Page 1 Operation & Maintenance WEAM012405 Manual PC16R PC16R -3HS HYDRAULIC EXCAVATOR SERIAL NUMBER PC16R F60241 and up PC16R F72480 -3HS and up WARNING ORIGINAL INSTRUCTIONS 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.
Page 3: Foreword 1.1 Foreword
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....
Page 4: Information On Safety
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;...
Page 5 WARNING 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.
Page 6 INFORMATION ON SAFETY 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.
Page 7: Introduction
IMPORTANT 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. 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.
Page 8: Main Characteristics
INTRODUCTION Komatsu machines are constructed exclusively for the handling, excavation and treatment of inert materials; there- fore, the following uses are absolutely forbidden: USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS. USE OF THE MACHINE FOR THE LIFTING OF PEOPLE.
Page 9: Positions And Directions Of The Machine
INTRODUCTION 1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE Forwards Right Backwards Operator seat Left Sprocket 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. WEAM012405...
Page 10: Product Identification
PRODUCT IDENTIFICATION 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.
Page 11: Machine Serial Number Plate (According Directive 2006/42/Ec)
PRODUCT IDENTIFICATION 1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC) SERIAL NUMBER MACHINE DESIGNATION TYPE OPERATING MASS YEAR OF CONSTRUCTION PRODUCT IDENTIFICATION NUMBER ENGINE POWER MANUFACTURER WEAM012405...
Page 12: Engine Serial Number And Exhaust Gas Emission Plate
PRODUCT IDENTIFICATION 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. RKA16540 The exhaust gas emission plate is applied to the counterweight. RKA16550 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...
Page 13: Swing Reduction Gear Serial Number
PRODUCT IDENTIFICATION 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. RKAB5920 1.4.6 CAB SERIAL NUMBER The serial number is stamped on the plate positioned on the up- per left side.
Page 14: Declaration Of Conformity (For Machines Placed On The Market As From 29 December 2009)
PRODUCT IDENTIFICATION 1.4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: Komatsu Italia Manufacturing S.p.A. Address: Via Atheste, 4 35042 Este (PD) Italy Authorized representative: Address:  Distributor name:...
Page 15: Komtrax System
1.5 KOMTRAX SYSTEM KOMTRAX is a system that uses wireless communication technology to monitor machines. The KOMTRAX system can be used only after contacting the Komatsu Distributor and having entered into a con- tract with him. 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....
Page 16 Even when the machine is outdoors, it cannot be used in areas where radio signals are weak or areas not covered by the signal. Do not disconnect or tamper with the KOMTRAX communication terminal; consult the Komatsu Distrib- utor in case of failures.
Page 17: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD FOREWORD............................INFORMATION ON SAFETY ........................ INTRODUCTION ........................... 1.3.1 INTENDED USE OF THE MACHINE ..................1.3.2 DEMOLITION WORK ....................... 1.3.3 IMPROPER OR UNAUTHORIZED USES................1.3.4 MAIN CHARACTERISTICS...................... 1.3.5 RUNNING-IN ..........................1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE .............. PRODUCT IDENTIFICATION .......................
Page 18 TABLE OF CONTENTS 2.2.15 FIRES CAUSED BY ELECTRICAL WIRING................2.2.16 HOW TO BEHAVE IN CASE OF FIRE..................2.2.17 DETERGENT FOR THE WINDOWS..................2.2.18 ASBESTOS DUST HAZARD PREVENTION ................2.2.19 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........2.2.20 FIRE EXTINGUISHERS AND FIRST AID KIT ................. 2.2.21 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION ..
Page 19 TABLE OF CONTENTS 2.8.10 STABILITY..........................2.8.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION ........................... 2.8.12 BATTERY MAIN SWITCH PRECAUTIONS ................2.8.13 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL ........2.8.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR ............2.8.15 USING LAMPS ........................
Page 20 TABLE OF CONTENTS 3.2.13 TECHNICAL DOCUMENTATION COMPARTMENT ............... 3.2.14 TOOL BOX ..........................USE OF THE MACHINE AND RELATED CONTROLS................ 3.3.1 BEFORE STARTING THE ENGINE..................3.3.1.1 VISUAL CHECKS....................3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ....3.3.1.3 ADJUSTMENTS...................... 3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ..
Page 21 4.2.1.1 OIL .......................... 4.2.1.2 FUEL ........................4.2.1.3 COOLANT ....................... KOWA  4.2.1.4 (KOMATSU OIL WEAR ANALYSIS) ............... 4.2.1.5 STORING OIL AND FUEL ..................4.2.1.6 FILTERS ......................... 4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM ........4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM........
Page 22 TABLE OF CONTENTS 4.8.2.b CHANGING THE HYDRAULIC OIL ................ MAINTENANCE PROCEDURES ......................4.9.1 WHEN REQUIRED........................4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE.... 4.9.1.b CHECKING THE BATTERY CHARGE LEVEL ............4.9.1.c CLEANING THE WATER SEPARATOR FILTER ..........4.9.1.d DRAINING THE FUEL TANK .................. 4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION......
Page 23 TABLE OF CONTENTS 6.1.3 PRECAUTIONS WHEN REMOVING OR INSTALLING............6.1.4 PRECAUTIONS WHEN USING ....................SPECIFICATIONS..........................6.2.1 ARM-PIN INFORMATION ......................ATTACHMENT GUIDE.......................... 6.3.1 COMBINATIONS OF WORK EQUIPMENT ................6.3.2 ATTACHMENT CONFIGURATION ..................MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS ........ 6.4.1 POSITION OF THE DEVICES ....................
Page 24 THIS PAGE WAS INTENTIONALLY LEFT EMPTY WEAM012405...
Page 25: Safety And Accident Prevention
SAFETY AND ACCIDENT PREVENTION WEAM012405...
Page 26: Safety, Noise And Vibration Plates
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Distributor. In case of replacement of a component provided with a safety plate, make sure that such a plate is applied also to the new part.
Page 27: Pictograms And Relevant Meanings
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine include or are accompanied by pictograms. The staff in charge with the operation and maintenance of the machine must be perfectly familiar with the symbols contained in the pictograms;...
Page 28 SAFETY, NOISE AND VIBRATION PLATES PLATFORM LIFTING SAFETY PLATE Insert a lock pin to keep tilted floor in a safe place. 22F-98-33690 RKA28230 CAUTION WHEN STOWING FRONT WINDOW (only with cab) Make sure that the front windshield is always locked. 09803-A0481 RKA29850 LATERAL STABILITY...
Page 29 SAFETY, NOISE AND VIBRATION PLATES BATTERY MAIN SWITCH 22E-98-21140 RKA24350 395-93-13551 RKA29490 10 - PRECAUTIONS WITH THE KOMTRAX  SYSTEM (if equipped) The signal indicates danger of explosion caused by a radio transmitter active in an explosive area. Keep the machine at a safe distance from an explosive area and from a detonator.
Page 30 SAFETY, NOISE AND VIBRATION PLATES CAUTION WHEN HANDLING BATTERIES Never smoke or use any naked flame near the batteries, no sparks. Always wear safety glasses when working with batteries. Keep children away from batteries. Caution - battery acid. WEAM012405...
Page 31 SAFETY, NOISE AND VIBRATION PLATES Read the operator’s manual before working with batteries. Caution - explosive gases. CAUTION WHEN STANDING IN OPERATOR CAB 09839-A0480 RKA29080 Before standing up from the operator's seat (such as when opening or closing the front window, or when adjusting the oper- ator's seat), always lower the work equipment completely to the ground, set lock lever (1) securely to the LOCK position, then stop the engine.
Page 32 SAFETY, NOISE AND VIBRATION PLATES HYDRAULIC OIL TOPPING UP (Only for machines in which synthetic biodegradable oil type HEES is used). BIO-OIL RKA14710 HYDRAULIC OIL TOPPING UP 22F-98-33630 RKA28970 ENGINE LUBRICATING OIL FILTER 22F-98-33640 RKA29000 FUEL FILTER 6217-71-6860 RKA29960 WEAM012405...
Page 33 SAFETY, NOISE AND VIBRATION PLATES AF-NAC ENGINE COOLANT Fill Komatsu genuine engine coolant AF-NAC to prevent radia- tor damage by corrosion. AF-NAC 09642-A0480 RKA29010 HYDRAULIC OIL TOPPING UP 21D-98-11230 RKA29760 REFUELLING 21D-98-11220 RKA29670 ENGINE OIL FILTER 21D-98-11190 RKA29770 FUEL FILTER...
Page 34 SAFETY, NOISE AND VIBRATION PLATES ENGINE AIR INTAKE FILTER 21D-98-11180 RKA30000 ENGINE COOLANT 21L-09-R4170 RKA29680 ENGINE COOLANT PRESSURE 21D-98-11150 RKA29790 HYDRAULIC OIL LEVEL 21D-98-12030 RKA29800 HYDRAULIC OIL FILTER 21D-98-12050 RKA29810 WEAM012405...
Page 35 SAFETY, NOISE AND VIBRATION PLATES POWER OUTLET 12 V 21D-98-12040 RKA30060 ANCHORAGE POINT 21D-98-11860 RKA28810 LIFTING POINT RKA28830 EMERGENCY EXIT (machines with cab) 22L-98-18270 RKA30050 WEAM012405...
Page 36 SAFETY, NOISE AND VIBRATION PLATES LIFTING CAPACITIES W=400mm kg 23 310kg 310kg 285kg 170kg L=965mm 300kg 165kg 140kg 280kg 155kg 145kg 825kg 280kg 195kg > L=1210mm 275kg 150kg 125kg RKA23190 LIFTING CAPACITY  (only for machines equipped with variable width lower car) W=400mm kg 23 310kg 310kg...
Page 37: Position Of The Noise Plates On Machines With Canopy
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Distributor. In case of replacement of a component provided with a noise...
Page 38: Position Of The Noise Plates On Machines With Cab
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Distributor. In case of replacement of a component provided with a noise...
Page 39: Vibrations To Which The Operator Is Subjected
SAFETY, NOISE AND VIBRATION PLATES 2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera- tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 40 SAFETY, NOISE AND VIBRATION PLATES The following guidelines can be effective to minimize risks of low back pain. • Operate the machine only when you are in good health. • Provide breaks to reduce long periods of sitting in the same posture. •...
Page 41: General Precautions
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES Only trained and authorized staff can use the machine and perform maintenance operations. Follow all the safety rules, precautions and instructions when using the machine or performing maintenance op- erations. When working with other operators or when the work site is often occupied by other operators, make sure that everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as to be able to see the machine and to be visible to the operator.
Page 42: Unauthorized Modifications
GENERAL PRECAUTIONS 2.2.5 UNAUTHORIZED MODIFICATIONS Any modification made without the authorization of Komatsu can involve hazards. Before making a modification, consult your Komatsu Distributor. Komatsu declines any responsibility for injury or damage caused by unauthorized modifications. 2.2.6 LEAVING THE OPERATOR SEAT When leaving the operator seat, even if temporarily, make sure that the machine is in a safe position.
Page 43: Emergency Exit
GENERAL PRECAUTIONS 3 - Attach the safety device for tower rotation control. RKAB9080 RKAB9090 4 - Lock the equipment control by shifting the safety lever (1) to the “locked” position (L). 5 - Stop the engine. (See "3.3.4 STOPPING THE ENGINE"). 6 - If you have to go so far away that you will not be able to see the machine, extract the ignition key.
Page 44: Getting On And Off The Machine
GENERAL PRECAUTIONS 2.2.8 GETTING ON AND OFF THE MACHINE Do not jump on or off the machine, neither when it is at rest nor when it is moving. When getting on or off the machine, always use the handles and the tracks; get on and off the machine very carefully. Do not hold or rest on the control levers.
Page 45: Is Forbidden To Climb On The Equipment
GENERAL PRECAUTIONS 2.2.9 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT Do not allow anyone to climb on the bucket, the grapple forks, or other equipment. There is the risk of falling down and be seriously injured. 2.2.10 ARTICULATED PARTS The free space around the work equipment changes depending on the movement of the articulated parts.
Page 46: Preventing Burns
GENERAL PRECAUTIONS 2.2.13 PREVENTING BURNS If the engine coolant, the engine oil and the hydraulic oil are hot, use heavy cloths and wear gloves, heavy clothing and safety goggles before carrying out any check or touching the hot parts. Before checking the coolant level, stop the engine and let the fluid cool down....
Page 47: Asbestos Dust Hazard Prevention
GENERAL PRECAUTIONS 2.2.18 ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste. Al- ways observe the following. Spray water to keep down the dust when cleaning.
Page 48: Falling Objects, Flying Objects And Intruding Objects Prevention
