 56
2.4.6 MOVING ON SLOPES ............................................................................................................ 57
2.4.7 WORKING ON SLOPES ......................................................................................................... 58
2.4.8 UNAUTHORIZED OPERATIONS............................................................................................. 58
2.4.9 PREVENTING ELECTROCUTION........................................................................................... 60
2.4.10 VISIBILITY ................................................................................................................................ 61
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES......................................................... 61
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 61
2.4.13 WORKING ON LOOSE GROUND ........................................................................................... 61
2.4.14 PARKING THE MACHINE........................................................................................................ 62
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES................................................................. 63
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 63
2.5.2 TRANSPORTING THE MACHINE ........................................................................................... 63
2.6 BATTERY .............................................................................................................................................. 64
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 64
2.6.2 STARTING WITH BOOSTER CABLES ................................................................................... 65
2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE ................................................................. 66
2.8 PRECAUTIONS FOR MAINTENANCE.................................................................................................67
2.8.1 WARNING PLATES ................................................................................................................. 67
2.8.2 TOOLS ..................................................................................................................................... 67
2.8.3 STABILITY................................................................................................................................ 67
2.8.4 MAINTENANCE STAFF ........................................................................................................... 67
2.8.5 EQUIPMENT ........................................................................................................................... 68
2.8.6 WORKING UNDER THE MACHINE ........................................................................................ 68
2.8.7 CLEANING THE MACHINE .....................................................................................................68
2.8.8 USE OF THE ENGINE DURING MAINTENANCE ................................................................... 69
2.8.9 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 69
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2.8.10 STABILITY................................................................................................................................ 69
2.8.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR
INSPECTION ........................................................................................................................... 70
2.8.12 BATTERY MAIN SWITCH PRECAUTIONS............................................................................ 70
2.8.13 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL ..................................... 71
2.8.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................................... 71
2.8.15 USING LAMPS ........................................................................................................................ 71
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE 
ALTERNATOR ......................................................................................................................... 72
2.8.17 PRECAUTIONS CONCERNING THE STARTER .................................................................... 72
2.8.18 HANDLING HIGH-PRESSURE HOSES .................................................................................. 72
2.8.19 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 73
2.8.20 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND 
HIGH PRESSURE .................................................................................................................... 73
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO 
ADJUST THE TRACK TENSION ............................................................................................ 74
2.8.22 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK 
ABSORBER UNIT .................................................................................................................... 74
2.8.23 HYDRAULIC ACCUMULATOR ............................................................................................... 74
2.8.24 COOLING FAN AND BELT ..................................................................................................... 75
2.8.25 CHEMICAL HAZARD ............................................................................................................... 75
2.8.26 WASTE MATERIALS .............................................................................................................. 75
2.8.27 COMPRESSED AIR ................................................................................................................. 75
2.8.28 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND 
ELASTOMERS ......................................................................................................................... 76
2.8.29 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL 
TYPE HEES ............................................................................................................................. 76
2.8.30 FINAL DISPOSAL OF THE MACHINE..................................................................................... 76
THE MACHINE AND ITS OPERATIONS
3.1 MACHINE ILLUSTRATIONS ................................................................................................................ 78
3.1.1 OVERALL VIEW OF THE MACHINE ....................................................................................... 78
3.1.2 CONTROLS AND GAUGES..................................................................................................... 79
3.2 INSTRUMENTS AND CONTROLS ....................................................................................................... 80
3.2.1 WARNING LIGHTS AND GAUGES ......................................................................................... 80
3.2.1.1 EMERGENCY WARNING LIGHTS......................................................................... 81
3.2.1.2 GAUGES................................................................................................................. 82
3.2.1.3 WARNING LIGHTS ................................................................................................. 83
3.2.2 SWITCHES AND PUSH BUTTONS ......................................................................................... 85
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 90
3.2.4 CAB (if provided) ...................................................................................................................... 98
3.2.4.1 WINDSCREEN (machines with cab)....................................................................... 98
