Komatsu PC18MR-3 Manual

Operation & Maintenance
Manual
WEAM012101
HYDRAULIC EXCAVATOR
PC18MR-3
SERIAL NUMBER
PC18MR-3 20668 and up
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or
maintaining this machine.
This manual should be kept inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
WARNING ORIGINAL INSTRUCTIONS

FOREWORD
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1.1 FOREWORD
qThis manual has been compiled by Komatsu Utility S.p.A. in order to supply customers with all the necessary in-
formation on the machine and on safety regulations, as well as the use and maintenance instructions that enable
the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over
time.
qThe operation manual, together with the spare parts catalogue, is an integral part of the machine and must ac-
company it, even when it is resold, until its final disposal.
qThe manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment inside the seat support, where the
registration documents and the logbook are usually kept.
qThis manual must be given to the staff who have to use the machine and carry out the routine maintenance 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.
qThe illustrations contained in this manual may represent machine configurations available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums
up all the information regarding the most recent technology applied at the moment in which the machine is
launched.
For any further and/or updated information, contact your Komatsu Distributor.
qPunctual periodic annotations regarding the maintenance operations that have been carried out are important,
since they provide a clear report on the situation and say exactly what has been done and what has to be done
after the next maintenance interval. Therefore, it is advisable to consult both the hour meter and the mainte-
nance plan frequently.
qOver 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.
qThe table included in this manual must be filled in with the machine data, which are also the data that must be
communicated to the Distributor when requiring assistance and ordering spare parts.
CAUTION
qIn this manual, the units of measurement of SI system are used, the similarities to English units of meas-
urements are indicated ( ).
qThe incorrect use of the machine and inappropriate maintenance operations may cause serious injury
and even death.
qOperators and maintenance personnel must carefully read this manual before using the machine or per-
forming maintenance operations.
qAny serious accident that may occur during the use of the machine or during maintenance operations is
due to failure to comply with the instructions given herein.
qThe application of the procedures and precautions described in this manual will ensure safety only 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.

INFORMATION ON SAFETY
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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
qIndicates a situation of imminent danger that, if not avoided, may cause serious injury and even death.
The use of this term must be limited to situations of extreme danger.
WARNING
qIndicates a situation of potential danger that, if not avoided, may cause serious injury and even death.
CAUTION
qIndicates a situation of potential danger that, if not avoided, may cause moderate injury. This term can
also be used as a warning against dangerous interventions.
Other terms used in the signs
In addition to those indicated above, the following warning terms are used to recommend the precautions to be
taken to protect the machine or to supply useful information.
IMPORTANT
qThis term is used to indicate precautions that must be taken in order to avoid actions that may shorten
the life of the machine.
NOTE
qThis word is used to indicate a useful piece of information.
Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation
or maintenance of the machine; for this reason, the safety warnings included in this manual and applied onto the
machine may not include all possible safety precautions.
If all the instructions given in relation to this machine are kept to, the operators and anyone in the vicinity can work
in total safety, and do not run the risk of damaging the machine. In case of doubt regarding the safety measures
necessary for some procedures, contact Komatsu or your local Komatsu Distributor.

INFORMATION ON SAFETY
WEAM012101 3
DANGER
qBefore starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of the equipment and the controls, and stop the en-
gine.
DANGER
qTo make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the hood is open, un-
less this is expressly prescribed for certain maintenance operations.
WARNING
qIt is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be
held liable for any damage to persons, property or the machine, if this has been tampered with by modi-
fying the standard settings of the hydraulic system.
WARNING
qBefore carrying out any electric welding, disconnect the battery and the alternator. (See "2.8.17 PRE-
CAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR").
WARNING
qInstall only optional tools or tools especially recommended and approved by Komatsu and that meet the
requirements included in section "6.3.2 ATTACHMENT CONFIGURATION".
DANGER
qIt is absolutely forbidden to operate the machine while standing on the ground.
Every single manoeuvre must be carried out by the operator, correctly seated in driving position.