Al- ways contact your Komatsu distributor for advice. In such a case, do not operate the machine without an addition- al guard. Be sure to consult with your Komatsu distributor about necessary guards. WEAM012405...
Page 49: Cautions Related To Rops
If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.
Page 50: Precautions To Be Taken Before Starting The Engine
(earth, stones, etc.). Check the seat belt and change it if it is broken or damaged. Replace any component only with homologated parts available at Komatsu or its Distributors. WEAM012405...
Page 51: Room Ventilation
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.4 ROOM VENTILATION Before starting the machine in confined or poorly ventilated places, provide for proper ventilation or connect the engine ex- haust pipe to a suction duct. The engine exhaust gases can be deadly.
Page 52: Precautions To Be Taken When Working
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.1 STARTING THE ENGINE Before getting on the machine, walk around it and check for people and objects that might be in the way. Do not start the engine if warning plates have been attached to the control levers.
Page 53: Hand Signals
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.3 HAND SIGNALS WARNING When it is necessary to position loads, make excavations or move the machine with reduced field of vi- sion, the operator must be helped by another person standing on the ground and making signals to indi- cate the manoeuvres to be carried out, according to the specific signals defined by the relevant regulations.
Page 54 PRECAUTIONS TO BE TAKEN WHEN WORKING 3 - MOVE THE LOAD AWAY IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical posi- tion directed towards the load to be moved away, move the hand in the direction of the movement to be carried out. RKA15160 4 - BRING THE LOAD NEARER IN HORIZONTAL DIRECTION...
Page 55 PRECAUTIONS TO BE TAKEN WHEN WORKING 9 - FOLD THE ARM With both hands clasped, point the thumbs inwards. RKA15220 10 - EXTEND THE ARM With both hands clasped, point the thumbs outwards. RKA15230 11 - FOLD THE BUCKET Keep one hand still and closed. Rotate the other hand verti- cally with the thumb pointed towards the clasped hand.
Page 56 PRECAUTIONS TO BE TAKEN WHEN WORKING 15 - TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels. RKA15280 16 - TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels. RKA15290 17 - DISTANCE TO BE COVERED...
Page 57 PRECAUTIONS TO BE TAKEN WHEN WORKING 21 - STOP THE ENGINE Pass thumb or forefinger across the throat. RKA15340 WEAM012405...
Page 58: Checks For Travelling In Reverse
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.4 CHECKS FOR TRAVELLING IN REVERSE When operating in areas that may be hazardous or have poor visibility, designate a person to direct the movements of the ma- chine and traffic on the work site. Make sure that no unauthorized person is within the machine operating range or in its travel direction....
Page 59: Moving On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 MOVING ON SLOPES Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip. On hills, banks or slopes, keep the bucket very close to the ground (20-30 cm from the ground), and in case of emergency quickly lower it to the ground to help the machine stop.
Page 60: Working On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.7 WORKING ON SLOPES Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip. When working on slopes (max. inclination 10°), avoid turning the turret, if possible, since this may cause the machine to lose balance and overturn....
Page 61 PRECAUTIONS TO BE TAKEN WHEN WORKING Do not pass the bucket over the heads of other workers or over the operator's seat of dump trucks or other haul- ing equipment. There is danger that the load may spill or the bucket may hit the dump truck and cause serious personal injury or death.
Page 62: Preventing Electrocution
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.9 PREVENTING ELECTROCUTION Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution; for this reason, when working near overhead electric lines always respect the minimum safety dis- tances prescribed by the competent authorities and by the accident-prevention rules in force.
Page 63: Visibility
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.10 VISIBILITY Make sure that there are no people or obstacles in the area surrounding the machine and check the conditions of the worksite to ensure that all operations and movements can be carried out safely. Switch on the work lights as soon as visibility decreases.
Page 64: Parking The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.14 PARKING THE MACHINE Park the machine on firm and level ground. If this is not possible and it is necessary to park on a slope, position the machine with the bucket directed downwards and carry out the following op- erations: 1 - Rotate the bucket to the dumping position and lower the arms until thrusting the teeth into the ground.
Page 65: Transporting The Machine On Motor Vehicles
TRANSPORTING THE MACHINE ON MOTOR VEHICLES 2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE Loading and unloading the machine on/from a motor vehicle al- ways involves potential hazards. Proceed with extreme care. Perform loading and unloading operations on firm, level ground. Maintain a safety distance from the edges of ditches or from road sides.
Page 66: Battery
BATTERY 2.6 BATTERY 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY Electrolytic batteries contain lead and sulphuric acid, which can cause burns. It can also corrode clothing and make holes in it. In case of contact with battery acid, immediately wash the af- fected part with plenty of water.
Page 67: Starting With Booster Cables
BATTERY 2.6.2 STARTING WITH BOOSTER CABLES When starting the machine with booster cables, always wear safety goggles. When starting the engine by means of another machine, avoid any contact between the two machines. Before connecting the additional cables, make sure that both the starter key and the battery main switch are turned to OFF.
Page 68: Precautions For The Removal Of The Machine
PRECAUTIONS FOR THE REMOVAL OF THE MACHINE 2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE Before removing the machine, make sure that all the controls are in neutral. Incorrect manoeuvres may cause serious damage, personal in- jury and even death. To move the machine, use properly dimensioned steel cables;...
Page 69: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE 2.8 PRECAUTIONS FOR MAINTENANCE 2.8.1 WARNING PLATES Before starting any maintenance operation, position the ma- chine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and the con- trols, and stop the engine.
Page 70: Equipment
60 cm, in order not to damage the warning plates and the pictograms. If the plates are damaged, request Komatsu or your Komatsu Distributor to send you spare plates and change them. Water into the electrical system provokes the oxidation of the contacts and may hinder the start of the machine or even make it start suddenly and abruptly.
Page 71: Use Of The Engine During Maintenance
PRECAUTIONS FOR MAINTENANCE 2.8.8 USE OF THE ENGINE DURING MAINTENANCE During maintenance operations, make the engine run only when indispensable. If it is necessary to have the en- gine running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator should constantly remain in the cab, in order to be able to stop the engine whenever necessary.
Page 72: Stop The Engine Before Carrying Out Any Maintenance Operation Or
PRECAUTIONS FOR MAINTENANCE 2.8.11 STOP THE ENGINE BEFORE CARRY- ING OUT ANY MAINTENANCE OPER- ATION OR INSPECTION Stop the machine only on firm and level ground and stop the en- gine before carrying out any maintenance operation or inspec- tion. If it is necessary to have the engine running during mainte- nance, shift the safety lever (1) to the “locked”...
Page 73: Rules To Be Followed When Refuelling Or Adding Oil
PRECAUTIONS FOR MAINTENANCE 2.8.13 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL Keep away from naked flames while refuelling or adding oil. Spilled fuel or oil make the ground slippery and may cause acci- dents; clean any dirty area immediately and carefully. Always tighten the safety caps of the fuel tank and of the hy- draulic oil tank securely.
Page 74: Precautions To Be Taken When Handling The Battery And The  Alternator
PRECAUTIONS FOR MAINTENANCE 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR When the electrical system is being repaired or when electric welds are made, turn the battery main switch to OFF (O) to in- terrupt the current (see "3.2.2 pos: 10. Battery main switch"). If electric welds are necessary for the machine, besides discon- necting the battery, disconnect the alternator and the KOMT- RAX system control unit.
Page 75: Precautions To Be Taken When Handling High-Pressure Oil
PRECAUTIONS FOR MAINTENANCE 2.8.19 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL Do not forget that the work equipment circuits are always under pressure; for this reason, when it is necessary to add or drain hydraulic oil or to perform maintenance operations or inspec- tions on the hydraulic circuit, it is advisable to lower the equip- ment to the ground and completely release the pressures and the residual pressure present in the tank....
Page 76: Precautions To Be Taken When Using High-Pressure Grease To
Do not attempt to remove the spring, since this may lead to serious accidents and even death. For any operation on the shock absorber unit, contact your Komatsu Distributor. 2.8.23 HYDRAULIC ACCUMULATOR The hydraulic accumulator contains pressurized nitrogen....
Page 77: Cooling Fan And Belt
2.8.25 CHEMICAL HAZARD During maintenance or dismalting operations, where there is a risk of contact with hazardous chemical substanc- es, relevant safety precautions should be taken. If any doubt exists, contact your Komatsu distributor. See also disposal of "2.8.26 WASTE MATERIALS".
Page 78: Elastomers
(see "3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE" - " CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP"). 2.8.30 FINAL DISPOSAL OF THE MACHINE At the end of the working life of the machine, ask Komatsu Distributor for the final disposal. WEAM012405...
Page 79: The Machine And Its Operations
THE MACHINE AND ITS OPERATIONS WEAM012405...
Page 80: Machine Illustrations
MACHINE ILLUSTRATIONS 3.1 MACHINE ILLUSTRATIONS 3.1.1 OVERALL VIEW OF THE MACHINE RKA22480 (1) Bucket (7) Track (2) Bucket cylinder (8) Sprocket (3) Arm (9) Undercarriage (4) Arm cylinder (10) Idler roller (5) Boom (11) Cylinder blade Boom cylinder (12) Blade WEAM012405...
Page 81: Controls And Gauges
MACHINE ILLUSTRATIONS 3.1.2 CONTROLS AND GAUGES RKA26570 (1) (16) Hour counter Operator seat (2) (17) Translation speed increase warning light Scraper selector switch/variable width  (18) Engine water temperature warning light (if fitted) (3) Control locking lever (19) Engine preheat warning light (4)...
Page 82: Instruments And Controls
INSTRUMENTS AND CONTROLS 3.2 INSTRUMENTS AND CONTROLS The following paragraphs describe the devices that are necessary for correct operation of the machine. To perform the required operations correctly and safely, it is important to understand the equipment operating methods and the meaning of the information displayed. 3.2.1 WARNING LIGHTS AND GAUGES (A):...
Page 83: Emergency Warning Lights
INSTRUMENTS AND CONTROLS 3.2.1.1 EMERGENCY WARNING LIGHTS CAUTION If a warning light does not go out or comes on when the engine is running, stop the machine immediate- ly and try to find the cause of the failure. Engine oil pressure warning light Battery charge level warning light Engine oil pressure warning light It comes on when the engine is off, when the start-up circuit is ac-...
Page 84: Gauges
INSTRUMENTS AND CONTROLS 3.2.1.2 GAUGES Fuel gauge Hour meter Fuel gauge It indicates the fuel level in the tank and functions only when the ignition key is in position ON (see "3.2.2 pos: 1. Ignition switch"). F: maximum level. E: minimum level.  If the quantity of fuel in the tank is less than 3.3 litres, the indicator reaches the red reserve area (A).
Page 85: Warning Lights
INSTRUMENTS AND CONTROLS 3.2.1.3 WARNING LIGHTS Engine preheating warning light Travel speed increase warning light (1) (2) Engine coolant temperature warning light Engine preheating warning light This warning light comes on when the ignition key is turned to the preheating position (HEAT) to start the engine at low tempera- tures.
Page 86 INSTRUMENTS AND CONTROLS Engine coolant temperature warning light This warning light comes on when the engine coolant exceeds the maximum temperature allowed; in this case, reduce the engine speed until the warning light goes out. If this inconvenience oc- curs again, make sure that the radiator is clean. RKA13940 WEAM012405...
Page 87: Switches And Push Buttons
INSTRUMENTS AND CONTROLS 3.2.2 SWITCHES AND PUSH BUTTONS NOTE For the details of proportional control switch see "6.5 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls)". RKA26580 (1) Starter switch (6) Power socket Horn  (2) (7) Windscreen wiper switch (machines with cab) Working lights switch ...