3.2.4.2 DOOR (machines with cab)..................................................................................... 101
3.2.4.3 SIDE SLIDING WINDOW (machines with cab)....................................................... 102
3.2.4.4 EMERGENCY EXIT HAMMER (machines with cab) ............................................. 102
3.2.5 COVERSWITH LOCK .............................................................................................................. 103
3.2.6 ENGINE HOOD ........................................................................................................................ 104
3.2.7 RADIATOR COVER ................................................................................................................. 105
3.2.8 BATTERY COVER ................................................................................................................... 106
3.2.9 TILTING THE CAB FLOOR (machines with canopy) ............................................................... 107
3.2.10 TILTING THE CAB FLOOR (machines with cab) ..................................................................... 110
3.2.11 FUSES...................................................................................................................................... 114
3.2.12 MAIN FUSE .............................................................................................................................. 115
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3.2.13 TECHNICAL DOCUMENTATION COMPARTMENT ............................................................... 115
3.2.14 TOOL BOX ............................................................................................................................... 115
3.3 USE OF THE MACHINE AND RELATED CONTROLS........................................................................ 116
3.3.1 BEFORE STARTING THE ENGINE......................................................................................... 116
3.3.1.1 VISUAL CHECKS.................................................................................................... 116
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE .................. 117
3.3.1.3 ADJUSTMENTS...................................................................................................... 124
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ......... 126
3.3.2 STARTING THE ENGINE......................................................................................................... 128
3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES............................... 128
3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES ................................. 130
3.3.3 AFTER STARTING THE ENGINE............................................................................................ 132
3.3.3.1 RUNNING IN A NEW MACHINE............................................................................. 132
3.3.3.2 WARMING-UP OPERATIONS................................................................................ 133
3.3.4 STOPPING THE ENGINE ........................................................................................................ 135
3.3.5 HOW TO MOVE THE MACHINE.............................................................................................. 136
3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE MOVING 
THE MACHINE........................................................................................................ 136
3.3.5.2 MOVING THE MACHINE FORWARD .................................................................... 136
3.3.5.3 MOVING THE MACHINE IN REVERSE ................................................................. 138
3.3.5.4 STOPPING THE MACHINE .................................................................................... 139
3.3.6 STEERING THE MACHINE......................................................................................................140
3.3.6.1 STEERING (CHANGING DIRECTION) .................................................................. 140
3.3.7 SWINGING THE TURRET .......................................................................................................142
3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS............................................................. 143
3.3.9 UNAUTHORIZED OPERATIONS............................................................................................. 146
3.3.10 PRECAUTIONS FOR USE....................................................................................................... 148
3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES...................................... 150
3.3.12 GETTING THE MACHINE OUT OF MUD ................................................................................ 152
3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR .......... 153
3.3.14 CHANGING THE BUCKET....................................................................................................... 155
3.3.15 PARKING THE MACHINE........................................................................................................ 156
3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK ...................................................... 158
3.3.16.1 BEFORE STOPPING THE ENGINE ....................................................................... 158
3.3.16.2 AFTER STOPPING THE ENGINE .......................................................................... 158
3.3.17 LOCKING THE MACHINE........................................................................................................ 158
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only)............................................ 159
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS .......................................................... 159
3.3.18.2 WARRANTY ON RUBBER TRACKS...................................................................... 159
3.3.18.3 USE OF THE RUBBER TRACKS ........................................................................... 160
3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME ................................ 160
3.4 TRANSPORTING THE MACHINE ........................................................................................................ 164
3.4.1 TRANSPORT PROCEDURE.................................................................................................... 164
3.4.2 LOADING AND UNLOADING THE MACHINE......................................................................... 164
3.4.3 LIFTING THE MACHINE .......................................................................................................... 171
3.5 USING THE MACHINE IN THE COLD SEASON ................................................................................. 174
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON ..... 174
3.5.1.1 FUEL AND LUBRICANTS....................................................................................... 174
3.5.1.2 COOLANT ............................................................................................................... 174
3.5.1.3 BATTERY................................................................................................................ 175
3.5.2 VENTILATION AND HEATING ................................................................................................ 176
3.5.3 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK................................. 177
3.5.4 HOW TO PROCEED AT THE END OF THE COLD SEASON................................................. 177
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