INFORMATION ON SAFETY
4WEAM012101
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

INTRODUCTION
WEAM012101 5
1.3 INTRODUCTION
1.3.1 INTENDED USE OF THE MACHINE
The Komatsu machines described in this manual have been designed and constructed to be used mainly for EX-
CAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the character-
istics illustrated in paragraph "6.3.2 ATTACHMENT CONFIGURATION".
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
qThis 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
qThe instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are enclosed to this
manual.
qThe instructions regarding the assembly of the authorized equipment, the controls requiring special 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.
Komatsu machines are constructed exclusively for the handling, excavation and treatment of inert materials; there-
fore, the following uses are absolutely forbidden:
qUSE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
qUSE OF THE MACHINE FOR THE LIFTING OF PEOPLE.
qTRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
qUSE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
qUSE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
qSimple and easy operation.
qHydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
qRotation of the revolving frame achieved by means of an axial piston hydraulic motor acting on an epicyclic re-
duction gear.
qMain equipment controlled through servo levers ensuring also combined movements that can be modulated pro-
portionally and continually.
qBoom swing and optional equipment operated through foot pedal controls.
qTravel and blade operated through levers.
qTravel speed selection push button.
qHydraulic track gauge adjustment.
qComplete series of instruments visible from the operating position.
qLever accelerator.
qEasy maintenance with simplified intervals.

INTRODUCTION
6WEAM012101
1.3.4 RUNNING-IN
Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to excessive work load at the beginning of operation, its potential productivity and its
functionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following instructions:
qAfter the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
qAvoid operating the machine with the limit loads allowed or at high speed.
qAvoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
For machines in which synthetic biodegradable oil type HEES is used, perform the following operations in addition
to the standard maintenance operations:
qAfter the first 50 hours of operation, change the hydraulic circuit drain filter.
qAfter the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
qWhen changing the oil filters (cartridges), check their inner part to make sure that there are no deposits.
If considerable deposits are observed, find out what may have caused them before starting the machine.
qThe number of operating hours is indicated by the hour meter.

INTRODUCTION
WEAM012101 7
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE
In this manual, the terms front/forward, rear/backward, left, and right refer to the travel direction as seen from the
operator seat when it is facing the front and the sprocket is at the rear of the machine.
(A) Forwards (D) Right
(B) Backwards (E) Operator seat
(C) Left (F) Sprocket

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 communi-
cated 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
RKAC0530

PRODUCT IDENTIFICATION
WEAM012101 9
1.4.2.1 MACHINE SERIAL NUMBER PLATE
1.4.2.2 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
A SERIAL NUMBER E MACHINE DESIGNATION TYPE
B OPERATING MASS F YEAR OF CONSTRUCTION
C
PRODUCT IDENTIFICATION NUMBER
G ENGINE POWER
D MANUFACTURER
A SERIAL NUMBER E MACHINE DESIGNATION TYPE
B OPERATING MASS F YEAR OF CONSTRUCTION
C
PRODUCT IDENTIFICATION NUMBER
G ENGINE POWER
D MANUFACTURER
MODEL
SERIAL NUMBER
MANUFACT. YEAR
MASS
ENGINE POWER
kg
kW
Product Identification Number
MANUFACTURER
Manufactured by Komatsu Utility Co., Ltd.
for Komatsu Ltd., Tokyo, Japan
09601-000J2
RKA30130
E
A
F
G
B
C
D
09601-00073
MACHINE DESIGNATION/TYPE
Manufactured by Komatsu Utility Europe S.p.A.,
Noventa Vicentina (VI), Italy for Komatsu Ltd., Tokyo, Japan
OPERATING MASS
Product Identification Number
ENGINE POWER
SERIAL No. YEAR OF CONSTRUCTION
kg kW
MANUFACTURER
RKA28710
A
E
F
G
B
C
D

PRODUCT IDENTIFICATION
10 WEAM012101
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 CAB SERIAL NUMBER
The serial number is stamped on the plate positioned on the up-
per left side.
1.4.5 HOUR METER
The hour counter is displayed on the machine monitor.
RKA16540
RKA16550
RKA25850

PRODUCT IDENTIFICATION
WEAM012101 11
1.4.6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
1.4.7 DECLARATION OF CONFORMITY
(for machines placed on the market as from 29 December 2009)
The manufacturer:
Komatsu Utility Europe S.p.A.
Via Atheste, 4
35042 Este (PD) Italy
Declares that this machine:
PC18MR-3
Fulfils all the relevant provisions of following EC Directive:
Machine serial No.
Engine serial No.
Product identification number
(PIN)
Manufacturers name:
Address:
Komatsu Utility Europe 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
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC

KOMTRAX SYSTEM
12 WEAM012101
1.5 KOMTRAX SYSTEM
qKOMTRAX is a system that uses wireless communication technology to monitor machines.
qThe KOMTRAX system can be used only after contacting the Komatsu Distributor and having entered into a con-
tract with him.
qAs 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.
qThe KOMTRAX system can be removed or disabled by the Komatsu Distributor as required, in case the machine
is sold or exported.
qKomatsu 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
qDo 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.
qDo 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.
qThis 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.
qThis 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.
qThe transmission rated power for the Komtrax transmitter is 5 - 10 watt.
qThe frequency operation interval for the Komtrax module is 148 - 150 MHz.
qIf 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
qEven 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.
qContact the Komatsu Distributor before installing protections or any other covering accessory onto the
opening roof.
qBe careful not to let water deposit on the communication terminals or their cables.
NOTE
qAs 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 cov-
ered by the signal.

KOMTRAX SYSTEM
WEAM012101 13
NOTE
qDo not disconnect or tamper with the KOMTRAX communication terminal; consult the Komatsu Distributor in
case of failures.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 cov-
ered by the signal.
qDo not disconnect or tamper with the KOMTRAX communication terminal; consult the Komatsu dealer in case of
failures.

14
THIS PAGE WAS INTENTIONALLY LEFT EMPTY

TABLE OF CONTENTS
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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 IMPROPER OR UNAUTHORIZED USES................................................................................ 5
1.3.3 MAIN CHARACTERISTICS...................................................................................................... 5
1.3.4 RUNNING-IN ............................................................................................................................ 6
1.3.5 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 ..................................................................... 9
1.4.2.2 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 CAB SERIAL NUMBER............................................................................................................ 10
1.4.5 HOUR METER ......................................................................................................................... 10
1.4.6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ........................................................... 11
1.4.7 DECLARATION OF CONFORMITY
(for machines placed on the market as from 29 December 2009) ........................................... 11
1.5 KOMTRAX SYSTEM............................................................................................................................. 12
1.5.1 GENERAL PRECAUTIONS ..................................................................................................... 12
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 CAB .......................................... 36
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY ................................. 37
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ................................................ 38
2.2 GENERAL PRECAUTIONS .................................................................................................................. 40
2.2.1 GENERAL SAFETY RULES .................................................................................................... 40
2.2.2 HOW TO BEHAVE IN CASE OF ANOMALIES........................................................................ 40
2.2.3 SAFETY DEVICES AND GUARDS.......................................................................................... 40
2.2.4 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 40
2.2.5 UNAUTHORIZED MODIFICATIONS ....................................................................................... 41
2.2.6 LEAVING THE OPERATOR SEAT ......................................................................................... 41
2.2.7 EMERGENCY EXIT ................................................................................................................. 42
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
2.2.15 FIRES CAUSED BY ELECTRICAL WIRING............................................................................ 44