Page 88 INSTRUMENTS AND CONTROLS corresponding warning light goes out. Release the key, which will automatically return to position OFF. Start the engine by rotating the key to position START. IMPORTANT If the engine has stopped due to lack of fuel, start it by proceeding as follows: turn the ignition switch to position ON, wait for 15 seconds and then turn the key to position START.
Page 89 INSTRUMENTS AND CONTROLS Blade/adjustable track gauge selection switch (if provided) WARNING Use the narrow track gauge only when it is necessary to go through narrow passages or when there is no other choice. For normal applications and digging operations, always se- lect the wide track gauge.
Page 90 INSTRUMENTS AND CONTROLS Windshield wiper switch (machines with cab) Switch (7) activates the front windscreen wiper and it is also used as windscreen washer switch. The switch functions as described below: Windshield wiper only Press the switch to position (B) to start the windshield wiper. Position (A): windshield wiper off.
Page 91 INSTRUMENTS AND CONTROLS 10. Battery main switch The battery main switch is located inside the engine compartment and can be reached by opening the engine bonnet (see "3.2.6 ENGINE HOOD"). Turn the key anticlockwise, to (O) OFF, to interrupt the current supplied by the battery to the electrical system;...
Page 92: Control Levers And Pedals
INSTRUMENTS AND CONTROLS 3.2.3 CONTROL LEVERS AND PEDALS RKA22530 Safety lever  (1) (7) 1st boom swing control pedal   (control locking lever) locking device Left work equipment control lever  (2) (8) 1st boom swing control pedal (3) Right work equipment control lever...
Page 93 INSTRUMENTS AND CONTROLS Safety lever (control locking lever) WARNING Before leaving the driver seat, lower the equipment to the ground and shift the safety lever to the “locked” position (L). If the safety lever is not in the “locked” position and the control levers are touched by mistake, this may lead to serious injury.
Page 94 INSTRUMENTS AND CONTROLS 2. - 3. Work equipment control levers NOTE For the details of proportional control switch see "6.5 PREPA- RATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls)". WARNING Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt.
Page 95 INSTRUMENTS AND CONTROLS The control lever (3) is positioned on the operator’s right and con- trols the boom and the bucket. Boom (e) Lift  (f) Lower Bucket (g) Open (h) Fold N (Neutral): the boom and the bucket are held in the position where they stopped.
Page 96 INSTRUMENTS AND CONTROLS Travel levers NOTE The travel pedals indicated in the figure are optional and are supplied only upon request. WARNING Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt.
Page 97 INSTRUMENTS AND CONTROLS Boom swing control pedal locking device WARNING Always shift the safety lever to position (L) when the boom swing is not required, during travel and when parking the machine. If the control pedal is inadvertently pressed, this may cause serious accidents.
Page 98 INSTRUMENTS AND CONTROLS Tower rotation locking lever WARNING When the machine is moved and transported, the lever should be set to the locking position; place the lever in the locking position after positioning the upper tower parallel to the lower car. While the machine is moved, make sure that the upper tow- er is oriented towards the scraper;...
Page 99 INSTRUMENTS AND CONTROLS 12. Platform locking lever (machines with cab) WARNING Always keep to the warnings when tilting or closing the cab floor. Any operation carried out incorrectly may cause seri- ous injury. Do not tilt or close the cab floor on slopes or if there is a strong wind.
Page 100: Cab (If Provided)
(ROPS/FOPS level 1). If there is a collision against the machine, or in case it turns over, have a Komatsu Distributor check that the cab complies with the stiffness and active safety standards the operator needs.
Page 101 INSTRUMENTS AND CONTROLS Seize the handles (A) at the right or left top of the front wind- screen and push the locking levers (B) down to release the windscreen. RKAB9680 RKAB9690 Seize the handles (C) and (D), pull up the windscreen and push it until the lock (E) is tripped.
Page 102 INSTRUMENTS AND CONTROLS Closing WARNING When closing the windshield, lower it slowly and pay atten- tion to your hands. Stop the machine on a level surface, lower the equipment completely to the ground, then stop the engine. Shift the safety lever to the “locked” position. Release the windscreen by means of the upper lock (E) le- ver.
Page 103: Door (Machines With Cab)
INSTRUMENTS AND CONTROLS 3.2.4.2 DOOR (machines with cab) WARNING When the cab door is opened or closed, always take the safety device lever to the locking position (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents.
Page 104: Side Sliding Window (Machines With Cab)
INSTRUMENTS AND CONTROLS SIDE SLIDING WINDOW  3.2.4.3 (machines with cab) WARNING When opening or closing the side window, always shift the safety lever to position “lock” (L). If the control levers are not locked and are inadvertently operated, there is the risk of serious accidents.
Page 105: Coverswith Lock
INSTRUMENTS AND CONTROLS 3.2.5 COVERSWITH LOCK Use the ignition key to open and close the covers with lock. For details on the position of the covers with lock, see "3.3.17 LOCKING THE MACHINE". Introduce the key completely (6 mm from the point where the key narrows), then turn it.
Page 106: Engine Hood
INSTRUMENTS AND CONTROLS 3.2.6 ENGINE HOOD WARNING Do not open the engine hood when the engine is running. Do not use the machine without engine hood and do not start the engine when the hood is open, unless this is expressly prescribed for certain maintenance operations. When carrying out an inspection or maintenance operation inside the engine hood, always open it com- pletely and make sure that it is kept open by the apposite rod.
Page 107: Radiator Cover
INSTRUMENTS AND CONTROLS 3.2.7 RADIATOR COVER WARNING When carrying out an inspection or maintenance operation inside the radiator cover, always open it completely and make sure that it is kept open by the apposite rod. OPENING THE BATTERY COVER Release the radiator cover lock (1) (see "3.2.5 COVERS- WITH LOCK").
Page 108: Battery Cover
INSTRUMENTS AND CONTROLS 3.2.8 BATTERY COVER When inspections and maintenance operations are required in- side the battery housing, remove the fixing screws (1) and com- pletely remove the housing (2). RKA22730 After the inspections or maintenance operations, reassemble the battery housing (2). RKA22740 WEAM012405...
Page 109: Tilting The Cab Floor (Machines With Canopy)
If there is something wrong in the locking function when the cab floor is tilted, interrupt work and have the necessary repairs carried out by your Komatsu Distributor. Always fasten the platform fixing screws to the torque in compliance with the values included in the sec- tion "4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS".
Page 110 INSTRUMENTS AND CONTROLS Position blocks under the tracks in order to prevent the ma- chine from moving. 9 J A 0 5 4 6 6 Open the engine hood (2) completely and make sure that it is kept open by the apposite rod (for further details, see "3.2.6 ENGINE HOOD").
Page 111 Tighten the cab floor fastening screws (3) applying the re- quired torque. Tightening torque: 156.8 to 196 Nm NOTE If any screw is damaged, replace it with an original Komatsu part having the same size. Close the engine hood (2). WEAM012405...
Page 112: Tilting The Cab Floor (Machines With Cab)
If there is something wrong in the locking function when the cab floor is tilted, interrupt work and have the necessary repairs carried out by your Komatsu Distributor. Always fasten the platform fixing screws to the torque in compliance with the values included in the sec- tion "4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS".
Page 113 INSTRUMENTS AND CONTROLS Position blocks under the tracks in order to prevent the ma- chine from moving. 9 J A 0 5 4 6 6 Open the engine hood (2) completely and make sure that it is kept open by the apposite rod (for further details, see "3.2.6 ENGINE HOOD").
Page 114 INSTRUMENTS AND CONTROLS After tilting the floor open, make sure that the locking pin (7) is inserted in the groove (9) of the locking plate (8). Insert the safety pin (10) into the hole (11) from the outside. 10. Turn until the coupling at the end of the safety pin (10) is completely engaged with the pin (12).
Page 115 Tighten the cab floor fastening screws (3) applying the re- quired torque. Tightening torque: 156.8 to 196 Nm NOTE If any screw is damaged, replace it with an original Komatsu part having the same size. Close the engine hood (2). WEAM012405...
Page 116: Fuses
INSTRUMENTS AND CONTROLS 3.2.11 FUSES IMPORTANT Before replacing fuses, be sure to first turn the starting switch to the OFF position, wait for over one minute, then switch the battery disconnect switch to OFF and take out the battery disconnect switch key. If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 117: Main Fuse
INSTRUMENTS AND CONTROLS 3.2.12 MAIN FUSE IMPORTANT Before replacing fusible links, be sure to first turn the start- ing switch to the OFF position, wait over one minute, then switch the battery disconnect switch to OFF and take out the battery disconnect switch key. If the starter does not run when the ignition switch is turned to po- sition ON, the fuse (1) may have blown.
Page 118: Use Of The Machine And Related Controls
Always perform thorough checks and carry out the necessary repairs; if any fault occurs repeatedly, contact your Komatsu Distrib- utor. Make sure that the cab floor is properly fastened with the screws (1). If it is not secured properly, it may cause serious injury.
Page 119: Checks To Be Carried Out Before Starting The Engine
(1) are correctly tightened. If there are loose screws, tighten them. If any anomaly is observed, carry out the necessary repairs or have them carried out by your Komatsu Distributor. 3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE Carry out the checks listed below every day before starting the engine.
Page 120 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE ENGINE OIL LEVEL AND TOPPING UP WARNING Soon after the machine has been stopped the engine is very hot and may cause burns; let the engine cool down to 40-45°C before carrying out any check. CAUTION When carrying out an inspection or maintenance operation inside the engine hood, always open it com- pletely and make sure that it is kept open by the apposite rod.
Page 121 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE FUEL LEVEL AND REFUELLING WARNING When refuelling, avoid spilling fuel, since this may cause a fire hazard. If fuel is spilled, wipe it up imme- diately. Fuel is highly flammable; do not use naked flames and do not smoke when refuelling. Hold the fuel gun constantly in contact with the filler.
Page 122 USE OF THE MACHINE AND RELATED CONTROLS CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP WARNING Carry out this check when the oil is cold, with the machine positioned on level ground, bucket and arm cylinders re- tracted and bucket teeth resting on the ground.
Page 123 USE OF THE MACHINE AND RELATED CONTROLS Extend the boom, arm and bucket cylinders completely, as shown in the diagram on the right, and remove the filler cap. Put back the cap and pressurize the tank, lowering the equip- ment to the ground. IMPORTANT If a constant or abnormal decrease in the oil level is ob- served, thoroughly check the hydraulic circuit, the pistons...
Page 124 OFF. If the wirings show traces of short circuits, contact your Komatsu Distributor, who will locate the fault and carry out any necessary repairs.
Page 125 Turn the ignition switch to position ON. Press the button positioned on the right lever and make sure that the horn functions correctly. If the horn does not sound, contact your Komatsu Distributor, who will carry out the necessary repairs. RKA10590...
Page 126: Adjustments
USE OF THE MACHINE AND RELATED CONTROLS 3.3.1.3 ADJUSTMENTS WARNING Adjust the position of the seat before starting work or when taking the place of another operator. Adjust the seat so that the control levers and the switches can be easily used by the operator seated with his back against the backrest.
Page 127 USE OF THE MACHINE AND RELATED CONTROLS SEAT BELT WARNING Before fastening the seat belt, make sure that the fastening brackets or the belt itself do not show any anomaly. If there are damaged or worn parts, change the belt. The safety belt can be replaced also if there are not failures or wear signs according to the following pro- gram.
Page 128: Operations To Be Carried Out Before Starting The Engine
If a warning light or a gauge does not come on, this may be due to a faulty fuse or bulb, or to an interruption in the wirings, therefore it is advisable to contact a Komatsu Dis- tributor, who will provide for the necessary repairs.
Page 129 If it does not function, this may be due to a faulty bulb, or to an interruption in the wirings, therefore it is advisable to contact a Komatsu Distributor, who will provide for the necessary repairs. RKA23540 3) Press the horn button (7) to make sure that the horn func- tions correctly.
Page 130: Starting The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2 STARTING THE ENGINE 3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES WARNING Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. From the moment at which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non- compliance with the safety regulations and the rule of the road..
Page 131 USE OF THE MACHINE AND RELATED CONTROLS Turn the ignition key (3) to position START to start the engine. RYA17360 As soon as the engine starts, release the key (3), which will automatically return to position ON. RYA17370 WEAM012405...
Page 132: Starting With Cold Engine Or In Cold Climates
USE OF THE MACHINE AND RELATED CONTROLS 3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES WARNING Before starting the engine, carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls. From the moment at which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non- compliance with the safety regulations and the rule of the road..
Page 133 USE OF THE MACHINE AND RELATED CONTROLS Turn the ignition key (3) to the preheating position (HEAT) and make sure that the preheating warning light (4) comes on. After approximately 10 seconds, the warning light (4) goes out, indicating that the preheating phase has been completed.
Page 134: After Starting The Engine
3.3.3.1 RUNNING IN A NEW MACHINE CAUTION Komatsu machines are adjusted and tested completely before shipment. However, operating the ma- chine under severe conditions at the beginning can adversely affect the performance of the machine and shorten its life. It is advisable to run in the machine for the first 100 hours of operation (as indicated by the hour meter)....
Page 135: Warming-Up Operations
USE OF THE MACHINE AND RELATED CONTROLS 3.3.3.2 WARMING-UP OPERATIONS IMPORTANT Do not carry out any operation and do not shift the levers suddenly when the hydraulic oil temperature is too low. Always carry out the warming up operations. This will lengthen the life of the machine. Do not accelerate abruptly before completing the warming-up operations.
Page 136 Make sure that the colour of the exhaust gases is normal and that there are no strange noises or vibrations. If any anomaly is observed, contact your Komatsu Distributor. Shift the safety lever (2) to the “locked” position (L), then make sure that the machine does not move even when the levers and pedals are operated.
Page 137: Stopping The Engine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.4 STOPPING THE ENGINE IMPORTANT The sudden stop of the engine while it is running shortens its life. Do not stop the engine suddenly, except in case of emergency. It is likewise recommended not to stop the engine suddenly if it has been running for a long period and is still hot;...
Page 138: How To Move The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.5 HOW TO MOVE THE MACHINE WARNING Before moving the machine, make sure that you perfectly know the control functions and all the relevant safety regulations. The operator must be seated in the driving position with fastened seat belt. Before operating the travel levers, check the direction of the undercarriage.
Page 139 USE OF THE MACHINE AND RELATED CONTROLS • When the sprocket (A) is at the rear of the machine, push the levers (3) slowly forward to move the machine off. • When the sprocket (A) is at the front of the machine, pull the levers (3) slowly backward to move the machine off.
Page 140: Moving The Machine In Reverse
USE OF THE MACHINE AND RELATED CONTROLS 3.3.5.3 MOVING THE MACHINE IN REVERSE Move the safety lever (2) to working position (F), then lift the working tools 40-50 cm off the ground. Lift the blade. Opearate both travel levers (3) as explained below. RKA01610 •...
Page 141: Stopping The Machine
USE OF THE MACHINE AND RELATED CONTROLS • When the machine is travelling at high speed, the travel speed increase warning light (5) comes on. For details on the travel speed, see paragraph ."5.1 TECH- NICAL SPECIFICATIONS" NOTE When the engine is started, the low speed is automatically selected. When the machine travels at high speed on soft ground or up a slope and the load increases, the low speed is automatically selected, but the travel speed increase warning light remains on.
Page 142: Steering The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.6 STEERING THE MACHINE 3.3.6.1 STEERING (CHANGING DIRECTION) WARNING Before operating the travel control levers, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levers is inverted. Avoid abrupt changes of direction as much as possible.
Page 143 USE OF THE MACHINE AND RELATED CONTROLS STEERING (CHANGING DIRECTION) When steering to the left: If the left travel lever is shifted back to the neutral position, the machine will steer to the left. NOTE To steer to the right, operate the right travel lever in the same way.
Page 144: Swinging The Turret
USE OF THE MACHINE AND RELATED CONTROLS 3.3.7 SWINGING THE TURRET WARNING Before rotation, make sure that the area surrounding ma- chine is free of any kind of obstacles. Before rotation, take the rotation locking lever (1) to the UN- LOCKING position.
Page 145: Work Equipment Controls And Functions
USE OF THE MACHINE AND RELATED CONTROLS 3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS The work equipment is controlled by means of the right and left work equipment control levers. The left lever con- trols the arm and the turret swing, while the right lever controls the boom and the bucket. When the levers are re- leased, they automatically return to the neutral position and the work equipment remain in the position where they stopped.
Page 146 USE OF THE MACHINE AND RELATED CONTROLS Boom swing control To swing the boom, use the boom swing control pedal. Blade control Select the use of the blade with the blade/adjustable track gauge selection switch. To operate the blade, shift the lever positioned to the right of the operator seat forward or backward.
Page 147 USE OF THE MACHINE AND RELATED CONTROLS Track gauge adjustment control (version with adjustable track gauge) WARNING Select the narrow track gauge only when the machine must travel in small spaces. For normal applica- tions and digging operations, always select the wide track gauge. Adjusting the track gauge on slopes is dangerous, since this may affect the lateral stability of the ma- chine.
Page 148: Unauthorized Operations
USE OF THE MACHINE AND RELATED CONTROLS 3.3.9 UNAUTHORIZED OPERATIONS WARNING If it is necessary to operate the work equipment control levers while the machine is moving, carry out this operation with the maximum care. PERATIONS FOR WHICH IT IS NOT ALLOWED TO EXPLOIT THE TURRET SWING...
Page 149 USE OF THE MACHINE AND RELATED CONTROLS OPERATIONS FOR WHICH IT IS NOT ALLOWED TO EX- PLOIT THE DROPPING FORCE OF THE BUCKET Do not exploit the dropping force of the bucket to use it as a pickaxe, breaker, or pile driver. This may considerably reduce the life of the machine.
Page 150: Precautions For Use
USE OF THE MACHINE AND RELATED CONTROLS 3.3.10 PRECAUTIONS FOR USE TRAVELLING Travelling on big stones, logs or other obstacles subjects the frame and in particular the tracks to considerable strain, which damages the machine. For this reason, it is always advisable to remove any obstacles or to avoid them, if possible.
Page 151 USE OF THE MACHINE AND RELATED CONTROLS MAXIMUM WATER DEPTH CAUTION When driving the machine out of water, if the inclination of the machine exceeds 15°, the rear of the turret will be sub- merged, and this may cause the cooling fan to break. Be extremely careful when driving the machine out of wa- ter.
Page 152: Precautions To Be Taken When Travelling On Slopes
USE OF THE MACHINE AND RELATED CONTROLS 3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES WARNING When travelling downhill on steep slopes, slow down using the travel levers and the hand accelerator. Do not travel downhill on slopes whose inclination exceeds 15°.
Page 153 USE OF THE MACHINE AND RELATED CONTROLS When travelling uphill on a slope, position the work equip- ment as shown in the diagram on the right. 20-30 cm 15˚max. RKA17480 BRAKING WHEN TRAVELLING DOWNHILL To brake when travelling downhill, shift the travel levers to the neutral position. This will automatically engage the brakes.
Page 154: Getting The Machine Out Of Mud
USE OF THE MACHINE AND RELATED CONTROLS 3.3.12 GETTING THE MACHINE OUT OF MUD Always proceed carefully to avoid getting stuck in mud. However, if the machine gets stuck in mud, proceed as in- dicated below. WHEN ONE SIDE ONLY GETS STUCK IMPORTANT When using the boom or arm to raise the machine, always place the bottom of the bucket in contact with the ground.
Page 155: Operations That Can Be Performed With The Hydraulic Excavator
USE OF THE MACHINE AND RELATED CONTROLS 3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR In addition to those indicated below, many other applications are possible, thanks to the use of various attach- ments. EXCAVATION When the machine is in the position shown in the diagram on the right, the maximum digging force and thrusting force of the single cylinders is obtained when the bucket cylinder and the relevant articulation, the arm cylinder and the arm are at 90°...
Page 156 USE OF THE MACHINE AND RELATED CONTROLS LEVELLING OPERATIONS Use the blade to fill excavations and level the ground surface. For refilling operations, widen the track gauge and the blade. RYA02570 SIDE DITCHING WORK It is possible to use the machine for side ditching work in limited spaces, by combining the turret and the boom swing.
Page 157: Changing The Bucket
USE OF THE MACHINE AND RELATED CONTROLS 3.3.14 CHANGING THE BUCKET WARNING When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet. The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during work.
Page 158: Parking The Machine
USE OF THE MACHINE AND RELATED CONTROLS 3.3.15 PARKING THE MACHINE WARNING Avoid stopping the machine abruptly. Always calculate a sufficient safety distance when stopping. Park the machine on firm and level ground. Avoid parking 120˚ the machine on slopes. If it is absolutely necessary to park the machine on a slope, put blocks under the tracks and thrust the work equipment into the ground to prevent the machine from moving.
Page 159 USE OF THE MACHINE AND RELATED CONTROLS Lower the bucket keeping it in horizontal position, until its bot- tom touches the ground. Lower the blade to the ground. RYA17850 Shift the safety lever (3) to the “locked” position (L). RKA22990 WEAM012405...
Page 160: Checking The Machine Every Day After Work
USE OF THE MACHINE AND RELATED CONTROLS 3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK 3.3.16.1 BEFORE STOPPING THE ENGINE At the end of work, before stopping the engine, check the engine coolant temperature warning light (1), the engine oil pressure warning light (2) and the fuel level on the gauge (3).
Page 161: Rubber Tracks (Machines Equipped With Rubber Tracks Only)
USE OF THE MACHINE AND RELATED CONTROLS 3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only) 3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS Rubber tracks have exceptional characteristics that cannot be found in steel tracks. However, if they are used in the same way as steel tracks, the advantages they offer cannot be fully exploited....
Page 162: Use Of The Rubber Tracks
USE OF THE MACHINE AND RELATED CONTROLS 3.3.18.3 USE OF THE RUBBER TRACKS UNAUTHORIZED USES Keep to the following instructions. Avoid performing rotations or other operations on broken rocks, very hard rocks, steel bars, scraps, or near the edges of steel plates, since this may damage the rubber tracks. In places like river beds, where there is a great quantity of large and small stones, these may get stuck in the tracks, and damage them or cause them to come off.
Page 163 USE OF THE MACHINE AND RELATED CONTROLS Avoid steering when moving on kerbs, rocks or areas with considerable differences in height (more than 20 cm). When the machine moves in these conditions, always position it perpendicular to the obstacles. RYA02770 When travelling up slopes in reverse, avoid steering at the beginning of the slope.
Page 164 USE OF THE MACHINE AND RELATED CONTROLS Detachment of the rubber track from the track frame When the machine moves over an obstacle, a gap forms be- tween the carrier roller and the rubber track. In these condi- tions, the rubber track may come off. RYA02800 Furthermore, if the machine travels in reverse, a gap forms between the carrier roller, the idler roller, and the rubber...
Page 165 USE OF THE MACHINE AND RELATED CONTROLS If the machine travels in reverse in these conditions, the rubber track will come off. RYA02820 If the machine steers in these conditions, the rubber track will come off. RYA02830 WEAM012405...
Page 166: Transporting The Machine
TRANSPORTING THE MACHINE 3.4 TRANSPORTING THE MACHINE When transporting the machine, observe all the laws and regulations in force, paying special attention to safety. 3.4.1 TRANSPORT PROCEDURE As a general rule, the machine must be transported on a trailer. Choose the trailer according to the weight and size of the machine, as indicated in paragraph "5.1 TECHNICAL SPECIFICATIONS"It is important to remember that the weight and transport size indicated in the technical data may vary according to the type of track, to the type of boom or to the other attachments installed on the machine.