TABLE OF CONTENTS
16 WEAM012101
2.2.16 HOW TO BEHAVE IN CASE OF FIRE..................................................................................... 44
2.2.17 DETERGENT FOR THE WINDOWS........................................................................................ 44
2.2.18 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ..................................................... 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 PRECAUTIONS CONCERNING THE ROPS STRUCTURE.................................................... 46
2.2.22 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 46
2.2.23 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 46
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 47
2.3.1 SAFETY AT THE WORK SITE................................................................................................. 47
2.3.2 FIRE PREVENTION ................................................................................................................ 47
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT ...................................................... 47
2.3.4 ROOM VENTILATION ............................................................................................................. 48
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 48
2.3.6 CAB WINDOWS ....................................................................................................................... 48
2.3.7 CLEANING THE WINDOWS AND CHECKING THE WINDSHIELD WIPER BLADES............ 48
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 49
2.4.1 STARTING THE ENGINE ........................................................................................................ 49
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 49
2.4.3 HAND SIGNALS ....................................................................................................................... 50
2.4.4 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 54
2.4.5 MOVING THE MACHINE ........................................................................................................54
2.4.6 MOVING ON SLOPES ............................................................................................................ 55
2.4.7 WORKING ON SLOPES .........................................................................................................56
2.4.8 UNAUTHORIZED OPERATIONS............................................................................................. 56
2.4.9 PREVENTING ELECTROCUTION........................................................................................... 58
2.4.10 VISIBILITY ................................................................................................................................ 59
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES......................................................... 59
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 59
2.4.13 WORKING ON LOOSE GROUND ........................................................................................... 59
2.4.14 PARKING THE MACHINE........................................................................................................ 60
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES................................................................. 61
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 61
2.5.2 TRANSPORTING THE MACHINE ........................................................................................... 61
2.6 BATTERY .............................................................................................................................................. 62
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 62
2.6.2 STARTING WITH BOOSTER CABLES ................................................................................... 63
2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE ................................................................. 64
2.8 PRECAUTIONS FOR MAINTENANCE................................................................................................. 65
2.8.1 WARNING PLATES ................................................................................................................. 65
2.8.2 TOOLS ..................................................................................................................................... 65
2.8.3 STABILITY................................................................................................................................ 65
2.8.4 MAINTENANCE STAFF ........................................................................................................... 65
2.8.5 EQUIPMENT ........................................................................................................................... 66
2.8.6 WORKING UNDER THE MACHINE ........................................................................................ 66
2.8.7 CLEANING THE MACHINE ..................................................................................................... 66
2.8.8 USE OF THE ENGINE DURING MAINTENANCE ................................................................... 67
2.8.9 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 67
2.8.10 REPAIR WELDS....................................................................................................................... 67
2.8.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 68

TABLE OF CONTENTS
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2.8.12 BATTERY MAIN SWITCH PRECAUTIONS (if installed) ........................................................ 68
2.8.13 SAFETY MEASURES TO OPEN (TILT) THE PLATFORM ..................................................... 69
2.8.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL..................................... 70
2.8.15 CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................................... 70
2.8.16 USING LAMPS ........................................................................................................................ 70
2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR 71
2.8.18 PRECAUTIONS CONCERNING THE STARTER .................................................................... 71
2.8.19 HANDLING HIGH-PRESSURE HOSES .................................................................................. 72
2.8.20 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 72
2.8.21 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES
AND HIGH PRESSURE ........................................................................................................... 72
2.8.22 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST
THE TRACK TENSION ........................................................................................................... 73
2.8.23 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK
ABSORBER UNIT .................................................................................................................... 73
2.8.24 HYDRAULIC ACCUMULATOR AND GAS SPRING ............................................................... 73
2.8.25 COOLING FAN AND BELT .....................................................................................................74
2.8.26 CHEMICAL HAZARD ............................................................................................................... 74
2.8.27 WASTE MATERIALS .............................................................................................................. 74
2.8.28 COMPRESSED AIR ................................................................................................................. 74
2.8.29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS
AND ELASTOMERS ................................................................................................................ 75
2.8.30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL
TYPE HEES ............................................................................................................................. 75
2.8.31 FINAL DISPOSAL OF THE MACHINE..................................................................................... 75
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 ................................................................................................................. 83
3.2.1.3 WARNING LIGHTS ................................................................................................. 85
3.2.2 SWITCHES AND PUSH BUTTONS......................................................................................... 86
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 92
3.2.4 CAB (if provided) ...................................................................................................................... 99
3.2.4.1 WINDSCREEN (machines with cab)....................................................................... 99
3.2.4.2 DOOR (machines with cab)..................................................................................... 102
3.2.4.3 SIDE SLIDING WINDOW (machines with cab)....................................................... 103
3.2.4.4 EMERGENCY EXIT HAMMER (machines with cab) ............................................. 103
3.2.5 COVERS WITH LOCK ............................................................................................................. 104
3.2.6 ENGINE HOOD ........................................................................................................................ 105
3.2.7 RADIATOR COVER ................................................................................................................. 106
3.2.8 BATTERY COVER ................................................................................................................... 107
3.2.9 TILTING THE CAB FLOOR ...................................................................................................... 108
3.2.9.1 MACHINES EQUIPPED WITH CANOPY ............................................................... 108
3.2.9.2 MACHINES WITH CAB........................................................................................... 112
3.2.10 AUXILIARY POWER OUTLET ................................................................................................. 115
3.2.11 FUSES...................................................................................................................................... 115
3.2.12 MAIN FUSE .............................................................................................................................. 116