Page 167 TRANSPORTING THE MACHINE During the loading and unloading operations, always use ramps or a platform and proceed as indicated below. LOADING THE MACHINE NOTE Load and unload the machine on/from the trailer on firm and level ground only, and widen the track gauge. Keep a safety distance from the edge of the road.
Page 168 TRANSPORTING THE MACHINE Position the work equipment at the front and the blade at the rear, with the turret and the undercarriage parallel to each other. Move the machine towards the ramps and lower the work equipment as much as possible, taking care to prevent them from touching the trailer.
Page 169 TRANSPORTING THE MACHINE Shift the safety lever to the “locked” position (L). Lock the sliding door (machines with cab) and the covers with lock, see paragraph. See paragraph "3.2.5 COVERSWITH LOCK". IMPORTANT Do not use the hole in the back of the undercarriage to tow or lift the machine.
Page 170 TRANSPORTING THE MACHINE Use chains or ropes of adequate resistance. Connect one end to the coupling holes placed on the lower frame and the other end of the trailer. X: 50-100 mm NOTE Make sure that the chains or ropes do not interfere with the low- er frame.
Page 171 TRANSPORTING THE MACHINE UNLOADING THE MACHINE NOTE Load and unload the machine on/from the trailer on firm and level ground only, and widen the track gauge. Keep a safety distance from the edge of the road. Firmly engage the trailer brakes and place the wedges (1) under the wheel to prevent it from moving.
Page 172 TRANSPORTING THE MACHINE Run the engine at low speed. (A): Idling Lift the blade. RKA16490 Lift the work equipment, make sure that the travel direction is in line with the ramps and start travelling slowly. Lower the work equipment as much as possible, without causing interferences....
Page 173: Lifting The Machine
TRANSPORTING THE MACHINE 3.4.3 LIFTING THE MACHINE WARNING To lift the machine, the cables and the upper lifting bar used must be properly sized; do not use worn ca- bles or cables with broken strands. Do not lift the machine before the operator has got off and make sure that there is no one around before lifting it.
Page 174 TRANSPORTING THE MACHINE Shift the safety lever to the “locked” position (L). Stop the engine, make sure that the space around the operator seat is clear, then get off the machine. RKA23010 Install shackles in the lifting holes on both ends of the blade (2 points), then pass the metal cables through them.
Page 175 TRANSPORTING THE MACHINE Install one shackle in the lifting hole provided in the boom, then pass the metal cable through it. AE147970 Connect the ropes to the upper lifting bar as indicated in the figure. IMPORTANT Always use the three coupling points provided for lifting the machine.
Page 176: Using The Machine In The Cold Season
The coolant containing antifreeze is flammable; do not smoke and do not use naked flames during the checks and when preparing the mixture. 1 - Use only Komatsu original coolant antifreeze (AF-NAC) to dilute according to the minimum atmospheric tem- perature indicated in the table in section "4.4.1 COOLANT".
Page 177: Battery
USING THE MACHINE IN THE COLD SEASON 3.5.1.3 BATTERY WARNING The battery produces flammable gas, therefore keep flames and sparks away from it. The battery electrolyte is dangerous. In case of contact with the eyes or the skin, wash with plenty of running water and consult a doctor without delay.
Page 178: Ventilation And Heating
USING THE MACHINE IN THE COLD SEASON 3.5.2 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the opera- tor’s stress both in summer and in winter; these functions also serve to eliminate condensate from the front windshield, thus en- suring visibility during both work and travel.
Page 179: Precautions To Be Taken Every Day At The End Of Work
USING THE MACHINE IN THE COLD SEASON 3.5.3 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK WARNING Making the tracks turn idly is dangerous, therefore it is advisable to keep away from the tracks when car- rying out this operation. To prevent the mud and water present on the undercarriage from freezing, thus making it impossible to move the machine the following morning, always take the following precautions.
Page 180: Long Periods Of Inactivity
LONG PERIODS OF INACTIVITY 3.6 LONG PERIODS OF INACTIVITY 3.6.1 BEFORE A PERIOD OF INACTIVITY IMPORTANT To protect the hydraulic cylinder rods while the machine is not used, position the work equipment as shown in the figure on the right.  (This prevents the cylinder rods from rusting).
Page 181: After A Period Of Inactivity
IMPORTANT If the machine has been stored without carrying out the monthly rust-prevention treatment, have mainte- nance performed by your Komatsu Distributor. Before using the machine after a long period of inactivity, carry out the operations listed below. Recharge the battery and install it on the machine.
Page 182: Troubleshooting
TROUBLESHOOTING 3.7 TROUBLESHOOTING 3.7.1 IF FUEL RUNS OUT COMPLETELY Before starting the engine after running out of fuel, refuel and bleed the fuel system. For details on the bleeding procedure, see "4.9.6.b CHANGING THE FUEL FILTER CARTRIDGE" - " BLEEDING THE FUEL CIRCUIT".
Page 183: Precautions To Be Taken When Working In Particular Conditions
TROUBLESHOOTING 3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDI- TIONS When carrying out digging operations in water, if water gets on the pins of the work equipment, always add grease to the buck- et articulations (1), (2), (3), (4) and (5) before work. When carrying out heavy duty digging and deep digging opera- tions, always add grease to the bucket articulations (1), (2), (3), (4) and (5) (total: 5 points) before work....
Page 184: Removing And Installing The Battery
TROUBLESHOOTING 3.7.5.1 REMOVING AND INSTALLING THE BATTERY Before removing the battery, stop the engine, wait at least one minute, and afterwards turn the battery main switch to OFF and extract the specific key. If a tool is touching the positive terminal and the machine frame at the same time, there is risk of sparking. Upon fitting the battery, make sure that the battery main switch is set to OFF and finally connect the (-) ground cable.
Page 185: Starting With Booster Cables
TROUBLESHOOTING 3.7.5.3 STARTING WITH BOOSTER CABLES When starting the engine with booster cables, proceed as indicated below. CONNECTING AND DISCONNECTING THE BOOSTER CABLES WARNING When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (–). When starting the engine with booster cables, always wear safety goggles.
Page 186 TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Before connecting the batteries via additional cables, make sure that the starter key of both the machines and the battery main switch of the machine to be started are turned to OFF. Connect the additional cables as instructed below and observing the number order in the diagram.
Page 187: Other Troubles
TROUBLESHOOTING 3.7.6 OTHER TROUBLES Always contact your Komatsu Distributor when you have to carry out this operation. If the anomaly or its cause is not included in the table below, contact your Komatsu Distributor for the necessary repair. 3.7.6.1 ELECTRICAL CIRCUIT...
Page 188: Frame
TROUBLESHOOTING 3.7.6.2 FRAME TROUBLE CAUSE SOLUTION • No hydraulic oil. • Restore level. See "CHECKS TO BE Travel speed, swing, boom, arm, CARRIED OUT BEFORE START- bucket slow. ING THE ENGINE". • Foreign body in the hydraulic tank fil- • Clean. See "Every 2000 hours OF Pump does not work correctly.
Page 189 TROUBLE CAUSE SOLUTION • No fuel. • Restore level. See"CHECKS TO BE  CARRIED OUT BEFORE STARTING THE ENGINE". • Air in fuel system. • Repair point where air is sucked in.  See "EVERY 500 HOURS OF OP- ERATION". •...
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Page 191: Maintenance
MAINTENANCE WEAM012405...
Page 192: Guide To Maintenance
Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu service engineer unless specific instructions are given in this manual. If any doubt exists, contact your Komatsu Distributor.
Page 193 GUIDE TO MAINTENANCE Do not use flammable fluids to clean any parts of the machine. Keep naked flames away from these fluids and avoid smoking. When O rings and gaskets are removed, clean the sealing surfaces thoroughly and replace the O rings and gaskets with new ones.  Fit the O rings and gaskets correctly when reassembling.
Page 194: Maintenance Notes
Use only Komatsu genuine spare parts. Do not mix different types of oil. Unless specified otherwise, the oils and the coolant used by Komatsu to fill the tanks before the delivery of the machine are the following: ITEM / TANK / SYSTEM SPECIFICATIONS •...
Page 195: Fuel
Do not use corrosion inhibitors containing soluble oil, since they damage the rubber couplings. In case of doubt regarding the applicable standards for the use of coolant, contact your Komatsu Distributor, who will supply you with exhaustive and precise information.
Page 196: Kowa
Many years of experience and the availability of countless data and information allow Komatsu to accurately deter- mine the conditions of the machine. This also allows us to locate troubles and suggest the most suitable and fast repair solutions.
Page 197: Storing Oil And Fuel
When changing the oil filters, check if metal particles are present. If you find large quantities of metal particles, contact your Komatsu Distributor. Do not open the spare filter packages before using them. Always use Komatsu original spare parts. WEAM012405...
Page 198: Notes On The Maintenance Of The Electrical System
3 - Check of the battery charge level. Do not remove or eliminate any electric component installed on the machine and do not install any electric com- ponent with characteristics different from those specified and approved by Komatsu. Keep the electric system dry.
Page 199: Parts Subject To Wear
Due to our constant efforts aimed at improving product quality, the spare parts codes may be changed, therefore when ordering spare parts it is advisable to indicate also the machine serial number to the Komatsu Distributor, in order to receive the most updated version of the component required.
Page 200: Fuel, Coolant And Lubricants
Window washer  based deter- — fluid gent Lithium EP+MoS2 (NLGI 2) Greasing GREASE e Original Komatsu oil, especially developed and approved to be used in hydraulic systems. a ASTM D975 N. 1 / EN 590 class 2 WEAM012405...
Page 201: Coolant
-10 temperature Coolant quantity litres 1.25 1.75 1.95 2.25 2.45 litres 2.95 2.45 2.25 1.95 1.75 Water quantity Volume percentage NOTE The percentage of original Komatsu coolant (AF-NAC) should never be below 30% in order to avoid corrosion. WEAM012405...
Page 202: Approved Synthetic Biodegradable Lubricants Type Hees
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended: SUPPLIER SYNTHETIC BIODEGRADABLE OIL TYPE “HEES” KOMATSU BO 46 G4 (KES 07.872) AGIP —...
Page 203: Tightening Torques
If not specified otherwise, tighten the screws and nuts applying the torques specified in the table. If it is necessary to replace a screw or a nut, always use Komatsu original spare parts having the same size of the part to be re- placed.
Page 204: Standard Tightening Torques For Hoses With Orfs
If not specified otherwise, tighten the nuts of the hoses applying the torque specified in the table. If it is necessary to replace a hose, always use Komatsu original spare parts having the same size of the part to be replaced.
Page 205: Lubrication
For details on how to lubricate specific parts, see "4.8 MAINTENANCE PLAN". The type of lubricant to be used is indicated in the lubricant table (see "4.4 FUEL, COOLANT AND LUBRI- CANTS"). Grease PC14R-3 PC14R-3 PC16R-3 PC16R-3 Fuel filter 2000h 1000h 500h...
Page 206: Periodical Change Of Safety-Related Components
PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS 4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS To ensure safety at any moment while driving and using the machine, the operator must carry out all the routine maintenance operations prescribed. Furthermore, the operator must periodically change the components indicat- ed in the table in the following page, which are especially related to safety and fire-prevention rules.
Page 207: Safety-Related Parts
PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS 4.7.1 SAFETY-RELATED PARTS Safety-related components that periodically need changing Q.ty Change interval Fuel pipe (fuel tank - water separator) Fuel pipe (water separator – fuel pump) Fuel pipe (fuel pump - fuel filter) Fuel pipe (fuel filter - injection pump) Fuel pipe (fuel filter –...
Page 208: Maintenance Plan
MAINTENANCE PLAN 4.8 MAINTENANCE PLAN If the machine is equipped with hydraulic breaker, the maintenance schedule for some components will be differ- ent. For further details, see "4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER". 4.8.1 MAINTENANCE PLAN WHEN REQUIRED CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE..............
Page 209 MAINTENANCE PLAN MAINTENANCE EVERY 2000 HOURS OF OPERATION CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER ............237 CHANGING THE COOLANT ............................239 CHECKING THE ALTERNATOR AND THE STARTER ....................240 WEAM012405...
Page 210: Maintenance Intervals In Case Of Use Of The Hydraulic Breaker
MAINTENANCE PLAN 4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER In machines equipped with breaker hydraulic oil deteriorates more rapidly than in machines equipped with stand- ard equipment. When using the breaker, always keep to the following maintenance plan. 4.8.2.a CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100–150 hours of...
Page 211: Maintenance Procedures
MAINTENANCE PROCEDURES 4.9 MAINTENANCE PROCEDURES 4.9.1 WHEN REQUIRED 4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE WARNING Remove the air filter only after stopping the engine and do not start the engine if the air filter is open. When compressed air is used to clean the filter, dust may get into the eyes. Wear safety goggles and a dust mask during the cleaning operations.
Page 212 MAINTENANCE PROCEDURES Slightly strike the filtering element (4) on the palm of your hand, in such a way as to remove the dust, and blow compressed air on the inner surface, keeping the air jet at a distance of approximately 15 cm and the pressure below 4-5 bars.
Page 213: Checking The Battery Charge Level
MAINTENANCE PROCEDURES 4.9.1.b CHECKING THE BATTERY CHARGE LEVEL WARNING Check the charge level only with the engine at rest. To prevent gas explosions, do not use naked flames, do not smoke and avoid producing sparks due to short circuits. The battery electrolyte is dangerous; in case of contact with the eyes or skin, rinse with plenty of water and consult a doctor without delay.
Page 214: Cleaning The Water Separator Filter
MAINTENANCE PROCEDURES 4.9.1.c CLEANING THE WATER SEPARATOR FILTER WARNING Change the filter after work, when the engine has cooled down to 40–45°C. During these operations some fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire. Open the radiator cover.
Page 215: Draining The Fuel Tank
MAINTENANCE PROCEDURES 4.9.1.d DRAINING THE FUEL TANK WARNING When draining the fuel tank, avoid spilling fuel, since this may cause fires. If some fuel is accidentally spilled, clean the dirty area immediately, in order to prevent it from getting slippery and to avoid fires. Turn the tower so that the discharge valve (1) under the tank is placed between the tracks.
Page 216 «S» of 0 mm and the track is not suffi- ciently stretched, this means that the pins and bushings are excessively worn. Therefore, it is necessary to exchange or replace the pins and bushings. For any replacement or repair, contact your Komatsu Distrib- utor. WEAM012405...
Page 217: Checking The Rubber Tracks
It is extremely dangerous to let the grease out following any procedure different from those illustrated below. If the track tension cannot be reduced with this operation, contact your Komatsu Distributor, who will provide for the necessary repairs. Gradually loosen the grease valve (1) to let the grease out;...
Page 218 If the length of the broken area is less then 30 mm or its depth is less than 10 mm, it is not necessary to repair the track. For any repair or replacement, contact your Komatsu Dis- tributor. RAY07530 WEAM012405...
Page 219: Checking And Adjusting The Rubber Track Tension
Do not loose any component apart from the valve (1). If the track tension does not decrease after this op- eration, contact your Komatsu Distributor. WARNING If the resistance met when injecting the grease is excessive, move the machine forward and backward covering a short distance.
Page 220 It is extremely dangerous to let the grease out following any procedure different from those illustrated below. If the track tension cannot be reduced with this operation, contact your Komatsu Distributor, who will provide for the necessary repairs. Gradually loosen the grease valve (1) to let the grease out;...
Page 221: Changing The Rubber Tracks
Do not loose any component apart from the valve (1). If the track tension does not decrease after this operation, con- tact your Komatsu Distributor. It is extremely dangerous to let the grease out following any procedure different from the one indicated below.
Page 222 MAINTENANCE PROCEDURES Stop the machine on a firm and level surface and lower the equip- ment to the ground. Raise the undercarriage using boom and arm. Carry out this operation shifting the control levers very slowly. Gradually loosen the grease valve (1) to let the grease out; do not give the valve more than one turn.
Page 223 MAINTENANCE PROCEDURES INSTALLING THE RUBBER TRACKS Raise the undercarriage using boom and arm and make sure that the grease contained in the cylinder has been eliminat- ed. Carry out this operation shifting the control levers very slowly. Install the rubber tracks on the sprocket by fitting the driving blocks.
Page 224: Windscreen Detergent Level Check And Topping Up  (Machines With Cab)
MAINTENANCE PROCEDURES 4.9.1.i WINDSCREEN DETERGENT LEVEL CHECK AND TOPPING UP  (machines with cab) The tank (1) is located under the driving cab and can be accessed after opening the sliding door. The tank holds liquid detergent used for cleaning the front windscreen; make sure that the reser- voir is always full.
Page 225: Lubrication Of Cab Door Hinges (Machines With Cab)
MAINTENANCE PROCEDURES 4.9.1.j LUBRICATION OF CAB DOOR HINGES (machines with cab) Lubricate when the cab door squeaks when it is opened or closed, or when there are oxidation traces around the shoulder washers or their pivots. Lubrication consists in filling the grease nipples placed on the hinge axis with grease....
Page 226: Windscreen Wiper Check
MAINTENANCE PROCEDURES 4.9.1.l WINDSCREEN WIPER CHECK Check only after the windscreen wiper mechanism has been activated. Checking consists in detecting the faulty cleaning of the wiper carried out with the washer in function. If after cleaning, there are scratches, it means that the scrapping blade is deteriorated and it is necessary to replace the wiper.
Page 227: Checks To Be Carried Out Before Starting The Engine
Dirt, oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires. Check frequently and repair any leakage immediately; if they occur repeatedly, contact your Komatsu Distributor. For details on the following items, see "3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE EN- GINE".
Page 228: Maintenance Every 100 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.4 MAINTENANCE EVERY 100 HOURS OF OPERATION 4.9.4.a LUBRICATION IMPORTANT Clean the grease nipples before applying the greasing pump. After lubrication, remove all the contaminated grease that may have spread out of the nipples. If the machine is used in difficult conditions, carry out this operation more frequently than usual. As a general rule, it is important to consider that each cylinder is provided with two grease nipples posi- tioned on the couplings and that each pin serving as fulcrum point for a movement is provided with at least one grease nipple.
Page 229 MAINTENANCE PROCEDURES (1) Bucket-link connection pins (1 point) (2) Arm–bucket connection pin (1 point) (3) Arm–link connection pin (1 point) (4) Bucket cylinder rod end (1 point) (5) Link connection pin (1 point) (6) Boom swing bracket pin (1 point) (7) Boom base pin (1 point) (8) Boom cylinder base pin (1 point) (9) Boom cylinder rod end (1 point)
Page 230: Maintenance After The First 500 Hours Of Operation (Only For Machines In Which Synthetic Biodegradable Oil Type Hees Is Used)
MAINTENANCE PROCEDURES 4.9.5 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used) The following maintenance operation must be carried out after the first 500 hours of operation, together with the maintenance operations to be carried out “EVERY 500 HOURS”.
Page 231: Maintenance Every 500 Hours Of Operation
MAINTENANCE PROCEDURES 4.9.6 MAINTENANCE EVERY 500 HOURS OF OPERATION 4.9.6.a CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE WARNING Change the oil with the machine parked on a level surface and the work equipment resting on the ground. Soon after the machine has been stopped the engine oil is very hot and may cause burns;...
Page 232: Changing The Fuel Filter Cartridge
MAINTENANCE PROCEDURES 4.9.6.b CHANGING THE FUEL FILTER CARTRIDGE WARNING Change the filtering element after work, when the engine has cooled down to 40–45°C. During these operations some fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire.
Page 233: Checking The Oil Level In The Final Reduction Gears
MAINTENANCE PROCEDURES 4.9.6.c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS WARNING Soon after the machine has been stopped, the engine oil is very hot and may cause burns; let the oil cool down to 40–45° C before carrying out any check. Loosen the cap slowly to release any residual pressure.
Page 234: Checking And Adjusting The Fan Belt Tension
IMPORTANT Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu ser- vice engineer unless specific instructions are given in this manual. ADJUSTMENT Loosen the adjusting screw (2) and the alternator fastening screws (3).
Page 235: Draining The Hydraulic Oil Tank (Only For Machines In Which Synthetic Biodegradable Oil Type Hees Is Used)
"3.2.9 TILTING THE CAB FLOOR (machines with canopy)" or have this opera- tion carried out by your Komatsu Distributor. Retract the arm and bucket cylinders completely, rest the bucket teeth on the ground and, after stopping the engine, eliminate the residual pressures from the equipment (by shifting the controls more than once) and from the tank (by slowly loosening the filler cap).
Page 236: Maintenance Every 1000 Hours Of Operation
"3.2.9 TILTING THE CAB FLOOR (machines with canopy)" or have this opera- tion carried out by your Komatsu Distributor. Soon after the machine has been stopped, the hydraulic oil is very hot and may cause burns; let it cool down to 40–45°...
Page 237 MAINTENANCE PROCEDURES Extend the boom, arm and bucket cylinders completely, as shown in the figure, and remove the filler cap (F). Put back the cap and pressurize the tank by lowering the equipment to the ground. IMPORTANT In machines equipped with breaker hydraulic oil deterio- rates more rapidly than in machines used for simple dig- ging operations.
Page 238: Changing The Oil In The Final Reduction Gears
Always use oil of the prescribed type (see "4.4 FUEL, COOLANT AND LUBRICANTS"). 4.9.7.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE Since these checks and adjustments require the use of special tools, have them carried out by qualified personnel supplied by your Komatsu Distributor. WEAM012405...
Page 239: Maintenance Every 2000 Hours Of Operation
"3.2.9 TILTING THE CAB FLOOR (machines with canopy)" or have this opera- tion carried out by your Komatsu Distributor. Retract the arm and bucket cylinders completely, rest the bucket teeth on the ground and, after stopping the engine, eliminate the residual pressures from the equipment (by shifting the controls more than once) and from the tank (by slowly loosening the filler cap).
Page 240 MAINTENANCE PROCEDURES Loosen the screws (1), remove the plate (2) and slowly loos- en the filler cap (F) to release the residual pressure from the tank. Remove the drain plug (P) and let the oil flow out, gathering it into a container with suitable capacity. Loosen the clamps (3), remove the suction pipe (4) and let the oil that is still in the tank flow out.
Page 241: Changing The Coolant
MAINTENANCE PROCEDURES IMPORTANT In machines equipped with breaker hydraulic oil deterio- rates more rapidly than in machines used for simple dig- ging operations.  Change the oil following the instructions given in the table. (B): Hydraulic oil replacement interval. 2000 (X): Hydraulic breaker - use percentage (%).
Page 242: Checking The Alternator And The Starter
CHECKING THE ALTERNATOR AND THE STARTER The brush may be worn or the bearing may be without grease. Contact your Komatsu Distributor for the necessary inspection or repair. If the engine is started frequently, carry out this check every 1000 hours.
Page 243: End Of Service Life
END OF SERVICE LIFE 4.10 END OF SERVICE LIFE For safe dismantling of the machine at end of service life, please contact your local Komatsu Distributor. WEAM012405...
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Page 245 TECHNICAL SPECIFICATIONS WEAM012405...
Page 246: Technical Specifications
TECHNICAL SPECIFICATIONS 5.1 TECHNICAL SPECIFICATIONS PC16R-3 (PC16R-3 HS) Unit of measurement 1620 (1770) (kg) Operating mass 0.044 Bucket capacity (m3) Komatsu Engine 3D67E-2A diesel engine Engine power (ISO 14396: 2002) KW (HP)/rpm 11.8(16.0)/2600 3500 Total length Total height 2320 1000...
Page 247 TECHNICAL SPECIFICATIONS PC16R-3 Operating characteristics Unit of measurement Max. digging outreach 3825 2160 Max. digging depth 3615 Max. digging height 1785 Max. vertical wall digging depth 2610 Max. dumping height 1470 Work equipment min. swing radius Work equipment min. swing radius ...
Page 248: Lifting Capacities