TABLE OF CONTENTS
18 WEAM012101
3.2.13 12V OUTLET FUSE.................................................................................................................. 116
3.2.14 TECHNICAL DOCUMENTATION COMPARTMENT ............................................................... 117
3.2.15 TOOL BOX ............................................................................................................................... 117
3.3 USE OF THE MACHINE AND RELATED CONTROLS........................................................................ 118
3.3.1 BEFORE STARTING THE ENGINE......................................................................................... 118
3.3.1.1 VISUAL CHECKS.................................................................................................... 118
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE .................. 120
3.3.1.3 ADJUSTMENTS...................................................................................................... 127
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ......... 130
3.3.1.5 STARTING THE ENGINE ....................................................................................... 132
3.3.2 AFTER STARTING THE ENGINE............................................................................................ 135
3.3.2.1 RUNNING-IN........................................................................................................... 135
3.3.2.2 ENGINE STARTING CAPACITY AND NOISE LEVEL CHECK .............................. 135
3.3.2.3 ENGINE ACCELERATION AND DECELERATION CHECK .................................. 135
3.3.2.4 WARMING THE ENGINE........................................................................................ 136
3.3.3 STOPPING THE ENGINE ........................................................................................................138
3.3.4 HOW TO MOVE THE MACHINE.............................................................................................. 139
3.3.4.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE MOVING
THE MACHINE........................................................................................................ 139
3.3.4.2 MOVING THE MACHINE FORWARD .................................................................... 139
3.3.4.3 MOVING THE MACHINE IN REVERSE ................................................................. 141
3.3.4.4 STOPPING THE MACHINE .................................................................................... 142
3.3.5 STEERING THE MACHINE...................................................................................................... 143
3.3.5.1 STEERING (CHANGING DIRECTION) .................................................................. 143
3.3.6 SWINGING THE REVOLVING FRAME ................................................................................... 145
3.3.7 WORK EQUIPMENT CONTROLS AND FUNCTIONS............................................................. 146
3.3.8 UNAUTHORIZED OPERATIONS............................................................................................. 149
3.3.9 PRECAUTIONS FOR USE....................................................................................................... 151
3.3.10 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES...................................... 153
3.3.11 GETTING THE MACHINE OUT OF MUD ................................................................................ 155
3.3.12 POSSIBLE APPLICATIONS OF THE HYDRAULIC EXCAVATOR.......................................... 156
3.3.13 CHANGING THE BUCKET.......................................................................................................158
3.3.14 PARKING THE MACHINE........................................................................................................ 159
3.3.15 CHECKS TO BE CARRIED OUT BEFORE STOPPING THE ENGINE................................... 160
3.3.16 CHECKS TO BE CARRIED OUT AFTER WORK .................................................................... 160
3.3.17 LOCKING THE MACHINE........................................................................................................ 161
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only)............................................ 162
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS .......................................................... 162
3.3.18.2 WARRANTY ON RUBBER TRACKS ...................................................................... 162
3.3.18.3 USE OF THE RUBBER TRACKS ........................................................................... 162
3.4 TRANSPORTING THE MACHINE ........................................................................................................ 167
3.4.1 TRANSPORT PROCEDURE.................................................................................................... 167
3.4.2 LOADING AND UNLOADING THE MACHINE......................................................................... 167
3.4.3 LIFTING THE MACHINE .......................................................................................................... 173
3.5 USING THE MACHINE IN THE COLD SEASON ................................................................................. 176
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON ..... 176
3.5.1.1 FUEL AND LUBRICANTS....................................................................................... 176
3.5.1.2 COOLANT ............................................................................................................... 176
3.5.1.3 BATTERY................................................................................................................ 177
3.5.2 VENTILATION AND HEATING ................................................................................................ 178
3.5.3 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK................................. 179
3.5.4 HOW TO PROCEED AT THE END OF THE COLD SEASON................................................. 179