LIFTING CAPACITIES 5.2 LIFTING CAPACITIES 5.2.1 LIFTING CAPACITIES DANGER According to the harmonized standard EN474-5 (§ 4.1.7.5), the machine cannot lift weights exceeding 1000 kg, unless it is provided with appropriate equipment. Carry out lifting operations only with the machine positioned on firm and flat ground. NOTE The load does not exceed 87% of the hydraulic lifting capacity or 75% of the tipping limit.
Page 249 LIFTING CAPACITIES ROPS CANOPY + STANDARD ARM + STANDARD COUNTERWEIGHT + RAISED BLADE Unit: kg 1.5 m 2.5 m 3.5 m Max. 3.0 m *311 *311 *312 *312 2.5 m *278 2.0 m *286 *286 *278 1.5 m *504 *371 1.0 m 0.5 m -0.5 m...
Page 250 LIFTING CAPACITIES ROPS CANOPY + LONG ARM + STANDARD COUNTERWEIGHT + RAISED BLADE Unit: kg 1.5 m 2.5 m 3.5 m Max. 3.0 m *255 2.5 m *219 *219 2.0 m *229 *229 1.5 m *296 *296 *268 1.0 m 0.5 m -0.5 m 1118...
Page 251 LIFTING CAPACITIES ROPS CAB + STANDARD ARM + STANDARD COUNTERWEIGHT + LOWERED BLADE Unit: kg 1.5 m 2.5 m 3.5 m Max. 3.0 m *311 *311 *312 *312 2.5 m *278 *285 2.0 m *286 *286 *278 *279 1.5 m *504 *504 *371...
Page 252 LIFTING CAPACITIES ROPS CAB + LONG ARM + STANDARD COUNTERWEIGHT + LOWERED BLADE Unit: kg 1.5 m 2.5 m 3.5 m Max. 3.0 m *255 2.5 m *219 *219 *244 2.0 m *229 *229 *235 *242 1.5 m *296 *296 *268 *249 *244...
Page 253: Authorized Optional Equipment
AUTHORISED OPTIONAL EQUIPMENT WEAM012405...
Page 254: General Precautions For Safety
When installing attachments or options to the machine, it is necessary to pay attention to safety. Please obey the following precautions strictly when selecting, installing, or using attachments or options. For attachment items other than those described in this operation manual please refer to your Komatsu Distributor. 6.1.1 PRECAUTIONS WHEN SELECTING Please consult your Komatsu distributor before installing attachments or options to the machine.
Page 255: Precautions When Using
WARNING When calculating the allowable mass of attachments, the mass of the bucket, see the explanation of lift- ing capacity chart PC16R-3 (see "5.2.1 LIFTING CAPACITIES").  For an attachment not intended to bear a load, for example a breaker, it should not exceed the minimum lift capacity of the machine as shown on the related lift capacity charts (see "5.2.1 LIFTING CAPACI-...
Page 256: Specifications
SPECIFICATIONS 6.2 SPECIFICATIONS Hydraulic specifications Max. Service valve flow (1st attachment) 35 litres/min Standard Service valve working pressure (1st attachment) 20.6 MPa (206 bar) Optional Safety service valve working pressure (1st attachment) — MPa ( — bar) Standard Service valve safety pressure (1st attachment) — MPa (— bar) 6.2.1 ARM-PIN INFORMATION A - A B - B...
Page 257: Attachment Guide
When installing any attachment or option, there may be problems with safety, so please contact your Ko- matsu distributor before installing. Installing attachments or options without consulting your Komatsu distributor may not only cause prob- lems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment.
Page 258 For digging or loading hard soil or soft rock, it is recommended that the strengthened bucket with high durability and high wear resistance be employed. Machine layout: Equipments characteristics (to be managed only by Komatsu or Komatsu Distributor) Working Working...
Page 259: Machine Configuration For The Installation Of Attachments
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4.1 POSITION OF THE DEVICES RKA23120 Quick couplers Optional equipment control pedal (1) (3) Pedal locking device  Selection valve (2) (4) (for the optional equipment control pedal) WEAM012405...
Page 260 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS Quick couplers The quick couplers (1) are used to connect the pipes to the ends of the equipment. When removing the equipment, protect the quick couplers with the plugs (A). When installing the equipment, remove the plugs (A) and carefully clean the quick couplers before connecting them to the pipes.
Page 261: Hydraulic Circuit
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4.2 HYDRAULIC CIRCUIT 6.4.2.1 INSTALLING AND CONNECTING THE EQUIPMENT WARNING The machine must be parked on a level surface, with the equipment resting on the ground. When the connecting pins are removed or installed, chips may come off; always wear gloves, safety goggles and helmet.
Page 262: Bleeding
MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS 6.4.2.3 BLEEDING After connecting the pipes, start the engine and let it idle for approximately 10 minutes (see "3.3.2 STARTING THE ENGINE"). Extend all cylinders 4-5 times, stopping them at approx. 100 mm from the end of stroke. IMPORTANT If the engine runs at maximum rpm or if the cylinders are brought to the end of stroke soon after starting, the air sucked in by the cylinders may damage the piston gaskets.
Page 263: Preparation For Equipment Installation (Only For Machines With Proportional Controls)
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) 6.5 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) 6.5.1 POSITION OF THE DEVICES RKA62970 (1) Quick coupler (1st attachment) (2) Equipment (2nd attachment) (3) Selection valve (4) Attachment proportional roller (1st line) / breaker activation (5) Attachment proportional roller (2nd-3rd line) (6) Horn button (7) 2nd line activation switch...
Page 264 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) Quick coupler (1st attachment) The quick coupling is used to connect the pipes equipped with quick coupling to the ends of the equipment. The components used for quick coupler (1st attachment) are: Cap, male (for piping on left side of arm) FASTER NV 1/2 GAS F CAP (G1/2M) Cap, female (for piping on right side of arm)
Page 265 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) Selection valve The selection valve regulates the flow of the hydraulic oil and has two positions. Position (a): for applications requiring the use of the generic equipment.  Spool (A) completely rotated clockwise. Position (b): for applications requiring the use of the hydraulic breaker.
Page 266 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) Horn button To activate the sound alarm, press the button positioned on the handle of the right lever. 7-8. 2nd and 3rd line activation switches When the right switch is pressed, the 2nd line is activated. Press the switch again the 2nd line is turned off.
Page 267 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) Hydraulic quick coupler activation switch This switch is used to activate the quick coupler or to release the attachment. For more details, see "6.6 HYDRAULIC QUICK COUPLER (SIN- GLE-EFFECT)". 10. Hydraulic quick coupler switch Pos.
Page 268: Work Equipment Control Levers
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) 6.5.2 WORK EQUIPMENT CONTROL LEVERS WARNING Before carrying out any manoeuvre with these levers, the operator must seat in the work position and fasten the seat belt. Before leaving the driver seat, lower the equipment to the ground, lock the controls with the safety lever and stop the engine.
Page 269: Lifting Capacities Tables
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) 6.5.3 LIFTING CAPACITIES TABLES DANGER According to the harmonized standard EN474-5 (§ 4.1.7.5), the machine cannot lift weights exceeding 1000 kg, unless it is provided with appropriate equipment. Carry out lifting operations only with the machine positioned on firm and flat ground. NOTE The load does not exceed 87% of the hydraulic lifting capacity or 75% of the tipping limit.
Page 270 PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) VARIABLE GAUGE RETRACTED + RAISED BLADEUnit of measurement: Max. 3.0 m 2.0 m 1.0 m -1.0 m VARIABLE GAUGE EXTENDED + LOWERED BLADEUnit of measurement: Max. 3.0 m 2.0 m 1.0 m -1.0 m VARIABLE GAUGE EXTENDED + RAISED BLADEUnit of measurement:...
Page 271: Hydraulic Circuit
For details about the components of quick coupler see " 1. Quick coupler (1st attachment)" and " 2. Equipment (2nd attachment)". IMPORTANT The equipment quick couplings must be in compliance with the ISO 7241-1 standard, series «B». If the quick coupler size does not match, please contact your Komatsu distributor. Quick coupler 1st line WEAM012405...
Page 272: Installing And Connecting The Equipment (3Nd Line)
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) Attachment (2nd line) RKA62980 Start the machine and perform several manoeuvres with the equipment control pedal, in order to check the seals. CAUTION When connecting the pipes, take care to prevent any impurities from getting into them. WARNING Wear thick gloves and safety goggles during this check.
Page 273: Using The Equipment
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) 6.5.5 USING THE EQUIPMENT WARNING In case you are not working with the breaker or two-way flow equipment, fit this switch on the normal mode. If an operation mode is selected, the involuntary activation of the proportional equipment switch or the breaker switch can cause serious incidents.
Page 274: Long Periods Of Inactivity
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) When using the breaker, shift the accelerator almost to max. idling and keep it in this position during work (position corresponding approximately to 80% of the engine maximum power). If the breaker is operated with the engine at full throttle, it will lead to failure.
Page 275: Programming The Control Unit
PREPARATION FOR EQUIPMENT INSTALLATION (only for machines with proportional controls) 6.5.8 PROGRAMMING THE CONTROL UNIT WARNING Programming the control unit should be carried out by the Komatsu dealer. (1) Leds (2) Programming button (3) Dip-switches IMPORTANT First carry out the programming of the roller and then the programming of the oil flow.
Page 276: Hydraulic Quick Coupler (Single-Effect)
The pressure adjustment valve (3) allows to limit the quick coupling pressure based on the manufacturer's recommendations. Check the quick coupling specifications and check that the valve is correctly set. Make sure that a duly qualified technician installs the quick coupling. In case of doubts, contact the Komatsu distributor.
Page 277: Position Of The Devices
HYDRAULIC QUICK COUPLER (SINGLE-EFFECT) 6.6.1 POSITION OF THE DEVICES RKA63040 (1) Hydraulic quick coupler switch (2) Quick coupler operation switch (3) Pressure adjustment valve (4) Hydraulic quick coupler connection (DIN CONICO M12x1,5) (unlock line) WEAM012405...
Page 278: Functioning
CAUTION At the start-up, the machine performs a self-check and verifies the operation of the buzzer. In case the buzzer is not functioning properly, contact the Komatsu distributor. To unlock the bucket or accessory 1 - If the bucket or accessory is hydraulically connected to the machine, before operating, disconnect the hydrau- lic connections.
Page 279 HYDRAULIC QUICK COUPLER (SINGLE-EFFECT) To connect another bucket or accessory WARNING Depending on the type or combination of the equipment, this may hit the cab or other parts of the ma- chine. When a working tool is used for the first time, check that it does not cause any interfere and work with caution.
Page 280: Operating The Equipment
The breaker is operated by pressing the lower part of the equip- ment control pedal (B). NOTE If it is necessary to adjust the oil flow, have this operation car- ried out by your Komatsu Distributor. RKA16510 Precautions for use Before using the breaker, make sure that the spool of the selection valve (1) is completely rotated clockwise and resting against its retainer, position (b).
Page 281: Long Periods Of Inactivity
Lower part (B) pressed: the oil flows to the left side of the arm (op- erator seat side). NOTE If it is necessary to adjust the oil flow, have this operation car- ried out by your Komatsu Distributor. RKA16500 Precautions for use Before using a crusher or other generic equipment, make sure that the spool of the selection valve (1) is completely rotated counterclockwise and resting against its retainer, position (a).
Page 282: Precautions To Be Taken When Using Optional Equipment
Choose the type of equipment that is most suitable to the hydraulic excavator on which it must be in- stalled. Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated (see "6.3.2 ATTACHMENT CONFIGURATION").
Page 283 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT When applying impact, push the chisel against the impact sur- face and operate so that the chassis rises approximately 5 cm off the ground. Do not let the machine come further off the ground than this amount.
Page 284 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT WRONG USAGE To ensure long machine life and safe work, the following operations should be avoided. Do not operate all cylinders to the end of their strokes. Always leave approximately 5 cm to spare. Using the mount to gather in pieces of rock Operations using the swing force Moving the tool while it is hitting the material to be broken.
Page 285 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT Pecking operations Extending the bucket cylinder rod fully and thrusting to raise the machine off the ground POSTURE OF HYDRAULIC BREAKER TO BE GREASED Be sure to grease the breaker, holding it in the right posture. RYA05800 IMPORTANT If grease is injected with the breaker in the wrong position,...
Page 286 WEAM012405...

This manual is also suitable for:

Pc16r-3hs

Komatsu PC16R-3 Operation & Maintenance Manual

Foreword 1.1 Foreword

Information on Safety

Introduction

Product Identification

Komtrax System

Table of Contents

Safety and Accident Prevention

Safety, Noise and Vibration Plates

General Precautions

Precautions to be Taken before Starting the Engine

Precautions to be Taken When Working

Transporting the Machine on Motor Vehicles

Battery

Precautions for the Removal of the Machine

Precautions for Maintenance

The Machine and Its Operations

Machine Illustrations

Instruments and Controls

Use of the Machine and Related Controls

Transporting the Machine

Using the Machine in the Cold Season

Long Periods of Inactivity

Troubleshooting

Maintenance

Guide to Maintenance

Maintenance Notes

Parts Subject to Wear

Fuel, Coolant and Lubricants

Tightening Torques

Lubrication

Periodical Change of Safety-Related Components

Maintenance Plan

Maintenance Procedures

Type HEES Is Used)")

THE HYDRAULIC OIL TANK (Only for Machines in Which Synthetic Biodegradable Oil

End of Service Life

Technical Specifications

Lifting Capacities

Authorized Optional Equipment

General Precautions for Safety

Specifications

Attachment Guide

Quick Links

Related Manuals for Komatsu PC16R-3

Summary of Contents for Komatsu PC16R-3